Patent Application
20060191226
This application claims priority to and the benefit of Korean Patent Application No. 10-2005-0015683 filed in the Korean Intellectual Property Office on Feb. 25, 2005, the entire contents of which are incorporated herein by reference.
(a) Field of the Invention
The present invention relates to a floor panel for a raised dry-floor system. More particularly, the present invention relates to a floor panel for a raised floor system having enhanced strength as well as small thickness by inserting a reinforcing member into a longitudinal groove of a plate type member.
(b) Description of the Related Art
A typical interior room of a house, an office, a computer room, and a factory for using IT-related electronic products, etc., therein, is applied with a raised floor system in which, for accommodating cables, pipes, etc., floor panels are arranged on equally spaced pedestals such that an under-floor space corresponding to a height and spacing of the pedestals may become available.
A typical raised floor system scheme involves a relatively heavy material such as a steel support and mineral panel such that it may endure a heavy load, and a disposing distance of the supports is about 500×500 mm or 600×600 mm and so the speed and quality of installation depends much on the skill of a worker.
In the case of Japan, raised floor systems are commonly applied to apartment buildings. However, the principal purpose for this is to provide room for under-floor pipes and to reduce light floor impact noises. That is, the reduction capability for heavy floor impact noises is minimal, and depending on the structure of the building, the reduction of impact noise is sometimes deteriorated. Further, soft rubber is adopted in order to maximize the reduction of floor impact noise, but this causes a wave when a person walks on the raised floor system. Such a wave causes an uneasy feeling to people who are accustomed to a hard and rigid floor, such as a cement mortar floor.
According to a conventional Japanese sound insulation raised dry-floor system, a plurality of pedestals are arranged on a concrete slab floor, and a plurality of floor panels are laid on the pedestals. In this case, when the spacing between pedestals is greater (i.e., when the number of pedestals is smaller), the number of trials for horizontal leveling is reduced, installation speed is enhanced, and a cost of the pedestals is reduced. However, when the spacing between pedestals is greater (that is, when each floor panel is larger), stiffness of the floor panels for a raised floor system is decreased and the wave phenomenon caused by walking, as well as a sagging problem, may occur. Due to such drawbacks, the spacing between pedestals for a conventional raised floor system (i.e., a size of the floor panel) has been realized as 600×455 mm, at best.
In addition, conventional floor panels are usually made of a single integral plate of particle board such that it may have a drawback of low absorption of floor impact noise. Furthermore, the high weight of such a floor panel produces a big load on the pedestals.
In manufacturing a floor panel of a raised floor system, a thickness of the floor panel must be generally increased in order to obtain a sufficient strength. This may cause a disadvantage in that a height of the raised floor system is limited. In addition, the feel when walking on the panels is one of the important criteria for a material for a raised floor system. When the stiffness of a floor panel is insufficient, the floor panel may wave due to walking thereon, and a person may feel uneasy or uncomfortable. In order to prevent such a phenomenon, the spacing between pedestals may be decreased. However, in this case, installation cost is increased since the number of pedestals required is increased.
Waterproof material is used to provide waterproof characteristics, and the kind of waterproof material can be divided into a material filling an empty space and a material forming an insoluble material by reacting with glass lime generated within concrete, and, as examples, there are various waterproof materials such as a waterproof cloth obtained by impregnating cotton cloth or hemp cloth with asphalt, an asphalt roofing such as a concrete block, a material providing a waterproof characteristic by being pasted on surfaces of mortar, concrete, cloth, paper, or fabric, and a material mixed with mortar or concrete to increase waterproof characteristics.
A particle board is used for commercial and residential raised floor systems since it has advantages of having enhanced strength and manufacturing ease compared to its low price, but it also has drawbacks in that a size and strength thereof may be changed and deteriorated by being exposed to moisture.
In order to solve problems of the particle board used for a floor panel of a raised floor system caused by moisture, various methods such as adding a waterproof sheet onto a surface of the particle board, spraying a waterproof material thereon, and forming a waterproof coating layer thereon can be considered.
Although there is a particle board formed with a waterproof sheet, it is expensive and has only a little increase of waterproof performance, about 40%. Further, most conventional waterproof coating liquid products are for blocking moisture in cement floors, outer surfaces of a building, and underground structures, and there is no product among conventional waterproof coating liquid products for a waterproof coating material for a particle board.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
The present invention has been made in an effort to provide a floor panel for a raised floor system having advantages of slim thickness, high stiffness, and light weight so as to provide a stable feel when walking and a wide spacing of pedestals.
