DETAILED DESCRIPTION OF THE INVENTION

[0032] With reference to the drawings, FIGS. 1-12 depict the preferred and alternative embodiments of the instant invention which is generally referenced as a prefabricated panel and, or system and, or method for making and, or method for installing prefabricated panels and, or by numeric character 10. Referring to FIGS. 1-12, the instant invention comprises a prefabricated panel or tile 10, panel system 10, 20, 30, 40, 50 process and system for making aggregated floor panels 100, 110 and process for installing the prefabricated aggregated floor panels 10. The prefabricated panels preferably comprise a terrazzo or terrazzo-based tile that may be installed on a floor surface, wall surface or other flat substrate. The panel system 10, 20, 30, 40, 50 comprises the components used to form and that facilitate installation of the panels 10, as shown in FIGS. 5, 6 and 12. The system for making the panels 10 comprises the components that facilitate the manufacture of the panels 10, as shown in FIGS. 7-9. The process for installing the prefabricated terrazzo panels 10 is described herein.

[0033] With reference to FIGS. 1 and 2, the prefabricated panels 10 comprise a tile substrate 11, top surface 12, bottom surface 14, sides 15 and at least one groove 16 formed in and along at least one side 15. The tile substrate 11 preferably comprises an aggregate or terrazzo mixture, such as epoxy terrazzo or aggregate having terrazzo-like specifications. The groove 16 preferably extends along each side and may extend completely across each side. Alternatively, the groove 16 may extend partially across one or more of the sides 15. The panels 10 are preferably at least substantially square or rectangular and have a thickness of approximately one-quarter inch (1/4″) to three-eights inch (⅜″) or thicker. In an alternative embodiment, the panels 10 may comprise alternative geometric shapes and, or dimensions. The groove(s) 16 provide a track for receiving a portion of a locking strip 20 when interlocking adjacent panels 10 during the installation process. The panels 10 can be made in various sizes, such as four feet (4′) by four feet (4′), five feet (5′) by five feet (5′), six feet (6′) by six feet (6′), or other dimensions. The bottom surface 14 of the cured aggregate panels 10 have a textured surface for facilitating bonding with a floor surface. The prefabricated panels 10 preferably comprise small pieces of marble, granite or other known substitutes set in mortar and having a high polish finish. The dimensions noted herein may vary without departing from the scope and spirit of the instant invention.

[0034] With reference to FIGS. 1-6, the panel system of the instant invention comprises a plurality of prefabricated panels 10 and corresponding number of locking strips 20 that facilitate installation. The locking strip 20 comprises a base 21, apertures 26 formed in the base 21, and a vertically projecting elongated tongue structure 22, as shown in FIGS. 3 and 4. The tongue structure 22 comprises a head 23 that is joined to the base 21 by a stem structure 24 and has an approximate overall height of 0.325 P.I. The head 23 has an approximate width of 0.150 P.I. at the upper end and 0.250 P.I. at its lower or widest end and an approximate height of 0.210 P.I. The stem 24 has an approximate height of 0.125 P.I. and width of 0.063 P.I. The angle of curvature at the lower end of the head 23 is approximately twenty (20) degrees. These dimensions may vary in accordance with design specifications. The base has an approximate thickness of 0.125 P.I. and width of 1.850 P.I. The locking strip 20 is manufactured with a custom prefabricated die in an extrusion process using plastic or a plastic-like material, such as those comprising thermoplastic or thermosetting polymers that can be molded, cast or extruded. The die forms the overall shape of the strip 20. The locking strip 20 may alternatively comprise zinc, aluminum or metals having properties similar to zinc and, or aluminum. A liquid, paste or pliable form of zinc or aluminum may be extruded through a die. The extrusion process produces the shape of the locking strip as shown in FIG. 4. The apertures 26 are punched through the base 21. The panel system may also comprise a coat of epoxy 40, preferably of a high viscous consistency that is similar to a wet paste and an epoxy primer 30. The epoxy primer 30 is placed on the installation surface prior to applying the epoxy 40.

[0035] With reference to FIGS. 11-12, the alternative locking strip 50 comprises a projecting elongated tongue structure 52. The alternative tongue structure 52 comprises a head 53 that is joined to a stem structure 54. The head 53 has an approximate width of 0.50 inches and an approximate height of 0.125 inches. The alternative stem structure 54 has an approximate height of 0.125 inches and width of 0.125 inches. These dimensions may vary in accordance with design specifications. The alternative locking strip 50 is also preferably manufactured with a custom prefabricated die in an extrusion process using plastic or a plastic-like material, such as those comprising thermoplastic or thermosetting polymers that can be molded, cast or extruded. The die forms the overall shape of the alternative strip 50. The alternative locking strip 20 may also comprise zinc, aluminum or metals having properties similar to zinc and, or aluminum. A liquid, paste or pliable form of zinc or aluminum may be extruded through a die. The extrusion process produces the shape of the alternative locking strip as shown in FIG. 11. Unlike the preferred locking strip 20, the alternative locking strip's 50 head 53 is inverted and the stem 54 aligns at or near the top surface of the panels 10 when installed, as shown in FIG. 12. Although the preferred method for installation of aggregated floor panels includes the use of the preferred locking strip 20 and is described with reference to using preferred locking strip 20, the method of installation may include the use of the alternative locking strip 50 without departing from the scope and spirit of the instant invention.

