WO2022053883A1

WO2022053883A1 - Low emission stable floor panel

Info

Publication number: WO2022053883A1
Application number: PCT/IB2021/056296
Authority: WO
Inventors: Dominique VAN DER VELDEN
Original assignee: Vdv R&D Bvba
Priority date: 2020-09-10
Filing date: 2021-07-13
Publication date: 2022-03-17
Also published as: BE1028596A1; BE1028596B1

Abstract

The invention provides a floor panel for a stable floor at least partly made of rubber or an elastic synthetic material, whereby the part made of rubber or an elastic synthetic material is provided with one or more discharge channels through the rubber or the elastic synthetic material, with dimensions for, in use, transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure, characterised in that one or more discharge channels widen downstream whereby the opening or surface of the transversal section increases from the upperside of the floor panel to the underside of the floor panel. The invention also provides a kit with components for composing a floor panel according to an embodiment of the invention. The invention further provides a stable floor comprising the floor panels and a method for the assembly of a low emission stable floor.

Description

LOW EMISSION STABLE FLOOR PANEL

TECHNICAL FIELD

The invention relates to a stable floor panel and a stable floor obtained with the stable floor panel. The invention also relates to a kit for the assembly of the stable floor panel, to the usage of the stable floor panel and to a method for manufacturing a low emission stable floor.

The invention is situated in the field of agriculture and stockbreeding, more specifically in environmental technology for reducing ammonia emissions in a stable.

BACKGROUND

Within the context of European regulations, nitrogen emissions need to be reduced. This also applies to stockbreeding. Although nitrogen is present in excrements, both manure and urine, the impact is different. In manure, the solid components in excrements, proteins are present. Manure proteins are released gradually and play a small role in the nitrogen problem. Urine, the liquid component of excrements, contains nitrogen in the form of urea. Urea is converted into ammonia (NH3) by the urease present in manure. Ammonia volatilises and therefore these emissions are important.

Stable floor panels and stable floors used in livestock stables are generally known. A distinction is made herein between grid floors and closed floors ; and corresponding stable floor panels . To reduce nitrogen emissions , various solutions have been proposed concerning the flooring of stables and the treatment of excrement .

EP 1563728 discloses a stable floor panel which essentially consists of a grid made of concrete . The stable floor panel is constructed from ribs which are placed at a distance from each other and are mutually connected by means of transversal ribs , also made of concrete . Such stable floor panels are made as integrated elements . The openings provided between the ribs are intended for the discharge of the excrements to a pit which is usually provided under such stable floor . A stable floor consisting of such known stable floor elements is usually cleaned by regularly scraping the floor, be it manual ly or automatically by a manure robot or a slide , whereby the scraped of f excrements are also discharged via the openings between the ribs into the underlying pit .

One of the disadvantages of said stable floor is that the discharged urine and manure are collected directly under the floor and that the ammonia, which is produced in the storage area, easily escapes into the outside air via the grid openings . Moreover, this open grid floor is not comfortable for the stable animals .

To increase the comfort of stable animals , the use of rubber mats was suggested . In a known embodiment , a mat is laid over the whole stable floor . A disadvantage of said embodiment is that the mat is loose on the stable f loor and may shi ft following use or when scraping of f . An attachment of said mats to the concrete floor is cumbersome and has the additional disadvantage that the fasteners , such as for example screws , may cause inj uries to the animals .

BE 1018081 and BE 1019414 disclose a stable panel whereby a concrete grid is combined with inserts made of rubber or an elastic synthetic material , to increase animal wel fare . This prevents the rubber or elastic synthetic material from shi fting . The excrements , manure and urine , are discharged to a cellar under the floor, through big openings in the rubber or elastic synthetic material .

EP 0626131 discloses a stable floor for reducing the emission of ammonia in a stable . The stable floor is constructed from floor plates covering a storage area . The floor plates are full tiles provided with grooves which extend in the longitudinal direction of the floor plates , perpendicular to the longitudinal direction of the storage area . The surfaces of the plates are slanted for an accelerated discharge of urine . The urine is discharged together with the manure to a storage area under the tiles , through slots between the tiles .

