JP2006097461A - Floor panel and manufacturing method for floor panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve manufacturing efficiency of a floor panel and also to increase strength of the floor panel, acquiring a good sound insulation. <P>SOLUTION: Between a pair of flat panels 21, 22, a corrugated-plate shaped material 23 is placed with the crest part 23a contacting to the upper plate 21 and the trough part 23b to the lower plate 22. Also, end-fitting members (end members) 24, 25 are arranged for holding the end parts 23c, d of the corrugated-plate shaped material 23 between either of the pair of flat panels 21, 22, in which arrangement the corrugated-plate shaped material 23 is adhered and fixed to the end-fitting members 24, 25 between the pair of flat panels 21, 22. Thereby, the floor backing panel (floor panel) 20 is manufactured. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a floor panel disposed above a slab of a building and a method for manufacturing the floor panel.

  Conventionally, as floor structures of apartment buildings such as condominiums, anti-vibration support legs are arranged at predetermined intervals on a slab that is a concrete floor, and a floor base panel made of a wood-based material is placed on the support board of the anti-vibration support legs. It is known that each edge is bonded and fixed, and flooring or the like is applied on the floor base panel. Patent Document 1 is a wooden thin piece laminated plate in which wooden thin pieces are laminated, and is formed with substantially trapezoidal cavities at regular intervals in the longitudinal direction (parallel to the floor surface), so that it is lightweight while obtaining sufficient strength. And the hollow base panel which enabled it to reduce a floor impact sound level is described.

The hollow base panel is formed as shown in FIG. That is, after attaching the binder to the wood flakes, the core 1 made of trapezoidal aluminum rods connected at equal intervals by the connecting plate 1a is arranged on one to several layers of the wood flakes, After one to several layers of dispersed cloth, the cores 2 made of trapezoidal aluminum bars connected at equal intervals by the connecting plate 2a are arranged, and the wood flakes are further sprayed. At this time, the core 1 and the core 2 are arranged so that the trapezoid is upside down. Next, the laminated body 3 in which the wood flakes are laminated is hot-press molded at a temperature of 140 to 220 ° C. and a pressure of 15 to 40 kg / cm ² for 6 to 15 minutes until the thickness becomes 1/3 to 1/30, and then cooled. After the cores 1 and 2 are later pulled out, a hollow base panel can be manufactured by trimming the outer periphery of the laminate 3. The manufactured hollow base panel has a solid end portion 4 that abuts against the anti-vibration support leg, and a plurality of cavities are formed in a region inside the end portion 4. Note that the angles formed between the lower base and the hypotenuse in the trapezoidal cavity are 60 degrees and 120 degrees.
JP 2003-172020 A

  In the above-described conventional technology, it is not easy to stack an appropriate amount of wood flakes that solidify the end 4, and it takes time to manufacture a floor base panel, and the wood flakes are laminated at the end 4. There was a problem that the amount was reduced and cramped when screwing.

  This invention is made | formed in view of the said subject, and while improving the manufacturing efficiency of a floor panel, it aims at improving the intensity | strength of a floor panel, obtaining favorable sound insulation.

  In order to achieve the above object, the invention of the floor panel according to claim 1 is arranged between a pair of flat plates composed of a lower flat plate and an upper flat plate, and the pair of flat plates, and peaks and troughs alternately. A floor panel in which a repeatedly formed corrugated member and an end member disposed at an end portion of the corrugated member are fixed to each other and disposed above the slab, and between the pair of flat plates The crest is brought into contact with the upper flat plate, the trough is brought into contact with the lower flat plate, the corrugated plate member is disposed, and the end of the corrugated plate member is connected to one of the pair of flat plates. The end members are arranged so as to be sandwiched between them, and the corrugated plate member and the end member are bonded and fixed between the same pair of flat plates in the arrangement.

  That is, the floor panel is formed easily because the corrugated plate member and the end member are bonded and fixed between a pair of flat plates. Thereby, the manufacturing efficiency of a floor panel can be improved. Here, if the end portion of the corrugated plate member is not sandwiched between the end member and the flat plate, the end portion of the corrugated plate member and the flat plate are not sufficiently bonded, and the corrugated plate is screwed at the end portion of the floor panel. In some cases, the end of the plate-like member or the end of the flat plate is cramped. In the present invention, since the end of the corrugated member is sandwiched and supported between the end member and the lower flat plate or the upper flat plate, the end of the corrugated member is securely bonded to the flat plate, It is possible to improve the strength of the floor panel while obtaining good sound insulation.

  The corrugated member is formed such that the crests and troughs alternately extend in parallel, and the end member is a direction in which the crests and troughs in the corrugated member are alternately and repeatedly formed. It is good also as a structure which is each provided along the direction where the said peak part and trough part extend, and is made into the shape of a rod, and the height in the said arrangement | positioning is mutually the same.

