AU720736B2

AU720736B2 - Floor panel

Info

Publication number: AU720736B2
Application number: AU89517/98A
Authority: AU
Inventors: Hirata Osamu; Kunpei Yamashita
Original assignee: Matsushita Electric Works Ltd
Current assignee: Panasonic Electric Works Co Ltd
Priority date: 1998-01-30
Filing date: 1998-10-27
Publication date: 2000-06-08
Anticipated expiration: 2018-10-27
Also published as: JPH11280242A; HK1021215A1; JP3460589B2; MY114824A; SG74090A1; CN1224788A; TW359712B; CN1096536C; AU8951798A

Description

P/00/01i1 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT a a. a a.

a a a a a a Invention Title: Floor Panel The following statement is a full description of this invention, including the best method of performing it known to me/us: FHPMELC698300005.7 CD199105006.3 2 FLOOR PANEL Field of the invention This invention relates to floor panels formed to allow passage of cables.

Background of invention Japanese patent publication (Kokai) 6-113433 discloses a floor panel which provides for electrical cables to be passed through the floor panel.

In this example, a cable screening cover, built into a wiring outlet on the panel at the time of constructing the floor panel, has two configurations: flush with the panel when no cable passage is required; or (ii) inclined with respect to the panel to provide an opening through the panel to allow for the passage of cables along the inclined surface of the cover through the panel.

The cable screening cover is installed in one of two configurations, and the installation is complicated as there are different individual parts used for each method, which increases the cost of manufacture.

e The necessary installation of the cable screening cover may be missed, and the cover may dislodge from the panel during construction or otherwise. Moreover, incorrect installation of the cable screening cover could occur since there are two kinds of installation methods provided.

'20: Further, existing floor panels, when filled with mortar as shown in Fig. 30, have a space S when mortar does not completely fill the volume of the floor panel. As a result of this space, the mortar is prone to cracking when the floor panel is subject to concentrated loads.

CD/99105006.3 3 Summary of the invention Accordingly, the invention provides a floor panel having a top plate and a bottom plate whose peripheries are joined together. The bottom plate has a bottom plate coupling piece projecting sideways at an upper open edge of a body portion of the bottom plate. This body portion includes a wall piece which is formed from its lower end to its upper end with a vertically extending recess for passing a cable through an upper opening of said bottom plate (which is occluded by said top plate). A top plate coupling piece provided on an outer peripheral edge of said top plate and said bottom plate coupling piece provided on an upper end outer peripheral edge of said bottom plate are coupled to each other for occluding said vertically extending recess. An occluded portion formed at an upper end of said i vertically extending recess is formed as a cutaway portion for forming an opening.

Preferably, a portion of the bottom plate coupling piece or the top plate coupling piece (for occluding the upper end of said vertically extending recess) is provided with a cutting assistant portion such as perforations and/or a thin groove.

Preferably, the cutaway portion has a width in the recessing direction of the recess o of about 1/2 of a diameter of a standard flexible electric cable tube.

S: Preferably, a plurality of projections are formed upwardly from a bottom of the 0: bottom plate, and the top plate and upper ends of the projections are coupled to S. 20 each other, wherein the projections are positioned at a plurality of locations spaced radially around a center of said top plate as viewed on a plane, and the number of projections located on diagonal lines of said top plate is greater than those located on other portions.

Preferably, a central portion of the bottom plate is recessed to form an internal projection for supporting mortar after the mortar is charged.

Preferably, the four corners of the body portion (which is rectangular as viewed on .I plane) are swelled outward with respect to lines forming four sides of a C0D/99105006.3 4 rectangle, thereby forming swelled corner portions.

Preferably, of the plurality of cutaway portions for forming openings, cutaway portions except one or more are cut except cap supporting portions, thereby forming the openings, and said openings are occluded by caps.

Preferably, the four sides of the bottom surface periphery of said bottom plate are formed with thin and long recessed or projected reinforcing portions.

Description of drawings Fig. 1 is a fragmentary isometric view of a portion of a floor panel constructed in accordance with an embodiment of the invention, showing a recess in the peripheral wall.

Fig. 2 is a cross-sectional view of the portion of floor panel shown in Fig. 1.

