Floor

Abstract: Floor, more specifically sports floor, which contains a springy under-layer (2), a pressure dividing layer (3) lying thereon which exists of plates which are harder than the springy under-layer (2) and a top layer (4) applied on this pressure dividing layer (2), characterized in that the pressure dividing layer (3) exists of one layer of plates which are made of synthetic particles - bound together with a moisture-proof binder under high pressure and temperature - with a closed cell structure and glued together by their edges by means of a moisture-proof glue.

Description: The invention relates to a floor, more specifically to a sports floor, containing a springy under-layer, a pressure distributing layer which lies on top thereof and consists of a single layer of plates from synthetic material which are harder than the springy under-layer and which are glued together with their edges, and a top layer applied on this pressure distributing layer. Floors of the above-mentioned kind with a springy under-layer, a pressure distributing layer and a top layer offer at the same time a large force breakdown, a small energy loss and a large ball reflection and are therefore often used as a sports floor. A floor of this kind is disclosed in DE-A-2.623.321. The pressure distributing layer consists of plates made, particularly by injection molding, from hard polyethylene foam. The plates are relatively expensive and have a limited thickness (in the forms of embodiment with a single layer of plates, a thickness of 3 mm). The edges of the plates are simply overlapping and overlapping parts are glued together. To obtain an efficient glueing, both tooth have to be pressed together until the glue has set sufficiently, which complicates the manufacturing of the floor. The invention aims at remedying these disadvantages and providing a floor, more specifically a sports floor, which is simple in construction and relatively cheap, but does have the desired properies which make it appropriate as a sports floor and more specifically has the correct elasticity and bending in horizontal direction and is insensitive to moisture. To this end, the plates of the pressure distributing layer consist of compressed synthetic foam particles with a closed cell structure, bound together with a moisture-proof binder and with a density of at least 600 kg/m³, and that the edges which are glued together are connected by means of a tooth-and-groove connection and are glued by means of a moisture-proof glue. The synthetic particles with closed cell structure can be granulates, and be for instance refuse matter from the synthetic foam material industry. In a particular embodiment of the invention, the edges of the plates of the pressure distributing layer are connected by means of a at least a double tooth-and-groove connection. The pressure distributing layer lies preferably loosely on the springy under-layer. Practically, the plates of the pressure distributing layer are glued together by their edges by means of one component polyurethane glue. Practically, the top layer is made of PVC, linoleum of polyurethane. In an advantageous embodiment of the invention, the floor contains a moisture screen under the springy under-layer. Other particularities and advantages of the invention will show from the following description of floors according to the invention. This description is only given as an example and does not limit the invention. The reference numbers concern the accompanying drawings, wherein: Figure 1 represents a top down view with partial cut-outs of a floor according to the invention; figure 2 represents a cross-section according to line II-II in figure 1 but on a larger scale; figure 3 represents a cross-section according to line III-III in figure 1 but on a larger scale; In figures 1 to 3, a floor according to the invention is represented which mainly consists of a moisture screen 1, a bottom springy under-layer 2 lying loosely on top thereof, a single-layered pressure distributing layer 3 lying loosely on top of this under-layer 2 and a top layer 4. The floor is of the floating type and lies loosely on an under-floor 5. The floor is surrounded along the entire circumference by a skirting which connects against the wall and is formed of an aluminium corner-profile 6 in combination with a hollow rubber lock-up profile 7. The moisture screen 1 exists of a PVC foil with high vapourtightness and tearing resistance and with a thickness of 0.5 mm. This screen exists of breadths of which the overlapping edges are glued together. Along the circumference of the floor, this moisture screen is folded upwards vertically and secured to the top layer 4 by means of the skirting 6, 7. The springy under-layer 2 exists of flakes of supple polyether or polyurethane foam which are bound together by means of a moisture-proof binder. This under-layer 2 has a specific gravity or density of 80 to 120 kg/m³ and a thickness of 10 to 20 mm. The under-layer 2 may eventually be made fire delaying. This kind of foam layers, mostly made of refuse matter of the synthetic foam industry, are available in commerce as such. They are used as isolation material, packing material or substrate for hydroculture. The pressure distributing layer 3 exists of one single layer of plates 8 which are placed next to each other, and glued together by their edges, and which are formed of polyurethane chips or a polyurethane granulate, for example of polyurethane hard foam refuse ground to a maximum size of 1 cm³. The chips or pellets are bound together under high pressure and temperature with a special moisture-proof binder, for instance on the basis of isocyanate. The chips or pellets have a closed cell structure which makes them insensitive to moisture. The plates have a density of minimum 600 kg/m³, for example 1000 kg/m³. The density and therefore also the hardness of the plates of the pressure distributing layer 3 are thus greater than the density and hardness of the springy under-layer 2. The plates 8 are rectangular so that they can be placed in patterns. Their thickness is about 20 mm. They are connected together by their edges by means of a glued tooth-and-groove connection 9, 10. One long and one short edge are thereto provided with a tooth 9 and a groove 10, whereas the other edges are provided with a corresponding groove 10 and a tooth 9. It is best to avoid continuing seams. Therefore, the plates 8 are preferably placed in a diagonal or herring-bone pattern as represented in figure 1, although other patterns are possible. Of course, insofar as necessary in case of a diagonal pattern, along the circumference parts of plates 8 are placed which can be obtain by sawing plates 8. The edges of the plates 8 are glued together with a moisture-proof glue, namely a foaming one component polyurethane glue which hardens under influence of the air humidity. This glue is applied to the teeth 9 and/or grooves 10 before the plates 8 are slid together with these teeth 9 and grooves 10. The pressure distributing layer 3 lies loosely on the springy under-layer 2 which is in its turn placed loosely on the moisture screen 1. A foil made of synthetic material may be placed between the layers 2 and 3. The top layer 4 exists in one embodiment of a supple, homogeneous one-layered PVC-covering with frosted smooth surface structures and a thickness of 2 mm. In an other embodiment, the top layer 4 exists of a supple one-layered linoleum with a thickness of 2; 2.5; 3.2; or 4 mm. In still another embodiment, the top layer 4 consists of supple polyurethane This top layer 4 is glued on the pressure distributing layer 3. The floors described above have a shock absorption of at least 60% and a large power breakdown with little stress as well as with large stress. The energy loss is very small and ball reflection very large. Also due to the high wear resistance and mechanical strength of the top layer 4, especially when it is made of linoleum, the floor is appropriate for all sports, even roller skating. Moreover, non-sporting activities can take place on this floor without problems, such as stage performances, exhibitions, festivities and dancing manifestations. The floor not only has unique sport-technical properties with optimal safety, but also a long life-span. It is very simple to maintain, has strong isolating properties and can easily be applied on an existing floor provided a flatness tolerance of 3 mm on 3 m. The present invention is in no way limited to the embodiments described above and represented in the drawing, but many alterations can be applied to the embodiments within the scope of the claims. More specifically, the top layer need not be a PVC covering, linoleum or polyurethane. Other top layers are possible. The skirting construction is no essential part of the invention and can be left out or of an other construction.

