EP0335927A1

EP0335927A1 - Mould for manufacturing plate-like floor elements for false floors and corresponding plate-like floor elements

Info

Publication number: EP0335927A1
Application number: EP88908219A
Authority: EP
Inventors: Martin Bard; Gottfried Cremer
Original assignee: Buchtal GmbH
Current assignee: Buchtal GmbH
Priority date: 1987-09-29
Filing date: 1988-09-27
Publication date: 1989-10-11
Also published as: ES2012553A6; US4993208A; WO1989002815A1; PT88617A; FI892504A; JPH02501374A; FI892504A0; CA1304594C

Abstract

Zur Herstellung von plattenartigen Bodenelementen für eine Doppelbodenkonstruktion wird eine Form verwendet, die aus einer Wanne aus einem Werkstoff mit hoher Zugfestigkeit und einer keramischen Deckplatte besteht und die Wanne oben abschließt sowie über ein Verbindungselement mit der Wanne fest verbunden ist. In diese Form wird über Öffnungen am Wannenboden eine fließfähige Kernschicht eingefüllt, deren Aushärtung zu einem festen Verbund zwischen Wanne und Kernschicht einerseits und Kernschicht sowie keramischer Deckplatte andererseits führt. Bei der Herstellung dieser Bodenplatte bildet die Form in ihrer Gesamtheit einen Teil des fertigen Bodenelementes. Abstract In order to manufacture plate-like floor elements for false floors, a mould is used that is composed of a tub made of a high traction-resistant material and a ceramic cover plate that closes the top of the tub and is rigidly secured to the tub by a joining element. This mould is filled through holes in the bottom of the tub with a fluid core layer which upon hardening ensures a solid link between the tub and the core layer on the one hand and between the core layer and the cover plate on the other hand. During manufacture of this floor plate, the mould forms in its totality part of a finished floor element.For the production of plate-like floor elements for a double floor construction, a mold is used which consists of a trough made of a material with high tensile strength and a ceramic cover plate and closes off the trough and is firmly connected to the trough via a connecting element. In this form, a flowable core layer is poured in via openings in the base of the tub, the hardening of which leads to a firm bond between the tub and the core layer on the one hand and the core layer and ceramic cover plate on the other. When producing this floor slab, the mold as a whole forms part of the finished floor element. Abstract In order to manufacture plate-like floor elements for false floors, a mold is used that is composed of a tub made of a high traction-resistant material and a ceramic cover plate that closes the top of the tub and is rigidly secured to the tub by a joining element. This mold is filled through holes in the bottom of the tub with a fluid core layer which upon hardening ensures a solid link between the tub and the core layer on the one hand and between the core layer and the cover plate on the other hand. During manufacture of this floor plate, the mold forms in its totality part of a finished floor element.

Description

Mold for the production of plate-like floor elements to form a raised floor construction and corresponding plate-like floor element.

The invention relates to a mold according to the preamble of claim 1 and a base plate according to the preamble of claim 13.

Raised floor constructions are known and well-introduced components in modern offices, data centers and production facilities, which are enjoying increasing demand due to the high flexibility associated with their application with regard to the electrical supply of machines installed there. It is generally a floor made of plate-shaped floor elements u. Like., Which are supported on supports on a substructure. The magazine "Fußbodenforum", issue 1, from January 1986 shows the latest state of the art and states that in the case of non-elastic coverings in the form of ceramic covering materials, application at the construction site is preferred, however with natural stone coverings as with all others, So also the elastic, such as carpets etc., the double floor constructions are manufactured as prefabricated elements.

