Patent Publication Number: US-2003230041-A1

Title: Prefabricated aggregated floor panel device and system and method for making and installing aggregated panels

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
     [0001] This application claims the benefit of provisional application Serial No. 60/388,993 filed Jun. 14, 2002. 
    
    
     
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002] N/A  
       COPYRIGHT NOTICE  
       [0003] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights rights whatsoever.  
       BACKGROUND OF THE INVENTION  
       [0004] 1. Field of the Invention  
       [0005] This invention relates generally to prefabricated aggregated floor panels, and more particularly, to a prefabricated terrazzo panel device and system and method for making and installing prefabricated terrazzo panels.  
       [0006] 2. Description of the Background Art  
       [0007] Aggregate floors, such as terrazzo, are well known in the art. Terrazzo is a form of mosaic flooring that consists of small pieces of marble or granite set in mortar and given a high polish. Binding agents are used to anchor marble, granite or other aggregate chips in the terrazzo floor. Three types of binders are used, which include cement, cement with an acrylic additive, and epoxy.  
       [0008] Terrazzo floors known in the art are poured and set on a supporting floor structure at the desired site of installation within set boundaries. Conventional terrazzo flooring and methods for making same are expensive and time consuming. The costs and time involved in creating terrazzo flooring are high because the floors must be formed and poured at the site of installation. Conventional methods for creating terrazzo flooring do not include prefabricating terrazzo panels. Based on conventional techniques, terrazzo panels cannot be prefabricated because they adhere to the supporting substrate when curing and are difficult to join without seams. If, however, terrazzo panels could be prefabricated off-site into panels it would facilitate more cost and time effective installation. In addition, it would be even more attractive if prefabricated panels could be joined without seams between their edges.  
       [0009] As noted in U.S. Pat. No. 5,339,589, terrazzo floors are constructed in accordance with well-established principles and methods. Conventional methods include placing a foundation layer of material composed of concrete on the ground or floor. A screed bed having divider strips are then installed over the foundation layer forming panels into which a mixture of cement, water and terrazzo aggregate is poured. A screed bed is a mixture of sand, cement and water and brings the foundation substrate layer closer to level, absorbs horizontal movement between the building structure and the aggregate surface, and serves as a setting bed for the panel forming divider strips. The divider strips serve as a gauge for leveling the floor and provide expansion joints and control paths for cracks. The resulting pour must be quickly leveled with a trowel to the top of strips. Thereafter matching aggregate is sprinkled over the surface, which is then compacted and compressed with static rollers. The rollers force out any trapped air and excess cement, and compact the aggregate to the greatest possible density. Once the mixture cures, it is polished so that the aggregate, usually marble, contained therein becomes decorative and formal in appearance.  
       [0010] This conventional process and similar processes have disadvantages. For instance, the leveling and compacting of the aggregate must be completed in a limited period of time before curing begins. Accordingly, a terrazzo floor must be poured in sections so that one section can be completed before a new section is started. In addition, the floor must be poured on cite. Consequently, constructing terrazzo floors is slow and labor-intensive. Other attempts have been made to address the above noted drawbacks, but have failed to realize adequate success. If a device and system existed that was more reliable, more efficient and less expensive it would be well received. The instant invention addresses this unfulfilled need in the prior art.  
       BRIEF SUMMARY OF THE INVENTION  
       [0011] In light of the foregoing, it is an object of the present invention to provide a prefabricated terrazzo or terrazzo-like panel.  
       [0012] It is another object of the instant invention to provide a terrazzo panel that can be prefabricated prior to installation.  
       [0013] It is an additional object of the instant invention to provide a process for manufacturing prefabricated terrazzo or terrazzo-like panels that can be transported to and installed at a remote site.  
       [0014] It is also an object of the instant invention to provide a method for installing prefabricated terrazzo or terrazzo-like panels.  
       [0015] It is a further object of the instant invention to provide a method for manufacturing prefabricated terrazzo or tertazzo-like panels that alleviates the problem of adherence to the supporting substrate during the curing process.  
       [0016] It is an additional object of the instant invention to provide a method for installing prefabricated terrazzo or terrazzo-like panels with virtually no seams between adjacent panels.  
       [0017] It is another object of the instant invention to provide an oral pharyngeal evacuation endotracheal tube that has a central valve in communication with a vacuum source for aspirating pooled secretions above the cuff.  
       [0018] It is a further object of the instant invention to provide a locking strip that facilitates the joining and seamless joining of adjacent terrazzo or terrazzo-like panels.  
