[0001] This invention relates to floor panels, particularly of the kind used in industrial
situations, such as in the provision of gratings supported on structural elements,
in the provision of walkways, platforms, and access flooring, hereinafter referred
to as a floor panel of the kind specified.
[0002] One kind of floor panel of the kind specified comprises longitudinal beams, conventionally
of T-section secured together at successive positions along the length by transverse
bars to provide a transversely and longitudinally extendable grating. This construction
is utilised in the provision of open flooring, in which the longitudinal beams bear
downward load to provide a grating, whilst the transverse bars are intended primarily
to hold the longitudinal beams in the required relative positions. Such a floor panel
is disclosed in our UK Patent No. 2036149.
[0003] Generally in the provision of such a floor panel, it is desirable to provide the
floor panel as large as possible, whilst providing adequate strength and minimal spacing
between longitudinal beams. However, a floor panel of this type suffers from the disadvantage
that it is necessary to assemble the floor panels, and this is a time consuming operation.
[0004] Another floor panel of the kind specified utilises moulded floor panels, the size
of which is limited essentially by the size of moulding it is possible to make economically.
[0005] According to one aspect of the invention there is provided an elongate floor panel
comprising a transversely and longitudinally extensive plate part having an upper
surface which providees a generally continuous floor surface and depending downwardly
therefrom and integral therewith a plurality of longitudinal beam parts, the panel
having been moulded in one piece by a pultruding operation.
[0006] Preferably the panel comprises fibre reinforced synthetic plastics material with
the fibres aligned or substantially aligned in the longitudinal direction of the panel,
thereby improving the strengh of the panel.
[0007] The pultruding operation causes the fibres to become aligned or more aligned in the
longitudinal direction.
[0008] The reinforcing fibre may comprise uni-directional rovings to provide properties
in the longitudinal direction of the member and continuous strand mat to provide transverse
properties.
[0009] The plastics material may comprise polyester or vinylester resin and may also comprise
at least one of filler, pigments, curing agents and processing aids as appropriate
and ultra-violet inhibitor.
[0010] The panel may have a surface veil of polyester non-woven fabric which encases the
glass fibre reinforcement and provides a layer of resin at the surface of the panel.
[0011] The veil may be capable of providing additional protection against ultra-violet degradation,
preventing fibre blooming and increasing corrosion resistance.
[0012] The plate part may comprise from top surface downwardly,
a surface veil,
a plurality of continuous filament mats,
a filling of uni-directional rovings,
a plurality of continuous filament mats,
a surface veil.
[0013] The beam parts may comprise,
a surface veil,
a continuous filament mat,
a filling of uni-directional rovings,
a continuous filament mat
a surface veil.
[0014] The filaments and the rovings may comprise glass filaments and rovings respectively.
[0015] Preferably the longitudinal beam parts are of inverted T-shape in cross-section,
the stem of the T is being integral with the plate part and the head of the T providing
oppositely directed flanges at the ends of the beam parts remote from the plate part.
[0016] Preferably the upper face of the floor surface is provided with longitudinal ribbing
or other protruberences, to improve grip.
[0017] Preferably the panel part is provided with a plurality of apertures intermediate
the beam parts.
[0018] The apertures may be punched apertures.
[0019] The panel may be provided with a longitudinally extending groove on one side and
a longitudinally extending tongue at the other side whereby the tongue and groove
of one panel may interengage with a groove and tongue respectively of the two other
adjacently juxtaposed panels to transfer load between the adjacent panels.
[0020] The panel may be placed on supports with the beam parts lowermost and engaging the
supports and the floor surface uppermost.
[0021] In this manner a floor panel may be produced in a more convenient size than by the
conventional moulding operation, without the need to carry out an assembly operation.
[0022] The generally continuous nature of the floor surface aids the overall strength of
the panel, allowing the longitudinal beams to be provided at increased transverse
spacing.
