GB2577267A

GB2577267A - Insulating block

Info

Publication number: GB2577267A
Application number: GB1815214.0A
Authority: GB
Inventors: Thornberry John
Original assignee: MOULDED FOAMS Ltd
Current assignee: MOULDED FOAMS Ltd
Priority date: 2018-09-18
Filing date: 2018-09-18
Publication date: 2020-03-25
Anticipated expiration: 2038-09-18
Also published as: GB201815214D0; GB2577267B

Abstract

An insulating block for use with spaced-apart beams to form a suspended floor, comprises a first portion which, in use, bridges a gap between the spaced-apart beams, and a second portion which, in use extends over an upper surface of at least one of the beams. The second portion further comprises a reinforcement member. The reinforcement member may be a friction fit in an aperture or hole provided for it in the second portion. The reinforcement member may be made from a polymeric material and may be in the form of an elongate member of oval cross section. It may have a hole formed through it and may be aligned with the length of the beam or positioned to extend through the second portion. The edges of the block may be formed to interlock with adjacent like blocks.

Description

Insulating Block

Field of the Invention

The present invention relates to an insulating block, and more specifically to an insulated block for use with beams in a suspended flooring system.

Background to the Invention

It is well known to form suspended floors in buildings by mounting a plurality of horizontal elongate beams, for example of pre-stressed concrete, between opposite side supporting structures of the building. Typically, the beams have a spaced relationship, extend parallel to each other and have an inverted T-shape in cross-section which provides oppositely-extending longitudinal side flanges.

A plurality of blocks of insulating material can then be fitted between the adjacent spaced-apart beams so as to bridge the gap therebetween and form a suspended floor. Each block comprises first and second sides arranged to engage and seat on flanges of respective beams. A screed material is then laid on top of the blocks to form a floor surface. However, whilst the insulation properties of a floor of this kind are acceptable in the areas between beams, cold spots form in areas of the suspended floor where the screed directly contacts the beams.

To address this problem, suspended flooring systems in which the insulating material extends above the beams have been developed. Whilst such systems do ensure the entire floor is adequately insulated, such an approach raises new problems. Many suspended floors are required to carry significant load, and the transfer of this load through the insulating material to the beam can result in significant deformation of the insulating material in areas surrounding the beam. Such deformation is frequently unacceptable and, therefore, the density of the insulating material has to be increased to ensure the required loads can be supported, resulting in greater costs and difficulty in installation.

As disclosed in our UK Patent GB 2,550,292 B one solution to this problem is to provide a two part solution Including a large insulating portion and an additional capping member, where the capping member is formed of a dense material and is further channel-shaped and designed to fit above a beam. In this way, the capping member provides thermal insulation above the beams without any unacceptable deformation of the suspended floor under load.

Whilst the system disclosed in GB 2,550,292 B works well, the requirement for separate blocks and capping members is not ideal. For example, having two separate building blocks can result in either the capping member or blocks from being inadvertently omitted from the suspended floor, resulting in the formation of cold spots. Additionally, the installation of two separate pieces can increase material and storage costs and may also Increase the installation time of the system.

Objects and aspects of the present claimed invention seek to alleviate at least these problems of the prior art.

Summary of the Invention

In accordance with the present claimed invention, there is an insulating block for use with spaced-apart beams to form a suspended floor, the insulating block comprising a first portion which, in use, bridges a gap between the spaced-apart beams, the insulating block further comprising a second portion which, in use extends over at least one of the beams, wherein the second portion further comprises a reinforcement member.

In use, the insulating block is placed such that the first portion bridges the space between adjacent beams and the second portion extends over a beam. The second portion which extends over the beam is reinforced by a reinforcement member. A suspend floor system can then be fabricated by placing the insulating blocks side by side and in contact with one another to fill a gap between adjacent beams, wherein a first portion of each block is touching or connected to a second portion of an adjacent insulating block to form an insulated suspended floor system with a continuous floor surface.

The applicant has found that the structural and mechanical properties of the present claimed invention are sufficient to allow the fabrication of a load-bearing suspended flooring system. Advantageously, this system allows an insulating block for use in a suspended floor to be provided with lower material costs and lower overall weight, where the insulating blocks can also be more easily assembled into a suspended floor.

