KR20070103475A - Floorboard Sheets and Modular Floorboard Systems - Google Patents

Abstract

The fiber reinforced cement floorboard sheets 1 suitable for use in wet area floorboards are less dense than conventional compressed fiber cement wet area floorboards and can be nailed. The floorboard sheet 1 comprises connecting means 2 on longitudinal edges suitable for use in wet areas, which join the sheets in an interlocking manner with adjacent sheets to form a substantially coplanar support surface. Allow it.

Description

Flooring sheet and modular flooring system

FIELD OF THE INVENTION The present invention relates to floorboards and, in particular, to wet area flooring. The present invention has been developed to provide a basically wet area floorboard, which will be described below with reference to this application. However, the present invention is not limited to this particular scope of use.

The following description of the prior art is intended to place the present invention in an appropriate technical environment, and thus will provide a more complete understanding of the advantages of the present invention. However, any description of the prior art throughout the specification should not be considered as an explicit or implied approval of which the technique is well known or forms part of the common general knowledge in the art.

One known method of laying the foundation for wet area floorboards involves buttling sheets of compressed fiber cement side by side across the required wet area and then attaching the sheets in place. A disadvantage of the compressed fiber cement products currently used in these applications is that they are particularly heavy, making transportation, handling and installation difficult. Moreover, the density of the compressed product impedes effective hydraulic or motorized nailing, and the screw holes must be predrilled and countersinked to secure the seat in place, which is a hydraulic or motorized nail. It takes time compared to nailing.

The butt joint edges of the sheets are typically fixed to joists wherever possible to minimize the relative movement between adjacent sheets. To provide adequate support for the edges and also to reduce the possibility of relative motion between butt joint edges of adjacent sheets, providing support on the trimmer between the bottom joists at corners that are not continuously supported at the floor joists. Is currently being carried out.

Once the floor sheeting is secured and adequately waterproof, the tiles can be placed in a conventional manner. In many situations, the floor cladding is installed directly on the subflooring. Subfloating may include particle boards, compressed boards, OMDs, or other such wood based subfloating products. If waterproofing is not installed correctly, deteriorates over time, or if the defects in the surface and connections become large, water penetrates into the bottom floor cladding, expanding according to the sheet floorboard material. And water effects such as and other mechanisms. This may in turn destroy the finish of the floorboard surface or the integrity of the underlying structure.

In addition to the need to avoid problems associated with moisture absorption after installation, there is a great need for products that resist moisture absorption (moisture resistance) during transportation and storage. For example, compressed fiber cement is generally resistant to moisture damage, but moisture absorption can increase the mass during storage prior to installation, thus increasing transport costs and making handling more difficult. Therefore, means for resisting moisture absorption during storage prior to installation are required for ease of handling, installation and transport.

It is an object of the present invention to solve or ameliorate one or more disadvantages of the prior art, and at least to provide a useful alternative.

Accordingly, as a first aspect, the present invention is suitable for use in wet area floorboards, and is less dense than conventional compressed fiber cement wet area floorboards, and can be nailed into, fiber reinforced cement. bound) provide floorboard sheets.

Preferably, the floorboard material can be nailed by conventional hydraulic or powered nailing equipment.

Preferably, the sheet is strong enough to meet the load conditions for home construction floorboards at support members spaced at 450 mm centers. In one preferred embodiment, the fiber reinforced cement sheet has a dry density of less than about 1.25 g / cm ³ . A fiber-reinforced cement-bonded sheet with a nominal thickness of 19 mm has sufficient bending strength to withstand a uniform load of 5 to 9 kPa when dry or saturated with moisture when supported at a 450 mm center along its length It is preferable.

Typically, the sheet has a front face or an outer face, a back face, and a thickness between the front face and the back face. In addition, the sheet has a corner of a substantially uniform load corresponding to the thickness between the front and rear surfaces. In one preferred form, the sheet described above has at least one surface sealed with a polymer surface coating to impart moisture resistance to at least one surface of the sheet. Typically, the outer surface of the sheet is sealed with a polymer coating. However, the secondary surface or alternative surfaces can likewise be coated, and the entire sheet is coated as a preferred embodiment. The polymer coating is preferably specially formulated to achieve and maintain a strong bond to the tile adhesive and bedding material. The bottom surface of the sheet is preferably configured to bond to a conventional adhesive used to bond the surface of the sheet to the floorboard. At the corners of the sheet it is preferred that the surface coating is configured to bond to the sealant or glue used to connect such sheets.

