Construction element for raised floors and the like and manufacturing method

Abstract

Construction element for raised floors and the like and manufacturing method thereof, which relates to a construction element for both indoor and outdoor raised floors and the like, characterized in that it is made up of a rigid component reinforced by a polymeric matrix composed of a resin, in a percentage by weight comprised between 80 and 95% of the total weight, combined with a catalyst, the percentage by weight of which being between 5 and 20% of the total weight, which has a filament fiber mesh completely embedded within, the proportion by weight of the embedded mesh being less than 50% relative to the assembly formed by the polymeric matrix plus mesh, and a method for the manufacture thereof. A method for the manufacture of said element is also described.

Claims

1. A construction element for both indoor and outdoor raised floors, comprising a flat rigid panel having two opposing planar sides and reinforced on one of the planar sides by a polymer matrix made up of a resin combined with a catalyst that has a filament fiber mesh completely embedded inside the polymer mesh, and the weight of the embedded filament fiber mesh is less than 50% of the weight of the assembly formed by the polymer matrix plus the mesh.

2. The construction element according to claim 1, wherein the rigid part is made of ceramic, glass, metal, natural or artificial stone materials, or wood.

3. The construction element according to claim 1, wherein the polymer matrix is made up of a resin, in a percentage by weight between 80 and 95% of the total weight, combined with a catalyst, the percentage by weight of which is between 5 and 20% of the total weight, which upon reacting with the resin, produces the hardening of the polymer matrix.

4. The construction element according to claim 3, wherein the resins used in the polymer matrix is one of or a mixture of one or more of epoxy, polyurethane, silicones, elastomers, acrlycs, or polyester.

5. The construction element according to claim 3, wherein the catalyst used in the polymer matrix is formed by organic acids, anhydrides, amines, thiols with reactive hydrogens, such as dicarboxylic acid anhydride, urea and thiourea derivatives and/or polyamides or mixtures thereof.

6. The construction element according to claim 3, wherein the resin and catalyst mixture is applied on one of the sides of the rigid part with a grammage between 0.1 and 5 mm.

7. The construction element according to claim 3, wherein the viscosity of the polymer matrix before hardening is between 2,000 and 14,000 centipoises.

8. The construction element according to claim 1, wherein the sheet or mesh is made up of glass filament fibers, polyester, carbon fiber, plastic-based or metal, organic polymers and a binder mixture.

9. The construction element according to claim 1, wherein the grammage of the mesh is between 150 and 1,000 gr/m2.

10. The construction element according to claim 1, wherein the rigid part includes a PVC edging on the contour thereof.

11. The construction element according to claim 1, wherein the thickness of the assembly formed by the polymer matrix plus the mesh is between 0.5 and 5.5 mm.

12. The construction element according to claim 1, wherein the weight of the polymer matrix with the embedded mesh is between 0.75 and 4 kg/m2.

13. The construction element according to claim 1, manufactured according to the following method: applying a mixture of the resin and the catalyst on one of substantially flat sides of the rigid part, with a viscosity of the mixture suitable for the product to self-level, such that 100% of the coated surface is completely covered, before hardening; meshing the part by a mesher, which arranges the mesh over the resin and catalyst mixture, which is still in a liquid state and with a viscosity low enough so that when said mixture hardens thereby forming the polymer matrix, the mesh is completely embedded therein.

14. The construction element according to claim 13, wherein a mixture of cork with resins is applied on the polymer matrix.

15. The construction element according to claim 13, further comprising the step of grinding the end assembly, in order to remove the fiber or adhesive fragments from the sides of the element.

16. The construction element according to claim 13, wherein the application of the mixture of resin and catalyst is by a spray gun, a knife, or a curtain.

17. The construction element according to claim 1, wherein the rigid part is made of ceramic or glass.

18. The construction element according to claim 3, wherein the resins used in the polymer matrix is epoxy, polyurethane, silicones, elastomers, acrlycs, polyester or a mixture of the above with a molecular weight of less than 700 Umas.

19. The construction element according to claim 3, wherein the resin and catalyst mixture is applied on one of the sides of the rigid part with a grammage between 0.3 and 2.5 mm.

20. The construction element according to claim 3, wherein the viscosity of the polymer matrix before the hardening thereof is between 3,000 and 12,000 centipoises.

21. The construction element according to claim 1, wherein: the polymer matrix is provided on only one of the planar sides of the rigid panel; the mesh is 0.5 mm apart from an outer surface of the polymer matrix that contacts that rigid panel; the catalyst, when mixed with the resin, hardens the resulting mixture to form the polymer matrix; and the rigid panel has a thickness within a range of 6 mm to 18 mm.

Description

DESCRIPTION OF THE FIGURES

(1) In order to complement the description being made below and with the aim of facilitating a perfect understanding of the present invention, a set of drawings is attached as an integral part of said description, in which by way of non-limiting examples the following has been represented:

(2) FIG. 1: Shows an exploded perspective view of the composition of the different elements that make up the finished assembly of one part obtained using the method of the present invention.

(3) FIG. 2: Shows, also from a perspective view, the part of the previous figure completely finished.

(4) FIG. 3: Shows the same finished part seen from the upper portion thereof, such that it is therefore verified that the upper portion of the part is not affected.

(5) FIG. 4: Shows the cross-section of the completely finished part, showing how the mesh is embedded in the polymer matrix.

DESCRIPTION OF A PREFERRED EMBODIMENT

(6) By way of non-limiting exemplary embodiment, below there is a description of the construction element for both indoor and outdoor raised floors and the like, represented in FIG. 4.

(7) Regarding FIG. 1, and as it can be observed, on the substantially flat face of a ceramic part of 12 mm, and with a weight of 15 kg/m2 (1), a polymer matrix (2) is applied by means of a spray gun made up of a mixture made up of 85% by weight of epoxy resin with an average molecular weight less than 700 Umas and 15% by weight of a catalyst formed with ethanol amines. The resin and catalyst mixture is applied with a grammage of 1.1 mm and has a viscosity of 6,000 centipoises.

(8) The thickness of the assembly formed by the polymer matrix (2) plus mesh (3), in this exemplary embodiment is 1.5 mm and its weight is 2 kg/m2.

(9) When said polymer matrix (2) is self-leveled, such that 100% of the coated surface is completely covered, and before hardening, i.e. while is still in a liquid state, a mesher, delivers a sheet or mesh (3) made up of glass filament fibers with a grammage of 500 gr/m2.

(10) As observed in FIGS. 2, 3 and 4, in which the construction element of the present example is represented completely finished, the upper portion of the rigid part (1) is not affected by the polymer matrix (2) and the mesh (3) is completely embedded in the polymer matrix (2), 0.5 mm apart from the surface or outer layer of the polymer matrix (2).

(11) The hardening or curing of the polymer matrix with the embedded mesh inside it is carried out at room temperature (unforced drying).