"Fig. 3 is a view similar to Fig. 1, showing the panel after removal of a segment of the rim to open a cable passage at the recess in the peripheral wall.

Fig. 4 is a cross-sectional view of the floor panel shown in Fig. 3, at the location of 15 the removed segment.

Fig. 5 is a diagrammatic isometric view of part of a raised panelled floor constructed from floor panels of the kind shown in Figs. 1 to 4, with a cable passing through an opening in the floor.

eq Fig. 6(a) to 6(d) are respectively underneath and side elevational views of a 20 bottom pan used to construct the floor panel shown in the preceding drawings. •oleo• Fig. 7(a) to 7(d) are respectively underneath and side elevational views of a top plate used to construct the floor panel shown in the preceding drawings.

Fig. 8(a) and are fragmentary diagrams depicting the engagement of coerative connective elements used in the floor panel shown in Fig. 1.

CD/991050 0 6.3 Fig. 9(a) and are similar views of alternative engagement arrangements for the co-operative connective elements.

Fig. 10O(a) is a partial cross-sectional view of the floor panel, indicating a corresponding projection and recess to enable secure stacking of the floor panels.

Fig. 10O(b) is a partial cross-sectional view of the floor panel, indicating an internal projection formed in the bottom pan of the floor panel.

Fig. 10(c) is a partial cross-sectional view of the floor panel, indicating joined cooperating connective elements formed integrally in the bottom pan and top tray of the floor panel.

Fig. 1 to l(d) are various views of the floor panel used in conjunction with a pedestal to form a raised floor as depicted in Fig. Fig. 12(a) and 12(b) are views indicating the operation of installing a cable screening cover in place of the rim segment removed to open the cable passageway at the recess in the peripheral wall.

15 Fig. 13(a) to 13(c) are perspective views indicating the operations involved in creating a wiring outlet in the floor panel.

q Fig. 14 is a viewof a raised floor similar to Fig. 5, but with the modification of Figs.

13(a) to 13(c).

Fig. 15(a) and 15(b) are respectively a bottom view and plan view showing the 20 provision of cutoff guidance in the floor panel.

Fig. 16(a) and are respectively a bottom view and plan view of further t..

examples of providing cutoff guidance in the floor panel.

Fig. 17 is a fragmentary plan view of two adjacent floor panels with two flexible cable tubes passing through the wiring outlet created between the floor panels.

Fig. 18(a) to 18(c) are respectively a base view, front view and side view of an alternative floor panel according to another embodiment of the invention.

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77 A3 CD/99105006.3 6 Fig. 19 is a base view of the alternative floor panel shown in Fig. 18, in which some of the recess passageways are closed with a cap.

Fig. 20 is a cross-sectional view of the alternative floor panel of Fig. 18, prior to being filled with mortar.

Fig. 21(a) is a cross-sectional diagrammatic view indicating how the alternative floor panel is filled with mortar.

Fig. 21(b) is a diagram showing the alternative floor panel on pedestals with an applied force.

Fig. 22 is a partial plan view of a modified corner of the alternative floor panel.

Fig. 23(a) and are cross-sectional views of floor panels placed on a pedestal, for indicating the effect of the modification of Fig. 22.

Fig. 24 is a perspective view of a wiring outlet and a cap for covering the wiring outlet.

*9 Fig. 25 is a perspective view of a wiring outlet when covered by the cap.

6 15 Fig. 26(a) to are cross-sectional views indicating the wiring outlet trimmed to "avoid the cap support area.

*9*9 Fig. 27 is a side view of the floor panel, illustrating a preferred slightly domed 9~e effect.

Fig. 28 is a cross-sectional view indicating a number of floor panels stacked on top 20 of each other.

Fig. 29 is a partial cross-sectional view of the floor panel, indicating a further example of a corresponding recess and projection for facilitating stacking of the floor panels.

Description of embodiment SWith reference to Figs. 1 to 4, floor panel 3 has a structure defined by a top plate

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T 0/ <1TEt~S CD/99105006.3 7 1 and a bottom pan 2, which are both preferably manufactured from a metallic material such as iron or steel. Between the top plate 1 and bottom pan 2 there is a volume filled with a core 40 which typically consists of mortar, but which is alternatively any suitable settable material, for example, expanded synthetic resin.

