Frame for an access panel

Abstract

The present invention relates to a frame for an access panel for an opening in the ground. The frame enables improved fitting in the opening in the ground since it allows easier installation and improved stability of the fixed frame. The invention also relates to an extrusion die for a metal profile and relates to a metal profile. Further aspects of the invention relate to an access panel and to a method for fitting a frame in an opening in the ground.

Description

[0001] Socket for an access panel

[0002] The present invention relates to the technical field of civil engineering, in particular the field of building construction. A first aspect of the invention relates to a socket for an opening in a floor. A second aspect relates to an extrusion die for a metal profile; a third aspect relates to a metal profile. A fourth aspect relates to an access panel. A fifth and final aspect relates to a method for mounting a socket in an opening in a floor.

[0003] In structural engineering, when constructing buildings, especially those with large spaces such as office buildings, event halls, shopping centers, or single-family and multi-family homes, it is essential to ensure flexible and comprehensive access to key infrastructure elements such as piping (e.g., plumbing lines and lines for liquid and gaseous media), and electrical cabling (e.g., data and power cables). Traditionally, such access points are often located on the side walls of rooms. However, this can lead to significant limitations in large rooms, as access to these critical elements is restricted to specific areas of the room.

[0004] In such cases, access panels for openings in the floors, also known as floor boxes, are used. These allow access to piping and wiring directly from the floor, significantly increasing accessibility and flexibility by eliminating the need for access points on the walls.

[0005] Such access panels typically comprise a socket which is fixed in an opening in the floor. Depending on the intended use of the access panel, a specially designed insert may be mounted in the frame. For example, the insert can be equipped with power sockets and / or network jacks which are connected to the building's power network and / or data network. Fittings for gases and liquids are also conceivable. The access panel can usually be closed with a cover which is connected to the socket either via a hinge and / or a snap connection, or can be placed loosely on the socket.

[0006] As a rule, it is desirable that, after applying a certain floor covering (for example carpet, linoleum, polyurethane coverings (PU coverings), parquet, stone slabs, cast flooring, hard concrete, terrazzo or ground subfloor) to the floor and to the cover of the socket, the access panel is flush with the surface of the floor.

[0007] The following sections describe the different floor types (subfloors, raised access floors and raised access floors) in which access panels are used.

[0008] With a subfloor, the desired floor installations (e.g., thermal and sound insulation, electrical conduits, underfloor ducts, and underfloor heating pipes) are first installed on the building's load-bearing floor. The material for the subfloor (e.g., anhydride or cement) is then poured in so that the entire floor is filled with the material up to the desired height. A hollow space floor (or cavity floor) is supported on supports on the load-bearing floor, creating a space for installations. After a separating layer (Schrenzlage) has been applied, the floor is poured.

[0009] A raised access floor, similar to a hollow floor, has a gap because it is raised by supports. In certain raised floor designs, individual panels are visible and can be removed. In other raised floor designs, the floor panels are attached to each other using a tongue-and-groove or tongue-and-groove adhesive connection. The floor covering is then laid over the entire surface.

[0010] These types of floors can be equipped with access panels to provide access to the installation elements. Often, the sockets for these access panels are supported on the underlying load-bearing subfloor and adjusted to the desired level. With subfloors, the socket is positioned at the desired location before pouring, and the internal volume of the socket is not filled. With hollow space floors and raised access floors, cutouts are made in the floor into which the sockets are inserted.

[0011] Because the sockets are supported on the supporting floor and therefore require height adjustment, installing such an arrangement is very complex and often leads to inaccuracies in the installation height of the sockets. Furthermore, subsequent adjustment of the height (particularly with subfloors) is very complicated or even impossible. Further problems that arise with this arrangement include increased sound transmission to the supporting floor, the formation of cracks in the floor, and the need for putty joints between the floor and the socket.

[0012] As an alternative, the prior art also describes sockets for access panels which are equipped with a flange which rests on the edge of the floor opening and supports the access panel. One such supporting flange is described, for example, in EP 1173647 B1 (CABSCAPE HOLDINGS, 23 September 2009). The socket does not stand on the supporting floor and therefore does not need to be adjusted in height. However, a supporting flange must be able to withstand a sufficiently high load-bearing capacity if the access panel is subjected to heavy loads. If the flange is too thin, there is a risk that the access panel will collapse under excessive load or that fatigue symptoms will occur after a certain period of time due to constant loading and unloading.Even if the flange is thick enough to withstand high static and / or cyclic loads over extended periods, the assembly often cannot be designed to sit flush with the floor surface. This prevents a level floor surface, making it difficult to push objects and roll carts. Furthermore, such raised areas in the floor pose dangerous tripping hazards.

[0013] If the socket's support flange is to be designed as thin as possible and thus no longer performs a load-bearing function, there are various state-of-the-art methods for securing a socket in a floor opening. Common techniques include mechanical fastening and bonding.

[0014] With mechanical fastening, the socket is fixed by means of

[0015] Screws or other fasteners are used to secure the floor opening. This method provides a robust connection but can be complex to use.

[0016] Bonding, on the other hand, uses adhesives to hold the socket securely in the base opening. This enables a slimmer design, but can entail limitations in terms of long-term stability and ease of maintenance. EP 2177689 B1 (BRECO-BAUELEMENTE AG, November 30, 2016) discloses a socket for a floor box which has a non-load-bearing flange for positioning the socket at the top of a base opening. The socket also has a lateral surface on which an undercut is formed. This undercut acts as an adhesive groove when the lateral surface is bonded to the inner wall of the base opening. The area between the start point of the undercut and the end point of the undercut is considered the adhesive area. According to EP 2177689 B1, this adhesive groove enables improved bonding of the socket in the base opening compared to a planar surface.Before inserting the socket into the base opening, the adhesive is applied to the outer surface. However, it has been found that with a socket prepared in this way, the adhesive is often not distributed evenly along the outer surface when the socket is inserted, and the adhesive groove, into which the adhesive should actually be applied, is only insufficiently filled with adhesive. In addition, the adhesive layer in the adhesive groove is very thick, which makes it difficult for the adhesive to dry completely. In practice, this often leads to an insufficiently strong adhesive bond, meaning the socket cannot withstand the necessary static and cyclic loads. In addition to being susceptible to poor adhesive bonds, the angular profile of the socket also has predetermined breaking points, which makes the socket even more susceptible to failure.This unreliable stability of the state-of-the-art adhesive floor boxes leads to costly repair work and also represents a high risk of accidents.

