WO2018007731A1

WO2018007731A1 - Composite slab and covering system comprising such slabs

Info

Publication number: WO2018007731A1
Application number: PCT/FR2017/051788
Authority: WO
Inventors: Robert Heinrich
Original assignee: Etablissements Heinrich Bock Et Cie
Priority date: 2016-07-05
Filing date: 2017-07-03
Publication date: 2018-01-11
Also published as: FR3053710A1

Abstract

The present invention concerns a composite slab, in particular for producing coverings for indoor or outdoor floors or terraces. A slab (1) consisting of a solid and rigid top display plate (2), rigidly secured to an underlying shock-absorbing layer (3) made from a resilient material with a density of 40 to 80 kg/m³, at least the lower face (4) of which, in contact with the surface on which the slab rests, has a layer (5) for keeping the slab (1) intact in the event of the display plate (2) breaking, said layer (5) for keeping the slab intact being made from a compact material with a density of 800 to 1600 kg/m³.

Description

COMPOSITE SLAB AND COATING SYSTEM

COMPRISING SUCH SLABS

The present invention relates to the field of building and public works, particularly the surface surfaces support for pedestrians and / or vehicles, such as outdoor or indoor flooring, roads, terraces or the like.

The invention more specifically relates to a composite slab for forming such coatings and a modular coating system implementing these slabs.

Rigid slabs made of concrete (whether or not surface-grained), ceramic or a similar material are already known which can in particular be installed with wedging on adjustable studs to form modular and removable coatings, with interstices between the adjacent slabs.

Slab-type pavements allow for pedestrian traffic, rainwater drainage and can be easily replaced in the event of damage or deterioration (of one or more slabs or the support).

Other coatings can be placed directly on a concrete screed, more or less loose soil such as sand and / or gravel.

However, the known rigid slabs have a hard and rigid surface which perfectly marries only strictly flat surfaces. In case of the presence of a game, even minimal, slabs can tilt creating an annoying noise interference or be weakened when they rest cantilevered. The installation of rigid slabs on studs is therefore delicate and requires in practice many adjustments and adjustments operations. In case of breakage, for example during an overload, the slab may burst into a multitude of sharp fragments. The user may sink or even fall through the slab, become completely stuck and be injured or damaged by debris and / or sharp fragments created.

The installation can be made even more difficult when, besides the problems of flatness and alignment, is added that of ensuring an effective evacuation of rainwater and / or runoff. For this purpose it is generally expected a spacing of a few millimeters between the various slabs to allow water to infiltrate and be absorbed by the soil or by an underlying drainage system, which complicates the proper positioning individual of each slab.

The general problem of the present invention is to provide a slab, for indoor and outdoor use, capable of being implemented to form coatings on pads or other stabilized surfaces and which does not have at least some of the disadvantages referred to above.

For this purpose, it relates to a composite slab, in particular for the production of interior or exterior flooring or terraces, characterized in that it consists of an upper, solid and rigid exposure plate, firmly attached to a underlying shock absorbing layer and made of a resilient material, preferably a thermoplastic material such as expanded polystyrene, a resilient material with a density of 40 to 80 kg / m ³ , at least the lower face of which is in contact with the surface on which the slab rests, has a layer for maintaining the integrity of the slab in the event of breakage of the exposure plate, said holding layer being made of a compact material, preferably a compact thermoplastic material such as compact polystyrene, preferably extruded, said compact material having a density of 800 to 1600 kg / m ³ .

Other features and advantageous embodiments are described below.

The invention will be better understood from the following description, which refers to preferred embodiments, given by way of non-limiting examples, and explained with reference to the appended diagrammatic drawings, in which:

Figure 1 is a side sectional view of a composite slab according to the invention;

Figure 2 is a top view of the composite slab of Figure 1 that has been cut in a horizontal plane at the shock absorbing layer, at the level of the presence of the channels;

Figure 3 is a bottom view of a composite slab according to the invention as shown in Figures 1 and 2 at the level of the holding layer; Figures 1 to 3 of the accompanying drawings show a composite slab 1, in particular for the realization of floor coverings or terraces, for example of type slabs on pads or soft ground stabilized.

