WO2019059783A1

WO2019059783A1 - A floor

Info

Publication number: WO2019059783A1
Application number: PCT/NZ2018/050126
Authority: WO
Inventors: Charles Bree
Original assignee: Charles Bree
Priority date: 2017-09-22
Filing date: 2018-09-19
Publication date: 2019-03-28
Also published as: NZ735772A

Abstract

A floor or part thereof formed by the following steps: a) connecting wooden sheets (13) so that they are co-planar; b) spraying joints (14) between the sheets so as to provide a seal between them; c) applying a foaming substance over the sheets and allowing it to set as a foam (15); d) spraying a coating (16) over the set foam; and e) inverting the wooden sheets plus foam so that the sheets are on top and become a walking surface for a building.

Description

TITLE

A Floor

FIELD OF INVENTION

A preferred form of this invention relates to a floor for a building.

BACKGROUND

It is known in the building industry to create floors out of concrete. A problem with this is that they can be inconveniently heavy and therefore prone to breaking in the event of movement. This can make it difficult to prepare them offsite and transport them to where they are needed.

OBJECT OF THE INVENTION

It is an object of a preferred embodiment of the invention to go at least some way towards addressing at least some of these shortcomings. While this applies to preferred embodiments, it should be understood that the object of the invention per se is simply to provide the public with a useful choice. Therefore any objects applicable to preferred embodiments should not be taken as a limitation on the scope of the monopoly claimed.

DEFINITIONS

The term "comprises" or "comprising" or derivatives thereof should not be interpreted as limiting. For example if used in relation to a combination of steps or features it should be taken to indicate that optionally, but not necessarily, there may be additional steps or features that have not been mentioned.

SUMMARY OF INVENTION

According to one aspect of the invention there is provided a floor or part thereof formed by the following steps:

a) connecting wooden sheets so that they are co-planar;

b) spraying joints between the sheets so as to provide a seal between them; c) applying a foaming substance over the sheets and allowing it to set as a

foam;

spraying a coating over the set foam; and e) inverting the wooden sheets plus foam so that the sheets are on top and become a walking surface for a building.

Optionally the wooden sheets at step a) comprises plywood.

Optionally upright sides are fixed around the perimeter of the wooden sheets before applying foam.

Optionally the upright sides comprise plywood.

Optionally the wooden sheets and upright sides are sprayed to provide a seal between them.

Optionally polyurea is sprayed at step b).

Optionally the coating at step d) comprises polyurea.

According to a further aspect of the invention there is provided a building element formed by combining foam chips with cement, foam dust and water such that they have set hard in a desired shape.

Optionally the element comprises a foundation pad.

Optionally the element comprises a structural beam.

Optionally the element comprises a panel. Optionally the panel forms part of the floor of a building. Optionally the foam chips and foam dust comprise polyurethane. Optionally the foam chips have a mean volume of 1 cm³ to 3cm³. Optionally the building element has a layer of concrete on either side.

Optionally each concrete layer comprises metallic reinforcing. Optionally the building element comprises an at least partial coating of polyurea.

Optionally the polyurea is approximately 1 mm to 6mm thick. Optionally the polyurea is approximately 1 mm to 3mm thick.

Optionally the foam chips, foam dust, cement and water form a body approximately 100mm to 250mm thick. Optionally the foam chips, foam dust, and cement are in a ratio of approximately five parts foam chips, one part foam dust and two parts cement, by volume, with water to mix.

DRAWINGS

Some preferred embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, of which:

Figure 1 is an isometric view of a foundation pad for a building;

Figure 2 illustrates a portable building resting on the pad;

Figure 3 is an isometric view of a similar pad formed to have a layer of reinforced concrete either side;

Figure 4 is an isometric view of a further similar pad having a polyurea coating; Figure 5 is a plan view of sheets of plywood forming part of the floor of a building; Figure 6 is an isometric view that illustrates the floor partially formed; and

Figure 7 is a cross sectional side view that illustrates the floor partially formed.

DETAILED DESCRIPTION

Referring to figure 1 , a foundation pad 1 for a building has a generally planar upper surface 2 and a lower surface 3. It is approximately 200mm thick as indicated at 4. The pad is produced by mixing polyurethane foam chips, polyurethane foam dust, cement and water and pouring it into a mould of the desired shape. In this regard, it may be formed in a similar manner to concrete but without stones or similar aggregate. Preferably the foam chips are approximately 1 cm³ in average volume although other sizes can also be used. They may be obtained by running a rotating plate with downwardly projecting sharp spikes against a hard-set foam body. More specifically the rotating spikes rip chips from the foam body. The foam dust is a by-product of cutting foam from foam blocks or panels, for example using a band saw. The ratio of foam chips, foam dust, and cement is preferably about five parts foam chips, about one part foam dust and about two parts cement, by volume, with sufficient water to cause curing. Referring to figure 2, the pad 1 provides a strong, light ground engaging foundation for a portable or permanent building 5.

Referring to figure 3, an alternative pad 6 is formed as above but it differs in that it has upper and lower layers of concrete 7, 8 with metallic internal reinforcing 9,10, for example steel mesh.

Referring to figure 4, a further alternative pad 1 1 is also formed as per the figure 1 version but has a complete coating of polyurea 12. The polyurea is preferably sprayed on and is approximately 1 mm to 3mm thick, but where added strength is desired it may be sprayed to a greater thickness, for example up to 6 mm. The inventor has found that the polyurea enhances the strength of the pad considerably, and also gives at least a significant degree of water-proofing.

