JP2005226343A - Placing and laying floor panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a placing and laying floor panel capable of efficiently preventing wiring failure by visibility, by imparting strength and impact resistance on a high level in a well-balanced state. <P>SOLUTION: This floor panel 10 is composed of nine square panel pieces in total including four panel pieces 1 to 4 positioned in a corner part, four panel pieces 5 to 8 adjacent to these panel pieces 1 to 4 and constituting an outer peripheral area, and a panel piece 9 adjacent to these panel pieces 5 to 8 and positioned in a central part. The adjacent panel pieces are integrally molded by a crystalline resin made amorphous in a state of being mutually connected via a hinge part H. Since this floor panel 10 is composed of the crystalline resin but is made amorphous, strength is relatively large, and impact resistance is improved. Due to having transparency, a wiring state can be confirmed from an upper part of the panel pieces. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a floor panel (laying floor panel) useful for accommodating wiring along a floor surface and a panel piece for forming the floor panel.

  Many floor panels for forming a wiring space on a floor surface in a building (for example, an office floor surface) are commercially available. Such a floor panel can accommodate wiring in the space between the panel and the floor surface, and a floor panel (built-in type) previously laid on the floor surface during construction of the building, and a building that has already been built. It is classified as a floor panel (laying down type) that lays the floor panel in the wiring space on the floor.

  As the latter floor panel (laying floor type), (i) a floor panel in which a panel block in which a resin panel that supports a load and a support leg that supports this panel against the floor surface is integrated is spread on the floor surface, (Ii) Described in a groove wiring type floor panel (for example, Japanese Patent Laid-Open No. 10-331403 (Patent Document 1)) having a groove capable of accommodating a wiring extending in a predetermined direction of the panel and a lid for opening and closing the groove. The floor panel etc.) are known.

  Of these laying type floor panels, the former floor panel that allows wiring to run along the floor surface is less expensive than groove wiring type floor panels because it is not necessary to form grooves, It is the mainstream of floor-laying type floor panels.

  For example, Japanese Patent Laid-Open No. 2002-294990 (Patent Document 2) regulates the separation of the divided panel pieces from each other in the panel pieces constituting the floor panel by engaging the divided panel pieces. A panel piece provided with connecting means that allows displacement in a direction horizontal to the floor surface is disclosed. This document describes that the panel piece is obtained by integrally molding a synthetic resin such as recycled polyethylene terephthalate. Japanese Patent Application Laid-Open No. 2002-294991 (Patent Document 3) describes a support for supporting a load as a crystalline resin (recycled polyethylene terephthalate resin (recycled PET resin), polyamide, polyacetal, polybutylene terephthalate resin (PBT). In the panel piece molded by resin), the panel is provided with a plurality of ribs having different dimensions with respect to the load acting direction, and an opening is provided between the ribs. In this document, from the viewpoint that the crystalline resin crystallizes and the entire floor panel becomes brittle, by providing a plurality of ribs having different dimensions and the opening, a heat dissipation effect of the ribs is enhanced and a portion that is easily crystallized is provided. It is reinforced.

However, in the floor panels of the laying type of these documents, a crystalline resin (recycled polyethylene terephthalate) having properties such as high hardness and high strength but low toughness (impact resistance) and brittleness against stress concentration. Etc.). Therefore, even if ribs are provided as described above, there is a limit to the reinforcement of the panel pieces. For example, when a large local stress acts on the floor panel, the floor panel is likely to break (break). In addition, the crystalline resin is usually opaque due to its crystallinity, and it is difficult to visually recognize the state of the wiring stored under the panel from the upper part of the panel. It is difficult to confirm (especially stepping of the support leg against a flat wiring with a small cross-sectional thickness such as a telephone line). Such destruction of the panel and poor wiring may cause disconnection.
JP 10-331403 A (Claims) JP 2002-294990 A (claims, paragraph numbers [0009] and [0029]) JP 2002-294991 A (claims, paragraph numbers [0026], [0028])

  Accordingly, an object of the present invention is to provide a floor panel (laying floor panel) having excellent mechanical properties (particularly, high strength and impact resistance) and a panel constituting the floor panel even though it is made of a crystalline resin. To provide a piece.

  Another object of the present invention is to provide a floor panel capable of imparting strength (load resistance) and impact resistance at a high level in a well-balanced manner and efficiently preventing wiring defects by visual recognition, and a panel piece constituting the floor panel. There is to do.

  Still another object of the present invention is to provide a method for easily and efficiently producing a floor panel and a panel piece thereof having high strength and excellent impact resistance even when a crystalline resin is used. It is in.

  Another object of the present invention is to use a recycled resin (particularly, a recycled flaky polyethylene terephthalate resin), which has excellent mechanical properties (particularly, high strength and impact resistance) and has a transparent floor panel ( Another object of the present invention is to provide a method for producing a panel piece) at low cost and efficiently.

