Patent Publication Number: US-7585556-B2

Title: Studded plate with fold line

Description:
RELATED APPLICATION 
   This application claims the benefit of priority from Norwegian Patent Application No. NO 20041545, filed on Apr. 15, 2004, in the Norwegian Patent Office, the disclosure of which is hereby incorporated herein by reference in its entirety. 
   AREA OF THE INVENTION 
   The present invention concerns a studded plate, such as a plate of a film like material, for use as a support against floors, walls, ceilings and roofs, and especially as a support for flooring on concrete floors with tiles, floor covering or wooden floors. The invention also concerns the use of the studded plate and a method of placement of the plate. 
   TECHNICAL BACKGROUND 
   Many different types of studded plates which may be used as supporting plates are known. They may be used as ordinary supporting plates, drainage plates, decoupling plates, or plaster plates for plastering or support for adhesive for tiles for example when flooring with ceramic tiles. 
   All concrete floors resting on the ground contain moisture. Floor coverings such as wooden floors can therefore not be placed directly on the concrete. Many years may be needed to dry out a concrete floor placed on the ground. The floor may also be affected by rising damp. Initially, all concrete floors contain residual moisture and the above problem therefore concerns cellars, basement floors, slab on ground floors and floor between different storeys of different types of concrete, including for example floors made of light expanded clay aggregate concrete and lightweight concrete. The moisture in the concrete is often invisible and difficult to detect. This results in an unawareness of the risks such as rot, moisture damage etc. Without an effective damp proof membrane with sufficient performance characteristics, moisture from the concrete will for example attack wood materials from underneath. The same problem also concerns tiled floors wherein the filled joints will allow passage of moisture. 
   The result is damaged floors with cracks, mould and rot. In addition, hazardous mould spores, bad smell and a poor in-door environment may result. 
   The same effect may arise on concrete walls, as in floors, and contain or be affected by rising damp, especially basements with below ground walls. 
   To solve this problem, studded plates are used for most problems related to moisture in cellars providing “passive” venting towards the room. The studded plates often comprise hollow studs with circular or rounded cross-section, i.e. the form of the circumference of the studs, with a height from 3 to 5 mm. The studs are often distributed in a diamond pattern or a check-board pattern providing adequate distribution of the loading as well as venting. The studded plates are places with the top of the studs facing downwards toward the base floor to obtain an air gap on the underside of the plate, between the studs. 
   The plates may be joined by sealing tape on the topside of the plates to obtain a sealed floor. In case of severe problems with moisture, smell or other emissions, the air gap beneath the studded plates may be ventilated mechanically in order to provide air flow over the concrete plate and create a negative pressure in relation to the room. A ventilated air gap may also contribute in the drying out of the concrete. 
   Recently, plates have been developed comprising studs with undercuts or overhangs, meaning that the area of the opening of a stud is smaller than the area of the top of the stud, giving a good anchoring of plaster or adhesive, independent of which face the plaster or adhesive is applied. Such a plate is described in EP 1 068 413 issued on Aug. 10, 2004 to Isola AS for example. 
   The studs in the above mentioned patent are characterized by a uniform shape of the studs which are distributed on the plate in a repeated pattern. The pattern often allows folding of the plate in the longitudinal and/or transverse direction of the plate, but also in a 45° angle. 
   However, it is a problem with the above mentioned solution that a plate placed on the floor should be turned up against the wall of the room, in order to guide the humid air out of the air gap. In other words, the air gap must be in contact with the room. In the simplest manner, this is achieved by folding the plate at the transition between the floor and the wall. The problem with this solution is that all the above mentioned plates thereby obtain a folding crease which either inhibits the transport of humid air or for example the plate comes in direct contact with the adhesive used against the floor thereby blocking the air gap. 
   It is also quite usual to laminate the studded plate with a fabric or a grid on the top of the studs in order to bond the plate temporarily or permanently to the concrete floor, so that the plate is evenly fixed to the substrate during installation of the floor covering or tiles. The fabric, which will be applied with adhesive, will also contribute in blocking the transport of air as it will be stretched against the folding crease of the plate and thereby block the air gap. 
   One solution to this problem has been to place the plate on the floor at a small distance from the wall and to use a special edge plate which is bonded onto the top face at the edge of the plate on the floor, to finish the venting towards the room. However, there is always a risk that plates on the floor are pushed towards the wall and will remain in contact with the wall, or that adhesive is pressed into the junction between the floor and the wall, thereby blocking the venting. 
