WO2015099541A1

WO2015099541A1 - Modular floor

Info

Publication number: WO2015099541A1
Application number: PCT/NO2014/050252
Authority: WO
Inventors: Rolf Heggland
Original assignee: Modul Tech As
Priority date: 2013-12-27
Filing date: 2014-12-23
Publication date: 2015-07-02
Also published as: NO20131740A1

Abstract

It is described module elements suitable for arrangement of a floor system and a system for laying of horizontal areas comprising a number of module elements fitting into each other in the edge areas, and where each module is carried by an underlying system of rails on which it is mounted. It is further described a method for production of the module elements, a method for assembly and maintenance of floor with the module elements, and the use of module elements in different floor systems.

Description

MODULAR FLOOR

Field of the invention The invention relates to a modular system for flooring of horizontal areas such as floors and bases in containers, scaffolds or other, in addition to a structural arrangement of elements included in the system and a method for legging of floors.

Thereby, the present invention relates to a system for flooring of horizontal areas, such as floors or bases in containers and scaffolds. The system comprises a number of plate formed elements, also called modules, for the construction of such horizontal areas. Such modules are made in a mainly rigid material, where the surface or finish of this mainly rigid material is mainly plane, to form a n

unsupported surface, and where there on the inside of this mainly rigid material is arranged an insert in the form of a core, preferably an element which is moulded into the mainly rigid material and which supports and reinforces the mainly rigid material, while the insert at the same time form a groove in the lower part of the module, where the g roove can be a protruding groove, which protruding groove is adapted for be held by a rail or scaffolding arrangement, on which rail or scaffolding arrangement, the insert, and thereby the module elements, a re arranged .

Background for the invention

In transport industry, the floors in e.g . containers, trucks, ferries etc. will be subjected to great loads, both dynamic loads when cargo is loaded or unloaded e.g . by means of forklifts or trolleys, and when the cargo is transported, and the transporting means in itself is moving, and static load from the actual cargo itself, which can have a high deadweight and be densely packed to utilize the space at a maximum. Because of this, there will be an extensive wear of the floors and breaks in floor plates are relatively common .

In contai ners, the floor is often made of chi pboards, plywood plates or the like, that are fixed to underlying beams, and it is a relatively extensive process to loosen and replace worn out and/or broken plates.

In building industry, it is common to use temporary bases or floors, e.g . in scaffolds or temporary tents or halls. In scaffolds, the decks must be lifted up to great heights if the work is done in tall buildings, and are handled before they a re lifted and when they are put in place on the platforms. As this bases also must withstand great dynamic load in addition to general wear and static loads, the decks are made with a sturdy frame and massive floor plates, which gives a high own weight.

Temporary tents and halls are also used under other circumstances, e.g. as party tents for parties, temporary halls or tents for trade fairs or sports events and to a smaller extent for use as garages or during temporary work in bad or cold weather. In these cases, temporary floors are made in the tents or halls. It is a desire that such temporary floors are easy to place, and that they at the same time are sufficiently durable and gives a good user comfort.

Therefore, there exist a lot of types of floors or bases where the above problems are relevant. Examples of such floors are floors in warehouses, floors in trailers, floors used in scaffolds, such as construction scaffolding and facades, floors in containers etc. and even floors in boats (deck/floor) or possibly in domestic residences. Prior art

To remedy the above maintenance problem(s), it has previously been common to replace the complete floor or plates. This however presents a long stoppage for the working place or storage space in question. Also on floors where there is used floor elements, it is common that these are permanently fixed to a supporting structure, where it is not possible to replace single parts of the old surface with new elements.

There is therefore a need for a system for flooring of floors and horizontal areas, where parts of or the complete floor or horizontal surface easily can be replaced, without compromising with the integrity of the floor. Such a system can for example comprise a number or modules and a rail system whereon the modules are placed, and where the rail system ensures a correct placing of the modules in relation to each other both horizontally and vertically to form a floor or horizontal areas that occur as a completely or mainly completely uniform surface.

It is an object of the present invention to present a module element suitable for use in a floor system that can be used both in transport industry, in construction industry and as temporary floors in temporary halls, tents or the like.

Further objects and advantages of the present invention will be apparent from the following description. General description of the invention

The module system according to the invention is made of module elements having mutually adjoining sides being adapted to each other so that they closely fit together on the joining edges. As an example, each module can be made of a polygonal element, for example a triangular, quadrangular, pentagonal, hexagonal etc. element, preferably quadrangular elements fitting into each other. With quadrangular elements, it is meant both quadratic and rectangular elements.

Thereby the invention relates to module elements for the formation of a continuous surface, where the module element is an elongated element of a given thickness and at least one mainly plane surface. At least one profile with an engaging part is added in the element in such a way that the engaging part penetrates a surface of the element, and so that the element mainly envelopes the part of the profile that is not penetrating the surface. Since the module element comprises profiles with engaging parts, it is possible to arrange the elements in engagement with a base, so that a relatively stable surface can be created in a quick and easy way. To further increase stability, the elements can be attached to the base by means of attachment elements. This will be further explained below.

In one aspect, the module element can be formed so that the at least one plane surface is provided with an anti-slip coating or profiled pattern. To ensure a good grip for trucks or others who will roll on the floor or for people walking on the floor, both when the floor is clean and when it is polluted by water, oil waste or other impurities, the module element can be coated with a layer with very high friction or be provided with a profiled pattern in the surface, which will give an uneven surface increasing the friction in relation to machines or people moving on the surface. Such an anti-slip coating or profiled patter is also beneficial to ensure that cargo is not moving or slipping on the surface of the elements, when the module elements are used in transport units like containers, lorries, trucks, freight wagons, trailers or other.

