SURFACE COVERING SYSTEM AND METHODS FOR PREPARING SUCH A SYSTEM

Abstract

The invention relates to a surface coverings system for a surface such as a roof, a floor or another substantially flat surface subjected to water and needs drainage, and methods for preparing such a system. The surface covering system comprises a rectangular plate with a mark marking a highest point, a substantially flat lower surface and an upper surface with a first slope facing from the mark towards a second mark provided in connection to the outer edge of the plate. The first slope is circular and has a linear radial inclination () facing from the mark towards essentially all points on the rectangular plate. The slope forms an elevation in the plate forming at least a part of a cone or blunt cone with the tip of the cone defined by the mark with the lowest point(s) of the upper surface of the disc defined by the second mark.

Claims

1. A surface covering system for a covering of a roof, a floor, or another substantially flat limited surface comprising at least one substantially rectangular, triangular, quadrangular or otherwise polygonal plate with a first mark marking a highest point, i.e. an apex and a substantially flat lower surface and an upper surface with a first slope facing from the first mark towards at least one second mark provided in connection to an outer edge of the plate, wherein the first slope is circular and has a radial linear inclination () facing from the first mark from essentially all points on the at least one plate such that the slope forms an elevation in the plate with the shape of at least a part of a cone or a blunt cone, with the apex of the cone defined by the first mark and with the lowest point or points of the upper surface of the plate defined by the at least one second mark.

2. The surface covering system according to claim 1, wherein the system comprises at least two separate, substantially rectangular, triangular, quadrangular or otherwise polygonal plates with a substantially flat lower surface and an upper surface, wherein the at least two plates are intended to be disposed side by side and wherein one of the at least two plates has a first mark marking an apex and wherein both of the at least two separate plates have an upper surface with a first common circular slope with a radial inclination () facing from the first mark towards at least one second mark, provided in connection to the outer edge of the plate, when the plates are disposed side by side.

3. The surface covering system according to claim 2, wherein the upper surface of the at least one lateral edge of the respective plate is beveled such that a beveled notch forms the junction arising between the plates when the plates are disposed side by side.

4. The surface covering system according to claim 1, wherein locally, closest to the first mark, there is a second circular slope having a second inclination () which is steeper than the first inclination () of the first circular slope.

5. The surface covering system according to claim 4, wherein the second slope with inclination () extends from the first mark to a radius up to 500 mm from the mark.

6. The surface covering system according to claim 1, wherein grooves are provided in the upper surface and/or the lower surface of the at least one plate.

7. The surface covering system according to claim 6, wherein at least two grooves are provided crossing each other such that they form a chequered pattern.

8. The surface covering system according to claim 6, wherein a device for heating and/or reinforcing is intended to be placed in at least one of the grooves.

9. The surface covering system according to claim 6, wherein the grooves are intended to be filled with liquid filler.

Description

SHORT DESCRIPTION OF THE DRAWINGS

[0036] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[0037] FIG. 1a shows a first embodiment of the invention in plan view,

[0038] FIG. 1b shows a cross section of the invention according to the first embodiment,

[0039] FIG. 1c shows a perspective view of the invention according to the first embodiment,

[0040] FIG. 1d shows a perspective view of the invention with exaggerated dimensions,

[0041] FIG. 2a shows a second embodiment of the invention in a plan view,

[0042] FIG. 2b shows a cross section A-A of FIG. 2a,

[0043] FIGS. 3a-3c shows some possible forms of the surface covering system adapted for different dimensions of the surface to which the system is to be adapted,

[0044] FIGS. 4a and 4b show a third embodiment with cutouts for floor heating and/or ventilation,

[0045] FIGS. 5a, 5b and 5c show moulds of two different manufacturing methods,

[0046] FIGS. 6a-6c show an alternative embodiment of the surface covering system comprising square plates, and

[0047] FIG. 7 shows an alternative embodiment of the surface covering system comprising square plates.

DETAILED DESCRIPTION

[0048] In the following is a detailed description of embodiments of the invention. All examples should be seen as parts of the general description and are therefore generally possible to combine.