In another preferred form, the sheet is reinforced with a substantially continuous layer of reinforcing material such as fibers or sheets of metal, plastic, inorganic fibers, polymer fibers, glass fibers, polymer coated glass fibers, or carbon fibers or mixtures thereof. The reinforcement material may be added to the plane of the sheet at any position throughout the sheet thickness and is preferably disposed on or towards the at least one outer surface. The reinforcement material may be unidirectional, multidirectional, spaced, matte or woven. The reinforcing material is preferably embedded in the sheet material during the green forming of the sheet, compressed to the surface of the greensheet article in the green state, or bonded to the surface in the hardened or green state. When glass fiber reinforcements are used, the fibers preferably have a resistant to alkali attack. Alkali-resistant glass or polymer coated glass fibers are examples of suitable materials.

Another aspect of the invention is a modular floorboard system for a wet area, the floorboard system interlocking at least one floorboard sheet as defined above and the floorboard sheet with an adjacent sheet to support substantially coplanar support. A modular floorboard system is provided that includes complementary connection means that allow for forming a face.

In one preferred form, adjacent complementary sheets are also formed as fiber cement and more preferably as density modified fiber cement sheets having a dry density of less than about 1.25 g / cm ³ . In another preferred form, the adjacent complementary sheet is formed as a particleboard.

Preferably, the fiber cement sheet is generally rectangular and the connecting means extend along the longitudinal edges. More preferably, the connecting means extends along both longitudinal edges. In one preferred form, the connecting means has tongue formation and groove formation respectively formed at opposite longitudinal edges of the sheet. In this embodiment, the tongues of one sheet and the complementary grooves of adjacent sheets are well formed to cooperate with each other to allow a firm coupling between the sheets. Various geometries of tongues and grooves are contemplated, with the locking system configured so that the tongue has small protrusions along its length, the grooves corresponding along their lengths to accommodate the protrusions. Consider a shape that is further configured to have a recess.

Preferably, the tongue and the groove are formed along their length between the tongue and the groove so that the glue can be inserted when the tongue and the groove in the contacted sheet are interlocked. In this case the glue serves to bond the connection and / or seal the connection against moisture as desired to waterproof the wet area such as the bathroom floor.

In another preferred form, the connecting means takes the form of complementary elongate joining members configured for simultaneous engagement with grooves formed in opposite longitudinal edges of each sheet and with each adjacent groove of the sheets in contact. .

Preferably, embodiments of the fiber cement sheet disclosed herein have a dry density of less than about 1.5 g / cm ³ . More preferably, the fiber cement sheet has a dry density of less than about 1.25 g / cm ³ .

Embodiments of the fiber cement sheet include elements such as microspheres, pearlite and volcanic ash.

In a particularly preferred form, embodiments of fiber cement sheet constructions include those disclosed in US Pat. No. 6,572,697, entitled "Fiber Cement Building Materials with Low Density Adhesives," the entire contents of which are incorporated herein by reference. It is clearly united. In addition, a preferred fiber cement sheet is implemented according to the embodiment disclosed in US Pat. No. 6,346,146, entitled "Building Product," and also disclosed in Australian Patent AU 515151, entitled "Fiber Reinforced Cement Article." Formulations may be made according to examples, and the entire contents of these patent documents are expressly incorporated herein by reference.

In some preferred embodiments, the average thickness of the fiber cement sheet is preferably between about 10 mm and 30 mm, more preferably between 16 mm and 22 mm. However, in some embodiments the thickness may be smaller or larger than the published thickness but still provides the advantageous properties considered in the disclosed embodiment.

According to another aspect of the present invention, as defined above, comprising aligning two or more floorboard sheets to a support platform and engaging the connecting means in the sheets in contact to form a coplanar support surface. The same modular floorboard system installation method is provided.

Preferably, the sheet is attached to a support surface platform formed by framing members disposed in spaced relation. Various materials can be used to form support surface platforms such as wood, steel or concrete.

The seat is preferably nailed to the support surface platform. However, other fastening techniques such as screws or glue may also be used to attach the sheets in place.

The connecting means at the opposite corners are well formed by machining. However, this can also be achieved by other methods such as casting, extrusion or fastening.

Preferred embodiments of the present invention will now be described by way of example with reference to the accompanying drawings.

1 is a perspective view of a first embodiment of a modular floorboard sheet according to the invention, having a tongue and groove connecting means;

FIG. 2 is a side view of a series of modular floorboard sheets interconnected in the manner shown in FIG. 1; FIG.

3 is a perspective view of an alternative embodiment of a modular floorboard sheet according to the invention, having connecting means in the form of grooves and joint members.