In addition, the present invention has been made in an effort to provide a floor panel for a raised floor system having the advantage of overcoming drawbacks of a size and strength thereof being changed and deteriorated by exposure to moisture.
An exemplary floor panel for a raised floor system according to an embodiment of the present invention includes a plate member with at least one longitudinal groove, and a reinforcing member at least a portion of which is inserted into the longitudinal groove.
The plate member may include an upper plate member and a lower plate member, and the at least one longitudinal groove may be formed on at least one of a lower surface of the upper plate member and an upper surface of the lower plate member.
The reinforcing member may include a stick type reinforcing member having the same sectional shape as the longitudinal groove.
The reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove, and a bent portion of the plate type reinforcing member may be inserted into the longitudinal groove.
The reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove and a stick type reinforcing member having the same sectional shape as the longitudinal groove, and a bent portion of the plate type reinforcing member may be inserted into the longitudinal groove. The stick type reinforcing member may be inserted into the bent portion of the plate type reinforcing member.
At least one longitudinal groove may be formed on each of a lower surface of the upper plate member and an upper surface of the lower plate member, and the reinforcing member may include a stick type reinforcing member having the same sectional shape as a coupling longitudinal groove formed by a combination of the upper plate and the lower plate, and the stick type reinforcing member is inserted into the coupling longitudinal groove.
At least one longitudinal groove may be formed on each of a lower surface of the upper plate and an upper surface of the lower plate, and the reinforcing member may include at least one plate type reinforcing member bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper plate and the lower plate. A bent portion of the plate type reinforcing member may be inserted into the coupling longitudinal groove.
At least one longitudinal groove may be formed on each of a lower surface of the upper plate and an upper surface of the lower plate, and the reinforcing member may include at least one plate type reinforcing member bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper plate and the lower plate and a stick type reinforcing member having the same sectional shape as the coupling longitudinal groove. The plate type reinforcing member may be inserted into the longitudinal groove, and the stick type reinforcing member may be inserted into a bent portion of the plate type reinforcing member.
The plate member may be formed as a single plate, and the at least one longitudinal groove may be formed on a lower surface of the plate member.
The reinforcing member may include a stick type reinforcing member having the same sectional shape as the longitudinal groove.
The reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove, and a bent portion of the plate type reinforcing member may be inserted into the longitudinal groove.
In another embodiment, the reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove and a stick type reinforcing member having the same sectional shape as the longitudinal groove. The plate type reinforcing member may be inserted into the longitudinal groove, and the stick type reinforcing member may be inserted into a bent portion of the plate type reinforcing member.
Sectional shapes of the longitudinal groove and the reinforcing member may be a tetragon, a circle, an ellipse, or a triangle.
The stick type reinforcing member may be an aluminum bar, a steel bar, or a high strength plastic bar.
The plate type reinforcing member may be a zinc-coated steel plate or a general steel plate.
The plate member may be a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.
The plate member may be coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.
A diameter of a particle of the acrylic resin may be between 0.1 to 0.5 μm.
The acrylic resin may be at least one selected from the group consisting of water-soluble acrylic resin, Styrene Maleic Anhydride copolymer (SMA), acrylic hybrid emulsion, and urethane hybrid resin.
The water repellent agent may be at least one selected from the group consisting of polyethylene wax, polypropylene wax, paraffin wax, fluorine-based water repellent agent, and silicone-based water repellent agent.
The hydrogenated rosin may be at least one selected from the group consisting of ester gum rosin, terpene phenol, petroleum resin, hydrocarbon, and synthetic resin emulsion.
The penetrating agent may be at least one negative ionic surfactant selected from the group consisting of sodium alkyl ester, naphthalene sulphonate, phosphate-based surfactant, and nonyl phenyl alkyl-based surfactant.
The high-boiling-point solvent may be at least one selected from the group consisting of ethylene glycol, propylene glycol, and diethylene glycol.
10: raised floor system
20: floor panel
21: upper plate type member
22: lower plate type member
23: stick type reinforcing member
24: upper plate type reinforcing member
25: lower plate type reinforcing member
30: pedestal
Exemplary embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
In an exemplary embodiment of the present invention, a high strength sandwich panel is used for the floor panel 20, and thus the pedestals 30 may be arranged with a spacing of at least 400×400 mm (for example, 600×600 mm, 900×900 mm, 800×1,200 mm, 1,200×1,200 mm, or 1,200×1,800 mm). Therefore, installation speed thereof may be enhanced, and the installation cost may be reduced by a reduction of the number of required pedestals 30.
