JP2002303017A - Deck floor with groove and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a deck floor with a groove having thin overall thickness, having sufficient rigidity, strength and sound-insulating properties, having superior workability and combining flooring and a supporting member, and to provide its manufacturing method. SOLUTION: In the deck floor with the grooves, in which a metallic corrugated plate and a lower plate are jointed and unified, the grooves are formed by disposing recessed sections in rows to the crest sections of the corrugated plate, and flexural rigidity is increased by installing reinforcing sections to the recessed sections.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a deck floor having a corrugated plate and a lower plate used for a veranda, a balcony, and an indoor floor of a building such as a house, and a groove for mounting a horizontal member such as a rain gutter. And a grooved deck floor which serves both as a floor material and a support member.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open No. 11-200544 discloses a method in which a metal corrugated sheet is superimposed on a flat lower surface of a floor panel, and the floor panel is joined to a crest of the metal corrugated sheet to integrate the floor panel and the metal corrugated sheet. A floor panel is shown that has a high rigidity due to the structure described above, and also realizes a reduction in weight of members.

[0003]

However, when this floor panel is used as a veranda or balcony deck floor,
The gutter must be lower than the rest. It is conceivable to form a groove by attaching a member for raising the floor to the upper part of the deck floor, but it takes time and effort to construct the groove. In addition, if the deck height is limited, sufficient rigidity cannot be secured, and the impact sound and vibration are more likely to be transmitted to the lower floor, which adversely affects the livability. As another method, it is conceivable to form a groove by cutting out a part of the upper part of the deck floor, but when the deck floor is subjected to its own weight and a load,
Compression acts on the notch due to the bending action, causing local buckling in the groove. Then, the corrugated sheet in the groove portion cannot resist the load at all, and only the lower plate resists.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has a groove having a small thickness, sufficient rigidity, strength, sound insulation, and good workability. It is an object of the present invention to provide an attached deck floor and a method of manufacturing the same.

[0005]

According to a first aspect of the present invention, there is provided a grooved deck floor, comprising a metal wave formed in a waveform in which a peak and a valley are continuous. A deck floor comprising a plate and a metal lower plate joined to a valley portion of the plate, and a concave portion arranged in a direction transverse to the peak portion with respect to the peak portion of the corrugated plate. By providing the groove, a groove is formed, and a reinforcing portion is provided around the concave portion. The production and construction of the grooved deck floor can be performed with a small number of steps and can be provided at a low cost, and the relatively thin member facilitates height adjustment with other indoor floors. Further, since the periphery of the concave portion is reinforced, the flexural rigidity of the groove portion is increased, and a floor structure excellent in sound insulation such as an impact sound is obtained.

According to a second aspect of the present invention, in the grooved deck floor, the concave portion is formed by a cutout of the peak portion, and the reinforcing portion is a convex or concave portion extending in a longitudinal direction on a slope around the concave portion. The grooved deck floor according to claim 1, wherein the floor is formed by protrusions. By providing a projection on the corrugated sheet surface of the groove, the bending rigidity of the corrugated sheet of the groove is increased. Then, even in the groove, the corrugated plate cross section resists the bending moment, and high rigidity and strength can be maintained. Further, a plate processed into a trapezoidal shape passing the notch may be joined by additional processing.

According to a third aspect of the present invention, in the grooved deck floor, the concave portion is formed by a cutout of the mountain portion, and the reinforcing portion is formed by folding back the cutout. The grooved deck floor according to claim 1, wherein By providing a fold on the corrugated sheet of the notch,
Since the rigidity of the notch end can be increased, the corrugated plate cross section resists the bending moment even in the groove, and it is possible to maintain high rigidity and strength. Furthermore,
By providing projections on the corrugated sheet surface, higher rigidity and strength can be ensured.

