WO2023062083A1

WO2023062083A1 - Self-levelling pedestal for raised flooring

Info

Publication number: WO2023062083A1
Application number: PCT/EP2022/078407
Authority: WO
Inventors: Caleb WHITE; Andrew Douglas
Original assignee: Ryno Ltd
Priority date: 2021-10-15
Filing date: 2022-10-12
Publication date: 2023-04-20
Also published as: GB2611797A; EP4416348A1; GB202114763D0

Abstract

A self-levelling pedestal (100) for supporting a flooring member, has a top plate pivotable relative to the floor such that the it can be oriented at a non-zero angle to the floor. A locking mechanism is provided configured to lock the position of the top plate in at least one non-zero angle.

Description

Self-levelling pedestal for raised flooring

Technical Field

[0001 ] The present invention relates to a self-levelling pedestal for supporting raised floor members. More specifically, the present invention relates to an adjustable-height pedestal for supporting at least one paving slab, decking member or support beam in use to form a raised floor surface.

Background Art

[0002] Raised flooring structures such as raised paving and decking systems typically use pedestals. Such pedestals come in a variety of forms, but fundamentally comprise a base which supports the pedestal on an underlying surface, and a support surface for supporting a flooring member such as a paving slab, decking member, support beam or the like. The base and support surface are spaced apart to provide a pedestal height, which in some cases is adjustable, e.g. by means of a two-part assembly having a threaded joint therebetween.

[0003] One such prior art pedestal is shown in Figure 1 . The prior art pedestal 10 comprises a lower assembly 12 having a base plate 14 with a threaded male shaft 16 projecting normal therefrom. An upper assembly 18 comprises a top plate 20 and threaded female shaft 22. A tightening nut 24 is provided. The top plate 20 defines a support surface 26.

[0004] The female shaft 22 is engaged with the male shaft 16 such that the pedestal height H (distance between the support surface 26 and the bottom of the base plate 14) can be adjusted by relative rotation. The nut 24 is also threaded onto the male shaft 16 and can be rotated to engage the free end of the female shaft 22 to lock it in position.

[0005] Once the desired height H / H' has been set, the pedestal is attached to an underlying surface 28 and floor members 30, 32 are installed on top to define a floor surface 34 / 34'. The floor members 30, 32 are shown in two different positions (30, 32 and 30', 32') to demonstrate the adjustment range of the pedestal 10).

[0006] A problem with prior art pedestals such as the one above, is that they are not well suited to situations where the underlying surface 28 and the desired plane of the floor surface 34 are not parallel (i.e. at a non-zero angle to each other). For example, the reason for the installation may be to "level out" a surface that is, for example, at a slope. [0007] Some known devices provide the ability to vary the angle between the base 1 4 and the top plate 20. One such example is disclosed in EP 3 1 81 779 to Buzon Pedestal International. In EP'779 a slope compensation device is provided comprising two relatively rotatable slope compensation elements. The device is placed underneath the pedestal. In order to adjust the compensation angle of the device, the two parts are rotated relative to one another.

[0008] A problem with this approach is that the adjustment angle needs to be known prior to installation. Therefore if the incorrect angle is selected, this may only be detected once the paving slabs are installed. Once such a mistake has been detected, the system needs to be disassembled to adjust the slope compensation angle.

[0009] A further example of a prior art system is the Impertek™ Balance Pro™. This system allows the top plate of the pedestal to rotate about horizontal axes (i.e. to tilt away from the horizontal) with respect to the shaft. In this way, flooring members can be supported at a non-zero angle to the base. Adjustment of the pedestal height is facilitated via a tool which penetrates the top plate to rotate the upper threaded member relative to the lower threaded member.

[001 0] A problem with this system is that it is only possible to lock the top plate in position at the zero-degree angle- i.e. it cannot be locked at a non-zero angle. Therefore if the product needs to support a flooring member at a non-zero angle it is still capable of tilt. This is not ideal for providing a stable flooring surface.

[001 1 ] It is an aim of the present invention to overcome, or at least mitigate, the above- mentioned problems.

