U.S. patent application number 11/624148 was filed with the patent office on 2007-08-02 for raised access floor.
This patent application is currently assigned to DAW Technologies, Inc.. Invention is credited to Brian Mazur, Peter J. Spransy.
Application Number | 20070175132 11/624148 |
Document ID | / |
Family ID | 38320609 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175132 |
Kind Code |
A1 |
Spransy; Peter J. ; et
al. |
August 2, 2007 |
RAISED ACCESS FLOOR
Abstract
A modular raised access floor panel includes a frame, a first
edge member, a second edge member, and a center member. The first
edge member has a first floor surface. The second edge member is
disposed substantially perpendicular to the first edge member and
has a second floor surface. The first center member is disposed
adjacent to the first edge member and has a third floor surface.
When the floor panel is assembled, the first floor surface, the
second floor surface, and the third floor surface are disposed
substantially within the same plane.
Inventors: |
Spransy; Peter J.; (Salt
Lake City, UT) ; Mazur; Brian; (Bend, OR) |
Correspondence
Address: |
MADSON & AUSTIN;GATEWAY TOWER WEST
SUITE 900, 15 WEST SOUTH TEMPLE
SALT LAKE CITY
UT
84101
US
|
Assignee: |
DAW Technologies, Inc.
Salt Lake City
UT
|
Family ID: |
38320609 |
Appl. No.: |
11/624148 |
Filed: |
January 17, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60759465 |
Jan 17, 2006 |
|
|
|
Current U.S.
Class: |
52/263 |
Current CPC
Class: |
F24F 13/06 20130101;
F24F 2221/40 20130101; E04F 15/02458 20130101; E04F 15/02405
20130101 |
Class at
Publication: |
52/263 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A modular raised access floor panel comprising: a frame,
comprising: a first extruded edge member having a first floor
surface; and a second extruded edge member disposed substantially
perpendicular to the first extruded edge member and having a second
floor surface; a first die-cast center member disposed adjacent to
the first extruded edge member and having a third floor surface;
and wherein the first floor surface, the second floor surface, and
the third floor surface are disposed substantially within the same
plane.
2. The modular raised access floor panel of claim 1, wherein the
first extruded edge member further comprises a support ledge and
the first die-cast center member rests on the support ledge.
3. The modular raised access floor panel of claim 2, wherein the
second extruded edge member further comprises a support ledge and
the first die-cast center member rests on the support ledges of the
first and second extruded edge members.
4. The modular raised access floor panel of claim 1, wherein the
first die-cast center member further comprises a plurality of
apertures.
5. The modular raised access floor panel of claim 4, wherein the
plurality of apertures comprise slotted perforations.
6. The modular raised access floor panel of claim 4, wherein the
plurality of apertures are die-cast with the die-cast center
member.
7. The modular raised access floor panel of claim 4, wherein the
plurality of apertures are drilled into the die-cast center
member.
8. The modular raised access floor panel of claim 1, wherein the
first die-cast center member further comprises a plurality of
support ribs.
9. The modular raised access floor panel of claim 8, wherein the
plurality of support ribs comprises a plurality of full-length
support ribs and a plurality of less than full-length support
ribs.
10. The modular raised access floor panel of claim 1, further
comprising a corner member.
11. The modular raised access floor panel of claim 10, wherein the
corner member further comprises a first ear and a second ear.
12. The modular raised access floor panel of claim 11, wherein the
first extruded edge member further comprises a cavity and the
second extruded edge member further comprises a cavity.
13. The modular raised access floor panel of claim 12, wherein the
first ear of the corner member press-fits into the cavity of the
first extruded edge member and the second ear of the corner member
press-fits into the cavity of the second extruded edge member.
14. The modular raised access floor panel of claim 1, further
comprising an extruded cross member disposed substantially
perpendicular to the first extruded edge member and having a fourth
floor surface and wherein the fourth floor surface is disposed
substantially within the same plane as the first, second, and third
floor surfaces.
15. The modular raised access floor panel of claim 14, wherein the
extruded cross member further has support ledges.
16. The modular raised access floor panel of claim 15, further
comprising a second die-cast center member disposed adjacent to the
extruded cross member and the second die-cast center member rests
on one of the support ledges of the extruded cross member.