With the dimensions of a single element of 60 x 60 cm, which are customary for raised floors, special demands are made of the load-bearing capacity, their deflection in the event of a load and the pressure load with regard to point and surface loading. Elastic coverings can WO »UH5, PCT / EP88 / 00869

nothing contributes to the static load bearing, so the double floor elements that support them must be designed so that they are able to meet the required values. For this reason, trough-shaped configurations with high tensile strength are used in such elements, which have a filling with low tensile strength, ie. H. have a low modulus of elasticity, for example anhydride (DE-Gbm 78 04 148 and 81 06740). Apart from the fact that such a structure is complex, such prefabricated elements have a relatively large overall height with a corresponding weight. This is largely due to the fact that the core layer, which has been ground flush and flat after bonding with the tub edge, is glued to the ceramic cover layer. As a result of the gluing, a shear-resistant bond can also not be achieved, so that the cover plates can gradually become detached as a result of the loads on the floor.

It is known (DE-PS 33 45 620) to reduce the inherent weight by adding spherical lightweight building materials, which, however, makes the production more expensive and does not contribute to an improvement in the overall height.

Although the use of ceramic flooring is known in double floor constructions (DE-Gbm 75 19 806), synthetic resin concrete is used here, which is reinforced with cast-in reinforcing grids. Such prefabricated elements are complex to manufacture and heavy due to reinforcement and have the major disadvantage of a correspondingly large overall height. Finally, a double floor construction is known (DE-OS 36 03 232), which is formed by a composite of a cover plate made of ceramic material with a low layer thickness, a core layer consisting of rigid material with low bulk density and a thin underlayer with high tensile strengths , with adhesive ensuring the connection between the composite layers. With regard to the risk of breakage of ceramic plates, adhesives with elastic properties are used. Since ceramic coverings, especially as a uniform panel, for example in the size 60 x 60 cm, show a production-specific curvature of the panel plane, when laying such panels the adhesive is dimensioned accordingly to compensate for the curvature and applied with excess, to ensure a full installation of the ceramic tiles.

According to a further known construction (DE-Gbm 86 20 150), a sheet steel trough filled with anhydride is provided to form a raised floor plate, to which a tile is glued. The adhesive required here serves at the same time as a band, that is to say as a joint component, so that this adhesive, too, must show relatively elastic behavior.

Finally, plate-like floor elements for raised floor constructions are known (DE-AS 22 42 607), in which a ceramic cover plate is placed on a tub, and the bond is achieved by curing the core layer filled in the tub. An additional adhesive layer is not required. The making of a Such plate-like base element is achieved by placing the open-topped pan with its opening facing downwards on a molding table which is provided with a recess for receiving the ceramic cover plate. Side flanges specially shaped on the upper edge of the tub are overlapped by clamping devices which are arranged over the circumference of the shaping table in order to press the tub firmly onto the shaping table. After the core layer has been poured in and hardened, the finished base element can be removed from the molding table. This plate-like base element is also of comparatively great height because the ceramic cover plate builds on the tub. Furthermore, special shapes are required to manufacture the floor elements.

The known constructions, insofar as they are able to transmit sufficiently high moving and static loads, have a comparatively large overall height, which leads to considerable problems particularly when renovating old buildings. Apart from this, the construction of these construction elements is comparatively high due to the additional measures required to increase the strength, which leads to correspondingly high manufacturing costs. In some cases, the shape itself is also complex to manufacture such floor elements, which in turn contributes to an increase in manufacturing costs. In the case of adhesives with elastic properties, the transferability of moving and static loads is limited. The object of the invention is to enable simple manufacture of plate-shaped floor elements for a double floor construction, which both ensure the transmission of high moving and static loads and are distinguished by a low overall height and a very long service life.

This object is achieved according to the invention by the features contained in the characterizing part of patent claim 1 or 15. Appropriate further training is characterized by the features contained in the subclaims.