A pedestal 30 used in the raised floor system 10 is generally composed of a head, a height adjustment bolt, and a supporting rubber. In more detail, it may include a plate shaped head, a bolt, and a supporting rubber. The plate shaped head includes a nut disposed at a center thereof and it supports the floor panel 20 of the raised floor system 10. The bolt has a slot-shaped or cross-shaped groove at its top end and is engaged with the nut, such that the vertical position of the head may be adjusted. The supporting rubber is provided with a bolt supporting recess that supports the bolt while permitting rotation of the bolt.
In order to absorb an impact incident on the floor and to reduce vibration of the floor, the supporting rubber may be made of a vibration-damping rubber material. The supporting rubber may be formed in various shapes, for example, in a cylindrical shape that is advantageous against a heavy load, in an inverse trapezoidal sectional shape for providing stability, or in an embossed structure for obtaining better performance of floor impact noise reduction.
For light weight of the floor panel 20, the stick type reinforcing member 23 may be formed as an aluminum bar having at least one hollow space at its interior or a recess portion on an outer surface thereof. For high stiffness of the floor panel 20, the stick type reinforcing member 23 may have at least one rib formed in its interior in a length direction thereof.
In the floor panel 20a of
In the floor panel of
The floor panel 20c of
In the floor panel 20d of
In the floor panel 20e of
The floor panel 20f of
In the floor panel 20g of
In the floor panel 20h of
The floor panel 20i of
In the floor panel 20j of
In the floor panel 20k of
In the floor panel 20l of
In the floor panel 20m of
In the floor panel 20n of
In the floor panel 20o of
In the floor panel 20p of
In the floor panel 20q of
In addition, although in the drawings the shapes of the longitudinal groove and the stick type reinforcing member are shown as a tetragon, a triangle, a circle, or an ellipse, the shapes thereof can be variously changed, and a combination of these shapes is also possible.
According to an exemplary embodiment of the present invention, for light weight of a floor panel, the stick type reinforcing member may be formed as a bar having a hollow space at its interior, and for high stiffness, it may have at least one rib formed in its interior in a length direction thereof.
The rib may be formed, in a cross-sectional view cut in a width direction thereof, by two triangular or semicircular members elongated in the width direction facing each and connected to a center vertical member, or by a long vertical member having a constant width.
In another exemplary embodiment of the present invention, the stick type reinforcing member may be an aluminum bar having a hollow space in its interior, and the hollow space may be arranged in a single layer structure or in a plurality of layers structure having the shape of an ellipse, a semi circle, a circle, or a tetragon.
In still another exemplary embodiment, the stick type reinforcing member may be an aluminum bar having at least one recess portion at an outer surface thereof.
In the embodiments of the present invention, the stick type reinforcing member may be an aluminum bar, a steel bar, or a high strength plastic bar.
In the embodiments of the present invention, the plate type reinforcing member may be a zinc-coated steel plate or a general steel plate.
In the embodiments of the present invention, the plate member may be a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.
A total thickness of a floor panel including an upper plate member, a lower plate member, and a reinforcing member may be between 20 to 70 mm, and a thickness of the reinforcing member may be 3 to 20 mm. If a thickness of the floor panel and the reinforcing member is too thin, a desired strength cannot be obtained. On the other hand, if a thickness of the floor panel and the reinforcing member is too thick, weight and manufacturing cost increase.
In addition, in the embodiments of the present invention, the plate may be coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.
Vinyl acetate-based emulsion is known as a waterproof agent, and it includes a copolymer such as vinyl acetate homo-polymer, vinyl acetate acryl, vinyl acetate-based adhesive, ethylene vinyl acetate, and the like. Such conventional waterproof agents have good adhesive characteristics and water tolerance characteristics because they do not use a surfactant. However, since they use a water-soluble polymer they have high viscosity, and so it is difficult to coat such waterproof agents. In addition, since a size of the particles of such conventional waterproof agents is relatively large water molecules can easily move between the particles, and so water easily permeates such a waterproof agent. Therefore, when such a conventional waterproof agent is exposed to water for a long time, there may be a problem in that water may permeate. For this reason, such a conventional waterproof agent is generally used for internal structures of buildings, and it is not suitable for being used for a plate member such as a particle board.