4 is a side view of a series of modular floorboard sheets interconnected in the manner shown in FIG.

Fig. 5 is a plan view showing a uniformly distributed load test apparatus and a sample of floorboard sheets mounted on the test apparatus.

6 is a front view of a portion of the test apparatus of FIG. 5 showing spaced support members for supporting a floorboard sheet sample.

In the drawings, the present invention connects at longitudinally opposite corners such that the sheet 1 is interlocked with adjacent complementary sheets to form a coplanar support surface 3 as shown in FIGS. 2 and 4. Provided is a modular floorboard system comprising at least one rectangular fiber cement sheet 1 with means 2. Adjacent complementarity sheets may be formed as any material with complementary connections, such as other fiber cement sheets or sheets of particleboard.

The connecting means 2 act to resist relative movement between the sheets butt bonded together along the joint, in particular co-planar misalignment. Those skilled in the art (hereinafter referred to as 'skilled persons') will understand that the means of connection may take many different forms. 1 and 2, the connecting means has the form of tongue formations 4 and grooves 5, respectively formed at opposite longitudinal edges of the sheet. Preferably, when the tongue and groove of the contacted sheet are interlocked, a cavity 6 is formed in which the glue can be inserted.

In another preferred form, as shown in Figs. 3 and 4, the connecting means comprises grooves 7 formed in opposite longitudinal edges of each sheet, and respective grooves of the sheet in contact as shown in Fig. 4; And an elongate complementary joint member 8 configured to engage at the same time.

Although the embodiment shown in the accompanying drawings illustrates a connecting means having a square or rectangular geometry, the cooperating tongues and grooves may have any desired shape and are not limited to a given geometry. The connecting means may be formed on the board by any suitable means such as extrusion during the sheet forming process or by machining after sufficient hardening has taken place. Other suitable methods of forming the connecting means are readily apparent to the skilled person.

The fiber cement sheet is preferably less than about 1.5 g / cm ³ , more preferably 1.25 g / cm, while maintaining strength properties that meet the relevant construction standards for sheet floorboards designed to run over floor joists. ^It has a dry density of less than ^three . Many other additives and materials such as density modifiers and strength enhancers can be used in the fiber cement sheet to achieve the required properties such as microspheres, pearlite, volcanic ash, or mixtures thereof.

These features provide the sheet with the strength properties needed for wet area floors. However, the time and cost for transportation and installation are reduced due to the light weight properties of the material compared to the currently available products. Moreover, this type of product eliminates the need to countersink the required screw holes in higher density materials when nails are used to attach the sheets to the underlying joists, thus reducing installation time and costs. Greatly reduced.

In use, the fiber cement sheet reduces the water absorption of the board to reinforce the board and promote the waterproofing properties, before or after curing of the autoclave, a sealant of polymer emulsion or solution and / or water repellent or Sealant mixtures, such as silane, siloxane, wax or stearate, and the like. Coating systems are air dried, multicomponent systems, reactive chemistries, using any curing / drying technique for water based, solvent based, or 100% solids (wet or powder) coating systems. Product curing, forced curing (eg, heat, steam, accelerators), or radiation cured coatings or combinations thereof. In one preferred embodiment, the edges of the sheet are continuously machined to form a connection form. However, in other embodiments, the edges of the sheet are machined or otherwise formed before the coating system is applied such that the edges exhibit the same low water absorption as the sheet surface.

Returning to the method of installation of the system now, initially the structural support platform is composed of wood frame material, steel frame material, concrete base or other suitable means to define wet areas such as bathroom floors. In the embodiment of the present invention shown in FIGS. 5 and 6, the wooden frame member 10 is used to support the joists 11, and the upper surfaces of the joists are gathered to form a floorboard support platform 12.

The sheets are then interlocked through the connecting means and placed across the wet area. The sheets may be connected to each other before being placed on the support platform. However, in the preferred embodiment, the sheets are laid in succession and each is attached to the previous sheet in turn and then to the underlying support platform. In some embodiments, glue is used between the connecting forms to attach the sheets together. There is no need to countersink the threaded holes in the seat when the density of the board can ideally attach the seats into the nail 14 by hydraulic or power nailing. However, if desired, screws can be used to attach the seat to the support subfloor or the underlying framework. Once the studs are attached in place, a suitable waterproof material is disposed on the support surface in a conventional manner. Tiles or other finishing products are then placed.

