CN111051628A - Grouted disc assembly with reinforcing ring - Google Patents

Abstract

A grouted disc assembly includes a reinforcement ring. In another aspect, the grout plate comprises a substantially planar bottom surface and a curved sidewall surrounding the bottom surface. In yet another embodiment, the grout plate assembly comprises a grout plate having a post or mechanical fastener extending from the back of the grout plate for attachment to a reinforcing ring or layer.

Description

Grouted disc assembly with reinforcing ring

Citations to related applications

This application claims priority to us patent application No. 15/690,360 filed on 30.8.2017, which is a continuation of us patent application No. 15/436,923 filed on 20.2.2017, a division of us patent application No. 14/490,012 filed on 18.9.2014, issued as us patent No. 9,580,916. This application also claims priority from US patent application No. 15/690,360 filed on 30.8.2017, which is a continuation of PCT international patent application sequence No. PCT/US2016/053355 filed on 23.9.2016, which requires priority from US provisional patent application sequence No. 62/232,123 filed on 24.9.2015. In addition, the present application claims priority from us patent application 15/690,360 filed on 30/8/2017, which is a continuation of us patent application sequence No. 15/405,361 filed on 13/1/2017. The entire disclosure of the above application is incorporated herein by reference.

Technical Field

The present disclosure relates generally to finishing of workpiece surfaces, and more particularly to filling voids and/or holes in a floor surface with a grouted pan assembly having a stiffening ring.

Background

Composite surfaces, such as epoxy, terrazzo or cement-like floors, typically include decorative aggregates, most commonly marble chips or any suitable aggregate supported in a matrix material. First, a solid, horizontal concrete base is built. Next, an underlying ground layer is formed on top of the substrate. Historically, this layer was a sand-containing concrete layer. The metal cell filler rod may be partially embedded in the concrete before the concrete has set to provide a panel in the surface. Finally, a top layer comprising a matrix material with decorative aggregate is placed into each panel. Historically, the matrix material was a cementitious material, but now the matrix material may be a polymer-based matrix, such as based on epoxy. The base material may be pigmented. While the decorative aggregate is typically marble chips, it may be any suitable aggregate, such as glass, ceramic, concrete, metal, nacre, abalone shell. Other aggregate may be applied to each panel when the mixture is still wet. Finally, the entire surface is pressed with a weighted roller.

In initial installation, these composite surfaces are porous or semi-porous in nature. Furthermore, in the case of a cement-like or polymer-based matrix curing, the gases released from the matrix cause surface defects, holes and voids under the surface in the top layer when the composite surface dries. To address this problem, a grindstone or diamond plate is used to rough cut the top layer step by step (24 mesh to 80 mesh). Rough cutting of the top layer flattens out surface defects but may leave slight depressions. Rough cutting hardly remedies the holes and may open up voids under the surface. If left untreated, these imperfections may collect excessive wax, dirt, and other debris, which affects the appearance and surface quality of the composite surface.

Thus, grouting of the composite surface is required in order to fill the remaining surface defects. The rough cut layer was grouted by manually applying the mortar to the composite surface with a spatula. The mortar was wiped back and forth over the surface with a manual spatula. When the scoop approaches a surface defect, the mortar covers the indentation and partially fills the void below the surface. However, when the shovel moves past a surface defect, the shovel may pull the mortar out of the void under the surface, thus leaving the surface defect. Even when the mortar dries or cures, voids under the surface already covered by the mortar may become exposed.

Therefore, it is desirable to develop a method of grouting rough cut ground that completely fills surface defects. Furthermore, it would be desirable to develop a tool for use in grouting processes and which is configured for use on a finishing machine typically used for conventional grinding and polishing of composite surfaces. Conventional pads also exhibit uneven flexibility, particularly at their periphery.