Summary of Invention

[0012] According to a first aspect of the present invention there is provided a self-levelling pedestal (1 00) for supporting a flooring member, the pedestal comprising: a base (1 02) having a support surface (1 1 6); a head (1 08), distal to the base; a top plate (1 1 0) coupled to the head to be pivotable relative thereto such that the top plate can be oriented at a non-zero angle to the support surface of the base; a locking mechanism configured to inhibit said pivoting of the top plate relative to the head, the locking mechanism being configured to lock the position of the top plate in at least one non-zero angle to the support surface of the base.

[0013] Advantageously, this arrangement allows the top plate to pivot to the desired level under the load of the slabs (i.e. self-level). It can then be locked into position in the selflevelled orientation, providing a stable floor support.

[0014] Preferably a plurality of tabs are provided extending from the top plate, the tabs providing abutments extending between two adjacent flooring members in use such that the flooring members are spaced apart to facilitate access to the locking mechanism with a tool. Preferably each of the plurality of tabs is formed from deforming part of the top plate out of plane. Preferably each of the plurality of tabs is formed from a U-shaped cut in the top plate, the U-shaped cut facing away from a centre of the top plate. In this way, the tabs can be bent to change their angle relative to the top plate to extend a suitable height from the plate.

[0015] Preferably a spherical joint is provided between the head and the top plate, and wherein the locking mechanism is configured to lock the spherical joint.

[0016] Preferably the locking mechanism is configured to lock the spherical joint by friction.

[0017] Preferably the locking mechanism comprises a resiliently compressible element configured to maintain a frictional force on the spherical joint to lock it.

[0018] Preferably the locking mechanism comprises a locking element configured to exert a compressive force on the spherical joint.

[0019] Preferably wherein the locking element engages an upper surface of the top plate.

[0020] Preferably the locking element is part-spherical in shape.

[0021 ] Preferably the top plate is constructed from a part-spherical sheet material, wherein the underside of the top plate forms a spherical joint against the head, and where the upper side of the top plate is engaged by the locking element.

[0022] Preferably the locking mechanism comprises a fastener engaging the locking element at a first end, and engaging the head at a second end to selectively apply a clamping force on the top plate between the head and the locking member. [0023] Preferably the fastener is threaded to the head to engage the locking mechanism by rotation thereof.

[0024] Preferably the spherical joint is oriented with its origin on the base side of the top plate such that the spherical joint is upwardly convex in use.

[0025] Preferably the spherical joint comprises a motion stop limiting the degree of movement of the spherical joint.

[0026] Preferably wherein the motion stop is formed by an opening in the top plate through in which a stop member is located, the motion stop being provided by abutment between the periphery of the opening and the stop member.

[0027] Preferably the stop member is the fastener of the locking mechanism.

[0028] Preferably the fastener is accessible between at least two flooring members supported on the upper surface of the top plate.

[0029] Preferably the head and the base are adjustable relative to each other to vary the distance between the support surface and the top plate to thereby alter the height of the pedestal.

[0030] Preferably the head and the base are connected by a threaded connection to alter the height.

[0031 ] Preferably the threaded connection comprises a male threaded part engaged with a female threaded part, and wherein a locking member is provided, the locking member having a further female threaded part engaged with the male threaded part, such that rotation of the locking member into abutment with the female threaded part locks the female threaded part into position on the male threaded part.

[0032] Preferably the head defines a formation configured to be engaged by a tool to facilitate rotation thereof.

[0033] Preferably the head defines a pair of diametrically opposed flats.

[0034] The invention also provides a flooring assembly comprising: a self-levelling pedestal according to any preceding claim; a first flooring member; a second flooring member; wherein the first and second flooring members are supported on the top plate, such that the outside edges of the flooring members abut two of the plurality of tabs such that a gap is provided therebetween allowing access to the locking mechanism.

[0035] Preferably the pedestal comprises four tabs, the assembly comprising a third flooring member and a fourth flooring member, wherein each flooring member abuts two tabs on adjacent edges.

[0036] Preferably each two flooring members abut either side of each tab to space them apart.

[0037] The invention is particularly well suited to flooring members being paving slabs constructed from a ceramic or stone material. This is because such members are not formed with grooves / receiving formations for components to mate to. They are unitary and cuboid in shape.

[0038] According to a second aspect of the invention, there is provided a method of installing a raised floor comprising the steps of: providing a plurality of pedestals according to the first aspect; positioning the pedestals in a spaced-apart arrangement; providing a plurality of flooring members; supporting each flooring member on a plurality of pedestals, and allowing each pedestal top plate to reach a desired inclination by movement relative to the head; locking each top plate in position with the locking mechanism.

