MODULAR HOLLOW FLOOR PANELS WITH INTEGRATED WIRING.

This specification describes a modular, hollow floor panel which when laid over a structural sub-floor, allows reticulation of electrical and communications cabling, without significantly increasing the height of the finished floor level.

It has a major application in automated office buildings, where the extensive use of computing and communications equipment has created a need to locate cabling throughout open office areas, and it is an alternative to the raised "access flooring" used in computer areas which has a depth of several hundred millimetres.

These systems have a greater flexibility in the location of outlets, but cable access between two adjacent points along the floor is only possible by routing the cable up one cell, along the header trench, and down the adjacent cell. Recent devlopments have included the system described in Australian specifications 48,697/85 and 32,227/85. (Specification 48,697/85 describes a header-trench module and specification 32,227/85 describes a cellular raceway module). This is a low-height floor laid onto the structural slab, but is generically a cellular floor of the type described above, and suffers from the same disadvantages; and

"Australian patent specification 39,227/85 discloses a module for use in supporting a floor load above a base. Each module comprises a formation which is adapted to be supported on the base and defines a first set of upwardly closed parallel cable ducts segregated from each other. Each of the ducts has a plurality of spaced apart hollow upstanding projections which support a floor sheet. These modules are laid side by side and end to end. Cables running through the ducts may be passed upwardly through the hollow upstanding projections and exit into the floor. This arrangement however does not allow for cables that are in the ducts to change their direction other than turning upwardly to exit through the floor sheet. The present inventor has perceived the need for a floor made up of modules wherein cables can change direction within the module to allow for more flexible cabling of buildings in which such floors are laid".

The purpose of this invention is to provide a low-height access floor which will allow both lateral and longitudinal cable access to any point on the floor, and which has integral ducting which will provide continuous structural support to the deck, and a means of segregating services, and ameans for creating orderly cable layouts.

According to a first aspect of the present invention, there is provided a modular panel which in use is laid in an extended array over a supporting sub-surface to form a hollow floor, wall or ceiling suitable for reticulating electrical, optic fibre, hydraulic or other conduit, and which comprise an upper load bearing deck which overlies structural support elements which form an interstitial duct zone between the deck and a supporting sub-surface, the elements define a lower duct zone which is partitioned by lateral ribs to form a set of lateral ducts running from one side of the panel to the other, and an upper duct zone which is partitioned by longitudinal ribs to form a set of longitudinal ducts running from one end of the panel to the other, characterised in that said panel comprises a set of vertical ducts which open onto the lower lateral ducts and into the upper longitudinal ducts, and in that each of the lateral, longitudinal and vertical duct sets is composed of two or more sub-sets of ducts and only corresponding ones of each sub-set of the lateral, longitudinal and vertical ducts are in communication, each of the lower lateral ducts being in communication with an upper longitudinal duct of a corresponding sub-set through a vertical duct of that corresponding sub-set.

According to a second aspect of the present invention, there is provided a floor comprising an extended array of modular panels in side-by-side and end to end abutment, in which each panel comprises an upper load bearing deck, bearing onto a plurality of structural support elements which form an intersitial duct zone between the deck and a supporting sub-surface, the structural support elements defining an upper set of ducts extending laterally from one side of the panel to the other and so located within the panel as to align with corresponding duct sets in abutting panels, and a lower set of ducts extending longitudinally from one end of the panel to the other end and so located within the panel as to align with corresponding duct sets in abutting panels, characterised in that the upper and lower sets of ducts are separated by wall means which is formed with holes or knock-out panels allowing communication between the upper sets of ducts and the lower sets of ducts.

Whereas the primary application of the invention is to floors in buildings (and the descriptions herein assume this), it should be understood that there are some situations where the system can be used on walls or ceilings (for example in sound studios) and so the invention is not limited to floor applications.

The invention is now described with reference to the drawings, in which:

1. FIGURE 1 shows an isometric view of a panel with two sets of ducts, each perpendicular, and located one above the other;
2. FIGURE 2 shows a plan-view of the construction shown in Figure 1; and
3. FIGURE 3 shows an isometric view of a panel base which has a series of upper ducts with continuous troughs, which interconnect with ducts on the underside of the panel base via vertical ducts located on each side of the upper ducts.

A critical need of various licencing authorities is that the various trunk cable networks within the floor-space are physically separated from each other. When the networks run only in one direction (for instance perpendicular to the walls) and are thus parallel to each other, separation can be achieved by physical spacing of the panels, or be providing solid barriers between vaults or groups or vaults, so that in effect the channels run in only one direction.

One means of allowing different cable networks to cross each other without passing through the same space is to provide a "tunnel vault" panel with a second set of channels above the tunnel vaults, but at right-hand angles to them. Figures 1 (isometric projection) and 2 (plan view) show such a construction, which has lower channels (40) and perpendicular upper channels (41), which are connected by holes or knock-out panels (42). The holes or panels can be arranged so that each upper channel or group of channels can be uniquely linked to one or a group of lower channels.