In accordance with the invention, the composite slab 1, in particular for the production of interior or exterior floor coverings or terraces, is constituted by an upper, solid and rigid exposure plate 2, firmly secured to an underlying layer 3 shock absorber and made of a resilient material, preferably a thermoplastic material such as expanded polystyrene, resilient material with a density of 40 to 80 kg / m ³ , at least the lower surface 4, in contact with the surface on which the slab rests, has a layer 5 for maintaining the integrity of the slab 1 in the event of breakage of the exposure plate 2, said holding layer 5 being made of a compact material, preferably a compact thermoplastic material such as compact polystyrene, preferably extruded, said compact material having a density of 800 to 1600 kg / m ³ .

Said resilient material of the underlying layer 3 and / or the material of the holding layer 5 may be preferentially selected from the group formed by thermoplastic plastics such as acrylic polymers, in particular PMMA or PAN, cellulosics (ethers, esters, etc.), polyamides, polyesters such as PET or PC, polyolefins, such as HDPE or LDPE, PP, polyurethanes, styrenics such as PS, vinyls (PVC, PTFE, polyacetates ...), as well as their mixtures.

Preferably, the materials used for the two aforementioned layers are identical or substantially identical (chemically) but have substantially different densities to achieve the different desired physical properties.

Advantageously, the resilient material of the underlying layer 3 and / or the material of the holding layer 5 incorporate glass fibers.

A particularly preferred embodiment consists in using a single material, which is chemically identical or almost identical, for the resilient material and the compact material, the difference being essentially in the density of the latter. For example, polystyrene (PS) can be used for the resilient material (low density PS) and the compact material (high or very high density PS). This includes Γ advantage of reducing costs, simplifying the manufacturing process and implementation and minimizing any problems of compatibility between materials.

According to one embodiment, the composite slab 1 according to the invention is characterized in that the holding layer 5 extends over the entire lower face 4 and over part of the lateral flanks of the underlying layer 3.

Advantageously, the composite slab 1 according to the invention is characterized in that the holding layer 5 extends over the entire lower face 4 and over part of all the lateral flanks of the underlying layer 3, preferably without reaching the display plate 2.

This allows to retain, in case of shock and rupture, the various fragments from the broken exposure plate 2.

If it may be desirable to keep a portion of the underlying layer 3 free of any coating by the holding layer 5, for example on some strips and / or on some sides of the slab 1, for example to ensure some flexibility or flexibility at this level, or to reduce manufacturing costs, better debris retention will be obtained when said holding layer 5 coats the entire underlying layer 3 all around. The lateral fixing means 7 may also be covered by the holding layer 5, for example, if this facilitates the manufacturing process or not.

In order to guarantee a wide variety of applications and to best meet the wishes of the consumers and / or users, the slab 1 according to the invention is characterized in that the exposure plate 2 is made of a material chosen from the group formed by mineral materials, glasses, ceramics, concretes, cements, hard organic substances, synthetic or natural, in particular methyl methacrylate and its derivatives, wood and metals, in particular stainless metals, for example stainless steel or stainless steel alloys.

Even more generally, any sufficiently rigid material may be suitable and the invention is particularly useful if said material is capable of generating dangerous fragments in case of wear or deterioration, for example sharp or sharp fragments, splinters, etc.

Preferably, the tackifier effecting the adhesive bonding of the underlying layer 3 to the plate Exposure 2 consists of a polyurethane glue, preferably a monocomponent adhesive of urethane prepolymer polymerizing by reaction with ambient moisture.

The polymerization reaction and setting can be, for this type of glue, greatly accelerated in the presence of a high humidity and by application of heat and / or pressure.

The tackifier may for example consist of a one-component polyurethane adhesive of the type known under the designation "reactive hot melt glue 706.1" manufactured by KLEIBERIT Chimie SARL.

It is expected that the underlying layer 3 has a sufficient thickness depending on the nature of the material used to report the damping properties, in particular an impact damping higher than a determined lower threshold value, in particular to threshold values defined by standard NF EN 1177.

Advantageously, the slab 1 according to the invention is characterized in that the lower face 4 comprises ribs and / or stiffening moldings 6.

This allows in particular a better stability, in particular better handling. By way of example, FIGS. 2 and 3 schematically illustrate, simplified and exaggerated, grooves or ribs of semi-cylindrical section parallel to one another and distributed on the lower face 4 as ribs and moldings. stiffening 6.

Of course, other shapes, dimensions and distributions on said lower face 4 of these stiffening means are also possible.

In order to facilitate the assembly of the slabs 1 with each other, a preferred embodiment is provided in which the slab 1 according to the invention is further characterized in that the underlying layer 3 comprises on at least some of its outer flanks fastening means 7 of the male-female type for attachment to identical complementary male-female fastening means located on another neighboring slab 1, in order to effect a tiling by an assembly of said slabs 1.