Preferably, the first portion and the second portion are integrally formed. In this case, the first portion and the second portion are formed together in a single manufacturing process. For example, the first portion and second portion may be formed together in a single moulding process. Such an approach is may be beneficial as it can be quicker to manufacture a block where the first portion and the second portion are integrally formed.

Preferably, the insulating material is an expanded insulating material. Preferably, the insulating materials is a formed of a polymeric material. Preferably, the insulating material is low-density. Preferably, the insulating material is expanded polystyrene, more preferably low-density expanded polystyrene.

Preferably, the reinforcement member is positioned within the second portion such that, in use, the reinforcement member is located above at least one of the beams. More preferably, the reinforcement member is positioned within the second portion such that, in use, the majority of the cross-section of the reinforcement member is located above at least one of the beams. More preferably still, the reinforcement member is positioned within the second portion such that, in use, the reinforcement member is wholly located above at least one of the beams. After the construction of a suspended floor areas of high load, for example due to the presence of a load-bearing wall, are frequently found or positioned directly above the beams of the suspended flooring system, As such, the provision of a insulation block with any of these preferred features ensures the reinforcement member can assist in transferring the weight placed on the suspended floor to the beams incorporated within the suspended floor.

Preferably, the second portion comprises a recess, cavity or aperture in which the reinforcement member is located. Preferably, the recess, cavity or aperture is dimensioned to be complementary in size and shape to the reinforcement member. Preferably, the reinforcement member is accommodated wholly within a recess or aperture. Preferably, the recess or aperture is dimensioned such that a surface of the reinforcement member is flush with an upper surface of the insulating block. Preferably, the reinforcement member is held within the recess or aperture via a friction fit.

Preferably, the reinforcement member is formed of a rigid material. Preferably, the reinforcement member is formed from a lightweight material. Preferably, the reinforcement member is formed of a polymeric material. Preferably, the reinforcement member is formed of at least one thermoset or thermoplastic material. The rigidity and resistance to compression of the reinforcement member increases the second portion's resistance to compression.

Preferably, the reinforcement member has an elliptical or oval cross section. Preferably, the reinforcement member is substantially cylindrical. Preferably, the reinforcement member is substantially hollow. Preferably, the reinforcement member comprises at least one internal cavity. Preferably, the reinforcement member comprises at least one internal support member. Preferably, the at least one internal support member is provided as a network that spans the internal cavity. Producing a reinforcement member which comprises an internal cavity assists in ensuring the reinforcement member, and therefore the insulating block is lightweight. Where the reinforcement member comprises an internal support member, this may assist in increasing the strength or rigidity of the support member.

Preferably, the reinforcement member is positioned within the second portion such that, in use, the longitudinal axis of the elliptical or oval cross section is parallel with the longitudinal axis of the at least one beam. Preferably, the reinforcement member is positioned within the second portion such that, in use, the longitudinal axis of the reinforcement portion is perpendicular with the longitudinal axis of the at least one beam. Preferably, the reinforcement member is positioned within the second portion such that, in use, the reinforcement member is centrally aligned with the longitudinal axis of the at least one beam.

Preferably, the reinforcement member extends through the thickness of the second portion.

Preferably, the reinforcement member is a different colour to the first portion and the second portion. When the suspended floor is constructed, the reinforcement member being a different colour to the remainder of the insulating block may assist a user in identifying the locations of the beams within the suspended floor.

Preferably, the second portion is channel shaped in cross section, the channel shape comprising a central portion which, in use, extends over at least one of the beams and further comprising opposite side portions which, in use, extend down opposite sides of at least one of the beams. Preferably, in use, both of the opposite side portions extend down opposite sides of the at least one beam. Preferably, the opposite side portions are asymmetrical.

Preferably, each of the opposite side portions extend down opposite sides of the beam to a different extent.

Preferably, in use, the central portion of the channel extends over a plurality of beams.

Preferably, the opposite side portions of the channel extend down opposite sides of the plurality of beams.