According to a fourth aspect of the present invention, in the grooved deck floor, the concave portion is formed by crushing the mountain portion, and the reinforcing portion is formed by a continuous portion in which slopes on both sides of the mountain portion are crushed. The grooved deck floor according to claim 1, wherein: The ridge is a depression formed by crushing, and since the members are continuous, buckling does not occur in the groove. Further, by providing the projections on the corrugated sheet surface, higher rigidity and strength can be secured.

A grooved deck floor according to a fifth aspect of the present invention is the grooved deck floor according to any one of the first to fourth aspects, wherein a floor plate is provided on the ridge. If metal plates are used for the upper and lower plates and corrugated plates of the grooved deck floor, the deck floor will have high rigidity and strength. In addition, by using a wooden board or a particle board for the upper board, a reasonable deck floor can be obtained.

According to a sixth aspect of the present invention, in the grooved deck floor, a gutter-like horizontal member is provided in the concave portion.
A grooved deck floor according to any one of claims 1 to 5.
The rain gutter portion can be easily configured as a veranda or balcony deck floor. In addition, since the height of a part of the deck is lower than the reference height, the floor can be used as an indoor free access floor.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a grooved deck floor, comprising: forming a corrugated metal sheet having a ridge and a valley formed by a roll; A method of manufacturing a grooved deck floor, comprising a joined metal lower plate, and grooves formed of concave portions arranged in a direction transverse to the peaks of the corrugated plate, wherein the thin plate before roll forming In the roll forming for forming the peaks and the valleys by performing notch processing arranged in a row on a portion corresponding to the peak, a protrusion extending in the longitudinal direction on the slope around the recess formed by the notch. Alternatively, the concave plate is formed by roll forming, and then the lower plate is joined. After cutting the metal plate and forming it into a corrugated sheet by roll forming, it is possible to manufacture a grooved deck floor simply by joining the lower plate to the valley of the corrugated sheet. The floor can be manufactured and constructed, and the deck floor can be provided at a significantly lower cost.

The method of manufacturing a grooved deck floor according to claim 8, wherein the corrugated metal sheet is formed into a corrugated shape in which peaks and valleys are made continuous by roll forming, and the valleys of the corrugated plate are formed on the corrugated sheet. A method of manufacturing a grooved deck floor, comprising a joined metal lower plate, and grooves formed of concave portions arranged in a direction transverse to the peaks of the corrugated plate, wherein the thin plate before roll forming The notches or slits are formed in a row corresponding to the peaks, and after the roll forming for forming the peaks and the valleys, the notches or the slits are pressed into the recesses. And forming a reinforcing portion by folding or crushing at the same time as forming the lower plate, and joining the lower plate. After performing notch or slit processing of the metal plate and performing roll forming to make a corrugated sheet, push in the notch or slit processing part and join the lower plate to the valley of the corrugated sheet, the grooved deck floor Since the manufacturing can be performed, the deck floor can be manufactured and constructed with a small number of steps, and the deck floor can be provided at a significantly low cost.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 3, a first embodiment of the present invention will be described.

FIG. 1 is a perspective view of a first embodiment to which the present invention is applied. A deck floor 1 includes a corrugated plate 2, a lower plate 3, and a floor plate 4. The corrugated plate 2 is made of a folded steel plate and has a peak 2a and a valley 2b formed in an R-shape and a slope 2c formed in a flat plate-like waveform. In the first embodiment, a projection 7 as a reinforcing portion is provided on the slope 2c. Corrugated plate concave portions 5 are arranged in a row in the direction crossing the peak portion 2a on the peak portion 2a of the corrugated plate 2. Reference numeral 3 denotes a metal lower plate, and a rising portion 3a is provided at the same height as the crest 2c of the corrugated plate 2 in a direction along the valleys 2b at both ends of the corrugated plate 2 and at a right angle upward from the lower plate 3. ing. A lower plate recess 6 is provided in the rising portion 3a in the direction in which the corrugated plate recesses 5 are arranged. In the deck floor 1, the corrugated plate 2 is joined to the lower plate 3 at the valley 2b, and the corrugated plate 2 is joined to the floor plate 4 at the crest 2a. The floor plate 4 is also joined at the ends of the rising portions 3a at both ends of the lower plate 3. Have been. Rivet, spot welding, adhesives, screws, nails, and the like can be used for joining the corrugated plate 2 and the lower plate 3, joining the corrugated plate 2 to the floor plate 4, and joining the floor plate 4 and the lower plate 3. When the bottoms of the corrugated plate recessed portion 5 and the lower plate recessed portion 6 are arranged at the same height, a groove A on which a horizontal member such as a gutter can be placed can be obtained. At this time, the groove A can be inclined by adjusting the height of the corrugated plate concave portion 5 and the lower plate concave portion 6. When the deck floor 1 is used for a balcony, a veranda, or the like, the position of the groove A for rain gutter is provided at the end, but in this case, a bending moment generated by its own weight or a load is small. Also, in the groove A part,
The floor plate 4 is not joined to place a horizontal member such as a rain gutter.

