WO2003066995A1

WO2003066995A1 - Flooring system

Info

Publication number: WO2003066995A1
Application number: PCT/GB2003/000284
Authority: WO
Inventors: Adam John Wallace; Neil Pengilly
Original assignee: E-Floor Systems Limited
Priority date: 2002-02-05
Filing date: 2003-01-22
Publication date: 2003-08-14
Also published as: GB0202605D0; AU2003244502A1

Abstract

A flooring system comprises a base (1) which is placed on a subfloor. The base (1) has an array of locators (5) for locating pedestals which support tiles or panels of a raised floor. The base (1) is conductive, for example being stamped from sheet metal to form a grid. Embodiments of pedestal are conductive and adjustable in height to accommodate variations in the subfloor.

Description

"Flooring System"

The present invention relates to a flooring system.

Electrical, and particularly computing, equipment often requires a large number of cables for connecting with other pieces of equipment and for power supply purposes. Having several cables crossing a floor is a considerable trip hazard and there is also a risk that the cables can become accidentally disconnected, thereby disrupting communications or the power supply.

A known solution to this problem is- to locate the cables in a space beneath the floor tiles. Specially designed flooring systems exist for this purpose, which are usually called "low profile" flooring because they are intended to take up minimal work space.

Existing low profile flooring systems have arrays of pedestals upon which tiles are placed after the cables have been arranged within channels between the pedestals. A carpet or another type of floor covering is then usually placed over the tiles. In existing arrangements, the pedestals extend from plastic or metal plates or bases that are fixed to the existing floor surface by means of an adhesive.

Unfortunately, such flooring systems have a number of problems. First, the pedestals are manufactured in a limited range of fixed heights. The existing floor surface must usually be screeded so that it is flat, otherwise the floor tiles placed upon the pedestals will be uneven. Furthermore, the plastic base is a high impedance material that slowly dissipates static charge. This can damage equipment connected to the cables and increases the risk of electromagnetic radiation interfering with the data being transmitted through the cables.

Embodiments of the present invention are intended to address the problems associated with existing flooring systems.

According to a first aspect of the present invention there is provided a flooring base including a frame for placing on a surface, the frame being formed of an electrically conductive material and having one or more locators for floor tile pedestals.

The frame is normally pre-manufactured and so it can be quickly installed on an existing floor surface, and pedestals and floor tiles can then be rapidly assembled upon the frame. Alternatively, the pedestals can be pre-installed on the base to form an assembly which can be transported and installed as a unit .

The conductive material may be a metal or alloy, such as steel or Zintec^® . The frame may be substantially web or grid-shaped, typically formed by stamping a sheet of the conductive material . The grid-shape can provide a multitude of directions through which high frequency emissions can flow as well as functioning as a zero impedance ground plane. This means that the frame can act as a signal reference grid. A similar effect can be achieved by forming an array from metal strips, for example with the strips being interleaved, or arranged criss-cross and optionally spot-welded.

The locators may be positioned at intersections of the grid lines. The locators may include a threaded member for threading into a corresponding thread in a said pedestal (or vice versa) . The frame may include one or more linking elements, such as apertures and/or bolts, for connecting to one or more other frames. Thus, by linking frames together, a large electrically continuous flooring base can be assembled.

The pedestal may include a connector portion for connecting onto the locator on the frame and an upper surface for supporting at least a portion of one or more floor tiles. In one embodiment the height of the upper surface with respect to the base frame is adjustable, thereby allowing the distance between a flooring tile and the- surface to be adjusted. The height of the upper surface may be adjustable by means of a threaded member for threading into a corresponding thread in the connector portion (or vice versa) . The pedestals are usually formed at least partially of electrically conductive material .

According to another aspect of the present invention there is provided a flooring system including one or more flooring bases substantially similar to that described above, one or more floor tile pedestals substantially similar to that described above and one or more floor tiles.