  In the injection molding of a crystalline resin, the present inventors paid attention to the fact that crystallization can be suppressed or prevented by rapid cooling, and as a result of intensive studies to achieve the above-mentioned problems, a crystalline resin (such as recycled polyethylene terephthalate resin) was injected. By molding, quenching, and molding (particularly integral molding), it is possible not only to balance strength (load resistance) and toughness (impact resistance) in a well-balanced manner, but also to cause poor wiring such as disconnection due to high transparency. As a result, it was found that a highly durable floor panel (or panel piece) capable of easily and efficiently realizing a wiring space excellent in safety without any problems was completed, and the present invention was completed.

  That is, the panel piece (panel piece constituting the floor panel) of the present invention is a panel piece made up of a support top plate and a support leg for supporting the support top plate and formed of a crystalline resin. Thus, the crystalline resin (polyethylene terephthalate resin or the like) is amorphized.

  The floor panel (free access floor) of the present invention can usually be formed by connecting such panel pieces, for example, comprising a plurality of the panel pieces and a connecting portion for connecting these panel pieces. Also good. The connecting portion may be formed of a member capable of imparting flexibility to the entire floor panel. For example, a molded product (particularly an integrally molded product) in which the plurality of panel pieces are connected via a hinge portion may be used. When the panel pieces are connected by such a connecting part, unevenness of the floor surface (irregularities, rattling) can be efficiently absorbed.

  The floor panel (and the panel piece) may have transparency. For example, the total light transmittance may be 60% or more (for example, about 60 to 95%). In a preferred floor panel (panel piece), the total light transmittance may be 70% or more (for example, about 70 to 95%) and may be composed of recycled polyethylene terephthalate resin. In such a transparent panel, the wiring state can be easily visually recognized, so that wiring defects can be efficiently prevented. The floor panel (and the panel piece) has a relatively high strength and impact resistance since the crystalline resin is amorphous, and can efficiently satisfy the required performance of the floor panel. For example, the minimum load that breaks due to the load on the support top plate may be 3000 N or more (for example, about 4000 to 10000 N), and the load-bearing performance of the JAFA (Free Access Floor Industry Association) standard (2000 N specification, 3000 N specification) Etc.) can be cleared sufficiently.

  The floor panel (and panel piece) can usually be manufactured by injection molding. For example, the crystalline resin is melted and injected into a mold cavity (a mold cavity corresponding to the floor panel), and the crystal It may be produced by cooling and molding (particularly integral molding) while preventing crystallization of the functional resin. Specifically, the molten crystalline resin may be rapidly cooled and molded. For example, the crystalline resin is melted and injected into a mold cavity, and the mold temperature is low (for example, 40 ° C. or less). You may cool and shape | mold. In particular, hydrolyzable crystalline resins may be subjected to melting under reduced water content. For example, crystalline resins having a water content of 250 ppm or less [polyethylene terephthalate resin (particularly flaky recycled polyethylene terephthalate resin) Etc.] may be melted and injected into a mold, and cooled at a mold temperature of 40 ° C. or lower (for example, about 5 to 40 ° C.) to form the floor panel of the present invention.

  In this specification, the measurement method (test method, measurement conditions) of the floor panel characteristics (such as the above-mentioned minimum load) is “free access floor constituent material standard” (issued by Free Access Floor Industry Association, September 1997). 2nd printing issuance etc. can be referred.

  Even if the floor panel (and panel piece) of the present invention is made of a crystalline resin such as polyethylene terephthalate resin, it is amorphous, and therefore has excellent mechanical properties (particularly high strength and impact resistance). It has high transparency. Therefore, strength (load resistance) and impact resistance can be imparted at a high level in a well-balanced manner, and wiring defects such as disconnection can be efficiently prevented by visual recognition. Further, in the present invention, even if a crystalline resin is used, depending on molding conditions (for example, mold temperature, etc.), such a high-strength and excellent impact-resistant floor panel (and this floor panel) The panel piece for forming can be easily and efficiently manufactured. In particular, by using recycled resin (especially recycled flaky polyethylene terephthalate resin), a floor panel having excellent mechanical properties (especially high strength and impact resistance) and transparency can be obtained at low cost. It can be manufactured efficiently.

  Hereinafter, the present invention will be described in detail with reference to the accompanying drawings as necessary. 1 is a plan view showing an example of the floor panel of the present invention, FIG. 2 is a side view of the floor panel shown in FIG. 1, and FIG. 3 is a sectional view (III-) of the floor panel shown in FIG. FIG. 4 is a plan view of the panel piece located at the first corner of the floor panel shown in FIG. 1, and FIG. 5 is a side view of the panel piece shown in FIG. 6 is a cross-sectional view (cross-sectional view taken along the line VI-VI) of the panel piece shown in FIG. 4, and FIG. 7 is a plan view of the back surface of the panel piece shown in FIG. In the following description, the same elements are denoted by the same reference numerals.