[0049] Below the surface covering system will be described as a roof system for a flat or essentially flat roof, but of course the system is possible to use for creating drainage on other essentially planar limited surfaces, for example on floors or on patios.

[0050] FIGS. 1a-1c show a first embodiment of the roof system comprising a plate 1 with a first mark 2 for a highest point, i.e. an apex which also may be called vertex. The first mark 2 may also be the apex itself. The first mark 2 is in this embodiment centered on the plate 1, but it may also be placed on another suitable place from the edge of the plate, e.g. 450 mm-600 mm from the edge of the plate. The plate is in this embodiment rectangular but may also be substantially rectangular (e.g. square), triangular, quadrangular or have another polygonal shape. The term substantially rectangular, triangular, quadrangular or otherwise polygonal also comprises plates comprising various form fit or connection details disposed at the edges of the plate in order to join or connect multiple plates with each other.

[0051] In connection to the outer edges of the plate, the lowest point or points of the system are defined by at least one second mark 12. At at least some of the marks 12, preferably the lowest mark 12, there may be disposed a device for draining, e.g. a hole connecting to a floor drain, gutter or drain pipe. In one embodiment, drain pipes are disposed along the entire outer edges of the plate in order to accumulate water along the edges of the entire plate and direct this towards at least the lowest of the marks 12. The plate 1 has a substantially flat lower surface 3 and an upper surface 4 with a slope facing from the mark 2. The slope is circular and has a radial inclination from the mark towards essentially all points on the at least one plate so that the decline forms an elevation in the plate with the shape of at least a part of a cone or a blunt cone with the tip of the cone corresponding to or defined by the mark 2. Since the plate has a polygonal shape, the elevation in the form of a blunt cone is cut down in its periphery, i.e. the straight edges of the plate end the circular slope, see FIG. 1c. Through this configuration the lowest point of the system, defined by the at least one second mark 12, will be disposed in connection to the outer edges of the plate. This lowest point will land in the corner or corners which are peripherally furthest away from the first mark 2 defining the apex of the plate. In FIG. 1d, the thickness of the plate is exaggerated in order to illustrate the cone shape of the elevation.

[0052] The plates may be made of e.g. polystyrene cellular plastic of the type EPS or XPS or polyamide plastic (PA), polypropylene (PP) or polyurethane (PUR). However, the plate material may also be glass foam or any other plate material suitable for the purpose. According to one embodiment, the plate material is Rockwool material, such as e.g. stone wool or roof plate. In additional embodiments, plates are cast with a circular slope of concrete or other material suitable for casting. It is also possible to compression mould or hot press the plates from other materials suitable for these manufacturing processes.

[0053] The plates used as separate parts in the surface covering system are substantially flat on the bottom part and are thus intended to lie on a flat underlying material. EPS plates with dimensions up to 600 mm3300 mm may preferably be used, but plates with any other dimensions may of course also be used. Square plates may for example be suitable from an assembling perspective.

[0054] Plates made from a water impermeable material, such as e.g. polyamide plastic (PA) or polypropylene (PP) may be an advantage when they are to be placed e.g. in a wet room. The plates may then act as a moisture barrier against the underlying floor structure and sealing is needed only along the walls and along any junctions between the plates.

[0055] FIGS. 2a and 2b show a second embodiment of the invention wherein the roof system comprises three separate rectangular plates 1a, 1b, 1c which are placed side by side in order to together form the upper surface 4 of the roof. Of course, more than three plates may also be used. The plates may be attached to each other by use of glue or other attachment devices, or they may be attached to the floor side by side. The junctions 5 between the plates may be sealed with a form of sealing tape. It is also possible to apply a sealing layer or a steam-proof cloth across the whole roof.