One of the disadvantages of said stable floor is that the discharged urine and manure are collected directly under the floor and that the ammonia, which is produced in the storage area, can still easily escape into the outside air via the openings or slots . The slanted position of the floor plates is not comfortable for the animals and farmer . NL 2005533 discloses a stable floor with openings for the discharge of manure and urine to a storage area . The stable floor is provided with means for sealing the openings between the tiles . However, the proposed mechanical solution requires extra maintenance and is vulnerable for pollution . It is customary in stables to remove excrements with manure slides . To this end it is customary to let the manure slides slide over the stable floor in the longitudinal direction such that the stable floor can be cleaned in one go in the longitudinal direction . However, the openings and slots will collect too much excrement in such cleaning operation which are particularly di f f icult to remove because of the shape of the openings and slots . Extra cleaning work is necessary .

NL 2013079 discloses a stable with a stable floor for reducing the emis sion of ammonia in the stable , whereby the stable comprises at least one stable section for livestock and a discharge section extending in a longitudinal direction along the at least one discharge section, whereby the stable floor is placed in the longitudinal direction on the discharge section, whereby the stable floor is provided with at least three , longitudinally extending, mutually parallel and transversely to the longitudinal direction spaced discharge gutters for discharging urine to a collection area located at an end of the floor . Said groove type floor requires regular cleaning to prevent or remedy a blockage of the discharge gutters . Cleaning the grooves requires a lot of water . This is not environmentally friendly . Consequently there is a need for further alternatives and improvements .

The purpose of the present invention is to provide a solution for one or more of the aforementioned problems .

SUMMARY OF THE INVENTION

A purpose of the invention is to provide a stable floor panel for reducing the emission of ammonia in a stable , with due regard of the wel fare of stable animals , and whereby at least one of the aforementioned drawbacks can at least be partially removed .

The present invention provides for a floor panel for a stable floor at least partly made of rubber or an elastic synthetic material , whereby the part made of rubber or an elastic synthetic material is provided with one or more discharge channels through the rubber or the elastic synthetic material , with dimensions for, in use , transporting urine from the uppers ide of the floor panel to the underside of the floor panel and stopping solid components in stable manure , characterised in that , one or more discharge channels are wider downstream, i . e . whereby viewed in the position of use , a narrower opening or smaller section of the discharge channel is provided at the top than at the bottom, whereby the floor panel comprises a prefabricated concrete or composite grid and at least one comfort element made of rubber or an elastic synthetic material , whereby the at least one comfort element is mounted in at least one opening of the prefabricated concrete or composite grid, characterised in that the openings in the prefabricated concrete or composite grid are filled, thus obtaining a full stable floor panel , and the at least one comfort element is provided with one or more of said downstream widening discharge channels through the comfort element .

The advantage of said floor panel is that urine can be discharged close to the source . This quick discharge of urine is important for the reduction of the emission of ammonia (NH3 ) . The contact time of urine with manure should be kept as short as possible . The small openings ensure a primary manure separation between liquid and solid products . The small dimensions o f the openings ensure a reduced emission compared to open gutters and grooves or slots .

The downstream widening discharge channels , which refer to discharge channels with a narrower opening at the top than at the bottom in a position of use , allow the urine to be immediately discharged through the openings whereas the solid manure temporarily stays on the upperside of the stable floor .

The combination of the flexible property of the material and the downstream widening discharge channels avoids that manure , which possibly ends up in the discharge channels anyway, blocks the passage .

Preferably, downstream widening discharge channels become generally wider from top to bottom in the position of use . Or in other words the surface of the cross-section of the discharge channel , also called transversal section, from top to bottom, viewed in position of use, does not decrease signi ficantly anywhere nor does it increase generally .

Indeed, the elastic property of the rubber or the synthetic material will ensure a massaging operation due to the movement of animals and/or machines which in combination with the global broadening or widening of the passage in a downward direction, will ensure that a quantity of infiltrated solid manure in a discharge channel will be moved through the discharge channel without the risk of blockage .

In a further aspect the invention provides for a kit of components for a stable floor panel according to an embodiment of the invention, comprising a prefabricated concrete or composite grid and at least one comfort element made of rubber or an elastic synthetic material , whereby the at least one comfort element has dimensions that are suitable for mounting in at least one opening of the prefabricated concrete or composite grid, characterised in that the number of comfort elements provided in the kit suf fices to fill the openings in the prefabricated concrete or composite grid with the comfort elements thereby obtaining a full floor panel , and that at least one of the provided comfort elements is provided with one or more discharge channels through the comfort element with dimensions for, in use , transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure after assembly in an opening of the prefabricated concrete or composite grid .