Disclosure of Invention

According to the present invention, a grouted disc assembly includes a reinforcement ring. In another aspect, a grout plate comprises a substantially planar bottom surface and a curved sidewall surrounding the bottom surface. Yet another aspect provides a grout plate having a curved sidewall including an angled portion and a rounded edge portion formed between a bottom surface and the angled portion such that an included angle in the form of an obtuse angle is formed between the bottom surface and the angled portion. In yet another aspect, the top surface of the grout disk is configured to secure the grout disk to a rotating head of a finishing machine. In another embodiment, the grout plate assembly comprises a grout plate having a post or other mechanical fastener extending from the back of the grout plate for attachment to a reinforcing ring or layer. A method of making and using the grout disc assembly with the stiffening ring or layer of the present invention is also provided.

The grouted disc assembly of the present invention is ideally suited for finishing composite surfaces or other workpiece surfaces. The assembly of the present invention may also spread the mortar over a rough composite surface having surface voids to form a prepared surface. An exemplary grout disk has curved side walls extending from a substantially flat bottom surface which contacts the prepared ground, the grout disk advantageously rotating over the prepared surface. By the rotational motion, the exemplary grout disks move in different directions relative to the composite surface such that the grout disks are pushed around surface imperfections of the composite surface. In doing so, these grout disks force the trapped air out and allow the grout to enter the holes and surface voids. Specifically, the sidewalls push the mortar into the surface defects, while the rounded edges and the planar bottom surface compress the mortar and force air out. This action also allows any filler to be thoroughly mixed with the mortar during grouting. The cured surface is conditioned to form a conditioned surface. The combination of the grouting disk of the invention and the specially shaped reinforcement ring also produces aesthetically pleasing decorative benefits compared to existing designs.

The assembly of the present invention is superior to conventional devices. For example, the flexible metal reinforcement layer or ring of the apparatus of the present invention advantageously allows for greater and more uniform ground contact over worn areas and cracks due to the disc-to-disc flexibility which is expected to improve grout fill performance. In addition, the posts extending from each tray and the method of manufacturing the apparatus advantageously provide for a more secure attachment of the components. The combination of the flexible metal stiffener ring and the metal grout disk provides increased durability and improved heat dissipation during use. In addition, the ring of the present invention increases the stiffness of the pad adjacent its outer periphery, which makes the pressure of the disc against the ground more uniform. Other advantages and features of the present invention will be readily understood from the following description, claims and drawings.

Drawings

FIG. 1 is a partially exploded top perspective view showing a grouted disc assembly including a power grooming machine;

FIG. 2 is a bottom perspective view showing several of the present grout disc assemblies secured to a counter rotating head of a power dresser machine;

FIG. 3 is a bottom perspective view showing the grout plate assembly of the present invention;

FIG. 4 is a bottom exploded perspective view illustrating the grout disc assembly of the present invention;

FIG. 5 is a bottom elevation view showing the grout disc assembly of the present invention;

FIG. 6 is a bottom perspective view of the grouting tray of the present invention;

FIG. 7 is an exploded cross-sectional view taken along line 8-8 of FIG. 5, illustrating the grout disk and stiffener ring of the present invention;

FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 5, illustrating a grouser tray assembly of the present invention;

FIG. 9 is a bottom elevation view showing an alternative embodiment of the grout disc assembly of the present invention;

FIG. 10 is a bottom elevation view showing another alternative embodiment of the grout disc assembly of the present invention;

FIG. 11 is a bottom elevation view showing yet another alternative embodiment of the grout disc assembly of the present invention; and

fig. 12 is a bottom elevation view showing yet another alternative embodiment of the grout disc assembly of the present invention.

Detailed Description

The grouser disk assembly 34 includes a base pad or layer 28 of rubber or elastomeric polymer, a reinforcing ring or layer 31, and a plurality of grouser disks 10 for finishing a composite ground or workpiece surface 11. This can be observed in fig. 1 to 6 and 8. The grouting pan 10 has a substantially planar bottom surface 12 and a curved side wall 14 surrounding the bottom surface 12. The curved sidewall 14 is defined by an angled portion 16 and a rounded edge portion 18. The curved sidewall 14 may also include a vertical portion 20 extending from the angled portion 16 to a top back surface 22. In a preferred embodiment, the grout plate 10 is metallic and more preferably stainless steel.