[0023] According to another aspect of the invention we provide a method of forming a floor
wherein a plastics composition containing filamentary reinforcement is formed by pultrusion
into a panel comprising a longitudinally and transversely extensive plate part having
a generally continuous floor surface at one face and a plurality of elongated, mutually
parallel beam part at an opposite face and wherein the panel is placed on supports
with the beam part lowermost and engaging the supports and the floor surface uppermost.
[0024] There will now be given a detailed description, to be read with reference to the
accompanying drawings, of a floor panel which is a preferred embodiment of this invention,
having been selected for the purposes of illustrating the invention by way of example.
[0025] In the accompanying drawings:
FIGURE 1 is a plan view showing a portion of the floor panel which is the preferred
embodiment of this invention;
FIGURE 2 is an end view of the panel of Figure 1;
FIGURE 3 is a fragmentary enlarged end view of one side of the panel;
FIGURE 4 is a fragmentary enlarged view of the opposite side of the panel;
FIGURE 5 is a diagrammatic cross-section to an enlarged scale showing how a panel
embodying the invention is fixed to a support;
FIGURE 5a ia a fragmentary perspective view showing the fixing arrangement of Figure 5;
FIGURE 6 is a fragmentary cross-section showing the internal structure of the panel
of Figures 1 to 5, and
FIGURE 7 is a schematic perspective view showing a portion of a conventional floor
panel.
[0026] The floor panel shown in Figure 7 comprises a plurality of elongate bars 10 secured
together at spaced intervals by transverse bars 12, the upper limb 11 of the longitudinal
beams cooperating together to provide a floor surface having gaps 13 between adjacent
longitudinal beams. The panel comprises a transversely and longitudinally extensive
plastic part 21.
[0027] Conversely, in accordance with the present invention, an elongate floor panel 20
is provided, having been made in one piece by a pultruding operation, from glass fibre
reinforced plastics material. The panel 20 comprises a transversely and longitudinally
extensive plate part 21 having an upper surface 22 which provides a generally continuous
floor surface. Depending downwardly from the plate part 21 and formed integrally therewith
are a plurality of longitudinally extending beam part 23, 23
a, 23
b. Except for first and second end beam parts 23
a, 23
b respectively, all the beam parts 23 are of the same shape which, in end elevation
and in cross-section, is of inverted T-shape each having a vertically downwardly depending
stem 24 formed integrally at one end with the plate part 21 and at the lower end a
transversely extending head 25.
[0028] As best shown in Figures 3 and 4, the first beam part 23
a has a configuration so as to provide a longitudinally extending rib or tongue portion
26 whilst the second end beam part 23
b has a configuration to provide a longitudinally extending groove portion 27. Accordingly,
a tongue portion 26 of one panel 20 can be received within the groove portion 27 of
an adjacent panel so that a load can be transferred between adjacent panels.
[0029] Suitable clip means may be provided to clip interengaged end beam parts 23
a, 23
b together or any other suitable means may be provided to join adjacent panels together,
or separate joining means may not be provided, reliance being placed on the fixing
of the panels to a support structure to maintain the parts in a desired juxtaposition.
[0030] The beam parts 23, 23
a, 23
b provide resistance to deformation of panel part 21 under load.
[0031] Elongate ribs 28 are provided on the upper surface 22 to improve grip although, if
desired, the other patterns of ribbing or other grip providing means may be provided,
or indeed omitted in any particular application.
[0032] A plurality of apertures 29 are provided distributed throughout the extent of the
plate part 21, as shown in Figure 1. In the present example each aperture 29 is identical
and comprises semi-circular longitudinallly opposite ends interconnected by parallel
side wall parts.
[0033] Provision of apertures permits drainage of water from the panel and also reduces
the weight of the panel. The apertures 29 are made by punching and each aperture in
a row may be punched at the same time and thus a relatively rapid rate of production
may be achieved. If desired, suitable sealant may be provided to the walls of the
punched apertures.