  It is good also as a structure by which the said edge member is formed with the clamping part which clamps the edge part of the said corrugated sheet member between one of said pair of flat plates at the said corrugated sheet member side. You may comprise the said clamping part by making it thin by the thickness of the edge part of the said corrugated member on the said corrugated member side. In this case, since the thickness of the corrugated plate member is reduced on the corrugated plate side, the end portion of the corrugated plate member can be easily sandwiched between the flat plate. Moreover, since the end member is thicker by the thickness of the corrugated member than the sandwiching portion on the side opposite to the corrugated member side, the end member comes into contact with the flat plate at this portion. Thereby, it becomes possible to form a floor panel only by applying an adhesive to the upper surface of the lower flat plate and the lower surface of the upper flat plate. For example, the end member is placed at a predetermined position on the lower flat plate, the end portion is aligned with the sandwiching portion of the end member, the corrugated plate member is placed on the lower flat plate, and the corrugated plate member and By placing the upper flat plate on the end member, each member can be quickly assembled to form the floor panel. When assembling each member upside down, the end member is placed at a predetermined position on the upper flat plate, and the corrugated plate member is placed on the upper flat plate with the end portion aligned with the clamping portion of the end member. Furthermore, a lower flat plate may be placed on the corrugated plate member and the end member.

  Here, the end member is formed in a rod shape and is disposed in a direction in which the crests and troughs are formed in the corrugated plate member, and the pair of members from the members having substantially the same height as the arrangement. The corrugated plate member may be cut out on the surface in contact with any one of the flat plates to form the holding portion. The floor panel can be quickly formed by easily sandwiching the end portion of the corrugated plate member between the end member and the flat plate with a simple structure in which the sandwiching portion is cut and formed.

  The end member has an outer end member having a height substantially the same as the height of the corrugated plate member and a height lower than the height of the outer end member by the thickness of the end portion of the corrugated plate member. It is good also as a structure formed by joining with the inner side end member which is arrange | positioned rather than the said outer side end member at the said corrugated member side, and forms the said clamping part. In this case, the distance between the pair of flat plates is determined by the height of the single outer end member, which is preferable in that the distance between the flat plates can be managed with high accuracy.

  Further, the end member includes a base end member having a height lower than a height of the corrugated plate member by a substantially thickness of an end portion of the corrugated plate member, and a thickness of the end portion of the corrugated plate member. And is laminated at a position opposite to the corrugated member side on the surface facing the non-contacting plate of the pair of flat plates in the base end member and the corrugated member side to the corrugated plate member side. It is good also as a structure made into the member formed by joining the lamination | stacking member which forms a clamping part. In this case, a plate made of the same material as that of the corrugated plate member can be used as a laminated member, which is preferable in that a sandwiching portion having a height lower by the thickness of the end portion of the corrugated plate member can be easily formed. is there.

The corrugated plate-like member has a shape that forms a trapezoidal cavity in a vertical cross section with respect to the direction in which the crests and troughs are alternately and repeatedly arranged between the pair of flat plates. It is good also as a structure. Then, the floor panel can be made light and strong. In addition, the angle of the inclination of the part which connects the same mountain part and the same valley part can be 45 degree | times, 60 degree | times, etc.
In addition, a plurality of the corrugated plate-like members are arranged in the horizontal direction with the end portions adjacent to each other between the pair of flat plates, and the end member has both of the end portions of the adjacent corrugated plate-like members as the pair of flat plates. It is good also as a structure arrange | positioned so that it may clamp between one of these. When a floor panel is formed by arranging a plurality of corrugated members between a pair of flat plates, the ends of adjacent corrugated members are securely bonded to the flat plates.

  By the way, the manufacturing method of the floor panel concerning Claim 6 arrange | positions between a pair of flat plate which consists of a lower side flat plate and an upper side flat plate, and the said pair of flat plate, and a peak part and a trough part are formed repeatedly alternately. A corrugated plate member and an end member disposed at an end portion of the corrugated plate member are fixed to each other and are disposed above the slab, and the method is for manufacturing a floor panel between the pair of flat plates. The corrugated portion is brought into contact with the upper flat plate, the corrugated portion is brought into contact with the lower flat plate, the corrugated member is disposed, and the end of the corrugated member is placed between one of the pair of flat plates. The above-mentioned end member is arranged so as to be sandwiched between, and the floor panel is manufactured by adhering and fixing the corrugated plate-like member and the same end member between the same pair of flat plates in the arrangement. To do. Of course, it is also possible to make the structure described in claims 2 to 5 correspond to the manufacturing method.

  The adhesive is applied to the mutually opposing surfaces of the pair of flat plates, and the corrugated plate member is placed with the adhesive-applied surface of one of the pair of flat plates facing upward. The end member is placed so that the end portion is sandwiched between one of the pair of flat plates, and the other flat plate is placed on the end member, so that the same corrugated plate shape is formed between the same pair of flat plates. It is good also as a structure which adhere | attaches and fixes a member and the same end member.

  In this case, the corrugated plate-like member is a roller that is formed such that the crests and troughs alternately extend in parallel, and applies an adhesive when applying the adhesive to the pair of flat plates. It is good also as a structure which apply | coats an adhesive agent to the said flat plate according to the position of the said peak part and trough part by using the roller which formed the unevenness | corrugation according to the position where the peak part and trough part of a corrugated plate member contact.

