Abstract:
An replacement floor panel is provided for a raised floor, and includes a top plate with corner-forming sections and leveling legs for height adjustment. Foot-print-expanding brackets engage the leveling legs for extending their foot print outwardly so that the floor panel can be used on different raised floor systems without misalignment problems with stanchion supports. A handle is pivotally mounted in the top plate between a flush position and a raised position for grasping to lift the replacement floor panel, the handle having a decor matching the top plate for aesthetics.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 11/744,341, issuing as U.S. Pat. No. 7,823,340, entitled AIR GRATE FOR RAISED FLOORS, by Mark O. DeJonge et al., filed May 4, 2007, the disclosure of which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to a raised floor panel for a raised floor system such as for a computer room, the floor panels being adapted to mate with various existing systems. 
         [0003]    Raised floor systems allow flexible installation and distribution of cabling and wires, and also allow air conditioning to be funneled under the floor and into the room through apertured panels (also called “air grates”) at selected strategic locations in the room. Improvements are desired to allow replacement floor panels to mate with a wide variety of existing raised floor panel systems, so that the replacement panels don&#39;t have to be customized. Still further, improvement is desired to provide a flush handle, where the panels and their handles are sufficiently sturdy to support substantial weight, yet where the handle is not a trip hazard and is sturdy enough to allow the panel to be lifted and removed without special tooling. It is also desirable to provide a handle that blends into the design of the floor, and that does not result in an unsightly “blemish” in an otherwise visually attractive floor. 
         [0004]    Thus, an apparatus and method having the aforementioned advantages and solving the aforementioned problems are desired. 
       SUMMARY OF THE PRESENT INVENTION 
       [0005]    In one aspect of the present invention, a universal raised floor panel is provided that is configured and adapted for use with different raised floor systems having support stands with different floor-panel support surface configurations, but for use without misalignment problems with the respective support stands of the different raised floor systems. The floor panel includes a top plate adapted to form a part of a selected one of the different raised floor systems, the top plate including support structure for supporting weight on the top plate and including corners. The floor panel further includes corner-attached components at each of the corners including an adjustable leveling leg and bracket with horizontally-enlarged flange engaging the leveling leg. The corner-attached components are adapted and configured to support the floor panel on any one of the different raised floor systems by adjustably extending a foot print of the leveling leg at each one of the corners beyond a size of an end of the leveling leg but without direct attachment of the corner-attached components to any of the differently-shaped floor-panel-supporting support stands. 
         [0006]    In another aspect of the present invention, a universal raised floor panel is configured and adapted for use with different raised floor systems having support stands with different floor-panel support surface configurations, where the floor panel includes a top plate and support structure for supporting weight on the top plate, the top plate including corner-forming sections that extend toward a perimeter of the top plate. The floor panel further includes leveling legs operably engaging the corner-forming sections for height adjustment, and foot-print-expanding brackets engaging the leveling legs for extending the foot print of the leveling legs nearer to outer edges of the top plate so that the floor panel can be used on different raised floor systems without misalignment problems caused by different support stands. 
         [0007]    In another aspect of the present invention, a universal raised floor panel configured and adapted for use with different raised floor systems having support stands with different floor-panel support surface configurations, and includes a top plate and support structure for forming a part of a raised floor system, the support structure supporting the top plate for supporting weight on the top plate and a handle, where the top plate includes marginal material defining an opening shaped to receive the handle. The handle has a top plate section shaped to fit within the opening and is pivotable between a flush position where its upper surface aligns with an upper surface of the top plate so that at most a small gap exists around a perimeter of the top plate section, and a raised position where the handle can be grasp for lifting the floor panel. 
         [0008]    In another aspect of the present invention, a universal raised floor panel configured and adapted for use with different raised floor systems having support stands with different floor-panel support surface configurations, and includes a top plate adapted to form part of a selected one of the different raised floor systems, the top plate including support structure for supporting weight on the top plate and including corners. The floor panel further includes corner-attached components at each of the corners, the corner-attached components being adjustable for vertical height adjustment and also including a bracket with a horizontally-enlarged flange adapted and configured to support the floor panel on any one of the different raised floor systems by extending a foot print of the corner-attached components at each one of the corners beyond a point location but without direct attachment of the corner-attached components to any of the differently-shaped floor-panel-supporting support stands. 
         [0009]    These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0010]      FIG. 1  is a perspective view of an air grate as part of a raised floor system. 
