Floor elements and hollow core floor systems

Abstract

The present invention relates to a floor element and to a hollow floor system comprising at least one floor element.

Description

[Technical Field]

[0001] The present invention relates to a floor element and to a hollow floor system comprising at least one floor element.

[0002] Floor elements for hollow floor systems are well known in the prior art and are commonly used. They are mounted on height-adjustable supports (support posts) and cover all building service installations, such as cables, wires, and communication equipment, but also cover possible defects in the subfloor (structural floor), such as undulations. In addition, these floor elements are feasibly designed and adapted to accommodate all load levels according to technical requirements. Furthermore, the floor elements allow free access to the state of the cavity floor cables, such as pipes and built-in floor tanks with connections.

[0003] Floor elements (also known as composite panels, or base plates, or elevated access floors) vary in the state of the art by carrier material, top surface, lining bottom, dimensions, and thickness. The carrier materials used are primarily highly compressed wood-based materials, calcium sulfate materials (e.g., gypsum), calcium silicate materials, or cement-bonded materials. The top cover can be fabric, elastic cover, or tile or parquet. Meanwhile, the back surface, or underlayment, can be protected from moisture with aluminum foil or paint. Double floor elements typically measure 600 / 600 mm, but special dimensions up to 1200 / 1200 mm are also possible. Depending on the material and load requirements, these floor elements can be used in thicknesses ranging from 19 to 50 mm, preferably 30 to 38 mm. Therefore, important characteristics of floor elements are load requirements, fire resistance (non-combustibility), acoustic requirements, electrostatic requirements, dissipation requirements, and anti-reverse static requirements.

[0004] Furthermore, as mentioned above, the floor elements are usually mounted on height-adjustable supports (support posts), which are usually made of metal, so that dissipation proceeds through the floor element (or at least its sides, in the state of the art).

[0005] For example, the base plate for the hollow floor in DE202007017237U1 may have an edge band of conductive plastic material coated with hot-melt adhesive on at least one end of the base plate. The base plate is electrically conductive between the top and bottom through this edge band, which provides good dissipation of static charge from the top to the bottom of the base plate and to the metal support posts. However, this is an additional step, and therefore, it would be costly to provide these edge bands on every base plate.

[0006] In DE 10 200 292 A1, the conductive properties of the flooring panels are achieved by panels made of, inter alia, polyurethane and metal pieces or flakes. Furthermore, the flooring panels can be enhanced with colored chips. However, due to the polyurethane body, the panels may only achieve the fairly low level of the fire resistance classification for construction products and building elements specified in DIN EN 13501-1:2010-01.

[0007] US2013 / 0047529A1 uses a different approach, where a core panel is encapsulated with two metal pans and a dissipative coating. Here, the core panel can be fiberboard, cement board, concrete board, etc. However, steel encapsulation is expensive and complicated.

[0008] As mentioned above, all these solutions have their drawbacks. Based on this prior art, the present invention is based on the objective of providing a solution for easily and inexpensively producing floor elements, preferably for hollow floor systems. These floor elements must be at least dissipative and therefore useful, for example, in operating rooms, radiology departments, laboratories, and supply rooms. In addition, the floor elements of the present invention can be used in industrial fields, for example, computer rooms, data rooms, clean rooms, and electronics departments. Furthermore, these panels must be stable, non-flammable, and visually appealing.

[0009] This object is achieved by a floor element having the features according to claim 1, a hollow floor system having the features according to claim 12 and a method for producing a floor element having the features according to claim 14.

[0010] Surprisingly, the floor element according to claim 1 is not only stable and non-combustible due to its cementitious core, but also preferably 10 6 ~10 9 It also has dissipative properties, with a resistance of ohms (Ω). Thus, the flooring elements of the present invention can be used where a combination of stability, non-flammability, and dissipative properties is required, for example, in computer rooms or hospitals as mentioned above. Additionally, without being bound by theory, it is believed that the flooring elements of the present invention do not lose their dissipative properties over time.

[0011] The cementitious core of the present application can include any material, substance, or chemically hardenable composition, such as cement or stucco, along with any suitable additives. Non-limiting examples of materials that can be used for the cementitious core include Portland cement, Sorel cement, slag cement, fly ash cement, calcium alumina cement, water-soluble calcium sulfate anhydrite, calcium sulfate α-hemihydrate, calcium sulfate β-hemihydrate ("stucco"), natural, synthetic, or chemically modified calcium sulfate hemihydrate, calcium sulfate dihydrate ("gypsum," "set gypsum," or "hydrated gypsum"), and mixtures thereof. As used herein, the term "calcium sulfate material" refers to any of the above-referenced forms of calcium sulfate. Preferably, the cementitious core includes cement, concrete, a calcium sulfate material, or a mixture thereof, preferably a calcium sulfate material. For example, calcium sulfate dihydrate contains a large amount of crystallization water, which can improve the fire resistance of the floor element. Preferably, the floor element of the present invention is preferably classified "A2" according to EN 13501-1:2010-01. fl -s1" is reached.

