WO2019030169A1

WO2019030169A1 - Floor cassette for the construction of a floor

Info

Publication number: WO2019030169A1
Application number: PCT/EP2018/071263
Authority: WO
Inventors: Marc DELFELD
Original assignee: Keep Silence
Priority date: 2017-08-09
Filing date: 2018-08-06
Publication date: 2019-02-14
Also published as: BE1024777B1

Abstract

The invention relates to a floor cassette (1) for the construction of a floating floor (10),the floor cassette comprising a wooden base panel (2) and a plurality of wooden beams (3) attached to one of the surfaces of the base panel (2), the beams (3) being essentially parallel to one another, characterized in that the floor cassette (1) further comprises a plurality of support devices (4) mounted between two adjacent beams (3), the support devices (4) comprising two ends (14) respectively fixed at least to a lateral wall (15) of the two adjacent beams (3), and a central part (13) connecting the two ends (14), the central part (13) being configured to support the floor (10) so that the latter is not directly attached to the beams (3).

Description

FLOOR CASSETTE FOR THE CONSTRUCTION OF A FLOOR

Field of the invention

[0001] The invention relates to a floor cassette for the construction of a floating floor in a building. This floor cassette will mostly be used for the construction of new wooden buildings.

[0002] A floating floor is a floor that is not fastened to the fixed structure of the building, which gives the floor advantageous acoustic characteristics, whilst allowing long spans.

Prior art

[0003] In the construction of wooden buildings, one solution for separating two successive storeys consists in laying floor cassettes in the form of a closed or open box comprising a panel provided with longitudinal and parallel beams fixed to a surface of the panel. Closed boxes comprise a second panel mounted parallel to the first panel, the beams then being placed between the two panels. This type of box is generally not the optimum from an acoustic point of view.

Characteristic elements of the invention

[0004] The present invention relates to a floor cassette as described in the claims. The invention relates firstly to a floor cassette for the construction of a floating floor, the floor cassette comprising a wooden base panel and a plurality of wooden beams attached to one of the surfaces of the base panel, the beams being essentially parallel to one another, characterized in that the floor cassette further comprises a plurality of support devices mounted between two adjacent beams, the support devices comprising two ends respectively fixed at least to a lateral wall of the two adjacent beams, and a central part connecting the two ends, the central part being configured to support the floor so that the latter is not directly attached to the beams. The beams are preferably rectangular section beams mounted upright on the surface of the base panel. The base panel is a load-bearing panel configured to rest on two lateral walls or equivalent support structures, such as two rows of support columns for example. The panel has sufficient thickness and thereby mechanical strength to serve as a base for a building level. This implies that the floor cassette itself is a structural element, that is to say a load-bearing element configured to support the loads caused by persons and objects located on a storey of a building.

[0005] According to one embodiment, the support devices are formed and sized so that the central parts of the support devices mounted on a plurality of pairs of adjacent beams are respectively able to support a plurality of joists configured to support the floor, a resilient material acoustic element being placed between each central part and the joist that it supports.

[0006] According to one embodiment, a plurality of acoustic elements respectively attached to the central parts of the support devices form part of the floor cassette.

[0007] According to one embodiment, a plurality of said joists attached to the acoustic elements form part of the floor cassette.

[0008] According to one embodiment, the floor cassette comprises a part of said floor attached to the joists.

[0009] According to one embodiment, the floor cassette comprises a thermal insulation material between the base panel and the support devices and/or above the support devices.

[0010] According to one embodiment, the base panel has a rectangular shape in which the length of the base panel exceeds the length of the beams on both sides of said beams.

[0011] According to one embodiment, the beams are attached to the surface of the base panel by at least a glue.

[0012] According to one embodiment, said glue is a polyurethane- based glue applicable in liquid form and hardening with moisture from the wood and/or from the air. [0013] According to one embodiment, the length of the floor cassette measured in the direction of the beams is between 6 and 12 m and the width of the floor cassette is between 1 and 3 m.

[0014] According to one embodiment, the support devices are mounted alternatingly on the channels formed by the beams.

[0015] According to one embodiment, at least one end of the support devices is a angle-bracket-shaped element comprising a vertical part and a horizontal part, the horizontal part being fixed to the upper surface of a beam and the vertical part being fixed to a lateral wall of the same beam, the central part being connected to the vertical part.