FIG. 2 is a sectional view of the corrugated plate 2 and the lower plate 3 in the groove forming portion of the deck floor 1 according to the first embodiment. Corrugated sheet 2
The projection 7 is provided on the inclined surface 2c of the projection. The projections 7 are formed on the inclined surface 2 c of the corrugated plate 2 so as to be uneven, and extend over the entire length of the corrugated plate 2 in the longitudinal direction. A compressive force acts on the slope 2 c of the corrugated plate 2 in the groove forming portion due to the bending action of the deck floor 1, causing local buckling. Therefore, a projection 7 is provided on the slope 2c of the corrugated sheet 2 to improve the bending rigidity of the corrugated sheet 2 and prevent local buckling. The more the projections 7 are provided at positions closer to the corrugated plate concave portion 5 and the greater the number thereof, the more effective. Also, since the compressive force acts in the direction of the corrugated plate, it is more effective if the protrusions are parallel to the waveform. The shape of the projections 7 may be various shapes such as a semicircle, and may be discontinuously arranged in a staggered manner in the longitudinal direction of the corrugated plate. The projection 7 is provided on the slope 2 c of the corrugated plate 2.
May be provided only around the corrugated plate recess 5.

FIG. 3 is a development view of a flat plate 2 'before roll forming of the corrugated plate 2 in the first embodiment. In FIG.
The dotted line indicates the peak 2a of the corrugated sheet 2 after the roll forming, the dashed line indicates the valley 2b of the corrugated sheet 2 after the roll forming, and the slope between the dotted line and the dashed line indicates the slope of the corrugated sheet 2 after the roll forming. 2 shows a part 2c. Flat plate 2 '
, A substantially hexagonal cutout 8 is formed around the dotted line. After the roll is formed, the notch 8 becomes the corrugated plate recess 5 and stress concentration occurs. Therefore, an R portion is provided at the intersection of the notch lines, or the portion of the notch line that intersects with the peak 2a is slightly inclined. Good. The interval between the notches 8 is a distance obtained by subtracting the elongation due to the roll processing from the total length including the protrusions 7 from the peak 2a of the corrugated sheet 2 after the roll forming to the adjacent peak 2a. As a method of manufacturing the corrugated sheet 2 according to the first embodiment, first, a notch 8 is formed on a flat plate 2 'using a punch or the like. Then, the peaks 2a are formed on the flat plate 2 'by roll forming.
The valley 2b is formed, and at the same time, the projection 7 is roll-formed on the slope 2c of the flat plate 2 '. For example, by providing irregularities on the surface of the roll, the projections 7 can be formed simultaneously with the formation of the peaks 2a and the valleys 2b of the corrugated sheet 2.

Next, a second embodiment of the present invention will be described with reference to FIGS.

