Prefabricated aggregated floor panel device and system and method for making and installing aggregated panels

Abstract

A prefabricated terrazzo panel and system, method for making terrazzo panels and method for installing terrazzo panels wherein the panels comprise terrazzo epoxy, a top surface, a bottom surface, sides and a groove along each side and the panel system comprises a plurality of panels, locking strips that join adjacent panels and terrazzo or terrazzo-like filler for joining and creating a seamless joint between adjacent panels. The method of manufacturing the panels generally includes providing, installing and, or preparing borders on a flat, level horizontal structure, applying an epoxy primer having a high viscous to the supporting structure to prevent adherence, introducing previously prepared epoxy terrazzo or comparable aggregate mixture into the border volume, leveling the pour mixture, allowing it to cure, grinding the surface of the cured aggregate to a desired thickness, sanding and polishing the top surface, and cutting the cured terrazzo into panels having predetermined dimensions. The method of installing prefabricated terrazzo panels comprises applying an epoxy primer to the selected floor surface, applying a coat of setting material to the floor surface with a notched trowel, aligning and setting panels and locking strips on the prepared floor surface in a manner that places the locking strip heads in the panel grooves, filling any with a terrazzo epoxy filler or similar filler, allowing setting time, grinding the filler flush with the top surface of the panels and polishing the top surface of the panels and joints.

What is claimed is:  
     
         1 . An aggregated floor panel system, said system comprising: 
 at least one substrate comprising at least a terrazzo-like material;    said substrate having a top surface, bottom surface, a plurality of sides and predetermined dimensions; and    a groove formed in at least one of said sides to facilitate joining to an adjacent substrate.    
     
     
         2 . A system as recited in  claim 1 , farther comprising: 
 a plurality of substrates; and    means for dividing and joining adjacent substrates.    
     
     
         3 . A system as recited in  claim 2 , wherein said dividing and joining means comprises: 
 a locking strip having a projecting tongue adapted for mating with said groove.    
     
     
         4 . A system as recited in  claim 3 , wherein said locking strip further comprises a stem having a width that is smaller than a width of said tongue.  
     
     
         5 . A system as recited in  claim 2 , wherein said locking strip further comprises: 
 a perforated base.    
     
     
         6 . A system as recited in  claim 2 , wherein said locking strip is elongated.  
     
     
         7 . A system m as recited in  claim 1 , wherein said system comprises a plurality of substrates.  
     
     
         8 . A method for making at least one terrazzo-based panel having at least one groove in at least one side, said method comprising the steps of: 
 employing a frame on a substantially flat and level surface having a volume and base layer of a plastic-based laminate therein, wherein said laminate has properties that prevent permanent adhesion of an aggregate terrazzo-based mixture thereto;    introducing a terrazzo epoxy based solution inside the volume and onto said base layer;    leveling said solution to a predetermined height and to establish a top surface;    allowing said solution to cure for a predetermined period of time so as to form a substrate; and    cutting said substrate into a plurality of panels having side edges and at least one predetermined shape.    
     
     
         9 . A method as recited in  claim 8 , further comprising the steps of: 
 grinding said top surface until a desired thickness is achieved; and    polishing said top surface after said grinding step.    
     
     
         10 . A method as recited in  claim 9 , further comprising the step of: 
 profiling at least one of said side edges so as to define at least one groove extending at least partially across said at least one side edge, said profiled side edge having a cross sectional shape that corresponds to a shape of a selected locking strip.    
     
     
         11 . A method as recited in  claim 9 , further comprising the step of: 
 sanding said top surface.    
     
     
         12 . A method for installing a plurality of terrazzo-based panels having grooves in at least one side edge, said method comprising the steps of: 
 (a) applying an epoxy primer to a surface on which panels are intended to be installed;    (b) applying an epoxy setting material over said epoxy primer, said setting material having a thick consistency similar to mayonaisse;    (c) installing a tongue portion of a locking strip in a corresponding groove in a panel;    (d) placing said panel and locking strip over and on said setting material;    (e) aligning a second panel side edge groove with said locking strip in said first panel, said second panel having a second locking strip installed in a second groove defined by said second panel;    (f) repeating steps a through e a predetermined number of times;    (g) filling in any gaps in or between said panels with a terrazzo epoxy corresponding the terrazzo epoxy used to make said panels; and    (h) sanding the top surface of said panels.