The reinforcement ring or layer 31 is secured to the bottom surface or surface 40 of the base pad 28 by a contact cement type adhesive. For one type of assembly, the reinforcement ring 31 is generally annular with a central opening having an inner diameter of about 110mm and an outer diameter of about 229 mm. Furthermore, the reinforcement ring 31 has a thickness greater than zero and up to 1.0mm, and more preferably has a thickness of 0.25 mm. The reinforcement ring or layer 31 is metallic and more preferably is a high carbon steel 1095, hardened and tempered spring steel material. The reinforcement ring 31 reinforces and adds some radial stiffness and toughness to the outer portion of the liner 28 to resist rotational centrifugal forces when in use, in any event, the ring advantageously allows the assembly 34 to have effective torsional and longitudinal flexibility and resilience so that it can flex with and follow any ground imperfections, thereby producing uniform disc-to-disc ground contact for grouting. This is particularly beneficial when worn areas of the ground or cracks located in the ground meet only some of the discs and not others.

The circular inner edge 33 of the reinforcement ring 31 defines a central opening or hole that exposes the central surface of the base pad 28. This large diameter inner edge 33 allows the ring to more easily twist flex during use. Preferably, base gasket 28 and ring 31 have concentrically aligned circular outer peripheral surfaces 39 and 41, respectively.

Alternatively, variations of reinforcement rings 31a-31d may have undulating or wavy inner edges 33a-33d, such as those shown in FIGS. 9-12. These curved inner edges have radially extending slots 61a-61d between radially enlarged peak locations 63a-63d of the mounting plate to achieve different flexibility characteristics of the ring. In any event, the edge shape of these rings also provides an aesthetically pleasing decorative design.

Referring to fig. 7 and 8, the ground contact disc 10 is secured to the ground facing surface 52 of the bottom of the reinforcing ring 31. Each disc comprises a generally circular body having an exemplary outer peripheral diameter of 54mm and an overall height of 8.0mm below the stiffening ring 31. Thus, the transverse width W of each disk is at least twice the longitudinal height T, and more preferably, the transverse width W is at least five times the longitudinal height T (the height exposed below the ring).

An optional and cylindrical post 55 projects from the back of each dish-like pan in a longitudinal direction that is substantially parallel to the axis of rotation of the cushioning device, and the post and the pan are integrally formed as a single piece. The post 55 is about 20mm wide and about 1.0mm long. In addition, the post 55 protrudes through a hole 57 in the penetrating ring 31. The plurality of holes are equally spaced in the ring. The distal end of the post 55 deforms and curls to spread outwardly like a mushroom head, thereby creating an enlarged head 59 (shown in fig. 8) that is laterally larger than the hole 57. Fig. 7 shows the post 55 before deformation. Thus, the ring 31 is sandwiched between the head 59 and the back of each disk 10 and compressed therebetween to mechanically attach and secure the disks 10 to the ring 31.

An adhesive may additionally or alternatively be employed to attach and secure the disk 10 to the ring 31 (whether with or without posts) depending on the particular durability requirements and roughness of the grit for grinding. Although four grout disks are preferably attached to the reinforcement ring, alternatively at least two disks (such as three, six or more) may be used with each ring. Alternatively, the post may be a longitudinally elongated threaded shaft of a bolt or other mechanical fastener, although it may not achieve some of the benefits of the preferred integral post.

Alternatively, it is contemplated that a plurality of parallel and spaced apart posts may project from each disc-like disc for insertion over the apertures of aligned reinforcement rings. Further, it is contemplated that one or more posts may alternatively have a generally polygonal shape, have flat side surfaces, or have a greater width in one lateral direction than in another direction (e.g., rectangular or oval). During grouting, these replaceable post configurations prevent the disks from rotating relative to the attached stiffener ring and base pad. In the example shown, four such discs 10 are fixed in an equally spaced manner around the circumference of the reinforcement ring 31. The posts may be solid or at least partially hollow. Alternatively, different sizes and/or different numbers of discs may be used. Furthermore, the ring's aperture 57 is preferably circular, but alternatively it may have one or more flat edges, or even elongated slots in the inner edge 33 or outer edge 41, respectively, of the ring 31.