The advantage of this embodiment i s that it combines animal wel fare and the reduction of nitrogen emissions .

In an additional aspect the invention provides for a stable floor comprising a floor panel according to an embodiment of the invention .

In a further aspect the invention provides for a method for manufacturing a low emission stable floor, comprising the steps : providing a prefabricated concrete or composite grid with at least one oblong-shaped opening; providing at least one comfort element made of rubber or an elastic synthetic material with corresponding oblongshaped form suitable for filling the at least one oblongshaped opening, wherein the comfort element is provided with one or more discharge channels through the comfort element with dimensions for transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure ; filling said at least one oblong-shaped opening with said at least one comfort element ; repeating the filling step until a full floor panel is obtained .

In a last aspect the invention provides for a use for a stable floor panel or for a kit of components for a stable floor panel , according to an embodiment of the invention, as a means for separating liquid and solid components in stable manure .

This use has the advantage that a quick separation of liquid and solid components of excrements takes place , the transport of urine to the storage area is extremely short , and the storage area is practically sealed by the stable floor panel , which limits emissions .

Further preferred embodiments are developed in the dependent claims .

DESCRIPTION OF THE FIGURES

Figure 1 shows a three dimensional representation of a stable floor panel according to a preferred embodiment of the invention .

Figure 2 shows a three dimensional representation of a kit for the assembly of a stable floor panel according to a preferred embodiment of the invention .

Figure 3 shows a cross-section view, according to a plane perpendicular to the walking surface , of four alternatives of a discharge channel .

DETAILED DESCRIPTION OF THE INVENTION

Unless otherwise defined all terms used in the description of the invention, including technical and scienti fic terms , have the meaning that is generally understood by a person skilled in the art in the area to which this invention refers. Definitions of the terms have been included for a better understanding of the description of the present invention .

As used here, the following terms have the following meaning :

"A", "an" and "the" as used here, refer both to the singular and the plural, unless the context indicates otherwise. "A compartment" refers, by way of example, to one or more than one compartment.

"Approximately" as used here, which refers to a quantifiable value such as a parameter, a quantity, a period of time, etc., is intended to comprise variations of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, even more preferably +/-1% or less, and most preferably +/-0.11 or less of the specified value, in so far such variations are suitable to execute in the described invention. However, it will be clear that the value to which the term "approximately" refers, is itself also specifically described. "Comprise", "comprising" and "comprises" and "consisting of" as used here, are synonym with "contain", "containing" or "contains" and are inclusive or open terms which specify the presence of what follows e.g. a component and the presence of supplementary, not mentioned components, characteristics, elements, parts, steps, that are well known in the state of the art or described therein, and do not exclude them. Citing numerical ranges with end points comprises all numbers and fractions included within that range , as well as the mentioned end points .

The invention provides a solution for the problem to combine animal wel fare with the reduction of nitrogen emissions .

In a first aspect the invention provides a floor panel for a stable floor . The floor panel is mainly aimed at the use in a stable for bovine animals , particularly cows . The floor panel is at least partly made of rubber or an elastic synthetic material . The part made of rubber or an elastic synthetic material is provided with one or more discharge channels through the rubber or the elastic synthetic material , with dimensions for, in use , transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure . The floor panel is characterised by one or more downstream widening discharge channels whereby, viewed in the position of use , a narrower opening or smaller section of the discharge channel is provided at the top than the bottom .

Preferably, the section of the cross-section of the discharge channels increases from the upperside of the floor panel to the underside of the floor panel .

In a preferred embodiment , the floor panel is entirely made of rubber or an elastic synthetic material . The floor panel is executed as a floor mat .

In an alternative preferred embodiment the floor panel comprises a prefabricated concrete or composite grid and at least one comfort element made of rubber or an elastic synthetic material . At least one comfort element is applied in at least one opening of the prefabricated concrete or composite grid . Preferably, all openings of said grid are filled with said comfort element . The floor panel i s a full floor panel , in which all openings in the pre fabricated concrete or composite grid are filled . Other possibilities to fill a grid opening are the use of cubes of composite material , aimed at claw wear of the bovine animals . The comfort element in a floor panel according to the invention is provided with one or more discharge channels through the comfort element with dimensions for, in use , transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure .

This full and practically closed floor panel has the advantage that , in use , a primary manure separation is obtained . The liquid and solid components are separated . The quick discharge away from the upperside of the floor panel limits the contact time with manure . The discharge through small holes limits emissions , the urine in the discharge channels may cause a fluid lock . The comfort element benefits animal wel fare . The separation of liquid and solid excrements results in a higher manure value .

The dimensions of the downstream widening discharge channels were chosen such that solid components in stable manure are stopped, but urine can pass . Preferably, the downstream widening discharge channels have an inside diameter situated between 6 and 25 mm on the upperside . A typical dimension is an inside diameter of 20 mm on the upperside .

Preferably, a downstream widening discharge channel has an inside diameter on the underside that is 2 to 12 mm bigger than the inside diameter on the upperside . A typical dimension is an inside diameter of 25 mm on the underside .

More preferably, a downstream widening discharge channel has an inside diameter of 20 mm on the upperside and 25 mm on the underside .

A downstream widening discharge channel can also be elongated . Preferably an elongated downstream widening discharge channel has an inside di stance between 2 and 8 mm on the upperside for the opposite long sides . Preferably, an elongated downstream widening discharge channel has an inside distance between 4 and 18 mm on the underside .

The stable manure can be discharged by regularly scraping the floor and discharging the excrements to a collection pit . The removal of the stable manure can be done manually or using a manure robot or manure slide .

Preferably, at least 10% of the total number of comfort elements that is used in the floor panel has a Shore 00 situated between 20 and 90 . More preferably, at least 50% of the total number of comfort elements used in the floor panel has a Shore 00 situated between 20 and 90 . Most preferably, at least 75% of the total number of comfort elements used in the floor panel has a Shore 00 situated between 20 and 90 . The Shore 00 20- 90 range points to an extra soft to soft rubber or elastic synthetic material . These comfort elements are easily deformable and mouldable . Solid components that do end up in a discharge channel are displaced by the impact of the stable animals ' hooves on the discharge channels of the comfort elements . This prevents blockages .

A floor panel according to the invention is characterised by one or more downstream widening discharge channels , whereby the opening of the downstream widening discharge channel increases from the upperside of the floor panel to the underside of the floor panel .

In an alternative embodiment , the discharge channels are slot-shaped .

Rubber and elastic synthetic materials have the advantage that the materials have a low urease activity . They do not contribute to nitrogen emissions .

In a preferred embodiment , the rubber is a natural rubber .

In a preferred embodiment , the elastic synthetic material is selected from closed-cell ethylene vinyl acetate (EVA) copolymer foam, natural rubber (NR) , Ethylene Propylene Diene monomer (EPDM) rubber, and combinations . This choice of material ensures durability, toughness , impact resistance .

Most preferably, ethylene vinyl acetate (EVA) copolymer foam is used. This ensures a soft cushion comfort. The material is non-porous, non-absorbing, impenetrable for liquids. Urine cannot penetrate into the material to form a stinking ammonia smell and bacterial growth is prevented.

Preferably, the at least one comfort element has a surface free from grooves and protrusions on the upperside of the floor panel. Consequently, a surface without pattern is obtained that is easy to clean. This is hygienic and good for the claw health of the bovine animals. It is comfortable for stable animals. More preferably, at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 100% of the comfort elements in a floor panel has a surface free from grooves and protrusions on the upperside of the floor panel .

In an alternative embodiment or additional embodiment, the prefabricated concrete or composite grid has a surface that is free from grooves and protrusions, or other patterns, on the upperside of the floor panel.

Most preferably, at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 100% of the floor panels in a stable floor has a surface free from grooves and protrusions, and other patterns, on the upperside of the floor panel.

The aforementioned embodiments facilitate a good cleaning.

It is advantageous for a hygienic floor and good claw health of bovine animals .

Preferably, ribs of the prefabricated concrete or composite grid form at least one oblong-shaped opening and the at least one oblong-shaped opening is filled by a single comfort element made of rubber or an elastic synthetic material with corresponding oblong-shaped form .

The use of oblong-shaped forms makes the production more ef ficient . The assembly of strips is easy .

Preferably, a single comfort element comprises at least 1 , 2 or 3 , more preferably at least 4 , most preferably at least 5 , of said discharge channels . Most preferably said discharge channels are cylindrical or slot-shaped .

This ensures a good discharge capacity per comfort element . By replacing comfort elements with a di f ferent number of discharge channels , the discharge capacity can be adapted . This also has the advantage that the emissions can be adapted, for example to the number of bovine animals in a stable or the type of animals kept in the stable .