The profile being added in the element can be U-shaped or Π-shaped, so that the inside of the profile is accessible through the open side of the U or Π. Such a design for the profile will give a good interface between the body of the element and the profile. The sides of the U or Π will give support for battens or other being arranged in the listen, while the open side at the same time gives easy access to the base and thereby an easy way to provide engagement between the base and module element(s). The inner transverse wall of the profile will form a stop surface for battens, beams or other standing on a base and which provide the engagement between the base and module element, which is beneficial when a given distance is requested between profile element and base.

The profile can also be T-shaped with a mainly horizontal part and a mainly vertical part. When using T-shaped profiles, the vertical foot of the T will be open as described above, while the "crossbar" of the T will form wings given extra engagement with the body of the module element.

The engagement part can be provided with at least one groove between two mainly vertical wall parts. It desirable, the profile can have any other suitable shape, where the engagement part, which is accessible from outside the profile, comprises a groove between to mainly vertical wall parts, in which groove it is possible to place a batten, beam or other forming engagement and transversal stability with the module element.

In one aspect of the invention, there is one or more beams arranged in the groove in the engagement part. The beams can be attached to it. Such beams are well suited to form a bridge between the module element and a base or for creating a further reinforcement for the module elements. Elements provided with beams can for example be suitable for use in scaffolds where the beams are resting on parts of the framework of the scaffold. It is also conceivable that elements with beams can give an advantageous distance to the ground below, if the elements are used in locations such as halls or tents. This will be further discussed below.

The beam can be provided with recesses. The recesses can advantageously correspond with a part of the cross section of at least one rail. Thereby, the beam can be arranged one the rail, so that the recesses engage with the rail. This provides an easy way to form a sufficiently stable connection between base and module elements, for example when the elements are used in a scaffold. Under such circumstances, one can envisage that the elements are secured against sideways movement by being arranged between to transversal or vertical parts of the framework of the scaffold. Thereby, a longitudinal movement is prevented in that the recesses of the beams engage with a part of a rail of the scaffold framework, while transversal movement of the position of the element in relation to the framework is prevented.

In one aspect, the module element can be provided with one or more suspension fittings. Such suspension fittings can be attached to one or more sidewalls of the module element or moulded into the core during the manufacturing process. The suspension fittings can be used to suspend the module elements on a scaffold framework.

The profile can be made in metal. For example, can the profile be made in aluminium or metal, such as an aluminium profile or a steel profile, or as an extruded aluminium profile. When the profile is made in metal, it will add strength to the element, while the module elements at the same time maintains a certain flexibility. This is an advantage when the elements are moved, either as part of a floor in a transporting unit which is moving or when the elements are transported to a place where they are set together. By choosing extruded aluminium profiles, a high flexibility in the design of the cross section of the profile is obtained, while at the same time having a profile with low weight and sufficient strength.

The element can advantageously be made in an expandable or pore-forming material. The pore forming material can be a polymer, a fibre-reinforced polymer, a concrete or a fibre- reinforced concrete. By the making of the element in an expandable or pore-forming material, it is obtained a relatively firm element with a low weight.

The module elements can have a triangular, quadrangular, pentagonal or hexagonal shape, preferably a quadratic or rectangular form. The module elements have a shape that makes it easy to place a number of elements closely together to form a floor. For use in transporting units such as for example containers, it is most advantageous to use four-sided elements. However, it is conceivable when using the elements in temporary locations, that it is desirable to achieve a decorative surface. By using e.g. hexagonal elements, it is possible to create a decorative pattern in the floor. By placing the profiles or the elements asymmetrical, but mating with underlying battens, it is also possible in an easy way to arrange the elements shifted in different patterns, it this is desired to obtain a floor with a specific appearance in the surface.

The invention also relates to a system for flooring of horizontal areas comprising a number of individual module elements as described above, where each module element comprises a plate of a moulded material, in which plate there is arranged one or more reinforcing or supporting profiles, which reinforcing or supporting profile(s) has an from the underside accessible part being able to cooperate with at least one rail for securing of the module element to the rail. As the module element has integrated profiles being able to interact with one or more skinner, it is possible in an easy way to obtain a floor area by placing a number of elements side by side, or a smaller floor area by simply arranging one module element on, for this purpose arranged battens beams.

In one aspect of the system, the one or more profiles are moulded into the module. As the profiles are moulded into the element, there is created a firm engagement between the element and profile, so that the likelihood of cracks in the elements is reduced to a minimum. The accessible part can in some embodiments project or protrude from the surface of the element, through which the profile is accessible. This way, it is possible to obtain a distance between the below base and the floor itself. The protruding part will also east attachment of e.g. beams in the accessible part. The accessible part of the profile can be provided with one or more holes for fastening of bolts or screws. Thereby is it possible to easily attach a beam, list or other that is arranged in the accessible part of the profile to the profile by means of suitable attachment means, either by e.g. welding or similar attachment methods or by the use of attachment means such as bolts, screws, rivets etc.

The accessible part of the profiles can advantageously cooperate with the above mentioned rails through a snap-fit system. A snap-fit system gives a detachable connection between battens and module elements, which makes it easier to replace single elements in a finished floor arrangement. A snap system can also be advantageous when the module elements are used in temporary locations. With temporary locations, it is meant any place where people or things are staying and where the construction is of a temporary nature. Examples of such temporary locations can be party tents, trade fair halls, other large and small tents, dance floors and corresponding floors on for example sporting arrangements or concerts, both in front of and on a scene, etc.

One or more beams can be mounted on the accessible part of the module elements in such a way that recesses in the beam or beams corresponds with the shape of tubular rails in a framework. The module elements with such beams be more self-supporting and suitable for use where there is little support in

surrounding or underlying elements, as is the case when using the elements in a scaffold.

Each module element in the system has a surface mating with the other module elements, for the formation of a continuous surface by side-by-side arrangement of a number of module elements. Thereby, it is possible in an easy way to lay out the necessary number of elements for the creation of a requested area of floor surface comprising the module elements. Since the elements are mating with each other, a continuous surface is obtain with a small extent of gaps between the elements.

