WO2007144244A2

WO2007144244A2 - A modular system for covering surfaces

Info

Publication number: WO2007144244A2
Application number: PCT/EP2007/054800
Authority: WO
Inventors: Gianfranco Sassi
Original assignee: Granitifiandre Societa' Per Azioni
Priority date: 2006-06-12
Filing date: 2007-05-17
Publication date: 2007-12-21
Also published as: ITRE20060070A1; WO2007144244A3

Abstract

A modular system for covering surfaces comprising a plurality of covering panels (2) that can be reciprocally brought side-by-side to give rise to an external covering of a surface, each of which covering panels (2) being associated with a support element (3) which covers at least a portion of the laying surface (23) of the covering panel (2); the support element (3) being made of a deformable closed-cell plastic material which, following a deforming action, expels the air trapped inside, creating a suction effect.

Description

A MODULAR SYSTEM FOR COVERING SURFACES

Technical Field

The invention concerns in general a modular system for covering surfaces, such as walls or floors, by laying single covering elements, generally panels arranged adjacent to each other in such a way as to cover the surfaces.

More in particular, the invention concerns a modular covering system in which the covering elements are of the loose-lay type, which do not need to be fixed unremovably to the surface using adhesives or glues, but are simply placed in position and reciprocally assembled to give rise to a removable covering.

Background Art A typical application for modular covering systems of this type is to obtain floorings to cover surfaces such as for example concrete bases or already existing damaged or spoilt floors.

The surfaces to be covered are generally referred to as the base.

A known modular flooring system consists of treadable covering panels of a polygonal shape, generally made of ceramics or natural stone, and of relative support blocks that are fixed to the base, and upon which the adjacent edges of a contiguous group of panels rest simultaneously.

These support blocks generally make available a flat surface upon which the corner portions of the laying surfaces of the covering panels rest, and a group of projecting ribs, which divide the flat surface into as many sectors as there are contiguous panels, and are interposed between the edges of the panels, in order to separate the panels by the space necessary to compensate for any finishing errors and to absorb the thrust generated by incident loads. With this type of flooring system, the support blocks must be fixed to the base before the relative covering panels can be laid; this must be done in a sufficiently precise and stable manner such as to ensure that the panels will subsequently be coplanar and adjacent, as far as possible seamlessly and free of play. For this reason the installation of the support blocks generally calls for high levels of manual skill and the use of suitable calibration tools, and can therefore be carried out only by expert professional layers. In order to obviate this drawback, in a known modular flooring system, a supporting frame is interposed between each covering panel and the base,. A supporting frame of this type generally comprises a flat perimeter frame having the same outline in plan view as the relative covering panel, and a series of internal stiffening ribs that form a grid upon which the laying surface of the covering panel rests.

Each supporting frame is provided with suitable interlocking means which lock the frame stably to the adjacent supporting frames, in order to position the covering panels alongside one other and give rise to continuous flooring on the base. Further, the supporting frame is provided with a set of ribs that project relative to the flat frame, which ribs extend at least along two consecutive edges of the relative covering panel, in such a way as to give rise to the space between adjacent panels of the flooring. Each individual supporting frame is generally a monolithic body of plastic material, obtained for example by injection moulding, and fastened in advance to the relative covering panel by adhesive.

These flooring systems have shown themselves to be effective and easy to install, but they have the serious drawback of being particularly expensive, since manufacture of the supporting frames is normally very complex and laborious.

Disclosure of Invention

The aim of this invention is to make available a modular system for covering bases - typically a modular flooring system - which makes it possible to obviate the above-mentioned drawbacks in the prior art. A further objective of the invention is to achieve the above-mentioned objective within the ambit of a simple, rational and inexpensive solution. These objectives are achieved by the invention as it is characterised in the claims. In particular, the invention provides a modular covering system for surfaces which comprises a plurality of covering elements, generally in the form of flat polygonal panels, each of which panels is associated with a support element which covers at least a portion of the laying surface thereof; the support element is made of a deformable closed-cell plastic material which, following a deforming action, expels the air trapped inside, thus creating a suction effect.

Thanks to this solution, each covering element can be secured to the surface to be covered, simply by exploiting the panel's weight, which compresses and deforms the support element, giving rise to the above-mentioned suction effect.