The invention may be performed in various ways, and, by way of example only, embodiments thereof will now be described, reference being made to the accompanying drawings, in which: -

Figure 1 is a plan view of the base frame; Figure 2 is a cross sectional view through a connector portion of a pedestal for use with the base frame; Figure 3 is an exploded diagram of the pedestal connector portion of Figure 2 ; Figure 4 is a cross sectional view through one embodiment of a floor tile support portion of a pedestal; Figure 5 is a perspective view of the support portion of Figure 4; Figure 6 is a perspective view of another embodiment of a support portion; Figure 7 is an exploded diagram of the support portion of Figure 6; Figure 8 is a cross sectional view though the base frame and pedestals supporting floor tiles; Figure 9 is a perspective view from below the arrangement of Figure 8; Figure 10 is an exploded cross-sectional view of an alternative form of pedestal; Figure 11 is an exploded isometric view, to a reduced scale, of the pedestal of Figure 10; and Figure 12 is a perspective view from above of part of a flooring system using the pedestals of Figures 10 and 11.

Referring to Figure 1, a base frame 1 is a grid shape punched out of a sheet of 0.8mm Zintec^® which is electro-zinc coated steel by Corus . The grid is defined by one set of four parallel grid lines 2 and another set of four parallel grid lines 3, the sets being mutually perpendicular to each other. Each grid line has a length of approximately 1220mm and a width of around 35mm. The grid lines define a 9 x 9 matrix of square spaces 4, each square having dimensions of around 265 x 265mm. Thus, the ends of each vertical 2 and horizontal 3 grid line form portions of around 132.5mm in length extending beyond the spaces 4.

At a substantially central location of the intersection of each vertical 2 and horizontal 3 grid line there is a locator 5. Each locator 5 is a M4X12 threaded insert that protrudes substantially perpendicularly from the plane of the frame 1.

Close to each end of the grid lines 2, 3 there is an aperture 6, of around 5.0mm in diameter. Bolts (not shown) or the like can be threaded through the apertures 6 so that a plurality of frames can be connected together to cover a larger floor surface.

It will be understood that the dimensions given above and below are examples only and that different materials and sizes could be used as required. It is also possible to have the grid shape formed by overlaying or interleaving struts of conductive material rather than punching it out of a sheet. However, it is preferred that the entire frame 1 forms a continuous electrical conductor. The shape of the frame 1 need not necessarily be a square grid and other arrangements could be used, for example configurations formed of combinations of diagonal as well as perpendicular struts.

Referring to Figures 2 and 3, an example of a portion 8 of a pedestal for connecting onto a locator 5 is shown. The lower pedestal portion 8 includes a base 10 which is a substantially circular 2mm plate having a diameter of 45mm. A S-M4-2 threaded PEM insert 12 is fitted into a central aperture of the base plate 10. A cylindrical tube 14 having a diameter of 32mm and a height of 20mm is fixed onto the base plate 10, for example by spot welding. An upper disc 16 is fitted on top of the tube 14. The upper disc 16 is a 2mm plate with a diameter of 45mm. The disc 16 has a central aperture suitable for receiving an M12 anchor rivet bush 18.

Turning to Figures • 4 and 5, a first example of a pedestal portion 20 for connecting onto the lower portion 8 and used for supporting floor tiles is shown. The portion 20 has a shape similar to that of a countersunk screw, the stem 22 of the screw having a diameter of 12mm and a height of 36mm. The head of the screw-shape is formed of a substantially frusto conical member 23, the narrower end of which has a diameter of 12mm, suitable for fitting on to the threaded member 22. The frusto conical member 23 has a height of 3mm and its wider end has a diameter of 45mm. The head of the screw-shape further includes a 3mm disc 24, also having a diameter of 45mm, fitted on top of the wide end of the frusto conical member 23. The disc 24 has a substantially central aperture of 15mm in diameter.

Four substantially rectangular blocks 25 are fitted on top of the disc 24. The blocks are arranged around the circumference of the disc at points spaced about 90° apart from each other, the blocks extending lengthwise towards the central aperture. The blocks 25 have dimensions of around 15 x 7 x 8mm. The upper corner of each block 25 that is located at the outer edge of the disc 24 is bevelled and the opposite inner wall of each block 25 is shaped to follow the edge of the central circular aperture of the disc 24. Thus, the four blocks 24 divide the upper surface of the disc into four quarters of substantially equal dimensions.