[0012] Furthermore, the cementitious core may contain stabilizing additives. For example, the cementitious core may contain glass fibers and / or paper fibers, preferably paper fibers. However, other fibers are also possible. Fibers (e.g., paper fibers) can help improve the stability of the floor element. The amount of fiber in the cementitious core of the floor element preferably does not exceed 15% by weight of the total weight of the cementitious core, preferably does not exceed 10% by weight of the total weight of the cementitious core. Furthermore, the thickness of the floor element of the present invention may be in the range of 19 to 50 mm, preferably 30 to 38 mm.

[0013] Most preferably, the cementitious core may include calcium sulfate material and paper fibers, a combination that can simultaneously improve fire resistance and stability.

[0014] The at least partially synthetic top layer can be a substantially transparent layer and / or a cured layer, preferably a UV light cured layer. However, an opaque layer is also possible. A substantially transparent top layer is useful because it allows the layers below the at least partially synthetic top layer to be visible, and can be well designed for flooring purposes. A transparent at least partially synthetic top layer is even more preferred. A cured layer, preferably a UV light cured layer, is advantageous because the layer can easily be hardened, for example, by simply shining UV light on the layer. Furthermore, curing with UV light is a fast curing method.

[0015] The at least partially synthetic top layer may comprise a metal and / or metal oxide, preferably a metal oxide, and may further comprise an acrylated resin, which may be a diacrylate.

[0016] In a preferred embodiment, the at least partially synthetic top layer may comprise two sublayers. The first sublayer may be identical to the at least partially synthetic top layer described above. The second sublayer, which may be positioned below the first sublayer, may comprise a metal and / or metal oxide, preferably a metal oxide, and may further comprise an acrylated resin as described above, and may additionally comprise an additive for abrasion resistance, such as aluminum oxide. Preferably, both sublayers may be curable by UV light. Furthermore, even with two sublayers, the product may still meet the classification "A2" according to EN13501-1:2010-01. fl -s1" can be secured.

[0017] Furthermore, as mentioned above in DE10200292A1, the flooring panels can include colored chips to improve and refine the design of the floor element. However, by providing colored chips, the motifs are very limited.

[0018] The present invention is therefore also based on the objective of providing a solution for the simple and inexpensive production of panels, preferably for hollow floor systems, by means of an improved design, which, however, must still have other properties such as non-combustibility and dissipation.

[0019] This object is achieved by a floor element with the features of claim 1, in which an ink layer is arranged between the cementitious core and the at least partially synthetic top layer. Surprisingly, this allows the floor element to maintain these aforementioned advantages. Preferably, the ink layer can be a printed ink layer, more preferably a digitally printed ink layer. However, the ink layer, when present in the at least partially synthetic top layer, preferably does not contain metals and / or metal oxides.

[0020] The ink layer, which can be designed in numerous ways, especially when printed (digitally) in numerous ways, can give floor elements a visually appealing surface and can greatly enhance the design of floor elements, which do not require covering with carpet or other materials, saving time and money.

[0021] It is a further advantage of the floor element of the present invention (with or without the ink layer) that it does not require any kind of top covering such as parquet, carpet or other, which would be more expensive and time consuming to install. Instead, the floor element is finished with a semi-synthetic top layer.

[0022] In a further preferred embodiment, a primer layer may be configured between the cementitious core and the ink layer. This primer layer may be a white paint, which may help to provide a uniformly bright surface onto which the ink layer can be applied. Preferably, the primer layer may include an acrylate oligomer.

[0023] Preferably, the underlayer may comprise a metal and / or metal oxide, preferably a metal oxide. The metal and / or metal oxide of the underlayer may help to maintain dissipative properties through the floor element.

[0024] In a further preferred embodiment, the metal and / or metal oxide may be in the form of powder or shavings, preferably powder. According to the present invention, the metal and / or metal oxide may also be applied to one or more substrate materials. Suitable substrate materials include, for example, mica, barium sulfate, titanium oxide, silicon oxide, aluminum oxide, and combinations thereof.