17. The modular raised access floor panel of claim 16, wherein the
first and second die-cast center members each further comprise a
plurality of apertures and the plurality of apertures in the second
die-cast center member are different from the plurality of
apertures in the first die-cast center member.
18. The modular raised access floor panel of claim 1, wherein the
raised access floor panel is comprised of aluminum.
19. A modular raised access floor panel comprising: a first edge
member comprising a cavity and a support ledge; a second edge
member disposed substantially perpendicular to the first edge
member, comprising a cavity and a support ledge; a first center
member disposed adjacent to the first edge member and having a
third floor surface, the first center member comprising a plurality
of apertures; a second center member disposed adjacent to the first
edge member and having a fourth floor surface, the second center
member comprising a plurality of apertures; a cross member
positioned between the first center member and the second center
member and having a fifth floor surface, the cross member
comprising a plurality of support ledges; wherein the first floor
surface, the second floor surface, the third floor surface, the
fourth floor surface, and the fifth floor surface are disposed
substantially within the same plane; wherein the first center
member rests on the support ledge of the first edge member, the
support ledge of the second edge member, and at least one of the
plurality of support ledges of the cross member; and wherein the
second center member rests on the support ledge of the first edge
member and at least one of the plurality of support ledges of the
cross member.
20. A modular raised access floor assembly comprising: a plurality
of modular raised access floor panels each comprising: a plurality
of edge members, the plurality of edge members comprising a first
floor surface, a cavity, and a support ledge; a center member
disposed adjacent to at least one of the plurality of edge members
having a second floor surface, the center member comprising a
plurality of apertures; a plurality of corner members comprising a
third floor surface, a first ear, and a second ear; wherein the
center member rests on at least one of the support ledges of the
plurality of edge members; and wherein the first ear of at least
one of the plurality of corner members press-fits into the cavity
of one of the edge members and the second ear of that corner member
press-fits into the cavity of another edge member; wherein the
first floor surfaces, the second floor surface, and the third floor
surfaces are disposed substantially within the same plane; and
wherein at least two of the plurality of corner members are
connected.
21. The modular raised access floor assembly of claim 20, wherein
one of the center members is the same structure as another center
member.
Description
RELATED APPLICATIONS
[0001] This application is related to and claims priority from
Provisional U.S. Patent Application Ser. No. 60/759,465 filed Jan.
17, 2006, for an Extruded and Die-Cast Aluminum Raised Access
Floor, with inventors Peter J. Spransy and Brian Mazur, which is
incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to flooring. More
specifically, the present invention relates to raised-access
floors.
BACKGROUND
[0003] Raised access flooring systems have been used for decades in
areas of buildings that require frequent access to the space
underneath the floor. Typically used in computer labs and cleanroom
areas, the space underneath the access floor is generally used to
route pipes, electrical wires, and signal lines. Often the area
under the floor is also used to return air that comes into the room
via filters in the ceiling. To provide easy access, the floor may
be made up of floor panels, typically two feet square, which may be
supported on pedestal stands. Removing a single panel or a number
of panels may thus allow access. Equipment may be either placed
directly on the floor or if extremely heavy supported on separate
stands. Recently in the microchip industry, the equipment in
cleanrooms has become significantly heavier, causing building
operators concern when moving in new equipment. If a heavily loaded
floor panel breaks, the expensive equipment might be significantly
damaged.
[0004] The typical die-cast aluminum floor panel generally has two
main limitations: first, the actual materials used and second, an
inefficient structural design.
[0005] First, the alloying materials used in the die-cast aluminum
may cause the material properties to be relatively brittle compared
to wrought or extruded aluminum alloys. This typically gives the
material low resistance to impact loading. In addition, the very
nature of the die-casting process may induce impurities,
inclusions, small gas pockets and other material irregularities
that may reduce the strength in general and may greatly increase
the variability of the strength properties. This is generally
compensated for by using a larger design factor of safety than that
used for wrought aluminum.