[0016] According to one embodiment, the ends comprise a second horizontal part that supports the central part.

[0017] According to one embodiment, the ends are angle-bracket- shaped elements comprising a vertical part and a horizontal part, the vertical part being fixed to a lateral wall of a beam, the horizontal part supporting the central part of the support device.

[0018] According to one embodiment, the ends are fastened to the central part and oriented at obtuse angles different from 180° defined relative to the central part in a horizontal plane when the floor cassette is installed, said angles being opposite one another.

[0019] According to one embodiment, the central part of the support devices is formed by a steel or wooden bar.

[0020] According to one embodiment, one or more of the support devices is fabricated from steel plate or formed by the assembly of a plurality of parts of a steel plate.

[0021] According to one embodiment, the length of the central part of at least one of the support devices is adjustable when said device is removed from the floor cassette.

[0022] The invention is further related to a floating floor comprising one or more floor cassettes as defined in any one of the preceding claims. [0023] The invention is also related to the use of one or more floor cassettes as described in any one of the preceding claims for the construction of a floating floor. Brief description of the figures

[0024] Figure 1 represents a floor cassette according to one embodiment of the invention.

[0025] Figure 2 represents plan and front views of a floor mounted on a plurality of floor cassettes according to the invention, resting on two walls.

[0026] Figure 3 represents a view in section in a plane perpendicular to the walls.

[0027] Figure 4 represents an embodiment in which the support devices forming part of a floor cassette according to the invention are oriented at a non-perpendicular angle relative to the beams of the floor cassette.

[0028] Figure 5 represents an embodiment in which the ends of the support device are oriented at an obtuse angle relative to the central part of the device.

[0029] Figure 6 represents an embodiment in which the central part of the support device is formed by a steel bar.

[0030] Figure 7 represents an embodiment in which the central part of the support device is formed by a wooden bar.

[0031] Figure 8 represents a 3D image of an embodiment in which the ends of the support device are oriented at an obtuse angle relative to the central part.

[0032] Figures 9 and 10 represent alternative embodiments of the support device forming part of a floor cassette according to the invention.

[0033] Figure 1 1 represents a further form of the support device that is provided with a central part of variable length. Detailed description of the invention

[0034] The invention is described in detail with reference to the figures, in which not all features are always represented. Features must often be considered optional and a combination of features present in the various figures may of course also be envisaged and covered by the subject matter of the invention.

[0035] In Figure 1 a floor cassette 1 according to a first embodiment of the invention for the construction of a floating floor is shown . The floor cassette 1 comprises a base element in the form of a wooden panel 2, preferably having a thickness between 25 and 75 mm and preferably formed of laminated wood such as LVL (Laminated Veneer Lumber). According to this preferred embodiment, the thickness of the base panel 2 is at least 33 mm. Depending on the material used, the use of a base panel at least 33 mm thick, preferably at least 50 mm thick, enables a floor cassette to be produced that resists fire for at least one hour. The base panel 2 preferably has a rectangular shape but may of course be adapted to any other shape. According to one embodiment of the invention, the width of the panel is between 1 and 2.5 m while the length may vary between 6 and 12 m. Wooden beams 3, preferably of rectangular section, are fixed upright on the upper surface of the base panel 2, the beams being mounted parallel to one another and oriented in the longitudinal direction of the rectangle constituting the upper surface of the panel 2. The beams 3 are preferably placed equidistantly, for example with a distance of approximately 40 cm between two adjacent beams. The beams 3 may equally be produced in laminated wood such as LVL. In the embodiment represented in the figures, and without constituting a limitation on the scope of the invention, the thickness of the beams 3 of a floor cassette 1 is preferably of the same order of magnitude as the thickness of the base panel 2 of said floor cassette 1 .

[0036] According to a preferred embodiment, the base panel 2 extends beyond the beams by a distance D measured in the longitudinal direction of the beams 3. This distance D will preferably be the same at both ends of the beams 3. The beams 3 are fastened to the base panel 2. According to a preferred embodiment, the fastening means provided consist of a glue that is described hereinafter in relation to the method of assembling the floor cassette.

