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WO2008139179A2 - Composite floors - Google Patents

Composite floors Download PDF

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Publication number
WO2008139179A2
WO2008139179A2 PCT/GB2008/001643 GB2008001643W WO2008139179A2 WO 2008139179 A2 WO2008139179 A2 WO 2008139179A2 GB 2008001643 W GB2008001643 W GB 2008001643W WO 2008139179 A2 WO2008139179 A2 WO 2008139179A2
Authority
WO
WIPO (PCT)
Prior art keywords
composite floor
floor panel
panels
panel according
composite
Prior art date
Application number
PCT/GB2008/001643
Other languages
French (fr)
Other versions
WO2008139179A3 (en
Inventor
Simon Crook
Original Assignee
Shire Structures Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GB0709199A external-priority patent/GB0709199D0/en
Priority claimed from GB0720522A external-priority patent/GB0720522D0/en
Application filed by Shire Structures Limited filed Critical Shire Structures Limited
Priority to GB0921599A priority Critical patent/GB2463189A/en
Publication of WO2008139179A2 publication Critical patent/WO2008139179A2/en
Publication of WO2008139179A3 publication Critical patent/WO2008139179A3/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/026—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of plastic
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
    • E04B7/22—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/07—Joining sheets or plates or panels with connections using a special adhesive material