In these illustrations there are shown two upper channels or ducts for every lower channel or duct. This arrangement has the advantage that the spans of the overlying deck are reduced, and it can be made thinner. A 2:1 ratio is not essential, however; a 1:1 or a 1:2 ratio may be equally satisfactory from the point of view of cable distribution.

This panel form can be constructed in a number of ways, for example by attaching two extrusions at right-angles, with permanent or removable connections. The panel shown in Figures 2 would be of injection-moulded construction, with a separate deck (43). This deck may be loose-laid or permanently attached or removably attached, and it may be attached over its full area or at the centre or for example along one edge. It may also incorporate the floor finish. In the case of a partially attached deck it may be provided with weakening grooves (44) over the supports or at right-angles to them which would enable it to flex upwards to provide access to the upper channels. The deck may also be fabricated with the upper channels (41) formed as vaults on its underside, so as to form two half-panels joined at the mid-line. This may allow the panels to be fabricated entirely from extruded sections.

The panel shown in Figure 1 may be permanently or removably attached to the sub-floor. It is advantageous to glue it to the sub-floor around the centre of the panel, and in this case grooves (44), (45) may be provided through the walls of the lower vaults, to allow the panel to be curled upwards so as to allow access to the lower vaults from above.

Removable areas (46) may be provided in the walls of the channels in non-structural areas to permit the passage of cables from one channel to the adjacent channel, to improve flexibility and to permit larger radii of curvature from the upper channels to the lower channels.

In the case of a panel comprising a rigid deck and an injection-moulded base, it will be too rigid to adapt to undulations in the sub-floor. Small irregularities may be taken up by bedding the lower ribs in high-build adhesive (46), but in the case of a very uneven sub-floor it may be advantageous to seat the panels in levelling trays.

In all of the arrangements described in this document, the cabling may be introduced into the sub-flooring system in either of two ways - the cable may be laid along its intended route, in which case the cable route must be exposed by lifting the deck or lifting the panel itself so that the cable can be laid, or alternatively the cable may be fed along its intended route, in which case the panel can remain undisturbed. The first method allows greater flexibility and the use of smaller and shallower cable channels, but the second method will minimise disruption to the room and the floor, and will allow the use of broadloom carpet rather than removable tiles.

The panel shown in Figure 1 is fairly simple in construction, but it is difficult to feed wires along the upper channels, because of the natural tendency of the wire to fall through the connecting hole into the lower channel.

An improvement on this basic principle is shown in Figure 3, which shows a moulded panel base to be used in conjunction with a removable deck, and perhaps with a levelling tray.

In this arrangement, sets of ducts are provided along three axes at right-angles to each other. A lateral duct set 51, 52, 53 lies along the underside of the panel base, a longitudinal duct set 61, 62, 63 lies along the upper side of the panel base at right angles to the lower ducts, and the vertical duct set 71, 72, 73 extends from the lower duct set, on each side of the upper horizontal ducts.

Each duct set is made up of a number of sub-sets; preferably three in number, to carry power, telephone and data services respectively.

Where a vertical duct abuts an upper horizontal duct of the same sub-set, an opening occurs between the two ducts (which may take the form of a knock-out panel); but where a vertical duct abuts an upper horizontal duct of a different sub-set, no opening occurs.

Thus each lower duct sub-set is connected to the corresponding upper duct sub-set via a vertical duct, and by such selective interconnections a series of physically separate duct networks are created.

In the example of Figure 3 the upper duct (51) is dedicated to power cabling, and inter-connects with lower ducts of the same sub-set (61) via vertical ducts (71) to create a power conduit grid. Similarly, duct sub-sets 52, 62, 72 form a telephone conduit grid, and duct sub-sets 53, 63, 73 form a data conduit grid.

It will be seen that in addition to the major advantage of this arrangement that cables can be fed along the upper ducts with less risk of deflecting into the lower ducts, a number of further advantages accrue. Firstly, the arrangement provides regular access to each lower duct to enable control of cable feeding without the need to lift all or part of the panel. Secondly, the arrangement allows greater turning radii, of the order required for co-axial cables and optical fibre. Thirdly, the vertical ducts provide superior access to services outlets on the deck above the panel.

Although Figure 3 shows three sets of ducts (for power, telephone and data), this number may of course be varied. In addition, there may be several levels of horizontal ducts. Advantages can be gained by providing four layers of horizontal ducts, with the upper two layers having narrow and closely spaced ducts to reduce distances between possible services outlet points, and with the lower two layers having wide ducts to maximise cable carrying capacity and bending radii.

By utilising the sides of the panel base shown in Figure 3, extending clips may be formed to attach the floor decking to the panel. These clips can be disengaged from the decking panel to allow its temporary removal, and if they are asymmetrical on each side (e.g. of different heights or in different relative locations) the decking will be unable to be mis-oriented when it is replaced. This will allow the decking to have pre-formed outlets, or to be marked with the locations of the services ducts in the panel underneath, so that services can be accessed through drilled holes without the need to remove the panel.