Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/02177—Floor elements for use at a specific location
  • E04F15/02188—Floor elements for use at a specific location for use in wet rooms
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
  • E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
  • E04D13/1687—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure the insulating material having provisions for roof drainage
  • E04D13/1693—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure the insulating material having provisions for roof drainage the upper surface of the insulating material forming an inclined surface
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
  • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
  • E04C1/24—Elements for building-up floors, ceilings, roofs, arches, or beams
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
  • E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
  • E04D13/0404—Drainage on the roof surface
  • E04D13/0481—Drainage guiding provisions, e.g. deflectors or stimulation by inclined surfaces
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
  • E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/02177—Floor elements for use at a specific location
  • E04F15/02183—Floor elements for use at a specific location for outdoor use, e.g. in decks, patios, terraces, verandas or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
  • E04F15/182—Underlayers coated with adhesive or mortar to receive the flooring
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
  • A47K3/00—Baths; Douches; Appurtenances therefor
  • A47K3/28—Showers or bathing douches
  • A47K3/40—Pans or trays
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2203/00—Specially structured or shaped covering, lining or flooring elements not otherwise provided for
  • E04F2203/02—Specially structured or shaped covering, lining or flooring elements not otherwise provided for having particular shapes, other than square or rectangular, e.g. triangular, hexagonal, circular, irregular
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
  • E04F2290/02—Specially adapted covering, lining or flooring elements not otherwise provided for for accommodating service installations or utility lines, e.g. heating conduits, electrical lines, lighting devices or service outlets
  • E04F2290/023—Specially adapted covering, lining or flooring elements not otherwise provided for for accommodating service installations or utility lines, e.g. heating conduits, electrical lines, lighting devices or service outlets for heating
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
  • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]

Definitions

• An object of the present invention is to provide a surface covering system including prefabricated building elements, with which a surface can easily and quickly be constructed having a sufficient drainage of water and an even decline towards a draining sewer.
• a surface covering system intended for covering a floor, a roof or another substantially flat, delimited surface according to Claim 1 , comprising at least one substantially rectangular, triangular, square or otherwise polygonal plate with a mark showing a drainage point and a
• the invention is characterised by the first decline being circular and having a radial slope directed towards the mark from every point on the at least one plate.
• the decline thus creates a cavity in the plate, which has the shape of at least a part of a blunt virtual cone with the apex of the cone directed towards the mark.
• each plate segment is unique and intended for a specific delimited surface. Centred on the mark for the drainage point an opening is preferably arranged, acting as a drainage sewer.
• One plate can be used as a wet room plate intended for a limited space in a bathroom, for instance a shower area.
• the surface covering system comprises at least two separate plates, intended to be arranged side by side. At least one of the plates has a mark showing a drainage point, and both the at least two plates have an upper surface with a first common circular decline with a radial slope directed towards the mark when the plates are arranged side by side.
• the upper surface of at least one side edge of each plate is bevelled, which gives a bevelled notch in the joint achieved between the plates when the plates are arranged side by side.
• the bevelled notch can be filled with e.g. liquid filler. If liquid filler is arranged in the joints between the plates as well as on the upper surfaces of the plates, the separate plates are moulded together to one single unit.
• a second circular decline which has a second slope, larger than the first slope of the first circular decline.
• the second decline with this second slope extends preferably from the mark to a virtual circle line arranged at a distance from the mark corresponding to a radius of up to 500 mm.
• Grooves arranged in the upper surface can be used for underfloor heating, and grooves arranged in the lower surface can be used for ventilating away moisture that may appear between the underfloor and the surface covering system.
• the grooves for underfloor heating are preferably arranged in a chequered pattern that follows the floor slope fully. It is also possible to arrange the grooves in the upper surface before the decline is created. In this embodiment the chequered pattern does not follow the slope of the floor but is flat. If the grooves are filled with liquid filler, the heat from the underfloor heating coils is distributed evenly over the floor, as liquid filler leads heat much better than the plate material.
• the invention further relates to a method for preparing a surface covering system comprising at least one plate with a decline towards a mark which marks a drainage points according to any of the above embodiments characterized in that the preparation of the decline on the at least one plate is done by any of the following manufacturing methods milling, hot pressing, compression moulding or casting of the at least one plate.
• An advantage of the above method for preparing a surface covering system is that a circular decline with an even slope can be prepared without any complicated manufacturing process for the one or more prefabricated plates comprised in the system.
• the method is characterised in that it comprises the steps of:
• the decline is machined with circular or linear movements starting from the mark. If the decline is machined with circular or linear movements starting from the mark, for instance with a milling machine, each floor can be specially made according to the desires of the customer.