Another embodiment of a pedestal support portion is illustrated in Figures 6 and 7. Similar to the first embodiment, the lower part of the portion 30 comprises a threaded bolt 31, preferably a M10X40 bolt. The head of the bolt 31 is fixed to a central point of a substantially square 5.0mm plate 32. The plate 32 has dimensions of 80 x 80mm and has a small triangular section cut away at each of its four corners. Small triangular indentations 33 are formed at substantially central points along each of its four sides.

The pedestal portion 30 further includes a first substantially rectangular 2.0mm plate 34 having rounded ends. The plate 34 has a length of 100mm and a height of about 15mm. A slot 35 having a depth of 4mm is formed around halfway along the upper side of the length of the plate 34. The opposite/lower side of the plate 34 has a rectangular portion 36 with dimensions of 70 x 5mmm cut away such that the ends of the plate 34 form lips protruding downwards. The shape and size of the rectangular portion 36 is such that the plate 34 can lie flat on the square plate 32 with the lips fitting into the triangular central indentations 33 on opposite sides of the square 32.

A second plate 37 is substantially identical to the first plate 34, except that its central slot 38 is formed above its rectangular cut-away portion 39. This allows the lips of the plate 37 also to fit over opposite triangular indentations 33 of the square 32 as its slot 38 engages with the slot 35 of the first plate 34. Thus, the two plates form a cross shaped protrusion on top of the square 32 and divide the surface into four substantially equal quarters.

Although the pedestal portions described above include mainly metal components, it will be understood that they can be of any manufacture. Pedestals manufactured for other purposes or other flooring systems can even be used. Parts of the pedestals, such as ^"the cap, may be^" formed of ^"piastre or other non-conductive materials. Electrical continuity can be achieved by inserting a conductive piece, such as a copper insert, through the plastic cap so that the insert protrudes through the top and bottom of the pedestal. Having a plastic cap also has the advantage of reducing or preventing the drumming effect of metallic contact.

Turning to Figures 8 and 9, it can be seen that in use the pedestals are fitted to the frame 1 by means of the frame locators 5 threading into the threaded insert 12 on the base portion 8 of each pedestal . The threaded member 31 of the upper pedestal portion 30 used in the example is screwed into the bush 18 of the pedestal base 8. It will be appreciated that as the member 31 is turned, the height of the top of the pedestal with respect to its base is adjustable, thereby allowing the height of the floor tiles 40 supported on the pedestal to be adjusted. To reduce the risk of the threading mechanism being compromised when a load is placed on the pedestal, a locking nut (not shown) can be threaded onto the member 31 to a desired position.

In the example, the corners of four adjacent floor tiles 40 rest on respective quarters of the upper pedestal square 32. It will be appreciated that this is only one configuration and that another number, for example one or two, of floor tiles could rest upon each pedestal. Furthermore, different pedestals, for example ones located around the edge ^"of a floor area, may support different^' numbers^" of^" tiles to other pedestals, e.g. ones at the centre.

Figures 10 and 11 show an alternative form of pedestal comprising a base portion 50 and an upper portion 51.

The base portion 50 comprises a base plate 52 to which is welded an upright tube 53. The base plate 52 has a central domed portion 54 which is apertured to receive a self-tapping screw 55. The outer surface of the tube 53 is threaded as seen at 56.

The upper portion 51 comprises a top plate 57 to which is welded a generally tubular portion 58, the lower part of which is internally and externally threaded as seen at 59. The upper part of the tubular portion 58 may be flared, as shown, to improve stability. The top plate 57 has a central aperture 60 which may be used to receive locating elements (not shown) for locating the edges of floor tiles.

The pedestal also comprises a lock nut 61 engagable with the thread 56 on the base portion 50.