One or more module elements can advantageously be attached to

underlying battens by means of an attachment element. When the module elements are made in an expandable or pore-forming material, it will be relatively easy to screw attachment elements through the element itself and down into the profile and battens below. This way, an extra anchoring of the elements is obtained in a quick and easy way, that will ensure a stable floor, while the anchoring at the same time is releasable so that the module element can be replaced.

An attachment means suitable for use with the module elements can for example be a bolt, rivet or screw. This will demand low costs for attachment means and thereby anchoring of the elements to the battens, at the same time obtaining a good anchoring for module elements to battens.

The invention further relates to a method for manufacturing of module elements, preferably of the type described above, comprising the steps of:

- arranging a shell arrangement comprising to longitudinally elongated wall plates, a number of transversal battens forming a sealing transition between the wall plates, and one or more inserts, where the insert or inserts penetrates one of the wall plates in a sealed manner,

- filling a filling material in the shell arrangement, and

- removing the shell arrangement when the filler is hardened.

In a sealed manner means that the contact between the insert or inserts and wall plate in the interface between these, is sufficiently tight to prevent that the filler material flows out between the elements. The filler material in the shell arrangement will normally be relatively viscous and start the hardening process soon after being poured into the shell arrangement, so that small spaces or gaps between the insert and wall plate can be accepted.

The method gives an easy, quick and cost efficient manufacturing of module elements with moulded in profiles, that is well suited for combining to form a larger floor area.

In one aspect of the method, it further comprises the steps of:

- shifting one of the elongated wall plates outwards, so that the volume of the shell arrangement increases,

- shifting the inserts so that they continuously form a mainly sealed connection with the wall plates.

By providing a tool with movable wall plates and insert, a flexible

manufacturing process is obtained, where the density and size of the pores in the filling material can be controlled by altering the volume of the mould.

The invention also relates to a method for flooring of floors comprising the steps of:

- providing two or more battens in a parallel arrangement,

- place a first module element as described above on at least a part of the rails, so that the rails engages with the accessible part of the profile in the element,

- placing an optional next module element adjacent to the first module element, so that the listen engages with the accessible part of the profile in the element, - placing an optional number of following and adjacent element next to the first elements, until a desired size and shape of the overall surface of the module elements is obtained.

By this method for the making of floors, an floor of an unlimited size can be obtained in a quick and secure way, that is both a small floor comprising as little as one single module element and a larger floor comprising the required number of elements. Rails the elements are in engagement with, allows the user to obtain a relatively stable surface immediately. Thereby it is also easy to replace one or more elements in the floor in that the elements to be replaced are lifted up from the floor arrangement and new elements are put down. The engagement between the moulded-in profiles and battens gives a good stability in a simple and secure way.

The method for making a floor as described above can also comprise the step of attaching one or more module elements to the profile by means of at least one attachment element. Such a further anchoring of the elements to the rails gives an increased stability in the floor arrangement.

Thereby, the invention also relates to a method for the maintenance of floors comprising a number of module elements as described above, where at least one module element is removed from the floor, while one or more module elements are kept on place, where after the one or more module elements being removed are replaced by new module elements for the formation of a continuous area. As maintenance of the floor can be done in a very simple process, the down time of the floor will be short and the utilization of the floor and the space in which the floor is situated, will increase.

The invention also relates to the use of module elements or system as described above, for parts of or the complete floor in a transporting unit. Such a transporting unit can be a container, a truck, a freight wagon, a vessel. The elements are made in a filling material having a certain flexibility, while the embedded profiles provides rigidity to the module element. The flexibility in the element, enables the element to bend to a certain degree as a response to natural movements of the transporting unit, for example when it is moving- The will increase the lifespan of the module elements. The strength of the profiles makes the elements to a certain degree self-supporting, so that a sufficiently sturdy floor is obtained with few underlying elements.

The invention also relates to the use of module elements or systems as described above as deck in a scaffold. The elements are provided with suitable anchoring arrangements such as beams with recesses or anchoring hooks, so that the elements can be placed onto or suspended in the framework of a scaffold. Since the elements are made in a foam material, a low weight of the elements is obtained, which makes it easier to handle the elements up into a scaffold that heavier deck plates.

The invention also relates to the use of module elements or systems as described above as temporary floors in temporary locations. The module elements are easy to handle due to a relatively low weight in relation to their size and are therefore well suited for temporary use, where the elements must withstand extensive handling such as placing, disassembling, transport and storing.

Furthermore, the system comprising module elements and battens comprises few different elements, which makes it easy to use without comprehensive training. This is also an advantage in this kind of use.

Examples of the module system and the structure of each module will be further explained below with reference to the attached figures where:

Fig. 1 shows a sectional view of an embodiment of a tool for the production of an exemplary module element for a module system according to the invention.

Fig. 2 shows a schematic view of an embodiment of the tool for production of modular plate elements, as shown in fig. 1.

Fig. 3 shows a sectional view of the tool used for production of a module element according to the invention, during production of an element.

Fig. 4 shows a sectional view of a corresponding embodiment of a module element as shown in fig. 3, but where the upper wear plate has been shifted in vertical direction at the injection of a filling material in the tool.

Fig. 5 shows in sectional view the basic principles of a tool for the production of module elements according to the invention.

Fig. 6 shows in sectional view the mounting of a module element as shown in figs. 1-4, provided with a holding rail for the module element according to the invention.

Fig. 7 shows in perspective a sectional view of the construction of a floor with one embodiment of a module system according to the invention.

Fig. 8 shows in perspective view a sectional view of a floor arrangement with module elements according to the invention.

Fig. 9 shows in perspective view the floor arrangement in fig. 8 with module elements according to the invention.