The top plate 1 and bottom pan 2 are joined at a peripheral rim 25 of the panel 3 to enclose an internal volume. The pan 2 defines a peripheral wall of the floor panel 3 which extends about the volume enclosed by the floor panel. The peripheral wall is shaped to define one or more external recesses 7 in the peripheral wall closed by the rim 25. Each recess is able to serve as a passageway across the panel for passing cables between the sides of the panel 3.

The structure of the panel 3 is shown in greater detail in Figs. 6 and 7.

Fig. 10 shows three cross-sectional views of part of the floor panel 3, respectively detailing a stacking projection 45 and recess 45, an inwardly extending portion 17 formed in the bottom pan 2, and an internal projection 14 formed in 15 the bottom pan 2 and extending to the top plate 1.

4499i4 4 The bottom pan 2 has an array of multiple internal projections 14 that extend upwardly from the base of the pan 2 to the top plate 1. The internal projections 14 are preferably provided in a spaced array distributed on the bottom pan 2: in the illustrated embodiment, they are formed primarily along the diagonals of the panel 20 3, though projections 14 are also formed in other positions in the bottom pan 2 as indicated in Fig. 6.

The projections 14 extend between the bottom pan 2 and the top plate 1 to enhance the strength of the floor panel 3. The projections 14 are preferably formed as local deformations in the surface of the bottom pan 2, in the shape of circularly-symmetrical mounds. Each of the internal projections 14 has a connective element 15(a) formed at the upper peak of each projection 14. The connective elements 15(a) are adapted to engage with corresponding connective elements 15(b) formed in the top plate 1. Preferably, the respective connective tements are pressed together to interengage in a firm fit.

CD/19910500 6 3 8 Figs. 8 and 9 show alternative arrangements that can be used for connective elements 15(a) and 15(b). When the bottom pan 2 and top plate 1 are attached, the connective elements 15(a) and 15(b) are securely engaged to ensure that the bottom pan 2 and top plate 1 do not come apart.

Also provided on the bottom pan 2 are inwardly extending portions 17 that do not extend to the top of the bottom pan 2. These portions 17 are, as with the projections 14, formed as local deformations of the surface of the bottom pan 2.

The portions 17 are also formed in the shape of circularly-symmetrical mounds, and are preferably smaller than the projections 14. The portions 17 are distributed amongst the projections 14. Fig. 6 shows the preferred arrangement of the inwardly extending portions 17 amongst the internal projections 14. The portions 17 increase the strength of the floor panel 3, and minimise the amount of filling needed to fill the volume between the bottom pan 2 and the top plate 1.

Stacking projection 45 and mortar filler opening 47 are also provided in the base 15 of the pan 2. Top plate 1 shown in Fig. 7 is a generally square plate having connective elements 15(b) as described above in relation to connective elements 15(a) formed on the projections 14 of the bottom pan 2. The top plate 1 has a number of connective elements 15(b) located to co-operate with the connecting elements 15(a) in the bottom pan.

20 Also shown in Figs. 6 and 7 are, respectively, small complementary projections and recesses 46. The projections 45 and recesses 46 are sized and located to g mate with each other when floor panels 3 are stacked on top of each other.

*fee .0 90 Floor panels 3 having these projections 45 and recesses 46 described above can be stacked for storage or transport without misalignment, as the aligned recesses 46 and projections 45 respectively formed on the upper and lower surfaces of the floor panel 3 engage to prevent relative transverse movement of adjacent floor panels 3.

Bottom pan 2 has an integral external flange 5 extending around the opening of the pan 2. Top plate 1 includes a peripheral edge 8, adapted to be securely CD/9910506.3 9 attached with the flange 5, as indicated in Figs. 1 and 2. The peripheral edge 8 and the integral flange 5 form the earlier mentioned peripheral rim 25 of the panel 3. The peripheral edge 8 extends to the edge of the flange 5 and turns under the flange 5. As the peripheral edge 8 encompasses the flange 5 on all sides of the panel 3, the flange 5 integral with the pan 2 is secured with the peripheral edge of the top plate 1 so that the top plate 1 is securely attached with the pan 2.