[0017] It is therefore an object of the present invention to overcome at least some, if not all, of the disadvantages of the prior art. It is a particular object of the invention to provide a socket for an access panel for an opening in a floor, which socket enables improved assembly. The improved assembly comprises both easier installation of the socket in the opening and improved stability of the installed socket under load. The improved stability should be guaranteed, in particular, even in the event of careless assembly.

[0018] The problem is solved by a socket for an opening in a floor, an extrusion die for a metal profile for producing a socket, a metal profile for producing a socket, an access panel for an opening in a floor, and a method for mounting a socket in an opening in a floor according to the independent patent claims. Advantageous embodiments and further developments are the subject of the dependent claims.

[0019] A first aspect of the invention relates to a socket for an opening in a floor. The floor is in particular a floor of a building. The socket comprises a flange for resting on the floor. It also comprises a casing surface for insertion into the opening. The casing surface in turn comprises an adhesive area for fixing the socket in the opening. The socket is characterized in that the distance between the flange and the adhesive area is at most 10 mm, preferably at most 5 mm, even more preferably at most 1 mm. Most preferably, the adhesive area borders directly on the flange.

[0020] In the context of the present invention, a socket as part of an access panel is a circumferential structure specifically designed for an opening in a floor, the opening having substantially vertical side walls. The main function of the access panel is to provide orderly and safe access to electrical wiring and / or piping running beneath the floor surface. The socket serves as a frame or housing that is inserted into the opening in the floor and provides a stable and defined interface to secure and support the access panel.

[0021] The socket can be prepared for different floor types and floor coverings. The floor covering is the topmost, visible part of the floor. Possible floor coverings include carpet, linoleum, polyurethane coverings (PU coverings), parquet, stone slabs, cast flooring, hard concrete and terrazzo. Depending on the type and thickness of the floor covering, the socket is prepared accordingly so that the access panel is flush with the surface of the floor. Floor type refers to the part of the floor between the load-bearing floor and the floor covering. The socket according to the invention can be used in various floor types. Possible floor types include subfloors, raised access floors and raised floors.

[0022] With a subfloor, the desired floor installations (e.g., underfloor ducts) are installed on the building's load-bearing floor. Where the access panels are to be positioned, appropriate formwork is placed as recesses on the load-bearing floor. The liquid material (anhydride or cement) for the subfloor is then poured in such a way that the entire floor is filled with the material up to the desired height. The recesses are not filled. The side walls of the recesses are then glued to the adhesive area of ​​the socket.

[0023] Both a hollow floor and a raised access floor are supported by supports on the supporting floor. Unlike a cavity floor, the individual floor panels of a raised floor are visible. For both types of floors, cutouts are made in the floor during installation, into which the sockets can be inserted.

[0024] In general, the frame according to the invention can also be installed in concrete slabs and wooden structures. Furthermore, the application of the frame according to the invention is not limited to access panels for openings in floors, but also for openings in walls and ceilings.

[0025] In the context of the present invention, a floor is a horizontally oriented structural element on which people and objects can be placed and / or moved.

[0026] The flange, as part of the socket according to the invention, is a structure that extends from the outside of the socket away from the center of the socket opening. During the assembly phase of the socket, the flange is placed on the floor and serves as a temporary support that holds the weight of the socket before the adhesive for bonding the socket to the opening in the floor has cured. The flange is not designed to bear heavy loads such as the weight of people and objects such as furniture or even cars. The shell surface, in the context of a socket according to the invention, refers to the part of a circumferential outside of the socket that lies below the flange when the socket is installed as intended in an opening in a floor. The shell surface is the part of the outside of the socket that is inserted into the opening in the floor and serves as a connecting element between the socket and the surrounding floor structure.After inserting the socket, there is a gap between the opening in the base and the surface of the casing, which can be at least partially filled, for example with an adhesive.

[0027] The adhesive area refers to a specific part or the entire outer surface of a socket according to the invention, which serves to fix the socket, in particular in an opening in a base. The adhesive area is a specially shaped surface that is designed so that an adhesive that is to be introduced into the gap between the socket and the base opening during intended use can cure to form a positive fit. Viewed from the flange in the installation direction, the adhesive area begins where the outer surface is not or no longer essentially vertical during intended use. Viewed from the flange in the installation direction, the adhesive area therefore begins at the section of the outer surface where an overlap between the adhesive and the outer surface is possible under vertical load.The positive connection between the adhesive area and the adhesive enables a permanent and stable connection between the socket and the surrounding structure. The adhesive area is preferably not a self-adhesive area of ​​the outer surface, but rather an area that is intended for bonding with an adhesive to be applied thereto. The outer surface is preferably arranged essentially vertically if the angle between a normal vector of the outer surface and a normal vector of the side of the flange facing the adhesive area is in the range of 85° to 95°, preferably in the range of 87° to 93°, most preferably in the range of 89° to 91°.

[0028] Preferably, the lateral surface between the flange and the bonding area comprises a planar surface that is vertically arranged during intended use. This vertically arranged surface is not part of the bonding area. In this case, this planar, vertically arranged surface and the bonding area form two separate areas of the lateral surface.

[0029] In the context of the present invention, the adhesive region has, in a section perpendicular to the longitudinal axis of a strip of the frame between a starting point and an end point at a cutoff wavelength of 2 mm, a waviness profile with a wave depth of between 0.6 mm and 2.4 mm, preferably between 1.0 mm and 2.0 mm, most preferably between 1.4 mm and 1.6 mm.