[0006] Second, with die-casting, it may be necessary to design
draft into the part being produced so the cast part can be ejected
from the die. Draft typically means that every surface of the cast
piece is tapered so it will release from the die after molding. In
the case of the panel design, this typically means that the
structural ribs are tapered so that the bottom of the ribs is
thinner than where the ribs join the top plate surface. This is
usually inefficient since to resist bending loads in the panel
there should be generally more material at the bottom, i.e., to get
an I-beam effect.
[0007] Attempts have been made to produce welded panels from
extruded shapes but the cost to manufacture this style has
generally precluded their adoption. Steel floor panels have also
been used sporadically, however, they are usually excessively
heavy, making them difficult to place and remove by one person and
are not typically recognized as cleanroom compatible since any
scratches in the finished surface could eventually rust becoming a
source of contaminates. Steel panels are also typically very
difficult and costly to cut in the field.
[0008] Therefore, a need exists for a raised access floor that is
strong, lightweight, and less expensive to manufacture.
SUMMARY OF THE INVENTION
[0009] [SUMMARY OF THE CLAIMED INVENTION--TO BE COMPLETED AFTER THE
CLAIMS ARE FINALIZED]
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Exemplary embodiments of the invention will become more
fully apparent from the following description and appended claims,
taken in conjunction with the accompanying drawings. Understanding
that these drawings depict only exemplary embodiments and are,
therefore, not to be considered limiting of the invention's scope,
the exemplary embodiments of the invention will be described with
additional specificity and detail through use of the accompanying
drawings in which:
[0011] FIG. 1 is an exploded perspective view of an embodiment of a
raised access floor panel;
[0012] FIG. 2 is a perspective view of another embodiment of a
raised access floor panel;
[0013] FIG. 3 is a perspective view of a further embodiment of a
raised access floor panel;
[0014] FIG. 4 is a bottom perspective view of the embodiment of a
raised access floor panel as shown in FIG. 3;
[0015] FIG. 5 is a bottom view of the embodiment of a raised access
floor panel as shown in FIG. 3;
[0016] FIG. 6 is a perspective view of an embodiment of a raised
access floor system;
[0017] FIG. 7 is a perspective view of the embodiment of a modular
raised access floor system shown in FIG. 6 with a supported load;
and
[0018] FIG. 8 is a perspective view of the embodiment of a modular
raised access floor system shown in FIG. 6 with a supported load
where some of the center members have been moved from the
disposition of FIG. 7 and positioned near the supported load.
DETAILED DESCRIPTION
[0019] Various embodiments of the invention are now described with
reference to the Figures, where like reference numbers indicate
identical or functionally similar elements. The embodiments of the
present invention, as generally described and illustrated in the
Figures herein, could be arranged and designed in a wide variety of
different configurations. Thus, the following more detailed
description of several exemplary embodiments of the present
invention, as represented in the Figures, is not intended to limit
the scope of the invention, as claimed, but is merely
representative of the embodiments of the invention.
[0020] The word "exemplary" is used herein to mean "serving as an
example, instance, or illustration." Any embodiment described
herein as "exemplary" is not necessarily to be construed as
preferred or advantageous over other embodiments.
[0021] While the various aspects of the embodiments are presented
in drawings, the drawings are not necessarily drawn to scale unless
specifically indicated.
[0022] FIG. 1 is an exploded perspective view of an embodiment of a
modular raised access floor panel 100. The modular floor panel 100
may be assembled from edge members 102, corner members 104 and a
center member 106. The edge members 102 may form the circumference
(or frame) of the modular floor panel 100. The edge members 102 may
include a floor surface 103. The edge members 102 may be extruded.
The edge members 102 may be made of aluminum.
[0023] Edge members 102 that are extruded and/or made of aluminum
may provide several advantages over die-cast and/or aluminum parts.
For example, die-cast aluminum is typically brittle and
unpredictable, generally requiring employing a larger safety
factor, which is inefficient. Overloaded die-cast aluminum may fail
quickly and catastrophically. Extruded aluminum is generally
ductile and may have higher impact resistance. When overloaded,
extruded aluminum will generally yield in bending, giving warning
of overload. Extruded aluminum may bend and even be permanently
damaged but will often not fail.