Fig. 1 and 2 show one of the plurality of disc assemblies 34 secured to a rotatable flange hub 71 of a larger counter-rotating rotor 73 of a motor-powered ground grinding machine 75. The hard rubber or elastomeric polymer disk 77 includes a plurality of clip or bolt receiving holes for releasably securing the disk 77 to the hub 71. The hook-and-loop fastener 103 (e.g.,

) Is secured to the bottom of the dish 77 and may be removably secured to the base pad 28; however, it is also contemplated that the liner 28 may be attached directly to the hub 71 in some configurations. A plurality of grouted disc assemblies 34 are fixed for rotation about the central axis of the rotor 73. Alternative power machines and pad accessories may be used. Further, the liner assembly of the present invention may be attached to a walk-behind or ride-on troweling machine that may be powered by propane fuel.

With particular reference to fig. 1 and 2, the grouted disc assembly 34 shown in fig. 5 is well suited for use on a dressing or grinding machine having a rotating head 73 supporting a set of counter-rotating planetary gears or hubs 71. For example, the grouter disk assemblies 34 (three shown) are secured to associated counter-rotating planetary gears 71 that rotate in a direction opposite to the rotating head 73. Other grouter disk assemblies 34 may be secured to the counter-rotating planetary gears 71 as desired for a particular application. During operation of the finishing machine, the head 73 rotates the grouted disc assemblies 10 in a clockwise direction, while the planet gears 71 rotate each assembly 10 in a counterclockwise direction relative to the head 73 over the prepared surface for painting mortar onto the rough composite surface and forcing the mortar into the surface voids to form the grouted surface.

As presently preferred, the geometry of the grout disk 10 is configured to effectively spread the grout over the rough cut layer. During operation of the finishing machine, the head rotates the grout disk 10 over the prepared surface and applies the grout with the sidewalls 14 to the rough composite surface and forces the grout with the bottom surface 12 into the surface voids to form the grout surface.

A method for finishing a composite floor surface will now be described. While the method described herein has particular application for grouting terrazzo floors, the process has broader application for finishing or refinishing any composite surface, including but not limited to epoxy, terrazzo or cementitious surfaces with or without decorative aggregates. First, it should be understood that the roughened composite surface has been prepared according to conventional methods described in the background above, with the following exceptions. The method described below, particularly for grouting rough composite surfaces that are rough, enables the grit used during rough cutting to be finer than the grit used at each step in conventional dressing. In particular, the rough composite surface may be finished to a 150 mesh or 200 mesh surface prior to grouting.

A method for finishing a composite surface includes spreading a mortar over a rough composite surface having surface voids to form a prepared surface. Alternatively, the filler may be applied on top of the mortar when the prepared surface is formed. The filler may be a very fine powder of powdered stone (e.g. marble, limestone, granite and/or quartz), calcium carbonate or cement. The grout plate is rotated over the prepared surface so that the curved sidewalls smear the grout onto the rough composite surface and the bottom surface 12 in contact with the prepared floor forces the grout into the surface voids, thereby forming the grout surface. The mortar on the grouted surface is cured to form a cured surface. The cured surface is then ground to remove excess grout and dressed with fine grit on the order of about 200 mesh or higher, then sealed and polished to form a finished surface. When practicing the above-described method, the grout disk 10 described herein is particularly suitable for use on the rotating head of a touch-up machine.