FIG. 4 shows a second embodiment in which the present invention is applied to a deck floor.
And a sectional view of the lower plate 3. A folded portion 9 as a reinforcing portion is provided in the corrugated plate concave portion 5. The folded length is preferably longer, but if the folded portions on both sides do not interfere with each other during the bending process, and the length is slightly shorter than half of the base of the notched triangle, the working is easy. The turning angle is preferably set to about 90 degrees. Grooves A are formed by arranging the corrugated plate concave portion 5 and the lower plate concave portion 6 in a row.

FIG. 5 is a development view of a flat plate 2 'before roll forming of the corrugated plate 2 in the second embodiment. In the flat plate 2 ′, the dotted line indicates the peak 2 a of the corrugated sheet 2 after the roll forming, the one-dot chain line indicates the valley 2 b of the corrugated sheet 2 after the roll forming, and the area between the dotted line and the one-dot chain line after the roll forming. The slope 2c of the corrugated sheet 2 is shown. A substantially I-shaped notch 8 is formed in the flat plate 2 'around the dotted line. After the roll is formed, the notch 8 becomes the corrugated plate recess 5 and stress concentration occurs. Therefore, an R portion is provided at the intersection of the notch lines, or the portion of the notch line that intersects with the peak 2a is slightly inclined. Good. The interval between the notches 8 is a distance obtained by subtracting the elongation due to the roll processing from the total length from the peak 2a of the corrugated sheet 2 after the roll forming to the adjacent peak 2a. As a method for manufacturing the corrugated sheet 2 according to the second embodiment, a notch 8 is formed on a flat plate 2 'using a punch or the like. Then, the peak 2a and the valley 2b are formed on the flat plate 2 'by roll forming. Thereafter, the folded portion 9 is formed according to the jig arrangement sectional view shown in FIG. The jig arrangement in FIG.
1a and a holding tool 11b. The corrugated plate base 11a has a cross section substantially the same as one of the peaks of the corrugated plate 2, and a portion corresponding to the peak 2a of the corrugated plate 2 is a concave portion conforming to the shape of the folded portion 9. The folded portion 9 is formed by placing the corrugated plate 2 on the corrugated plate base 11a, pressing it down with the presser 11b, and pushing it down with the presser 11c.

Next, a third embodiment of the present invention will be described with reference to FIGS.

FIG. 7 shows a corrugated plate 2 in a groove forming portion of a deck floor 1 according to a third embodiment in which the present invention is applied to a deck floor.
And a sectional view of the lower plate 3. In the corrugated plate concave portion 5, a crushed portion 10 as a reinforcing portion is provided. In this case, corrugated sheet 2
Since the members are continuous at the peak 2a, buckling does not occur at this portion. Grooves A are formed by arranging the corrugated plate concave portion 5 and the lower plate concave portion 6 in a row.

FIG. 8 is a developed view of a flat plate 2 'before roll forming of the corrugated plate 2 in the third embodiment. In the corrugated sheet 2, the dotted line indicates the peak 2a of the corrugated sheet 2 after the roll forming, the dashed line indicates the valley 2b of the corrugated sheet 2 after the roll forming, and the area between the dotted line and the dashed line indicates the value after the roll forming. The slope 2c of the corrugated sheet 2 is shown. Two slits are formed on the flat plate 2 ', centering on the dotted line. After the roll is formed, the notch 8 becomes the corrugated plate recess 5 and stress concentration occurs. Therefore, an R portion is provided at the intersection of the notch lines, or the portion of the notch line that intersects with the peak 2a is slightly inclined. Good. The interval between the notches 8 is a distance obtained by subtracting the elongation due to the roll processing from the total length from the peak 2a of the corrugated sheet 2 after the roll forming to the adjacent peak 2a. As a method of manufacturing the corrugated sheet 2 according to the third embodiment, a notch 8 is formed on a flat plate 2 'using a punch or the like. Then, the peaks 2a and the valleys 2b are formed on the corrugated sheet 2 by roll forming. Thereafter, the crushed portion 10 is formed by the jig arrangement shown in FIG. FIG.
Has a corrugated board base 11a and a holding tool 11b. The corrugated board 11a has a cross section having substantially the same shape as one of the peaks of the corrugated sheet 2, and a portion corresponding to the peak 2a of the corrugated sheet 2 is a concave portion corresponding to the shape of the crushed portion 10. . The squashed part 10 is formed by placing the corrugated plate 2 on the corrugated plate base 11a, pressing the corrugated plate 2 with the presser 11b, and pressing the corrugated plate 2 downward with the presser 11c.