Excuse me 1

One example of the floorboard sheet described herein was prepared according to the formulation given in Table 1 below. A given formulation represents only one exemplary formulation within the scope of US Pat. No. 6,572,697, entitled “Fiber Cement Building Material with Low Density Additives,” which does not constitute all embodiments of the floorboard sheet disclosed herein. Should be interpreted as not.

TABLE 1

The test has dimensions of 2410 mm x 1210 mm made from 90 mm x 45 mm thick radiata pine frame wood at 450 mm stud centers to confirm the strength of the board described in response to uniformly distributed load (UDL). The wood frame was formed according to AA 1170.1, "AN / NZS Structural design actions-Permanent, imposed and other actions".

The frame was sheeted by a wet area floorboard fiber cement sheet with tongues and grooves as described herein. The sheet used in this example was nominally 900 mm x 1800 mm x 19 mm. The sheet was trimmed to the sample dimensions needed to fit the 1210 mm width of the wooden frame. The resulting sheet was 1200 mm x 900 mm, with the tongue and groove joints extending across the width of the frame at right angles to the longitudinal joists. The layout of the test material and the device of Example 1 is shown in FIGS. 5 and 6.

Uniformly distributed load tests were conducted according to ASTM E72-98, "Standard Test Method for conducting Strength Tests of Panels for Building Construction." Each frame was placed across the horizontal hole of the uniformly distributed load tester and it was ensured that the sample was sealed against the device. Appropriate sealers were applied to ensure an airtight seal between the sample and the peripheral edge of the test chamber.

After the sample is installed in the test apparatus, the air in the laboratory is evacuated, thereby creating a uniformly distributed load on the sample. The applied load is monitored by a water manometer and a pressure transducer connected to the appropriate data acquisition system. The resulting test added suction pressure to the bottom of the test sample and thus produced a uniformly distributed load.

A linear displacement differential transformer (LVDT) 13 was used in conjunction with a computerized data acquisition system to capture deflection data. The LVDT was placed midway between the studs to measure the maximum deflection of the sheet.

The test was run again after the samples were saturated with water per test standard. The edge of the frame was properly sealed to the sample to provide an airtight seal. The frame was then filled with water and a minimum head of water of 25 mm was maintained for at least seven days. The water was then drained and the test was performed substantially as described above. The results of the dry and wet deflection tests are shown in Table 2 below.

TABLE 2

The test continued until the uniform pressure exceeded 9.7 kPa, at which point the pressure was released and the test was completed. According to the above data, the fiber cement wet area floorboards with water-saturated 19 mm tongue and grooves installed at joists at 450 mm centers exceeded the average UDL value exceeding 9.7 kPa, significantly exceeding the 5 kPa condition of AS / NZS 1170.1 Could endure. Moreover, the floorboard sheets and floorboard types described above meet the load concentration activity conditions imposed on the floorboards for home and residential activities described in AS / NZS 1170.1.

Applicants have not previously known that such fiber cement wet area floorboard materials could withstand such high loads and also maintain a dry density of 1.25 g / cm ³ to accommodate installation methods such as nailing. The strength and waterproofness of the fiber cement sheet is also suitable for use in exterior wet areas such as decks and other areas of residential homes that are typically exposed to wet floor areas.

It will be appreciated that the present invention provides a modular floorboard system that is lightweight, nailable, hygroscopic and relatively easy to transport and install. Moreover, the floorboard system herein reduces the need for the use of trimmers, and greatly reduces the likelihood that the chemical structure of the fiber cement sheet will expand when the sheet is in contact with water. In this and other respects, the present invention provides a practical and commercially significant improvement over the prior art.

While the invention has been described with reference to specific examples, those skilled in the art will understand that the invention may be embodied in many different forms.

Claims (37)