[0024] In another example, die-cast material may need to be cut to
create specialty floor panels for pass-throughs, vacuum ports,
electrical connections, and other unique requirements. Cutting
die-cast material often results in a compromised floor panel and
may result in inadequately supported panel loads. Additionally,
welding die-cast material may be very unreliable and may
consequently render a welded floor panel structurally
undependable.
[0025] In comparison to die-cast material, extruded material may be
welded very easily. This may facilitate welding suitable
reinforcement onto the panel which may reestablish a permanent
structural design after the panel has been modified. Furthermore,
specialty panels may be cast into the center member 106 of the
panel 100 and/or the center member 106 may be removable creating an
access hatch in the floor panel 100. Unusual size panels, i.e.,
rectangular panels, may also be easily fabricated, which is
typically not possible from existing die-cast panels.
[0026] Modular floor panels 100 that include edge members 102 may
provide an advantage over entirely die-cast floor panels, because
producing a new die-casting die typically includes exorbitant costs
and long lead-times. In embodiments where the edge members 102 are
extruded, preparing a new extrusion die is typically minimal in
comparison. Furthermore, when the edge profiles 102 are extruded
rather than die-cast with the center member 106, the die-cast
portions of the floor panel 100 may be reduced, which may reduce
the size of the parts to be die-cast. Reductions in the size of the
parts to be die-cast may significantly reduce the cost of
manufacture and installation.
[0027] The edge members 102 may be essentially rectangular tubes in
shape. The edge members 102 may include cavities 112. In
embodiments where the edge members 102 are rectangularly shaped
tubes, the edge members 102 may form a box-beam at the full
perimeter where bending stresses are highest. This may give the
edge members 102 a high strength to weight ratio. This provides a
further advantage over die-cast edge members because die-cast parts
typically require draft so that the cast part may release from the
die. Draft may limit the amount of load that can be applied to a
floor whether such loads are stationary loads or loads caused by
equipment move-in. Making the entire panel from die-cast material
may weaken the floor system because the edge of the floor panel is
typically the weakest part of the panel particularly when
supporting a rolling load that is passing over the edge of one
panel onto another.
[0028] In other embodiments, the edge members 102 may also include
ribs (not shown) and/or pretension cabling to increase the strength
of the panel 100. This may provide a strengthening option that may
not restrict the space beneath the panel 100, unlike simply
increasing the depth of the panel 100.
[0029] The center member 106 may form the center section of the
panel 100. The center member 106 includes a floor surface 107. The
center member 106 may be made of aluminum and/or die-cast. The
center member 106 may include a pattern of apertures 108. In some
embodiments, the apertures are integrally formed with the center
member 106. The apertures 108 may provide sufficient open area to
facilitate airflow. For example, in a cleanroom application, the
apertures 108 may allow a user to take advantage of the space
underneath the floor panel 100 for the return of filtered air. The
apertures 108 may be drilled, die-cast with the center member 106,
and/or otherwise formed. In embodiments where the apertures 108 are
drilled into a die-cast center member 106, drilling may be
simplified because drilling a die-cast center member 106 may
generate granular shavings versus the long stringy shavings
typically generated while drilling an extruded center member
106.
[0030] The corner members 104 may include floor surfaces 105. The
corner members 104 may include ears 110. The ears 110 may be
press-fit into the cavities 112 of edge members 102 forming a
rectangular or square outer frame. The corner members 104 may be
die-cast and/or aluminum. Each of the corner members 104 may be
shaped substantially identically such that they are interchangeable
and may be positioned at any corner of the frame.
[0031] The edge members 102 may include a support ledge 114. When
used opposite each other, the support ledges 114 may provide
support for the center member 106. Because the center member 106,
of the present embodiment, does not interlock with the edge members
102, it is removable. This may provide the advantage of being able
to first assemble the edge members 102 and corner members 104 and
then place the center members 106 into place. This may make
installation by a single installer possible. In other embodiments,
the center member 106 may be fixed to at least one support ledge
114. The center member 106 may be fixed to a support ledge 114 by,
for example, screws. Fixing the center member 106 to a support
ledge 114 may help to prevent rattling between the center member
106 and other components of the floor panel 100.