[0037] Moreover, the floor cassette of the invention comprises a plurality of support devices 4, each of these devices being mounted between two adjacent beams 3 so as to be able to support a floor (not represented in Figure 1 ), whilst allowing this floor not to be directly attached to the beams 3 of the floor cassette 1 .

[0038] According to embodiments of the invention, the support devices 4 are formed and sized so that they allow the supporting of joists oriented essentially parallel to the beams 3 and on which the floor will be mounted. At least two support devices 4 are mounted between two adjacent beams 3. The support devices 4 are preferably installed alternately in the hollows or channels formed by the beams, as shown in Figure 1 : the floor cassette 1 comprises 6 beams 3, separated by 5 channels C1 to C5, support devices 4 being mounted in channels C1 , C3 and C5. The floor cassette represented in Figure 1 has a limited length that enables the various elements to be seen clearly: it comprises only two support devices 4 mounted on each of channels C1 , C3 and C5. Of course, the floor cassette may have a greater length, which will necessitate a greater number of support devices 4. The support devices 4 mounted on a pair of beams 3 may for example be placed at a distance from one another between 1 and 4 m.

[0039] Figure 2 represents plan and front views of a floor 10 installed on a plurality of floor cassettes 1 as defined by the present invention. A single floor cassette 1 is represented in the figure, although the floor 10 may be supported by a plurality of floor cassettes mounted alongside one another (which is symbolized by the dashed ends of the lines in Figure 2). The base panel 2 and the beams 3 can be seen. The longitudinal ends of the panel rest on two lateral walls 1 1 . The support devices 4 represented in Figures 1 and 2 are stirrup- shaped. Each of the stirrups 4 comprises a central part 13 and two ends 14 that constitute angle-bracket-shaped fixing elements. Each end 14 comprises a vertical part 15 and a horizontal part 16. The ends 14 are fixed directly to the beams 3, by fixing the horizontal parts 16 to the upper surface of the beams 3, preferably using vertical screws. The vertical parts 15 of the ends are fixed to the lateral walls of the beams 3, preferably by horizontal screws. This double fixing of the ends 14, facilitated by the angle-bracket shape of these ends, enables resistance to transverse vibrations to be provided. On the other hand the invention is not limited to the shapes of the support devices 4 as shown in the figures. As a general rule, the support devices 4 comprise a central part 13 and two ends 14, these ends comprising at least one vertical part 15 fixed to a lateral wall of a beam 3, the central part 13 connecting the ends 14. Other embodiments of the support devices 4 are described later in the present description.

[0040] The central part 13 of the support devices 4 operates as a support for a joist 17, for example in metal or in wood or in a combination of the two, which rests on an acoustic element 18, preferably a block of resilient material, which serves as acoustic insulation. The floor 10 is in its turn supported by the joists 17. The floor 10 may for example be screwed to the joists 17. The total height of the elements 18 and the joists 17 is calculated so that the floor 10 does not come into contact with the beams 3 of the floor cassettes 1 . In other words, the upper surface of the joists 17 is situated at a greater height than the beams 3 of the cassette 1 . The floor 10 is thereby not directly attached to the beams 3. If the ends of the support devices 4 comprise ends 14 that extend on the upper surface of the beams 3 (as is the case in Figures 1 and 2) the combined height of the blocks 18 and the joists 17 is such that the floor 10 is also not directly attached to these ends themselves, nor to the means for fixing them to the beam (such as the screws attaching the horizontal parts 16 to the beams 3).

[0041] The joists 17 are supported by at least two stirrups 4 placed at a regular distance, for example at a distance of 2.5 m for a distance between the beams 3 of approximately 40 cm. In the example shown, the joists 17 are placed at the middle of the central parts 13 of the stirrups.

[0042] The preferred embodiment of a floor cassette 1 according to the invention comprises the base panel 2, the beams 3 fixed to the panel and a plurality of support devices 4 such as the stirrups fixed to the beams 3.