• the mill may advantageously be a programmable 5-axis mill.
• the mill is preferably programmed with information about the desired size of the surface to which the system is to be adapted, the thickness of the plates and the position of the drainage point.
• the manufacturing process may be simplified further. If a programmable 5-axis mill is used, the manufacturing process is faster, and the lead times are diminished.
• the mill is preferably provided with information from a platform programmed with information about the desired size of the surface to which the system is to be adapted, the thickness of the plates and the intended position of the drainage point. The platform is chosen according to the intended number of drainage points of the surface covering system.
• the method is characterised by it comprises the steps of:
• the preparation of the at least one plate is achieved by any one of the preparation methods hot pressing, compression moulding or casting of the at least one plate.
• the method further comprises the steps of choosing also at least one second mould, the inner volume of which corresponds to the volume of a second separate plate, which has a decline common with the second plate and to supply material to the second mould in an amount regarding the second plate.
• At least one of the mould parts may be used in prefabrication/manufacturing of several of the plates that together constitute the surface covering system.
• the whole mould i.e. both the first and the second mould part, can be used for making several plates, because several plates here have the same decline.
• at least four plates have the same decline.
• the outer dimensions of the at least one mould are the same as the outer dimensions of the at least one second mould.
• any one of the above methods also comprises the steps of creating a hole for a drainage sewer, centred around the mark for the drainage point, and/or of machining grooves in the upper surface and/or the lower surface of the at least one plate, which extend over the whole of that surface.
• Fig. 1d shows a perspective view of the invention with exaggerated dimensions.
• Fig. 2a shows a second embodiment of the invention as a plane view.
• Fig. 2b shows a section A-A of Fig. 2a.
• Figs. 3a-3c show some possible shapes of the surface covering system, adapted to different dimensions of the surface to which the system is intended to be adapted.
• Figs. 4a and 4b show a third embodiment with cuts for underfloor heating and/or ventilation.
• Figs. 5a, 5b and 5c show moulds belonging to two different manufacturing methods.
• Figs. 6a-6c show an alternative embodiment of the surface covering system, comprising square plates.
• FIGS 1 a-1 c show a first embodiment of the floor system, which comprises a plate 1 with a mark 2 for a drainage point in the form of a floor drain.
• the mark 2 may also be the drainage point/floor drain as such.
• the mark 2 is in this embodiment centred on the plate 1 , but it may also be placed at another suitable place away from the edge of the plate, e.g. 450 mm to 600 mm in on the plate.
• the plate is in this embodiment rectangular, but it may also be substantially rectangular (for instance square), triangular, quadrangular or have another polygonal shape.
• substantially rectangular, triangular, quadrangular or polygonal also include plates comprising different shaping or connecting details arranged in the edges of the plate to permit joining or connecting several plates to one another.
• the plate 1 has a substantially flat lower surface 3 and an upper surface 4 with a decline directed towards the mark 2.
• the decline is circular and has a radial slope a towards the mark from every point on the at least one plate, so that the decline creates a cavity in the plate 1 in the shape of at least a part of a blunt cone with the apex of the cone directed towards the mark 2.
• the plate has a polygonal shape, the cavity in the shape of a cone is truncated in its periphery, i.e. the straight edges of the plate end the circular decline, see Figure 1c.
• the thickness of the plate is exaggerated to make the conical shape of the cavity clear.
• the plates may be made from e.g. expanded polystyrene of the EPS or XPS type or polyamide plastics (PA), polypropene (PP) or polyurethane (PUR).
• the plate material may also be glass foam or any other plate material, suitable for the purpose.
• plates with a circular decline are cast from concrete or another material suitable for casting. It is also possible to compression mould or hot press the plates from other materials, suitable for these
• the plates which are used as separate parts in the surface covering system are substantially flat on the lower side and thus intended to be put on a flat substrate. It is advantageous to use EPS plates with dimensions up to 1200 mm ⁇ 3000 mm or XPS plates with dimensions up to 600 mm ⁇ 3300 mm, but it is of course also possible to use plates with any other dimensions. Square plates may for instance be suitable for assembling reasons.
• Plates made from a water impermeable material may be preferable when they are intended to be placed for instance in a wet room or an inner yard.
• the plates as such may then act as moisture barriers against the underlying floor structure, and sealing is only needed along the walls or edges and along any joints between the plates.
• FIGs 2a and 2b show another embodiment of the invention, wherein the floor system comprises three separate rectangular plates 1a, b, 1c, placed side by side in order to jointly form the upper surface/floor surface 4 of the wet room. More than three plates may of course also be used.
• the plates can be fastened together with glue or other fastening means, or they can be fastened to the floor side by side.