[0032] In the present embodiment, when fully assembled, the floor
surfaces 103 of the edge members 102, the floor surfaces 105 of the
corner members 104, and the floor surface 107 of the center member
106 may be disposed substantially within the same plane.
[0033] FIG. 2 is a perspective view of another embodiment of a
modular raised access floor panel 200. The floor panel 200 of the
present embodiment is similar to the previously described floor
panel 100, because it may be assembled from edge members 202, which
are essentially rectangular tubes in shape, and corner members 204.
The center member 206 forms the center section of the panel 200.
The center member 206 may include integral full depth ribs to
create slotted perforations 208 instead of apertures 108. The
slotted perforations 208 may be longer than the apertures 108,
which may provide more airflow through the slotted perforations 208
than the apertures 108. The center member 206 may include small
ribs (not shown) that may add stiffness between the larger full
depth ribs (not shown). Another embodiment that uses integral full
depth ribs and small ribs is shown in FIG. 4.
[0034] The edge members 202 may include a floor surface 203. The
corner members 204 may include floor surfaces 205. The center
member 206 may include a floor surface 207. In the present
embodiment, as assembled, the floor surfaces 203 of the edge
members 202, the floor surfaces 205 of the corner members 204, and
the floor surface 207 of the center member 206 may be disposed
substantially within the same plane.
[0035] In other embodiments, the edge members 202 may have tongue
and groove interlocking edges (not shown), which may eliminate the
need for welding the basic panel. In the present embodiment, the
edge members 202 are made of aluminum and/or extruded. The corner
members 204 and/or the center members 206 may be die-cast and/or
aluminum.
[0036] Referring to FIGS. 3, 4 and 5, FIG. 3 is a perspective view
of a further embodiment of a modular raised access floor panel 300;
FIG. 4 is a bottom perspective view of the floor panel 300; FIG. 5
is a bottom view of the floor panel 300. The floor panel 300, in
the present embodiment, may be similar to the previously described
floor panels 100, 200, because it may be assembled from edge
members 302, 330 and corner members 304. The edge members 302, 330
may essentially be rectangular tubes in shape. The edge members
302, 330 may be cut to length. Two of the edge members 330 may be
longer than the other two edge members 302.
[0037] Additionally, a cross member 332 may be positioned near the
middle of the longer edge members 330. The cross member 332 may
include support ledges 340 that may support the center members 306.
Likewise, the edge members 302, 330 may have support ledges
314.
[0038] The cross member 332 may be attached using bolts, may simply
rest on the support ledges 314 of the longer edge members 330, may
rest on the support ledges 314 and be bolted to the longer edge
members 330, and/or may be attached using other attachment methods.
There are myriad methods for connecting the cross member 332 to the
longer edge members 330 to create a support for the center members
306.
[0039] In embodiments where two of the edge members 330 are longer
than the other two edge members 302, the modular raised access
floor panel 300 may be used with open waffle slab subfloors.
Typically, an elaborate under floor substructure may be required to
support the square floor pedestals when used in conjunction with
open waffle slab subfloors. Because two of the edge members 330 are
longer than the other two edge members 302, the floor panel 300 may
span across the openings in the concrete slab potentially
eliminating the need for any additional substructure.
[0040] Further, two center members 306 may form the center section
of the panel rather than the single center members 106, 206 of the
previous embodiments. The top surface of the center members 306,
shown in FIG. 3, may include apertures 308 similar to FIG. 1. These
apertures 308 may be combined with integral full depth ribs 320.
The center member 306 may include small ribs 322 that may add
stiffness between the larger full depth ribs 320.
[0041] The edge members 302, 330 may be extruded and/or aluminum.
The corner members 304 and/or the center members 306 may be
die-cast and/or aluminum. The edge members 302, 330 may include a
floor surface 303. The corner members 304 may include floor
surfaces 305. The center members 306 may include floor surfaces
307. In the present embodiment, the floor surfaces 303 of the edge
members 302, 330, the floor surfaces 305 of the corner members 304,
and the floor surfaces 307 of the center members 306 may be
disposed substantially within the same plane.
[0042] These floor panels 100, 200, 300 may be modular, with center
panels 106, 206, 306 that may be easily removed and/or replaced.
