WO2013028141A1

WO2013028141A1 - Panel with filling

Info

Publication number: WO2013028141A1
Application number: PCT/TR2012/000122
Authority: WO
Inventors: Ayhan SENTURK
Original assignee: Senturk Ayhan
Priority date: 2011-08-24
Filing date: 2012-08-08
Publication date: 2013-02-28

Abstract

The present invention relates to a panel with filling (1) forming a space under the floor and allowing some installments like electricity, water and ventilation to pass through this space, characterized in that the said panel with filling (1) comprises encapsulated panel or coated panel with filling.

Description

DESCRIPTION

PANEL WITH FILLING Technical Field

The present invention relates to a panel with filling used as a floor covering in places like information processing centers and modern offices.

The present invention especially relates to a panel with filling which creates a space under the used floor and provides the installations like electricity, water and ventilation to pass through.

State of the Art

The raised floor that are recently used have many positive aspects for the user in many terms. Through the space that have been created thanks to this raised floor, the electricity, water and ventilation installments are allowed to pass. Therefore, the user can immediately interfere in possible conditions.

However, such kind of recently-used panels of raised floor have some advantages, but they have many disadvantages in many aspects.

One of these relates to the coated panels. Coated panels are produced as chipboard-based and calcium sulphate-based. These panels comprise an upper coating made of materials such as PVC, HPL (laminate). Following the application, no new coating is needed.

Chipboard-based coatings are not appropriate for many reasons.

One of these reasons is that the chipboard-based panels are produced by coating the bottom, upper and side parts after the chipboard provided by the chipboard-producers has been sized. Therefore, the size stability of the panel depends on the quality of the chipboard.

Another disadvantage is that as the chipboard-based panels are affected by water, the cleaning process should be performed sensitively and it requires a high level of caution. Another disadvantage is that the chipboard is a burnable material. Therefore, the chipboard- based elevated flooring panels have to bear B-class (EN 13501-1 hard-to-burn) characteristics. Another disadvantage is that such panels need a big area of production and expensive machinery (equipment pool). Moreover, the fact that they consume high level of electricity and they are produced with heavy labor force is another disadvantage causing them not to be used.

The calcium sulphate-based panels, on the other hand, are fire-resistant unlike the chipboard-based panels (A class (EN 13501-1)); however, they are not appropriate for many reasons.

One of these reasons is that the period of provision is quite long since the calcium sulphate- based panels are produced only abroad. This period is almost 4 weeks. Following the order, it takes 2 weeks for it to be produced, and 2 weeks for the transportation. Another reason is that as it gets damaged by water, and so it is not appropriate for wet- cleaning.

Another disadvantage is that it is more expensive compared to the chipboard-based panels as they are provided from abroad.

Another disadvantage is that it requires a big area of production, expensive machinery, high level of energy consumption and high labor cost.

Another application in the state of the art relates to an encapsulated panel. The encapsulated panel is covered with galvanized metal sheet from the upper, bottom and side parts (in the form of capsule). As the panel-base, chipboard or calcium-sulphate are used as in the coated panels. As the chipboard and calcium-sulphate are used as the panel base, it has all the disadvantages experienced in the coated panel. Another application used in the state of the art, on the other hand, relates to the panels with filling. Such panels are not preferred in Turkish and European market; therefore, they are not produced. Such panels are produced in China. Different from the other panels, the upper metal sheet on the side parts of the panel is folded over the bottom metal sheet and the two sheets are combined. The bottom metal sheet is shaped with a deep-pull process and spot welding is made on the points where the two sheets are combined. After the panel bottom sheet and the upper sheet have been combined, the inner part of the panel is filled with filling. As the panel filling, cement-based filling is used. However, in this type of panel, again some disadvantages are experienced.

One of these disadvantages is that as the panel filling is cement-based concrete, the panel is very heavy compared to the other panel types. Therefore,, it imposes a burden which is more than planned on the place where it will be applied.

Another disadvantage is that because of the weight, the cost of transportation is high; therefore, it is not economical when transported to long distances. Moreover, because of its weight, its exportation is limited. Furthermore, excessive amount of weight causes the user to have difficulty in lifting the panel.

Another disadvantage is that as the upper metal sheet is folded over the bottom metal sheet on the side parts of the panel, there is not a large contact surface on the side parts of the panels; therefore, the mounting processes of the panels have become difficult. In order to provide the panels to stay stable, the panels are fixed to the legs with the help of screws through the screw holes. The necessity to use screw decreases the mounting speed of the system. Moreover, due to use of screws, When the user wants to reach to the bottom part of the raised floor, he/she has to undo four screws for each panel. Therefore, the user loses time and does not prefer such a product.

Another disadvantage is that because of side folding, the size of the panel cannot be kept within the range of standard tolerance values. Another disadvantage is that as the cement-based concrete filling makes it hard for the panel to be cut, special cutting devices are needed, which increases the cost of mounting.

