WO2013190400A1

WO2013190400A1 - A modular panel for the composition of ventilated floors or walls

Info

Publication number: WO2013190400A1
Application number: PCT/IB2013/053175
Authority: WO
Inventors: Mauro Ettore PARIS
Original assignee: Roofingreen S.R.L.
Priority date: 2012-06-22
Filing date: 2013-04-22
Publication date: 2013-12-27
Also published as: ITTO20120552A1

Abstract

A modular panel (10) for the composition of ventilated floors or walls comprises a polygonal plate (11) of plastic material, which forms peripheral mechanical connection protrusions (12) for connecting to other similar modular panels. A first face (13) of the plate has recesses (14) for partially accommodating a certain number of supporting spacers (15) which protrude from the plate so as to bear on an underlying floor or a vertical wall, leaving a ventilated gap between the panel and the floor or wall. A substrate (19) having thermal and acoustic insulation properties is applied to a second, opposite face (17) of the panel. A superficial coating layer (18), visible in use, is applied to the insulating substrate (19).

Description

A modular panel for the composition of ventilated floors or walls

The present invention relates to a modular panel adapted to cover pre-existing floors and/or vertical walls, for the composition of ventilated floors and walls.

The qualities of thermal and acoustic insulation provided by ventilated facades and floors are known and appreciated. The object of the present invention is to provide panels that can offer the advantages of a ventilated floor or facade, with the specific aim of reducing assembly costs, facilitating, in particular, the coupling of the panels to other similar panels, and simplifying the operations of installation and maintenance of the resulting ventilated surface. Another object is to provide a ventilated floor or vertical wall having a high level of thermal and acoustic insulation.

These and other objects and advantages, which will be made clearer below, are achieved according to the invention with a panel having the features defined in Claim 1. Preferred embodiments of the invention are defined in the dependent claims.

A few preferred, but non-limiting, embodiments of the invention will now be described, with reference to the attached drawings, in which:

- Figure 1 is a perspective view of a panel with a supporting spacer;

Figure 2 is a perspective view showing the lower face of the panel of Figure 1 ;

Figure 3 is a perspective view showing the panel of Figure 1 with a first type of external superficial coating;

Figure 4 is a partial view of a ventilated floor, produced by the combination of a plurality of coated panels, of the type shown in Figure 3;

Figure 5 is a perspective view of another embodiment of a panel, provided with a second type of external superficial coating;

Figure 6 is an exploded schematic perspective view of the panel of Figure 5;

Figure 7 is an exploded schematic perspective view of a panel and of an accessory for mechanical connection between the panels;

Figure 8 is an exploded perspective view of a supporting spacer and of a recess in which the spacer is partially accommodated; Figure 9 is a perspective view of two different supporting spacers of different heights, to allow coarse adjustment;

Figures 10, 11 and 12 are plan views of a face of the panel in which various possible configurations of the supporting spacers are shown schematically;

- Figure 13 is a perspective view of a type of supporting spacer having an adjustable height;

Figure 14 is a perspective view of another type of supporting spacer having an adjustable height; and

Figure 15 is a view in vertical section which schematically shows two panels fixed to a vertical wall, for the composition of a ventilated vertical wall or facade.

Referring initially to Figures 1 to 4, the number 1 1 indicates a polygonal plate of plastic material forming part of a modular panel for the composition of a ventilated floor. This ventilated floor is adapted to rest on a pre-existing floor, so as to form a ventilated gap between the underlying floor and the panels. The same panel can also be used to construct a ventilated facade or at least a portion of ventilated vertical wall, supported on a vertical wall located behind it.

The plate 11 forms, in one piece, a multiplicity of peripheral interlocking formations 12 which serve as mechanical connection means for connecting to other similar modular panels. In the present example, the mechanical connection means 12 include dovetail formations; in other embodiments, the peripheral connection means may have different shapes, for example rounded lug shapes or L- or T-shapes, provided that they can be coupled to peripheral recesses formed between adjacent complementary protrusions of an adjacent panel. The specific shape of the connection means 12 is not to be considered as limiting the invention.