In a preferred embodiment of the invention the floor panel is rectangular and the oblong-shaped openings are parallel to the longitudinal axis of the floor panel .

In an alternative preferred embodiment of the invention the floor panel is rectangular and the oblong-shaped openings are positioned perpendicularly relative to the longitudinal axis of the floor panel . The floor panels can be executed taking into account the walking direction of the animals in a stable and taking into account how the stable floor is cleaned .

The number of ribs in relation to the number of comfort elements positioned in a parallel way with the ribs , is preferably 6 : 5 .

This ratio has the advantage of a frequent alternation between concrete and rubber/elastic synthetic material . This benefits animal wel fare , as contact with the concrete use surface allows the animals to wear down their hooves or claws . Moreover, a varying foundation of fers a better grip which increases the safety . The floor panels are made antiskid with this .

Preferably, a stable floor panel comprises a bearing element , with a use surface located on the upperside in use and a bottom surface located on the underside , whereby the use surface is provided with one or more levels , recesses or openings , whereby in at least one of said levels , recesses or openings a said comfort element is mounted, said comfort element extending from the internal space in the recess or opening in which it has been mounted to attach the comfort element , to j ust below, flush with or above the use surface , all this viewed from the pos ition of use of the stable floor panel . Preferably, the bearing element is made of concrete .

This embodiment has the advantage that a very simple mounting method of the comfort elements is achieved . The comfort elements can be simply mounted in the recesses or openings , without additional mechanical attachment being required, which could be harmful for the health and safety of the stable animal s . This results in a very economical stable floor, the comfort elements of which can be simply replaced, for example when they are due for replacement as a result of wear and tear, or when the stable floor will be used for other animals .

Due to the presence of a bearing wall which is parallel or practically parallel to said use surface and/or said bottom surface , said comfort element receives good support . The good support ensures the comfort element is kept in place . A good operation of the floor plate is obtained .

Preferably the stable floor plate is provided with locking means which prevent the rotation of the comfort element in the grid opening . The locking means are executed, for example , in the form of two engaging coupling parts which are provided to the comfort element and to the bearing element respectively .

The presence of said locking means prevents the comfort element in the grid opening from rotating .

The present invention also relates to a comfort element which is used in the manufacture o f a stable floor plate according to the invention .

In a second aspect the invention provides for a kit of components for a stable floor panel according to an embodiment of the invention, comprising a prefabricated concrete or composite grid and at least one comfort element made of rubber or an elastic synthetic material , whereby the at least one comfort element has dimensions that are suitable for mounting in at least one opening of the prefabricated concrete or composite grid, characterised in that the number of comfort elements provided in the kit suf fices to fill the openings in the prefabricated concrete or composite grid with the comfort elements thereby obtaining a full floor panel , and that at least one of the provided comfort elements is provided with one or more discharge channels through the comfort element with dimensions for, in use , transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure after assembly in an opening of the prefabricated concrete or composite grid .

More preferably, at least 10% , 20% , 30% , 40% , 50% , 60% , 70% , 80% , 90% or 100% of the comfort elements in the kit are provided with said one or more discharge channels .

In a third aspect the invention provides for a stable floor comprising a floor element according to an embodiment of the invention . Preferably, the stable floor is rectangular .

Preferably, the ribs of the prefabricated concrete or composite grid form at least one oblong-shaped opening and the at least one oblong-shaped opening is filled by a single comfort element made of rubber or an elastic synthetic material with corresponding oblong-shaped form, and in which the single comfort element comprises at least five of said discharge channels through the comfort element ; and in which said oblong-shaped comfort element is positioned perpendicularly relative to the longitudinal axis of the floor .

This orientation is advantageous to prevent slipping .

In a fourth aspect the invention provides for a method for manufacturing a low emission stable floor, comprising the steps : providing a prefabricated concrete or composite grid with at least one oblong-shaped opening; providing at least one comfort element made of rubber or an elastic synthetic material with corresponding oblongshaped form suitable for filling the at least one oblongshaped opening, in which the comfort element is provided with one or more discharge channels through the comfort element with dimensions for transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure ; filling said at least one oblong-shaped opening with said at least one comfort element ; repeating the filling step until a full floor panel is obtained; transporting the filled full floor panels to a stable comprising a bearing structure for a floor ; mounting said floor panels on said bearing structure .