Claims: Floor, more specifically sports floor, which contains a springy under-layer (2), a pressure distributing layer (3) lying thereon which is comprised of a single layer of plates (8) of synthetic material which are harder than the springy under-layer (2) and the edges of which are glued together, and a top layer (4) applied on this pressure distributing layer (3), characterized in that the plates (8) of the pressure distributing layer (3) consist of compressed synthetic foam particles with a closed cell structure, bound together with a moisture-proof binder and with a density of at least 600 kg/m³, and that the edges which are glued together are connected by means of a tooth-and-groove connection (9-10) and are glued by means of a moisture-proof glue. Floor according to the preceding claim, characterized in that the edges of the plates (8) of the pressure distributing layer (3) are connected together with at least a double tooth-and-groove (9-10) connection. Floor according to the preceding claim, characterized in that the double tooth-and-groove connection (9-10) between two edges comprises at least one tooth (9) and at least one groove (10) on each of the edges. Floor according to either one of the preceding claims, characterized in that the presure dividing layer (3) lies loosely on the springy under-layer (2). Floor according to either one of the preceding claims, characterized in that the synthetic particles of the composite pressure dividing layer (3) are polyurethane particles. Floor according to claim 5, characterized in that the plates of the pressure distributing layer (3) are made of polyurethane hard foam refuse, ground to a maximum size of 1 cm³. Floor according to either one of the preceding claims, characterized in that the plates (8) of the pressure distributing layer (3) are glued together by their edges by means of one component polyurethane glue. Floor according to either one of the preceding claims, characterized in that the plates of the pressure distributing layer (3) have a thickness of almost 20 mm. Floor according to either one of the preceding claims, characterized in that the springy under-layer (2) is a layer of bound flakes of synthetic foam. Floor according to either one of the preceding claims, characterized in that the top layer (4) is made of one of the substances formed by PVC, linoleum and polyurethane. Floor according to either one of the preceding claims, characterized in that the top layer (4) is glued on the pressure distributing layer (3). Floor according to either one of the preceding claims, characterized in that it contains a moisture screen (1) under the springy under-layer (2). Floor according to either one of the preceding claims, characterized in that between the springy underlayer (2) and the pressure distributing layer (3) a synthetic foil is applied.

Inventors: WAUMANS ANDRE, WAUMANS, ANDRE, Waumans, André
Applicants: TOPFLOOR NAAMLOZE VENNOOTSCHAP, TOPFLOOR, NAAMLOZE VENNOOTSCHAP
Application year: 1992
Main classification: E04F15
IPC codes: E04F15