Because of all these disadvantages, some developments are being made in the raised floor panels, and new embodiments are needed which will eliminate the above-mentioned disadvantages and which will provide solutions to the current systems.

Object of the Invention

The present invention relates to a panel with filling meeting all the above mentioned requirements, eliminating all the disadvantages and providing some extra advantages.

The object of the present invention is to produce the bottom and upper parts, determining the sizes of the panel, with the help of moulds. Thus, size stability is provided. An object of the present invention is to provide a raised floor panel with an A-class (EN13501-1) fire-resistance. A further object of the present invention is that the main production components are galvanized metal sheet, black metal sheet and plaster which are domestically provided. Therefore, it has a high potential of export in terms of cost.

A further object of the present invention is that the filling material is not affected by the water and dampness, thanks to the alpha plaster or cement-based fillings. Moreover, as it is not affected by water and dampness, it is made possible to be used on the wet surfaces in a ceramic-coated form, and on the outer floors with appropriate type of coating. As there is no effect of water and dampness, its useful life is long, which is another object. A similar object of the present invention is that it has a low production cost and a quick production capacity.

A similar object of the present invention is to obtain a cheap panel type thanks to different recycled additives (organic wastes like cellulose wastes, nutshell, wood chips, and inorganic wastes like calcite, sand and pearlite) mixed with alpha plaster or cement, which are used as filling materials. Therefore, environmental protection is also supported.

A similar object of the present invention is that although the other panel types are heavy, the panel used within the present invention is light. What makes it light is that it has a porous structure because of gas bubbles inside the alpha plaster in the panel base.

Another object of the present invention is that the porous structure of the alpha plaster which is the panel base can be produced in different densities depending on the choice. Therefore, panels of different weights can be obtained. For example, for a multi-floor skyscraper, a light panel with low intensity can be produced; while for an information processing center where there are many heavy devices, a kind of panel with high intensity which is resistant to load can be produced.

A further object of the present invention is that as the panel base is alpha plaster, it is easy to cut the panel and it provides quick and low-cost mounting. In order to achieve the above mentioned objects, the present invention relates to a panel with filling comprising at least one upper metal sheet, at least one bottom sheet, at least one fixing point located on the joint of the said upper sheet and bottom sheet, forming a space under the floor and allowing electricity, water, and ventilation installments to pass through this space; characterized in comprising

- at least one junction edge providing the said upper metal sheet and the bottom metal sheet to be combined on the side part,

- filling material forming the inner part of the panel.

In order to achieve the above mentioned objects, the present invention relates to a panel with filling comprising at least one upper metal sheet, at least one bottom sheet, at least one fixing point located on the joint of the said upper sheet and bottom sheet and at least one upper coating, forming a space under the floor and allowing electricity, water, and ventilation installments to pass through this space; characterized in comprising;

- at least one side coating increasing the side resistance of the said upper coating,

- filling material forming the inner part of the panel.

The structural and characteristic aspects and all the advantages of the present invention will be understood more clearly thanks to the following figures and the detailed description written with references to these figures; therefore, these figures and the detailed description should be taken into account while making an evaluation.

Brief Description of the Figures

In order for the advantages of the present invention to be best understood with its configuration and extra elements, it should be evaluated together with the figures described below.

Figure 1 is the view of the panel with filling according to the present invention.

Figure 2 is the view of a preferred embodiment of the panel with filling according to the present invention.

Figure 3 is the view of another preferred embodiment of the panel with filling according to the present invention.

Figure 4 is the view of the panel with filling having legs. The drawings do not necessarily need to be scaled, and the details which are not necessary to understand the present invention may have been ignored. Moreover, the parts which are identical to a great extent or which have identical functions to a great extent are shown with the same number.

Reference Numerals

1. Panel with filling

2. Upper metal sheet

3. Bottom metal sheet

4. Junction edge

5. Fixing point

6. Filling material

7. Junction part

8. Upper coating

9. Side coating

10. Leg

Detailed Description of the Invention

In this detailed description, the preferred embodiments of the panel with filling according to the present invention are described only for a better understanding of the subject without posing any limiting effect.

In Figure 1 , the panel with filling (1) according to the present invention is shown. In Figure 2, on the other hand, a preferred embodiment of the panel with filling (1) according to the present invention is shown.

The panel (1) shown in Figure 2 is the encapsulated panel with filling. This panel (1) consists of an upper metal sheet (2), bottom metal sheet (3), junction edge (4), fixing point (5) and a filling material (6).