Preferably, the first portion comprises at least one rib which is positioned such that, in use, it rests on a flange extending from a beam. Preferably, the rib extends along an entire face of the first portion of the insulating block. Preferably, the rib extends substantially perpendicularly to a surface of the first portion of the insulating block.

Preferably, an edge or side of the first portion comprises a first engagement formation, and an edge of the second portion comprises a second engagement formation, wherein the first engagement formation and the second engagement formation are complementary to one another. In this way, when a suspended floor is assembled, the first and second engagement portions of adjacent blocks may engage with one another to hold adjacent insulating blocks in position relative to one another.

Preferably, a surface of the insulating block is textured or comprises an array or protrusions. Preferably, in use, the surface is the upper surface of the insulating block.

Preferably, the second portion comprises a plurality of reinforcement members. Preferably, the plurality of reinforcement members are evenly distributed along a line extending across the surface of the second portion. Preferably, each of the reinforcement members of the plurality of reinforcement members are orientated such that their longitudinal axes are parallel to each other. Preferably, the longitudinal axis of the cross-section of each of the reinforcement members is aligned.

Preferably, the plurality of reinforcement members are evenly distributed along a line extending across the surface of the second portion, the plurality of reinforcement members distributed and aligned such that the distance between adjacent reinforcement members is approximately double the distance between each of the peripheral reinforcement members and the edges of the second portion, where the edges are perpendicular with the line along which the plurality of reinforcement members are distributed. This distribution of reinforcement members ensures that the reinforcement members are evenly distributed along entire beam.

Preferably, the block comprises two planar opposing surfaces. Preferably, the block comprises two separate sets of two planar opposing surfaces.

Also in accordance with the present invention, there is provided a suspended floor comprising a plurality of spaced apart beams, the suspended floor further comprising a plurality of insulating blocks as previously described, wherein the first portion of each insulating block bridges a gap between the beams, and wherein the second portion of each insulating block extends over at least one of the beams.

Preferably, the plurality of insulating blocks are connected to one another via complementary engagement formations located on a first edge of the first portion and a first edge of the second portion.

Also in accordance with the present claimed invention, there is provided a kit of parts comprising a plurality of insulating blocks as previously described, the kit of parts further comprising a plurality of beams.

Detailed Description

Embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings, in which: Figure 1 is an isometric view of an embodiment of an insulating block in accordance with the present invention; Figure 2 is side view of the block of Figure 1 looking towards the second portion 50; Figure 3 is side view of the block of Figure 1 looking towards the rib 90; Figure 4 is an isometric view of a reinforcement member showing a closed end of a reinforcement member; and Figure 5 is an isometric view of a reinforcement member showing an open end of a reinforcement member.

Figure 6 is an isometric view of a suspended floor according to the present invention; Figure 7 is an end view of the suspended floor of Figure 6; Figure 8 is a plan view suspended floor of Figure 6; Figure 9 is a bottom view of the system of Figure 6; Referring to Figures 1 to 3, there is shown an insulating block 10 according to the present invention comprising a first portion 40, a second portion 50 and four reinforcement members 60. The first portion 40 is substantially cuboid and is dimensioned such that, in use, it can span the distance between adjacent beams in a suspended flooring system. The block 10 also comprises an upper surface 70 and lower surface 80 where, in use, the upper surface 70 is the surface upon which the screed is applied to form the final flooring. The lower surface 10 15 20 BO opposes the upper surface 70 and faces downwards towards to the ground when the insulting block 10 is in use.

On one side of the first portion 40 is a rib 90, and on the other opposing side of the first portion 40 is the second portion 50. The rib 90 and the second portion 50 are located on sides adjacent and perpendicular to the upper surface 70 and the lower surface 80.

The rib 90 protrudes substantially perpendicularly from the side of the first portion 40 and, in use, engages with a beam. The rib 90 is shaped to complement a side flange of a beam with an inverted T-shape. The rib 90 has a uniform cross-section along its length and further extends along the entirety of the side of the first portion 40 in a direction substantially parallel to the plane occupied by the upper surface 70 and the plane occupied by the lower surface 80. The rib 90 is located approximately centrally between the upper surface 70 and the lower surface 80 and has a width of approximately 33% of the distance between the upper surface 70 and the lower surface 80.