Although different embodiments are disclosed, it should be understood that other variations of the grout pad assembly are contemplated. For example, while preferred dimensions and metallic materials are disclosed above, it will be appreciated that other dimensions and metallic materials may alternatively be employed. By way of example, the stiffening ring may be made of a polymeric material, although it may not achieve the heat dissipation benefits of the preferred metallic ring. Furthermore, a circular outer peripheral shape is preferred for the liner, the reinforcement ring and the disc; however, other arcuate or even substantially polygonal peripheral shapes may be used, although this may result in some of the advantages of the present invention not being fully realized. Alternative base pads 25 may be used, such as fibers, foam, felt, or other such flexible materials. It should also be noted that any of the aforementioned features may be interchanged or mixed with any other feature. Furthermore, it is alternatively possible to have different shaped inner edges or even no central hole in the reinforcement ring or layer, although for some applications this may result in insufficient torsional deflection and such a construction may result in unwanted additional material costs and weight. Thus, any and/or all dependent claims may depend on all of the preceding claims thereof and may be combined together in any combination. Variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope and spirit of the invention.

Claims (38)

1. A grout plate assembly comprising:

(a) a rotatable pad comprising a top surface, a bottom surface facing the ground, and an outer peripheral surface;

(b) a reinforcement layer attached to the bottom surface of the pad, the reinforcement layer being a flexible material; and

(c) a plurality of grout disks attached to the ground facing surface of the reinforcing layer.

2. The assembly of claim 1, wherein each of the grout plates comprises at least one mechanical fastener protruding from a back of the grout plate.

3. The assembly of claim 2, wherein the fasteners comprise posts, each post extending through an associated hole in the reinforcing layer, and a distal end of each post flaring laterally on an upper side of the reinforcing layer to mechanically attach the associated grout pan to the reinforcing layer.

4. The assembly of claim 1, wherein each of the grouting trays includes a bottom surface facing the ground and a curved sidewall connected to the bottom surface of the tray, the curved sidewall including an angled portion and a rounded edge portion between the bottom surface and the angled portion such that an included angle in the form of an obtuse angle is formed between the bottom surface and the angled portion.

5. The assembly of claim 4, wherein the included angle is 110 degrees^oTo 135^o。

6. The assembly of claim 1, wherein the reinforcement layer is an annular ring having a rounded inner edge and a rounded outer edge, and a central portion of the liner is exposed through a hole defined by the inner edge of the ring.

7. The apparatus of claim 1, wherein the flexible material of the reinforcement layer is metallic.

8. The assembly of claim 1, wherein:

the gasket comprises a rubber or elastomeric material; and is

The reinforcing layer provides radial stiffness and torsional flexibility to enable one of the grout disks to move longitudinally relative to the other of the grout disks.

9. The assembly of claim 1, wherein the reinforcement layer is a metal ring and the grout disk is metal such that the reinforcement layer acts as a heat sink for the disk.

10. The assembly of claim 1, further comprising:

an electric or fuel powered machine adapted to rotate a plurality of said pads simultaneously to grind concrete, stone or terrazzo ground;

the reinforcement layer allows for flexing to allow all of the grout pan to contact the ground even if uneven ground conditions are encountered; and is

The reinforcing layer has a thickness of no more than 1 mm.

11. The assembly of claim 1, wherein:

the outer peripheral surface of the gasket is circular;

the pad is flexible;

the outer peripheral surface of the reinforcing layer is substantially circular and has a diameter substantially equal to the diameter of the liner, which is at least 7 inches; and is

The periphery of the grouting disk is substantially circular with a diameter of 1.5-2 inches.

12. The assembly of claim 1, wherein:

having at least four of said grout disks which are metallic and which are attached to said reinforcing layer which is metallic; and is

The liner and the reinforcing layer have a circular outer periphery.

13. The assembly of claim 1, further comprising grout pushed into voids in the surface of a composite or cementitious floor by rotation of the grout disk.

14. The assembly of claim 1, wherein the inner edge of the reinforcing layer has an undulating shape, the grout disk being located in radially enlarged peak locations of the undulating shape, between which peak locations are radially extending slots.

15. A grout plate assembly comprising:

(a) a flexible liner;

(b) a metallic stiffening ring attached to the liner;

(c) a plurality of metallic grout disks attached to the ring;

(d) an electrically powered machine adapted to rotate the grout plate to propel grout into voids in concrete, stone or terrazzo ground; and

(e) the ring is adapted to torsionally flex to allow all of the grout disk to contact the ground even if uneven ground conditions are encountered.