As a bearing structure for a floor, an earth or concrete floor can serve ; or a concrete , metal or plastic tub ; or an existing floor .

In a preferred embodiment the method comprises : transporting the filled full floor panels to a stable comprising a floor with openings suitable for the removal of urine and stable manure of f the floor ; and at least partly replacing or sealing said floor with said filled full floor panels .

The result of the method is that a low emission stable floor is obtained .

In an alternative embodiment , first the grids are installed . The grid openings are subsequently filled with comfort elements .

In a last aspect the invention provides for a number of uses .

Preferably, a floor panel for a stable floor or a kit of components for assembly of a stable floor according to an embodiment of the invention is used as a means for separating liquid and solid components in stable manure . The ef fect of the separation is that urine and excrements can no longer come into contact . This is advantageous for avoiding that urea in urine is converted into nitrogen . Additionally, the small openings of the discharge channels ensure that a collector under the floor is practically sealed of f by the floor panels . Urine in the small tubes may ensure a fluid lock due to a capillary ef fect and reduction of nitrogen emissions from below the floor panels . Every time a bovine animal or cow walks over the rubber or the elastic synthetic material , it is partially compressed . Said massage operation pushes the possibly present solid fraction from the opening . There is a sel fcleaning ef fect .

Preferably, said floor panel or said kit is used for reducing emissions in stables of bovine animals , preferably stables for cows .

With the intention of better showing the characteri stics of the invention, some preferred embodiments according to the present invention are described hereinafter by way of an example , without any limiting nature , with reference to the accompanying drawings .

Example 1

Figure 1 shows a stable floor plate which is built according to the invention .

The stable floor plate 1 is rectangular in form and comprises a prefabricated concrete grid 2 that is filled with oblong-shaped, rectangular rubber comfort elements 3 . The comfort element has a Shore 00 60 softness .

The grid 2 consi sts of a number of ribs 11 , in this case six parallel ribs installed at a distance from each other . The ribs 11 are mutually connected here by means of five transversal ribs 13 , one at each of the ends of the ribs and three in the middle . The middle rib shows a groove or gutter 12 . Said recess 12 can be used for the chain of a manure slide .

Apart from a gutter 12 there are no grooves , gutters , recesses or protrusions in the concrete part of the stable floor plate 1 . The comfort elements 3 are in the recesses of the grid 2 . The design and the si zes of the comfort element 3 are such that it can be mounted precisely in an opening 4 between the ribs 11 of the grid 2 .

The comfort element 3 reaches from the internal space of the opening 4 , in said embodiment the space between the ribs 11 , 13 in which the comfort element 3 is mounted for its attachment , up to the use surface 9 .

The surface of the comfort elements on the upperside 9 of the grid 2 runs parallel with the surface of the ribs 11 , 13 of the grid on the upperside 9 of the grid in the embodiment shown . To this end, the side of the comfort element 3 which in use is located on the upperside 9 , is executed flat . The ribs are executed without notches , grooves , gutters or other structure, with the exception of the central rib with gutter 12 . This forms an even walking surface in which concrete and rubber strips alternate frequently .

The assembly of a stable floor panel 1 according to the invention is simple and as follows . A concrete or composite grid 2 with at least one oblong-shaped opening 4 was made . A comfort element 3 from rubber or an elastic synthetic material was also made . The comfort element has an oblongshaped form which corresponds with the oblong-shaped opening between the ribs of the grid 2 .

The comfort element was perforated to obtain one or more discharge channels 6 , 7 . As an alternative to perforating, a comfort element can be made in a mould or in an inj ection mould .

Subsequently, the openings 4 in the floor panel are filled with at least one said comfort element 3 . In the embodiment shown all openings 4 are filled with said comfort elements 3 . When all openings 4 are filled, a full floor panel 1 is obtained .

The mounting method for a floor panel 1 according to the invention can be done as follows .

A kit of components as shown in figure 2 can be used . The kit comprises a grid 2 and a number of comfort elements 3 . The number of comfort elements in the kit suf fices to fill the openings 4 , 5 in the prefabricated concrete or composite grid 2 with the comfort elements 3 thereby obtaining a full floor panel 1 . At least one of the provided comfort elements 3 is provided with one or more discharge channels 6 , 7 with dimensions for transporting urine from the upperside 9 of the floor panel to the underside 10 of the floor panel and stopping solid components in stable manure . The discharge channels can be cylindrical or slot-shaped . The openings of the grid 2 are filled with the comfort elements 3 .