On the opposite side of the first portion 40 to the rib 90, the first portion comprises an indentation 110. The indentation 110 extends along the entire side of the first portion 40, wherein the indentation 110 is again designed to engage and complement a flange extending from a beam with an inverted T-shape.

The second portion 50 is located on the opposite side of the first portion 40 to the rib 90. The second portion 50 extends from the side of the first portion 40. The second portion 50 comprises a channel 100 and a lip 120. The channel 100 and lip 120 extend along the entire side of the first portion 40, such that the second portion 50 has uniform cross-section along its entire length and along the length of the side of the first portion 40. The channel 100 extends from the lower surface 80 towards the upper surface 70 and is substantially U-shaped with squared corners. The channel 100 is designed such that in use, it accommodates and engages with a beam.

The side of the second portion 50 most distant from the indentation 110 comprises the lip 120. The lip 120 extends perpendicularly from the base of the channel 100 towards the lower surface 80. The lip 120 extends approximately 33 % of the distance between the upper surface 70 and the lower surface 80.

The second portion 50 further comprises four recesses, each recess holding a reinforcement member 60. The recesses and thus reinforcement members 60 are evenly distributed along the longitudinal axis of the channel 100 and in the upper surface 70 to form an array of reinforcement members 60. The recesses housing the reinforcement members 60 are dimensioned to be complementary to the reinforcement members 60 such that the top of the reinforcement member 60 is substantially flush with the upper surface 70. The reinforcement members 60 are substantially cylindrical with a hollow body and a substantially oval cross-section.

The longitudinal axis of the cross-sections of the recesses and reinforcement members 60 are orientated such that, in use, these longitudinal axes lie in a direction substantially parallel and centrally aligned with a beam 20 above which they are located. The reinforcement members comprise rigid polymeric materials, such that they offer reinforcement to the area between the channel 100 and the upper surface 70.

The upper surface 70 of the block 10 is criss-crossed with an array of protrusions. The array of protrusion 150 create a textured surface on the upper surface 70. Each protrusion 150 is in the form of two adjacent and parallel lined protrusions. The dual-lined protrusions 150 form a grid over the surface of the upper surface 70.

The first portion 40 and the second portion 50 also combine to form two planar surfaces 130 which are substantially perpendicular to both the upper surface 70 and the lower surface 80.

Both side surfaces 130 extend between the upper surface 70 and the lower surface, joining the two surfaces.

Referring to Figures 4 and 5, the structure of the reinforcing member 60 can be seen in more detail. As illustrated in Figure 5, the reinforcement member 60 is substantially hollow, comprising a plurality of cavities. Additionally, the reinforcement member 60 comprises support members 140. The support members 140 increase the strength and rigidity of the reinforcement member 60 but keep the weight and material costs of the reinforcement member 60 low. The support members 140 span the height of the cylindrical reinforcement member 60 from top to bottom.

Referring to Figures 6 to 9, there is illustrated a suspended flooring system in accordance with the present claimed invention. As depicted, the suspended flooring system comprises a plurality of insulating blocks 10 and beams 20. In the suspended flooring system, the beams 20 extend parallel to each other and the blocks 10 are placed such that they engage the beams 20. More specifically, the blocks 10 are placed such that the beams 20 occupy the channel 100 of a first block 10 and a flange 30 of the beam 20 engages the indentation 110. The lip partially extends down the side of the beam, such that there is a gap between the lip 120 and the flange 30 of the beam 20. This gap can then be occupied by the rib 90 of an adjacent block 10 that is also part of the suspended floor system. The rib 90 of the adjacent block engages both the lip 120 of the first block 10 and the flange 30 of the beam 20 simultaneously.

In this manner, insulating blocks are laid out in in an end-to-end fashion to form a row. If required, to extend the width of the floor two or more rows may abut one another in a side to side fashion. In this case, adjacent rows of insulating blocks 10 can sit on the same or independent beams. Additionally, in such an arrangement, the position of a second insulating block 10 in relation to a first insulating block 10 block can be described by a 2-dimensional translation vector.