[0039] Preferably the step of locking comprises the step of passing part of a tool between adjacent flooring members to thereby engage the locking mechanism.

Brief Description of Drawings

[0040] An embodiment of the present invention will now be described with reference to the following figure in which: FIGURE 1 is a side view of a prior art pedestal;

FIGURE 2 is an exploded, perspective view of a first pedestal in accordance with the present invention;

FIGURE 3 is a plan view of the pedestal of FIGURE 2;

FIGURE 4 is a section view through IV-IV in FIGURE 3;

FIGURE 5 is a detail view of a part of FIGURE 4; and,

FIGURE 6 is a section view through IV-IV in FIGURE 3, of a single component only.

Description of the first embodiment

[0041 ] A first pedestal 100 is shown in Figures 1 to 6.

Configuration

[0042] The pedestal 100 comprises a base plate 102, a base shaft 104, a locking nut 106, a head shaft 108, a top plate 1 10, a friction locking member 1 12, a mechanical fastener 1 14 and a spring washer 1 15.

[0043] The base plate 102 and the base shaft 104 are attached (e.g. are unitary or e.g. welded together. The base plate 102 is square in shape (other shapes are possible) defining a lower surface 1 16 for contact with an underlying surface 98. The base plate 102 defines a plurality of openings 1 18 for receiving fasteners to secure it to the underlying surface 98. An upturned lip 122 is provided around the periphery of the plate 102 to ensure the underlying surface is not damaged by the plate 102.

[0044] The base shaft 104 projects perpendicularly from the centre of the base plate 102 defining a pedestal axis PA. The shaft 104 defines an external threaded formation 124. The shaft 104 is hollow having a circular free end 126.

[0045] The locking nut 106 defines a threaded inner surface 128 and an outer surface having gripping formations 130 to facilitate rotation by hand.

[0046] The head shaft 108 is shown more detail in section in Figure 5. It comprises a first shaft portion 132 having an internal threaded formation 134. The first shaft portion 132 tapers outwardly to a second (upper) shaft portion 136. At the end of the second shaft portion 136 there is provided a bearing member 138 constructed from sheet material and shaped as part of a sphere having radius R. As such, the bearing member defines an upwardly convex (inverted U-shaped) first bearing surface 140. At the geometric centre of the member 138 (in line with the axis of the shaft portions 132, 136) there is provided a central internally threaded opening 142. The bearing member 134 defines a pair of diametrically opposed flats 134a, 134b.

[0047] The top plate 1 10 is a generally flat, square component (other shapes are possible) having an outer annular portion 144 and an inner, shaped portion 146. The annular portion 144 defines four tabs 148a - 148d, each of which are constructed from outwardly facing U- shaped openings in the material of the plate 1 10. As such, the tabs can be bent upwardly and radially outwardly to extend from the upper surface of the plate 1 10 as shown in Figure 2. The inner portion 146 is recessed into the plate 1 10 in a first direction (downwardly in Figure 2) but defines a concave part-spherically curved bearing portion 150 having a downwardly facing, concave second bearing surface 152 of radius R. The bearing portion 150 also defines an upwardly facing convex surface 153 of radius (R+t) where t is the thickness of the inner portion 146. The concave curved bearing portion 150 defines a central opening 154.

[0048] The friction locking member 1 12 is constructed from a thin metal material. The member 1 12 is generally part-spherical and defines a lower concave locking surface 156 of radius (R+t). It has a central opening 158.

[0049] The spring washer 1 15 is helical in shape, and is resiliently deformable in axial compression.

[0050] All of the above components are constructed from metal material in the present embodiment, which offers excellent fire resistance. It will be noted that other materials (such as plastics) may be employed for applications that require less fire-resistant properties.

Assembly

[0051 ] To assemble the pedestal 100, the locking nut 106 is first threaded onto the base shaft 104. The female threaded formation of the head shaft 108 is then engaged with the base shaft 104, above the locking nut 106. The top plate 1 10 is placed onto the head shaft 108 such that the concave second bearing surface 152 receives the convex first bearing surface 140. This engagement forms a spherical joint between the two components that permits relative rotation movement about the origin O of circle of radius R (which origin O lies on the pedestal axis PA).