Definitions

  • Composite panels used in this invention generally consist of a top and bottom layer with an insulating material between.
  • the insulated material can either be injected between the top and bottom layers or laid between them and bonded in position.
  • the floors would be constructed from either insitu concrete, pre-cast concrete units, composite metal decks and concrete, pre-cast beam and blocks, or timber joists with floorboards over.
  • Traditional floor systems are slow and difficult to construct. They also do not give much insulation.
  • Composite panels are widely used in construction. These are usually used to form wall or roof panels.
  • the composite panels would typically consist of a wood or cement fibreboard with a insulating material between.
  • the lower layer of a composite floor panel consists of a sheet material of good tensile strength.
  • the sheet material of the lower layer may comprise metal or reinforced polymer such as fibreglass.
  • the upper layer consists of sheet material of good compressive strength that is suitable for use as a floorboard. This allows the panel to span greater distances.
  • material of low water vapqur permeability is used as the lower layer so that it acts as a waterproof membrane.
  • the sides of the panels contain jointing strips to allow adjacent panels to be connected together without mechanical fixings.
  • the sheet material of the lower layer turns up the sides of the panel. This shape makes connection of adjacent panels easier and significantly increases the strength of the unit.
  • the sheet material of the lower layer that turns up the sides of the panel also forms the jointing strips.
  • the upper layer of the panel comprises an insitu topping. This could be concrete.
  • the sheet material of the lower layer is profiled or contains stiffening ribs. This significantly increases the strength of the panel.
  • the sheet material of the lower layer and the sheet material of the upper layer are joined by an intermediate layer, preferably an insulation layer, of good shear strength.
  • the composite panels may be provided in a series of pre-determined size. Panels of the same or different size may be assembled together to produce a floor of any required size and shape. The panels may be cut to size if required, for example panels forming an edge of the floor.
  • Panels may be connected together along adjacent side edges by jointing strips received in recesses in the side edges.
  • the side edges of adjacent panels may be provided with male and female formations.
  • composite panels according to the first aspect of the invention are provided in a series of pre-determined size.
  • a plurality of composite panels according to the first or second aspects of the invention are connected together to form a composite floor.
  • the composite floor may be employed in a conservatory.
  • Figure 1 shows a typical section through a composite floor panel in accordance with this invention.
  • Figure 2 shows a composite floor panel with side jointing strips.
  • Figure 3 shows a composite panel with the bottom layer extended to form the sides of the panel.
  • Figure 4 shows a composite panel with insitu concrete topping.
  • Figure 5 shows composite panel with a profiled bottom layer.
  • Figure 6 shows a composite panel with stiffening ribs.
  • Figure 7 shows a composite panel according to another embodiment of the invention.
  • Figure 8 shows a floor constructed from the composite panels of Figure 1 or Figure 7
  • Figure 9 shows a method for joining adjacent composite panels.
  • Figure 10 shows an alternative method for joining two adjacent panels.
  • FIG. 1 shows a section through a composite floor panel in accordance with this invention.
  • the top layer 1 generally acts mainly in compression when the floor panel is under load and also (but not always) forms the structural top of the floor.
  • the material will preferably be suitable to receive the type of floor finishes normally used in a domestic property. Typical materials for the top layer would be cement particle board (CPB) or oriented strand board (OSB) .
  • the infill of the panel (2) will preferably provide insulation and will preferably resist shear forces when the floor panel is under load.
  • the insulation will preferably either be injected/poured in to the void or be a pre-formed slab bonded onto the top and bottom layers.
  • the insulation will preferably be an expanded polystyrene foam or a similar material.
  • the bottom layer 3 will preferably act mainly in tension when the floor panel is under load.
  • Suitable materials for the bottom layer have good tensile strength and typically include metals, for example aluminium, steel or plastics, preferably reinforced plastics, for example fibre reinforced polymer such as fibreglass.
  • Figure 2 shows a composite panel with jointing strips 4 and 5.
  • the jointing strips could be constructed from timber, aluminium, plastic or fibreglass. These preferably contain mateable connectors (not shown) so that two panels can be pushed together, for example the connectors may snap together. This ensures that the panels form a continuous damp proof membrane and prevent differential movement between adjacent panels.
  • the detailing of the junction between panels 4 and 5 can also be adapted to incorporate a surface filler, glue or sealant between the adjacent units.
  • Figure 3 shows a composite panel where the lower member 6 is extended up the sides of the panel. A similar arrangement could be made where the top member is extended down the sides of the panel. This increases the strength of the panel.
  • the side extensions of the lower member may be configured to allow adjacent panels to be secured together and may replace the jointing strips shown in Figure 2.
  • Figure 4 shows a composite panel consisting of bottom layer 3 and insulation 2 where the top layer has not been provided.
  • the compression strength of the panel is provided by a topping, 7, added after construction of the floor from one or more panels.
  • Figure 5 shows a composite panel where the bottom layer 8 is constructed from a profiled sheet.
  • the profiled sheet could be constructed from metals, for example aluminium, steel or plastics, preferably reinforced plastics, for example fibre reinforced polymer such as fibreglass. This increases the strength of the panel.
  • Figure 6 shows a composite panel where the bottom layer 9 contains stiffening ribs 10. This increases the strength of the panel.
  • the stiffening ribs could be part of the bottom layer 9 or could be separate structural elements inserted in the panel, similar to the jointing strips 4 and 5 shown in Figure 2.
  • FIG 7 shows an alternative composite panel according to invention.
  • the top and bottom layers 11a, lib are made of fibreglass with an in-fill material lie.
  • the in-fill material lie may be similar to the in-fill material of the panel described above with reference to Figure 1.
  • the weight of the panel may be reduced compared to the panel of Figure 1 of similar size.
  • Other lightweight fibre reinforced polymers may be used for the top and/or bottom layers.
  • Figure 8 shows a floor area 12 indicated in broken lines formed by a plurality of composite panels as described above.
  • the floor area 12 is of rectangular shape formed by four composite panels of uniform size smaller than the floor area that are arranged side-by-side. As shown, one of the panels 13 is uncut and the three other panels 14 are cut to size to form the required shape of the floor area.
  • other sizes and shapes of floor area 12 may be formed by composite panels of uniform size. We may provide one size of panel for all floor areas. Alternatively, we may form panels in a range of sizes that can be assembled with panels of the same or different sizes to provide any desired floor area.
  • the floor area may be suitable for a conservatory.
  • Figure 9 shows a method for joining edges of adjacent panels such as shown in Figures 1 and 7 that form a floor area as described above with reference to Figure 8.
  • the in-fill insulation 15c between the top and bottom layers 15a, 15b of the panels 15 is provided with a recess 15d in the side edge to receive a matching jointing strip 16 that connects the panels along the adjacent side edges.
  • the jointing strip 16 may include insulation.
  • the strength of the joint may be increased by using glue 17 at the interface between the members.
  • FIG 10 shows an alternative method for joining edges of two adjacent panels 18, 19.
  • the panels 18, 19 are cut to provide mating male and female formations 18a, 19a along the side edges that are engageable to connect the adjacent side edges of the panels 18, 19. Again the strength of the joint may be increased by using glue at the interface between the members.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Floor Finish (AREA)

Abstract

A composite floor panel comprises a top layer (1), a bottom layer (3) and an insulation layer (2) between the top and bottom layers (1, 3). The top layer (1) acts mainly in compression and the bottom layer (3) acts mainly in tension when the floor is under load.