Fig. 10 shows in perspective view of the floor arrangement in fig. 8 seen from below. Detailed description

The figures 1 to 4 shows different steps in a production process to produce module elements according to the present invention. Fig. 1 shows in sectional view the middle part of an embodiment of a module element 1 according to the invention. The plate element 3 is moulded around the insert 2 in a separate special tool comprising a mould, which will be further explained below. Under production of a module element 1, one or more inserts 2 are placed in an insert holder 4 in the tool. The insert holder is in relation with a mould enveloping a hollow space corresponding to the shape of the module element.

Figure 2 shows a side view of a tool arrangement suitable for the production of module elements in different sizes. The mould 5 comprises an outer shell arrangement 6 and one or more mainly vertical battens 7. The battens 7 are used to delimit the mould 5 lengthwise, so that the size or surface area of the module element to be produced can be limited or expanded by sideways shifting of the mainly vertical battens 7. The exemplary shell arrangement 6 can be used to produce symmetrical module elements in the widths, in addition to a number of asymmetrical module elements. The inserts 2 and battens 7 are arranged in the shell arrangement 6 before the filling material is filling the hollow space around the inserts 2. The inserts 2 are fixed by means or the insert holders 4, as shown in fig. 1.

An expanding filling material 8 is filled in the shell arrangement 6, se fig. 3. The wall plates 9 of the shell arrangement 6 together with the transversal rails 7 and one or more inserts form a closed hollow space. This one of the wall plates 9 form the part of the shell arrangement 6 that will be the surface of the module element. This wall plate 9 is movable and is held by an number of cylinders. The shell arrangement 6 is gradually moved outwards as the filling material is expanding after introduction in the mould. By controlling the moving speed of the wall plate 9 and rails 7, the surface of the module element can be controlled with regard to hardness and pore size in the filler. Since the expansion of the filling material is controlled by movement of the shell arrangement or wall plate 9 and rails 7, a more even quality is obtained in the element, with a more even pore size in the filler or even smaller pores.

Thereby, for the moulding of module plates, there can be made a tool for plate production, where the plate dimensions can be varied up and down. Under production of module plates according to the invention there can furthermore be moulded into the module body 1 inserts 2 of for example aluminium or steel. The module bodyl is moulded in a mould and holders 2 are held in place during the moulding process by means of one or more holders 4. The holders 4 are supported and locked as shown in fig. 1. The side walls 7 will follow when smaller modules are moulded, so that the side walls are sealed towards the top plate.

Fig. 5 shows a view of the basic principles of a tool for the production of module elements according to the invention. The tool comprises a shell

arrangement with a first and a second longitudinal wall plate 9, 9' and a number of transversal battens 7 forming a wall connection between the wall plates 9, 9'. Two way arrows are shown at the side of the movable parts, to show the moving direction of these parts.

One of the wall plates 9 is fixed and is therefore not movable. This wall plate

9 is provided with a number of valves 19, suitable for injection of compressed expandable material. In the drawing, it is shown to valves, but it is obvious to a person skilled in the art, that it is possible to assign the number of valves necessary to fill the shell arrangement with filling material, such as expandable material, but with a sufficient hardness and a sufficiently even distribution. An example of a suitable valve can be a needle valve, but a skilled person within the art is free to choose the type of valve being most suitable for each specific tool.

Furthermore is there in the non-moving wall plate provided conducts suitable for the arrangement of profiles 2. On fig. 5 there is shown to different embodiments of a profile 2 suitable for being embedded in the module element. However, at the production of module elements it will be natural to arranged a desires amount of similar profiles in the shell arrangement. The two profiles on fig. 5 should be understood as a suggestion of possible profiles and how where can be arranged in the shell arrangement.

For one of the shown embodiments of a profile 2, there is arranged an i nsert holder 4 in the profile 2, to keep it in place during the production process, that is during filling and hardening of filling material in the shell arrangement. For the second shown embodiment of a profile 2', there is arranges an insert holder 4 around the protruding part of the profile 2' and a movable insert holder part 4' which will hold the profile 2' steadily towards the insert holder 4 during the production process.

The second wall plate 9' is movable outwards and inwards, so that the volume in the shell arrangement can be increased or decreased. The wall plate 9' can be moved in any suitable manner. In the shown example, hydraulic cylinders 10 are connected to the wall plate pulling the wall plate forwards and backwards, as outlined by arrows at the side of the cylinders.

When the second wall plate 9' is moving, the rails 7 are moved a

corresponding distance, so that there is always maintained contact between the listen 7 and both wall plates 9, 9'. It is especially important that the rails deli miting parts of the hollow space of the shell arrangement, but which are not the outermost, are movable and continuously in contact with the movable wall plate 9'. Listen 7 is moved by mechanical or hydraulic means being coupled to the rails in ordinary ways.

The production method can be performed as the following :

1) Before moulding, one or more profiles 2 in metal or another material with high rigidity are introduced into the tool. The insert can for example be aluminium profiles, for example profiles from extruded aluminium or steel profiles, for example rolled and welded profiles. The profiles 2 are supported and locked in the insert holders 4, as shown in fig. 1.

2) Module elements can be moulded by adding battens moving vertically with the drawing at foaming of the filling material, see figs 2 to 5.

3) Moulding of sandwich, see figs. 3 and 4. A foaming agent is added to the compressed expandable material with a given speed where the foaming material is evenly distributed in the mould before the material is crystallised, under sufficiently high pressure to obtain the requested injection speed. Calculation of the injection speed is done in generally known manners. When the injection is finished, the valves are closed and the foaming process is started, e.g . in that the drawing plate 9 in one half of the tool is released and moved with a speed being controlled by the drawing cylinders. In this way it is obtained an even and controlled foaming, which gives an optimum structure with evenly sized cells in the foam.