Returning to Fig. 1, the peripheral rim 25 covers the top of recess 7. The cutaway portion (indicated by reference number 9) of the rim 25 which closes or covers the recess 7 can be opened by cutting it away to create a wiring outlet 10 so that the recess 7 which extends between the bottom and top of the floor panel 3 is open on the upper side of the floor panel 3, as well as the lower side, as shown in Figs.

3 and 4. The wiring outlet 10 so formed serves as a passageway across the panel 3 to allow for the passage of a cable or the like between the sides of the panel 3.

In this way, cable 26 can pass through a floor formed from panels 3, from one side 15 of the floor to the other, via the wiring outlet 10. Fig. 5 shows an example of a i cable 26 connected through a terminal join 27a to the cable tray 27 placed on the floor base such as a slab 19. If no passage for electrical cables is required, there .4f is no need to cut away any portion of the rim 25 around the periphery of the panel 3 which covers the top of the recess 7, as the recess 7 is closed by portion 9 of rim 25, comprising integral flange 5 and peripheral edge 8 as shown in Fig. 1 and be 2.

Figs 12 and 13 show how portion 9 of the rim 25 can be cut out to create a wiring *ee outlet 10 (Fig. 12a, Fig. 13b). The initial step of cutting out part of the rim S" formed by the integral flange 5 and peripheral edge 8 can be aided by a cutaway assistant portion such as perforations or a thin groove 9a as shown in Fig. 13a.

Various types of indications can be used to show where the rim 25 is to be cut, for example, a dotted line, a fine groove or similar indication. Figs. 15 and 16 show some examples.

When wiring outlet 10 is created by trimming the rim 25, a cable screen cover 12 r n be installed as shown in Fig. 12. Cable screen cover 12 in Fig. 12 has two U-L i~an be installed as shown in Fig. 12. Cable screen cover 12 in Fig. 12 has two U- CD/99105006.3 shaped knockouts 11, and a grooved fixing part 12a provided on the edge of the cover 12. Fixing part 12a of the cover 12 is slotted onto the edge of the wiring outlet 10. Either of the two knockouts 11 from the cover 12 can be cut off with a jig such as a pair of pliers as shown in Fig. 12(a). Thus cutoff part 31 is formed so that a cable 26 passing through recess 7 (as shown in Fig. 12b) passes through the opening so formed. Each of the knockouts 11 can be designated for a particular purpose. For example, one can be reserved for an electrical cable and the other for a communications cable.

Alternatively, a U-shaped guard 32 as shown in Fig. 13 can be used. Guard 32 is preferably made from a pliable material such as rubber, synthetic resins etc. and can be inserted into the edge of wiring outlet 10 as shown in Fig. 13(a) to 13(c), as with cover 12. The arrangement of corresponding recesses 7 on all sides of the floor panel 3 is intended to allow maximum flexibility in using the floor panel 3. Fig.

14 shows, in use, floor panels 3 including a wiring outlet 10 having a guard 32 as in Fig. 13.

In the various arrangements described above, the wiring outlets 10 are conveniently about half the desired dimensions, so that adjoining wiring outlets :a on adjacently positioned floor panels 3 can be cut out to create two adjoining wiring outlets 10 of the desired size that co-operate as a single opening in the 20 floor. This avoids openings in the floor formed from the floor panels 3 being larger than necessary. Fig. 17 illustrates two adjoining wiring outlets 10 which, together, 9* are just able to accommodate two flexible cable tubes 13.

a Figs. 5 and 11 show use of the floor panel 3 when installed. Fig. 11 shows in greater detail how the panels 3 are positioned when a raised floor is installed.

so e 25 Each panel 3 is supported at each of its corners on a respective pedestal 20, and each pedestal 20 can in turn support four panels. Floor panels 3 are placed at each of the corners of pedestal 20 on panel supports 22. The panel supports 22 are separated by a generally cross-shaped panel positioning member 23. Each arm of the panel positioning member 23 has a spacer 24 which is provided to Sg-suitably space adjacently positioned floor panels 3.

(2/ CD/99105006.

3 11 At the corners of each floor panel, there is a small rebate 18 cut away from the rim (as shown). This small rebate 18 is dimensioned to match the spacer 24 provided on the cross-shape positioning member 23. The relative dimensions of the cut away rebate 18 and the spacer 24 are adapted to allow a small space (for example, 1 mm) between adjoining floor panels 3 of the floor.