16. The assembly of claim 15, further comprising at least one post protruding from a back of each of the grout disks.

17. The assembly of claim 16, wherein each post is integrally connected as a single piece with the associated grout plate, and the post assists in securing the grout plate to the ring.

18. The assembly of claim 15, wherein the ring is annular, having a circular inner edge and a circular outer edge, and a central portion of the liner is exposed through a hole defined by the inner edge of the ring.

19. The assembly of claim 15, wherein an inner edge of the stiffening ring has an undulating shape, the grout disk being located in a radially enlarged peak location of the undulating shape.

20. The assembly of claim 15, further comprising a hook and loop fastener removably securing the liner to the rotatable head of the machine, and the liner is an elastomeric polymer or rubber material having a circular outer periphery.

21. An apparatus, comprising:

(a) a rotatable, flexible liner comprising a top surface, a bottom surface facing the ground, and a circular outer peripheral surface;

(b) a reinforcement layer having a circular outer periphery attached to the bottom surface of the liner, the reinforcement layer comprising a plurality of holes; and

(c) a plurality of dishes contacting the ground, each said dish comprising at least one post projecting from a back of said dish, each said post extending through an associated one of said holes in said reinforcing layer.

22. The apparatus of claim 21, wherein the disks are grout disks each having a circular outer periphery.

23. The apparatus of claim 21, wherein the dish is metallic and the pad is of an elastomeric polymer or rubber material.

24. The apparatus of claim 21, wherein the dish pushes grout into voids in concrete, stone or terrazzo ground as the dish rotates.

25. The apparatus of claim 21, wherein a distal end of each of the posts is flared laterally on an upper side of the reinforcement layer to mechanically attach the associated disc to the reinforcement layer.

26. The apparatus of claim 21, wherein:

each said dish is a grouting pan comprising a solid body including a flat bottom facing the ground and tapered side walls; and is

The post is a unitary, single piece with the body.

27. The apparatus of claim 21, wherein the lateral width of each of the posts is at least twice the protruding longitudinal length of each of the posts.

28. The apparatus of claim 21, wherein:

the reinforcement layer is an annular ring having a circular inner edge and a circular outer edge, and a central portion of the liner is exposed through a hole defined by the inner edge of the ring; and is

The reinforcing layer is made of flexible metal materials.

29. A method of manufacturing a grouted disc assembly, the method comprising:

(a) attaching a metallic stiffener to the flexible liner; and

(b) attaching a plurality of ground contacting grout disks to the reinforcement.

30. The method of claim 29, further comprising mechanically fastening the grout disk to the stiffener as at least part of the attaching step (b).

31. The method of claim 29, further comprising adhesively securing the grout disk to the stiffener as at least part of the attaching step (b).

32. The method of claim 29, further comprising adhesively securing the stiffener to the gasket as at least part of the attaching step (a), the gasket being of an elastomeric polymer or rubber material.

33. The method of claim 29, wherein the attaching step (b) comprises deforming a distal end of a post extending from a back of the laterally enlarged body of the grout disk to sandwich a portion of the stiffener between the distal end and the back of the laterally enlarged body of the grout disk.

34. The method of claim 29, further comprising:

providing the grouting pan with a flat and ground-contacting bottom and curved and tapered side walls; and

attaching at least three of said grouting discs to a reinforcement in an equally spaced manner.

35. The method of claim 29, further comprising:

providing the stiffener made of metal with a corrugated central opening; and

rotating the grout disk to push grout into the ground void.

36. The method of claim 29, further comprising providing a plurality of holes in the stiffener, each hole aligned with the grout disk.

37. The method of claim 29, further comprising:

attaching the pad to an electric or fuel powered machine that rotates the pad to push grout into voids in concrete, stone or terrazzo ground; and

the stiffeners flex to allow all of the grout disks to contact the ground even if uneven ground conditions are encountered.

38. The method of claim 29, further comprising providing each of said grouting discs with a laterally enlarged ground contacting body and at least one post extending longitudinally from a back of the body, a distal end of the post being laterally deployable.

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