In accordance with the invention, the plate-like floor elements are produced using a mold which, in its entirety, is part of the finished floor element. The mold is formed from a trough forming the lower layer of the base element, which is preferably made from galvanized sheet steel, and a ceramic cover plate which closes the trough at the top and, together with the trough, delimits the mold cavity for receiving the core layer. The cover plate is partially inserted into the tub so that it is sunk in the tub and with its visible surface protrudes over the upper tub rim, which has a favorable effect on the sealing of the shape and the height of the floor element. The ceramic cover plate is fixed in position relative to the trough by means of spacers which are formed in a simple manner by rods or tabs which are welded to the trough or fastened to the trough in some other suitable manner, such as screwing or stapling. The fixed connection between the cover plate and the trough is accomplished by means of a plastic connecting element molded on from the outside. To produce the floor element, only the core layer to be filled, which takes place via openings in the tub floor. As a result of the firm connection of the components of the mold, which at the same time all constitute components of the finished floor element itself, the unfilled mold can be transported to the destination, where the core layer is then filled. This greatly simplifies transport, because only the shape and not the finished floor element has to be transported, while the filling can be selected according to local conditions and requirements for the finished element. It is only on site that the floor elements are manufactured before they are installed.

The connecting element is formed from a joint-forming, tough-elastic material. The floor slabs produced in this way can be laid in a butt joint to one another without additional joint-filling material having to be introduced between the slabs after the laying, but rather the joint function between the ceramic cover slabs of the floor covering is virtually taken over by the connecting elements already formed.

The solid bond resulting from the hardening of the core layer by the frictional connection between the tub and the core layer on the one hand and the core layer and ceramic cover plate on the other hand is further favored in that the contact surfaces of these layers are irregular, for example by a relief with a low height. This also achieves a positive fit between the contact surfaces.

In special applications, it is expedient to provide an adhesive bridge between the ceramic cover plate and the core layer on the one hand and between the core layer and the tub on the other. This is done before filling a thin layer of modified, solvent-free synthetic resin dispersion is applied as an adhesive bridge to the core layer on the corresponding contact surfaces of the tub and the ceramic cover plate with the core layer. The shear strength of the adhesive bridge is equal to or greater than that of the core layer.

The trough base is expediently provided with large-area openings, so that the trough base is largely open and for the support function only a support frame running around the edge or a support cross or support grid is provided. The resulting large-area openings on the tub floor allow air inclusions to escape during the pouring in of the core layer, and moisture can also be removed, which could make it more difficult for the flowable core layer to set.

The finished floor element is characterized by a low height, since the ceramic cover plate is embedded in the tub and only partially protrudes outwards beyond the upper tub edge. The connecting element, which ensures that the ceramic cover plate and the trough are fixed immovably before the core layer is poured in, also serves as edge protection for the ceramic cover plate, but in particular also as a joint filler between the adjacent ceramic cover plates of the finished floor covering, since after the finished floor elements have been laid butt-to-butt, the adjoining connecting elements of adjacent floor elements no longer require subsequent grouting. To create a uniform joint pattern, it is advantageous that the upper cover surface of the connecting element is slightly opposite the protruding visible surface of the ceramic cover plate is set back.

The invention is particularly suitable for raised floor constructions with a format of 60 x 60 cm for the single element. The thickness of the finished floor element is preferably 30 to 40 mm. The thickness of the ceramic cover plate is preferably 8 mm. The adhesive bridge is less than 1 mm thick.

Preferred exemplary embodiments of the invention are described below with reference to the drawing. In it show:

Fig. 1 is a schematic sectional view through a

Base plate or a mold according to the invention as well

2 to 4 rear views of the floor of various embodiments of the floor element according to the invention.

Fig. 1 shows schematically and in section in the right half a trough designated 1, which forms part of the shape for producing the plate-shaped floor element described in more detail below. The left half in FIG. 1 shows a section through the plate-like floor element, generally identified by the reference number 2, consisting of the tub 1, a core layer 3 filled therein and a ceramic cover plate 4 accommodated in the tub 1, which is connected via a connecting element 5 is firmly connected to the tub 1. The shape for the production of the base plate 2 comprises the tub 1 shown in the right half of FIG. 1, consisting of a tub bottom 7 provided with large openings 6 and side walls 8, which have between them a receiving space 9 for the core layer filled in via the openings 6 3 limit. On the side opposite the floor 7, the trough 1 is open and designed to receive the ceramic cover plate 4. To accommodate this cover plate 4 8 spacers 10 are arranged on the inside of the side wall, which serve to fix the position of the cover plate 4. It should be noted here that the trough 1 is arranged with its bottom 7 facing downwards in order to produce the mold, so that the cover plate 4 is placed on the spacers 10 from above. The illustration in FIG. 1, in which the trough base 7 is located at the top, shows only the filling position of the mold for the purpose of producing the base plate, in which the ceramic cover plate 4 at the bottom and the base 7 of the trough for easier pouring of the flowable core material lies above.