   The present invention is aimed at solving the above problems and to provide a plate and a method for placing it so that transport of moisture is secured away from the substrate, such as a floor, in a simple and sure manner. 
   BRIEF DESCRIPTION OF THE INVENTION 
   The present invention concerns a studded plate wherein at least one edge in the longitudinal direction of the plate has a fold line which maintains airflow even when the plate is folded at 90° along the edge. The described studded plate thereby secures venting and equalization of the water vapour pressure across the floor, as well as reducing the risk of capillary action. 
   The present invention therefore concerns a studded plate, comprising a first longitudinal edge and a second longitudinal edge between which are arranged a main area in the longitudinal direction of the plate comprising a first type of studs, wherein the main area comprises at least one sub area, in the longitudinal direction of the plate, with a second type of stud which have an elongated or oblong shape in the longitudinal direction of the plate and at least one adjacent longitudinal row of a similar stud and/or a third type of stud comprising a longitudinal adjacent border to the first row of studs, wherein studs in the first row are offset in the longitudinal direction in relation to the studs in the adjacent row(s). 
   The main advantage with this system is that a whole room may be covered with one type of plate without the need for other specialty plates and parts other than a jointing tape. 

   
     DESCRIPTION OF THE DRAWINGS 
     In order to explain the invention in more detail, basis is made in four embodiments of the invention and the attached drawings wherein: 
       FIG. 1  shows a perspective view of a studded plate according to a first embodiment of the invention viewed from underneath. 
       FIG. 2  shows a planar view of a studded plate according to a second embodiment viewed from underneath. 
       FIG. 3  shows two cross sections of the studded plate in  FIG. 2  along the lines A-A and B-B respectively placed against a floor support. 
       FIG. 4  shows the studded plate in  FIG. 2  with an applied fabric. 
       FIG. 5  shows two cross sections of the studded plate in  FIG. 4  along the lines C-C and D-D respectively placed against a floor support. 
       FIG. 6  shows two cross sections of the studded plate in  FIG. 4  along the lines C-C and D-D respectively placed in a folded up state against a supporting floor and wall. 
       FIG. 7  shows an extended planar view of the studded plate in  FIG. 2 . 
       FIG. 8  shows a planar view of a studded plate according to a third embodiment viewed from underneath. 
       FIG. 9  shows a planar view of a studded plate according to a fourth embodiment viewed from underneath. 
       FIG. 10  shows a perspective view of two studded plates arranged in an interior corner against a supporting floor and wall. 
   

   DETAILED DESCRIPTION 
   The invention will be further described in greater detail by examples of embodiments which are not meant to limit the scope of the invention, which is defined by the attached set of claims only. 
   The present invention is mainly directed at studded plates having studs protruding only on one surface side of the plate. However, plates containing studs protruding on both surface sides of the plate are also contemplated. 
   In the further description the following terms will be used: 
   “Longitudinal” is assigned to the direction of a sheet of the plate with the largest dimension which may be the production direction and the direction in which the sheet may be rolled up. 
   “Transverse” is assigned to the direction of a sheet of the plate perpendicular to the longitudinal or production direction. 
   “Longitudinal edge” is assigned to edges of the plate parallel to the longitudinal direction. 
   “Studs” is assigned to the protrusions extending out of the surface of the plate. 
   “Bottom face” and “underneath” is meant to refer to the face of the plate where the studs protrude out of the surface of plate, the area being uneven according to the shape, number and height of studs in the plate. 
   “Top face” is meant to refer to the face of the plate normally visible after placing it on a substrate, the area being relatively smooth with hollows leading into the plate. 
   “Channels” are referred to the spaces formed between the studs protruding out on the bottom face of the plate. 
   “Undercut” or “overhang” refers to studs having non-perpendicular walls in relation to the surface of the plate. In the following embodiments some of the studs have a smaller opening on the top face of the plate, than the top of the stud, giving the stud an undercut or overhang. In the drawings viewed from underneath, this effect may be seen from the dotted lines of the studs representing the opening hole of the stud on the opposite top face of the plate, which may be smaller than the solid lines of the stud, representing the outer circumference of the top of the stud resting against the substrate. The position of the opening of the stud may in addition be different from the position of the top of the stud, giving a larger or lesser degree of overhang in different parts of the stud. 