  In this example, the floor panel 10 connects a plurality of panel pieces 1 to 9 arranged in a plurality of rows (three rows in this example) in the vertical and horizontal directions and a plurality of adjacent panel pieces, and is not flat. It is comprised with the hinge part H for absorbing (backlash). That is, the floor panel 10 is configured by a panel piece row, and is adjacent to the four panel pieces 1 to 4 located at the corners or corners, and the four pieces constituting the outer peripheral area. A total of nine square (in this example, square) panel pieces 1 to 9 including the panel pieces 5 to 8 and the panel pieces 9 adjacent to the panel pieces 5 to 8 and positioned in the center. It consists of And the adjacent panel pieces 1-9 are mutually connected via the hinge part H in the adjacent area, respectively. The floor panel 10 (or each of the panel pieces 1 to 9) is integrally formed of a crystalline resin, becomes amorphous, and has transparency.

  Among the panel pieces 1 to 4, the panel piece 1 located at the first corner portion extends from the support top plate 11 for supporting the load and the corner portion of the support top plate 11 to the floor surface. On the other hand, it is comprised by the four support legs 12 for supporting the said support top plate 11, and these support legs 12 form the arch-shaped accommodation space curved on each side. More specifically, the side wall portion 13 of the panel piece 1 is formed so as to protrude from the corner portion on the back surface of the support top plate, and adjacent to the four leg portions 12a having a square cross section (square shape) and a hollow shape. The supporting leg 12 is composed of an arch-shaped rib portion 12b that extends downward between the leg portions 12a. The arched rib 12b can form a curved wiring space between the support top plate 11 and a floor surface (not shown).

  The support top plate 11 is composed of a top portion (thin portion) and ribs 11e for reinforcing the top portion. The support top plate 11 (or the body part) is formed in a square shape (in this example, a square shape) in a planar shape, and a central area (a square or square region) of the support top plate 11 is formed. A decorative part is formed. This decoration part is comprised by the square-shaped center part 11a and the some block-shaped decoration unit 11b formed in the circumference | surroundings of this center part 11a. The decoration unit 11b arranged around the square central portion 11a is formed of a square frame (frame), and a plurality of ribs 11c are spanned between corner portions of each frame. The plurality of ribs 11c form a triangular space (gap) portion 11d. Reinforcing ribs 11e are formed radially from the center on the back side of the square support top plate 11 (that is, the support leg side). The reinforcing ribs 11e extend diagonally from the center of the back surface of the support top plate 11 and also extend in the vertical and horizontal directions toward the side edges.

  Of the side wall portions in the vertical direction (X direction) and the side wall portions in the horizontal direction (Y direction), the side wall portions 13a and 13b on the side of the adjacent corner portions have cross-sections having point-like small protrusions at the tips. A plurality of convex portions 14 and 15 having a shape and a semicircular arc-shaped cutout portion 18 are formed. That is, the vertical side wall portion 13a is formed with a first convex portion 14a formed in contact with the end portion of the stopper portion 16 formed at adjacent corner portions, and a predetermined distance from the convex portion. The second convex portion 14b and the cutout portion 18 formed away from the second convex portion 14b and formed in the central portion in the vertical direction are formed, and the first convex portion 14a The 2nd convex part 14b is biased and formed in the corner part side adjacent to each other. Moreover, between the 1st convex part 14a and the 2nd convex part 14b, the convex part (the said convex part 15 and the said convex part 15) which has the same shape and structure as shown in FIGS. A concave portion 17a in which the same convex portion) can be engaged or meshed is formed. Further, the lateral side wall portion 13b includes first and second convex portions 15a and 15b spaced apart from the corner stop portion 16 by a predetermined distance, and a notch portion 18 adjacent to the second convex portion 15b. Is formed. Between the stopper 16 and the first protrusion 15a and between the two protrusions 15a and 15b, the protrusions of other floor panels having the same shape and structure as shown in FIGS. A recess 17b is formed in which the (projection similar to the projection 14) can be engaged. In addition, the side wall end surface of the stop part 16 is located on the extension of the end surface of the side wall part of the vertical direction and the horizontal direction. That is, the vertical side wall part 13a and the horizontal side wall part 13b are formed in a structure that can be engaged or mated with each other, and the vertical and horizontal side wall parts 13a and 13b have other floors having the same structure. The side wall portion (not shown) of the panel can be disposed while being positioned. Then, by combining the notch 18 with a notch (not shown) provided at a corresponding position on the side wall (not shown) of another floor panel having the same structure, the cross-section is circular. Holes (wiring holes, not shown) can be formed.

  The panel pieces 5 and 8 adjacent to the panel piece 1 located in the first corner portion in the vertical and horizontal directions are constituted by the same support top plate and support legs as those of the panel piece 1, and these panel pieces 5. , 8 are formed with notches similar to those described above. That is, the panel piece 5 adjacent to the first panel piece 1 in the vertical direction has the cutout portion on the side surface in the vertical direction, and is adjacent to the first panel piece 1 in the horizontal direction. The panel piece 8 to have has the said notch in the side surface part of a horizontal direction.