Figs. 18 to 29 depict an alternative floor panel. Fig. 18 and other drawings show a hole 55 diagonally opposite the mortar opening 47. The hole 55 and the mortar opening 47 are both formed in the pan 2, and allow air to escape whilemortar is filled into the upturned floor panel 3. The mortar opening 47 is desirably of sufficient diameter to allow for rapid filling and to avoid blockage, for example mm. The escape hole 55 also provides an opening for excess mortar to flow out from the floor panel 3, when the floor panel 3 is completely filled with mortar.

As the panel is filled with mortar through the bottom pan 2, the mortar collects and sets in the "upper" side of the floor panel 3 closed by the top plate 1. Accordingly, 15 when the volume enclosed by the panel 3 is not fully occupied by mortar, there is °:.009 a space remaining between the surface of the set mortar 40a and the bottom of 0 *pan 2. This can be seen in Fig. 21(a). A centrally located inward projection 50 is o.o.

formed in the bottom pan 2, and is intended to support the mortar when the panel .e3 is partially filled. This discourages the mortar from cracking when concentrated loads are applied to the top plate 1, as indicated in Fig. 21(b).

0° Fig. 20 shows channels 54 formed around the edges of the floor panel 3 in the as 4609 bottom pan 2. These channels 54 are also indicated in Figs. 18 and 19 as being a formed along the majority of each edge of the floor panel 3. The inner edges of the channels 54 adjoin ridges 2a, as seen in Fig. 20. The combination of the 25 channels 54 and ridges 2a assist in increasing the strength of the bottom pan 2, and guard against deformation of the bottom pan 2 when the floor panel 3 is filled with mortar, and while the panel is being used after installation.

Fig. 22 shows a modified corner section 51 of the floor panel 3, as also indicated in Figs. 18 and 19. The modified corner section 51 is an outside enlargement of -3P the generally rectangular side wall of the pan 2. The modified corner section 51 is

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CD/99105006.

3 12 of use when the floor panel 3 is placed on the alternative form of'pedestal 20 as indicated in Fig. 23. The corner section 51 extends closer to the edge of the rim of the floor panel 3 than the main edges of the pan 2. This allows (when the panel 3 is installed) the distance from the centre of the pedestal to the edge of the panel support 22 to be shortened, which assists in stabilising the floor as explained below.

Fig. 23(b) shows floor panels 3 without modified corner sections 51 supported on a pedestal 20. This is in contrast with the arrangement shown in Fig 23(a) in which the floor panels have modified corner sections 51. The distance L 1 without modified corner sections 51, is longer than L 2 the distance with modified corner sections 51, for a given width W as indicated in Figs. 23(a) and The reduced distance L 2 reduces the moment of force against the panel support 22 and, as a result, the floor is more stable.

Fig. 24 shows an alternative arrangement which uses cap 53 to cover the wiring outlet 10. Figs. 25 and 26 show this arrangement in greater detail. In this case, the wiring outlet 10 is pre-formed during manufacture of the components of the floor panel 3, with a cap support 52 provided in the form of a pair of support ledges.

The cap 53 is an insert installed in the floor panel 3 to block or close the recess 7, and can be removed to open the recess 7 and thus provide a wiring outlet The cap 53 is snap-fastened to the floor panel 3 by means of the resilient Vshaped legs 53a shown in Fig. 24. The legs 53a engage under the support ledges to prevent the cap 53 from separating from the floor panel 3 during ordinary handling. The opening 53b on the cap 53 allows a tool to be inserted into this hole eeeoo i S 25 53b to assisting in removing the cap 53 once the floor panel is installed. This is 25 convenient, because once the floor is installed, the cap 53 must be removed in i this way as the underside of the cap cannot be accessed to "push out" the cap out, due to the close spacing of adjacent floor panels.

Thus, the cap 53, and the cap support 52 allow the recess 7 to be closed and Sopened to provide a wiring outlet 10 as required.