Figure 2 shows a first face 13 of the plate 11, which in the present example is the lower face of the panel, adapted for facing, in use, a pre-existing floor. The face 13 has a plurality of recesses 14, in which supporting spacers 15 can be partially accommodated. In the assembled condition, each supporting spacer protrudes partially from the plate 1 1 , or more precisely from the face 13 of the plate 1 1 , and serves to hold the panel at a distance from an underlying floor, or from a vertical wall, thus leaving a ventilated gap 16 between the panel and the aforesaid floor or wall.

An intermediate insulating substrate 19, made of a material having thermal and acoustic insulation properties, is applied to the second face 17 of the plate 11, as shown in Figure 1. A superficial coating layer 18, visible in use, is applied to the insulating substrate 19 (Figure 3). For a ventilated floor, the coating layer 18 is turned upwards and forms the surface of the panel to be walked on; if the panel is to be used as a covering panel for a vertical ventilated wall, the superficial coating layer forms the surface visible to an observer.

The superficial coating layer 18 can form a surface for pedestrian or vehicular traffic, and may comprise, according to requirements, one of the materials included in the following non-exhaustive list: synthetic turf; natural or artificial stone; a ceramic material, preferably stoneware; resilient materials such as PVC, linoleum or rubber; natural wood or composite wood (WPC); walk-on glass; and walk-on photovoltaic or solar thermal panels. In the example of Figures 3 and 4, the superficial coating layer 18 is made of synthetic grass. The mechanical connection means 12, by means of which a plurality of panels of the type shown in Figure 3 are mutually interlocked, can be used to construct a ventilated floor, as shown in Figure 4.

In the example shown in Figure 5, the superficial coating 18 comprises a set of parallel strips 18a of wood-plastic composite material, known by the trade name WPC, or of other materials. Advantageously, the superficial coating may be thin, so as to limit the overall cost of the panel and the floor. The superficial coating, of WPC or other material, can be applied equally well either before or after the installation of the panel.

The substrate 19 includes at least one material having thermal and acoustic insulation properties. The type of insulating material used for the substrate 19, and particularly its density, as well as the thickness of the substrate, may vary according to the desired physical and technical performance, particularly according to the level of thermal and/or acoustic insulation, and, if appropriate, the degree of resilient yielding. For example, the following materials are suitable: cross-linked expanded polyethylene, extruded expanded polyethylene, extruded expanded polystyrene, extruded expanded polypropylene, cross- linked expanded polypropylene, sintered expanded polystyrene, and nanoporous solids produced by nanotechnology (such as Aerogel). The preceding list is not exhaustive.

In order to provide a more effective shielding action against solar radiation and/or protection from electromagnetic pollution, the insulating substrate 19 may include one or more sheets 19a of aluminium or of materials having shielding properties (Figure 3). In one embodiment, the insulating substrate 19 may be divided into two or more superimposed layers. In the example of Figure 3, the insulating substrate 19 may comprise two superimposed substrates 19b, 19c of insulating material, of which the upper substrate 19c, closer to the superficial layer 18, is relatively more rigid than the underlying, more yielding, substrate 19b. The greater rigidity or mechanical strength of the upper substrate 19c serves to prevent damage to the panel by pointed objects such as shoe heels. The sheets of aluminium 19a or other shielding material can be interposed between the different substrates 19b and 19c. The thickness of each of the two substrates, each of which may be, for example, about 8 mm thick, and the density of the constituent material (for example, 30 to 100 kg/m³) may vary according to the desired level of thermal insulation.

The insulating substrate 19 may be joined permanently both to the superficial layer 18 and to the plate 1 1, for example by means of adhesive or by heat or infrared bonding. Alternatively, the insulating substrate 19 may be coupled to the superficial layer 18 and to the plate 1 1 by mechanical connection means.

In an alternative embodiment (Figure 6), the superficial coating 18a may be joined to the second face 17 of the plate 1 1 in a detachable way, for example by using a plurality of pins or other engagement members 20, received in holes 21 formed, respectively, in the second face 17 of the plate 11 and in a face of the coating placed next to the second face 17.

The second face 17 can be penetrated by channels 22 so as to allow rainwater to run through. As shown in Figure 2, the recesses 14, in one embodiment, are formed in part by the first face 13 of the panel, and in part by a plurality of ribs 24, 25 protruding from the face 13. In the illustrated example, the ribs comprise a first set of parallel ribs 24 extending in a given direction, and a second set of parallel ribs 25 which intersect the first set of ribs 24 in a substantially perpendicular direction.