The foaming can take place in that gas pockets are created in the polymeric material 17 between the drawing plate and the surface of the module through a chemical process, for example by the creation of pockets of carbon dioxide or the foaming can be done mechanical in that vacuoles are created in the polymeric material 17 when the drawing plate 9' is raised by means of the cylinders 10.

Additionally, the cylinder 10 holds the drawing plate 9' in correct position. Injection is performed in a generally known way. Injection speed, drawing speed/pulling time and counterweight for the cylinders are decided for each situation to obtain optimum core structure and pore size and distribution.

The thickness of the surface or skin of the element is decided by the time before releasing the drawing plate. With skin it is meant the outer layer that will form the surface of the element. The tool is made in such a way that it can produce plates or modules with different thickness. Injection of material is done through a manifold distributing the material to a number of injection/closing nozzles or valves. These nozzles or valves, for example needle shut-off nozzles are closed hydraulically or mechanically at the end of the injection cycle. Ejection or unmoulding of a ready moulded detail is done by releasing the hydraulic pressing device for the steel inserts and ejection can start. The thickness is decided by shifting the drawing plate 9' outwards the desired distance. If the drawing plate 9' is shifted less, a more compressed material is obtained. The height of the side walls decides the height limit for the element.

4) The module elements are mounted on beams 11, see fig. 6. Under the mounting of such beams, the module elements are place side by side directly on an area, so that the module elements 1 together form a floor arrangement.

The system according to the invention has great flexibility, there can be produced a number of products where each module plate is mounted on supporting constructions. Strength requirements for the product are easily met by individual adaption of shape and thickness of embedded profiles and beams.

The mounting system according to the invention comprises modules or elements, as shown in figs. 1-10. Each of these modules or elements 1 comprises one or more inner attachment and reinforcing profiles, which are arranged as inserts 2 in the module elements. In one of the shown embodiments, the inner profile(s) have a T-shaped cross section, where the horizontal and transversal part of the attachment and/or reinforcing profiles in this embodiments run parallel with the mainly horizontal upper surface of the module, see e.g. fig. 3. The mainly vertical part 13 of the profile 2 is stretching out in at least the surface 14 of the module element 1, but can also protrude from the module element, thereby also being able to function as a spacer when mounting the module elements on the place where they are being used.

The inner attachment and/or reinforcing profiles 2 are preferably moulding in the material of the module 1 in question. The moulding material of the module or element 1 can preferably be an expanding mass, such as different types of expandable material, such as plastic material with an added foaming agent, but it can also e.g. be concrete, other plastics or other mouldable material. The embedded attachment and/or reinforcing profiles 2 can be made in a stiffening material such as a metal, e.g. steel or aluminium. However, it is also conceivable that the profiles are made in for example fibre reinforced plastic material or other types of metals, as long as the profiles add the sufficient strength and a certain flexibility to the module element.

It is also possible to assemble the floor or base in question by modules that as similar or different with regard to shape and/or composition and/or design to create variations in the floor area with regard to shape, structure and/or colour.

The mainly vertical part 13 of the T-shaped profile is designed as a mainly vertical downwardly protruding part comprising one or more grooves. In the shown embodiment, the profile comprises a groove being formed between two downwardly protruding parts of the profile 2. The groove ca n run along parts or the complete module 1 in transversal or longitudinal direction.

When the terms "longitudinal" or "transversal" are used, it refers to an element with a rectangular upper area, where the longest side of the rectangle is the "longitudinal" side and the shortest side of the rectangle is the "transversal" side.

With the skin of the module element it is meant the outer layer that will form the surface of the element, that is the 1- 10 outermost mm of the element, e.g. the outer 1-2 mm of the element in a plate with a thickness of 28 mm.

An embodiment of a mounting system according to the invention is shown in fig2. 7a and 7b. The mounting system comprises a number of rails 12 in addition to the module elements, on which rails 12 the profile 2 can be placed by means of the vertically protruding part 13. The rail and the mainly vertically protruding part 13 are mutually interacting parts in the shown embodiment. The profile of such interacting parts can be chosen by the skilled person, but it is preferred that they do not contain barbs, since barbs can make it more difficult to replace the modules 1 on the rails 12. However, the interacting parts can be designed with a click or snap system where e.g. the rail is made as a rod with a round or oval cross section and the protruding part 13 comprises a gripping profile that suitable can fit releasable around the rail profile 12. Alternatively, there can be provided a number of bulges or recesses in the inner surface of the vertical part 13 of the profi les 2, corresponding to recesses or bulges in the outer surface of the rails 12, so that the module elements to some extent are locked in position when the bulges are placed in the recesses. However it is preferred that the interacting parts 2, 12 have mutual at least mainly smooth surfaces, so that they easily slide mutual to each other.

If the interacting parts 2, 12 does not have a snap locking, e.g. as explained above, the interacting parts can in one embodiment be locked to each other by means of attachment elements, for example one or more screws, self-boring screws or locking bolts 14, see fig. 7b. Such locking bolts are attached for example through the fill material and further down into the profiles 2 and rails 12. Alternatively the interacting parts can be locked to each other by means of an adhesive or they can be welded or soldered to each other. However it is preferred that the locking of the interacting parts 2, 12 is reversible, so that the parts can be released from each other if it necessary to replace one or more separate module elements. Each module element 1 can comprise one or more profiles 2 with protruding parts 13, interacting with corresponding rails 12 on the base or scaffold in question. The rails holding the module elements according to the invention can be placed on framework and scaffolds or on horizontal areas, e.g. floors in storing spaces, in trailers, as deck in boats etc. The material in the rails 12 is preferably metal, such as aluminium, iron, stainless steel, hard plastics, as for example PVC (polyvinylchloride), PU (polyurethane), PE (polyethylene), PS (polystyrene), etc., carbon fibre reinforced hard plastics, a ceramic material or other. However, it is preferred to use aluminium and/or stainless steel.