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CD/99105006, 3 13 Fig. 27 shows a floor panel 3 having a slightly domed effect. The top plate 1 of the floor panel 3 is higher at its centre by about 0.5mm. As a result, the "joins" between adjacent floor panels 3 tend to be less noticeable when a floor formed from the floor panels 3 is carpeted. When floor panels 3 having a slightly domed effect are as shown in Fig. 27, it is desirable, as shown in Fig 28, to provide a ridge 2a around the outer edge of the bottom of pan 2. The height of the ridge 2a compared with the main portion of pan 2b is about 1mm. The ridge 2a allows the slightly domed panels 3 to be safely stacked "upside down" after they have been filled with mortar. A clearance of about 1 mm between the ridge 2a and the rest of the pan 2b allows the panels 3 to be securely stacked even if the curvature of the top plate 1 is further accentuated after being filled with mortar.

Fig. 29 shows an alternative recess 46 and projection 45 for stacking the panels 3.

The projection 45 is surrounded by recesses 45a. Floor panels 3 which use this combination of recesses and projections can be stacked in a similar fashion as the earlier described floor panels.

The described floor panel 3 involves no modifications when cables are not i. required to pass across the floor panel. Instead, wiring outlets 10 can be opened as required by a simple procedure of removing a portion of the rim 25, or detaching a cap insert from the rim 25. The wiring outlets 10 that are pre-formed before installation of the floor panels 3 can be rimmed with a guard 32, or a cable screening cover 12 can be installed so that wiring outlets can be selectively formed by removing knockouts 11. As the width of the wiring outlet 10 is minimised by collocating the recesses 7 of adjacently located floor panels 3, the strength of the floor panel 3 is maintained, making it suitable for construction of S: 25 weight-bearing floors. The mortar in floor panels 3 which are not completely filled is not prone to cracking as it is supported by a centrally located projection extending from the bottom of the pan 2. The stability of the resulting floors is enhanced by the use of modified corner portions 51.

It will be understood that the invention disclosed and defined in this specification 01Q extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations CD/99105006.3 14 constitute various alternative aspects of the invention.

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Claims

1. A floor panel having a top plate and a bottom plate whose peripheries are joined together, characterized in that said bottom plate has a bottom plate coupling piece projecting sideways at an upper open edge of a body portion of said bottom plate, said body portion including a wall piece which is formed from its lower end to its upper end with a vertically extending recess for passing a cable through an upper opening of said bottom plate being occluded by said top plate, and a top plate coupling piece being provided on an outer peripheral edge of said top plate and said bottom plate coupling piece provided on an upper end outer peripheral edge of said bottom plate being coupled to each other for occluding said vertically extending recess, and an occluded portion formed at an upper end of said vertically extending recess being formed as a cutaway portion for forming an opening.

O, A floor panel according to claim 1, wherein a portion of said bottom plate .e 15 coupling piece or said top plate coupling piece for occluding the upper end of said vertically extending recess is provided with a cutting assistant i portion such as perforations and/or a thin groove.

3. A floor panel according to claim 1, wherein said cutaway portion has a width i. in the recessing direction of said recess of about 1/2 of a diameter of a 20 standard flexible electric cable tube. SSSS*0 o S

4. A floor panel according to claim 1, wherein a plurality of projections are formed upwardly from a bottom of said bottom plate, and said top plate and upper ends of said projections are coupled to each other, wherein said projections are positioned at a plurality of locations spaced radially around a center of said top plate as viewed on a plane, and the number of projections located on diagonal lines of said top plate is greater than those located on other portions.

A floor panel according to claim 1, wherein a central portion of said bottom CD/99105006.3 16 plate is recessed to form an internal projection for supporting mortar after the mortar is charged.

6. A floor panel according to claim 1, wherein four corners of said body portion which is rectangular as viewed on a plane are swelled outward with respect to lines forming four sides of a rectangle, thereby forming swelled corner portions.

7. A floor panel according to claim 1, wherein of said plurality of cutaway portions for forming openings, cutaway portions except one or more are cut except cap supporting portions, thereby forming the openings, and said openings are occluded by caps.

8. A floor panel according to claim 1, wherein four sides of the bottom surface periphery of said bottom plate are formed with thin and long recessed or projected reinforcing portions. Matsushita Electric Works, Ltd. By its Registered Patent Attorneys Freehills Patent Attorneys

9 October 1999 S