  As described above, according to the first and sixth aspects of the invention, the manufacturing efficiency of the floor panel can be improved and the end of the corrugated plate member is securely bonded to the flat plate, so It is possible to improve the strength of the floor panel while obtaining good sound insulation.

  In the invention according to claim 2, since the floor panel is formed by sandwiching both ends of the corrugated plate member between the end member and the flat plate, the strength of the floor panel can be further improved.

  In the invention according to claim 3, the end portion of the corrugated plate member can be easily sandwiched between the end member and the flat plate to form the floor panel quickly, and the upper surface of the lower flat plate and the lower surface of the upper flat plate can be formed. A floor panel can be formed simply by applying an adhesive.

In the invention concerning Claim 4, the intensity | strength of a floor panel can be improved.
In the invention according to claim 5, since both ends of the adjacent corrugated plate members are securely bonded to the flat plate, there is no possibility of being crooked at the time of screwing, and the floor panel is obtained while obtaining good sound insulation. Strength can be improved.

In the invention concerning Claim 7, a floor panel can be easily manufactured by the simple structure of apply | coating an adhesive agent to the upper surface of a lower flat plate, and the lower surface of an upper flat plate.
In the invention concerning Claim 8, the usage-amount of an adhesive agent can be reduced and the cost of a floor panel can be reduced.

Hereinafter, embodiments of the present invention will be described in the following order.
(1) Outline of the floor panel:
(2) Description of floor panel manufacturing method:
(3) Action and effect of floor panel and manufacturing method thereof:
(4) Various modifications:

(1) Outline of the floor panel:
FIG. 1 is a vertical sectional view showing a sound insulation floor 10 of a dry sound insulation double floor using the floor panel of the present invention. The sound insulation floor 10 includes a vibration isolation support leg 14 disposed at an interval on a slab 12 which is a housing of a building, and a floor foundation panel supported by the vibration isolation support leg 14 and disposed above the slab 12. (Floor panel) 20 and a finishing material 16 placed on the floor base panel 20. The finishing material 16 is a flooring material, a tatami mat, a carpet or the like, and a scraping material may be disposed between the finishing material 16 and the floor foundation panel 20 as necessary.

  The anti-vibration support leg 14 includes a support bolt 14b that is rotatably supported by a frustum-shaped anti-vibration rubber 14a, and a support board 14c that is screwed to the support bolt 14b. A hexagonal hole is formed on the upper end surface of the support bolt 14b, and the floor base panel 20 is placed on the support board 14c with an interval so that the hexagonal hole can be seen from above. It is possible to adjust the height (leveling) of the floor foundation panel 20 by rotating the support bolt 14b using a wrench. The floor base panel may be bonded and fixed to the support board, or may be fixed to the support board using screws or bolts.

  FIG. 2 is an exploded perspective view showing a state in which the members 21 to 25 are assembled to form a floor foundation panel by turning upside down, and FIG. 3 shows the floor foundation panel after assembling each member from the direction A1 in FIG. FIG. The floor foundation panel 20 is disposed between the pair of flat plates 21 and 22 and the pair of flat plates 21 and 22, and the ridges 23a and the valleys 23b are alternately and repeatedly formed. The corrugated plate member 23 and end fitting members (end members) 24, 25 arranged at the end portions 23c, d of the corrugated plate member 23 are fixed to each other. Here, the opposing surfaces of the pair of flat plates 21 and 22 are application surfaces 21a and 22a to which an adhesive is applied, and the peak portion 23a is brought into contact with the upper flat plate 22 between the pair of flat plates 21 and 22. The corrugated plate member 23 is arranged with the valley 23b in contact with the lower flat plate 21 and the end portions 23c, d of the corrugated plate member are sandwiched between one of the pair of flat plates 21, 22. End fitting members 24 and 25 are arranged. The floor base panel 20 is manufactured by bonding and fixing the corrugated member 23 and the end fitting members 24 and 25 between the pair of flat plates 21 and 22 in such an arrangement.

Each of the members 21 to 25 is made of a wood material. As the wood-based material, plywood such as fiber board (prepreg mat), particle board, strand board, veneer board, wood other than plywood, and the like can be used. By making each member of the floor base panel a wood-based material, an impact sound generated when an impact force is applied to the floor, such as dropping an object on the floor, can be reduced.
As the flat plates 21 and 22, when a strand board that exhibits a strong resistance against a partially applied impact force is used, the floor base panel can have a very good strength. As the corrugated member 23, it is preferable to use a fiber board because it can be easily formed into a corrugated plate to obtain a corrugated member.

  The flat plates 21 and 22 of the present embodiment are wood-based strand plates that are press-formed into a square shape having a thickness of about 5 to 10 mm. The flat plate can have various shapes such as a rectangular shape, a shape obtained by cutting out a part of the rectangle, and a trapezoidal shape.