[0056] One of the plates, in this case the middle plate 1b but it may also be any of the other plates 1a, 1c has a first mark 2 equivalent to apex. The roof surface 4 has a first circular slope with a radial inclination from the mark 2. According to one embodiment, there is, locally closest to the first mark, preferably distance with a radius r up to 500 mm from the apex, a second circular slope which has a steeper inclination than the first slope (not shown). For a roof, the first radial inclination is preferably in the range 2-10 mm/m and the second radial inclination in the range 7-200 mm/m. For other substantially flat limited surfaces such as e.g. floors and patios, the inclination from apex may be within other ranges.

[0057] Since the floor surface 4 is formed by multiple plates, in this case three, the separate plates 1a, 1b, 1c have an upper surface 4a, 4b, 4c with parts of the common circular slope. The middle plate 1b comprises the apex and the circular slope around it forms an elevation with the form of a cone with its tip defined by the first mark 2. The two outer plates 1a, 1c comprise a slope forming an elevation in the plates 1a, 1c with the shape of a part of a cone or blunt cone due to the cone being cut in one or both sides. The lowest point or points of the system marked with the second mark 12 end up in the periphery of the total surface formed by the multiple plates, typically at points of it that are at a maximal radial distance from apex. At these second marks, draining points are preferably provided which function as draining sewers possibly coupled to waste pipes/gutters.

[0058] FIGS. 3a-4c show three different irregularly shaped roofs constructed with the roof system according to the invention. The roof systems shown in FIGS. 3a-3c are all constructed by one or more rectangular plates 1a, 1b, 1b, 1c, 1d, 1 e, 1f, 1g, with an upper roof surface 4 having a circular slope towards a floor drain, draining sewer or gutter. The outer edges of the roof are cut according to the desired shape. Regardless of what the roof looks like, no cutout is needed on site. The plates may already in the factory be specially manufactured according to the form of the roof. The lowest point or points of the system marked with the second mark 12 end up in the periphery of the total surface formed by the multiple plates, typically at points of it that are at a maximal radial distance from the apex. It is of course also possible to provide draining points at other places than those that are at a maximal radial distance from apex.

[0059] FIGS. 4a and 4b show an embodiment of a roof system with machined grooves 6 provided in the upper surface 4 of the plates 1. The grooves are in this embodiment created in a chequered pattern that may extend all the way to the edges of the plate (4a) or terminate a distance inwards from the edge (FIG. 4b). In the grooves, a cable or pipe (not shown) for heating coils may be placed, for instance with the purpose to melt snow or ice on the roof. The roof heating coils are cast on site with liquid filler. By the grooves crossing each other and being filled with a heat spreading liquid filler, the heat from the roof heating coils is spread out evenly across the roof.

[0060] It is also possible to put the grooves 6 in a chequered pattern so that it matches a reinforcement device, e.g. a prefabricated reinforcing steel mat or separate reinforcing bars put into the grooves 6 one by one, or attached to each other by means of frapping. If a reinforcement device is used, the entire construction becomes stronger and the separate plates are held together. When the reinforcing steel mat is put into the grooves, they may be filled with e.g. liquid filler or concrete. Of course, these tracks may also be machined in the plate shown in FIG. 1a-1d. The reinforcement then reinforces the plate itself.

[0061] In the embodiment shown in FIG. 4a, the edges of the plates have a bevel 7 which may be existing from the factory, or that may be machined with the machine creating the slope. When the plates 1a, 1b, 1c are positioned side by side, a beveled notch arises in the junction 6 between the plates. This notch may be filled with e.g. liquid filler. Thus there may be liquid filler both in the junctions 6 between the plates and on the upper surface 4 of the plates. The separate plates 1a, 1b, 1c are then cast together to one unit 1.

[0062] It is also possible to machine/mill grooves 8 in the lower surface 3 of the plates 1. These grooves 8 preferably extend across the entire lower surface 3 of the roof and contribute to an air flow between the lower roof and roof system. Thus the roof becomes better ventilated and the risk for moisture damage decreases.

[0063] It is also possible to instead provide the at least one plate on a distance from the surface it is to cover. The distance between the roof and the plate may be used for ventilation or for placing electrical cables or water conduits.

[0064] The roof system may be manufactured through different machining/manufacturing processes.