[0030] Preferably, the measured surface profile is determined using a non-contact measuring device, preferably a white light interferometer. The waviness profile is determined from this measured surface profile. The waviness profile (W-profile) is the profile resulting from electronic low-pass filtering of the measured surface profile with a cutoff wavelength of 2 mm.

[0031] The cutoff wavelength is used to decompose the surface profile into two components: the waviness profile (long wavelength) and the roughness profile (short wavelength). Wavelengths longer than the cutoff wavelength are assigned to the waviness profile, while shorter wavelengths are assigned to the roughness profile. When analyzing a surface, the measured overall profile is decomposed into these two components using appropriate filtering techniques so that the macroscopic waves (waviness) can be distinguished from the microscopic irregularities (roughness). The cutoff wavelength is the wavelength at which the Gaussian filter used attenuates the wavelength by 50%. This also means that this wavelength is transmitted at 50%.

[0032] The distance between the flange and the bonding area is the shortest distance between the side of the flange facing the bonding area and the beginning of the bonding area.

[0033] It has been shown that a socket according to the first aspect of the invention enables particularly good installation in a floor opening. This good installation includes both easier installation of the socket and improved stability of the installed socket under load.

[0034] It has been shown in particular that placing the start of the bonding area as close as possible, in particular directly next to the flange, leads to improved distribution of the adhesive along the entire bonding area. Even if the adhesive is applied to the edge between the flange and the outer surface, the adhesive is distributed in the intended bonding area and not outside it (as for example in EP 2177689 B1, BRECO-BAUELEMENTE AG, November 30, 2016). Thus, in a socket according to the invention, the adhesive is applied to the desired location even in the event of careless assembly. Firstly, this makes installation of the socket easier, and secondly, it leads to improved stability and thus to less susceptibility to errors in the installed socket under load compared to sockets of the prior art.

[0035] In addition to easier installation and increased stability, the socket according to the invention requires a shorter outer surface than comparable prior art sockets, since the bonding area begins closer to the flange. This saves material and also makes the socket according to the invention suitable for shallower openings in floors.

[0036] In a preferred embodiment of the first aspect of the invention, in a section perpendicular to the longitudinal axis of a strip of the frame, the chord length between a starting point and an end point of the adhesive region is at least 13 mm, preferably at least 18 mm, most preferably at least 23 mm.

[0037] A strip of a frame preferably refers to a specific, elongated side part formed from metal profiles. These strips are created, for example, by cutting and beveling the metal profile and then welding several such beveled metal profiles together. The definition of a strip, as described here, also applies to all subsequent preferred embodiments.

[0038] For the purposes of the present invention, the longitudinal axis of a strip is defined as the imaginary line that extends in the longitudinal direction of the strip and determines its course. It runs parallel to the longest sides of the strip.

[0039] For the purposes of the present invention, a cut perpendicular to the longitudinal axis of a frame strip refers to an imaginary cut that runs at right angles to the longitudinal axis of the strip. This cut does not represent a physical separation or processing of the strip as a structural feature, but rather serves as a conceptual reference and / or viewing plane.

[0040] The starting point and the end point of the bonding area refer to specific positions on the section perpendicular to the longitudinal axis of a strip of the frame. Within the scope of the present invention, the starting point of the bonding area is defined as the point at which the bonding area begins, while the end point marks the end of this area.

[0041] Mathematically speaking, the chord length between two points on a plane curve is the straight line connecting the two points, without taking the curve itself into account. The chord length between the starting point and the end point in the context of the present invention refers to the shortest connecting line between these two points.

[0042] It has been shown that a bonding area as long as possible, perpendicular to the longitudinal axis of a socket strip, and thus the largest possible bonding area on the socket's outer surface, is particularly advantageous for the adhesive's adhesion when bonding the socket to the side wall of the opening in the base. This leads to greater stability of the socket in the opening and thus contributes to improved installation of the socket.

[0043] In a further preferred embodiment of the first aspect of the invention, the adhesive region of the frame is an adhesive region which, in a section perpendicular to the longitudinal axis of a strip of the frame, is edgeless and corrugated, preferably sinusoidally corrugated. An edgeless and corrugated adhesive region in the context of the present invention refers to a region which has no sharp or pronounced edges and whose surface has a wave-like structure. The waves can have different shapes, wavelengths and amplitudes. The waves can be harmonic waves, in which the wavelength and amplitude are constant, or inharmonic waves, in which the wavelength, the amplitude or both parameters vary along the length of the wave.For edgeless harmonic waves, examples of possible waveforms are sine waves, edgeless sawtooth waves, edgeless square waves, and edgeless triangular waves, with any edges of the waveform being rounded off. The radius of the rounding is at least 0.50 mm, preferably at least 0.75 mm, and most preferably at least 1.00 mm. Superimposed waveforms are also possible.

[0044] In a sinusoidal corrugated adhesive area, the wave has a sinusoidal shape.

[0045] It has been shown that a corrugated adhesive area and its edgeless design ensures a uniform and trouble-free connection between the socket and the opening in the base:

[0046] The corrugated adhesive area enables a particularly well-developed form fit (which was already described above) between the adhesive area and the adhesive. When the socket is loaded in the assembly direction, the wave crests of the corrugated adhesive area are pressed evenly onto the form-fitting, cured adhesive, which leads to an even transfer of force to the adhesive. The wave shape also increases the contact area between the adhesive area and the adhesive. When the socket is inserted into the opening in the base, the adhesive is also evenly distributed in the corrugated adhesive area, which in turn leads to an even distribution of the load on the adhesive bond. In addition, if the adhesive is better distributed, it can dry better than if the entire volume of the adhesive is in a single place, which makes drying of the core of the volume difficult or even impossible.