  The corrugated plate member 23 is formed such that the crests 23a and the troughs 23b extend alternately and in parallel, and the crests 23a and the troughs are disposed between the pair of flat plates 21 and 22. A shape in which trapezoidal cavities 26 and 27 are formed by forming a trapezoidal wave shape in a vertical section (cross section perpendicular to the direction facing FIG. 3) with respect to the direction (front-rear direction shown in FIG. 2) in which 23b is formed. Has been. Here, a trapezoidal cavity 26 having a lower lower base than the upper base is formed on the lower side from the peak portion 23a, and a trapezoidal shape having a longer upper base than the lower base on the upper side from the valley portion 23b. A cavity 27 is formed, and two types of cavities 26 and 27 are alternately arranged in the left-right direction. The angle formed by the lower base and the hypotenuse in the cavity 26 (corresponding to the angle of inclination of the inclined part 23e, which is the part connecting the peak part 23a and the valley part 23b with respect to the horizontal plane) is approximately 45 °. Further, the angle formed between the lower base and the hypotenuse in the cavity 27 is approximately 135 ° obtained by subtracting 45 ° from 180 °. For this reason, both the force applied in the vertical direction of the floor surface (vertical direction in FIG. 3) perpendicular to the floor surface and the force applied in the parallel direction of the floor surface (horizontal direction in FIG. 3) parallel to the floor surface are waves. Since it works in a substantially compressing direction with respect to the longitudinal direction of the inclined portion 23e of the plate member, the strength against the force applied from both directions is high.

  Further, since the inclined portions 23e of the corrugated plate member are alternately inclined symmetrically with respect to the vertical direction of the floor surface, the strength is evenly applied to the force applied from any direction parallel to the floor surface. Is maintained high. Accordingly, the floor foundation panel 20 can maintain a high strength (rigidity) in the direction perpendicular to the floor surface and in the direction parallel to the floor surface, although the weight is reduced by having a hollow structure. As a result, the floor base panel can have a higher strength / weight ratio (ratio of strength to weight) than a floor base panel that does not have a cavity, and thus has the same strength as a conventional floor base panel. Panel weight can be reduced.

  The corrugated plate-like member 23 of the present embodiment is a wood-based fiber plate that is press-molded into a trapezoidal corrugated section having a thickness of about 2 to 4 mm. The corrugated plate member can have various cross-sectional wave shapes other than a trapezoidal cross-sectional shape, a shape closer to a sine wave, a shape closer to a triangular wave, a shape closer to a square wave, etc. be able to.

  The end fitting members 24 and 25 of the present embodiment are respectively provided at left and right end portions 23c and d where the crest portions 23a and trough portions 23b of the corrugated plate member 23 appear alternately. And it arrange | positions in the direction of the front-back direction in which the trough part 23b was formed. The heights of the end fitting members 24 and 25 in this arrangement are the same H1. Further, each end fitting member 24, 25 is made thinner by the thickness H2 of the end portions 23c, d of the corrugated member on the corrugated member side, and between the pair of flat plates 21, 22 is corrugated. Clamping portions 24a and 25a sandwiching the end portions 23c and d of the shaped member are formed. That is, the positions of the end portions 23c and d of the corrugated plate member are aligned with the positions of the clamping portions 24a and 25a of the end fitting member, and the corrugated plate member 23 and the end fitting members 24 and 25 are interposed between the pair of flat plates 21 and 22. The end portions 23c and d of the corrugated plate member can be easily sandwiched between the end member sandwiching portions 24a and 25a and the flat plate 21 to quickly form the floor base panel.

  In addition, since the vibration energy propagated from the impact point of the floor foundation panel 20 is repeatedly reflected at the boundary between the solid part which is the end of the floor foundation panel 20 and the hollow part where the cavities 26 and 27 are formed, It attenuates in a short time by repeatedly passing through the complicated propagation path of the hollow part. Thereby, the sound insulation floor 10 can reduce the vibration energy transmitted to the slab 12 from the floor foundation panel 20 through the vibration isolation support leg 14 and the acoustic energy transmitted to the slab 12 by the vibration of the floor foundation panel 20. It is possible to significantly reduce the impact sound level. Further, as shown in FIG. 3, since impedance discontinuity occurs between the thickness L1 and the thickness L2, the vibration energy propagating from the impact point in the direction parallel to the floor surface also occurs at the boundary portion of the thickness. Reflected and attenuated in a short time.

(2) Description of floor panel manufacturing method:
As shown in FIG. 2, when the end portions 23c, d of the corrugated plate member placed on the upper side of the slab are on the lower side, the respective members are assembled upside down as shown in FIG. When the panel is formed, the operation of manufacturing the floor base panel can be made in a relatively short time.
First, a method for forming the members 21 to 25 constituting the floor foundation panel 20 of the present embodiment will be described.

For the flat plates 21 and 22, the binder is attached to the wood flakes, the wood flakes are dispersed and laminated, and the laminate of the wood flakes is heated at a temperature of 140 to 220 ° C. and a pressure of 15 to 40 kg / cm ² for 6 to 15 minutes. What is necessary is just to heat-pressure-mold until it becomes a predetermined thickness of about 5-10 mm, and to trim the outer periphery of a laminated body after cooling. Then, a flat plate made of a wood-based strand board press-formed into a predetermined shape is formed. About a wood flake and a binder, what was described in Unexamined-Japanese-Patent No. 2003-172020 can be used.