Next, a fourth embodiment of the present invention will be described with reference to FIG.

FIG. 10 is a sectional view of a corrugated plate 2 and a lower plate 3 in a groove forming portion of a deck floor 1 according to a fourth embodiment in which the present invention is applied to a deck floor. A trapezoidal plate 12 as a reinforcing portion is passed over and joined to the corrugated plate concave portion 5. Trapezoidal plate 1
2 is formed by a trapezoidal continuation having a flat portion closing the corrugated plate concave portion 5 and a slope portion having a shape extending halfway along the slope portion 2c. By joining and fixing the slope 2c of the corrugated plate 2 and the slope of the trapezoidal plate 12, the corrugated plate recess 5 is reinforced. Grooves A are formed by arranging the corrugated plate concave portion 5 and the lower plate concave portion 6 in a row.

The embodiment of the present invention has been described above. However, the corrugated plate 2 may have a trapezoidal shape in which the peak 2a and the valley 2b are flat, and the corrugated plate 2 may have a peak 2a and a valley. The cross-sectional shape of the corrugated plate 2 can be a repetition of a rectangle such as a square by increasing the flat portion in 2b and making the slope 2c perpendicular to the lower plate 3.

When a metal plate is used for the floor plate 4, a floor material having high rigidity and strength can be obtained.
Since the strength of the groove A greatly affects the floor plate 4, a reasonable deck floor can be obtained by using a base material of a square plate such as a plywood or a particle board. Regarding the construction of the floor plate 4, even if the floor plate 4 is mounted on the deck floor with the corrugated plate 2 and the lower plate 3 at the site, the floor plate 4 is previously installed on the grooved deck floor with the corrugated plate 2 and the lower plate 3. It may be brought to the site after joining.

In the first to fourth embodiments,
By providing the lower plate 3 and the lower plate rising portion 3a with the protrusions 7 in the direction along the valleys 2b at both ends of the corrugated plate 2, the buckling becomes stronger. Further, in the second to fourth embodiments, the projections 7 are further provided on the slope 2 c of the corrugated plate 2,
The rigidity of the deck floor can be further increased.

The lower plate 3 may be divided in the longitudinal direction of the peaks and valleys of the corrugated plate 2. In the cross section of the corrugated sheet 2, both ends in the longitudinal direction of the peaks and troughs are troughs 2b.
If the corrugated plate 2 is made upside down and both ends in the longitudinal direction of the valleys are ridges 2a, the lower plate 3 is joined only to the valley 2b closest to both ends in the longitudinal direction of the valleys. Can be eliminated.

[0029]

According to the grooved deck floors of the first to sixth aspects, a relatively thin member facilitates height adjustment with respect to other indoor floors. Also, by providing protrusions on the corrugated sheet surface, providing folds in the concave parts, and providing concave parts by crushing the crests of the corrugated sheet, the groove section is reinforced, so that the corrugated sheet cross section is reduced with respect to bending moment. It is possible to resist, maintain high rigidity and strength, and to have a floor structure excellent in sound insulation such as an impact sound.

According to the method of manufacturing the grooved deck floor according to the seventh and eighth aspects, the grooved deck floor can be manufactured and constructed with a small number of steps, and can be provided at a significantly low cost.

[Brief description of the drawings]

FIG. 1 is a perspective view of a grooved deck floor according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of a corrugated plate and a lower plate in a groove portion of the grooved deck floor.

FIG. 3 is an exploded view of a corrugated plate of the grooved deck floor.