In this way, fixing takes place without using adhesives or glues, and with no need to reciprocally interlock the adjacent covering elements. Thus each covering element can be removed and laid anew independently of all the other adjacent covering elements, simply by applying a force capable of overcoming the cohesive force due to the suction effect.

Further, the deformability of the support element enables effective compensation for any unevenness in the surfaces being covered, without the intervention of expert layers. In a preferred embodiment of the invention, the support element comprises a set of elongate strips of the deformable closed-cell plastic material, each of which extends parallel and adjacent to a respective edge of the covering element, so as to give rise to a frame that covers the perimeter areas of the laying surface of the covering element. The strips can be distinct and separate from each other, or they can be portions of a single monolithic substantially frame-shaped body. -A-

Further, the support element also comprises a plurality of separate blocks of the same deformable closed-cell plastic material, each of which covers a small portion of the laying surface of the support element, and which are distributed in a generally uniform way thereon. Preferably these blocks are positioned in parallel rows, so that overall they assume a matrix arrangement.

In a different variant, the support element comprises a single monolithic layer of the deformable closed-cell plastic material, which has a plurality of openings that substantially give it the appearance of a grid covering the laying surface of the covering element.

Thanks to these solutions, the support element is compressible at a multiplicity of distinct points, thus compensating more effectively for any unevenness in the surface being covered, and better distributing upon the latter the stresses that bear upon the covering element. According to the invention, the covering element can consist simply of a finishing element which constitutes the visible surface of the flooring. This finishing element can be made of ceramic material, for example vitrified stoneware, natural stone, for example marble or granite, or also wood. Alternatively each finishing element can be stuck to a respective base element, the flat under-surface of which constitutes the laying surface of the covering element.

This base element can possess special heat, electricity or sound insulation properties; further it can be extremely fire-resistant. Preferably it is made of a plastic material, for example PVC with class 1 fire- resistant properties.

In a preferred embodiment of the invention, the base element has an outline in plan view corresponding to that of the finishing element, and comprises a projecting wall that extends along at least two contiguous perimeter edges of the finishing element. In this way, when covering elements are laid on the surface to be covered, adjacent to one another as a set, the projecting wall makes it possible to keep the covering elements separate by an adequate space.

Preferably, the projecting wall extends along all the perimeter edges of the finishing element, so as to frame the finishing element completely.

In a variant of the invention, a rubber gasket is fixed to the surface of the projecting wall opposite the perimeter edges of the finishing element, which gasket extends substantially along the whole extension of the edges.

In this way, the gasket makes it possible to compensate for any differences of calibre and/or manufacturing tolerances of the finishing elements, and to absorb the lateral stress to which the finishing elements are subjected when laid adjacently on the surface to be covered.

Brief description of the Drawings

Further characteristics and advantages of the invention will become evident from the following description provided as a non-limiting example, with the aid of the figures in the attached tables, wherein: figure 1 shows a portion of flooring obtained with the system of the invention; figure 2 is a perspective view from below of a covering element; figure 3 is a side view showing the covering elements being laid on a surface to be covered; figures 4 to 6 are all perspective views of the covering element of Figure 2.

Best Mode for Carrying Out the Invention

Figure 1 illlustrates a modular system 1 for covering surfaces, for example coplanar concrete bases or existing floors. This type of surface to be covered is generally known as a base.

This modular system 1 comprises a plurality of flat covering panels 2, which are removably laid on the base, adjacent to one another, in order to achieve a continuous covering.

In the illustrated example, the covering panels 2 are identical and have a square outline in plan view. The covering panels 2 could however have any outline shape, as long as they can be brought alongside one another so as to fit together. For example, the outline of the covering panels 2 could be any regular polygon.

As illustrated in Figures 2, 3 and 5, each covering panel 2 comprises a flat treadable finishing element 20, the upper surface 21 of which remains visible after the flooring has been laid.

The finishing element 20 is made of a ceramic material such as vitrified stoneware; however, it could also be a slab of natural stone, such as marble or granite, or a panel of wood. The finishing element 20 is fixed to a base element 22 made of class 1 fire- resistant PVC, the free lower surface 23 of which constitutes the laying surface of the covering panel 2.