[0043] On site, the ends of the base panel 2 that extend beyond the beams 3 are placed on two supporting walls 1 1 or on any equivalent pair of support structures, e.g. two rows of pillars, or a row of pillars on one side and a wall on the other. The insulating material blocks 18, the joists 17 and the floor 10 are in this case assembled in situ. According to another embodiment, the acoustic elements 18 form part of the floor cassette 1 as produced and shipped to the site. The elements 18 may be glued to the central parts 13 of the support devices 4. According to a further embodiment, the elements 18 and the joists 17 form part of the floor cassette 1 . The joists 17 may in this case be glued or retained beforehand on the elements 18 which are themselves preferably glued to the central parts 13 of the support devices 4. According to a further embodiment, the floor cassette of the invention is provided with the elements 18, the joists 17 and also a part of the floor 10, preferably a part the area of which corresponds to the area of the floor cassette. The floor part is preferably mounted on the joists 17 in a way that is known in the art for the assembly of a floor on a set of joists. After assembling a plurality of floor cassettes of this type, the various parts of the floor will preferably be connected together by appropriate connecting means.

[0044] There will advantageously be placed in the spaces located between the beams 3 and below the support devices 4 a thermally insulating material 19 such as rock wool. For example rock wool with a density of at least 35 kg/m³ may be placed during the construction of the floor using floor cassettes 1 according to the invention. This insulating material 19 may fill not only the spaces under the support devices 4 but also above these devices, thus the spaces located on either side of the joists 17. According to one embodiment, the thermally insulating material 19 forms part of a floor cassette according to the invention, and the floor cassette arriving on site is therefore provided with thermally insulating material 19 under and/or above the support devices 4.

[0045] Figure 3 represents a view in section in a plane perpendicular to the walls 1 1 . It is seen therein that the floor 10 is separated from the walls 1 1 by a distance 'a'. The floor is therefore entirely 'floating', i.e. not only is it not directly attached to the beams 3 but it is also not directly attached to the walls 1 1 . Thanks also to the presence of the resilient material block 18, there is therefore no rigid connection between the floor 10 and the fixed structure of the building, which represents an ideal situation acoustically. The noise generated by persons or tools carried by the floor 10 is not or not greatly distributed to the other storeys of the building. The floor cassette 1 according to the invention allows this floating floor construction on each storey of a new building, thus creating an acoustic solution for the entire building. [0046] The support devices 4 may be assembled at an angle a (not a right angle) relative to the beams 3, as shown in Figure 4. Fastening the vertical parts 15 against the walls of the beam 3 using screws remains possible, provided that the angle a remains below a given value.

[0047] Figure 5 represents another embodiment of the support devices 4, again stirrup-shaped, but the ends 14 of which are oriented at an obtuse angle (i.e. at an angle β between 90° and 180°) relative to the central part

13, the orientation of one end 14 being opposite the orientation of the other end

14, so that the same angles β and -β are present between the central part 13 and each of the ends 14. This embodiment allows the device 4 to be mounted between two beams 3 located at a distance less than the length of the central part 13 whilst maintaining the optimum fastening between the device 4 and the horizontal surface of the beams 3 and the lateral walls of the beams 3.

[0048] The support devices 4 that are represented in Figures 1 -5 are preferably made from steel plate, or formed by an assembly of a plurality of parts of a plate (including the ends 14 and the central part 13 which are parts of plates). According to preferred embodiments, the plate has a thickness of 3 to 7 mm, preferably 5 to 7 mm.

[0049] Figure 6 shows a support device 4 the central part 13 of which takes the form of a steel bar connected by welding to the ends 14. This embodiment combines the features described above with an increased mechanical strength. The ends 14 take the form of angle-bracket-shaped parts connected to the central bar. These are preferably steel parts, made from steel plates between 4 and 7 mm thick (preferably between 5 and 7 mm thick) welded to the bar 13. The ends 14 are advantageously provided with holes 26 in their vertical parts 15 and horizontal parts 16 in order to facilitate vertical and horizontal screwing of the ends 14 against the beams 3.

[0050] An alternative is shown in Figure 7: the central part 13 of the device 4 is a wooden bar that is connected to the ends 14 in the form of steel angle-brackets provided with horizontal plates 28 that support the bar 13 and vertical plates 29 that retain the bar in place. Openings 30 may be provided for screwing the bar 13 to the vertical plates 29. The wood used for the bar 13 must have sufficient mechanical strength.

[0051] Figure 8 shows a support device 4 with the central part 13 in the form of a bar and with the ends 14 oriented at an obtuse angle relative to said bar 13. It is seen that in this embodiment the ends 14 are provided with horizontal plates 28 that are positioned under the bar 13. The horizontal plates 28 may equally be present in the embodiment shown in Figure 6.

