Abstract:
An access floor panel may have a core panel placed between a top pan and a bottom pan. The top pan and the bottom pan may be made from metal and may be formed around the core panel. The top pan may have a coating applied thereto, the coating may have one or more of several advantageous properties such as fire resistance, electrostatic dissipation properties, slip resistance, wear resistance and the like. In an embodiment, the coating may also have a predetermined surface pattern to give the panel an aesthetically pleasing look.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates to flooring systems, and more particularly to access flooring systems for computing environments. 
       BACKGROUND 
       [0002]    Access flooring systems are commonly used in buildings where access may be required to cabling such as electric, networking and phone cabling, and heating, ventilation and air conditioning (HVAC) equipment. 
         [0003]    Access flooring systems often comprise a plurality of metal-clad floor panels supported by a number of supports posts over a structural floor. The metal-clad panels are generally arranged so that they abut to each other in an end to end fashion so that a continuous floor is created that is raised above the structural floor. The access floor in some cases is made up of metal-clad panels, vent panels, transparent panels and the like. A carpet is often laid on top of the access floor panels. 
         [0004]    Access panels for computer rooms involve several unique challenges. For example, computer rooms may require access panels that are slip-resistant and also provide electrostatic discharge (ESD) properties. Metal-clad floor panels are often used in computer rooms because of their static dissipation properties. One such metal-clad panel is constructed from a composite core that is covered with a steel top pan and bottom pan. 
         [0005]    A prior art access floor panel is shown in  FIG. 1   a,b . The prior art floor panel has a core panel placed in between a metal top pan and metal bottom pan. A high pressure laminate (HPL) is adhered to the top pan and a trim edge is applied. Other surface finishes are often applied to prior art panels such as vinyl, wood, rubber, etc. 
         [0006]    Prior art panels unfortunately suffer from disadvantages, some of which include the cost of applying the surface finish, delamination between the HPL (or other surface finish) and protection of the brittle edge of the HPL with costly vinyl trim or additional routing process. Delamination is a particular problem and results from the different coefficients of thermal expansion between the top pan and the HPL. As the temperature changes in a given environment, the HPL often becomes delaminated from the top pan, which reduces the lifespan of the panels and necessitates replacement or repair of the panels. 
         [0007]    There is therefore a need for an access floor panel which overcomes or mitigates one or more of the defects of the prior art. 
       SUMMARY OF THE INVENTION 
       [0008]    In its broad aspect, the invention provides an access floor panel suitable for use in a computing environment such as a data center. The access floor panel includes a core panel, a top pan and a bottom pan. The top pan and the bottom pan may be made from a metal such as steel. The top pan includes a coating that has static dissipative properties. The coating may also be fire-resistant, scratch resistant, wear resistant, etc. 
         [0009]    In another aspect, the invention provides a method for assembling an access floor panel. The method may include the steps of providing a core panel having a top side and a bottom side, providing a top pan made out of a suitable material such as metal, providing a bottom pan made out of a suitable material such as metal and forming the top and bottom pans onto the core panel. 
         [0010]    In yet another aspect, the coating applied to the top panel may have a predetermined aesthetic surface pattern. 
         [0011]    In another aspect, the invention provides an access flooring system. The access flooring system may include a plurality of support posts adapted to receive at least one access floor panel. A pedestal may be placed on each support post for resting the access floor panels thereupon. 
         [0012]    In an aspect, the coating is applied to the top pan before the top pan is formed on the core panel. 
         [0013]    In one aspect, the core panel may be made from composite board material such as non-urea, particle board, medium or high density fiberboard, strawboard, cement board, concrete board, fire resistant materials and the like. 
         [0014]    In another aspect, the area of the top pan is larger than the top side area of the core panel so that the portion of the top pan that extends beyond the top side of the core panel can be bent around the core panel. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0015]    The invention will be better understood with reference to the drawings, in which: 
           [0016]      FIG. 1   a  is a diagram illustration of a floor panel of the prior art that includes a high pressure laminate;  FIG. 1   b  is a cross-sectional illustration of the prior art floor panel of  FIG. 1   a;    
           [0017]      FIG. 2  is a diagram illustration of an embodiment of an access floor system of the invention; 
           [0018]      FIG. 3  is a diagram illustration of another embodiment of an access floor system of the invention; 
           [0019]      FIG. 4  is a diagram illustration showing an isometric view of an access floor panel of the invention; and 
           [0020]      FIG. 5  is a side view of an access floor panel of  FIG. 4 . 
       
    
    
       [0021]    Like reference numbers and designations in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0022]    An access floor panel  100  may be formed from a core panel  104 , a top pan  102  having an advantageous coating  108  and a bottom pan  106  resulting in an access floor panel  100  that provides benefits in many environments, including computer rooms. 
         [0023]    The access floor panel  100  of the present invention provides properties that are advantageous for use in access flooring systems. In an embodiment, the access floor panel  100  may provide slip-resistant, electrostatically dissipative, fire resistant, scratch resistant and/or other advantageous properties. 