  For the corrugated plate member 23, a fiber of polyethylene terephthalate (PET) is added as a tether to a fiber of wood or hemp, and a phenol resin which is a thermosetting resin is further added, and the thickness is about 2 to 4 mm. It may be formed by hot-pressing into a trapezoidal cross section and cooling. What is necessary is just to trim an outer periphery as needed. Then, a corrugated member made of a wood fiber board press-molded into a predetermined corrugated shape is formed. In the present embodiment, a corrugated member is formed in which the crest portion 23a is one more than the trough portion 23b except for the end portions 23c and d.

  For the end fitting members 24 and 25, a rod-shaped square bar made of a wood material having a rectangular cross section is cut to a height H 1 that is substantially the same as the height of the corrugated plate member 23, and is further in contact with one of the pair of flat plates 21 and 22. What is necessary is just to process notch the corrugated plate-like member 23 side by the height H2 of the end portions 23c, d of the corrugated plate-like member to form the clamping portions 24a, 25a. The floor panel can be quickly formed by easily sandwiching the end portion of the corrugated plate member between the end fitting member and the flat plate with a simple structure in which the ridge line portion of the rod-shaped member is cut out to form a sandwiching portion.

As shown in the upper part of FIG. 4, the end fitting members 34 and 35 arranged at both ends of the corrugated plate member are divided into rod-shaped outer end members 34 a and 35 a having a rectangular section and a rod-shaped inner end member having a rectangular section. It is good also as a member formed by joining 34b and 35b. Here, the outer end members 34a and 35a have a height H1 that is substantially the same as the height of the corrugated plate member, and are disposed outside the inner end members 34b and 35b. The inner end members 34b and 35b are both set to a height (H1-H2) lower than the height H1 of the outer end members 34a and 35a by the thickness H2 of the end portion of the corrugated member. It is arrange | positioned rather than 35a at the corrugated member side (inner side), and the clamping parts 34c and 35c are formed. Then, the inner side surfaces of the outer end members 34a and 35a and the outer side surfaces of the inner end members 34b and 35b are bonded with an adhesive so that the surfaces (the upper surface in the figure) that do not sandwich the end portions of the corrugated plate members coincide with each other. When they are joined together, an end fitting member having a clamping portion is formed.
With the above configuration, the process of forming the notch is not required when producing the end fitting member having the clamping portion, and therefore the end fitting member can be easily formed. And since the space | interval of a pair of flat plate can be determined by the height of the outer end member which is a single member, the space | interval between flat plates can be managed with high precision, and the dispersion | variation in the height of a floor foundation panel is possible. Can be suppressed.

Further, as shown in the lower part of FIG. 4, the end fitting members 44 and 45 arranged at both ends of the corrugated plate member are made up of bar-shaped base end members 44a and 45a having a rectangular cross section and bar-shaped spacers having a rectangular cross section (lamination). (Members) 44b and 45b may be joined to each other. Here, the base end members 44a and 45a are set to a height H1-H2 that is lower than the height of the corrugated plate member by the substantially thickness of the end of the corrugated plate member, and above or below the spacers 44b and 45b. Placed in. Each of the spacers 44b and 45b has the same height H2 as the thickness of the end portion of the corrugated member, and the base end members 44a and 45a are not in contact with each other among the pair of flat plates (the lower flat plate 21 in the figure). Is sandwiched at a position opposite to the corrugated member side (outer side) on the surface (lower surface in the figure) to form the sandwiching portions 44c and 45c on the corrugated member side (inner side). Since the spacers 44b and 45b have the same height as the end portion of the corrugated member, a plate made of the same material as that of the corrugated member can be used, for example, when the end portion of the corrugated member is trimmed. End materials can be used. Then, when the base end members 44a and 45a and the spacers 44b and 45b are joined by bonding with an adhesive or the like so that the outer surfaces coincide with each other, an end fitting member having a sandwiching portion is formed.
Also with the above configuration, since the process of forming the notch is not required when the end fitting member having the holding portion is manufactured, the end fitting member can be easily formed. And since the board | plate of the same material as a corrugated plate member can be used as a laminated member, the clamping part of the height lower by the thickness of the edge part of a corrugated plate member can be formed easily.

  When each member constituting the floor foundation panel is formed, the floor foundation panel 20 is manufactured as shown in FIG. The figure shows a state in which the floor base panel is formed upside down. In the example of the figure, first, an adhesive is applied to the entire coating surface 22a which is the lower surface of the upper flat plate 22. As the adhesive, epoxy resins, phenol resins, urea resins, acrylic resins, and other synthetic resins, starch paste, and the like can be used. The same applies to the following.