Description

COMPOSITE FLOORS
This invention concerns the design of a composite panel. The invention has particular, but not exclusive application to floors. Composite panels used in this invention generally consist of a top and bottom layer with an insulating material between. The insulated material can either be injected between the top and bottom layers or laid between them and bonded in position.
Traditionally the floors would be constructed from either insitu concrete, pre-cast concrete units, composite metal decks and concrete, pre-cast beam and blocks, or timber joists with floorboards over. Traditional floor systems are slow and difficult to construct. They also do not give much insulation.
Composite panels are widely used in construction. These are usually used to form wall or roof panels. The composite panels would typically consist of a wood or cement fibreboard with a insulating material between.
Existing composite panels have been used to construct floors but because of their relatively low strength they need to be supported on a separate structural sub frame, with supports at close spacings.
In a first aspect of this invention, the lower layer of a composite floor panel consists of a sheet material of good tensile strength.
The sheet material of the lower layer may comprise metal or reinforced polymer such as fibreglass. Preferably, the upper layer consists of sheet material of good compressive strength that is suitable for use as a floorboard. This allows the panel to span greater distances.
Preferably, material of low water vapqur permeability is used as the lower layer so that it acts as a waterproof membrane.
Preferably, the sides of the panels contain jointing strips to allow adjacent panels to be connected together without mechanical fixings.
Preferably, the sheet material of the lower layer turns up the sides of the panel. This shape makes connection of adjacent panels easier and significantly increases the strength of the unit.
Preferably, the sheet material of the lower layer that turns up the sides of the panel also forms the jointing strips.
In an alternative arrangement, the upper layer of the panel comprises an insitu topping. This could be concrete.
Preferably, the sheet material of the lower layer is profiled or contains stiffening ribs. This significantly increases the strength of the panel.
Preferably, the sheet material of the lower layer and the sheet material of the upper layer are joined by an intermediate layer, preferably an insulation layer, of good shear strength.
The composite panels may be provided in a series of pre-determined size. Panels of the same or different size may be assembled together to produce a floor of any required size and shape. The panels may be cut to size if required, for example panels forming an edge of the floor.
Panels may be connected together along adjacent side edges by jointing strips received in recesses in the side edges. Alternatively, the side edges of adjacent panels may be provided with male and female formations.
In a second aspect of this invention, composite panels according to the first aspect of the invention are provided in a series of pre-determined size.
In a third aspect of this invention, a plurality of composite panels according to the first or second aspects of the invention are connected together to form a composite floor.
The composite floor may be employed in a conservatory.
The invention will now be described in more detail by way of example only with reference to the accompanying drawings in which like reference numerals indicate corresponding parts and wherein:
Figure 1 shows a typical section through a composite floor panel in accordance with this invention.
Figure 2 shows a composite floor panel with side jointing strips.
Figure 3 shows a composite panel with the bottom layer extended to form the sides of the panel.
Figure 4 shows a composite panel with insitu concrete topping. Figure 5 shows composite panel with a profiled bottom layer.
Figure 6 shows a composite panel with stiffening ribs.
Figure 7 shows a composite panel according to another embodiment of the invention.
Figure 8 shows a floor constructed from the composite panels of Figure 1 or Figure 7
Figure 9 shows a method for joining adjacent composite panels.
Figure 10 shows an alternative method for joining two adjacent panels.