• the joints 5 between the plates may be sealed with some kind of sealing tape. It is also possible to lay a sealing layer or a steam
• One of the plates in this case the middle plate 1 b, but it can of course also be any one of the other plates 1 a, 1c, has a mark 2, which is in this case a cut for a floor drain.
• the hole can also be milled or produced in any other way when the floor system is manufactured or when the floor is laid in place at the building area.
• the floor surface 4 has a first circular decline with a radial slope a directed towards the floor drain mark 2. Locally closest to the floor sewer mark, preferably at a radius r up to 500 mm from the middle of the sewer, there is a second circular decline having a greater slope ⁇ than the first decline a.
• the first radial slope a is preferably in the range of 2-10 mm/m and the second radial slope ⁇ in the range of 7-20 mm/m.
• the slope directed towards the drainage sewer may be in other ranges.
• the separate plates 1 a, 1 b, 1 c have an upper surface 4a, 4b, 4c with parts of the common circular decline.
• the middle plate 1 b comprises the hole for the floor sewer, and the circular decline around this forms a cavity in the shape of a cone with its apex directed towards the centre of the hole for the floor sewer.
• the two outer plates 1 a, 1 c comprise a decline forming a cavity in the plates 1 a, 1 c in the shape of a part of a blunt cone, because the cone is truncated in one or both sides.
• Figures 3a-3c show three different irregularly shaped bathroom floors, built with the floor system according to the invention.
• the floor systems shown in Figures 3a-3c are all built from one or several rectangular plates 1 a, 1 b, 1 b', 1 c, 1d with an upper floor surface 4 having a circular decline directed towards a floor sewer.
• the outer edges of the floor are cut to the desired shape. Irrespective of how the bathroom floor looks, no cutting in situ is needed.
• the plates can be specially made according to the shape of the floor even in the factory.
• Figures 4a and 4 show an embodiment of a floor system with machined grooves 6 arranged in the upper surface 4 of the plates 1.
• the grooves are in this embodiment created in a chequered pattern, which can extend out to the edges of the plate (Fig. 4a) or end some way from the edge (Fig. 4b).
• a cable or a tube (not shown) for underfloor heating may be placed in the grooves.
• the underfloor heating coils are cast in place with liquid filler. As the grooves cross one another and are filled with heat dissipating liquid filler, the heat from the underfloor heating coils is distributed evenly on the floor.
• the grooves 6 in a chequered pattern to match a reinforcement device, e.g. a prefabricated reinforcement carpet or separate reinforcement bars laid in the grooves 6 one by one or bound to each other. If a reinforcement device is used the entire construction becomes stronger, and the separate plates are held together. When the reinforcement carpet is laid in the grooves these can be filled with e.g. liquid filler or concrete. These grooves can of course also be machined in the plate shown in Figures 1a-1d. The reinforcement then strengthens the plate as such.
• a reinforcement device e.g. a prefabricated reinforcement carpet or separate reinforcement bars laid in the grooves 6 one by one or bound to each other. If a reinforcement device is used the entire construction becomes stronger, and the separate plates are held together. When the reinforcement carpet is laid in the grooves these can be filled with e.g. liquid filler or concrete.
• These grooves can of course also be machined in the plate shown in Figures 1a-1d. The reinforcement then strengthens the plate as such.
• the edges of the plates have a bevelling 7, which may be there from the factory or which may be machined by the machine creating the decline.
• a bevelled notch appears in the joint 6 between the plates.
• This notch can be filled with e.g. liquid filler. There may thus be liquid filler both in the joints 6 between the plates and on the upper surface 4 of the plates.
• the separate plates 1a, 1 b, 1c are then moulded together to a single unit 1.
• the floor system may be manufactured by different machining/manufacturing processes.
• a single mould 9 is used, preferably made from steel or another suitable material, with a mirror shaped decline.
• Se Figure 5a showing the centre plate with the mark/hole 2 for the floor drain centrally placed on the plate as a protruding cylinder.
• the mould 9 is delimited by a frame 9a and a lower frame surface 9b having at least one determined desired radial negative slope ( ⁇ , ⁇ ) directed away from the protruding mark 2, marking the drainage point, towards the outer, lower placed, edges of the mould.
• the radial slope corresponds to the decline of the upper surface 4 of the plate.
• the mould is filled with concrete or another corresponding hardening material with possible reinforcing additives in a suitable way. It is also possible to reinforce the plates with a reinforcing net, reinforcing bars or separate needles or fibres. When the plate is finished, the upper moulding surface becomes the substantially flat lower surface 3 of the plate.
• a double mould comprising a first part 0 and a second part 11 , enclosing an inner volume that at least partially corresponds to the volume of the at least one plate 1 , 1a, 1 b, 1c.