         [0024]    In one embodiment, the access floor panel  100  may include a composite core panel  104  that has a top side  120  and a bottom side  122 . The top side  120  is adapted to provide support for people and equipment that may be placed on the access floor panel  100 . A top pan  102  may be positioned on the top side  120  of the core panel  104  and bottom pan  106  may be positioned on the bottom side  122  of the core panel  104 . The top pan  102  may comprise metal such as steel, as may the bottom pan  106 . In an embodiment, the top pan  102  and the bottom pan  106  are approximately 0.02 inches in thickness plus or minus 0.002 inches, although other thicknesses and tolerances may also be used. An advantageous coating  108  may be applied to the top pan  102 , the coating  108  having one or more of the following properties: slip-resistance, electrostatic dissipation, fire resistance, and a pre-determined surface pattern. In an embodiment, the coating  108  is applied to the top pan  102  before the top pan  102  is placed on the top side  120  of the core panel  104 . The coating  108  may be applied to one or both sides of the top pan  102 . In one embodiment, the coating  108  is applied to one side of the top pan  102  after the top pan  102  is placed on the top side  120  of the core panel  104 . 
         [0025]    In some exemplary embodiments, the coating  108  is a substance that is not too conductive but will slowly conduct static charges away. The coating  108  may be selected to slowly conduct static charges away from sensitive equipment, and in some exemplary embodiments, the coating  108  has resistivity values in the range of 10 5  to 10 10  ohm-meters. The coating  108  may be applied to the top pan  102  using one or more of several methods, such as but not limited to, spraying, brushing, rolling, dipping the pan in a container having the coating  108 , and the like. 
         [0026]    In an embodiment, the core panel  104  may be formed from various composite board materials. 
         [0027]    In an embodiment, a person may select a surface pattern from variety of known surface patterns or the person may create their own surface pattern to increase the attractiveness of the floor panel  100 . 
         [0028]    In an embodiment, the invention provides a method for assembling an access floor panel  100 . The method includes the step of providing a core panel  104  having a top side  120  and a bottom side  122 . The core panel  104  may be made from composite board material. The method may include the step of providing a top pan  102  and a bottom pan  106 . The top pan  102  and/or the bottom pan  106  may be made from a metal such as steel. In an embodiment, the top pan  102  and the bottom pan  106  are slightly larger than the core panel  104  in surface area which enables forming of the top pan  102  and the bottom pan  106  according to the layout shown in  FIG. 3 . In an embodiment, the forming of the bottom pan  106  may involve bending a portion of the bottom pan  106  that extends beyond the bottom side  122  of the core panel  104  along the side of the core panel  104 . Similarly, forming of the top pan  102  may involve bending a portion of the top pan  102  that extends beyond the top side  120  of the core panel  104  along the side of the core panel  104 . In embodiment, such as is shown in  FIG. 3 , the top pan  102  may be formed after the bottom pan  106  is formed, thus allowing the top pan  102  to overlap the bottom on the side of the core panel  104  which provides the advantage of holding the bottom pan  106  in place. The forming of the top and bottom pan  106  may be done in a forming die and press. 
         [0029]    In one embodiment, the invention provides a system for assembling an access floor suitable for use in a computer data room. The system may include a structural floor and a plurality of support posts  128  adapted to support at least one access floor panel  100 . As shown in  FIG. 2 , each support post  128  may be positioned below a pedestal  126 , the pedestal  126  being configured to support up to four stringers  130 . Four stringers  130  may be configured to support an access panel. The access panel of one system of the invention may include a core panel  104 , top pan  102  having an advantageous coating  108 , and a bottom pan  106  as is described above. 
         [0030]    In one embodiment, a system of the invention uses a plurality of support posts  128 , each support post  128  having a pedestal  126 . An access panel may be placed on a plurality of pedestals  126  suitably arranged (as shown in  FIG. 3 ) and the access panel may be secured to the plurality of pedestals  126  with corner bolt screws  124 . The access panel may be provided with holes  110  for the corner bolt screws  124  during the assembly process of the access panel. 
         [0031]    Some or all of the material used in a system of the invention may be made of dissipative material, and the dissipative material may be grounded. 
         [0032]    The system may provide a continuous path between the top pan  102  of the access panels and the ground to facilitate static to discharge to the ground. This helps discharge any static charge which a worker has built up, as well as any static charge on tools or exposed components that are placed on the access panels. In embodiment, the static dissipative coating  108  on the top pan  102 , the bottom pan  106 , the supports posts  128  and the pedestal  126  may together or in part provide a continuous discharge path to the ground. As will be appreciated, the ground path may be provided with a pre-determined resistance or range of resistances so that static is discharged at a pre-determined rate that is suitable for computing environments. 
         [0033]    In one exemplary embodiment, the panel  100  is assembled by firstly running the composite board core  104  through a roll coater which applies an adhesive to both top  120  and bottom surface  122 , then the composite core  104  is placed into the formed bottom pan  106  and then the top pan  102  is placed on top of the composite core  104 . The assembly of top pan  102 , the core  104 , and bottom pan  106  are then fed through a nip roll which applies pressure to the assembly  100  and fuses the parts together. The part  100  is then left for a period of time (such as for example, 24 hours) for the adhesive to cure. Once cured the assembled panel  100  is then formed to final size and corner holes  110  drilled if desired. A coating  108  with statically dissipative properties is then applied to the top pan  102 , and in some embodiments, to the bottom pan  106  as well. In another embodiment, the coating  108  is applied to the top pan  102  and/or the bottom pan  106  before the pans are attached to the core panel  104 . 
         [0034]    While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of the above description, will appreciate that other embodiments may be devised which do not depart from the scope of the present invention as described herein. In addition, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the claims.