[0052] Two examples of another embodiment are given in Figures 9 and 10. It is seen that the end 14 consists in a vertical part 15' that is screwed against the lateral wall of a beam 3 while the horizontal part 16' carries the central part 13 in the form of a bar. In this embodiment the floor 10 is moved closer to the beams by the absence of a part of the ends 14 on the upper surface of the beams 3. The bar 13 may be replaced by a central part according to any of the other embodiments described above or equivalent embodiments.

[0053] The central part such as the bar 13 can advantageously pivot relative to the horizontal parts 16' about a vertical axis. In the embodiment of Figures 9 and 10, this is realized with the aid of pins 40, whilst maintaining the contact between the bar 13 and said horizontal parts 16'. This embodiment therefore allows adjustment of the angle of the central part 13 relative to the ends 14 so as to adapt the support device as a function of the distance between two beams 3 during the assembly of a floor cassette according to the invention or when the support device 4 is removed from the floor cassette 1 .

[0054] Another embodiment of a support device usable in a floor cassette according to the invention is shown in Figure 1 1 . According to this embodiment, the length of the central part 13 of the support device is adjustable.

In the example shown in Figure 1 1 , the central part 13 is a steel bar, designed in two parts 50 and 51 , one being movable relative to and inside the other so as to adjust and to modify the length of the bar. During the assembly of a floor cassette according to the invention, this device can be adapted to the distance between two beams 3. The device is therefore usable for the assembly of floor cassettes that comprise beams 3 placed at different or variable distances. [0055] The floor 10 may be made from any material available for this use, such as OSB (Oriented Strand Board) panels. The floor may comprises a plurality of layers. According to one specific embodiment, fibre cement panels are used for the floor 10. According to another embodiment, the floor is provided with an underfloor heating system.

[0056] As already mentioned, the beams 3 of a floor cassette according to the invention are preferably glued to the base panel 2. In a preferred embodiment, the beams 3 are made of laminated wood and the glue used is a glue based on polyurethane (PUR), which is applied in liquid form and which hardens with moisture from the wood and/or the surrounding air, and under the impact of a contact pressure between the glued components. One glue that may be used is Jowapur® type 686.60 glue. The glue is preferably applied over the entirety of the face of the beams (full dip application) in contact with the panel by an automated process to obtain an ideal and reproducible distribution of the glue. The beams 3 are then pressed against the panel 2, for example by a mechanical press that applies the pressure required according to the specifications of the glue, for a time period necessary for the polymerization of the glue. Instead of using a mechanical press, the glued beams 3 may be pressed against the panel 2 by screws, screwed in from the panel side. The screws will remain in the finished floor cassette, in which the connection between the beams 3 and the panel 2 is therefore established by the glue and by the screws.

[0057] The use of glue based on PUR in combination with an automated process for assembling the beams 3 to the panel 2 has resulted in a structure that has a high mechanical strength compared to existing floor cassettes that have an open structure, thus without the beams being mounted between two parallel panels. This has enabled the inventors to produce floor cassettes having a span greater than 6 metres, preferably between 6 and 12 m, that necessitate only two support points (like the two walls 1 1 in Figure 2).

[0058] The invention is equally related to the use of one or more cassettes according to the invention for constructing a floating floor, and to a floating floor comprising one or more cassettes according to the invention. When applying cassettes which are provided only with the support devices 4, the above- named use is equivalent to a method comprising the steps of :

- mounting one or more cassettes 1 according to the invention on support structures such as walls or their equivalent (e.g. rows of pillars), wherein each cassette is supported by at least two support structures,

- mounting acoustic elements 18 on the central parts 13 of the support devices 4 of said one or more cassettes,

- mounting joists 17 onto said acoustic elements 18, the joists being oriented transversely to the central parts 13, wherein the upper surface of the joists 17 is at a height that is superior to the beams 3 of the one or more cassettes 1 ,

- mounting one or more floor boards 10 onto said joists, to thereby form a floating floor, i.e. a floor that is not directly attached to the beams 3.

The second step of the above method is not required when cassettes are used which are already provided with acoustic blocks 18. The second and third step of the above method are not required when cassettes are used which are already provided with acoustic blocks and with joists 17.