Figure 1 shows a section through a composite floor panel in accordance with this invention. The top layer 1 generally acts mainly in compression when the floor panel is under load and also (but not always) forms the structural top of the floor. The material will preferably be suitable to receive the type of floor finishes normally used in a domestic property. Typical materials for the top layer would be cement particle board (CPB) or oriented strand board (OSB) . The infill of the panel (2) will preferably provide insulation and will preferably resist shear forces when the floor panel is under load. The insulation will preferably either be injected/poured in to the void or be a pre-formed slab bonded onto the top and bottom layers. The insulation will preferably be an expanded polystyrene foam or a similar material. The bottom layer 3 will preferably act mainly in tension when the floor panel is under load. Suitable materials for the bottom layer have good tensile strength and typically include metals, for example aluminium, steel or plastics, preferably reinforced plastics, for example fibre reinforced polymer such as fibreglass.
Figure 2 shows a composite panel with jointing strips 4 and 5. The jointing strips could be constructed from timber, aluminium, plastic or fibreglass. These preferably contain mateable connectors (not shown) so that two panels can be pushed together, for example the connectors may snap together. This ensures that the panels form a continuous damp proof membrane and prevent differential movement between adjacent panels. The detailing of the junction between panels 4 and 5 can also be adapted to incorporate a surface filler, glue or sealant between the adjacent units.
Figure 3 shows a composite panel where the lower member 6 is extended up the sides of the panel. A similar arrangement could be made where the top member is extended down the sides of the panel. This increases the strength of the panel. The side extensions of the lower member may be configured to allow adjacent panels to be secured together and may replace the jointing strips shown in Figure 2.
Figure 4 shows a composite panel consisting of bottom layer 3 and insulation 2 where the top layer has not been provided. The compression strength of the panel is provided by a topping, 7, added after construction of the floor from one or more panels.
Figure 5 shows a composite panel where the bottom layer 8 is constructed from a profiled sheet. The profiled sheet could be constructed from metals, for example aluminium, steel or plastics, preferably reinforced plastics, for example fibre reinforced polymer such as fibreglass. This increases the strength of the panel. Figure 6 shows a composite panel where the bottom layer 9 contains stiffening ribs 10. This increases the strength of the panel. The stiffening ribs could be part of the bottom layer 9 or could be separate structural elements inserted in the panel, similar to the jointing strips 4 and 5 shown in Figure 2.
Figure 7 shows an alternative composite panel according to invention. In this embodiment the top and bottom layers 11a, lib are made of fibreglass with an in-fill material lie. The in-fill material lie may be similar to the in-fill material of the panel described above with reference to Figure 1. By using fibreglass for both the top and bottom layers, the weight of the panel may be reduced compared to the panel of Figure 1 of similar size. Other lightweight fibre reinforced polymers may be used for the top and/or bottom layers.
Figure 8 shows a floor area 12 indicated in broken lines formed by a plurality of composite panels as described above. In this embodiment, the floor area 12 is of rectangular shape formed by four composite panels of uniform size smaller than the floor area that are arranged side-by-side. As shown, one of the panels 13 is uncut and the three other panels 14 are cut to size to form the required shape of the floor area. It will be understood that other sizes and shapes of floor area 12 may be formed by composite panels of uniform size. We may provide one size of panel for all floor areas. Alternatively, we may form panels in a range of sizes that can be assembled with panels of the same or different sizes to provide any desired floor area. The floor area may be suitable for a conservatory.
Figure 9 shows a method for joining edges of adjacent panels such as shown in Figures 1 and 7 that form a floor area as described above with reference to Figure 8. In this method, the in-fill insulation 15c between the top and bottom layers 15a, 15b of the panels 15 is provided with a recess 15d in the side edge to receive a matching jointing strip 16 that connects the panels along the adjacent side edges. The jointing strip 16 may include insulation. The strength of the joint may be increased by using glue 17 at the interface between the members.
Figure 10 shows an alternative method for joining edges of two adjacent panels 18, 19. In this embodiment, the panels 18, 19 are cut to provide mating male and female formations 18a, 19a along the side edges that are engageable to connect the adjacent side edges of the panels 18, 19. Again the strength of the joint may be increased by using glue at the interface between the members.