To replace the tread surface of the floor in question, the appropriate one or more worn out modules 1 are replaced . Possible locking bolts or other are released, so that the module elements are lying freely on the surface. Thereafter, the worn out module elements can be lifted up and exchanged with new ones, while the module elements that are not worn out remains on place. It beams 11 are attached to the vertical part 13 of the inserts 12, see fig. 6, the module elements 1 with beams 11 can be lifted up from the floor arrangement with module elements and replaced.

As an example it can be moulded sizes of the modules in any width or form, as long as the module elements are suited for assemblage to a floor arrangement. For example can module elements with a width of 500 and 400 mm be produced on the same shell arrangement in a production tool in that battens 7 are placed inside and delimiting the moulding or foaming hollow and that can be moved sideways during the course of the moulding or foaming process, if requested.

The supporting parts and profiles of a floor system according to the invention, such as embedded profiles, rails and beams are dimensioned according to geometry and thickness based on strength requirements and loads each product will undergo. Decisions for the sizes being used in each circumstance will be done by the skilled person. E.g. a container floor must support the load of a fork lift, that is the axle load of the fork lift distributed to the wheels of the fork lift, and the weight of the cargo being placed on the floor. The floor should also support both static and dynamic loads, as explained above. The foam material being crystallised is elastic and supports a large deflection. Containers are continuously moving, the plates take up dynamic loads from the movements. Fork lifts arriving with cargo gives dynamic loads. Normal known floors support the static load, but breaks due to dynamic loads.

To form tight edge joints between the module elements in a container floor, sealants or sealing elements can be used. An example of the use of sealing elements is to provide grooves in the side walls of the module elements where an O-ring or sealing list with an O-shaped cross section is put in the interface between two adjacent module elements. Based on the choice of materials, where e.g. plastic will have a poorer strength than metals, e.g. steel or aluminium, the sizes and dimensional relations of the parts will be given for the skilled person.

As the element is moulded in a porous material, a low weight is obtained for the element, at the same time will the embedded profiles provide great strength. The element will have a sufficient strength to be unsupported. The inherent elasticity in the materials being used to produce the module element furthermore makes the elements withstand both static and dynamic loads. This combination of properties gives a very user-friendly and versatile element that can be used in almost any situations where a floor area is needed.

With reference to figs. 7a and 7b, module elements 1 are shown in the form of plates with embedded profile 2 to take on strength and mounting to supporting constructions. The profiles 2 can be in steel, aluminium or other material such as hard plastics. The plates are put together to a floor area such as a container floor or floor in a warehouse or vessel. The plates are arranged so that the embedded profiles fit with corresponding rail profiles 12, e.g. arranged on floor. If desirable, the module elements 1 can be attached to the rail profiles 12 by means of locking bolts or the like. It is conceivable that the rails are part of a supporting

construction. Mounting is simple and secure and form a stable construction.

Damaged module elements are easily replaced, if the plates are fixed by locking bolts or self-drilling screws 14, see fig. 7b.

The load-bearing profiles, such as embedded profiles, rails or beams, are dimensioned according to the knowledge of the skilled person, based on geometry and thickness and based on the strength requirements for each floor arrangement.

Figs. 8-10 shows an embodiment of a floor arrangement with module elements according to the present invention. The module elements 1 are provided with three transversal inserts in the form of T-shaped profiles 2, where the mainly vertical part 13 projects under the element 1. Furthermore, the mainly vertical part 13 has a longitudinal groove, as explained above. Beams 11 are attached to the groove of the mainly vertical part 13 of the profile 2. The beams can

advantageously be attached to the profile with bolts, screw or the like.

In this example of an embodiment, the beams 11 have a cross section like a isosceles cross, where the upper vertical leg of the cross is attached to the vertical part 13 of a profile 2, where the sideways legs are projecting as mainly horizontal stiffener, and where the lower vertical leg has a number of recesses corresponding to parts of a frame work, for example on a scaffold or as floor battens in a container, trailer or marine floor. Thereby, the module elements 1 ca n be places on the frame work (not shown) and will then lie in steady engagement with the frame work and at a distance to the underlying constructions or floor. The module elements 1 can be fixed to the frame work with screws or bolts or by gluing, welding or other suitable attachment method . If a module element 1 is damaged or worn out, it is easy to release it from the frame work and replace it with a new element 1, while the module elements that are not damaged or worn out stays in place.

At the installation of beams one the module elements, elements are obtained that are suitable for use on scaffolds, so-called crossbar, that is transverse plates or decks, that is longitudinal plates. By the use of module elements in scaffolds, there can be a gap between the individual module elements for draining and unwatering. Such a gap can be up to 15 mm in breadth. However, it should be noted that the floor in a container should be tight, so that gaps between the element cannot be accepted. On contrary, it will often be added extra sealing elements or sealant, as explained above.

To place the load-bearing beams 11 on top of a frame work in a scaffold (not shown) or possibly directly on battens on the base, the rails 16 of the frame work can be arranged parallel to each other, see fig. 10, preferably in longitudinal or transversal direction of the space in question, but they can also be placed in another direction, for example diagonally. However, in that case the form of the recesses in the beams or vertical parts of the module elements 1 in question should be adapted to the direction of the rails 12, 16, if it is requested a specific aesthetic design of the finished floor, if the frame work must be adapted to the shape of the room in question or on account of something else. However, it is most practical if the beams 11 generally are placed perpendicular to the rails 12, 16.

As shown in Figs. 8-10, the module system for flooring of horizontal areas according to the present invention comprises a rail system comprising singular rails 12, 16 fitting into the embedded profiles 2. The interacting areas between the rails 12, 16 and embedded profiles 2 are smooth in the shown embodiments, so that the embedded profiles are easily placed on the rails 12, 16, so that the rails 12, 16 falls into place in the groove in the profiles 2 or the beams 11 falls onto the rails 16 of a frame work. It may also be possible to design the rails 12, 16 with grooves and the profiles 2 with one or more projecting flanges fitting onto the groove or grooves.