  Moreover, the panel pieces 2-4 located in the 2nd-4th corner part are comprised with the support top plate and support leg similar to the panel piece 1 of the said 1st corner part, The said convex part, The concave portion and the stopper portion are similarly formed at corresponding positions of the panel pieces 2 to 4. And the said notch part respond | corresponds with the side wall part of the panel piece 2 adjacent to the panel piece 1 of the said 1st corner part in the vertical direction, and the side wall part of the panel piece 4 adjacent to the said panel piece 1 in the horizontal direction. Each is formed at a position. In other words, the vertical side wall portion of the panel piece 2 located at the second corner portion is cut off with the convex portion with the same (or symmetric) structure as the lateral side wall portion of the panel piece 1 at the first corner portion. A notch portion is formed, and a convex portion is formed on the lateral side wall portion of the panel piece 2 with the same structure as the vertical side wall portion of the panel piece 1.

  Furthermore, the panel piece 6 laterally adjacent to the panel piece 2 positioned at the second corner portion, the panel piece 7 adjacent to the panel piece 2 positioned at the fourth corner portion in the vertical direction, and the panel pieces 5 to 5 A panel piece 9 adjacent to 8 and located at the center of the floor panel is also composed of a support top plate 11 and support legs 12 similar to the panel piece 1.

  Although such a floor panel is made of a crystalline resin as described above, it is amorphous so that the panel as a whole has flexibility and strength and impact resistance as will be described later. Can be achieved at a high level. Therefore, even if the floor panel is formed by a thin portion, it can be stably integrally formed. In particular, even if a thin connecting means such as the hinge part is integrally formed with a plurality of panel pieces (or panel piece rows), a good connecting part (hinge part) having flexibility and high strength can be formed. In addition, since it is a thin and uniform amorphous state, it is transparent, and the wiring state can be easily seen from the top of the floor panel, and wiring can be stably arranged without causing disconnection.

  Moreover, such a floor panel is excellent also in workability (or arrangement | positioning property). For example, each panel piece is connected via a hinge part and can be more flexibly provided with the floor panel, so it can effectively follow the unevenness of the floor (backlash). Can be imparted, and can be efficiently placed on the floor while maintaining high flatness. Moreover, the floor panels different from each other can be connected easily and efficiently without being displaced by the occlusion of the concave and convex portions of the side surface portion. In addition, a slight gap can be formed between the convex portion and the concave portion by the small protrusion, and the concave portion and the convex portion can be point-contacted. It is possible to effectively prevent squeak noise (rubbing sound between panels) that occurs when the vehicle passes over. Furthermore, since the wiring hole can be formed between the adjacent floor panels by the notch, wiring (for example, a power outlet, etc.) can be easily taken out from the floor surface onto the floor panel.

  As described above, the panel piece (and the floor panel) of the present invention is made of a resin generally called a crystalline resin, but the crystalline resin is made amorphous. That is, the panel piece (and floor panel) of the present invention has a relatively high strength (load resistance) by using a crystalline resin that is brittle while having high strength while being brittle. In addition, it has excellent toughness (impact resistance, etc.) and satisfies the performance required for floor panels. Moreover, the transparency can be improved even when a crystalline resin is used.

  Examples of the crystalline resin include polyester resins [eg, polyalkylene terephthalate (polyethylene terephthalate (PET), polybutylene terephthalate, etc.), polyalkylene naphthalate, liquid crystalline aromatic polyester, etc.], polyamide resins (polyamide 6, Aliphatic polyamide resins having a short chain segment such as polyamide 66), polyacetal resins (polyoxymethylene resins), polyphenylene sulfide resins (polyphenylene sulfide resins, etc.), polyether ether ketone resins, olefin resins [polyethylene, etc. Polyethylene resins, polypropylene, polypropylene resins such as propylene-ethylene copolymer, poly (methylpentene-1), etc.], halogen-containing resins [eg, vinylidene (Such as vinylidene chloride resin) resin, a fluorine resin, a thermoplastic resin such as polyether nitrile resin can be exemplified. These crystalline resins may be used alone or in combination of two or more. Further, these crystalline resins may be recycled resins (used plastics and recycled resins).

  A preferred crystalline resin is an aromatic polyester resin (particularly, polyethylene terephthalate resin). In addition, recycled resin (used resin) is inexpensive and can be suitably used from the viewpoint of environmental protection. In particular, recycling of beverage bottles made of polyethylene terephthalate resin is under the guidance of local governments. For these reasons, recycled aromatic polyester resins (particularly recycled polyethylene terephthalate resins) are excellent in mechanical properties (strength, impact resistance, etc.) and advantageous in cost.

  Note that the degree of crystallinity of an amorphous crystalline resin (hereinafter sometimes simply referred to as an amorphous resin) is 10% or less (for example, 0 to 8%), preferably 5% or less (for example, 0 to 4%), more preferably about 3% or less (for example, 0 to 2%).