The filled full floor panels 1 are brought to a stable .

The stable may already have a floor, which will be used as the foundation for a new floor or replace it . The stable may also not yet have a floor and consist of an earth base or a receptacle for example .

The full floor panels are installed on the underlying structure to seal a receptacle or existing floor with openings . I f there is only an earth base , first a receptacle is provided . It is important there is a structure on which the floor panels can be installed .

In use , the upperside of the floor plates will receive urine and manure . By providing frequent discharge channels on the comfort elements , the urine is discharged toward the underside of the floor plate . Under the floor plate the urine can be collected in a receptacle or discharge pipe . Manure is stopped by the discharge channels . I f solid components do end up in the discharge channels and form a plug, the animals ' impact on the soft discharge channels pushes the plug further through the channels . The massaging impact of the animals on the soft material makes sure that the channel is freed . The small dimensions of the narrow passages also ensures that fluid can remain in the channels . The capillary ef fect ensures a fluid lock above the receptacle or the discharge pipe .

When the comfort elements show signs of wear, they can easily be replaced . They are easy to clean .

Figure 3 shows a cross-section o f four alternatives of a discharge channel 6 , 7 by way of an example . The crosssection is according to a plane perpendicular to the walking surface of the comfort elements 3 on the upperside .

In the first alternative in the top left-hand corner shown in figure 3 the discharge channel of the walking surface located at the top, viewed in position of use , runs to the plane located at the bottom, first with a constant section after which the section gradually widens .

Section here refers to the surface of the cross-section according to a plane parallel to the walking surface located at the top .

In the second alternative in the top right-hand corner shown in figure 3 the discharge channel runs from the walking surface located at the top, viewed in position of use , to the panel located at the bottom, first with a constant section after which the section first widens quickly, then less quickly, subsequently the section decreases slightly but only to a limited extent , after which the section gradually widens . In this way, said variant provides for a volume in which pressure can be built with which a possible plug can be removed .

In the third alternative in the bottom left-hand corner shown in figure 3 , the discharge channel gradually widens from the walking surface located at the top, viewed in position of use , to the plane located at the bottom

In the fourth alternative in the bottom right-hand corner shown in figure 3 the discharge channel runs from the walking surface located at the top, viewed in position of use , to the plane located at the bottom first with a constant section after which the section gradually widens , subsequently a zone is provided with constant section and in the end the section gradually widens up to the plane located at the bottom .

In the broadest interpretation, the downstream widening discharge channels are understood to mean that at the top, viewed in position of use , a narrower opening or smaller section of the discharge channel is provided than at the bottom, which allows urine to be discharged immediately through the openings while the solid manure temporarily stays on the upperside of the stable floor .

Preferably, downward widening discharge channels widen generally from top to bottom, viewed in position of use . Or in other words the surface of the cross-section of the discharge channel , also called transversal section, from top to bottom, viewed in the position of use , does not decrease signi ficantly anywhere nor does it increase generally .

Claims

1. A floor panel for a stable floor at least partly made of rubber or an elastic synthetic material, whereby the part made of rubber or an elastic synthetic material is provided with one or more discharge channels through the rubber or the elastic synthetic material, with dimensions for, in use, transporting urine from the upperside of the floor panel to the underside of the floor panel and stopping solid components in stable manure, characterised in that, one or more discharge channels are widening downstream, i.e. whereby viewed in the position of use, a narrower opening or smaller section of the discharge channel is provided at the top than at the bottom, characterised in that the floor panel comprises a prefabricated concrete or composite grid (2) and at least one comfort element made of rubber or an elastic synthetic material (3) , whereby the at least one comfort element (3) is mounted in at least one opening (4) of the prefabricated concrete or composite grid (2) , characterised in that the openings (4, 5) in the prefabricated concrete or composite grid (2) are filled, thus producing a full stable floor panel (1) , and the at least one comfort element (3) is provided with one or more of said downstream widening discharge channels (6, 7, 8) through the comfort element (3) .

2. Floor panel (1) according to claim 1, characterised in that at least 10% of the total number of comfort elements

(3) has a Shore 00 situated between 20 and 70. 30

3. Floor panel (1) according to any one of the previous claims 1 to 2, characterised in that the elastic synthetic material was selected from ethylene vinyl acetate (EVA) copolymer foam, natural rubber (NR) , Ethylene Propylene Diene Monomer (EPDM) rubber, and combinations.