Regarding the structure of a module element, can such an element have a varying thickness in the longitudinal direction, where the length that is not affected by the insert, has a thickness f, an intermediate phase d between the lengths without inserts and the length with inserts, has a slanting thickness and where the length with inserts has a thickness a+b+c, where a and c indicate the thickness of the filling material over and under the insert, while b indicates the thickness of the insert 2. The thickness a+b+c of the length a, where the insert 2 is embedded in the core of the element 1, can have a thickness larger than the thickness of the unaffected parts. See for that matter fig. 1. It should be noted that the suggested proportional numbers are suitable for use with scaffold platforms. However, the proportional numbers will be different for a container floor, see fig. 7a.

The size of the intervals a, b and c can be equal or different, but it is preferred that the size of the intervals a and c are mainly equal, while the size of the interval b corresponds principally with the thickness of the horizontal part of the supporting profile 2. Due to the embedding of the supporting profile 2 in the module 1 according to the present invention, a middle part e of the support profile 1 can in its lower part be thicker than the outer are of the module 1 to provide sufficient strength to the element at the inserts 2. Such an element 1 with varying thickness will be an advantage when beams 11 are used for mounting of module elements on a frame work, such as supporting beams or rails 16 in a scaffold, as shown in figs. 8-10.

In horizontal direction, the different sizes of the module 1 is divided into the following intervals: e = the breadth (or length) of the supporting profile 2; d = the distance between the end of the support profile 2 and the start of the outer region of the module 1, g = thickness of the outer part of the insert holder 4; i = thickness of the facing outer part of the insert holder 4. Between the region g/h and h/i there is a distance corresponding to the thickness of the projecting parts 13 of the support profile 2. In one embodiment, the distance is equal, however each projecting leg 3 does not necessarily have to have the same thickness for the system according to the present invention to function. Thicknesses and dimensions are determined according to use and strength requirements. The solution is very flexible with regard to dimensioning and adaption.

However, it is conceivable that the elements 1 have a mainly constant thickness, where the inserts 2 follow the surface of the element instead of being protruding, as shown in fig. 7. This is beneficial with the use of module elements in such a way that the embedded profiles 2 are lying directly on rails 12 on a floor space or similar.

The width of each module element can be moulded in different sizes and the width can also be varied based on the distance between the transversal rails 7. In the course of moulding different widths in the shell arrangement of the tool, the individual transversal rails 7 can be used.

The upper surface of the module element 1 is raised in situ during production of the element after injection of an pore forming or expandable material 17 between the draw plates 9, 9' and rails 7 delimiting the module element 1. The situation after completion of the injection of an expandable material 17 is shown in fig. 4 where the original placement of the draw plate 9' is marked and where the expansion of the expandable material is shown with dotted lines. In this case the draw plate 9' has moved a distance x vertically corresponding to the distance y, z the cylinders 10 have pulled the draw plate upwards. Thereby the sizes in fig. 4 x = y = z.

Detailed decisions on thicknesses and placing of support profiles and rails can however from the present description be determined by a skilled person without excessive experimenting.

Figs. 8 to 10 shown an example of an embodiment of the invention used on crossbars or decks for a fagade or scaffold, where the module system is used. Three plates 1 are in this case attached to three carriers 16 with bolt/screw 18. The example shown here shows a Haki crossbar placed crosswise. Other known scaffold systems place floor or platforms lengthwise. Attachment devices for suspension is then done on the carrier itself, and will not be in conflict with the module plates.

Production is effective and material saving, and thereby cost efficient. The plates have a low weight and great strength by expansion of plastic material, so- called sandwich. The method gives an even structure of the material with closed and evenly sized cells in the foam.

However, it is also conceivable to have other forms of moulding of the module elements, for example in fibre reinforced plastic, concrete or fibre reinforced concrete. Preferably, there sis used a mouldable material with great strength and low own weight, for example different form of materials with pore formation during moulding or forming.

Example 1 : Production of module element

It is chosen an expandable filling material with a preferred melt index, that is the filling material should crystalize before it penetrates possible joints. It is used meld indexes that gives a sufficiently viscous material that will not flow out, but sufficiently liquid to get evenly distributed in the mould. Preferred melt index according to ISO 1133 at 230 °C and 2, 16 kg, gives 10,0 to 13,0 g/10 min.

It is chosen a mould with plate dimensions of 120 x 250 (width) cm and where introduced battens give widths of 125 cm or 82 cm.

By the use of a 3700 ton injection moulding machine, with injection during

8-10 sec, it is necessary to use a pressure between 120 and 130 kg/cm², preferably around 125 kg/cm², and a temperature of 200-250 °C for a module element of 120 x 250 cm. Example 2: Use of module element

A container floor should withstand a forklift load of 7260 kg, i.e. an axle load of 7260 kg divided on the wheels of the forklift. Dimensioning for a forklift load of 7260 divided on two sets of wheels is according to ISO standard

It is used cross beams that are already part of the container in addition to guiding battens being lied over the cross beams. The module elements are placed against each other on cross beams and the guiding battens until the complete container has a floor. Self-drilling screws are screwed through the module elements and down into the cross beams. The interfaces between the module elements is sealed with elastic sealant and the sealant is evened out to form a smooth floor surface. The interfaces between the module elements can also be sealed with an CD- ring or the like, as described above.

If a module element is to be replaced, the self-drilling screw is screwed out of the element. The module element is lifted up from the floor and a new module element is placed down. The new module element is fixed to the cross beams with self-drilling screws. The interfaces between the new module element and the remaining floor is sealed with sealant.

The floor in a container should also withstand both static and dynamic loading. The module elements according to the present invention combine low weight and great strength and can at the same time stand both static and dynamic loads.