FIG. 4 is a sectional view of a corrugated plate and a lower plate in a groove portion of a grooved deck floor according to a second embodiment of the present invention.

FIG. 5 is a development view of a corrugated sheet of the grooved deck floor.

FIG. 6 is a layout view of a jig for forming a folded portion in a groove portion of the grooved deck floor.

FIG. 7 is a sectional view of a corrugated plate and a lower plate in a groove portion of a grooved deck floor according to a third embodiment of the present invention.

FIG. 8 is a development view of a corrugated plate of the grooved deck floor.

FIG. 9 is a layout view of a jig for forming a crushed portion in a groove portion of the grooved deck floor.

FIG. 10 is a sectional view of a corrugated plate and a lower plate in a groove portion of a grooved deck floor according to a fourth embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Deck floor 2 Corrugated plate 2a Corrugated peak 2b Corrugated valley 2c Corrugated plate slope 2 'Flat plate 3 Lower plate 3a Lower plate rising portion 4 Floor plate 5 Corrugated plate recess 6 Lower plate concave portion 7 Protrusion 8 Notch portion 9 Folding portion DESCRIPTION OF SYMBOLS 10 Crushed part 11a Corrugated board 11b Holder 11c Pusher 12 Trapezoidal plate A groove

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Akio Sugimoto 1-5-5 Takatsukadai, Nishi-ku, Kobe City, Hyogo Prefecture Kobe Steel, Ltd. Kobe Research Institute

Claims (8)

[Claims] 1. A deck floor comprising: a corrugated metal sheet formed in a corrugated shape in which ridges and valleys are continuous; and a metal lower plate joined to the valleys of the plate. A groove is formed by providing concave portions arranged in a direction transverse to the peak portion with respect to the peak portion of the corrugated plate, thereby forming a groove, and providing a reinforcing portion around the concave portion. Deck floor. 2. The method according to claim 1, wherein the concave portion is formed by a cutout of the mountain portion, and the reinforcing portion is formed by a convex or concave protrusion extending in a longitudinal direction on a slope around the concave portion. The grooved deck floor according to claim 1, wherein: 3. The grooved deck according to claim 1, wherein the concave portion is formed by a cutout of the mountain portion, and the reinforcing portion is formed by folding back the cutout. floor. 4. The device according to claim 1, wherein the concave portion is formed by crushing the mountain portion, and the reinforcing portion is formed by a continuous portion in which slopes on both sides of the mountain portion are crushed. The grooved deck floor described. 5. The grooved deck floor according to claim 1, wherein a floor plate is provided on the mountain portion. 6. The grooved deck floor according to claim 1, wherein a gutter-like horizontal member is provided in the recess. 7. A metal corrugated sheet formed into a waveform in which a peak and a valley are made continuous by forming a roll, and a metal lower plate joined to a valley of the corrugated sheet; A method of manufacturing a grooved deck floor in which grooves formed of concave portions arranged in a direction crossing a peak portion of a corrugated sheet are arranged in a row at a portion corresponding to a peak portion of a thin plate before roll forming. Notch processing,
At the time of roll forming for forming the peaks and valleys, a convex or concave protrusion extending in the longitudinal direction is formed on a slope around the concave portion formed by the notch by roll forming, and then the lower plate is joined. A method for manufacturing a grooved deck floor, comprising: 8. A metal corrugated sheet formed into a corrugated shape in which peaks and valleys are made continuous by roll forming, and a metal lower plate joined to the valleys of the corrugated sheet, A method of manufacturing a grooved deck floor in which grooves formed of concave portions arranged in a direction crossing a peak portion of a corrugated sheet are arranged in a row at a portion corresponding to a peak portion of a thin plate before roll forming. After performing notch processing or slit processing and forming the peaks and valleys by roll forming, the notches or slits are subjected to indentation processing to form a reinforcing part by folding or crushing simultaneously with the formation of the recess. And then joining the lower plate to the grooved deck floor.