[0065] For example, it is possible to prefabricate plates with a circular slope through casting the separate plates in a cast form, through compression moulding or through plastic deformation of the plates by a hollow cone shaped pressing tool with heat, so called hot pressing.

[0066] When manufacturing through casting, a one-part casting mould 9 is used, preferably made of steel or other suitable material, with a mirror-inverted slope. See FIG. 5a, showing the center plate with the first mark 2 for apex centrally located on the plate. I.e. the mould 9 is defined by a frame 9a and a lower frame surface 9b having at least one determined desired radial positive inclination (, ) in a direction from the first mark 2 marking the apex towards the outer edges of the mould. The radial inclination corresponds to the slope of the upper surface 4 of the plate.

[0067] For other moulds intended to cast the plates that are to be disposed around the center plate 1b, there is no part intended to form the apex but instead the inclination originates from all, or essentially all, of the points on the frame surface, i.e. no part of the lower frame surface is entirely flat which in practice means that the apex will be in its center point.

[0068] The casting mould is filled with concrete or other correspondingly cured material with any reinforcing additions in a suitable way. It is also possible to reinforce the plates with a reinforcing net, reinforcing bar or with separate needles or fibers. When the plate is completed, the upper casting surface forms the substantially planar lower surface 3 of the plate.

[0069] It is also possible to use multiple materials in the plates. For example, a layer of cellular plastic may be put on the not fully cured concrete, or it may be glued at a later time.

[0070] When manufacturing with compression moulding, see FIGS. 5b and 5c, a two-part mould form comprising a first part 10 and a second part 11 is used, which encompasses an inner volume that at least partly corresponds to the volume of the at least one plate 1, 1b, 1b, 1c. FIG. 5c shows a triangular two-part mould that may also be used for manufacturing plates with a circular slope.

[0071] The first part 10 of the mould has at least one determined desired radial positive inclination (, ) in a direction from the first mark 2 which marks the apex towards the outer edges of the mould. The second part 11 of the mould has a flat inner surface that corresponds to the substantially planar lower surface 3 of the plate. Preferably the second part 11 of the mould may be used for manufacturing all separate plates 1a-1g. The other moulds intended for casting the plates which are to be disposed around the center plate 1b, do not have an indentation part intended to form the apex, but instead the inclination originates from all, or essentially all, of the points on the frame surface, i.e. no part of the lower frame surface is entirely flat.

[0072] The plates are manufactured by the material which is to constitute the plate being supplied to the inner volume between the first and second part 10, 11 of the mould. When the material has been cured, the first and second part of the mould are separated and the completed plate with parts of a circular slope is taken out.

[0073] When manufacturing with hot pressing, not shown, e.g. a pre-heated plate made of polyamide plastic (PA) or polypropylene (PP) is placed in a lower part of a moulding tool. After placing the material kit, the tool is closed and the material is pressed out into the mould room. When the material has been cured, the tool is opened and the plate with a completed circular slope is removed.

[0074] It is also possible to mill the slope from a flat plate, not shown. If the decline and shape of the floor is milled, it is preferably machined with a 5-axes (X, Y, Z, A and C axes) programmable mill with a work area of 3300 mm5000 mm. The mill comprises a milling spindle which may be tilted to a desired inclination. The machine has automatic tool switching and vacuum table so that the plates are held in place. The Y-axis extends horizontally in the longitudinal direction of the machine, the X-axis extends horizontally laterally across the longitudinal direction of the machine, and the Z-axis extends in the vertical direction. Movements around the A-axis tilts the milling spindle to a desired number of degrees and in case of movements around the C-axis, the spindle rotates around its own axis.