The modular floor panels 100, 200, 300 may be supported on
pedestals (not shown) that leave space between the structural floor
and the assembled floor panels 100, 200, 300. Floor panels 100,
200, 300 in the USA are typically 24 inches by 24 inches square. In
embodiments with two center members 306, the floor panels 100, 200,
300 may be 48 inches by 24 inches square. In two center member 306
embodiments, the cross member 332 may have substantially twice the
width as an edge member 102. In further embodiments, multiple edge
members 102, multiple center members 106, and/or multiple cross
members 332 may be used to create larger floor panels 100. For
example, a floor panel 100 with four center members 106 may be
contemplated.
[0043] FIG. 6 is a perspective view of an embodiment of a modular
raised access floor system 450. The modular raised access floor
system 450 may include multiple floor panels 100, 400. The floor
panels 100, 400 may be assembled from edge members 102, corner
members 104 and center members 106, 406. In some embodiments, the
center members 106, 406 may be die-cast. Some center members 106
may include apertures 108. Other center members 406 may not include
apertures 108. In other embodiments, the center members 206 (shown
in FIG. 2) may include slotted perforations 208 and/or other
apertures.
[0044] The center members 106, 406 may be modular. The edge members
102 may form the circumference (or frame) of the modular floor
panels 100, 400.
[0045] The floor panels 100, 400 may be supported by pedestals 460.
The pedestals 460 may secure the corner members 104 together. The
pedestals 460 may secure the corner members 104 using bolts and/or
other securing methods.
[0046] In some embodiments, the modular raised access floor system
450 may include a covering after being fully assembled. For
example, a vinyl covering may be used to give the floor system 450
a smooth surface for rolling loads and/or other purposes.
[0047] FIG. 7 is a perspective view of the embodiment of a modular
raised access floor system 450 shown in FIG. 6 with a supported
load 470. As shown in FIG. 7, the perforated center members 106 are
not located around the supported load 470. Rather, non-perforated
center members 406, which may not allow for the passage of a
significant amount of air, are positioned under and around the
supported load 470. In cleanroom applications, airflow may be
generally directed near machinery, if desired. In FIG. 7, the
airflow may be generally directed away from the supported load 470
and toward the lower edge of the floor system 400 because the
non-perforated center members 406 are positioned under and around
the supported load 470.
[0048] FIG. 8 is a perspective view of the embodiment of a modular
raised access floor system 450 shown in FIG. 6 with a supported
load 470 where some of the center members 106, 406 have been moved
and positioned near the supported load 470. The floor system 450
shown in FIG. 8 may provide more airflow directed toward the
supported load 470 because some of the non-perforated center
members 406 that were positioned around the supported load 470, as
shown in FIG. 7, have been replaced with perforated center members
106. Airflow may be further increased by replacing the
non-perforated center members 406 and/or perforated center members
106 that are positioned near the supported load 470 with perforated
center members 206 (shown in FIG. 2) having slotted perforations
208.
[0049] Because cleanroom layouts and equipment may be routinely
changed, in embodiments where the center members 106 are removable,
the modular raised access floor system 450 may provide simpler
modification of the floor's airflow without disrupting walls (not
shown) that are usually located on the joints between panels, which
would remain in place. This may avoid the problem of moving walls
and/or portions of walls when the panel to be removed lies under
the wall.
[0050] Furthermore, because the center members 106 are removable,
the total weight of the floor panels 100 may be significantly
reduced. This may reduce installation costs because a job that
otherwise may require two workers, based on weight restrictions
and/or fatigue, may generally be accomplished by one worker. The
modular nature of the center members 106, 206, 306, 406 may also
permit early installation of floors and walls which may prevent
installation delays based on the final airflow requirement
determinations, because, while these determinations are being made,
the installer may assemble the edge profiles 102 and corner members
104.
[0051] While specific embodiments and applications of the present
invention have been illustrated and described, it is to be
understood that the invention is not limited to the precise
configuration and components disclosed herein. Various
modifications, changes, and variations, which will be apparent to
those skilled in the art, may be made in the arrangement,
operation, and details of the methods and systems of the present
invention disclosed herein without departing from the spirit and
scope of the invention.
* * * * *