           [0011]      FIGS. 2-4  are top, bottom, and side views of the air grate of  FIG. 1 ,  FIG. 3  being a bottom view with dampener panels installed and  FIG. 3A  a similar view without dampener panels. 
           [0012]      FIG. 5  is a side view of the air grate with dampener panels shown thereon. 
           [0013]      FIGS. 6-7  are side cross-sectional views showing installation of a dampener panel. 
           [0014]      FIGS. 8-9  are perspective bottom and fragmentary bottom views of the air grate showing installation of the dampener skirt and showing the stress-distributing Z-shaped corner bracket. 
           [0015]      FIG. 10  is a cross-sectional view of the air grate including a showing of the leveling leg and the support-engaging stress-distributing Z-shaped corner bracket. 
           [0016]      FIGS. 11-12  are a bottom exploded view and cross-sectional view of the corner arrangement of the present air grate including its leveling leg and Z-shaped corner bracket, and  FIG. 11A  is similar to  FIG. 11  but illustrates an alternative design. 
           [0017]      FIG. 13  is another cross-sectional view showing the present air grate and including its handle. 
           [0018]      FIG. 14  is an enlarged cross-sectional view showing the handle and pivot member, the handle having its top surface apertured to match a pattern of the apertures in the air grate. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0019]    A replacement raised floor panel (illustrated as an air grate  20 , see  FIG. 1 ) is shown embodying the present invention. It is noted that specific dimensions are given to facilitate an understanding of the present invention, but that the present invention is not limited to only those dimensions, nor to only air grates. 
         [0020]    The present air grate  20  is configured for use in a raised floor system as shown in  FIG. 1 , and includes a top plate  21  with apertures  22  for air flow, and includes a matrix of interconnected reinforcement ribs for structural support. Notably, the density of apertures  22  can be increased or decreased depending on the particular requirements of an installation. The illustrated apertures  22  provide up to about 50% open area for air flow. The illustrated ribs include perimeter ribs  23 - 26  ( FIG. 6 ) of a first dimension D 1  (approximately 2 inches high) welded to top plate  21 , first parallel ribs  27 - 33  of a shorter second dimension D 2  (about 1½ inches high) welded to top plate  21 , and shorter second transverse parallel ribs  34  of a third dimension D 3  (about ⅝ inch high) welded between the ribs  23 ,  25 ,  27 - 33  and to the top plate  21  for strength. The ribs  27  and  30  include L-shaped bottom edge flanges  35  and  36  that extend toward each other to define the bottom of a horizontal track for receiving a flat dampener panel  38 . The bottom surfaces of the ribs  28  and  29  form a top of the horizontal track for sliding engagement with the dampener panel  38 . The ribs  30  and  33  include edge flanges (similar to flanges  35  and  36 ) to define a second horizontal track for dampener panels  38 . 
         [0021]    The illustrated dampener panels  38  are flat sheet metal components shaped to temporarily flex to slip between the edge flanges for assembly. However, it is contemplated that the dampener panels  38  can be made of other materials, such as plastic and other non-metal materials. The sheet metal is resilient such that it springs back to an original flat shape (i.e., it “unflexes”), such that its edges engage the track for adjustable movement along the track between different overlapping positions. This allows for very low cost assembly, allows the use of low cost components, and allows for adjustable controlled air flow. The illustrated dampener panels  38  include a single short slot, allowing top adjustment using a tool such as a screwdriver without removing the air grate  20  from the floor. 
         [0022]    The top plate  21  of the air grate  20  includes corner-forming sections  40  ( FIG. 11 ) that include first and second threaded bosses  41  and  42  attached to a bottom of each corner section  40 . In the illustrated arrangement, the boss  41  is attached by welding, and the boss  42  is attached by a friction-fit. However, it is contemplated that other attachment ways could be used if desired. A hole  43  ( FIG. 1 ) extends through the top plate  21  for top access to adjustable leveling legs  44  (also sometimes called “leveling screws”) ( FIG. 11 ). The legs  44  are threaded into the bosses  41 , and include a downward foot that engages a top  71  of a vertically adjustable stand  70  ( FIG. 12 ) for supporting the raised floor system. A foot-print-expanding stress-distributing corner bracket  45  ( FIG. 11 ) is Z-shaped in side view, and includes a first flange  46  retained very loosely slipped onto the boss  42 . A retainer screw  47  captures the flange  46  on the boss but allows the bracket  45  to slip vertically on the boss  42 . The bracket  45  further includes a second perpendicular flange  48  extending from flange  46 , and a third flange  49  extending from flange  48 . The third flange  49  extends under the tip of the leveling leg  44  and extends to an outboard position that is approximately equal to the edge of the top plate  21 . This extends the foot print of the leveling leg  44  outward to the edge of the air grate  20 , allowing the air grate  20  to be used on different raised floor systems without misalignment problems with their respective stands  70  ( FIG. 12 ) and the adjacent existing raised floor panels  73 . 