[0047] In addition, it has been shown in the case of sockets with edged adhesive areas of the prior art (such as in EP 2177689 B1, BRECO-BAUELEMENTE AG, November 30, 2016) that the adhesive bond is not particularly stable. It was surprisingly found that an adhesive seam which is connected to an edged surface is more likely to break than an edgeless adhesive area. It was therefore found that the angular cross-section is one of the factors responsible for this instability. In addition to the more stable adhesive seam, the edgeless design of the adhesive area also makes the socket itself more stable. The edges of the adhesive area are predetermined breaking points which can lead to the socket breaking if the load is too great. The edgeless adhesive area of ​​the socket according to the invention therefore leads to increased stability.

[0048] Due to the greatly improved stability of the adhesive bond and the socket compared to state-of-the-art sockets, a shorter shell surface is required, which (as described above) leads to material savings and enables the socket to be installed in less deep openings.

[0049] It has also been shown that a sinusoidally corrugated adhesive area is particularly advantageous for ensuring better stability of the socket and the adhesive bond. Thus, an edgeless and corrugated, preferably sinusoidally corrugated, adhesive area enables improved mounting of the socket.

[0050] In a further preferred embodiment of the first aspect of the invention, the ratio between the arc length and the chord length between a starting point and an end point of the edgeless and corrugated, preferably sinusoidally corrugated, adhesive region in a section perpendicular to the longitudinal axis of a strip of the frame is greater than 1.2, preferably greater than 1.3, even more preferably greater than 1.4, most preferably greater than 1.5.

[0051] The arc length of a plane curve is used to describe the physical length of the curve between two points lying on the curve. Unlike the chord length, which describes the shortest distance between the two points, the arc length describes the distance of the path along the curve. For the purposes of the present invention, the arc length refers to the length of the potentially curved path connecting the two points within the bonding region.

[0052] It has been shown that a ratio of the arc length to the chord length according to the invention is particularly advantageous for achieving the properties of the adhesive region according to the invention described above. In particular, this increases the surface area of ​​the adhesive region, which strengthens the adhesive bond and thus increases the load-bearing capacity of the frame.

[0053] A further preferred embodiment of one of the two preceding embodiments of the first aspect of the invention relates to a frame in which the edgeless and corrugated, preferably sinusoidally corrugated, adhesive region in a section perpendicular to the longitudinal axis of a bar of the frame has a wavelength of between 4.7 mm and 6.0 mm, preferably between 5.0 mm and 5.7 mm, most preferably between 5.3 mm and 5.4 mm. Furthermore, said adhesive region has an amplitude of between 0.3 mm and 1.2 mm, preferably between 0.5 mm and 1.0 mm, most preferably between 0.7 mm and 0.8 mm.

[0054] It has been shown that a corrugated bonding area with such a wave structure is particularly advantageous for achieving the object of the invention. On the one hand, these wavelength and amplitude dimensions lead to a stable, positive connection between the adhesive and the bonding area. On the other hand, the recesses of the wave structure are not too deep, which allows for rapid and complete drying of the adhesive.

[0055] In a preferred embodiment of the preceding embodiment of the first aspect of the invention, the length of the edgeless and corrugated, preferably sinusoidally corrugated, adhesive region in a section perpendicular to the longitudinal axis of a strip of the frame is at least 2.5, preferably at least 3.5, most preferably at least 4.5 wavelengths.

[0056] It has been shown that an edgeless and corrugated adhesive area which has a plurality of corrugation cycles is particularly advantageous. When the socket is loaded, the force can be transferred from the socket to the cured adhesive via a plurality of bulges in the adhesive area. With a plurality of corrugation cycles, the distribution of the adhesive along the adhesive area is also better, which is advantageous (as described above). In a further preferred embodiment of the first aspect of the invention, the flange of the socket is at most 1.0 mm, preferably at most 0.8 mm, most preferably at most 0.5 mm thick in the vertical direction when used as intended.

[0057] In this context, the intended use refers to the use of the socket in a soil.

[0058] A flange that is as thin as possible allows the floor to be as level as possible after the floor covering has been applied, even where the flange of the socket rests on the floor surface below the floor covering. Raised floor coverings above the flange are not only aesthetically undesirable, but also lead to damage to the floor covering if people repeatedly walk on them, if the access panel is repeatedly driven over, or if objects are pushed over it.

[0059] In a further preferred embodiment of the first aspect of the invention, the socket additionally comprises a projection extending toward the center of the socket for supporting an insert and / or a cover. An upper side of the projection is lower than a side of the flange facing the adhesive area. Furthermore, the distance between the upper side of the projection and the side of the flange facing the adhesive area is between 4 mm and 9 mm, preferably between 5 mm and 8 mm, most preferably between 6 mm and 7 mm.

[0060] In this context, the expression "deeper" means the spatial position of the upper side of the projection in relation to the side of the flange facing the adhesive area when the socket is intended to be inserted into an opening in the floor. The projection, as part of the socket according to the invention, is a structure which extends from the inside of the socket towards the centre of the opening in the socket. The projection is arranged such that an insert and / or a cover can be placed thereon such that a top side of the cover is arranged substantially coplanar with the side of the flange facing the adhesive area. This enables the top side of the access panel to be arranged coplanar with the top side of the floor when the floor covering is applied to the floor and to the cover.

[0061] In a preferred embodiment of the preceding embodiment of the first aspect of the invention, at least one connecting edge between an inner surface of the socket and the projection is rounded with a radius of at least 1 mm, preferably at least 2 mm, most preferably at least 3 mm.

[0062] An inner surface of the socket is a surface whose normal vector is directed to the center of the socket and which is both perpendicular to the flange and perpendicular to the section which is perpendicular to the longitudinal axis of a ledge of the socket.

[0063] The connecting edges between the inner surface of the socket and the projection are edges that extend parallel to the longitudinal axis of a strip of the socket. They form the transition between the inner surface of the socket and the projection, which are preferably arranged perpendicular to each other.

