Patent Application
20160083967
The present disclosure relates generally to finishing of composite surfaces, and more particularly relates to a method for filing voids and/or pin holes in the composite surface and grouting pans for use in the method
This section provides background information related to the present disclosure which is not necessarily prior art.
Composite surfaces such as epoxy, terrazzo, or cementitious floors generally include a decorative aggregate most commonly marble chips but also g or any suitable aggregate supported in a matrix material. First, a solid, level foundation typical of concrete is established. Next, a subflooring layer is formed on top of the foundation. Historically, this layer is a sandy concrete layer. Metal divider strips may be partially embedded in the concrete before it cures to provide panels in the surface. Finally, a top layer including the matrix material with the decorative aggregate is placed into each of the panels. Historically, the matrix material was a cementitious material but now may be a polymer-based matrix such as epoxy-based. The matrix material may be color-pigmented. The decorative aggregate, while typically marble chips, may be any suitable aggregate e.g., glass, porcelain, concrete, metal, mother of pearl, abalone. While the mixture is still wet, additional aggregate may be broadcast into various panels. Finally, the entire surface is rolled with a weighted roller.
As initially installed, these composite surfaces are porous or semi-porous in nature. Moreover, as the composite surface dries in the case of a cementitious matrix or cures in the case of polymer-based matrix, gases are released from the matrix causing surface imperfections, pin-holes and subsurface voids in the top layer. To address this concern, the top layer is rough cut using very course to course (24-grit to 80-grit) grinding stones or diamond plates. Rough cutting the top layer evens out the surface imperfections but may leave slight depressions. Rough cutting does little to remedy the pin holes and may open up subsurface voids to the surface. If left untreated, these flaws can collect excess wax, dirt and other debris which affects the look and surface quality of the composite surface.
Accordingly, it is necessary to grout the composite surface in an effort to fill the remaining surface imperfections. The rough cut layer is grouted by hand trowelling a mortar onto the composite surface. The mortar is repeatedly wiped back and forth over the surface with a hand trowel. As the trowel approaches a surface imperfection, the mortar covers the indentations and partially fills the subsurface voids. However, as the trowel moves past the surface imperfection, the trowel can pull mortar out of the subsurface void, thus leaving surface imperfections. Even subsurface voids that have been covered with mortar may become exposed as the mortar dries or cures.
Accordingly, it is desirable to develop a method of grouting a rough cut floor which completely fills the surface imperfections. In addition, it is desirable to develop a tool useful in the grouting process and which is configured for use on the finishing machines typically used in conventional grinding and polishing of composite surface. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
In one embodiment, an apparatus in the form of a grouting pan is provided for grouting a composite surface. The grouting pan includes a substantially planar bottom surface and a curved sidewall surrounding the bottom surface. The curved side wall has an angled portion and a rounded edge portion formed between the bottom surface and the angled portion such that an obtuse included angle is formed therebetween. A top surface is configured to affix the grouting pan to a rotating head of a finishing machine.
In another embodiment, an apparatus in the form of a grouting pan assembly is provided for grouting a composite surface. The grouting pan assembly includes a carrier having a first face configured to affix the grouting pan assembly to a rotating head of a finishing machine and a second face opposite the first face with a plurality of grouting pans extending therefrom. Each grouting pan includes a substantially planar bottom surface and a curved sidewall surrounding the bottom surface. The curved side wall has an angled portion and a rounded edge portion formed between the bottom surface and the angled portion such that an obtuse included angle is formed therebetween. A top surface is configured to affix the grouting pan to a rotating head of a finishing machine.
In a further embodiment a method is provided for finishing a composite surface. The method includes spreading a mortar over a rough composite surface having surface voids to form a prepped surface. A grouting pan having a curved sidewall extending from a generally flat bottom surface in contact with the prepped floor is rotated over the prepped surface. By way of the rotary movement, the grouting pans are moved in different directions relative to the composite surface so that they are pushed across the surface imperfection composite surface. In doing so, the grouting pans force trapped air out of and mortar into of the pin holes and surface voids. In particular, the sidewall push the mortar into the surface imperfections, while the rounded edge and the planar bottom surface compress the mortar in and force air out. This action also thoroughly mixes any filler with the mortar during grouting. The cured surface is finished to form a finished surface.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings. There is no intention to be limited by any principle presented in the preceding background or the following detailed description.
With reference now to
With specific reference to
As presently preferred, the geometry of the grouting pan 10 is configured to efficiently spread mortar over the rough cut layer. In one embodiment, the grouting pan 10 is generally frusto-conical in shape having a top surface 22 with a diameter (D) of about 80 mm and a bottom surface 12 with a diameter (d) of about 64 mm. The height of the sidewall 14 (measured perpendicular to the bottom surface) is about 10 mm. The thickness of the intermediate layer 28 is about 6 mm. The included angle (α) is in the range of 100°-135°,and preferably in the range of 110°-120°. The rounded edge has a radius (R) of at least 4 mm and preferably greater than or equal to 6 mm.
With particular reference to
With particular reference to
With reference now to
The carrier 36 provides sufficient surface area to accommodate the proscribed number of grouting pans. In this regards, the carrier 36 defines the top surface 22′ configured to affix the grouting pan assembly 34 to a finishing machine 300 as best seen in
With particular reference to
With reference now to
The method 400 for finishing a composite surface include spreading a mortar over the rough composite surface having surface voids to form a prepped surface as shown at block 402. Optionally, a filler may be broadcast on top of the mortar when forming the prepped surface as shown at block 404. The filler may be a very fine powder of pulverized stone (e.g., marble, lime stone, granite and/or quartz), calcium carbonate or cement. Grouting pans are rotated over the prepped surface such that the curved sidewalls trowel the mortar onto the rough composite surface and the bottom surface 12 which is in contact with the prepped floor forces the mortar into the surface voids such that a grouted surface is formed at block 406. The mortar on the grouted surface is allowed to cure such that a cured surface is formed at block 408. Then, the cured surface is ground to remove excess grout and finished using to a fine grit finish on the order of 200-grit or higher, then sealed and polished such that a finished surface is formed at block 410. The grouting pans 10 described herein are particularly well suited for use on a rotating head 102, 202, 302 of a finishing machine 100, 200, 300 when practicing the method 400 described above.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