By way of non-limiting example, there are shown such means

7 in Figures 1 and 2, in the form of trapezes (or dovetail-shaped) which laterally protrude as male elements of the flanks of slab 1 to collaborate with a corresponding female recess located on a slab 1 neighbor suggested dashed.

Indeed, the slab 1 according to the invention is further characterized in that the fastening means 7 of the male-female type are recesses or flanges on at least one side, preferably all sides, with respect to the plate. 2, preferably of trapezoidal shape and made in or protruding from the underlying layer 3.

Variants for these fastening means 7 which can take other shapes, dimensions and distributions on said flanks are obviously also possible.

Advantageously, the fastening means 7 extend physically in two perpendicular planes so as to guarantee both locking in the horizontal plane and in the vertical plane of the slabs 1 assembled.

In order to allow evacuation of rainwater, washing, runoff, etc., the slab 1 according to the invention is further characterized in that the underlying layer 3 and the holding layer 5 comprise one or several orifices through 8 and in that the underlying layer 3 comprises one or more drainage channels 9 for the evacuation of said rainwater or runoff flowing along the edges and side flanks delimiting the slab 1 to said through holes 8.

The gap 10 between two adjacent slabs 1 allows the surface water to flow as schematically suggested by Figures 1 and 2, first along the walls of the slab 1 and along the channels 9 to be evacuated through the through holes 8 to the sewers or the ground.

Advantageously, the slab 1 according to the invention is characterized in that the slab 1 is, seen from above, of square or rectangular shape, or the through holes 8 being of square or rectangular shape with sides that are not parallel to the sides of the slab 1.

This is particularly clearly visible in FIG.

Such a configuration has the advantage of further increasing the structural rigidity of the entire composite slab 1.

Of course, other shapes (circular, rhombic, oval, polygonal, conical ...), dimensions and distributions of the through holes 8 through the underlying layer 3 and the support layer 5 on the lower face 4 are also possible. Preferably, the slab 1 according to the invention is characterized in that the total area of the cross-sectional openings 8 represents 20 to 60% of the total surface of the exposure plate (2).

This represents a good compromise between stiffness and evacuation capacity and makes it possible to offer a particularly efficient product in terms of cost and efficiency.

The composite slab 1 according to the invention is manufactured conventionally by the techniques well known to those skilled in the art.

The method of manufacturing a composite slab 1 as described above can be summarized in that it essentially consists in arranging a rigid exposure plate-shaped element 2 in a hollow lower mold part, the side walls of which surround said plate 2 and extend beyond the upper face of said plate 2, to apply a sticking or adhering agent of the thermosetting type on said upper face of said rigid plate 2, to deposit at least one underlying layer 3 in a resilient material on said upper surface bonded with said rigid plate 2, to be subsequently produced, with a complementary mold part, a hot compression of said underlying layer 3, against said exposure plate 2 with a pressure, at a temperature and for a time sufficient to result in an intimate adhesion of said layer 3 to said plate 2 and, finally, to extract the resulting composite slab 1 e said mold.

The holding layer 5 is preferably manufactured by overmolding, shuttering or wrapping the underlying layer 3.

For this purpose, the hot compression referred to above is carried out at a temperature between 100 ° C and 120 ° C, preferably about 110 ° C, at a pressure between 0.8 bar and 1 bar, preferably about 0.9 bar, and for a period of between 0.2 minutes and 0.4 minutes, preferably about 0.3 minutes with a thickness of the underlying layer 3 between 0.27 mm and 0.33 mm preferably about 0.30 mm.

According to a particularly advantageous embodiment, the exposure plate 2 and the underlying layer 3 may be bonded, preferably by gluing with a polyurethane adhesive, preferably a one-component adhesive of urethane prepolymer polymerizing by reaction with the adhesive. humidity. Mutual bonding resulting from hot-compression bonding as exemplified above is also possible. It is also possible to provide a more conventional assembly, for example by crimping. This latter technique is also well known to those skilled in the art and does not require other explanations.

Finally, the present invention also relates to a modular coating system for interior or exterior floors or terraces, consisting of a plurality of polygonal slabs, preferably rectangular or square, with forming slit-like passage interstices between adjacent slabs, characterized in that the slabs consist of slabs 1 composites according to the invention.