[0064] Rounding at least one connecting edge between the inner surface of the socket and the projection increases the strength of the projection and thus the entire socket. This prevents or at least reduces deflection of the projection or other parts of the socket when forces are applied to the access panel cover.

[0065] It is also possible that further edges of the frame are rounded to ensure greater stability.

[0066] An alternative aspect to the first aspect of the invention relates to a socket for an opening in a floor, in particular a floor of a building. The socket comprises a flange for resting on the floor and a casing surface for insertion into the opening. The casing surface comprises an adhesive region (as defined above) for fixing the socket in the opening. This alternative aspect is characterized in that the adhesive region is an adhesive region which is edgeless and corrugated, preferably sinusoidally corrugated, in a section perpendicular to the longitudinal axis of a strip of the socket.

[0067] The advantageous embodiments of the first aspect of the invention, in particular with regard to the edgeless and corrugated adhesive area, also apply to this alternative aspect.

[0068] As has been described with regard to the first aspect of the invention, the shortest possible distance between the flange and the adhesive area is particularly advantageous for a particularly strong adhesive bond between the socket and the base opening. However, it has also been shown that an edgeless and corrugated, preferably sinusoidally corrugated, adhesive area on its own can lead to an extremely stable adhesive bond, regardless of where the adhesive area is arranged on the outer surface. A second aspect of the invention relates to an extrusion die for a metal profile, in particular an aluminum profile, for producing a socket according to the first aspect of the invention by cutting to length, beveling and welding.

[0069] An extrusion die is a specialized tool used in manufacturing, particularly in the extrusion process (also called extrusion molding). It consists of a robust mold, often made of hardened steel or other durable materials, with one or more openings with a specific cross-section. These openings correspond to the desired shape of the final product, such as a metal profile.

[0070] In the extrusion process, a heated and malleable material, such as aluminum or plastic, is forced through the extrusion die. The material takes on the shape of the openings in the die and solidifies upon cooling, creating the desired profile.

[0071] To produce the frame, a metal profile produced by the extrusion process, preferably aluminum profile, is processed by:

[0072] - cutting to length, wherein the cutting to length comprises cutting the metal profile into individual metal profile parts, preferably aluminum profile parts;

[0073] - chamfering, wherein the chamfering comprises cutting the ends of the metal profile parts, preferably aluminum profile parts, to a desired angle; and

[0074] - Welding, where the welding comprises joining the beveled metal profile parts, preferably aluminum profile parts, to form a socket. For a square or rectangular socket, the ends are beveled at a 45° angle. For a square or rectangular socket, four beveled metal profile parts are welded together to obtain the finished socket. These metal profile parts are strips as part of the socket.

[0075] Cutting, beveling, and welding are the only substantial steps required. Other steps such as grinding cut edges and surface treatment (e.g., cleaning, sanding, polishing, painting, galvanizing, or anodizing) are also possible, although these steps do not significantly alter the profile. The structural characteristics of the strips of the finished frame correspond to the structural characteristics of the metal profile produced by the extrusion process, preferably the aluminum profile. Therefore, for example, no additional recesses are milled into the profile.

[0076] In a preferred embodiment, the socket of the first aspect of the invention comprises a protective edge for protecting the floor covering, wherein the protective edge is a circumferential projection formed on the side of the flange facing away from the adhesive area. Thus, the extrusion die of the second aspect of the invention comprises a corresponding recess for this protective edge. This protective edge can be cut to the desired length after extrusion of the metal profile, preferably aluminum profile, depending on the thickness of the floor covering, which is the only significant change to the profile of the socket.

[0077] An extrusion die according to the second aspect of the invention enables the production of a socket according to the first aspect of the invention with the above-mentioned advantages. The second aspect of the invention thus enables the provision of a socket for an access panel for an opening in a floor, which enables improved assembly.

[0078] A third aspect of the invention relates to a metal profile, in particular an aluminum profile, for producing a frame according to the first aspect of the invention by cutting to length, beveling and welding.

[0079] The frame is manufactured from the metal profile, preferably an aluminum profile, as described in the second aspect of the invention; the manufacture is also subject to the restrictions stated therein. The essential structural features of the metal profile according to the invention, preferably an aluminum profile, correspond to those of a strip of the frame of the first aspect of the invention.

[0080] The third aspect of the invention also enables the provision of a socket for an access panel for an opening in a floor, which enables improved assembly.

[0081] A fourth aspect of the invention relates to an access panel for an opening in a floor, in particular a floor of a building. The access panel comprises a frame according to the first aspect of the invention.

[0082] The access panel also optionally includes an insert. The insert can be placed on a projection of the socket and is mountable to the socket. It is preferably mounted using a screw connection and / or clamp connection.

[0083] For the purposes of this invention, the term "or" is to be understood as an exclusive disjunction. "A or B" indicates that exactly one of the two statements is true (if the disjunction is true).

[0084] The access panel also includes a cover. The cover is placeable onto the socket projection and / or the optional insert to close the access panel. A top surface of the cover is substantially coplanar with a side of the socket flange facing the bonding area when the access panel is closed.

[0085] The access panel also optionally includes a damping element made of a rubber-elastic material. Preferably, the rubber-elastic material is an ethylene-propylene-diene rubber from the M group (EPDM). The damping element can be placed between the cover and the socket and / or between the cover and the optional insert. The damping element is preferably glued to the cover, the socket, or the optional insert.

[0086] The insert usually consists of a robust metal or plastic construction that can be placed on the projection and fastened there. For example, after the insert has been placed, screws can be fitted into the socket so that the insert is firmly in place and cannot be removed from the socket without loosening the screws. An adhesive connection for mounting the insert is also conceivable. The insert can, for example, be prepared for power sockets and / or network connections so that corresponding sockets can be built into the insert and the corresponding cables can be connected to the sockets. The insert can also include fittings for gases and / or liquids which are connected to corresponding lines. If the access panel includes such an insert, it is also referred to as a junction box.If the access panel only allows access to underfloor ducts, for example, it is referred to as a pull-out box.