       [0019] In light of these and other objects, the instant invention comprises a prefabricated terrazzo panel and system, method for making terrazzo panels and method for installing terrazzo panels. The panels comprise terrazzo epoxy, a top surface, a bottom surface, sides and a groove along each side. The panels are fabricated from a terrazzo epoxy or terrazzo like material. The panel system comprises a plurality of panels, locking strips that join adjacent panels and terrazzo or terrazzo-like filler for joining and creating a seamless joint between adjacent panels. The system of the invention generally comprises a plurality of panels, locking strips for joining adjacent panels and terrazzo, terrazzo-like and, or epoxy filler adapted for providing a seamless joint. The method of manufacturing the panels generally comprises providing, installing and, or preparing borders on a flat, level horizontal structure, applying an epoxy primer having a high viscous consistency similar to a paste to the supporting structure to prevent adherence of the terrazzo epoxy to the supporting structure during curing, preparing and, or introducing previously prepared epoxy terrazzo or comparable aggregate mixture into the border volume, leveling the pour mixture, allowing it to cure, grinding the surface of the cured aggregate to a desired thickness, sanding and polishing the top surface, and cutting the cured terrazzo into panels having predetermined dimensions and preparing the panels for installation. The method of installing prefabricated terrazzo panels comprises applying an epoxy primer to the selected floor surface, applying a coat of setting material having fine powder and, or marble dust fillers that achieve proper consistency to the floor surface with a notched trowel, aligning and setting panels and locking strips on the prepared floor surface in a manner that places the locking strip heads in the panel grooves, filling any voids including voids between panels with a terrazzo epoxy filler or similar filler, allow setting time, grinding the filler flush with the top surface of the panels and polishing the top surface of the panels and joints. 
     
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
     [0020]FIG. 1 is a perspective view of the preferred embodiment of the prefabricated terrazzo panel in accordance with the instant invention.  
     [0021]FIG. 2 is an end view of the preferred embodiment of the prefabricated terrazzo panel in accordance with the instant invention.  
     [0022]FIG. 3 is a perspective view of the preferred embodiment of the locking strip in accordance with the instant invention.  
     [0023]FIG. 4 is an end view of the preferred embodiment of the locking strip in accordance with the instant invention.  
     [0024]FIG. 5 is an end view of the preferred embodiment of the prefabricated terrazzo panel and locking strip as joined in accordance with the instant invention.  
     [0025]FIG. 6 is an end view of the preferred embodiment of the prefabricated terrazzo panel and locking strip system in accordance with the instant invention.  
     [0026]FIG. 7 is a perspective view of the preferred embodiment of the system for making prefabricated terrazzo panels in accordance with the instant invention.  
     [0027]FIG. 8 is an end view of the preferred embodiment of the system for making prefabricated terrazzo panels in accordance with the instant invention.  
     [0028]FIG. 9 is a plan view of an alternative embodiment of the system for making prefabricated terrazzo panels in accordance with the instant invention.  
     [0029]FIG. 10 is a plan view of the alternative embodiment of the prefabricated terrazzo panel in accordance with the instant invention.  
     [0030]FIG. 11 is an end view of an alternative locking strip used in accordance with the system of the instant invention.  
     [0031]FIG. 12 is an end view of the preferred embodiment of the prefabricated terrazzo panel and alternative locking strip in accordance with the instant invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0032] With reference to the drawings, FIGS.  1 - 12  depict the preferred and alternative embodiments of the instant invention which is generally referenced as a prefabricated panel and, or system and, or method for making and, or method for installing prefabricated panels and, or by numeric character  10 . Referring to FIGS.  1 - 12 , the instant invention comprises a prefabricated panel or tile  10 , panel system  10 ,  20 ,  30 ,  40 ,  50  process and system for making aggregated floor panels  100 ,  110  and process for installing the prefabricated aggregated floor panels  10 . The prefabricated panels preferably comprise a terrazzo or terrazzo-based tile that may be installed on a floor surface, wall surface or other flat substrate. The panel system  10 ,  20 ,  30 ,  40 ,  50  comprises the components used to form and that facilitate installation of the panels  10 , as shown in FIGS. 5, 6 and  12 . The system for making the panels  10  comprises the components that facilitate the manufacture of the panels  10 , as shown in FIGS.  7 - 9 . The process for installing the prefabricated terrazzo panels  10  is described herein.  