The spacers 10 provided in the exemplary embodiment shown are formed from bolts or rods which are fastened to the trough, for example by welding, tacking or screwing on or, in the case of sheet metal brackets, by bending sections punched out of the trough. II illustrated embodiment, in which the tub has a quadratic plan, two spacers 10, ie a total of eight spacers 10, are provided on each tub side, on which the ceramic cover plate 4 is placed. As FIG. 1 shows quite clearly, the spacers 10 are arranged so far below the upper tub edge 11 that the ceramic cover plate 4, which is positioned by the spacers 10, is only partially embedded within the tub 1, so that the ceramic deck ¬ plate 4 protrudes with a part of its height or thickness over the upper tub edge 11, that is, cover plate 4 and tub edge overlap in height. The fixed connection between the tub 1 and the ceramic cover plate 4 fixed in position in the tub is provided by a connecting element 12 which is molded or molded onto the upper tub edge section from the outside. In order to prevent the material of the connecting element 12 from penetrating into the interior of the mold, a sealing ring 13 is provided which is placed on the spacers 10 and is arranged between the side edge of the ceramic cover plate 4 and the opposite trough surface. The partially recessed embedding of the ceramic cover plate in the tub as a result of position fixation favors the sealing of the mold, since there is a defined gap between the tub and the edge of the ceramic cover plate, in which the sealing ring 13 is inserted and in particular the molded material of the connecting element can penetrate.

In the exemplary embodiment shown, a recess designated by 14 is provided in the upper region of the trough 1, which is preferably made of a galvanized steel sheet, for receiving the connecting element. The recess is formed by bending the side wall 8 at the point 15, so that the upper wall section 16 of the side wall is slightly offset inwards. In the resulting free space, i.e. in the recess 14, the material is poured or injected rial of the connecting element 12.

The connecting element 12 is made of a joint-forming and tough-elastic material, which is formed by a castable or sprayable plastic, preferably polyurethane. When the connecting element is formed, the polyurethane engages behind the upper wall section 16 and fills the very narrow annular gap between the ceramic cover plate 4 and the opposite tub surface. The sealing ring 13, which seals this gap towards the inside of the mold and serves as a lost seal, is made, for example, of foam rubber, since the seal is only required until the material of the cast-on plastic has solidified.

The side surface 15 of the connecting element 12 runs essentially flush with the side wall 8 of the mold 1 and is also seen somewhat from the bottom of the mold, as is indicated by the angle in FIG. 1. The preferred angle of inclination is 3 degrees. The cover surface 16, on the other hand, is arranged slightly behind the visible surface 17 of the ceramic cover plate 4, preferably by 0.4 mm, so that the ceramic cover plate 4 protrudes slightly above the cover surface 16 of the connecting element 12.

The shape of the trough 1, ceramic cover plate 4 and connecting element 12 produced after the connecting element 12 has been molded on is sufficiently firm that the mold does not have to be filled in place, but the shape can also be transported to the place where the Floor element to be completed. This means that the filling can only be applied directly at the place of use occur. The filling material can be selected according to the application.

To produce the base plate itself, a flowable material is filled in via the openings 6 in the base 7 of the trough 1 or the mold to form the core layer, anhydride being preferably used. After casting, the core layer 3 comes into full-surface contact with the inner surfaces of the mold 1 and the surface of the ceramic cover plate 4 opposite the visible surface 17. When the core layer 3 has hardened, an intimate bond takes place between the trough 1 and the core layer and between the core ¬ layer and the ceramic cover plate 4, the composite of tub, core layer and ceramic cover plate is shear resistant. A corresponding positive connection can additionally be achieved by corresponding relief of the contact surfaces of the trough and / or the cover plate.