  Since the amorphous resin is molded while preventing crystallization as will be described later, it has relatively high strength and excellent toughness (impact resistance), and balances these properties in a balanced manner. doing. Therefore, in this invention, the required performance of a floor panel can be satisfied efficiently. For example, in the floor panel (or panel piece), the minimum load that breaks due to the load on the support top plate (or the floor panel surface) (that is, the maximum load that can withstand the breakage) is 3000 N or more (for example, 3000 to 18000 N), Preferably it is 4000 or more (for example, 4000-15000N), More preferably, it is 5000N or more (for example, 5000-12000N), Especially about 6000-10000N (for example, 6000-8000N), JAFA [Free Access Floor Industry Association (Japan Access Association) (Floor Association)] standard load bearing performance (2000N specification, 3000N specification, etc.) can be sufficiently cleared. The deformation amount (deflection) when a load of 3000 N (and 2000 N) is applied to the support top (or the floor panel surface) is, for example, 4 mm or less (for example, 0.1 to 4 mm), preferably 2. It is 5 mm or less (for example, 0.5 to 2.5 mm), more preferably about 1 to 2.5 mm. The minimum load and the amount of deformation can be measured based on the test method specified in JIS A 1450.

  Furthermore, the floor panel of the present invention is also excellent in impact resistance. For example, a weight having a predetermined weight (0.5 kg) is formed on the surface of the support top plate or the floor panel (the central portion thereof). On the other hand, when dropped, the minimum height of the weight (that is, the maximum height that can withstand the breakage) at which the support top plate (center portion) breaks due to the load is 80 cm or more (for example, 80 to 300 cm), preferably May be about 90 cm or more (for example, 90 to 250 cm), more preferably about 100 cm or more (for example, 100 to 200 cm). In addition, the measurement of the said minimum height can be performed according to the test method prescribed | regulated to the said JISA1450.

  The panel piece (floor panel) of the present invention is made of an amorphized resin, and is usually transparent or translucent, particularly transparent. In such a transparent (or translucent) panel, the wiring state under the panel can be easily confirmed without lifting the floor panel. In addition, it is possible to visually check whether the support leg of the panel piece has stepped on the wiring (particularly a weak electric wire having a small thickness such as a telephone line or an Internet cable line) during wiring work, and can efficiently prevent disconnection.

  The transparency of the panel piece (or floor panel) can be selected from the range of 30% or more of total light transmittance (for example, about 30 to 95%), although it depends on the degree of amorphization and the thickness of the support top plate, For example, 60% or more (for example, 60 to 99.9%), preferably 60 to 95%, more preferably 70% or more (for example, 70 to 95%), particularly 80% or more (for example, 80 to 95%). It may be a degree. In addition, the transparency is a panel piece (or support top plate) having a predetermined thickness (thickness of the top part of the support top plate) [for example, thickness (or average thickness) of 0.5 to 5 mm, preferably about 1 to 3 mm]. Alternatively, the total light transmittance of the floor panel can be determined by measuring based on JIS K 7361-1 (Testing method for total light transmittance of plastic-transparent material). The panel piece (or floor panel) may be transparent, and may be colored as long as the wiring state can be visually recognized from above the panel.

  The floor panel (panel piece) of the present invention may be opaque as long as it is amorphous. For example, a colorant (black pigment such as carbon black, blue pigment, yellow pigment, red pigment, etc.) Etc.) and may be opaquely colored with a filler or the like.

  Moreover, the floor panel (panel piece) of this invention may contain the granular or fibrous filler reinforcement | strengthening agent. In the present invention, a relatively high strength can be imparted without containing a reinforcing agent. In addition, the reinforcing agent may make the panel piece opaque, but transparency can be maintained with a specific filler (glass fiber or the like). For this reason, when providing transparency to a floor panel (panel piece), you may use such a filler suitably.

  The floor panel of the present invention may be composed of a single floor panel piece, but usually a plurality of panel pieces are connected as described above. The number of connected panel pieces may be 2 to 30, preferably 4 to 20, and more preferably about 6 to 12. In addition, the shape of the floor panel (or panel piece) may be rectangular as long as it can be efficiently arranged on the floor surface. The width and length of the floor panel may be about 100 to 2000 mm, preferably about 200 to 1000 mm, and more preferably about 300 to 700 mm.

  The connecting means for the panel pieces is not limited to the hinge as long as it can impart flexibility to the floor panel, and may not necessarily be integrally formed. For example, the plurality of panel pieces may be connected by a connecting means such as a hinge (such as a metal hinge), a hinge, or a staple (such as an industrial or architectural staple). Adjacent panel pieces may be connected by at least one connecting means (hinge), and may be connected by, for example, about 1-4, preferably about 2-3 connecting means. Further, the length of the gap between adjacent panel pieces may be in a range that can maintain the flexibility of the floor panel, and is, for example, about 0.3 to 9.5 mm, preferably about 0.5 to 5 mm. Also good.