[0087] The lid is adapted to receive the same flooring as is used for the rest of the room floor, such that the top surface of the flooring on the lid and the top surface of the flooring on the rest of the floor are substantially coplanar with each other.

[0088] To close the lid, it can either be placed loosely on the socket's protrusion and / or the optional insert. It is also possible for the lid to be attached to the socket with a hinge and / or a clamp connection.

[0089] In the context of the present invention, the term «substantially coplanar» means that two surfaces lie at least almost in the same geometric plane. Minor deviations or irregularities that may occur in practice are permitted. However, these deviations are so minimal that they do not significantly impair the intended function of the objects in question. In the present case, the fact that the upper side of the cover, when the access panel is closed, is arranged substantially coplanar with a side of the flange of the socket facing the adhesive area means that the planes in which the two surfaces lie are at most 3.0 mm, preferably at most 2.0 mm, even more preferably at most 1.0 mm, most preferably at most 0.5 mm apart. The optional damping element serves as sound insulation and also protects the material of the socket, the optional insert and the cover.

[0090] Ethylene-propylene-diene rubbers from the M group (EPDM) are terpolymers of ethylene, propylene and an unspecified diene and are defined by the standard ASTM D1418-22 (as of June 15, 2015).

[0091] The access panel of the fourth aspect of the invention comprises the socket of the first aspect of the invention, the advantages of which have been described in detail above; thus, the access panel according to the fourth aspect of the invention also enables improved mounting of the socket.

[0092] In a preferred embodiment of the fourth aspect of the invention, the access panel comprises a first protective edge for protecting the floor covering. The first protective edge is formed as part of the frame or as a separate component attached to the frame. Optionally, the access panel comprises a second protective edge for protecting the floor covering, the second protective edge being formed as part of the cover.

[0093] If the first protective edge is formed as part of the socket, the first protective edge is a projection surrounding the socket, which is formed on the side of the flange facing away from the adhesive area.

[0094] If the first protective edge is a separate component attached to the frame, it is preferably secured by an adhesive bond to a recess formed in the frame and running around the frame. Such a protective edge can also be referred to as a plug-in edge. Typically, a material is selected for such a first protective edge that matches the appearance of the floor covering, since the first protective edge is visible when the access panel is closed.

[0095] The second protective edge is a projection on the top of the lid that runs around the lid.

[0096] In a socket installed in the floor, the first and / or second protective edge is / are directed upwards. The length of the first and / or second protective edge is defined by the thickness of the respective floor covering such that a planar upper surface of the respective protective edge is arranged substantially coplanar with the surface of the floor covering.

[0097] The first protective edge and the optional second protective edge protect the edges of the flooring against damage when people repeatedly walk on them or when the access panel is repeatedly driven over or objects are pushed over it.

[0098] A fifth aspect of the invention relates to a method for mounting a socket according to the first aspect of the invention in an opening in a floor. The opening is larger than the socket. The method comprises the step of gluing the socket in the opening. The gluing is carried out in such a way that an adhesive is distributed in a gap between the adhesive region and the opening such that the gap is at least partially filled with adhesive.

[0099] The opening in the floor has substantially vertical side walls and provides access to electrical wiring and / or pipes. The socket is preferably part of an access panel according to the fourth aspect of the invention.

[0100] Bonding is achieved by applying a suitable adhesive so that the bonding area is filled with adhesive after the socket is inserted into the opening. Depending on the loads that will later be exerted on the cured bond, care must be taken to ensure that at least 80%, preferably at least 90%, and most preferably 100% of the bonding area is covered with adhesive. This ensures a sufficiently stable bond.

[0101] After the adhesive is applied, the socket is inserted into the opening. The flange then rests on the base and supports the socket while the adhesive cures. Before the socket cures, no additional load should be placed on the socket other than its own weight. In this state, the socket can support the insert and / or the lid, for example, but not heavier loads such as people, furniture, or vehicles.

[0102] After curing, the adhesive forms a positive connection with the adhesive surface of the socket, which imparts particularly high stability to the connection between the socket and the floor opening. The advantages of the method of the fifth aspect of the invention correspond to the advantages of the preceding aspects. Thus, the fifth aspect of the invention also enables improved assembly of a socket for an access panel for an opening in a floor.

[0103] In a preferred embodiment of the fifth aspect of the invention, the socket is bonded in the opening in such a way that the adhesive is applied to the bonding area of ​​the socket.

[0104] In addition, the adhesive can also be applied to the bottom opening or to the flange of the socket.

[0105] The second and subsequent aspects of the invention relate to both the first and the alternative first aspect of the invention.

[0106] The invention will now be described using specific embodiments. These embodiments are not intended to limit the scope of the invention in any way, but rather serve to facilitate understanding of the invention.

[0107] Fig. 1: Sectional drawings of the strips of various embodiments of the frame according to the invention;

[0108] Fig. 2: Sectional drawing of a strip of a socket according to the invention glued into an opening of a base;

[0109] Fig. 3: Illustration of the lateral surface and the

[0110] Adhesive area of ​​a frame according to the invention;

[0111] Fig. 4: Sectional drawing of an extrusion die according to the invention;

[0112] Fig. 5: Illustration of the manufacturing process of a frame according to the invention starting from a metal profile;

[0113] Fig. 6: Sectional drawing of an access panel according to the invention in a floor opening; Fig. 7: Perspective exploded view of an access panel according to the invention; and

[0114] Fig. 8: Sectional drawing of a strip of an inventive

[0115] Socket glued into an opening in a base with a planar surface that is vertically arranged between the flange and the adhesive area when used as intended.