The modular coating system for interior or exterior floors, terraces, etc., may also consist of a plurality of polygonal, preferably rectangular or square, polygonal composite slabs resting with wedging at their corners on studs with interstices slit-shaped passageway between said adjacent slabs 1, this system being characterized in that the aforementioned slabs consist of slabs 1 according to the invention, as described above.

Such a coating can be installed directly on a raw support (concrete slab, hard floor, stabilized soil ...), on a support coated with at least one sealing layer or on a support coated with at least one sealing layer and an insulation layer, the leveling of the various slabs 1 is effected by adjusting the height of the various pads (self-adjusting pads or placement of shims).

The composite slabs 1 according to the invention, as well as floor coverings of the type of floor slabs or slabs formed with such composite slabs 1, can be implemented in applications and for the most varied purposes.

Of course, the invention is not limited to the embodiments described and shown in the accompanying drawings. Modifications are possible, particularly from the point of view of the constitution of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims

1. A composite slab, in particular for the production of interior or exterior flooring or terraces, consisting of an upper, solid and rigid exposure plate (2) intimately joined to an underlying absorption layer (3). shock and made of a resilient material, preferably a thermoplastic material such as expanded polystyrene, resilient material with a density of 40 to 80 kg / m ³ , at least the lower face (4) in contact with the surface on which the slab rests, has a layer (5) for maintaining the integrity of the slab (1) in the event of the exposure plate (2) being broken, said holding layer (5) being made of a compact material , preferably a compact thermoplastic material such as compact polystyrene, preferably extruded, said compact material having a density of 800 to 1600 kg / m ³ , characterized in that the underlying layer (3) and the maintenance layer in (5) have one or more through holes (8) and in that the underlying layer (3) has one or more drainage channels (9) for draining rain or runoff water, along the edges and side flanks delimiting the slab (1) to said through holes (8).

2. Composite tile according to claim 1, characterized in that the holding layer (5) extends over the entire lower face (4) and a portion of the lateral flanks of the underlying layer (3).

Composite tile according to claim 2, characterized in that the holding layer (5) extends over the whole lower face (4) and over part of all the lateral flanks of the underlying layer (3), preferably without reaching the exposure plate (2).

4. Slab according to any one of claims 1 to 3, characterized in that the exposure plate (2) is made of a material selected from the group consisting of mineral materials, glasses, ceramics, concretes, cements, hard organic substances, synthetic or natural, especially methyl methacrylate and its derivatives, wood and metals, especially stainless metals, for example stainless steels or stainless alloys.

5. Slab according to any one of claims 1 to 4, characterized in that the lower face (4) comprises ribs and / or stiffening moldings (6).

6. Slab according to any one of claims 1 to 5, characterized in that the underlying layer (3) comprises on at least some of its outer flanks fixing means (7) of the male-female type for fixing to identical, male-female, complementary fastening means located on another adjacent slab (1), in order to effect a tiling by an assembly of said slabs (1).

Slab according to claim 6, characterized in that the fastening means (7) of the male-female type are recesses or flanges on at least one side, preferably all sides, with respect to the exposure plate. (2), preferably of trapezoidal shape and made in or protruding from the underlying layer (3).

8. Slab according to any one of claims 1 to 7, characterized in that the slab (1) is, seen from above, of square or rectangular shape, or the through holes (8) being of square or rectangular shape with sides that are not parallel to the sides of the slab

(1).

9. Slab according to claim 7 or 8, characterized in that the total area of the cross-sectional openings (8) is 20 to 60% of the total area of the exposure plate (2).

10. Slab according to any one of claims 1 to 9, characterized in that the exposure plate (2) and the underlying layer (3) are bonded by gluing, preferably by gluing with a polyurethane glue, preferably a one-component glue of urethane prepolymer polymerizing by reaction with ambient humidity.

11. Slab according to any one of claims 1 to 10, characterized in that the resilient material of the underlying layer (3) and / or the material of the holding layer (5) are selected from the group consisting of thermoplastic plastics such as acrylic polymers, cellulosics, polyamides, polyesters, polyolefins, polyurethanes, styrenics, vinyls and mixtures thereof, the material used for the underlying layer (3) being preferably identical to that of the holding layer (5).

12. Slab according to any one of claims 1 to 11, characterized in that the resilient material of the underlying layer (3) and / or the material of the holding layer (5) incorporates glass fibers.

13. Modular coating system for indoor or outdoor floors or terraces, consisting of a plurality of polygonal slabs, preferably rectangular or square, with slit-like passage interstices between adjacent slabs, characterized in that the slabs consist of in slabs (1) composites according to any one of claims 1 to 12.