[0036] With reference to FIGS. 7-10, the process and technology for manufacturing the panels 10 generally comprises providing, installing and, or preparing the manufacturing system 100, introducing the epoxy terrazzo or comparable aggregate mixture (generally referenced herein as an epoxy terrazzo mixture 13) into the manufacturing system 100, allowing it to cure, grinding the surface of the cured aggregate to a desired thickness, polishing, cutting the cured terrazzo into panels 10 and preparing the panels 10 for installation. With reference to FIGS. 7-9, the manufacturing system 100 comprises at least one frame 101 preferably formed by a plurality of forms or partitions 102 having an interior surface 104, and a base layer 106 of urethane, Plexiglas or other type of plastic laminate with similar properties, such as Lexan, that is placed on the support substrate 1 within the frame structure 101. The base layer 106 is preferably formed with a liquid urethane that is applied to the support substrate and cured. The liquid urethane is also used to fill in cracks that form in the base layer 106 when tile panels 10 are cut from the epoxy terrazzo deck 15. The interior surface 104 is substantially flat. In an alternative embodiment the interior surface 104 may comprise an elongated, substantially horizontal contoured projection for forming the groove 16 in the panel 10 during the manufacturing process.

[0037] Still referring to FIGS. 7-10, when making the aggregate panels 10 in accordance with the invention it is necessary that the support substrate 1 have a substantially or perfectly level and flat surface. The support substrate 1 is preferably made of a solid material such as concrete. The base layer 106 separates the epoxy terrazzo mixture 13 from the support substrate surface 1, prevents it from adhering to the support substrate surface 1 and has properties that allow the epoxy terrazzo mixture 13 to temporarily adhere to the base layer surface such that it can be released therefrom without damaging the cured aggregate or panel 10. The base layer 106 is adhered to the supporting substrate 1, such as a concrete floor, and bonded thereto with an epoxy or adhesive 108 that prevents the base layer 106 from releasing.

[0038] Once the platform is secured on the support substrate 1, the epoxy terrazzo mixture 13 in a liquid form and with the aggregate mixed therein can be applied to the base layer 106 within the frame structure 101 until the desired thickness is reached and, or as required. The aggregate mixture 13 preferably comprises a liquid form of epoxy terrazzo. Once the epoxy terrazzo mixture 13 has been poured and leveled, the mixture 13 cures for approximately eight (8) hours. Upon completing the curing process, the cured mixture 13 comprises one large sheet or deck-like structure 15. In one embodiment, the deck 15 may comprise a thirty (30) foot by sixty (60) foot panel resulting in 1,800 square feet of cured terrazzo. The next step is to grind the top surface of the terrazzo deck 15 until achieving a consistent thickness. The terrazzo deck 15 is preferably grinded by an inline grinding and polishing machine. The machine travels above the deck 15. After completing the grinding and polishing steps, the terrazzo aggregate 13 is cut into panels 10. The panels 10 can be cut into various sizes and shapes depending upon request or installation requirements, such as 4′×4′, 5′×5′ or 6′×6′. Thereafter, the panels 10 are removed easily from the frame 101 and base layer 106. The back of the panel 10 has a glossy finish after curing. To remove the glossy finish, the panels 10 are lightly sanded to give them a texture finished that facilitate bonding with the installation support surface, i.e. floor. After grinding, polishing and cutting the panels 10, the edges of the panels 10 are profiled with a router bit specifically designed to form grooves 16 that correspond to the shape of the locking strip tongue structure. The grooves 16 mate with the locking strip 20 tongue structure 22 in a manner that locks the panels 10 together to facilitate installation in the field, as shown in FIGS. 5 and 6.

[0039] The prefabricated panels 10 are installed after floor preparation at the installation site is completed. With reference to FIG. 6, the floor 2 is prepared with an epoxy primer 30 and then a coat of setting material, such as epoxy 40, is applied to the floor 2 with a notched trowel. The setting material (epoxy) 40 preferably has a thick consistency, such as mayonnaise, to allow the epoxy 40 to stand vertical until the panel 10 is applied to the floor 2. Proper consistency in the epoxy 40 is achieved by adding a fine type of powder, such as marble dust, to the epoxy 40 in its liquid form until the right consistency is met. The panel 10 is set over the epoxy 40 with a locking strip 40 in place. The panels 10 and strips 20 are installed simultaneously, which locks the system together.

[0040] With reference to FIGS. 9 and 10, an alternative panel 10′ is shown. The alternative panels 10′ are made with contoured edges to facilitate mating of adjacent panels 10′. The contour edges provide more surface area and structure for enhanced surface tension to accommodate an epoxy filler. During installation, the alternative panels 10′ are set next to each other approximately one inch apart to form a gap. The gap between the panels 10′ are filled with an epoxy terrazzo, similar to that used to form the panels 10′ and grinded and polished such that the joined panels 10′ appear seamless. The alternative panels 10′ are made in an alternative frame structure 110 with alternative partitions 114, as shown in FIG. 9, with virtually the same process disclosed herein with respect to the preferred embodiment. The partitions 114 are contoured to form the contoured edges in the panels 10′.

[0041] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious structural and/or functional modifications will occur to a person skilled in the art.