[0116] Figure 1 shows sectional views of the strips (1130) of three different embodiments of the inventive frame (1100). The sectional view corresponds to the section (1140) perpendicular to a longitudinal axis (1131) of a strip (1130). A frame (1100) is typically composed of several metal profile elements, which form the individual strips (1130) in the finished frame (1100) (see below).

[0117] The socket (1100) comprises a flange (1110) directed away from the center of the socket (1100) and a lateral surface (1120). In Figure 1, the lateral surface (1120) begins below the flange (1110) and extends to the lower end of the socket (1100). A sinusoidally corrugated adhesive region (1121) is formed on the lateral surface (1120). In the exemplary embodiments shown, essentially the entire lateral surface (1120) is the adhesive region (1121). The side (1111) of the flange (1110) facing the adhesive region (1121) directly borders the adhesive region (1121) in all three exemplary embodiments. A projection (1150) directed toward the center (to the right in Figure 1) of the socket, comprising a top surface (1151) and a rounded connecting edge (1152), is located lower than the flange (1110) in Figure 1. The three embodiments differ in their respective design of the protective edge (1160) for protecting the floor covering.The embodiment in Figure 1A has a lower protective edge (1160') than the protective edge (1160") in Figure 1B. The socket (1100) in Figure 1A is designed for less thick floor coverings (2300) than the socket (1100) in Figure 1B. Figure 1C shows a socket (1100) without a protective edge. Instead, this embodiment includes a recess (1170) which is provided for receiving a protective edge as a separate component. This separate protective edge is attached to the socket (1100) by an adhesive connection.

[0118] Figure 2 shows a sectional view of the socket (1100) of the exemplary embodiment from Figure 1A. The outer surface (1120) is inserted into an opening (2210) of a base (2200). The side (1111) of the flange (1110) facing the adhesive area (1121) rests on the surface (2220) of a base (2200). Between a side wall (2211) of the opening (2210) and the adhesive area (1121) there is a gap (2230) which is filled with adhesive (3000). The cured adhesive (3000) forms a positive connection with the adhesive area (1121) of the socket (1100). If a load acts on the socket (1100) in the vertical direction, the elevations of the adhesive area (1121) are pressed onto the positive elevations of the adhesive (3000) for optimal force transmission.The adhesive bond is particularly stable because the adhesive area (1121) begins directly beneath the flange (1110) (in this exemplary embodiment, there is no gap (1122) between the flange (1110) and the adhesive area (1121)) and because the adhesive (3000) is distributed over the entire adhesive area (1121) by the inventive holder (1100) upon insertion. The terms "vertical" and "horizontal" refer to the horizontal surface (2220) of the base (2200) with respect to the direction of gravity.

[0119] The upper side (1151) of the projection (1150) lies at a certain distance (1153) below the side (1111) of the flange (1110) facing the adhesive area (1121) so that a cover (1300) can be placed on the projection (1150). After applying the floor covering (2300), which is not shown in Figure 2, to the base (2200) and the cover (1300), the surface of the floor covering (2300) is substantially coplanar with the upper side of the protective edge (1160') to form an overall flat surface.

[0120] Figure 3 shows a detailed illustration of the surface area (1120) of a sinusoidally corrugated bonding region. The bonding region (1121) is the part of the surface area (1120) that lies between the starting point (1141) and the end point (1142). The chord length (1143) between these two points is their direct connecting line (dotted line). The arc length (1144) is the actual length of the curve between the two points (dash-dotted line). The wavelength (1145) corresponds to the distance between two adjacent vertices of the wave structure. The amplitude (1146) describes the distance between the imaginary center line of the wave structure and the vertices.

[0121] Figure 4 illustrates an extrusion die (4000) for a metal profile (5000) for producing a frame (1100) according to the invention. The inner region of the contour of the frame (1100) is milled out of the extrusion die (4000). The process for producing a square frame (1100) according to the invention starting from a metal profile (5000) is illustrated in Figure 5. The metal profile (5000) is first divided into profile parts of the desired length by cutting to length (i). By beveling (ii) the profile parts, they can be joined together by welding (iii). The four profile parts form the individual strips (1130) of the finished frame (1100). Figure 5 also shows the longitudinal axis (1131) of a strip (1130), as well as a section (1140) perpendicular to the longitudinal axis (1131) of a strip (1130).

[0122] The socket (1100) according to the invention is shown in the sectional drawing in Figure 6 as part of the access panel (1000) according to the invention with protective edges (1160, 1320). In this embodiment, a subfloor (2200) is applied to the supporting floor (2100), wherein an opening (2210) has been cut out in the floor (2200) for the access panel (1000). An insert (1200) lies on the socket (1100) and is fastened (the fastening is not visible in Figure 7). The insert (1200) comprises socket openings (1210) to which power cables can be connected. In addition, access openings (1220) allow connected cables to be fed through from the access panel (1000). A cover (1300) is placed on the insert (1200), and between them is a damping element (1400), which is attached to the cover (1300). The cover (1300) is also equipped with a second protective edge (1320).The floor covering (2300) is applied to the surface (1310) of the lid (1300) and to the base (2200), wherein the floor covering (2300) on the lid (1300) and the floor covering (2300) on the base (2200) are arranged substantially coplanar to one another.

[0123] Figure 7 shows an isometric exploded view of the access panel (1000) according to the invention without a protective edge, comprising a socket (1100), an insert (1200), a cover (1300) and a damping element (1400) attached to the cover (1300).

[0124] Figure 8 shows a socket (1100) similar to that in Figure 2. The socket (1100) shown in Figure 8 differs from that in Figure 2 in that the distance (1122) between the adhesive area (1121) and the flange (1110) is greater. The distance (1122) is less than 10 mm. Thus, this embodiment comprises a planar, vertical surface (1123) between the adhesive area (1121) and the flange (1110). This surface (1123) does not belong to the adhesive area (1121), which only begins at the point where the first wave-shaped depression in the lateral surface begins.