Moreover, as shown in FIG. 5, when apply | coating an adhesive agent to the coating surface 22a of an upper side flat plate, the metal rotating shaft members 81-84 provided with the longitudinal direction turned to the left-right direction, the said axis | shaft Even if the adhesive is applied using rollers 85 to 88 fixed to the members 81 to 84, the end members 89 and 89, an adhesive supply mechanism (not shown), and a driving device (not shown). Good. In the figure, a large number of points are attached to locations where the adhesive is present.
The roller 85 is an embossing roller to which an adhesive is attached, and irregularities are formed in accordance with the positions where the crests 23a and the troughs 23b of the corrugated plate member come into contact. In general, the roller 85 has a small diameter in the concave portion 85b that contacts the position where the crest portion 23a or the trough portion 23b contacts in the flat plates 21 and 22, and a large diameter in the convex portion 85a other than the portion. Further, both end portions of the roller 85 protrude outward from the flat plates 21 and 22, and are formed as concave portions 85c and 85c within the width in the left-right direction of the flat plates 21 and 22, and more than the concave portions 85c and 85c. On the outer side in the width direction, the convex portions 85d and 85d are formed long in the left-right direction. The roller 85 is configured to rotate clockwise in the drawing together with the rotary shaft member 81 by a driving mechanism. The roller 86 is not in contact with the flat plates 21 and 22, the clearance between the convex portion of the embossing roller 85 is set to 0, and the roller 86 is rotated together with the rotating shaft member 82 counterclockwise in the drawing. Yes. Adhesive is supplied from the adhesive supply mechanism above the contact portion of both rollers 85 and 86, and the adhesive adheres to the entire outer surface of the embossing roller 85. The rollers 87 and 88 are brought into contact with the surface opposite to the contact surface of the embossing roller 85 in the flat plates 21 and 22, and are rotated counterclockwise in the drawing together with the rotary shaft members 83 and 84 by the driving mechanism. Is moved to the left in the figure. At both left and right end portions, end members 89 and 89 fixed so as to be in sliding contact with the outer periphery of the convex portions 85d and 85d of the embossing roller and the outer periphery of the roller 86 are provided above the contact portion of the rollers 85 and 86. The adhesive is blocked so that it does not protrude outward in the left-right direction.
With the above configuration, of the adhesive that adheres to the entire outer periphery of the embossing roller 85 on the upper side of the contact portion between the rollers 85 and 86, the adhesive that adheres to the convex portion 85a does not move downward from the contact portion of the rollers 85 and 86. It does not move and is in a state of being attached only to the concave portions 85b and 85c. Then, the adhesive adhered to the concave portions 85b and 85c is transferred to the flat coating surface (22a) in a band shape. Thereby, an adhesive agent is apply | coated to the flat plates 21 and 22 according to the position of the peak part 23a and the trough part 23b.
As described above, since the adhesive is not applied to the portion of the flat plate where the crests or troughs do not contact, the amount of adhesive used can be reduced, and the manufacturing cost of the floor foundation panel can be reduced.
Further, since a relatively long concave portion 85c is formed at the end of the embossing roller, when the contact position of the crest or trough is different between the upper flat plate and the lower flat plate, the position of the flat plate is adjusted to the contact position. The adhesive can be applied with the same application apparatus by shifting the position.
In addition, a scraping member for scraping only the adhesive adhered to the convex portion 85a so as to leave the adhesive adhered to the concave portions 85b and c of the embossing roll is provided, and the adhesive adhered to the concave portions 85b and c is flattened. Even if the transfer is performed, the same operation and effect can be obtained. In addition, even if the adhesive is attached only to the convex part of the embossing roll and the adhesive attached to the convex part is transferred to the application surface of the flat plate in a strip shape, only the positional relationship between the convex part and the concave part changes. Similar actions and effects can be obtained.

  When the adhesive is applied to the application surface of the upper flat plate, the end fitting members 24 and 25 with the sandwiching portions 24 a and 25 a facing upward and the corrugated member side are placed at predetermined positions on the upper flat plate 22. At this time, the end fitting members 24 and 25 adhere to the application surface 22a of the upper flat plate with an adhesive. Next, the end portions 23c and d are aligned with the clamping portions 24a and 25a of the end fitting members, and the corrugated plate member 23 is placed on the upper flat plate. Then, the crest 23a of the corrugated plate member adheres to the coating surface 22a of the upper flat plate with an adhesive.

Further, an adhesive is applied to the application surface 21 a that is the upper surface of the lower flat plate 21. Here, the adhesive may be applied to the entire application surface 21a, or the adhesive may be applied while moving the plurality of rollers 82 according to the position where the corrugated portion 23b of the corrugated plate member contacts as shown in FIG. At the same time, the adhesive that adheres at a position where the valley portion 23 b does not contact may be collected by the plurality of scraping members 83.
Thereafter, the lower flat plate 21 is placed on the corrugated plate member 23 and the end fitting members 24 and 25. Here, since the height reduction of the sandwiching portions 24a and 25a is the height H2 of the end portion of the corrugated member, the trough portion 23b of the corrugated member and the sandwiching portions 24a and 25a of the end fitting member are The formed surfaces 24b and 25b are simultaneously adhered by an adhesive.
As described above, the corrugated plate member 23 is disposed between the pair of flat plates 21 and 22 and the end fitting members 24 and 25 are arranged so that the end portions 23 c and d of the corrugated plate member are sandwiched between the flat plate 21. Will be placed. Then, a pressing force is applied in the vertical direction to the pair of flat plates 21 and 22 by a press machine (not shown). Then, each member 23-25 pinched | interposed into the flat plates 21 and 22 and the flat plates 21 and 22 adhere | attach with an adhesive agent, the end fitting members 24 and 25 are pressed on the upper side flat plate 22, and the end fitting members 24 and 25 are made to press. The corrugated plate member 23 and the end fitting members 24, 25 are fixed between the pair of flat plates 21, 22 with the end portions 23 c, d of the corrugated plate member sandwiched between the lower flat plate 21. . The upper flat plate 22 is a flat plate on the side of the pair of flat plates 21 and 22 that does not sandwich the end portions 23c and d of the corrugated plate member, and the lower flat plate 21 sandwiches the end portions 23c and d of the corrugated plate member. It is a flat plate on the side to be made.
Thereafter, the floor foundation panel is formed by cutting it to an exact size.