  The size of the support top plate may be in a range that can efficiently absorb unevenness of the floor surface (floor surface irregularities and protrusions), and may be, for example, about 50 to 500 mm, preferably about 100 to 250 mm. Further, the panel piece (or the support top plate) may have a thickness of, for example, 5 to 50 mm, preferably about 10 to 30 mm. In the support top plate, it is not necessary to form a space portion penetrating the decorative portion or the support top plate, but the space portion is formed from the viewpoint of reducing the weight of the panel piece or the floor panel and reducing the amount of resin used. Is preferred. In the present invention, since the amorphous resin is used, the required performance (load resistance, impact resistance, etc.) of the floor panel can be satisfied even if the space is formed. Further, the shape of the space portion is not limited to a triangular shape as long as a predetermined strength can be ensured, and may be a rectangular shape, a circular shape, or the like. The support top plate only needs to be configured with at least a top meat portion (thin wall portion) (a portion excluding the back rib from the support top plate), and may be configured only with the top meat portion, When forming the space, it is advantageous to reinforce the support top plate with reinforcing ribs. Moreover, you may form a decoration part by an uneven | corrugated | grooved part.

  The height of the support leg (or the height of the panel piece) is, for example, about 10 to 150 mm, preferably about 20 to 120 mm. Note that the arched rib is not necessarily required if the supporting leg can sufficiently support the load, and it is not necessary to form the arched rib. In the panel piece, the leg portion only needs to be able to support the support top plate against the load, and there are at least one, particularly a plurality. Further, the support legs are usually formed at the corners (particularly, four corners) of the support top plate, and may be formed at other positions such as the central portion of the support top plate.

  Moreover, if the position shift of a floor panel can be prevented efficiently, the said convex part (and recessed part) is not essential, and the shape and position are not specifically limited, either. For example, connecting means of other shapes that can be fitted to each other, connecting means that can connect a support top plate between floor panels (for example, the staples) may be used as the connecting means, A slip prevention sheet or the like may be affixed to the contact portion (for example, the bottom of the leg portion), or a combination thereof may be used.

  The notch for forming the wiring hole is not essential, and the number of wiring holes can be appropriately selected according to the amount of wiring to be laid. For example, the number, shape, and formation position of the wiring holes (or notches) are not particularly limited as long as the wiring can pass therethrough. For example, the wiring hole may be a hole (such as a wiring hole described in Japanese Patent Laid-Open No. 2001-12062) in which the size of the hole can be changed.

  In addition, crystalline resin (PET resin etc.) changes a material characteristic greatly with the crystallinity degree. That is, the crystalline resin is melted by heat and then molded by cooling, but crystallization of the resin is promoted by a normal cooling method. Therefore, a molded product (injection molded product) of a crystalline resin (particularly PET resin or the like) is difficult to be uniformly molded, and tends to be a molded product in which a crystalline part and an amorphous part are mixed. The crystallized portion becomes a brittle material that is hard and brittle, and constitutes a defective portion in the molded product. Therefore, load resistance and impact resistance performance are lowered, and the floor panel standard cannot be satisfied. In particular, when crystallization proceeds in a thin portion such as the hinge portion, cracks and breakage are likely to occur, and it is extremely difficult to ensure quality as a molded product.

  In the present invention, toughness (stickiness) is imparted to the floor panel by molding while preventing crystallization by utilizing the characteristics of such a crystalline resin, and the strength and impact resistance are balanced at a high level. Manufacturing a floor panel.

(Panel piece or floor panel manufacturing method)
That is, the panel piece (and the floor panel) of the present invention can be produced by molding while preventing (or suppressing) crystallization of a molten crystalline resin (hereinafter sometimes referred to as molten resin) in the molding process. . A method for preventing (or suppressing) crystallization is not particularly limited, but can be usually performed by promoting cooling (cooling temperature, cooling rate, etc.) of the molten resin in the molding process. In the present invention, the injected molten crystalline resin is rapidly cooled to make it uniformly amorphous and to obtain a stable quality floor panel. The molding method is not particularly limited, and conventional molding methods such as injection molding, extrusion molding, foam molding, blow molding, and vacuum molding can be used. Of these molding methods, injection molding, extrusion molding, and particularly injection molding are preferred.

  The shape of the crystalline resin to be used for molding is not particularly limited, and may be, for example, granular, pellet-like, flake-like (scale-like), or the like. When using recycled resin (recycled polyethylene terephthalate resin, etc.), it can be used for molding in the form of recycled resin (for example, flakes) from the viewpoint of low energy consumption and low cost reuse. Good. For example, since the recovered recycled polyethylene terephthalate resin (such as a beverage bottle) is usually pulverized into flakes, the flake PET resin may be used for molding as it is.

  More specifically, in injection molding, a crystalline resin (recycled polyethylene terephthalate resin or the like) is melted and injected (or injected) into a mold cavity corresponding to the panel piece (or floor panel). A panel piece (or a floor panel) can be formed by cooling while preventing crystallization of the functional resin. In particular, in the present invention, even if a plurality of panel pieces are integrally formed, a relatively uniform (or homogeneous) floor panel having high strength and impact resistance can be manufactured.

  Cooling of the molten resin in injection molding can be easily and efficiently performed by adjusting the mold temperature. The mold temperature can be selected according to the shape (thickness) of the molded body, the temperature of the molten resin, the type of the mold, etc., and the temperature at which the molten resin can be rapidly cooled, for example, 50 ° C. or less (for example, 0 to 50 ° C.) The temperature may be preferably 40 ° C. or lower (for example, 5 to 40 ° C.), more preferably 30 ° C. or lower (for example, 10 to 30 ° C.). By cooling the molten resin at such a low temperature, crystallization can be efficiently prevented by advancing the cooling time of the molten resin, and the cost can be reduced by shortening the molding cycle.

