FLOOR PANEL
A floor panel is provided including a floor chassis, an acoustic-mat layer and a gypsum concrete layer. The floor panel may be prefabricated and quickly installed on the job site thereby cutting construction time and costs.
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This application claims the benefit of U.S. Provisional Application No. 62/760,432 for FLOOR AND WALL MODULAR SYSTEM filed on Nov. 13, 2018, which is incorporated by reference as if fully set forth.
FIELD OF INVENTIONThe present invention relates generally to the art of building construction, and more specifically to a floor panel, and a method of assembling a floor panel.
BACKGROUNDFloors are typically built on the job site. Floors are constructed layer by layer. This piecemealed construction is tedious and time consuming, which ultimately results in higher construction costs.
SUMMARYA floor panel is provided including a floor chassis, an acoustic-mat layer and a gypsum concrete layer. The floor panel may be prefabricated and quickly installed on the job site thereby cutting construction time and costs.
The foregoing summary, as well as the following detailed description will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, there is shown in the drawings different embodiments. It should be understood, however, that the teachings are not limited to the precise floor panel arrangement shown.
A floor panel is provided. The floor panel includes a floor chassis, an acoustic-mat layer and a gypsum concrete layer. The floor panel may be prefabricated, and can be quickly and efficiently installed at the job site thereby saving time and money.
The method of assembling 400 may also include step 450 of connecting a flooring membrane 140 to the gypsum concrete layer 130. The method of assembling 400 may also include step 460 of connecting a finish flooring 150 to the flooring membrane 140. The method may also include step 470 of shipping the floor panel 100 to a job site. The method may also include step 480 of installing the floor panel 100 in a room, such as a bathroom, bedroom, office, dining room, basement, etc. The steps in the method 400 described herein and illustrated in the flow chart in
Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the floor panel and the method of assembling the floor panel without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.
Claims
1. A floor panel comprising:
- a floor chassis;
- an acoustic-mat layer connected to the floor chassis; and
- a gypsum concrete layer connected to the acoustic-mat layer.
2. The floor panel of claim 1, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are segments that fit together.
3. The floor panel of claim 1, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are laminated together.
4. The floor panel of claim 1, further comprising a flooring membrane connected to the gypsum concrete layer.
5. The floor panel of claim 4, further comprising a finish flooring connected to the flooring membrane.
6. The floor panel of claim 1, wherein the floor chassis includes at least one opening.
7. The floor panel of claim 1, wherein the floor panel is prefabricated.
8. A room modular system comprising:
- a room including at least one wall frame including a top plate, a bottom plate, a plurality of studs; and
- a floor panel comprising a floor chassis, an acoustic-mat layer on top of the floor chassis, and a gypsum concrete layer on top of the acoustic-mat layer;
- wherein the bottom plate of the at least one wall frame is connected to the floor chassis.
9. The room modular system of claim 8, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are segments that fit together.
10. The room modular system of claim 8, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are laminated together.
11. The room modular system of claim 8, further comprising a flooring membrane connected to the gypsum concrete layer.
12. The room modular system of claim 11, further comprising a finish flooring connected to the flooring membrane.
13. The room modular system of claim 8, wherein the floor panel is prefabricated.
14. The room modular system of claim 8, wherein the floor chassis includes at least one opening.
15. The room modular system of claim 14, wherein the bottom plate includes at least one other opening that aligns with the at least one opening of the floor chassis.
16. A method of assembling a floor panel comprising:
- connecting an acoustic-mat layer to a floor chassis;
- connecting a gypsum concrete layer to the acoustic-mat layer and the floor chassis;
- cutting the floor chassis, the acoustic-mat layer, and the gypsum concrete layer into segments configured to fit together; and
- shipping the floor panel to a job site.
17. The method of claim 16 further comprising connecting a floor membrane to the gypsum concrete layer.
18. The method of claim 17 further comprising connecting a finish flooring to the floor membrane and the gypsum concrete layer.
19. The method of claim 17 further comprising laminating the floor chassis, the acoustic-mat layer, and the gypsum concrete layer.
20. The method of claim 17 further comprising installing the panel in a room at the job site.
Type: Application
Filed: Nov 13, 2019
Publication Date: May 14, 2020
Applicant: Katerra Inc. (Menlo Park, CA)
Inventors: Darrin Griechen (Spokane, WA), Robert Stanford (Flowery Branch, GA)
Application Number: 16/682,192