The outline of the base element 22 corresponds to, and perfectly matches, that of the finishing element 20 positioned above it, and the base element 22 has two projecting walls 24 which extend along two contiguous edges of the finishing element 20 (see also figure 6).

A respective PVC gasket 25 is fixed to the outside of each of the projecting walls 24, which extends substantially for the entire extension of the relative perimeter edge of the covering panel 2. The gaskets 25 project from the relative projecting wall 24 by approximately 1.5 mm.

It should be noted that other embodiments of the invention do not include use of the gaskets 25.

The finishing element 20 is fixed by gluing to the base element 22, using an appropriate polymer adhesive.

The overall thickness of the covering panel 2, consisting of the finishing element 20 and the base element 22, is generally between 10 and 15 mm.

A support element denoted by 3 in the figures of the drawings is fixed directly below the base element 22, which support element 3 partially covers the laying surface 23 of the covering panel 2, in such a way as to be interposed between the latter and the base when laying has been performed.

In the illustrated example, the support element 3 comprises four elongate strips 30 made of a deformable closed-cell plastic material. Each of the strips 30 extends parallel and adjacent to a respective side of the covering panel 2, so as to give rise to a frame which covers the perimeter areas of the laying surface 23 of the covering panel 2.

Alternatively, the strips 30 could be portions of a single monolithic body made of a deformable closed-cell plastic material, shaped substantially like a frame.

The support element 3 further comprises a plurality of distinct blocks 31 of the same deformable closed-cell plastic material which are separated from each other and distributed in a generally uniform way on the remaining part of the laying surface 23 of the covering panel 2. In particular the blocks 31 are arranged in rows, parallel to the sides of the covering panel 2, in such a way that overall they exhibit a matrix-like arrangement.

In greater detail, the strips 30 and the blocks 31 are of identical thickness, between 0.5 mm and 50 mm, and the plastic material of which they are made is a closed-cell polymer foam, typically PVC.

Preferably the closed-cell polymer foam has a density of between 50 and 300 kg/m³, and elasticity compression modulus of between 0.8 and 9 N/cm², and Shore (00) hardness of between 10 and 60.

In another variant (not shown), the support element 3 could comprise a monolithic layer of the closed-cell plastic material which has a plurality of openings that substantially give it the appearance of a grid, preferably with a regular mesh, covering the laying surface 23 of the covering panel 2.

When the flooring is being laid, the covering panels 2 are laid on the base adjacent to each other, and oriented in such a way that around each finishing element 20 a frame complete with gaskets 25 is defined (see Figures 1 and 3). The gaskets 25 space the finishing elements 20 by a predetermined distance which allows any differences of calibre and/or manufacturing tolerances of the finishing elements to be effectively compensated for, and the lateral stresses due to the loads that bear upon the finishing elements 20 to be absorbed.

It is emphasised that if the edges of the finishing element 20 are rectified, and there is therefore no need to compensate for differences in the size and/or manufacturing tolerances of the finishing elements, the gaskets 25 are not strictly necessary. In this case in fact, the projecting walls 24 of the base elements 22 would be sufficient to ensure an adequate space between the covering panels 1.

The securing of each covering panel 2 to the base is the result of the general properties of the material of which the support element 3 is made. In fact when a covering panel 2 is laid, its weight is loaded onto the support element 3, pressing it against the base.

This pressure deforms the polymer foam out of which the support element is entirely made, and the foam expels the air contained within its closed cells thereby creating a suction effect which fixes the covering panel 2 to the base.

In this way, each covering panel 2 can be secured, and if necessary removed independently of all the others simply by applying a force capable of overcoming the cohesive force due to the suction effect.

Further, thanks to the deformability of the support element 3, it is possible to compensate in a simple way for any unevenness of the base.

It must be emphasised that very good results have been obtained by making the support element 3 from PVC foam with a density around 100 kg/m³, an elasticity compression modulus of approximately 1.2 N/cm², and a Shore 00 hardness of approximately 12. A PVC foam with these characteristics is marketed by Saint-Gobain under the trade mark Norseal, model V380. Obviously an expert in the sector could make numerous modifications of a technical/applicative nature to the system of flooring as described, without for this reason forsaking the ambit of the invention as claimed.