As a result of the special design of the connecting element 12, the floor panels for forming the double floor construction can be laid on supports arranged side by side so that the side edges of adjacent floor panels abut one another without any joints remaining to be filled by additional joint material. This way of laying is favored by the inclined course of the side surfaces of the connecting elements, which practically form the joint between adjacent ceramic cover plates of the floor covering.

In a preferred embodiment, the trough 1 serves to receive ceramic cover plates with a size of approximately 60 x 60 cm, the trough 1 being correspondingly square in plan. The total height of the base plate is between 3 and 4 cm. The height of the connecting element, calculated from the inflection 15, is approximately 1.5 to 2 cm. The thickness of the ceramic cover plate is preferably 8 mm. The side surfaces are inclined outwards at an angle of 2 to 5 degrees, advantageously 3 degrees. The width of the top surface 16 of the connecting element 12 is approximately 4 mm.

It can be seen from FIGS. 2 to 4 that the floor is largely open, with the exception of a supporting scaffold or support grid. In the embodiment according to FIG. 2, the side walls 8 of the tub 1 are designed to be closed, but the tub bottom shown in FIG. 2 is provided with an opening 6, so that the majority of the outer surface of the core layer 3 facing away from the ceramic cover plate 4 is exposed, i.e. is not covered by the tub floor. However, the vertical side walls 8 of the tub 1 are drawn over the edges of the core layer 3, so that the tub bottom is formed by a circumferential support flange 18 which delimits the opening 6 between them. In the case of a ceramic cover plate 4 with the external dimensions 60 × 60 cm, the width of the support flange is preferably approximately 2 cm, so that the clear width of the essentially square opening 6 is approximately 56 cm.

In the embodiment according to FIG. 3, the bottom of the tub 1 is essentially formed by a support cross 19 which defines openings 6 with the edges of the tub 1. In the modified embodiment according to FIG. 4, instead of a support cross 19, a grid-like support grid 20 is provided, which forms the trough bottom and openings 6 between them leaves. The openings 6 in the trough bottom in the exemplary embodiments according to FIGS. 2 to 4 are of such a size that the essential part, that is to say the large part, of the surface of the core layer 3 facing away from the ceramic cover plate is exposed to the outside, that is to say through the Tub floor is not covered. The support flange 18 or the support cross 19 or the support grid 20 represent a tensile lower layer of the base plate and are therefore sufficiently stable and rigid. The openings in the tub floor have the advantage that the core layer can be poured in via the openings provided in the tub floor. In particular, however, these embodiments allow adequate ventilation by allowing air pockets remaining inside the trough to escape when the flowable core layer is poured in. Furthermore, moisture can escape through the openings in the tub floor, which could make it more difficult for the flowable core layer to set. If necessary, it can be expedient to consolidate the core layer by embedding short-fiber fibers, in particular glass fibers. After the setting has taken place, it is possible to protect the existing openings against re-penetrating moisture by means of a cover, for example a film.

Not shown in the exemplary embodiment according to FIG. 1 is an optionally used adhesive bridge which is provided between the ceramic cover plate and the core layer and between the core layer and the surfaces of the tub 1 contacted by the core layer. As a material for the adhesive bridge, which is applied in a very thin layer to the corresponding sides of the ceramic cover plate and the Trough is applied before filling the core layer, a modified solvent-free synthetic resin dispersion is used. The adhesive bridge promotes the bond between the tub and the core layer and the core layer and the ceramic cover plate after the core layer has hardened.