In the embodiments of the present invention, in order to solve the problem of the conventional waterproof agent, a waterproof composition using a resin having a small particle size, wax, and various additives is coated on the plate member, thereby obtaining stabilization of the plate member. The plate member coated by the waterproof composition has good durability and a small twisting phenomenon, and in addition, emission of formalin during manufacturing of the plate member can be prevented.
At this time, a diameter of a particle of the acrylic resin may be between 0.1 to 0.5 μm. The particle diameter of acrylic resin is generally between about 0.1 to 1.5 μm. If the particle diameter of acrylic resin is greater than 1.0 μm, the amount of coating material remaining on a coated surface is larger than the amount of coating material penetrating. On the other hand, if the particle diameter of the acrylic resin is less than 0.1 μm, the opposite phenomenon may occur.
Furthermore, the acrylic resin may be at least one selected from the group consisting of a water-soluble acrylic resin, a Styrene Maleic Anhydride copolymer (SMA), an acrylic hybrid emulsion, and a urethane hybrid resin. Since water-tolerance of a water-soluble acrylic resin increases depending on evaporation of moisture, a water-soluble acrylic resin may be preferable.
The water repellent agent may be at least one selected from the group consisting of polyethylene wax, polypropylene wax, paraffin wax, a fluorine-based water repellent agent, and a silicone-based water repellent agent. In the case of paraffin wax or polyethylene wax, if a softening point is low, stability in a coated surface or in an interior of a coated surface may deteriorate. Thus, it is preferable to use wax at a temperature at which a softening point is relatively high, and a preferable temperature range of a softening point is about 80 to 110° C.
The hydrogenated rosin may be at least one selected from the group consisting of ester gum rosin, terpene phenol, petroleum resin, hydrocarbon, and synthetic resin emulsion.
The penetrating agent may be at least one negative ionic surfactant selected from the group consisting of sodium alkyl ester, naphthalene sulphonate, phosphate-based surfactant, and nonyl phenyl alkyl-based surfactant.
The high-boiling-point solvent may be at least one selected from the group consisting of ethylene glycol, propylene glycol, and diethylene glycol.
The additive agent may be a leveling agent, a wetting and dispersion agent, or the like. BYK-348 (BYK Chemie) can be used as the leveling agent, and BYK-190 (BYK Chemie) and Dispers 610S (TegoChemie) can be used as the wetting and dispersion agent.
In order to manufacture an adhesive material or a coating material, a material having various components is needed, and each component may have an effect on the physical or chemical characteristics of the resultant material. In the embodiments of the present invention, the weight % of acrylic resin, the water repellent agent, the hydrogenated rosin, the penetrating agent, the additive agent, and the high-boiling-point solvent form the optimal range for such effects.
Hereinafter, experimental examples for checking effects of a floor panel according to an exemplary embodiment of the present invention will be described.
A floor panel of an experimental example is manufactured in the structure shown in
At first, four tetragonal grooves are respectively formed on a lower surface of the upper plate 21 and an upper surface of the lower plate 22 in a length direction of a shorter side, and the aluminum bar is inserted into each tetragonal groove. Then, they are glued to each other and pressed to form the floor panel 20 in a thickness of 36 mm.
Table 1 and
Referring to table 1 and
Comparison example: upper plate 15 mm + lower plate 15 mm + aluminum bar 8 mm = total 38 mm
Experiment example: upper plate 18 mm + lower plate 18 mm (aluminum bar 8 mm) = total 36 mm
Furthermore, by an application of a high stiffness floor panel 20, spacing between the pedestals 30 can be enhanced up to 800×1,200 mm for a raised floor system as shown in
In addition, in the case that the waterproof composition is formed in accordance with Table 2 and the particle board is coated by the formed waterproof composition, an expansion rate of absorption thickness is decreased from 10.13% before coating to 4.34% after coating, that is, water tolerance has been increased.
As above stated, in the present invention, by forming a longitudinal groove in the plate of a floor panel of a raised floor system and by inserting a stick type reinforcing member and/or a plate type reinforcing member into the longitudinal groove, a thickness of a floor panel can be reduced and at the same time high stiffness and light weight of the floor panel can be achieved. Therefore, a better walking feeling can be obtained, and a wider spacing of pedestals can be achieved.
In addition, by achieving a light weight of the floor panel and a wider spacing of pedestals, installation speed may be enhanced, and installation cost may be reduced. Furthermore, floor impact noise can be substantially decreased.
In addition, by coating the plate with a waterproof composition, it is possible to overcome drawbacks of a size and strength thereof being changed and deteriorated by exposure to moisture.
While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2005-0015683 | Feb 2005 | KR | national |