[0034] The panel is arranged to be supported on a support structure 30 with the undersurface
31 of the heads 25 engaging the upper suface of the support structure 30. A fixing
clip assembly, shown generally at 32 in Figure 5, is provided to fix the panel to
the support 30. The clip assembly 32 comprises a glass fibre reinforced plastic holder
plate 33 which engages the upper surface 34 of flanges 35 of the heads 25. A stainless
steel bottom clip 36 is clamped beneath a flange 37 of the support structure 30 by
a screw 38 and nut 38
a, access to the head 39 of the screw being provided through one of the apertures 29.
To assemble the fixing assembly the screw 38 is inserted through the holder plate
33 and the stainless steel bottom clip 36 and the nut 38
a engaged with the screw. The assembly is then slid along the flanges 35 to the desired
location and then a plodring, not shown, may be positioned on the support 30. The
fixing assembly 32 is then slid into position, as shown in Figure 5
a and then the screw 38 is rotated with a screwdriver from above through the aperture
29 with nut 38
a being prevented from rotation by the configuration of the bottom clip 36.
[0035] If desired, any other suitable means for holding the panel to a support structure
may be provided.
[0036] Referring now to Figure 6, the panel, as mentioned before, is made by a pultrusion
process. The plate part 21 has the following structure. Starting at the top surface
22, there is a 20g/m² chemical resistant surface veil 40 of a polyester non-woven
fabric to encase the glass fibre reinforcement and add a layer of resin to the surface.
This is to provide additional protection against ultra-voilet degradation, to prevent
the fibre blooming and increase corrosion resistance.
[0037] Below the veil are four 600g/m² E glass continuous filament mats 41
a-
d and then a uni-directional E glass roving filling 42. Beneath the roving 42 are two
further 600g/m² E glass continuous filament mats 44
a,
b.
[0038] The uppermost mat 41
a extends downwardly over the side edges 43 of the plate part 21 and over a majority
of the tongue part 26 and groove part 27. A further 600g/m²E glass continuous filament
mat 44
c is overlapped by an end part of the mat 41
a in the groove 27 and extends around the head 25 of the associated beam part 23
b and provides a third mat for the plate portion 21 beneath the mats 44
a, 44
b. A further similar mat 44
d extends around the next adjacent beam part 23 and overlaps an end part 44
c' of the mat 44
c, the mats 44
a, 44
b being deflected as shown to make the undersurface 47 of the plate part 21 between
the beam parts 23 planar. An end part 44
d' of the mat 44
d is similarly overlapped by a further mat 44
e which extends around the next adjacent beam part 23 and this is repeated across the
transverse extent of the panel.
[0039] A penultimate beam part 23 has a further mat 44
f. At the first end beam part 23
a, the uppermost mat 41
a extends past the majority of the tongue portion 26 and overlaps an end part of a
further mat 44
g which overlaps an end part 44
f' of the mat 44
f. A polyester surface veil 40, as described above, extends over the whole of the external
surface of the panel including the beam parts.
[0040] Each beam part 23, 23
a, 23
b, in addition to the polyester mats 44
c -
f previously described, comprises uni-direction E glass rovings 45 to fill.
[0041] The above mentioned mats and rovings reinforce a suitable synthetic plastics resin
such as polyester or vinylester resin which may also comprise pigment, curing agent
and processing agent as appropriate, as well as ultra-voilet inhibitor to impart resistance
to the effects of ultra-voilet radiation.
[0042] If desired the panel may have, for example, three mats above the rovings or may contain
more than four and three mats respectively above and below the rovings. If desired
more layers of rovings may be provided between different mats. The beam parts may
have more mats distributed as desired. The mats and rovings may be made of other suitable
material.
[0043] The panels described hereinbefore have a cross-sectional area of approximately 5200mm
²and may be 500mm wide, 40mm deep and 6 metres long.
[0044] The panel has a weight of approximately 20kgs per square metre which is considerably
lighter than the equivalent steel panel, which is of a weight of approximately 81kgs.
The above mentioned 20kg weight is the weight prior to the provision of apertures
29. Of course, the weight is further reduced when the panel is thus slotted.
[0045] The panel of the present invention, being a one-piece construction, has the necessary
strength and deflection resistance without any need to assemble individual components,
thereby avoiding problems hitherto associated with jointing.