• Figure 5b shows the central plate, which also has the mark/hole 2 for the floor drain centrally placed on the plate in the form of a protruding cylinder.
• Figure 5c shows a triangular double mould that can also be used for manufacturing plates with a circular decline.
• the first part 10 of the mould has at least one determined desired radial negative slope ( ⁇ , ⁇ ) directed away from the mark 2, marking the drainage point, towards the outer edges of the mould.
• the second part 11 of the mould has a flat inner surface, corresponding to the substantially flat lower surface 3 of the plate.
• the second part 11 of the mould can be used in the manufacture of all separate plates 1 a to 1g.
• the other moulds, intended for casting the plates that will be arranged around the central plate 1 b have no protruding part that will give the floor drain, but rather the slope goes from all points on the frame surface and has the desired shape of a part of a virtual, upwards directed, cone, i.e. no part of the lower frame surface is fully flat.
• the inner surface of the other moulds have a decline corresponding to the inner surface of the first mould so that a common decline is created.
• the plates are manufactured by supplying the material that will constitute the plate to the inner volume between the first and the second parts 10, 11 of the mould. When the material has hardened the first and the second mould parts are separated, and the finished plate with parts of a circular decline is taken out.
• a pre- warmed plate of polyamide plastics (PA) or polypropene (PP) is placed in the lower part of a shaping tool. After placing the material batch, the tool is closed and the material is pressed out in the shaping space. When the material has hardened the tool is opened, and the plate with a finished circular decline is taken out.
• PA polyamide plastics
• PP polypropene
• the decline in a flat plate it is preferably machined with a 5-axis (X, Y, Z, A and C axis) programmable mill with a work area of 3300 mm ⁇ 5000 mm.
• the mill comprises a milling spindle that can be tilted to the desired slope.
• the machine has an automatic tool changer and a vacuum table to keep the plates in place.
• the Y axis is horizontal in the longitudinal direction of the machine, the X axis is horizontal laterally transversely to the longitudinal direction of the machine and the Z axis extends vertically. Movements around the A axis tilt the milling spindle in a desired degree, and movements around the C axis rotate the spindle around its own axis.
• the decline is milled by circular or linear movements with a flat mill, and the centre point of the sewer is always the starting point for the movements.
• the floor size is milled out from the plates by cutting the edges.
• the floor may in this step be given different shapes, se Figures 3a to 3c. Holes are also milled for the floor sewer and if necessary for draining pipes from toilet and sink. The plates are then marked with a mark corresponding to an attached drawing. The waste produced is recycled.
• a chequered pattern may be milled in the upper surface 4 of the floor, which fully follows the slope of the floor. It is also possible to create a flat chequered pattern independent of the upper decline of the floor, which for example makes it possible to use a prefabricated reinforcement net.
• a "floor sewer plate” is designed in at least two varieties. In one of the two varieties the sewer or the mark for the sewer is placed centrally on the plate, in its middle point. In the other variety the sewer or the mark for the sewer is placed e.g. at least one quarter of the way into the plate from one of the plate edges.
• each separate plate is manufactured in a shape having an inner volume that at least partly corresponds to the volume of the at least one plate 1 , 1 a-1 g.
• This circular multisystem is shown in Figures 6a-6c.
• This system is built from substantially square plates 1 a-1 g, (other shapes of the plates are thus possible) where the floor drain or the mark 2 for the drainage point is centrally placed on a first plate 1 b and other plates 1 a, 1 c-1 g continue around the first plate 1 b in a radially outward directed pattern, see Figures 6a and 6b.
• the first plate 1 b with the floor sewer is manufactured in a mould.
• the radial slope of the decline on the other plates is the same for at least four of the other plates 1 a, 1 c-1g.
• These at least four additional plates are thus manufactured in a second mould which mah be reused to create several plates. This creates a flexible system with a cost effective manufacturing since only a limited amount of moulds are needed.
• Figures 6a-6c at most seven varieties of plates are shown. The system may of course be enlarged with an unlimited number of plates if desired.
• a central part of the present invention is achieving a prefabricated floor with an even circular decline from every point of the floor surface.
• the decline starts from the point where the floor sewer is placed, and the floor is to be manufactured with the smallest possible number of rectangular plates.
• a floor system with one to three plates is described, but in the case of large wet rooms it is of course possible to use more plates. In production common standard sizes of the plates are preferably used.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Floor Finish (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)
• Sink And Installation For Waste Water (AREA)
• Application Of Or Painting With Fluid Materials (AREA)
• Building Environments (AREA)
• Agricultural Chemicals And Associated Chemicals (AREA)

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• 2013
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