In Figure 3, another preferred embodiment of the panel with filling (1) according to the present invention is shown. The panel (1 ) shown in Figure 3 is the coated panel with filling. This panel (1) consists of an upper metal sheet (2), bottom metal sheet (3), junction edge (4), fixing point (5), upper coating (8), side coating (9) and a filling material (6). The upper metal sheet (2) available both in the encapsulated panel (1) with filling and in the coated panel (1) with filling according to the present invention is produced from galvanized or black metal sheet in 0.40-2.00 mm thickness. When black metal sheet is used, it is colored. The bottom metal sheet (3) forms the bottom coating of the panel (1). It is made of galvanized metal sheet or black sheet of 0.40-2.00 mm-thickness. When black metal sheet is used, it is colored. The bottom metal sheet (3) and the upper metal sheet (2) determine the sizes of the panel (1). And they are produced with the help of moulds. Therefore, stability of size is provided. The panel (1) is shaped with the combination of upper (2) and bottom metal sheets (3). A deep-pull method is used for this shaping process.

The junction edge (4) available in the panels (1) shown in Figure 2 and 3 provides the bottom metal sheet (3) and the upper metal sheet (2) to be combined on the side part. It contributes to load resistance. In order for the junction edge (4) to be created, it is formed on the side surface. As a large contact surface is provided, the panels (1) lean on one another and they are fixed by means of a panel (1) connection element. The junction edge (4) can be created by means of welding or coupling method.

The fixing point (5), on the other hand, is applied on the junction parts (7) of the bottom metal sheet (3) and upper metal sheet (2), and contributes to the load-resistance of the panel (1). The fixing point (5) can be created by means of coupling, welding or another type of connection.

In these panels (Figure 2 and Figure 3); in order to fill the inner part of the panel (1), alpha plaster is used as the filling material (6). The filling material (6) is the substance which fills the panel content (inner part). Different re-cycled additives which are mixed with alpha plaster can also be used as the filling material (6). These are organic wastes like cellulose wastes, nutshell, wood chips, and inorganic wastes like calcite, sand and pearlite. By means of the gas bubbles inside the alpha plaster used in the inner part of the panel (1), a porous structure is created. This, in turn, makes the panel (1) lighter. This porous structure can be produced in different intensities. Therefore, panels (1) of different weights can be produced.

In addition to what is mentioned above, the coated panel with filling according to the present invention comprises an upper coating (8) and side coating (9). The upper coating (8) is the latest coating in the panel (1). The upper coating (8) is made of coatings like PVC (polyvinyl chloride) and HPL (high pressure laminate) as in other panels (1). The_. side coating (10) in the panel (1) is made of hard PVC in 0.50-1.00 mm thickness. It is used to improve the side resistance of the upper coating (8).

The upper (8) and side coatings (9) available on the coated panel with filling shown in Figure 3 are configured on the metal sheets (2). However, the upper and side coating on the coated panels in the state of the art are applied to the panel content.

In Figure 4, the panel (1) with filling having legs (10) is shown. Lastly, there are legs (10) on the panel with filling (1). The legs (10) are made of metal. And they provide the panel (1) to be elevated to a certain height.

Method of obtaining the raised floor according to the present invention: - The bottom metal sheet (3) is produced in the sizing line by means of moulds

(corner-cutting or length-cutting),

The produced bottom metal sheet (3) is shaped in the shaping press, The upper metal sheet (2) is produced in the sizing line by means of moulds (corner-cutting or length-cutting),

- The produced upper metal sheet (2) is shaped in the shaping press,

- The junction edge (4) is created by combining the shaped upper metal sheet (2) and bottom metal sheet (3) on the side part by means of closing press,

- A fixing point (5) is created on the junction part (7) of the bottom (3) and upper (2) metal sheets by means of welding, coupling or another connection type, - The inner part of the panel (1 ), the bottom (3) and upper (2) metal sheets of which are combined, is filled with alpha plaster or other mixtures in the filling unit,

- Glue is applied onto the upper surface and the upper coating (8) is applied in 610*610 mm sizes,

- The panels (1) are superimposed and pressed,

- The excess of upper coating (8) is trimmed, covered over the side surface by means of melted glue, and a side coating (9) is applied,

- The excess of side coating (9) is cleaned,

- The panel (1) that has been produced is piled up and packed.

The above mentioned method is applied both in the encapsulated panel with filling, and also in the coated panel with filling, in the panel (1) according to the invention. However, in the encapsulated panel with filling application, there is no upper (8) and side (9) coating application.

In a preferred embodiment of the present invention (1), the following materials can be used as the filling material (6);

bare alpha plaster,

- puffed and lightened alpha plaster,

- alpha plaster mixed with inorganic materials such as pearlite, calcite, sand, floatstone, glass, etc.

- alpha plaster mixed with organic materials such as paper, shaving, shaving dust, nutshell, sun flower stem chips, wheat (barley) straw.