  The material (metal) of the mold is not particularly limited as long as it can be rapidly cooled, and examples thereof include copper, aluminum, zinc, and alloys thereof. In particular, a metal mold having high thermal conductivity [for example, copper alloy (beryllium copper (BeCu) alloy (beryllium steel), copper nickel (CuNi) alloy, etc.), aluminum alloy, zinc alloy, especially copper alloy] is used. By doing so, the cooling time can be further accelerated and the cooling can be rapidly performed. The thermal conductivity of the metal or metal alloy constituting the mold is, for example, 50 to 450 W / m · K, preferably 70 to 400 W / m · K, more preferably 80 to 400 W / m · K (for example, 100 to 400 W / m · K).

  In addition, the water | moisture content in resin may reduce the mechanical characteristic of a molded object. In particular, a crystalline resin having a high water absorption rate (for example, polyethylene terephthalate resin) may cause hydrolysis when it contains a large amount of water in a molten state (plasticized state), and other general-purpose resins (for example, polypropylene). Molding is difficult compared with injection molding. In addition, recycled resin (flaked recycled polyethylene terephthalate resin or the like) often contains a lot of moisture. Therefore, the panel piece (floor panel) of the present invention may be molded under sufficiently dry conditions in order to impart stable physical properties. For example, a crystalline resin (recycled resin such as PET resin, particularly flaky recycled PET resin) has a water content of 300 ppm or less (for example, 0 to 280 ppm), preferably 250 ppm or less (for example, 10 to 220 ppm), more preferably You may use for melting as resin of about 200 ppm or less (for example, 20-180 ppm). The moisture content can be measured based on the Karl Fischer coulometric method (Method B of JIS K 7251).

  The moisture content can be adjusted (reduced) by, for example, drying (heating and drying) the crystalline resin before molding (before melting). In the drying process, a dryer (such as a hopper dryer), temperature, and time can be selected as appropriate. Moreover, since it may have high water absorption or hygroscopicity, the crystalline resin maintains a low water content (for example, 200 ppm or less) (or avoids contact with outside air as much as possible, for example, a dryer and a molding machine. May be supplied to a molding machine (such as an injection molding machine). In particular, when the crystalline resin that has been heat-dried is supplied to the molding machine in a heated state, the energy required for melting can be reduced.

  The present invention is useful as a floor panel (laying floor panel) useful for accommodating wiring along a floor surface or a panel piece for forming the floor panel.

  Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited to these examples.

(Example 1)
Flaked recycled polyethylene terephthalate resin (flaked PET resin regenerated from PET bottle, manufactured by Environmental Development Business Cooperative) was dried by heating and 850-ton injection molding machine (Mitsubishi Heavy Industries, 850MM), melted at a processing temperature (molding temperature) of 270 ° C., injected into a mold using beryllium steel, cooled at a mold temperature (cooling temperature) of 20 ° C., and the floor similar to FIG. A panel [length 500 mm × width 500 mm × height 50 mm (9-block hinge connected product) size] was integrally molded. In addition, in the injection molding, when the water content was measured by the Karl Fischer coulometric method (a method corresponding to the B method of JIS K 7251), the water content before the PET resin was melted (immediately before being supplied to the injection molding machine). Was 100 ppm.

(Example 2)
Flaked recycled polyethylene terephthalate resin (flaked PET resin regenerated from PET bottle, manufactured by Environmental Development Business Cooperative) was dried by heating and 850-ton injection molding machine (Mitsubishi Heavy Industries, 850MM), melted at a processing temperature (molding temperature) of 270 ° C., injected into a mold using beryllium steel, cooled at a mold temperature (cooling temperature) of 30 ° C., and the same floor as in FIG. A panel [length 500 mm × width 500 mm × height 50 mm (9-block hinge connected product) size] was integrally molded. In the injection molding, when the water content was measured by the Karl Fischer coulometric method (a method corresponding to the method B of JIS K 7251), the water content before melting the PET resin (immediately before being supplied to the injection molding machine). Was 150 ppm.

(Example 3)
Flaked recycled polyethylene terephthalate resin (flaked PET resin regenerated from PET bottle, manufactured by Environmental Development Business Cooperative) was dried by heating, and 850-ton injection molding machine (Mitsubishi Heavy Industries, Ltd., 850MM), melted at a processing temperature (molding temperature) of 270 ° C., injected into a mold using beryllium steel, cooled at a mold temperature (cooling temperature) of 40 ° C., and the floor similar to FIG. A panel [length 500 mm × width 500 mm × height 50 mm (9-block hinge connected product) size] was integrally molded. In the injection molding, when the water content was measured by the Karl Fischer coulometric method (a method corresponding to the method B of JIS K 7251), the water content before melting the PET resin (immediately before being supplied to the injection molding machine). Was 200 ppm.