Claims

Patent claims 1. Socket (1100) for an opening (2210) in a floor (2200), in particular a floor of a building, the socket (1100) comprising: - a flange (1110) for resting on the floor (2200); and - a lateral surface (1120) for insertion into the opening (2210), the lateral surface (1120) comprising an adhesive region (1121) for fixing the socket (1100) in the opening (2210); characterized in that the distance (1122) between the flange (1110) and the adhesive region (1121) is at most 10 mm, preferably at most 5 mm, even more preferably at most 1 mm, most preferably that the adhesive region (1121) directly adjoins the flange (1110).

2. Socket (1100) according to one of the preceding claims, wherein in a section (1140) perpendicular to the longitudinal axis (1131) of a strip (1130) of the socket (1100), the chord length (1143) between a starting point (1141) and an end point (1142) of the adhesive region (1121) is at least 13 mm, preferably at least 18 mm, most preferably at least 23 mm.

3. Socket (1100) according to one of the preceding claims, wherein the adhesive region (1121) is an adhesive region (1121) which is edgeless and corrugated, preferably sinusoidally corrugated, in a section (1140) perpendicular to the longitudinal axis (1131) of a strip (1130) of the socket (1100).

4. The socket (1100) according to claim 3, wherein the ratio between the arc length (1144) and the chord length (1143) between a starting point (1141) and an end point (1142) of the edgeless and corrugated, preferably sinusoidally corrugated, adhesive region (1121) in a section (1140) perpendicular to the longitudinal axis (1131) of a strip (1130) of the socket (1100) is greater than 1.2, preferably greater than 1.3, even more preferably greater than 1.4, most preferably greater than 1.

5.

5. Socket (1100) according to one of claims 3 and 4, wherein the edgeless and corrugated, preferably sinusoidally corrugated, adhesive area (1121) in a section (1140) perpendicular to the longitudinal axis (1131) of a strip (1130) of the socket (1100) - a wavelength (1145) of between 4.7 mm and 6.0 mm, preferably between 5.0 mm and 5.7 mm, most preferably between 5.3 mm and 5.4 mm; and - has an amplitude (1146) of between 0.3 mm and 1.2 mm, preferably between 0.5 mm and 1.0 mm, most preferably between 0.7 mm and 0.8 mm.

6. The socket (1100) according to claim 5, wherein the length of the edgeless and corrugated, preferably sinusoidally corrugated, adhesive region (1121) in a section (1140) perpendicular to the longitudinal axis (1131) of a strip (1130) of the socket (1100) is at least 2.5, preferably at least 3.5, most preferably at least 4.5 wavelengths (1145).

7. Socket (1100) according to one of the preceding claims, wherein the flange (1110) in the vertical direction during intended use is at most 1.0 mm, preferably at most 0.8 mm, most preferably 0.5 mm thick at most.

8. Socket (1100) according to one of the preceding claims, wherein the socket (1100) additionally comprises a projection (1150) extending towards the center of the socket (1100) for supporting an insert (1200) and / or a cover (1300), wherein - an upper side (1151) of the projection (1150) is lower than a side (1111) of the flange (1110) facing the adhesive area (1121); and - the distance (1153) between the upper side (1151) of the projection (1150) and the side (1111) of the flange (1110) facing the adhesive area (1121) is between 4 mm and 9 mm, preferably between 5 mm and 8 mm, most preferably between 6 mm and 7 mm.

9. Socket (1100) according to claim 8, wherein at least one connecting edge (1152) between an inner surface of the socket (1100) and the projection (1150) is rounded with a radius of at least 1 mm, preferably at least 2 mm, most preferably at least 3 mm.

10. Extrusion die (4000) for a metal profile (5000), in particular an aluminum profile, for producing a socket (1100) according to one of the preceding claims by cutting to length, beveling and welding.

11. Metal profile (5000), in particular aluminum profile, for producing a socket (1100) according to one of claims 1 to 9 by cutting to length, beveling and welding.

12. Access panel (1000) for an opening (2210) in a floor (2200), in particular a floor of a building, the access panel (1000) comprising: - a socket (1100) according to one of claims 1 to 9; - optionally, a bet (1200) , where - the insert (1200) can be placed on a projection (1150) of the socket (1100), and - the insert (1200) can be mounted on the socket (1100), preferably by a screw connection and / or clamp connection; a cover (1300), wherein - the cover (1300) for closing the access panel (1000) can be placed on the projection (1150) of the socket (1100) and / or the optional insert (1200), and - an upper side (1310) of the cover (1300) is arranged substantially coplanar with a side (1111) of the flange (1110) of the socket (1100) facing the adhesive area (1121) when the access panel (1000) is closed; and - optionally, a damping element (1400) made of a rubber-elastic material, preferably an ethylene-propylene-diene rubber from the M group, wherein - the damping element (1400) can be placed between the cover (1300) and the socket (1100) and / or between the cover and the optional insert (1200), and - the damping element (1400) is preferably glued to the cover (1300), to the socket (1100) or to the optional insert (1200).

13. Access panel (1000) according to claim 12, wherein the access panel (1000) - a first protective edge (1160) for protecting the floor covering (2300), wherein the first protective edge (1160) is formed as part of the frame (1100) or is a separate component attached to the frame (1100); and - optionally, a second protective edge (1320) for protecting the floor covering (2300), wherein the second protective edge (1320) is formed as part of the cover (1300).

14. Method for mounting a socket (1100) according to one of claims 1 to 9 in an opening (2210) in a floor (2200) , wherein the opening (2210) is larger than the socket (1100) , the method comprising the step: - Bonding the socket (1100) in the opening (2210) in such a way that an adhesive (3000) is distributed in a gap (2230) between the adhesive region (1121) and the opening (2210) such that the gap (2230) is at least partially filled with adhesive (3000).

15. The method according to claim 14, wherein the bonding of the frame (1100) in the opening (2210) such that the adhesive (3000) is applied to the adhesive area (1121) of the socket (1100).

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