Claims

1. Floor cassette (1 ) for the construction of a floating floor (10), the floor cassette comprising a wooden base panel (2) and a plurality of wooden beams (3) attached to one of the surfaces of the base panel (2), the beams (3) being essentially parallel to one another, the base panel (2) being configured to rest on two lateral walls, so that said floor cassette forms a load- bearing element configured to support the loads caused by persons and objects that are located on a storey of a building, characterized in that the floor cassette (1 ) further comprises a plurality of support devices (4) mounted between two adjacent beams (3), the support devices (4) comprising two ends (14) respectively fixed at least to a lateral wall (15) of the two adjacent beams (3), and a central part (13) connecting the two ends (14), the central part (13) being configured to support the floor (10) so that the latter is not directly attached to the beams (3).

2. Floor cassette according to Claim 1 , in which the support devices (4) are formed and sized so that the central parts (13) of the support devices (4) mounted on a plurality of pairs of adjacent beams (3) are respectively able to support a plurality of joists (17) configured to support the floor (10), a resilient material acoustic element (18) being placed between each central part (13) and the joist (17) that it supports.

3. Floor cassette according to Claim 2, in which a plurality of acoustic elements (18) respectively attached to the central parts (13) of the support devices (4) form part of the floor cassette (1 ).

4. Floor cassette according to Claim 3, in which a plurality of said joists (17) attached to the acoustic elements (18) form part of the floor cassette (1 ).

5. Floor cassette according to Claim 4, in which the floor cassette (1 ) comprises a part of said floor (10) attached to the joists (17).

6. Floor cassette according to any one of Claims 1 to 5, in which the floor cassette (1 ) comprises a thermal insulation material (19) between the base panel (2) and the support devices (4) and/or above the support devices (4).

7. Floor cassette according to any one of the preceding claims, in which the base panel has a rectangular shape and in which the length of the base panel (2) exceeds the length of the beams (3) on both sides of said beams (3).

8. Floor cassette according to any one of the preceding claims, in which the beams (3) are attached to the surface of the base panel (2) by at least a glue.

9. Floor cassette according to Claim 8, in which said glue is a polyurethane-based glue applicable in liquid form and hardening with moisture from the wood and/or from the air.

10. Floor cassette according to any one of the preceding claims, in which the length of the floor cassette measured in the direction of the beams (3) is between 6 and 12 m and the width of the floor cassette is between 1 and 3 m.

11. Floor cassette according to any one of the preceding claims, in which the support devices (4) are mounted alternatingly on the channels (C1 -C5) formed by the beams (3).

12. Floor cassette according to any one of the preceding claims, in which at least one end of the support devices (4) is a angle-bracket- shaped element comprising a vertical part (15) and a horizontal part (16), the horizontal part (16) being fixed to the upper surface of a beam (3) and the vertical part (15) being fixed to a lateral wall of the same beam, the central part (13) being connected to the vertical part (15).

13. Floor cassette according to claim 12 in which the ends (14) comprise a second horizontal part (28) that supports the central part (13).

14. Floor cassette according to any one of Claims 1 to 1 1 , in which the ends (14) are angle-bracket-shaped elements comprising a vertical part (15') and a horizontal part (16'), the vertical part (15') being fixed to a lateral wall of a beam (3), the horizontal part (16') supporting the central part (13) of the support device (4).

15. Floor cassette according to any one of Claims 12 to 14, in which the ends (4) are fastened to the central part (13) and oriented at obtuse angles (β) different from 180° defined relative to the central part (13) in a horizontal plane when the floor cassette is installed, said angles (β) being opposite one another.

16. Floor cassette according to any one of Claims 13 to 15, in which the central part (13) of the support devices (4) is formed by a steel or wooden bar.

17. Floor cassette according to any one of Claims 12 to 15, in which one or more of the support devices (4) is fabricated from steel plate or formed by the assembly of a plurality of parts of a steel plate.

18. Floor cassette according to any one of the preceding claims, in which the length of the central part (13) of at least one of the support devices (4) is adjustable when said device is removed from the floor cassette.

19. Floating floor comprising one or more floor cassettes as according to any one of the preceding claims.

20. Use of one or more floor cassettes according to any one of the preceding claims for the construction of a floating floor.