  As described above, the floor base panel can be manufactured by quickly assembling the members. Further, since the end portion of the corrugated plate member is sandwiched and supported by the end fitting members 24 and 25 pressed by the upper flat plate 22 and the lower flat plate 21, the corrugated plate member is reliably interposed between the pair of flat plates. And the end fitting member are bonded and fixed to improve the strength of the floor base panel.

(3) Action and effect of floor panel and manufacturing method thereof:
According to the method for manufacturing a floor base panel, it is not necessary to form a strand by laminating an appropriate amount of wood flakes in order to make the end of the floor base panel solid. Therefore, buckling or the like at the time of screwing due to a small amount of laminated wood flakes at the end of the floor base panel does not occur.
In addition, when the end fitting members 94 and 95 which do not form the clamping part like the floor base panel 90 shown in FIG. 6 are used, even if a pressing force is applied to the pair of flat plates 91 and 92 in the vertical direction, Since the pressing force is not applied to the end portions 93c, d of the plate-like member, the end portions 93c, d and the flat plate 91 may not be sufficiently bonded. If the end portion of the corrugated plate member and the flat plate are not firmly bonded, the end portion of the corrugated plate member or the end portion of the flat plate may be cramped when screwed at the end portion of the floor base panel. In the present invention, since the end of the corrugated member is sandwiched and supported between the end fitting member and the flat plate, the end of the corrugated member is securely bonded to the flat plate and Don't bend. Further, in the floor base panel 90 shown in FIG. 6, when the corrugated member is arranged after the both end fitting members are arranged on the flat plate due to a dimensional error of each member, the corrugated plate members are fitted on both ends. It may not be accommodated between the members. Such a problem does not occur in the floor foundation panel of the present embodiment.
Since the trapezoidal cavities 26 and 27 having a trapezoidal cross section are formed in the floor base panel in the direction parallel to the floor surface, the floor impact sound level can be reduced while obtaining sufficient strength and light weight. it can. Therefore, the manufacturing efficiency of the floor base panel can be improved, and the end of the corrugated plate member is securely bonded to the flat plate, so that it is not cramped when screwing and the like while obtaining good sound insulation. It is possible to improve the strength of the floor foundation panel.

  Further, the end fitting members 24 and 25 are thinned by the thickness H2 of the end portion of the corrugated member on the corrugated member side, and the sandwiching portion 24a sandwiching the end portion of the corrugated member between the flat plates. , 25a, the end of the corrugated plate member can be easily sandwiched between the flat plates. Here, since the end fitting members 24 and 25 are thicker by the thickness H2 of the corrugated member than the sandwiching portion on the side opposite to the corrugated member side, the end portions 23c and d of the corrugated member are sandwiched. When facing the positions of 24a and 25a, the opposing surface to the flat plate formed by the end portions 23c and d of the corrugated plate members and the end fitting members 24 and 25 becomes a substantially flat surface. That is, since the surfaces 24b and 25b of the end fitting member on which the clamping portions are formed are in contact with the flat plate, it is possible to easily form the floor base panel simply by applying an adhesive to the upper surface of the lower flat plate and the lower surface of the upper flat plate. it can. Further, when the end fitting member is placed at a predetermined position on one flat plate, and the end portions 23c and d are aligned with the sandwiching portions 24a and 25a of the end fitting member, the corrugated plate member 23 is placed on the flat plate. The corrugated member is positioned. Then, by placing the remaining flat plates on the corrugated plate member 23 and the end fitting members 24, 25, it is possible to quickly assemble each member and form a floor foundation panel. Thereby, a homogeneous floor foundation panel is formed quickly.

  Conventionally, the angle between the lower base and the hypotenuse in the trapezoidal cavity formed in the floor base panel is 60 ° and 120 ° and the hypotenuse is on the vertical side, so press molding is not easy and press molding is quick. Could not be done. In the present embodiment, since the same angle is set between 45 ° and 135 ° and between the vertical direction and the horizontal direction, press molding can be performed quickly and the manufacturing efficiency of the floor foundation panel can be improved. A floor base panel having the same angle of 60 ° and 120 ° is formed, and the center portion of the upper surface of the floor base panel is formed with respect to this floor base panel and the floor base panel having the angles of 45 ° and 135 ° of the present embodiment. When a strength test was performed in which a load of 100 kg was applied vertically downward, the amount of deflection at the center of the panel was smaller in the floor base panel of this embodiment. That is, by setting the angle to 45 ° and 135 °, the strength of the floor foundation panel is also improved.