   A first embodiment of the invention is shown in  FIG. 1 , which is a part of a studded plate according to the invention. The plate has a longitudinal direction L and normally such sheets are rolled up in lengths of 20 meters. The plate has a transverse direction W, and the width of a sheet is normally about 1 or 2 meters. The height of the studs in this example is constant at about 3 millimeters, but may be smaller or larger or possibly of varying height. 
   In the longitudinal direction, the plate is divided in areas of different widths, comprising different types of studs  11 ,  12 ,  13  and  14  of different shapes and sizes when following the line a-b. The width of the different areas may vary and the line c-d designates an unidentified width. The line e-f marks an incomplete longitudinal edge as the plate may have different widths, either with the same type of studs, or other studs as shown on other parts of the plate in  FIG. 1 . 
   As may be seen from  FIG. 1 , an edge area of round small studs  11  is present along one longitudinal edge. These studs  11  have a constant circumference in the whole depth of the stud and the diameter in this example is about 8 millimeters. The width of the area may for example be from about 3 to about 5 centimeters. 
   In the present invention, an improvement of the plate in EP 1 068 413 is used, wherein the longitudinal edges of the sheet includes another type of studs, as given in the Norwegian registered design 77826 and the corresponding US Design No. 29/178,693. The studs  11  in the longitudinal edges have the object of securing that a continuous air gap is maintained in the joining of plates, and of providing extra load bearing strength at the edges and joints of the plates. The circular studs  11  are smaller and differently shaped than the main studs  12 , which in this embodiment are square, and are distributed in a pattern providing more channels than the main studs  12 . In the jointing with main studs  12 , the small studs  11  will secure that the air gap is continuous across the joint and provide relative good transport for moisture being directed across. 
   The area of small studs  11  borders an area with the mentioned main studs  12 . In this example, the studs have a rounded square form and lie in a diagonal pattern in the longitudinal direction L. The main studs  12  contain undercuts by being truncated at the opening in relation to the top of the stud. These overhangs or undercuts may be used to anchor different types of materials such as plaster or adhesives for tiles on either face of the plate. The studs in this example are of a mean width and length of about 1.7 centimeters and the area containing these studs, is from about 8 to 10 centimeters wide. Part studs  13  with a triangular form are placed along the edge of this area of main studs  12 . 
   The next area has oblong studs  14 , placed in rows oriented in the longitudinal direction L of the plate  1 . These studs define a fold line of which the centre is indicated by the line k-k in  FIG. 1 . The sub area with oblong studs  14  is in this example about 2.5 centimeters wide. 
   On the other side of the sub area with studs  14 , half studs  13  border another area of main studs  12  which continue past the line e-f. The width of this area with studs  12  is dependent on the width of the plate  1  and constitutes the main part of the plate placed against the floor. This area may be completed with the same type of main studs  12 , or preferably an edge area with small round studs  11  for simplifying possible joints against plates that are cut, or to increase the strength. 
   As may be seen from  FIG. 1 , the rows of the oblong studs  14  provide longitudinal channels  21  with transverse openings  20  in-between, the openings  20  being offset in relation to each other in the longitudinal direction. The channels  21  are especially designed for the folding of the plate, for example at the transition from a floor to a wall. The oblong studs  14  do not contain undercuts in this embodiment. 
   In order to better understand the shape of the studs, a similar second embodiment of a studded plate  1  is shown in  FIG. 2 , viewed from the bottom side with two marked sectional lines A-A and B-B. In  FIG. 3  the profiles of cross sections A-A and B-B are represented with the plate placed against a substrate  3 . 
   In order to fasten the studded plate to the substrate, it is an advantage, as mentioned initially, to use a fabric or a grid  2  as shown in  FIG. 4  which may be applied to the studded plate in advance. The top of the studs  11 ,  12 ,  13  and  14  in  FIG. 1  are for example provided with a fabric  2  in  FIG. 4  of a suitable material by adhesive or lamination. This fabric  2  may then be used for fixing the plate to the substrate, such as a concrete floor or a wall, either permanently or temporarily. In  FIG. 5  the profiles of the cross sections C-C and D-D are respectively reproduced when the plate  1  with fabric  2  is placed against a floor  3 . As may be seen from the  FIG. 5 , the offset positioning in the longitudinal direction of the transverse openings  20 , always provide at least one oblong stud  14  in the fold line placed against the substrate, in this case the floor. 