In a preferred embodiment of the present invention (1), the following materials can be used as a filling material (6);

- bare beta plaster,

puffed and lightened beta plaster,

- beta plaster mixed with inorganic materials such as pearlite, calcite, sand, floatstone, glass, etc.,

- beta plaster mixed with organic materials such as paper, shaving, shaving dust, nutshell, sun flower stem chips, wheat (barley) straw.

In another preferred embodiment of the present invention (1), mixtures with cement-based organic and inorganic fillings can be used as the filling material (6). In another preferred embodiment of the present invention (1), clay and other earth-oriented materials can be cooked and used as the filling material (6).

In another preferred embodiment of the present invention (1), the organic or inorganic materials are mixed with polyurethane-based adhesives and used as the filling material (6).

In another preferred embodiment of the present invention (1), any kind of construction waste can be mixed with cements and used as the filling material (6).

In the preferred embodiments of the present invention (1), the following materials can be used as bottom (3) and upper (2) metal sheets of the panel (1);

- uncoated steel sheet,

- steel sheet with zinc coating (hot or electro-galvanized), - colored steel sheet,

- colored and galvanized steel sheet,

- aluminium sheet or

- colored aluminium sheet.

In the preferred embodiments of the present invention (1), the following materials can be used as the final (upper) panel coating (8);

- rubber floor coatings,

- ceramic or ceramic granite of different sizes,

- marble,

- granite,

- laminated parquet,

- laminate parquet,

- floor tile carpet, or

- any kind of flooring that can be applied to the floor.

In the preferred embodiments of the present invention (1), the following materials can be used as the side coating (9) material;

- PVC (polyvinyl chloride) in different thicknesses and characteristics,

- ABS (acrylonitrile-butadiene-styrene) of different thicknesses and characteristics, or wooden profile.

In a preferred embodiment of the present invention (1), different panel bottom shapes can be used depending on load resistance requirements.

.

In a preferred embodiment of the present invention (1), the upper surface can be used in flat form.

In a preferred embodiment of the present invention (1), different combining forms can be used on the side surface, such as coupling, welding one over another, etc. After the bottom (3) and upper (2) metal sheets have been welded one over the other, they are inclined towards the bottom part and a large contact surface is obtained on the side surface.

The panels (1) in the preferred embodiments of the present invention (1) can be produced in different thickness such as 18 mm, 22 mm,' 28 mm, 30 mm, 38 mm, 40 mm, 42 mm.

Claims

The present invention relates to a panel with filling (1) comprising at least one upper metal sheet (2), at least one bottom sheet (3), at least one fixing point (5) located on the joint part (7) of the said upper sheet (2) and bottom sheet (3), forming a space under the floor and allowing electricity, water, and ventilation installments to pass through this space; characterized in comprising;

- at least one junction edge (4) providing the said upper metal sheet (2) and the bottom metal sheet (3) to be combined on the side part,

- filling material (6) forming the inner part of the panel (1).

The present invention relates to a panel with filling (1) comprising at least one upper metal sheet (2), at least one bottom sheet (3), at least one fixing point (5) located on the joint part (7) of the said upper sheet (2) and bottom sheet (3), and at least one upper coating (8), forming a space under the floor and allowing electricity, water, and ventilation installments to pass through this space; characterized in comprising;

- at least one side coating (9) increasing the side resistance of the said upper coating (8),

- filling material (6) forming the inner part of the panel (1).

3. The panel with filling (1) according to Claims 1 and 2, characterized in comprising a filling material (6) made of at least one of the material groups that are bare, puffed and lightened alpha plaster mixed with inorganic materials such as pearlite, calcite, sand, floatstone, glass, or with organic materials such as paper, - shaving, shaving dust, nutshell, sun flower stem chops, wheat (barley) straw, or made of the combinations thereof.

4. The panel with filling (1) according to Claims 1 and 2, characterized in comprising a filling material (6) made of at least one of the material groups that are bare, puffed and lightened beta plaster mixed with inorganic materials such as pearlite, calcite, sand, floatstone, glass, or with organic materials such as paper, shaving, shaving dust, nutshell, sun flower stem chops, wheat (barley) straw, or made of the combinations thereof.

5. Panel with filling (1 ) according to Claims 1 and 2, characterized in comprising filling material (6) made of mixtures with cement-based organic and/or inorganic fillings.

6. Panel with filling (1) according to Claims 1 and 2, characterized in comprising a filling . material (6) made of mixtures of polyurethane-based adhesives with organic or inorganic materials.

7. Panel with filling (1 ) material according to Claim 2, characterized in comprising side coating (9) made of PVC (polyvinyl chloride) of different thickness and characteristics.

8. Panel with filling (1) material according to Claim 2, characterized in comprising side coating (9) made of ABS (acrylonitrile butadiene styrene) of different thickness and characteristics.

9. Panel with filling (1) material according to Claim 2, characterized in comprising side coating (9) made of wooden profile.