4. Floor panel (1) according to any one of the previous claims 1 to 3, characterised in that the at least one comfort element (3) has a surface free from grooves and protrusions, on the upperside (9) of the floor panel (1) .

5. Floor panel (1) according to any one of the previous claims 1 to 4, characterised in that the prefabricated concrete or composite grid (2) has a surface free from grooves and protrusions, on the upperside (9) of the floor panel ( 1 ) .

6. Floor panel (1) according to any one of the previous claims 1 to 5, characterised in that ribs of the prefabricated concrete or composite grid (2) form at least one oblong-shaped opening (4) and the at least one oblongshaped opening (4) is filled with a single comfort element (3) made of rubber or an elastic synthetic material with corresponding oblong-shaped form, and in which the single comfort element (3) comprises at least 1 of said downstream widening discharge channels (6, 7, etc) .

7. Floor panel (1) according to claim 6, characterised in that the floor panel (1) is rectangular and the oblongshaped openings (4, 5) are parallel with the longitudinal axis (L) of the floor panel (1) .

8. Floor panel (1) according to claim 7, characterised in that the floor panel (1) is rectangular and the oblongshaped openings are positioned perpendicularly relative to the longitudinal axis of the floor panel.

9. Floor panel (1) according to any one of the previous claims 1 to 8, characterised in that the number of ribs (11) relative to the number of comfort elements (3) is positioned parallel with the ribs, is 6:5.

10. A kit of components for a stable floor panel (1) according to any one of the previous claims 1 to 9, comprising a prefabricated concrete or composite grid (2) and at least one comfort element (3) made of rubber or an elastic synthetic material, whereby the at least one comfort element (3) has dimensions that are suitable for mounting in at least one opening (4) of the prefabricated concrete or composite grid (2) , characterised in that the number of comfort elements (3) provided in the kit suffices to fill the openings (4, 5) in the prefabricated concrete or composite grid (2) with the comfort elements (3) thereby providing a full floor panel (1) , and that at least one of the provided comfort elements (3) is provided with one or more downstream widening discharge channels (6, 7) through the comfort element (3) with dimensions for, in use, transporting urine from the upperside (9) of the floor panel (1) to the underside (10) of the floor panel (1) and stopping solid components in stable manure after assembly in an opening (4) of the prefabricated concrete or composite grid (2) , and whereby the opening of the downstream widening discharge channels increases from the upperside of the floor panel to the underside of the floor panel .

11. A stable floor comprising a floor panel (1) according to one of the claims 1 to 10.

12. Stable floor according to claim 11, with a rectangular shape characterised in that ribs (11) of the prefabricated concrete or composite grid (2) form at least one oblongshaped opening (4) and the at least one oblong-shaped opening (4) is filled with a single comfort element (3) made of rubber or an elastic synthetic material with corresponding oblong-shaped form, and in which the single comfort element (3) comprises at least 1 of said discharge channels (6, 7, etc.) through the comfort element (3) , and in which said oblong-shaped comfort element is positioned perpendicularly relative to the longitudinal axis of the floor .

13. Method for manufacturing a low emission stable floor, comprising the steps: providing a prefabricated concrete or composite grid (2) with at least one oblong-shaped opening (4) ; providing at least one comfort element (3) made of rubber or an elastic synthetic material with corresponding oblong-shaped form suitable for filling the at least one oblong-shaped opening (4) , in which the comfort element (3) is provided with one or more downstream widening discharge channels (6, 7) through the comfort element (3) with dimensions for transporting urine from the upperside (9) of the floor panel to the underside (10) of the floor panel (1) and stopping solid components in stable manure and whereby the opening of the downstream widening discharge channels increases from the upperside of the floor panel to the underside of the floor panel; filling of said at least one oblong-shaped opening (4) with said at least one comfort element (3) ; repeating the filling step until a full floor panel (1) is obtained.

14. Use of a floor panel (1) for a stable floor according to any one of the claims 1 to 9 or a kit of components (2, 3) for a stable floor panel (1) according to claim 10, as a means for separating liquid and solid components in stable manure .

15. Use according to claim 14, for reducing emissions in stables of bovine animals, preferably in stables with cows.