[0025] In a further preferred embodiment, the metal and / or metal oxide may be selected from the group consisting of aluminum, iron, silver, copper, indium, rhenium, antimony, tin, titanium, any of the rare earth metals, rhenium(IV) oxide, aluminum oxide, antimony oxide, antimony(III) oxide, indium oxide, tin oxide, tin(IV) oxide, titanium oxide, titanium(II) oxide, titanium(III) oxide, and titanium(IV) oxide, oxides of rare earth metals, or any mixtures thereof, preferably antimony, tin oxide, indium oxide, antimony oxide, aluminum oxide, titanium oxide, any of the rare earth metals, and mixtures thereof. When the oxidation state of a metal in an oxide is not given, all possible oxidation states are implied. The powdered metal and / or metal oxide can be easily mixed with other components, such as the at least partially composite top layer, as well as the above-mentioned sublayers and / or underlayers, thereby preserving the dissipative properties of the bed element.

[0026] In a further preferred embodiment, the amount of metal and / or metal oxide in the at least partially synthetic top layer and / or underlayer may be 2-10% by weight, preferably 3-8% by weight, most preferably 4-6% by weight. All amounts are subject to the total weight of the respective layer. Thereby, the amount of metal and / or metal oxide may be kept as low as possible, but as large as required to maintain the dissipation properties through the floor element.

[0027] Additionally, the amounts of metal and / or metal oxide described above may also take into account the sublayers described above or other layers that may be part of the bed element, some of which are discussed below.

[0028] However, it should be emphasized that not all layers within one bed element containing metal and / or metal oxide necessarily have to contain the same amount of metal and / or metal oxide. Furthermore, it should be noted that generally higher amounts of metal and / or metal oxide are possible, but may not be economical.

[0029] In a further preferred embodiment, the floor element is 6 ~10 9 ohmic resistance and / or may be non-flammable according to EN13501-1:2010-01. 6 ~10 9 Ohmic resistance qualifies for dissipation characteristics according to EN1081:2017-04.

[0030] In further preferred embodiments, the cementitious core may have a thickness of 19 to 50 mm, preferably 30 to 38 mm, and / or the at least partially synthetic top layer may have a thickness of 30 to 150 μm, preferably 40 to 120 μm, and / or the ink layer may have a thickness of 15 to 50 μm, preferably 20 to 40 μm.

[0031] Further, other layers may be applied. For example, a putty layer may be applied between the cementitious core and the base layer. Furthermore, if a putty layer is applied, a layer of adhesion promoter may be applied between the cementitious core and the putty layer. However, all of these layers may preferably contain a small amount of metal and / or metal oxide.

[0032] It should be noted that it is also possible to apply other layers, for example a protective layer to the bottom surface of the cementitious core, which may be, for example, a layer of aluminium foil, to protect the floor element from moisture.

[0033] Another embodiment of the present invention is a hollow floor system for providing access below the floor comprising a structural floor, at least one floor element according to the present invention, and at least one support post extending substantially upward from the structural floor.

[0034] Support posts for hollow floor systems are known to those skilled in the art. Preferably, a pedestal for resting an access floor element on it can be arranged on each support post. Preferably, at least one support post can be at least dissipative, and preferably conductive. Most preferably, the support post is made of a (conductive) metal.

[0035] Another embodiment of the present invention is a method for producing a floor element, the method comprising the steps of: - a cementitious core is provided; - A primer layer is applied to the top surface of the cementitious core; - the ink layer is printed, preferably digitally printed, onto the substrate layer; - an at least partially synthetic top layer is applied to the ink layer.

[0036] This method allows for the easy production of floor elements with the above-mentioned advantages over the state of the art. The top surface of the cementitious core is the surface that is visible when the floor element is installed and does not have any layer on it, in other words it stands out in the installed state. Preferably, the at least partially synthetic top layer can comprise a first and a second sublayer.

[0037] Preferably, the method includes providing a cementitious layer between the top surface of the cementitious core and the base layer. - a layer of adhesion promoter, and / or - putty layer, It may be characterized in that

[0038] The adhesion promoter may include an acrylate. The putty may include an acrylate oligomer. Both layers preferably include a metal and / or metal oxide, for example, as defined for the at least partially synthetic top layer. Both layers may preferably be curable by UV light.

[0039] However, many more layers are possible, and preferably all of these layers may comprise metal and / or metal oxide, for example as defined for the at least partially synthetic top layer.

[0040] Another embodiment of the invention is the use of at least one floor element according to the invention for a hollow floor system according to the invention.

[0041] Additional advantages and novel features of the present invention will be set forth in the examples set forth below, and in part will become apparent to those skilled in the art upon examination of the above description, or may be learned by practicing the invention. The examples illustrate preferred embodiments of the invention as an illustration of the best mode contemplated for carrying out the invention. As will be understood, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the scope and spirit of the present invention. Accordingly, the specification is to be regarded as illustrative and not restrictive. [Example]

[0042] The floor element according to the invention is produced by the method described above.