     [0033] With reference to FIGS. 1 and 2, the prefabricated panels  10  comprise a tile substrate  11 , top surface  12 , bottom surface  14 , sides  15  and at least one groove  16  formed in and along at least one side  15 . The tile substrate  11  preferably comprises an aggregate or terrazzo mixture, such as epoxy terrazzo or aggregate having terrazzo-like specifications. The groove  16  preferably extends along each side and may extend completely across each side. Alternatively, the groove  16  may extend partially across one or more of the sides  15 . The panels  10  are preferably at least substantially square or rectangular and have a thickness of approximately one-quarter inch ( 1 / 4 ″) to three-eights inch (⅜″) or thicker. In an alternative embodiment, the panels  10  may comprise alternative geometric shapes and, or dimensions. The groove(s)  16  provide a track for receiving a portion of a locking strip  20  when interlocking adjacent panels  10  during the installation process. The panels  10  can be made in various sizes, such as four feet (4′) by four feet (4′), five feet (5′) by five feet (5′), six feet (6′) by six feet (6′), or other dimensions. The bottom surface  14  of the cured aggregate panels  10  have a textured surface for facilitating bonding with a floor surface. The prefabricated panels  10  preferably comprise small pieces of marble, granite or other known substitutes set in mortar and having a high polish finish. The dimensions noted herein may vary without departing from the scope and spirit of the instant invention.  
     [0034] With reference to FIGS.  1 - 6 , the panel system of the instant invention comprises a plurality of prefabricated panels  10  and corresponding number of locking strips  20  that facilitate installation. The locking strip  20  comprises a base  21 , apertures  26  formed in the base  21 , and a vertically projecting elongated tongue structure  22 , as shown in FIGS. 3 and 4. The tongue structure  22  comprises a head  23  that is joined to the base  21  by a stem structure  24  and has an approximate overall height of 0.325 P.I. The head  23  has an approximate width of 0.150 P.I. at the upper end and 0.250 P.I. at its lower or widest end and an approximate height of 0.210 P.I. The stem  24  has an approximate height of 0.125 P.I. and width of 0.063 P.I. The angle of curvature at the lower end of the head  23  is approximately twenty (20) degrees. These dimensions may vary in accordance with design specifications. The base has an approximate thickness of 0.125 P.I. and width of 1.850 P.I. The locking strip  20  is manufactured with a custom prefabricated die in an extrusion process using plastic or a plastic-like material, such as those comprising thermoplastic or thermosetting polymers that can be molded, cast or extruded. The die forms the overall shape of the strip  20 . The locking strip  20  may alternatively comprise zinc, aluminum or metals having properties similar to zinc and, or aluminum. A liquid, paste or pliable form of zinc or aluminum may be extruded through a die. The extrusion process produces the shape of the locking strip as shown in FIG. 4. The apertures  26  are punched through the base  21 . The panel system may also comprise a coat of epoxy  40 , preferably of a high viscous consistency that is similar to a wet paste and an epoxy primer  30 . The epoxy primer  30  is placed on the installation surface prior to applying the epoxy  40 .  
     [0035] With reference to FIGS.  11 - 12 , the alternative locking strip  50  comprises a projecting elongated tongue structure  52 . The alternative tongue structure  52  comprises a head  53  that is joined to a stem structure  54 . The head  53  has an approximate width of 0.50 inches and an approximate height of 0.125 inches. The alternative stem structure  54  has an approximate height of 0.125 inches and width of 0.125 inches. These dimensions may vary in accordance with design specifications. The alternative locking strip  50  is also preferably manufactured with a custom prefabricated die in an extrusion process using plastic or a plastic-like material, such as those comprising thermoplastic or thermosetting polymers that can be molded, cast or extruded. The die forms the overall shape of the alternative strip  50 . The alternative locking strip  20  may also comprise zinc, aluminum or metals having properties similar to zinc and, or aluminum. A liquid, paste or pliable form of zinc or aluminum may be extruded through a die. The extrusion process produces the shape of the alternative locking strip as shown in FIG. 11. Unlike the preferred locking strip  20 , the alternative locking strip&#39;s  50  head  53  is inverted and the stem  54  aligns at or near the top surface of the panels  10  when installed, as shown in FIG. 12. Although the preferred method for installation of aggregated floor panels includes the use of the preferred locking strip  20  and is described with reference to using preferred locking strip  20 , the method of installation may include the use of the alternative locking strip  50  without departing from the scope and spirit of the instant invention.  
     [0036] With reference to FIGS.  7 - 10 , the process and technology for manufacturing the panels  10  generally comprises providing, installing and, or preparing the manufacturing system  100 , introducing the epoxy terrazzo or comparable aggregate mixture (generally referenced herein as an epoxy terrazzo mixture  13 ) into the manufacturing system  100 , allowing it to cure, grinding the surface of the cured aggregate to a desired thickness, polishing, cutting the cured terrazzo into panels  10  and preparing the panels  10  for installation. With reference to FIGS.  7 - 9 , the manufacturing system  100  comprises at least one frame  101  preferably formed by a plurality of forms or partitions  102  having an interior surface  104 , and a base layer  106  of urethane, Plexiglas or other type of plastic laminate with similar properties, such as Lexan, that is placed on the support substrate  1  within the frame structure  101 . The base layer  106  is preferably formed with a liquid urethane that is applied to the support substrate and cured. The liquid urethane is also used to fill in cracks that form in the base layer  106  when tile panels  10  are cut from the epoxy terrazzo deck  15 . The interior surface  104  is substantially flat. In an alternative embodiment the interior surface  104  may comprise an elongated, substantially horizontal contoured projection for forming the groove  16  in the panel  10  during the manufacturing process.  