(Comparative Example 1)
Flaked recycled polyethylene terephthalate resin (flaked PET resin regenerated from PET bottle, manufactured by Environmental Development Business Cooperative) was dried by heating, and 850-ton injection molding machine (Mitsubishi Heavy Industries, Ltd., 850MM), melted at a processing temperature (molding temperature) of 270 ° C., injected into an iron mold, cooled at a mold temperature (cooling temperature) of 70 ° C., and the floor panel [length 500 mm × width 500 mm × height 50 mm (9-block hinge connected product) size] was integrally molded. In the injection molding, when the water content was measured by the Karl Fischer coulometric method (a method corresponding to the method B of JIS K 7251), the water content before melting the PET resin (immediately before being supplied to the injection molding machine). Was 100 ppm.

(Comparative Example 2)
Flaked recycled polyethylene terephthalate resin (flaked PET resin recycled from PET bottles, manufactured by the Environmental Development Business Cooperative) is heated and dried, and then transferred to an 850-ton injection molding machine (Mitsubishi Heavy Industries, 850MM) by air transportation. 1 is supplied and melted at a processing temperature (molding temperature) of 270 ° C., injected into an iron mold, cooled at a mold temperature (cooling temperature) of 70 ° C., and a floor panel similar to FIG. 1 [length 500 mm × width 500 mm × height 50 mm (9 block hinge connected product) size] was integrally molded. In the injection molding, when the water content was measured by the Karl Fischer coulometric method (a method corresponding to the method B of JIS K 7251), the water content before melting the PET resin (immediately before being supplied to the injection molding machine). Was 400 ppm.

  The performance of the floor panels obtained in Examples 1 to 3 and Comparative Examples 1 to 2 was evaluated as follows.

(Total light transmittance)
Based on JIS K 7361-1 (Testing method of total light transmittance of plastic-transparent material), the total light transmittance of the floor panel [or the top portion of the support top plate (2 mm thick portion)] was measured. A haze meter (manufactured by Suga Test Instruments Co., Ltd., HGM-2D type) was used as a measuring instrument, and a halogen lamp was used as a light source.

(Fracture load)
The minimum load that breaks due to the load on the support top plate (or the floor panel surface) of the obtained floor panel was measured based on the test method specified in JIS A 1450.

(Falling weight impact)
According to the test method prescribed in JIS A 1450, when a mold weight of 0.5 kg is dropped on the support top plate of the floor panel, the support top plate (center portion) is broken by the load. The minimum height (cm) of the weight was measured.

(Hinge function)
The hinge function was evaluated according to the following criteria.

○… The unevenness of the floor surface (backlash, unevenness) was absorbed and the flatness of the floor panel could be maintained well. ×… The unevenness of the floor surface could not be absorbed and the flatness of the floor panel could not be maintained.

  The results are shown in Table 1.

  As shown in Table 1, the floor panels of the examples were high in strength and excellent in impact resistance. Moreover, the floor panel of the Example had high transparency and was able to absorb the unevenness of the floor surface efficiently.

FIG. 1 is a plan view showing an example of the floor panel of the present invention. FIG. 2 is a side view of the floor panel shown in FIG. 3 is a cross-sectional view of the floor panel shown in FIG. 1 taken along the line III-III. 4 is a plan view of a panel piece located at a first corner portion of the floor panel shown in FIG. FIG. 5 is a side view of the panel piece shown in FIG. 6 is a cross-sectional view taken along the line VI-VI of the panel piece shown in FIG. FIG. 7 is a plan view of the back surface of the panel piece shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1-9 ... Panel piece 10 ... Floor panel 11 ... Support top plate 11b ... Block-shaped decoration unit 11c ... Rib 11d ... Space part 11e ... Reinforcing rib 12 ... Support leg 12a ... Leg part 12b ... Arch-shaped rib part 13, 13a, 13b ... Side wall part 14, 15 ... Convex part 16 ... Stop part 17a, 17b ... Concave part 18 ... Notch part H ... Hinge part

Claims (9)

  A panel piece comprising a support top plate and support legs for supporting the support top plate and formed of a crystalline resin, wherein the crystalline resin is amorphized.   The panel piece of Claim 1 comprised by the polyethylene terephthalate resin.   A floor panel comprising a plurality of panel pieces according to claim 1 and a connecting portion for connecting these panel pieces.   The floor panel according to claim 3, wherein the plurality of panel pieces according to claim 1 are integrally molded products connected via hinges.   The floor panel according to claim 3, wherein the total light transmittance is 60% or more.   The floor panel according to claim 3, wherein the total light transmittance is 70% or more and is made of recycled polyethylene terephthalate resin.   The floor panel according to claim 3, wherein a minimum load that is broken by a load on the support top plate is 3000 N or more.   A method for producing a floor panel, in which a crystalline resin is melted and injected into a cavity of a mold, and cooled and molded while preventing crystallization of the crystalline resin.   The manufacturing method according to claim 8, wherein a flaky recycled polyethylene terephthalate resin having a water content of 250 ppm or less is melted, injected into a mold cavity, and cooled at a mold temperature of 40 ° C or lower.

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