In the embodiments shown here, the panel has a generally square or rectangular shape (in plan view), and the ribs extend parallel to the principal dimensions of the rectangle. In other embodiments, the panel may have a polygonal shape other than a rectangular or square shape, for example a triangular or hexagonal shape, or any other shape, provided that the panels can be combined to form a ventilated surface. In further different embodiments (not shown), the ribs may be orientated parallel to the diagonals of the panel.

The ribs 24, 25 help to define the recesses intended to accommodate the supporting spacers, while also preferably extending continuously along the whole of the first face 13 of the plate, thereby stiffening it to oppose bending and cutting. This extension is preferable but not strictly essential, especially if the panel is intended to build a vertical wall, rather than a horizontal walk-on floor. Even if the panel is to be used to build a floor, in the absence of continuous stiffening ribs the bending or deflection of the panel can be limited by additionally distributing the supporting spacers 15 suitably in one or more recesses 14 located near the centre of the panel. It is also possible to provide ribs (not shown) orientated in diagonal directions.

In one embodiment, the supporting spacers 15 are made of plastic material, and each of them comprises a body protruding perpendicularly from the plate 1 1 and having a cross section with an outer contour matching a cross section of a respective recess 14, when viewed in a section plane parallel to the faces of the plate.

In the embodiment shown in Figure 6, the body of each spacer has a prismatic portion 26 (with a rectangular or square cross section in this example), matching the cross section of the recesses 14 into which the spacers are to be partially inserted. It is possible to design the spacers 15 and the recesses 14 in relation to each other in such a way that the spacers are inserted and locked by an interference fit in the respective recesses.

In the embodiment shown in Figure 7, an accessory member 33 for improving the mechanical joint between two adjacent panels is also shown. The member 33 has a generally elongate shape in a perimetric direction, and has a base 34, from one side of which there protrude two alternating sets of formations 35, 36, adapted to engage, respectively, in the empty spaces 12a (Figure 2) between two consecutive connection means 12, and in the recesses 12b formed by each of the connection means or protrusions 12. The formations 36 are housed in the recesses 12b of the connection protrusions of the adjacent panel when the latter is coupled. Thus both panels bear on the support plane defined by the base 34, which provides better coplanarity between two consecutive panels, and improves the coupling, if the floor is intended to bear on a surface (such as a sandy surface) requiring greater integration between two consecutive panels. In addition to the interference fit, and/or as an alternative thereto, the spacers and recesses of the plate, particularly in the ribs of the plate, may be provided with respective releasable locking means and seats, for example in the form of protruding pins or bosses 27 (Figure 8) and respective housing holes 28, in which the pins or bosses are locked by snap-fitting when the spacers are inserted into the recesses 14 of the plate 1 1.

In one embodiment, in order to make the supporting spacers 15 more stable, each of them has a bottom wall 29 (Figure 9) which closes one end of the prismatic portion 26.

As shown schematically in Figure 10, the shapes and dimensions of the cross sections of the recesses and of the supporting spacers may match each other without being identical to each other. For example, the spacers may be made with cylindrical portions 26 which can be inserted into the recesses 14, and which have a diameter equal to the side measurement of the recesses. In this case, the recesses have a square cross section. The distribution and number of supporting spacers is chosen according to the load requirements (Figures 1 1 and 12). Similarly, the length of the spacers is selected according to the thickness of the ventilated gap that is to be provided. Purely by way of example, the supporting spacers may protrude from the plate for a distance in the range from 2 - 3 to 10 cm.