The profiles being embedded in the module elements provides strength to the plates. These profiles can have any desired shape, but should have a groove or a projecting part that can engage with adjacent battens. The profiles can be provided with extra wings for further strength.

Module elements as described above provides increased strength and great durability compared to known floor plates or bases. They are at the same time easy to arrange and simple to replace. The module elements are also easy to handle in that they have a lower weight and are made in a stronger material than for example chipboards or "forklift-reinforced plates", which is being used among other in containers.

The module elements according to the present invention has a broad spectre of areas of use, both within transport, in containers, trailers, truck bodies or lorries, goods wagons, vessels, etc., within construction industry, in scaffolds, halls, quays, warehouses and within temporary structures, such as different halls and tent arrangements. It is described module elements suitable for laying or flooring of a floor system and a system for laying or flooring of mainly horizontal, plane areas comprising a number of module elements fitting into each other in the edge areas, and where each module is carried by an underlying system of rails to which it is mounted. It is further described a method for production of the module elements, a method for laying and maintaining floors with the module elements and the use of the module elements in different floor systems.

Claims

P a t e n t c l a i m s

Module element (1) for mounting of a continuous area, characterised in that the module element is an elongated element of a given thickness and with at least one plane surface, at least one profile (2) with an engaging part (13) is embedded in the element in such a way that the engaging part (13) penetrates a surface of the element, and that the element mainly envelopes the part of the profile (2) which is not penetrating the surface.

Module element (1) according to claiml, comprising at least one of the following features:

- the at least one plane surface is provided with an anti-slip coating or profiled pattern,

- the engaging part (13) is provided with at least one groove between two mainly vertical wall parts,

- the module element (1) or the beams (11) of the module element is/are provided with one or more suspension fixings.

Module element (1) according to claim 1, where the profile (2) is U- shaped or Π-shaped, so that the inside of the profile (2) is accessible through the open side of the U or Π or the profile is T-formed with a mainly horizontal part and a mainly vertical part (13).

Module element (1) according to one of the proceeding claims, comprising at least one of the following features:

- a beam (11) arranged in the groove of the engagement part (13) or arranged in the groove of the engagement part (13) and attached to it,

- the beam (11) is provided with recesses,

- the recesses correspond to a part of the cross section of at least one rail (16).

Module element (1) according to one of the proceeding claims, where the profile is made in metal.

Module element (1) according to claim 10, where the profile (2) is made of an extruded aluminium profile or a steel profile. Module element (1) according to one of the proceeding claims, where module element is made in an expandable or pore forming material.

Module element (1) according to claim 12, where the expandable or pore forming material is a polymer, a concrete, a fibre reinforced polymer or a fibre reinforced concrete.

9. Module element (1) according to one of the proceeding claims, where the module element has a triangular, quadrangular, pentagonal or hexagonal shape, preferably a quadratic or rectangular shape.

System for flooring of horizontal areas comprising a number of individual module elements (1) according to one of the claims 1-9,

characterised in that each module element (1) comprises a plate (1) in a moulded material, in which plate (1) there is arranged one or more reinforcing or supporting profiles (2), which reinforcing or supporting profiles (2) has an accessible part (13) on the underside of the module element (1) interactable with at least one rail (12, 16) for holding of the module element (1) onto the rail (12, 16).

System according to claim 10, comprising at least one of the following features:

- the one or more profiles (2) is/are embedded in the module (1), the projecting part (13) comprises one or more holes for attachment of bolts or screws,

- the projecting part (13) of the profiles interact with the rails (12, 16) through a snap system.

System according to one of the claims 10-11, where one or more beams (11) are mounted to the projecting part (13) of the module elements in such a way that recesses in the beam or beams (11) corresponds with the shape of the tubular rails (16) of the frame work.

System according to one of the claims 10-12, where each module element of the system has a fitting or mating shape with the other module elements for the formation of a continuous surface by a side by side arrangement of a number of module elements (1). System according to one of the claims 10-13, where one or more module elements are attached to underlying battens by means of an attachment element.

Method for production of a module element (1) according to one of the claims 1-9 comprising the steps of:

- arranging a shell arrangement (6) comprising to longitudinal elongated wall plates (9), transversal battens (7) forming a sealing transition between the wall plates and one or more inserts (2), where the inserts penetrated a lower mainly horizontal wall plate in a sealed manner,

- filling filling material into the shell arrangement (6), and

- removing the shell arrangement (6) when the filling material has solidified.

Method according to claim 15 further comprising the steps of:

- shifting one of the elongated wall plates (9') outwards, so that the volume inside the shell arrangement increases,

- shifting the battens (7) so that the continuously form a mainly tight connection with the wall plates.

Method for laying of floor comprising the steps of:

- arranging a number of rails (12, 16) in a parallel arrangement,

- placing a first module element (1) according to one of the claims 1-9, on the battens, so that the rails are in engagement with the accessible part (13) of the profile (2) of the element,

- placing an optional next module element (1) according to one of the claims 1-9, adjacent to the first module element, so that the rails are in engagement with the accessible part (13) of the profile (2) in the element,

- placing an optional number of further and adjacent module elements against the first module elements, until a requested size and shape of the total surface of the module elements is obtained.

18. Method according to claim 17, further comprising the step of:

- attaching one or more module elements according to one of the claims

1-9, to a rail (12) by means of an attachment element (4). Method for maintenance of floor comprising a number of module elements (1) according to one of the claims 1-9, where at least one module element (1) is removed from the floor while one or more module elements (1) are remaining, where after the one or more module elements being removed are replaced with new module elements (1) for the formation of a continuous area.

Use of module elements according to one of the claims 1-9 or system according to one of the claims 10-14, as floor in a transporting unit or as deck in a scaffold or as temporary floor in a temporary location.