[0052] The friction locking member is placed onto the top plate 1 10 such that its concave locking surface 156 engages the convex upwardly facing convex surface 153 of the plate 1 10. The spring washer 1 15 is fed onto the shaft of the mechanical fastener 1 14, which in turn is fed along the axis PA, passing through the central opening 158 of the friction locking member 1 12, the opening 154 of the top plate 1 10 and into the central internally threaded opening 142 of the head shaft 108 where it is rotated into threaded engagement.

Use

[0053] In order to use the pedestal, the installer can select the type of member to be secured. In doing so, he may extend all four tabs 148a - d of the top plate 1 10, or a subset thereof. The pedestal is then secured to the underlying surface 98 using screws through the holes 1 18 as required.

[0054] In order to set the height of the pedestal, the head shaft is rotated relative to the base shaft 104 to the desired height H. Once in position, the locking nut 106 is rotated to move upwardly along the shaft 104 to engage the bottom of the head shaft 108 and secure it in position.

[0055] Flooring members 30, 32 are then positioned on top of the top plate 1 10 as required. It will be noted that the top plate 1 10 will pivot relative to, and rotate about, the pedestal axis PA in order to settle in the correct position. The top plate has three rotational degrees of freedom provided by the spherical joint- with reference to Figure 2:

• Rotation about PA (axis Z);

• Rotation about horizontal axis X; and,

• Rotation about horizontal axis Y.

[0056] The last two rotations are referred to as "pivoting".

[0057] It will be noted that rotation about Z is unlimited- the top plate 1 10 can rotate 360 degrees. Rotation about X and Y (and combined rotation about any axis in the XY plane) is limited by the periphery of the opening 154. If the top plate pivots by angle [3 (Figure 4) the fastener 1 14 limits movement. It follows that although the openings in the head shaft 108 and the friction locking member 1 12 are just large enough to accept the fastener with no free movement, the opening 154 is considerably larger to permit the required degree of freedom.

[0058] Once the pedestal has aligned to the desired orientation, the installer can insert a tool (such as a hex key) between the flowing members to tighten the fastener 1 14. The head of the fastener compresses the spring washer 1 15 and locking member 1 12 downwards, and sandwiches the top plate 1 10 between the locking member 1 12 and the top of the head shaft 108. This acts to restrict further rotation due to friction. The spring washer 1 15 acts to maintain the tension in the fastener 1 14 and prevent the locking force from being released. Of course, the installer is free to use the tool to release the pedestal rotation again.

[0059] It will be noted thatthe height of the pedestal 100 can be adjusted in situ, even when loaded by flooring members. A tool (such as an adjustable spanner) can be used to rotate the head shaft 108 to raise / lower the pedestal. It is desirable that this step is carried out when the fastener 1 14 is loosened, so thatthe head shaft can rotate relative to the top plate 1 10, which is supporting the flowing members.

Variations

[0060] Although the bottom plate 102 and top plate 1 10 are square in this embodiment, they may be circular or any other shape suitable for fulfilling their functions as described above.

Claims

1. A self-levelling pedestal (100) for supporting a flooring member, the pedestal comprising: a base (102) having a support surface (1 16); a head (108), distal to the base; a top plate (1 10) coupled to the head to be pivotable relative thereto such that the top plate can be oriented at a non-zero angle to the support surface of the base; a locking mechanism configured to inhibit said pivoting of the top plate relative to the head, the locking mechanism being configured to lock the position of the top plate in at least one non-zero angle to the support surface of the base; wherein a plurality of tabs (148a, 148b) are provided extending from the top plate, the tabs providing abutments extending between two adjacent flooring members in use such that the flooring members are spaced apart to facilitate access to the locking mechanism with a tool.

2. A self-levelling pedestal (100) according to claim 1 , wherein each of the plurality of tabs (148a, 148b) is formed from deforming part of the top plate (1 10) out of plane.

3. A self-levelling pedestal (100) according to claim 2, wherein each of the plurality of tabs is formed from a U-shaped cut in the top plate (1 10), the U-shaped cut facing away from a centre of the top plate (1 10).

4. A self-levelling pedestal (100) according to any preceding claim, wherein the head and the base are adjustable relative to each other to vary the distance between the support surface and the top plate to thereby alter the height of the pedestal.