With reference to Figure 13, in an alternative embodiment, the spacers comprise, in addition to the body of plastic material, a foot 30 which is adjustable in a direction perpendicular to the plate, and which can bear on the underlying floor or the vertical wall on which the ventilated surface is to be provided. The foot 30 may be adjusted, for example, by means of a threaded coupling 31. In a further embodiment (Figure 14), each spacer 15 may comprise two tubular cylindrical members, in the shape of sleeves for example, coupled coaxially by a threaded means, of which one (26) is engaged in a recess 14, while the other (30) serves as an adjustable bearing foot. The cylindrical threaded members 26, 30 may be tubular members open at both of their ends or closed at one of their ends by a base wall (not shown in Figure 14, but similar to the wall 29) to increase the rigidity and the support surface. The adjustment should allow the total length of the spacer to be varied from a few millimetres to about 1 to 2 cm at the most. In order to obtain considerably larger or smaller overall lengths, it is preferable to choose a longer or shorter supporting spacer. In order to provide a vertical ventilated wall, as shown in Figure 15, it is convenient to use cup-shaped spacers, whose base walls 29 can be used for fixing, by means of fastening members F, to brackets S or other support devices fastened to a pre-existing vertical wall P. The invention can also be modified in respect of the shapes, dimensions, and arrangement of parts, the details of construction and the materials used. For example, the number and arrangement of the ribs or the recesses may be varied according to requirements, with the aim of distributing and spreading the loads acting on the panels. In the same way, the supporting spacers may be made as members elongated in a dimension parallel to one of the sides of the plate. It is to be understood that each embodiment may be combined with any other embodiment. Furthermore, the invention is not limited to the embodiments described, but may be modified within the scope defined by the appended claims.

Claims

1. A modular panel (10) for the construction of ventilated floors or walls, characterized in that it comprises:

a polygonal plate (1 1) of plastic material, which forms peripheral mechanical connection means (12) for connecting to other similar modular panels, a first face (13) of the plate providing a plurality of recesses (14), and a second face (17) of the plate, opposite the first face (13);

a plurality of supporting spacers (15) partially accommodated in the recesses (14) of the first face (13) and partially protruding from the plate so as to bear on an underlying floor or a vertical wall, so as to leave a ventilated gap between the panel (10) and the floor or wall;

at least one intermediate insulating substrate (19) made of a material having thermal and acoustic insulation properties, applied to the second face (17) of the plate (11), and a superficial coating layer (18) visible in use and applied to the insulating substrate

(19).

2. A panel according to Claim 1, wherein the material of the insulating substrate (19) is chosen from among the following: cross-linked expanded polyethylene, extruded expanded polyethylene, extruded expanded polystyrene, extruded expanded polypropylene, cross-linked expanded polypropylene, sintered expanded polystyrene, and nanoporous solids.

3. A panel according to Claim 1 or 2, wherein the panel includes one or more sheets of aluminium (19a) or of other material having shielding properties.

4. A panel according to Claim 1, 2 or 3, wherein the insulating substrate (19) is divided into two or more superimposed substrates (19b, 19c), of which a first substrate (19c), closer to the superficial coating layer (18), is more rigid than a second substrate (1 b), farther from the superficial coating layer (18).

5. A panel according to Claims 3 and 4, wherein at least one sheet of aluminium (19a) or of other material having shielding properties is interposed between two superimposed substrates (19b, 19c) of the insulating substrate (19).

6. A panel according to Claim 1, wherein the recesses (14) are formed in part by two sets of ribs (24, 25) which protrude from the first face (13) of the plate (11), a first set of parallel ribs (24) being oriented in a first given direction, and a second series of parallel ribs (25) being oriented in a second direction perpendicular to said first given direction.

7. A panel according to Claim 6, wherein at least some of the ribs (24, 25) are stiffening ribs which extend continuously between two opposite sides of the first face (13) of the plate.

8. A panel according to Claim 1, wherein the supporting spacers (15) each comprise a body of plastic material having a cross section with an outer contour matching a cross section of one of the recesses (14), when viewed in a section plane parallel to the faces (13, 17) ofthe plate (l l).

9. A panel according to Claim 8, wherein the body of each of the supporting spacers (15) has a prismatic or cylindrical portion (26) partially insertable into a respective recess

(14) ofthe plate (l l).

10. A panel according to Claim 1, wherein each supporting spacer (15) comprises an element (30) which is coupled to the body of plastic material in an adjustable manner, preferably by a threaded means, in a direction perpendicular to the plate (1 1), and has a surface for resting on an underlying flooring or a vertical wall.

1 1. _' A panel according to Claim 1, wherein the superficial coating layer (18) is chosen from among the following:

synthetic grass; natural or artificial stone; ceramic materials; resilient materials; natural wood; a wood-plastic composite material (WPC); walk-on glass; and walk-on photovoltaic or solar thermal panels.

12. A ventilated floor or vertical wall comprising a plurality of modular panels (10) according to any of the preceding claims.