[0075] When preparing a floor or a wet room, or a roof, for example with the dimensions 2700 mm3500 mm, i.e. 9.45 m.sup.2, three plates with the dimensions 1200 mm3000 mm are preferably used, which are put side by side on the work area of the mill. In a computer program, a number of platforms are stored depending on how many sewers or draining points the room or the roof, respectively, should have, most bathrooms have a sewer. The platform is programmed with information regarding the size of the floor and roof and the thickness of the plate, as sewer as the placement of the sewer and the apex on the floor and roof, respectively. The mill is tilted to a desired inclination, and the slope is milled in circular or linear movements with a planar mill and the center point of the sewer or roof is constantly the origin of the movements. When the plates have acquired their slopes, the size of the floor or roof is milled out of the plates through cutting the edges. The floor or roof may in this step be given different shapes, see FIGS. 3a-3c. Also, holes are milled for the draining point(s) and possibly additional holes. The plates are then marked with a mark that corresponds to an accompanying drawing. Any waste is recycled.

[0076] If the roof is to have heating, a chequered pattern may be milled in the upper surface 4 of the roof, which completely follows the inclination of the roof.

[0077] The above method is directed at each roof system being specially made on demand and wherein there is information regarding the size and shape of the roof and the placement of the draining sewer or draining point.

[0078] It is also possible to manufacture a flexible roof system, wherein the plates are held in store at special sales outlets and are at a later stage adapted to the roof of a specific customer, it may be done in the following way: [0079] An apex plate is provided in two variants. On one of the two variants, the first mark for the apex is disposed centrally on the plate, on its center point. On the other variant, the first mark for the apex is disposed e.g. at least a fourth into the plate from one of the edges of the plate. [0080] With the apex as origin, the plates side by side are machined in the same way as described previously.

[0081] It is also possible to manufacture and install a flexible roof system where each separate plate is manufactured in a mould having an inner volume which at least partly corresponds to the volume of the at least one plate 1, 1a-1g. This circular multi system is shown in FIGS. 6a-6c.

[0082] This system is constructed by substantially square plates 1a-1g wherein the first mark 2 for the apex is centrally located on a first plate 1b, and remaining plates 1a, 1c-1g add on around the first plate 1b in a radially outwards facing pattern, see FIGS. 6a and 6b. The first plate 1b with the apex is made in one mould. Due to the apex being centrally located on the first plate 1b, the radial inclination of the slope on remaining plates is the same on at least four of the remaining plates 1a, 1c-15. Thus the same mould may be reused for multiple plates. In the FIGS. 6a-6c, there is shown maximally seven variants of plates. Of course the system may be extended with an infinite amount of plates if desired. According to one embodiment shown in FIG. 7, apex is divided in four central identical plates, numbered 1, and remaining plates 2-36 in this example build onto six rows disposed underneath each other, each one of the rows essentially facing away from apex, i.e. from a higher point towards a lower point of the roof, in each of the surrounding apex of the four quadrants. Thus this example of a surface system comprises four sets with 32 identical plates. Thus a surface covering system is achieved which is easier to use and faster to distribute, e.g. for a roofing professional.

[0083] From a system with plates 1a-1g, e.g. laying in store at a sales outlet, the end customer or entrepreneur may, based on the size of the room and the placement of the apex, choose the amount of plates of each form that are needed to create the roof. On site on the construction site, the sales outlet or in the factory, the outer plates are cut and adapted to the outer limits of the roof, see FIG. 6c.

[0084] Central to this invention is to achieve a prefabricated roof having an even circular slope from all points, or essentially all points, of the roof or a single plate constituting part of the upper surface of the room. According to one embodiment, essentially all points means 50%-100% of the area of the roof or a single plate constituting a part of the upper surface of the roof. According to one embodiment, essentially all points means 75%-100% of the area of the upper surface of the roof. According to one embodiment, essentially points means 90%-100% of the area of the roof or a plate constituting a part of the upper surface of the roof. According to one embodiment, essentially all points means 95%-100% of the area of the roof or a plate constituting a part of the upper surface of the roof. According to one embodiment, essentially all points means 100% of the area of the roof or a plate constituting a part of the upper surface of the roof. The slope originates from the place where the apex is placed and the roof should be manufactured with as few rectangular plates as possible. In the description above, there is described a roof system with one to three plates, but in case of large roofs it is of course possible to use multiple plates. In production, preferably standard sizes of the plates are used.