5. A self-levelling pedestal (100) according to claim 16, wherein the head and the base are connected by a threaded connection to alter the height.

6. A self-levelling pedestal (100) according to claim 5, wherein the head comprises a female part of the threaded connection, and the base comprises a male part of the threaded connection.

7. A self-levelling pedestal (100) according to claim 1 7, wherein a locking member is provided, the locking member having a further female threaded part engaged with the male threaded part, such that rotation of the locking member into abutment with the female threaded part locks the female threaded part into position on the male threaded part.

8. A self-levelling pedestal (100) according to any of claims 5 to 7, wherein the head defines a formation configured to be engaged by a tool to facilitate rotation thereof relative to the base.

9. A self-levelling pedestal (100) according to claim 8 wherein the head formation defines a pair of diametrically opposed flats.

10. A self-levelling pedestal (100) according to claim 8 or 9 wherein the head formation is distal to the base.

1 1 . A self-levelling pedestal (100) according to any preceding claim, wherein a spherical joint is provided between the head and the top plate, and wherein the locking mechanism is configured to lock the spherical joint.

12. A self-levelling pedestal (100) according to claim 1 1 , wherein the locking mechanism is configured to lock the spherical joint by friction.

13. A self-levelling pedestal (100) according to claim 12, wherein the locking mechanism comprises a resiliently compressible element configured to maintain a frictional force on the spherical joint to lock it.

14. A self-levelling pedestal (100) according to claim 12 or 13, wherein the locking mechanism comprises a locking element configured to exert a compressive force on the spherical joint.

15. A self-levelling pedestal (100) according to claim 14, wherein the locking element engages an upper surface of the top plate.

16. A self-levelling pedestal (100) according to claim 15, wherein the locking element is part-spherical in shape.

17. A self-levelling pedestal (100) according to claim 16, wherein the top plate is constructed from a part-spherical sheet material, wherein the underside of the top plate forms a spherical joint against the head, and where the upper side of the top plate is engaged by the locking element.

18. A self-levelling pedestal (100) according to any of claims 14 to 17, wherein the locking mechanism comprises a fastener engaging the locking element at a first end, and engaging the head at a second end to selectively apply a clamping force on the top plate between the head and the locking member.

19. A self-levelling pedestal (100) according to claim 18, wherein the fastener is threaded to the head to engage the locking mechanism by rotation thereof.

20. A self-levelling pedestal (100) according to any of claims 1 1 to 19, wherein the spherical joint is oriented with its origin on the base side of the top plate such that the spherical joint is upwardly convex in use.

21. A self-levelling pedestal (100) according to any of claims 1 1 to 20, wherein the spherical joint comprises a motion stop limiting the degree of movement of the spherical joint.

22. A self-levelling pedestal (100) according to claim 21 , wherein the motion stop is formed by an opening in the top plate through in which a stop member is located, the motion stop being provided by abutment between the periphery of the opening and the stop member.

23. A self-levelling pedestal (100) according to claim 22, wherein the stop member is the fastener of the locking mechanism.

24. A flooring assembly comprising: a self-levelling pedestal according to any preceding claim; a first flooring member; a second flooring member; wherein the first and second flooring members are supported on the top plate, such that the outside edges of the flooring members abut two of the plurality of tabs such that a gap is provided therebetween allowing access to the locking mechanism.

25. A flooring assembly according to claim 24, wherein the pedestal comprises four tabs, the assembly comprising a third flooring member and a fourth flooring member, wherein each flooring member abuts two tabs on adjacent edges.

26. A flooring assembly according to claim 24 or 25, wherein the flooring members are paving slabs constructed from a ceramic or stone material.

27. A method of installing a raised floor comprising the steps of: providing a plurality of pedestals according to any of claims 1 to 23; positioning the pedestals in a spaced-apart arrangement; providing a plurality of flooring members; supporting each flooring member on a plurality of pedestals such that each pedestal abuts at least one tab, and allowing each pedestal top plate to reach a desired inclination by movement relative to the head; locking each top plate in position with the locking mechanism.

28. A method of installing a raised floor according to claim 27, wherein the step of locking comprises the step of passing part of a tool between adjacent flooring members to thereby engage the locking mechanism.