Claims

1. A composite floor panel having a lower layer that consists of a sheet material that acts mainly in tension when the panel is under load.
2. A composite floor panel according to claim 1 wherein the sheet material of the lower layer comprises metal or reinforced polymer.
3. A composite floor panel according to claim 1 or claim 2 further comprising an upper layer that consists of a sheet material that acts mainly in compression when the panel is under load.
4. A composite floor panel according to any preceding claim wherein the sheet material of the lower layer has a low water vapour permeability.
5. A composite floor panel according to any preceding claim wherein jointing strips are provided in the sides of the panel to allow adjacent panels to be connected together without mechanical fixings.
6. A composite floor panel according to any preceding claim wherein the sheet material of the lower layer turns up the sides of the panel.
7. A composite floor panel according to claim 6 as dependent on claim 5 wherein the sheet material of the lower layer that turns up the sides of the panel also forms the jointing strips.
8. A composite floor panel according to claim 1 further comprising an upper layer that comprises an in-situ topping.
9. A composite floor panel according to any preceding claim wherein the sheet material of the lower layer is profiled or contains stiffening ribs.
10. A composite floor panel according to any preceding claim wherein the composite panel is provided in a series of pre-determined sizes.
11. A composite floor panel according to any preceding claim wherein panels of the same or different size are assembled together to produce a floor of any required size and shape.
12. A composite floor panel according to claim 12 wherein the panels are connected together along adjacent side edges by jointing strips received in recesses in the side edges.
13. A composite floor panel according to claim 12 wherein the panels are connected together along adjacent side edges by male and female formations.
14. A composite floor constructed from a plurality of floor panels according to any of the preceding claims.
15. A composite floor according to claim 14 comprising a conservatory floor.
PCT/GB2008/001643 2007-05-12 2008-05-12 Composite floors WO2008139179A2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0921599A GB2463189A (en) 2007-05-12 2008-05-12 Composite floors

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB0709199A GB0709199D0 (en) 2007-05-12 2007-05-12 Composite floors
GB0709199.4 2007-05-12
GB0720522A GB0720522D0 (en) 2007-10-22 2007-10-22 Composite floors
GB0720522.2 2007-10-22

Publications (2)

Publication Number Publication Date
WO2008139179A2 true WO2008139179A2 (en) 2008-11-20
WO2008139179A3 WO2008139179A3 (en) 2008-12-31

Family

ID=39800664

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2008/001643 WO2008139179A2 (en) 2007-05-12 2008-05-12 Composite floors

Country Status (2)

Country Link
GB (1) GB2463189A (en)
WO (1) WO2008139179A2 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2273024A3 (en) * 2009-07-09 2011-02-23 Unilin BVBA Building element and roof construction
WO2016177979A1 (en) * 2015-05-06 2016-11-10 Masurel Augustin Permanent form panel, assembly of said panels, and method for producing a concrete floor slab
WO2017004465A1 (en) * 2015-06-30 2017-01-05 Grenier Kevin E Composite insulated panels

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0074732B1 (en) * 1981-09-02 1986-04-09 Ramage, L. Lee, D. Hook, D. Norman, P. Richmond, B. Jenkins, E. Churchman, A. Miles, K. trading as G. Maunsell & Partners Improved structural panel
AUPO389996A0 (en) * 1996-11-28 1996-12-19 Verzantyoort, Timothy Wilhelmus Building element
US6233892B1 (en) * 1997-10-25 2001-05-22 The Namlyt Company Structural panel system
US20050183358A1 (en) * 2004-02-24 2005-08-25 Kjmm, Inc. Structural panel for use in buildings

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2273024A3 (en) * 2009-07-09 2011-02-23 Unilin BVBA Building element and roof construction
BE1018822A5 (en) * 2009-07-09 2011-09-06 Unilin Bvba BUILDING ELEMENTS AND ROOF CONSTRUCTION.
WO2016177979A1 (en) * 2015-05-06 2016-11-10 Masurel Augustin Permanent form panel, assembly of said panels, and method for producing a concrete floor slab
WO2017004465A1 (en) * 2015-06-30 2017-01-05 Grenier Kevin E Composite insulated panels

Also Published As

Publication number Publication date
WO2008139179A3 (en) 2008-12-31
GB0921599D0 (en) 2010-01-27
GB2463189A (en) 2010-03-10

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