A fiber-reinforced cement bonded floorboard sheet suitable for use in wet area floorboards, less dense than conventional compressed fiber cement wet area floorboards, and capable of nailing. The floorboard sheet of claim 1, wherein the sheet is strong enough to meet the load conditions for home construction floorboards in support members spaced 450 mm apart. The floorboard sheet of claim 1, wherein the floorboard sheet has a dry density of less than about 1.5 g / cm ³ . The floorboard sheet of claim 1, wherein the floorboard sheet has a dry density of less than about 1.25 g / cm ³ . The floorboard sheet according to claim 1, wherein the floorboard sheet has a thickness between 10 mm and about 30 mm. 6. The floorboard sheet according to claim 1, wherein the floorboard sheet has a thickness between 16 mm and about 22 mm. 7. The floorboard sheet of claim 1 having a thickness of about 19 mm. 8. The bending according to claim 1, having a bending strength sufficient to withstand a uniformly distributed load of up to 5 kPa when supported at 450 mm centers along the length of the sheet when dry or saturated with moisture. Floorboard sheets. 9. The method of claim 1, having a bending strength sufficient to withstand a uniformly distributed load of up to 9 kPa when supported at 450 mm centers along the length of the sheet when dry or saturated with moisture. Floorboard sheets. The floorboard sheet according to claim 1, wherein the floorboard sheet has at least one surface sealed with a surface coating that provides moisture resistance. The floorboard sheet according to claim 10, wherein said surface coating is formed as a polymer material. 12. The floorboard sheet according to claim 10 or 11, wherein the surface coating is applied to the outer surface of the sheet. 13. The floorboard sheet of claim 10, wherein the surface coating is applied to substantially all surfaces of the sheet. The floorboard sheet according to claim 10, wherein said surface coating is suitable for bonding to tile adhesives and bedding materials. The floorboard sheet according to claim 1, wherein the floorboard sheet is reinforced with a substantially continuous layer of reinforcing material. 16. The floorboard sheet of claim 15 wherein the reinforcing material is formed as one or more materials selected from the group consisting of metals, plastics, inorganic fibers, polymer fibers, glass fibers, polymer coated glass fibers, or carbon fibers. The floorboard sheet according to claim 15 or 16, wherein the reinforcing layer of reinforcing material is disposed between the sheet outer surfaces. 18. The floorboard sheet of claim 17, wherein the reinforcing material is embedded between outer layers during green forming of the sheet. 18. The floorboard sheet of claim 17, wherein the reinforcing material forms an outer layer of the sheet. 18. The floorboard sheet of claim 17, wherein the reinforcing material is inserted between the outer layers of the sheet after curing of the outer layers. The floorboard sheet according to any one of claims 17 to 20, wherein the reinforcing material is configured to have alkali resistance. A modular floorboard system for a wet area, said floorboard system being substantially identical by interlocking at least one floorboard sheet according to any one of claims 1 to 21 with said floorboard sheet with an adjacent sheet. A floorboard system comprising complementary connecting means allowing to form a planar support surface. 23. The floorboard system of claim 22, wherein the adjacent sheet is formed substantially as a particleboard. 23. The floorboard system of claim 22, wherein the adjacent sheet is a floorboard sheet as defined in claims 1-21. 25. A floorboard system as claimed in claim 22, wherein the floorboard sheet is generally rectangular and the connecting means is disposed at at least one longitudinal edge of each sheet. 27. The floorboard system according to claim 25, wherein the connecting means extends along both longitudinal edges of each floorboard sheet. 27. The sheet according to claim 26, wherein the connecting means comprises tongue formation and groove formation respectively disposed at opposite longitudinal edges of each floorboard sheet, wherein the groove portion of the sheet adjacent to the tongue portion of one sheet is formed. Floorboard system that provides a secure interlocking engagement between the seats in cooperative contact. 28. The method of claim 27, wherein the tongue is configured to have a protrusion along its length, and the groove is configured to have a corresponding recess along its length, and wherein the tongue is configured to separate the sheets in contact with the recess. Floorboard system providing a lock mechanism resistant. 29. The floorboard system of claim 27 or 28, wherein a longitudinal cavity is formed between the tongue and the groove that interlocks to allow the sealant or glue to be inserted between the contacted sheets. 27. The joining device of claim 26, wherein the connecting means comprises grooves disposed respectively at opposite longitudinal edges of each floorboard sheet, and complementary joint members configured to engage the grooves to provide a firm interlocking engagement of the contacted sheets. Floorboard system. 31. The floorboard system of claim 30, wherein the joint member comprises an elongated strip of connecting material. 32. The floorboard system of claim 22, wherein the floorboard sheet is substantially formed from a fiber reinforced cement formulation comprising microspheres, pearlite or volcanic ash. 33. A method of installing a modular floorboard system according to any one of claims 22 to 32, comprising the steps of aligning two or more floorboard sheets to a support platform and connecting the sheets in contact to form a coplanar support surface. A method of installing a modular floorboard system comprising coupling means. 34. The method of claim 33, wherein the support platform is formed as spaced framing members. 35. The method of claim 33 or 34, further comprising attaching a floorboard sheet to the support surface. 36. A method according to claim 35, wherein the floorboard sheet is attached to the support surface by fastening means selected from the group comprising nailing, screwing and splicing. 37. A method according to any one of claims 33 to 36, wherein the connecting means is formed using a manufacturing technique selected from the group comprising machining, casting, extrusion and fastening.

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