     [0037] Still referring to FIGS.  7 - 10 , when making the aggregate panels  10  in accordance with the invention it is necessary that the support substrate  1  have a substantially or perfectly level and flat surface. The support substrate  1  is preferably made of a solid material such as concrete. The base layer  106  separates the epoxy terrazzo mixture  13  from the support substrate surface  1 , prevents it from adhering to the support substrate surface  1  and has properties that allow the epoxy terrazzo mixture  13  to temporarily adhere to the base layer surface such that it can be released therefrom without damaging the cured aggregate or panel  10 . The base layer  106  is adhered to the supporting substrate  1 , such as a concrete floor, and bonded thereto with an epoxy or adhesive  108  that prevents the base layer  106  from releasing.  
     [0038] Once the platform is secured on the support substrate  1 , the epoxy terrazzo mixture  13  in a liquid form and with the aggregate mixed therein can be applied to the base layer  106  within the frame structure  101  until the desired thickness is reached and, or as required. The aggregate mixture  13  preferably comprises a liquid form of epoxy terrazzo. Once the epoxy terrazzo mixture  13  has been poured and leveled, the mixture  13  cures for approximately eight (8) hours. Upon completing the curing process, the cured mixture  13  comprises one large sheet or deck-like structure  15 . In one embodiment, the deck  15  may comprise a thirty (30) foot by sixty (60) foot panel resulting in 1,800 square feet of cured terrazzo. The next step is to grind the top surface of the terrazzo deck  15  until achieving a consistent thickness. The terrazzo deck  15  is preferably grinded by an inline grinding and polishing machine. The machine travels above the deck  15 . After completing the grinding and polishing steps, the terrazzo aggregate  13  is cut into panels  10 . The panels  10  can be cut into various sizes and shapes depending upon request or installation requirements, such as 4′×4′, 5′×5′ or 6′×6′. Thereafter, the panels  10  are removed easily from the frame  101  and base layer  106 . The back of the panel  10  has a glossy finish after curing. To remove the glossy finish, the panels  10  are lightly sanded to give them a texture finished that facilitate bonding with the installation support surface, i.e. floor. After grinding, polishing and cutting the panels  10 , the edges of the panels  10  are profiled with a router bit specifically designed to form grooves  16  that correspond to the shape of the locking strip tongue structure. The grooves  16  mate with the locking strip  20  tongue structure  22  in a manner that locks the panels  10  together to facilitate installation in the field, as shown in FIGS. 5 and 6.  
     [0039] The prefabricated panels  10  are installed after floor preparation at the installation site is completed. With reference to FIG. 6, the floor  2  is prepared with an epoxy primer  30  and then a coat of setting material, such as epoxy  40 , is applied to the floor  2  with a notched trowel. The setting material (epoxy)  40  preferably has a thick consistency, such as mayonnaise, to allow the epoxy  40  to stand vertical until the panel  10  is applied to the floor  2 . Proper consistency in the epoxy  40  is achieved by adding a fine type of powder, such as marble dust, to the epoxy  40  in its liquid form until the right consistency is met. The panel  10  is set over the epoxy  40  with a locking strip  40  in place. The panels  10  and strips  20  are installed simultaneously, which locks the system together.  
     [0040] With reference to FIGS. 9 and 10, an alternative panel  10 ′ is shown. The alternative panels  10 ′ are made with contoured edges to facilitate mating of adjacent panels  10 ′. The contour edges provide more surface area and structure for enhanced surface tension to accommodate an epoxy filler. During installation, the alternative panels  10 ′ are set next to each other approximately one inch apart to form a gap. The gap between the panels  10 ′ are filled with an epoxy terrazzo, similar to that used to form the panels  10 ′ and grinded and polished such that the joined panels  10 ′ appear seamless. The alternative panels  10 ′ are made in an alternative frame structure  110  with alternative partitions  114 , as shown in FIG. 9, with virtually the same process disclosed herein with respect to the preferred embodiment. The partitions  114  are contoured to form the contoured edges in the panels  10 ′.  
     [0041] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious structural and/or functional modifications will occur to a person skilled in the art.