In this formation, the upper surfaces 70 of the adjacent blocks 10 form a continuous planar surface layer onto which a screed material can be applied. It will be appreciated that the screed layer is therefore entirely insulated from the beams 20 and any void belowthe suspended floor by the insulating material of the blocks 10. Thus, the suspended floor system is insulating and does not suffer from cold spots.

There may be a requirement to build an internal wall or to place another heavy structure on the floor surface which has been laid on top of the screed. The load will be preferentially located above a beam 20 for additional support. Accordingly, the insulating material forming the second portion 40 of each insulated block 10 located between the channel 100 and the upper surface 70 is reinforced by four reinforcement members 60. There is a layer of the insulating material at the bottom of the recesses which prevents direct contact between the reinforcement members 60 and the beam 20, wherein this layer of insulating material is sufficiently thin that it will not unduly compress under load.

In some embodiments of the invention, the edge of the first portion comprises a first engagement formation and the edge of the second portion comprises a second engagement formation. The first and second engagement formations are complementary to one another, such that a resilient engagement can be formed between the first and second blocks 10 such that the first block and the second block are held in planar alignment with one another. Examples of such an engagement formation may include a tongue and groove arrangement or interlocking projections.

Claims

CLAIMS1. An insulating block for use with spaced-apart beams to form a suspended floor, said insulating block comprising a first portion which, in use, bridges a gap between said spaced-apart beams, said insulating block further comprising a second portion which, in use, extends over at least one of said beams, wherein said second portion further comprises a reinforcement member.
2. The insulating block of claim 1, wherein said first portion and said second portion are integrally formed.
3. The insulating block of claim 1 or claim 2 wherein said reinforcement member is positioned within said second portion such that, in use, said reinforcement member is located above at least one of said beams.
4. The insulating block of any one preceding claim, wherein said second portion comprises a recess, cavity or aperture in which said reinforcement member is located.
5. The insulating block of claim 4, wherein said reinforcement member is held within said recess or aperture via a friction fit.
6. The insulating block of any one preceding claim, wherein said reinforcement member is formed of a polymeric material.
7. The insulating block of any one preceding claim, wherein said reinforcement member has an elliptical or oval cross section.
8. The insulating block of claim 7, wherein said reinforcement member is positioned within said second portion such that, in use, the longitudinal axis of said elliptical or oval cross section is parallel with the longitudinal axis of said at least one beam.
9. The insulating block of any one preceding claim, wherein said reinforcement member comprises at least one internal cavity.
10. The insulating block of any one preceding claim, wherein said reinforcement member extends through the thickness of said second portion.
11. The insulating block of any one preceding claim, wherein said reinforcement member is a different colour to said first portion and said second portion.
12. The insulating block of any one preceding claim, wherein said second portion is channel shaped in cross section, said channel shape comprising a central portion which, in use, extends over at least one of said beams and further comprising opposite side portions which, in use, extend down opposite sides of at least one of said beams.
13. The insulating block of claim 12, wherein, in use, said central portion extends over a plurality of beams and wherein said opposite side portions extend down opposite sides of said plurality of beams.
14. The insulating block of any one preceding claim, wherein the first portion comprises at least one rib which is positioned such that, in use, said at least one rib rests on a flange extending from said at least one beam.
15. The insulating block of any one preceding claim, wherein an edge or side of said first portion comprises a first engagement formation, and an edge of said second portion comprises a second engagement formation, wherein said first engagement formation and said second engagement formation are complementary to one another.
16. The insulating block of any one preceding claim, wherein a surface of said insulating block is textured or comprises an array or protrusions.
17. The insulating block of claim 16, wherein in use, said surface is the upper surface of said insulating block.
18. The insulating block of any one preceding claim, wherein said second portion comprises a plurality of reinforcement members. 30
19. A suspended floor comprising a plurality of spaced apart beams, said suspended floor further comprising a plurality of insulating blocks according to any preceding claim, wherein said first portion of each insulating block bridges a gap between said beams, and wherein said second portion of each insulating block extends over at least one of said beams.
20. A suspended floor according to claim 19, wherein said plurality of insulating blocks are connected to one another via complementary engagement formations located on a first edge of said first portion and a first edge of said second portion.