In use, the base portion 50 is secured to a base frame 101 (Figure 12) similar to the base frame 1 of Figure 1 but without the locators 5. The screw 55 is passed through an aperture at the grid intersection and screwed into the aperture in the domed portion ^"54^". ^"A^" pedestal ^" base portion 50 may be secured to each grid intersection and the base plate with sixteen base portions 50 may be transported and laid as a unit, if desired. Once a given base portion 50 is in the required position, the lock nut 61 is run down the tube 53, the upper portion 51 is engaged with the lower portion and screwed to achieve the desired height, and the lock nut 61 is run up the tube 53 to engage the upper portion 51 and lock it in position. Figure 12 shows one exemplary system using the pedestals of this form. In Figure 12, floor tiles 102 are rendered as translucent to allow the positioning of the tiles with respect to the pedestals to be seen; it will be appreciated that in practice the tiles will be of steel or other opaque material. In the system shown, each tile 102 is supported on nine pedestals, but different sizes of tiles could be supported on four, six or twelve pedestals, for example.

The various parts of the pedestal of Figures 10 and 11 may conveniently be of metal, preferably of steel which may be plated for corrosion resistance. As discussed above, non-metallic materials may alternatively be used, in which case it is preferred to use conductive materials or inserts to maintain electrical continuity.

The flooring system, can include a greater number of pedestals than existing systems. Thus, tiles can be supported at ^"locations other than^" just at^" their ^"four corners, which means that weight is distributed over more pedestals. This allows the thickness of the tiles 40 to be reduced to around 19mm. The minimum space between the lower surface of the tiles 30 and the base frame 1 is around 36mm and the adjustable pedestals mean that the space can be modified to virtually any size. The space is sufficient for neatly positioning cables in the channels between the pedestals, and which allows them to be identified as power or date lines on site. Some of the tiles 40 can have apertures to allow the cables to be connected to equipment above the floor.

The embodiments described above allow a raised floor surface to be provided without the need for the existing floor surface to be made completely flat by screeding as the adjustability of the pedestals can compensate for the irregularities on the existing floor surface. In addition, the base plates can be made of a grid of thin metal, typically about 1 mm in thickness, which gives the grid considerable flexibility and allows it to conform to unscreeded, uneven subfloors . The adjustable pedestals also mean that the height of the floor tiles can be modified in accordance with customer specifications without new pedestals of non-standard height having to be manufactured.

As the base frame 1 is a continuous conductor of electricity it can be used as a signal reference grid to provide a multitude of paths for earth leakage if it is connected to ground.

Claims

1 A flooring base including a frame for placing on a surface, the frame being formed of an electrically conductive material and having one or more locators for floor tile pedestals .

2 A base as claimed in Claim 1 wherein the frame is pre-manufactured.

3 A base as claimed in either preceding claim where the conductive material is a metal or alloy.

4 A base as claimed in claim 3 in which the conductive material is plain or coated steel .

5 A base as claimed in claim 3 or claim 4 in which the frame is formed by stamping a sheet of the conductive material.

6 A base as claimed in any preceding claim wherein the frame is substantially web or grid- shaped.

7 A base as claimed in claim 6 wherein the grid- shape provides a multitude of directions through which high frequency emissions can flow as well as functioning as a zero impedance ground plane.

8 A base as claimed in claim 6 or claim 7 wherein the locators are positioned at intersections of the grid lines. 9 A base as claimed in any preceding claim wherein the locators include a threaded member for threading into a corresponding thread in a said pedestal (or vice versa) .

10 A base as claimed in any preceding claim wherein the frame includes one or more linking elements, such as apertures and/or bolts, for connecting to one or more other frames.

11 A base as claimed in any preceding claim in combination with at least one said pedestal which includes a connector portion for connecting onto the locator on the frame and an upper surface for supporting at least a portion of one or more floor tiles.

12 The combination of claim 11 wherein the height of the upper surface with respect to the base frame is adjustable, thereby allowing the distance between - - a flooring tile and the- surface to be adjusted.

13 The combination of claim 12 wherein the height of the upper surface is adjustable at each pedestal by means of a threaded member for threading into a corresponding thread in the connector portion (or vice versa) .

14 The combination of any of claims 11 to 13 wherein the or each pedestal is formed at least partially of electrically conductive material. 15 A flooring system including one or more flooring bases as claimed in any of claims 1 to 10 or the combination of any of claims 11 to 14.

14 A flooring base substantially as hereinbefore described with reference to the accompanying drawings .

15 A flooring system substantially as hereinbefore described with reference to the accompanying drawings .