For example, it is possible to provide each covering panel 2 with projecting walls 24, and possibly with gaskets 25, on all the lateral edges of the relative finishing element 20, in such a way as to obtain a complete frame surrounding the finishing element 2.

Further, the support element 3 can have different configurations of the strips 30 and blocks 31 , in terms of number, form, dimensions and arrangement.

Finally the covering panels 2 might not include the base element 22, in which case the support element 3 would be fixed directly to the lower surface of the finishing element 20.

In particular, if the finishing element 20 is a ceramic tile provided with the usual geometrical or random profiles that project from its lower surface defining a brand, the support element 3 would preferably be made of blocks of deformable closed-cell material whose thickness is greater than that of the profiles, and the blocks would be fixed to the surface of the tile in the spaces left free by the profiles.

Claims

1. A modular system for covering surfaces, comprising a plurality of covering panels (2) that can be positioned side-by-side in order to provide an external covering of a surface, each covering panel (2) being associated to a support element (3) which covers at least a portion of the laying surface (23) of the covering panel (2), characterised in that the support element (3) is made from a deformable closed-cell plastic material which, after a deforming action, expels air trapped inside the support element (3), giving rise to a suction effect.

2. The system of claim 1 , characterised in that the deformable closed- cell plastic material is a polymer foam.

3. The system of claim 2, characterised in that the polymer foam is a PVC foam.

4. The system of claim 2, characterised in that the density of the polymer foam is between 30 and 300 kg/m³.

5. The system of claim 2, characterised in that an elasticity compression modulus of the polymer foam is between 0.8 and 9 N/cm².

6. The system of claim 2, characterised in that the Shore 00 hardness of the polymer foam is between 10 and 60.

7. The system of claim 1 , characterised in that the support element (3) is between 0.5 and 50 mm thick.

8. The system of claim 1 , characterised in that the at least a support element (3) is secured in direct contact with the laying surface (23) of the covering panel (2).

9. The system of claim 1 , characterised in that the support element (3) comprises a set of elongate strips (30) of the deformable closed-cell plastic material, each of which extends parallel and adjacent to a respective edge of the covering panel (2), in such a way as to give rise to a frame that covers the perimeter areas of the laying surface (23) of the covering panel (2).

10. The system of claim 9, characterised in that the elongate strips (30) are portions of a monolithic body made of the deformable closed-cell plastic material.

1 1. The system of claim 1 , characterised in that the support element (3) comprises a plurality of separate blocks (31 ) of the deformable closed-cell plastic material, which blocks (31 ) cover respective separate portions of the laying surface (23) of the covering panel (2).

12. The system of claim 1 1 , characterised in that the blocks (31 ) are distributed in a matrix-like arrangement.

13. The system of claim 1 , characterised in that the support element

(3) comprises:

- a set of elongate strips (30) of the deformable closed-cell plastic material, each of which strips (30) extends parallel and adjacent to a respective edge of the covering panel (2), such as to give rise to a frame which covers the perimeter areas of the laying surface (23) of the covering panel (2), and

- a plurality of individual blocks (31 ) of the same deformable closed- cell plastic material, which singly cover respective separate portions of the laying surface (23) of the covering panel (2).

14. The system of claim 1 , characterised in that the support element

(3) comprises a monolithic layer of the plastic closed-cell material, which monolithic layer affords a plurality of openings which substantially give the monolithic layer a grid-like appearance covering the laying surface (23) of the covering panel (2).

15. The system of claim 1 , characterised in that each covering panel

(2) comprises a finishing element (20) which remains visible after the covering has been laid.

16. The system of claim 15, characterised in that each covering panel (2) comprises a base element (22) upon which the finishing element (20) is positioned.

17. The system of claim 16, characterised in that the base element (22) is glued to the finishing element (20).

18. The system of claim 16, characterised in that the base element (22) is made of PVC.

19. The system of claim 16, characterised in that the base element

(22) is provided with a projecting wall (24) which extends along at least two contiguous edges of the relative finishing element (20).

20. The system of claim 1 , characterised in that each covering panel

(2) comprises a spacer gasket (25) which develops along at least two contiguous edges of the covering panel (2), the spacer gasket (25) projecting laterally with respect to the contiguous edges.