As the pads described above have a relatively high content of polyurethane foam, they are both light and provide for significant thermal insulation. They can be moulded in a factory and transported to a building site without difficulty. Preferably all of the pad embodiments are lighter than an equal volume of water and can act as a foundation raft able to remain intact in the event of ground subsidence, for example in the case of liquefaction resulting from an earthquake. They may be impervious to water and can therefore set directly on the ground to act as a foundation for a building, or alternatively held up by piles or some other means.

In further embodiments of the invention the same techniques may be used to produce floor or wall panels which do not engage the ground directly. When formed as panels, the items may be considerably thinner. In still further embodiments of the invention, structural beams may be formed using the same techniques described above. In this case they would be moulded to have elongated shapes. Referring to figures 5 and 6, a floor is created for a building by taking the following steps:

• connecting plywood sheets 13 so that they are co-planar (see figure 5);

• spraying the joints 14 between the sheets with polyurea so as to provide a seal between them;

· pouring a foaming substance over the sheets, skimming such substance to give it a generally level surface and allowing it to set as a foam 15;

• spraying polyurea 16 over the set foam; and

• inverting the combination so that the sheets are on top and become a walking surface for a building (see figure 6).

Ideally the floor measures 2.4m to 3m in width, but is most preferably no wider than 2.5m, so as to enable easy transport between the place of manufacture and a building site. Figure 7 is a cross-sectional view of a preferred version of the floor. It is formed by fixing upright plywood sides 17 to horizontal sheets of plywood 18. The sheets and sides may be combined by stapling or any other suitable means. The joints between the sheets of plywood 18, and between those sheets and the sides 17, are sealed by spraying lines of polyurea as indicated at 19. The spray also serves to enhance the strength of the joints.

A fill of foaming substance 20 is poured or sprayed into the mould formed by the sides 17 and sheets 18, skimmed-off so as to be flush with the sides 17, and allowed to set. A polyurea envelope 21 (eg 1 -3 mm thick) is then sprayed over the exposed surface of the fill 20 and around the sides 17 (but not over the lower face of the plywood sheets 18). This enhances strength and provides water-proofing. In some embodiments the polyurea envelope may be sprayed to 6 mm thick, if for example extra strength is needed at joints or other parts. The combination is then inverted (not shown) so that the sheets of plywood 18 face upwards. The dimensions of the floor depend on the end-use requirements; they may be thicker when needed for heavier loads and lighter for lessor loads. In a particularly preferred embodiment the upright sides 17 may be 18 mm thick and 180 mm high, and the horizontal sheets 18 may be 5-ply with a thickness of 9 mm. However these dimensions are not critical.

The foaming substance 20 may be created by combining a suitable resin and hardener (for example isocyanate hardener). In some embodiments the foaming substance comprises polyurethane.

The floor of figure 7 may be used directly on the ground or on top of supportive framing, whatever is preferred. The upward facing plywood layer may be varnished to give it aesthetic appeal. Preferably the floor is lighter than water and is raft like and able to float if need be, for example in the case of liquefaction resulting from an earthquake.

While some preferred forms of the invention have been described by way of example, it should be understood that modifications and improvements can occur without departing from the scope of the following claims.

Claims

1. A floor or part thereof formed by the following steps:

a) connecting wooden sheets so that they are co-planar;

b) spraying joints between the sheets so as to provide a seal between them; c) applying a foaming substance over the sheets and allowing it to set as a foam;

d) spraying a coating over the set foam; and

e) inverting the wooden sheets plus foam so that the sheets are on top and become a walking surface for a building.

2. A floor according to claim 1 , wherein the wooden sheets at step a) comprises plywood.

3. A floor according to claim 1 or 2, wherein upright sides are fixed around the

perimeter of the wooden sheets before applying foam.

4. A floor according to claim 3, wherein the upright sides comprise plywood.

5. A floor according to claim 3 or 4, wherein joints between the wooden sheets and upright sides are sprayed to provide a seal between them.

6. A floor according to any one of claims 1 to 5, wherein polyurea is sprayed at step b).

A floor according to any one of claims 1 to 6, wherein the coating at step d) comprises polyurea.

A building element formed by combining foam chips with cement, foam dust and water such that they have set hard in a desired shape.

A building element according to claim 8, comprising a foundation pad.

10. A building element according to claim 8, comprising a structural beam.

11. A building element according to claim 8, comprising a panel.

12. A building element according to claim 1 1 , wherein the panel forms part of the floor of a building.

13. A building element according to any one of claims 8 to 12, wherein the foam chips and foam dust comprise polyurethane.

14. A building element according to any one of claims 8 to 13, wherein the foam chips have a mean volume of 1 cm³ to 3cm³.

15. A building element according to any one of claims 8 to 14, wherein the building element has a layer of concrete on either side.

16. A building element according to claim 15, wherein each concrete layer comprises metallic reinforcing.

17. A building element according to any one of claims 8 to 16, wherein the building element comprises an at least partial coating of polyurea.

18. A building element according to claim 17, wherein the polyurea is approximately 1 mm to 6mm thick.

19. A building element according to claim 17, wherein the polyurea is approximately 1 mm to 3mm thick.

20. A building element according to any one of claims 8 to 19, wherein the foam chips, foam dust, cement and water form a body approximately 100mm to 250mm thick.

21. A building element according to any one of claims 8 to 20, wherein the foam chips, foam dust, and cement are in a ratio of approximately five parts foam chips, one part foam dust and two parts cement, by volume, with water to mix.