[0046] A panel embodying the invention, described hereinbefore, was tested and found to
have the following properties:
Modulus of Elasticity (Full section) |
GPa |
30 |
Flexural Strength (Full section) |
MPa |
300 |
Short beam shear strength |
MPa |
30 |
Bearing strength |
MPa |
200 |
[0047] The strength provided to the plate part 21 by the generally continuous nature that
the floor surface improves the overall strength of the panel, allowing the beam parts
23 to be provided at more greatly spaced intervals than floor panels of the assembled
type.
[0048] Thus the invention provides the benefit of a moulded floor panel, with the benefits
of an elongate assembled floor panel, without the need for assembly, particularly
in that gaps between the longitudinal beams is obviated.
[0049] The panel is made by a pultrusion process in which the mats and rovings are fed into
a pultrusion die together with the resin, there being means continuously to draw the
mats and/or rovings through the die.
[0050] The features disclosed in the foregoing description, or the following claims, or
the accompanying drawings, expressed in their specific forms or in terms of a means
for performing the disclosed function, or a method or process for attaining the disclosed
result, as appropriate, may, separately or in any combination of such features, be
utilised for realising the invention in diverse forms thereof.
1. An elongate floor panel comprising a transversely and longitudinally extensive plate
part having an upper surface which providees a generally continuous floor surface
and depending downwardly therefrom and integral therewith a plurality of longitudinal
beam parts, the panel having been moulded in one piece by a pultruding operation.
2. A panel according to claim 1 wherein the panel comprises fibre reinforced synthetic
plastics material with the fibres aligned or substantially aligned in the longitudinal
direction of the panel, thereby improving the strengh of the panel.
3. A panel according to claim 2 wherein the reinforcing fibre comprises uni-directional
rovings to provide properties in the longitudinal direction of the member and/or continuous
strand mat to provide transverse properties.
4. A panel according to claim 1 or claim 2 wherein the plastics material comprises polyester
or vinylester resin and may also comprise at least one of filler, pigments, curing
agents and processing aids as appropriate and ultra-violet inhibitor.
5. A panel according to any one of claims 2 to 4 wherein the panel has a surface veil
of polyester non-woven fabric which encases the glass fibre reinforcement and provides
a layer of resin at the surface of the panel.
6. A panel according to any one of claims 2 to 5 wherein the plate part comprises from
top surface downwardly,
a plurality of continuous filament mats,
a filling of uni-directional rovings,
a plurality of continuous filament mats and/or
the beam parts comprise, from one side surface to the other,
a continuous filament mat,
a filling of uni-directional rovings,
a continuous filament mat and/or
the surface of the panel is provided with a surface veil.
7. A panel according to any one of claims 2 to 5 wherein the filaments and the rovings
comprise glass filaments and rovings respectively.
8. A panel according to any one of the preceding claims wherein the longitudinal beam
parts are of inverted T-shape in cross-section, the stem of the T is being integral
with the plate part and the head of the T providing oppositely directed flanges at
the ends of the beam parts remote from the plate part.
9. A panel according to any one of the preceding claims wherein the plate part is provided
with a plurality of apertures intermediate the beam parts.
10. A panel according to claim 9 wherein the apertures are punched apertures.
11. A panel according to any one of the preceding claims wherein the panel is provided
with a longitudinally extending groove on one side and a longitudinally extending
tongue at the other side whereby the tongue and groove of one panel may interengage
with a groove and tongue respectively of the two other adjacently juxtaposed panels
to transfer load between the adjacent panels.
12. A method of forming a floor wherein a plastics composition containing filamentary
reinforcement is formed by pultrusion into a panel comprising a longitudinally and
transversely extensive plate part having a generally continuous floor surface at one
face and a plurality of elongated, mutually parallel, beam parts at an opposite face
and wherein the panel is supported on supports with the beam part lowermost and engaging
the supports and the floor surface uppermost.