         [0023]    It is contemplated that the screw  47  can be replaced by various mechanisms to allow movement of the corner bracket  45  during adjustment of the leveling leg  44 . For example, it is contemplated that the boss  42  can be elongated vertically, and that the screw  47  can be replaced with a sleeve  47 ′ ( FIG. 11A ) that slips onto an end of the boss  42 . In this arrangement, the sleeve frictionally engages an outer surface of the boss  42  to retain the corner bracket  45  on the boss  42 . The sleeve  47 ′ can be made of different materials, including for example metal, plastic, or rubber. Where the sleeve  47 ′ has a relatively low friction on the boss  42 , the sleeve  47 ′ can be used to secure the corner bracket  45  tight against a bottom of the top plate  21 , but will slide in a manner that allows the corner bracket  45  to slide downward on the boss  42  as the leveling leg  44  is extended during an installation. This allows the corner bracket  45  to be held securely to facilitate manufacture and shipping, but allows for an “automatic” adjustment of the sleeve  47 ′ during installation. 
         [0024]    The top plate  21  ( FIG. 14 ) includes a rectangular opening  55  in which a handle  56  is pivotally mounted by a spring wire member  57 . The ribs  34  under the opening  55  define a pocket for the handle  56  to rest in when the handle  56  is in a closed flush-to-top-plate position. The handle  56  includes a top panel  58  that aligns with the top plate  21  when the handle  56  is closed. Edge flanges  59  extend from the top panel  58  and stiffen the top panel and also support the handle  56  on the ribs structure thereunder. The spring wire member  57  is generally U-shaped, and includes first and second legs  59 - 60  connected by a transverse section  61 . A pivot-forming section  62  extends from each of the legs  59 - 60 , with each being configured to fit through a hole  62 ′ in the edge flanges  59 ′ and into a mating hole  62 ″ in the adjacent reinforcement rib  34  of the air grate  20 . The spring wire member  57  is sufficiently resilient such that the legs  59 - 60  can be sprung apart for assembly, and when released, they move to the assembled position where they pivotally support the handle  56  in the opening  55 . The pivot axis formed by the pivot-forming sections  62  is such that the handle  56  moves to an over-center position when in the raised position (such that the handle stays open and can easily be grasp in opening  58 ′ for lifting the air grate  20  out of a floor system). However, the pivotal support is sufficiently low-friction, such that the handle  56  can be bumped and easily moved to its lowered, flush, closed position. Notably, the top panel  58  is apertured to match the pattern of apertures in the top plate  21  of the air grate  20 . This provides an aesthetic match which thus avoids an unsightly blemish in the floor surface at the location of the handle. This is highly desirable to many customers, since a uniform and uninterrupted “clean” appearance of floors is important to many customers and users of raised floor systems. 
         [0025]    Dampener skirts  66  ( FIGS. 6-7  and  FIG. 3 ) are placed between the perimeter rib  23  and the adjacent reinforcement rib  27 , and between the perimeter rib  25  and the adjacent reinforcement rib  33  to block undesired air flow if desired. The illustrated dampener skirts  66  are held in position by spring clips  67  that have a first portion that frictionally clips onto the dampener skirt  66  (such as onto the marginal material at a small hole in the skirt) and have a second portion with barbs that frictionally engage one of the ribs  34  under the skirt. 
         [0026]    By the present construction, an air grate is provided that has exceptional weight-bearing strength, yet that can be mated flush to many existing raised floor systems without customization. Dampening can be adjusted easily on-site, and without separate tools, including elimination of one or more of the dampening panels. The leveling legs can be easily and quickly adjusted on-site. The air grate can be easily pulled up from the raised floor system due to the integral handle, yet the overall appearance remains very attractive since the handle does not produce an unsightly blemish in the overall floor appearance. 
         [0027]    It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.