Claims

P aen t'a claims

1. mold for the production of plate-like floor elements for a double floor construction, with a trough made of a material with high tensile strength for receiving a flowable, hardenable core layer consisting of rigid material with the lowest possible weight, and a cover plate consisting of ceramic material, which forms the floor element in combination with the core layer and the tub, characterized in that the ^" shape in its entirety is part of the floor element (2) in that the tub (1) and ceramic cover plate are fixed in position by spacers (10) and are firmly connected to one another to form the shape over the circumferential edge of the cover plate by a joint-forming, viscoplastic material, and that the flowable core layer is filled into this mold, which after hardening forms a shear-resistant bond with trough (1) and ceramic cover plate (4) forms.

2. Mold according to claim 1, characterized in that the ceramic cover plate (4) and the trough (1) are irregularly formed on the side facing the core layer, so that when the core layer hardens a positive connection of the core layer with the trough and the ceramic cover plate is achieved.

3. Mold according to claim 1, characterized in that an adhesive bridge is provided between the ceramic cover plate (4) and Kern¬ layer (3) and between the core layer (3) and trough (1), the shear strength equal to or greater than that of the core layer ( 3) is.

4. Mold according to one of claims 1 to 3, characterized in that the adhesive bridge consists of modified solvent-free synthetic resin dispersion as the basis.

5. Mold according to one of the preceding claims, characterized in that the ceramic cover plate (4) from the one or the spacer (10) in the trough (1) is such that the cover plate with a part of its thickness evenly over the Tub rim (11) protrudes outwards.

6. Mold according to one of the preceding claims, characterized in that the upper tub edge portion (16) by a bend (15) is slightly offset relative to the side wall (8) of the tub (1) in the lower tub area to the inside by a circumferential Recess (14) to form at the top of the tub, which serves to accommodate the joint-forming material.

7. Mold according to one of the preceding claims, characterized in that a circumferential sealing ring (13) is arranged between the ceramic cover plate (4) and the adjacent side wall (8) of the tub (1).

8. Mold according to one of the preceding claims, characterized in that the spacers (10) are formed by bolts or straps which are formed or fastened to the tub (1) and protrude into the interior of the tub (1).

9. Mold according to one of the preceding claims, characterized in that two spaced bolts are provided as spacers (10) on each side of the tub.

10. Mold according to one of the preceding claims, characterized in that the bottom (7) of the trough (1) has one or more open areas (6) with a size that a substantial part of the ceramic cover plate (4) facing surface of the core layer (3) is cover-free.

11. Mold according to claim 10, characterized in that the bottom (7) of the trough (1) by a umlau¬ fenden, only the edge areas of the ceramic cover plate (4) facing away from the surface of the core layer (3) covering support flange (18) is formed between see an opening (6) limited.

12. The mold according to claim 10, characterized in that the bottom (7) of the trough (1) is formed by a support cross (19) or a support grid (20).

13. Plate-like floor element for a double floor construction, in which the plate-like floor elements are directly or indirectly supported on supports erected at predetermined intervals on a load-bearing substructure and each of them is made of a composite of a tub made of a material with high tensile strength, one filled therein hardened core layer and a ceramic cover plate that closes the open top pan, characterized in that the ceramic cover plate (4) is inserted into the pan (1) and with its outward-facing surface (17) evenly over the upper pan edge ( 11) protrudes outwards, and that the overlapping peripheral edge of the tub (1) and ceramic cover plate (4) is covered all around from the outside by a connecting element (12) made of a joint-forming, tough-elastic material.

14. Floor element according to claim 13, characterized in that the connecting element (12) is substantially flush with the side wall (8) of the tub (1).

15. Floor element according to claim 14, characterized in that the side surfaces of the floor element (2) under one Angles of 2 to 5 degrees, preferably 3 degrees, are inclined outwards from the tub floor (7).

16. Floor element according to one of claims 13 to 15, characterized in that the Siσhtflache (17) of the ceramic Deck¬ plate (4) surrounding the top surface (16) of the Verbindungsele¬ elements (12) slightly behind the visible surface (17) of the ceramic Cover plate (4) is set back.