   The latter is important in the folding of the plate  1  with fabric  2 , as shown in  FIG. 6  wherein the cross sectional profiles in  FIG. 5  are represented in a folded up state. The plate  1  is placed against a floor  3  and the longitudinal edge of the plate is folded up against a wall  4 , and the fabric  2  may be glued to both the floor  3  and the wall  4 . From the profile of C-C it may be seen that the fabric  2  is stretched out by the studs  14  and are prevented from contacting the surface of the plate  1  between studs. In this manner the transverse openings  20  are maintained open as shown by profile D-D in the same figure. It is important that neither the width nor the length of the transverse opening  20  is too large so that the fabric  2  may contact the surface of the plate  1  between studs. In this example the width of the opening is about 5 millimeters, and approximately the same width as the oblong stud  14 . However the person skilled in the art will be able to determine the suitable width without undue experimentation based on the disclosure of the present invention. It is also important that there are not too many openings  20  and that they are not in the same position in adjacent rows so that there always is one oblong stud  14  stretching the fabric  2  as shown by the profile D-D. A too long unsupported distance for the fabric will result in the fabric contacting the plate. In this embodiment of the plate, as shown in  FIG. 4-6 , the fabric will be stretched out by two rows of oblong studs  14 , and thereby secure continuation of the air gap. As mentioned above the person skilled in the art will also be able to determine this feature without undue experimentation based on the present disclosure. 
     FIG. 7  shows a typical width of a plate  1  cut in the transverse direction with edges  50 , with longitudinal edges  60  and  61 , wherein the main area  90  with square studs  12  is divided by a sub area  100  with oblong studs  14  making up the fold line, and wherein both longitudinal edges of the plate  1  have areas  80  with small round studs  11 . The lines  200  and  300  indicate that the width of the main area  90  is not restricted on either side of the sub area  100 . 
     FIG. 8  shows a third embodiment of a plate according to the invention comprising a fold line. In this embodiment the main areas comprise two types of studs, such as circular studs  112  and propeller shaped studs  110 , both of which have undercuts, although somewhat offset. The fold line is made up of a central longitudinal row of oblong propeller shaped studs  114 , and one row on each side, comprising oblong studs  113 . As in the embodiments described earlier, this arrangement also secures a continuous air gap when the plate is folded in 90° along the line k-k which is the centre line of the folding crease. A continuous air gap is secured through the combination of channels  120  generally in the transverse direction and channels  121  generally in the longitudinal direction. The staggering of the studs in the three rows of the fold line will also prevent an optional fabric  2  on the bottom side of the plate in blocking the channels. 
   Similarly  FIG. 9  shows a fourth embodiment of a plate according to the invention comprising a fold line. In this embodiment the main areas comprise two types of studs, such as a cross shaped stud  210  and a circular stud  212 , both of which have undercuts, although somewhat offset. The fold line is made up of a central row of oblong propeller studs  214 , and two adjacent rows, one on each side, comprising jelly baby-shaped studs  213  that are oblong on the side adjacent to the central row of studs  214 . As in the embodiments described earlier, this arrangement also secures a continuous air gap when the plate is folded in 90° along the line k-k, which is the centre line of the fold line. The width of the jelly baby-shaped studs  214 , has the advantage of preventing adjacent areas to the fold line in bending when the plate is folded. A continuous air gap is secured through channels  220  and channels  221  generally in the longitudinal and transverse directions respectively. The staggering of the studs in the three rows of the fold line also prevents an optional fabric  2  in blocking the channels. 
     FIG. 10  shows a method of placement of a plate according to the invention. 
     FIG. 10  shows how a first plate  101  is placed against an interior corner by making a cut in the main area, of the part of the plate placed against the floor  3 , so that the folded up edge follows the wall  4 . In this embodiment the main studs  12  have a diagonal pattern making it simple to adapt the plate to an interior corner in a room by cutting the plate in 45° along two edges, in towards the fold line as indicated in  FIG. 2 , by cutting lines m and n. The resulting edges will then be laid edge to edge and may be sealed with sealing tape. Another plate may then be placed adjacent to the first plate so that round studs  11  secure a continuous air gap in the joint against the second plate  102 . 
   The result obtained by the use of a plate according to the present invention is a secure and good venting of the floor wherein the plate may be bonded to the floor and/or the wall either temporarily or permanently. 
   The studded plate is preferably produced in sheets of a plastic or polymer film like material such as for example polypropylene or polyethylene. The fabric or grid material may be comprised of synthetic material such as a polymer material.