[0043] The cementitious core used was "GIFAfloor DB36 Green." "GIFAfloor DB36 Green" contains gypsum and fiber. The fiber content is less than 15% by weight.

[0044] The cementitious core used in this example has a slightly inclined top surface. However, none of the layers applied to the top surface of the cementitious core reach any of the side surfaces of the cementitious core. The side surfaces of the cementitious core are surfaces that are between the top surface and the bottom surface of the cementitious core and are substantially perpendicular to the top and bottom surfaces of the cementitious core.

[0045] First, a layer of adhesion promoter was applied, followed by curing with UV light. Then, a putty layer was applied, followed by curing with UV light. Then, a primer layer was applied, followed by curing with UV light. Then, an ink layer was digitally printed. Then, a second sublayer of at least a partially synthetic top layer was applied, followed by curing with UV light. Then, a first sublayer of at least a partially synthetic top layer was applied, followed by curing with UV light. All layers except the ink layer and the cementitious core comprise about 5% by weight of metal and / or metal oxide in this example.

[0046] The floor elements are tested according to fire resistance (EN13501-1:2010-01) and are A2 fl It was further tested for dissipation properties in accordance with EN1081. 6 ~10 9 Furthermore, the floor elements have been tested for formaldehyde according to EN 16516:2018-01, resulting in the Eurofins "indoor air comfort gold" classification.

Claims

1. A floor element comprising a cementitious core and a top layer at least partially composite to said cementitious core, said top layer comprising a metal and / or a metal oxide, the cementitious core comprises calcium sulfate material and paper fibers; an ink layer is formed between the cementitious core and the top surface layer; a base layer is formed between the cementitious core and the ink layer; A floor element characterized in that the underlayer comprises a metal and / or a metal oxide.

2. 2. A floor element according to claim 1, characterized in that the top layer is a substantially transparent layer and / or a hardened layer or a UV light hardened layer.

3. 3. A floor element according to claim 1 or 2, characterized in that the ink layer is a printed ink layer or a digitally printed ink layer.

4. 4. A floor element according to any one of claims 1 to 3, characterized in that the metal and / or metal oxide is selected from aluminium, iron, silver, copper, indium, rhenium, antimony, tin, titanium, any of the rare earth metals, rhenium(IV) oxide, aluminium oxide, antimony oxide, antimony(III) oxide, indium oxide, tin oxide, tin(IV) oxide, titanium oxide, titanium(II) oxide, titanium(III) oxide and titanium(IV) oxide, oxides of the rare earths, or any mixture thereof.

5. 5. A floor element according to claim 4, characterized in that the metal and / or metal oxide is selected from antimony and / or tin oxide, indium oxide, antimony oxide, aluminum oxide, titanium oxide, oxides of any of the rare earth metals, and mixtures thereof.

6. Floor element according to any one of claims 1 to 5, characterized in that the amount of metal and / or metal oxide in the top layer and / or the base layer is 2 to 10% by weight.

7. 7. Floor element according to claim 6, characterized in that the amount of metal and / or metal oxide in the top layer and / or the base layer is 4 to 6% by weight.

8. The floor elements are 10 ６ ~10 ９ Floor element according to any one of claims 1 to 7, characterized in that it has an ohmic resistance and / or is non-combustible according to EN 13501-1:2010-01.

9. the cementitious core has a thickness of 19 to 50 mm; and / or the top layer has a thickness of 30 to 150 μm; and / or A floor element according to any one of the preceding claims, characterized in that the ink layer has a thickness of 15 to 50 μm.

10. 10. Floor element according to claim 9, characterized in that the cementitious core has a thickness of 30 to 38 mm.

11. 10. Flooring element according to claim 9, characterized in that the top layer has a thickness of 40 to 70 μm.

12. 10. Floor element according to claim 9, characterized in that the ink layer has a thickness of 20 to 40 μm.

13. A hollow floor system for providing access beneath the floor comprising a structural floor, at least one floor element according to any one of claims 1 to 12, and at least one support post extending substantially upwardly from the structural floor.

14. 14. The hollow floor system of claim 13, wherein the support posts are at least dissipative or conductive.

15. A method for producing a floor element according to any one of claims 1 to 12, comprising the steps of: - a cementitious core is provided; - a primer layer is applied to the top surface of said cementitious core; - an ink layer is printed onto said base layer; a method characterized in that an at least partially synthesized top layer is applied to said ink layer.

16. Between the top surface of the cementitious core and the base layer, a layer of adhesion promoter, and / or - putty layer, 16. The method of claim 15, wherein