  In addition, conventionally, since wood thin pieces have been laminated and press-molded, press molding is not easy, and press molding cannot be performed quickly. In this embodiment, since the corrugated plate member having a complicated shape is a fiber board, press molding can be performed quickly, and the manufacturing efficiency of the floor foundation panel can be improved.

(4) Various modifications:
When applying the adhesive, it is only necessary to join the corrugated member and the end fitting member to the flat plate, and after applying the adhesive to all locations where the adhesive is applied, each member is assembled. May be. Moreover, an adhesive agent may be apply | coated to a corrugated plate-shaped member or an end fitting member, and members may be adhere | attached. Further, the members may be adhered by attaching a double-sided tape or the like.
Further, since the members only need to be bonded, the step of applying a pressing force in the vertical direction to the pair of flat plates can be omitted.
When the corrugated plate member is formed by alternately paralleling the crests and troughs, the corrugated plate and the trough may be formed in parallel with a curved line or a polygonal line. Of course, if it is a corrugated plate member in which peaks and troughs appear alternately in a vertical section, the effect of improving the strength of the floor panel can be obtained while obtaining good sound insulation.
The surface on the corrugated member side of the end fitting member may be a surface that is obliquely deviated from the vertical in addition to the vertical surface. The surface in the vertical direction of the sandwiching portion may also be a surface that is obliquely deviated from the vertical.
Even when the end fitting member is provided only on one side of both ends of the floor base panel, an effect of improving the strength of the floor panel while obtaining good sound insulation can be obtained. Of course, it is good also as a structure which arrange | positions the end fitting member to which this invention is applied to the perimeter of a floor foundation | substrate panel.

As shown in the upper part of FIG. 7, a corrugated plate member 53 having a shape opposite to that of the corrugated plate member shown in FIG. 3 may be used. Unlike the corrugated plate member 23, the corrugated plate member 53 has one more trough portion 53b than the peak portion 53a except for the end portions 53c and d. The end fitting members 54 and 55 may be formed with sandwiching portions 54 a and 55 a that sandwich the end portions 53 c and d of the corrugated plate member with the upper flat plate 52.
When manufacturing the floor foundation panel 50, end fitting with the sandwiching portions 54a and 55a facing the upper side and the corrugated member side at a predetermined position on the lower flat plate 51 where the adhesive is applied to the coating surface serving as the upper surface. The members 54 and 55 are placed. Further, the corrugated plate member 53 is placed on the lower flat plate with the end portions 53c and d aligned with the pinching portions 54a and 55a of the end fitting member. Further, the upper flat plate 52 with the adhesive applied to the lower application surface is placed on the corrugated member 53 and the end fitting members 54 and 55.
When a pressing force is applied to the pair of flat plates 51 and 52 in the vertical direction with the press machine in the above arrangement state, the members 53 to 55 and the flat plates 51 and 52 sandwiched between the flat plates 51 and 52 by the adhesive. In the state in which the end fitting members 54 and 55 are pressed against the lower flat plate 51 and the end portions 53c and d of the corrugated plate member are sandwiched between the end fitting members 54 and 55 and the upper flat plate 52. A corrugated plate member 53 and end fitting members 54 and 55 are fixed between the pair of flat plates 51 and 52.

Further, as shown in the lower part of FIG. 7, corrugated members 63 whose both end portions 63 c and d are different from each other may be used. The corrugated plate member 53 has the same number of peaks 63a and valleys 63b. In the example in the lower part of the figure, the left end fitting member 64 is formed with a sandwiching portion 64a that sandwiches the left end portion 63c of the corrugated plate member with the lower flat plate 61, and the right end fitting member 65 is connected with the upper flat plate 62. It is shown that a sandwiching portion 65a that sandwiches the right end portion 63d of the corrugated plate member is formed.
When the floor base panel 60 is manufactured, the right end fitting with the sandwiching portion 65a facing upward and the corrugated member side at a predetermined position on the lower flat plate 61 in which an adhesive is applied to the coating surface serving as the upper surface. The member 65 is placed. Further, the corrugated plate member 63 is placed on the lower flat plate with the right end portion 63d aligned with the clamping portion 65a of the end fitting member 65. Further, the end fitting member 64 is placed on the lower flat plate by aligning the sandwiching portion 64a of the left end fitting member 64 with the left end 63c of the corrugated plate member. Then, the upper flat plate 62 in which an adhesive is applied to the application surface serving as the lower surface is placed on the corrugated plate member 63 and the end fitting members 64 and 65.
When a pressing force is applied in the vertical direction to the pair of flat plates 61 and 62 with the press machine in the above arrangement state, the members 63 to 65 and the flat plates 61 and 62 sandwiched between the flat plates 61 and 62 by the adhesive Are bonded to form a floor base panel 60.

Furthermore, as shown in FIG. 8, you may use the end fitting members 74 and 75 in which the clamping part is not formed. The end fitting members 74 and 75 have a height H1− that is lower by the approximate thickness of the end portions 73c and d of the corrugated plate-like member than the height of the corrugated plate-like member 73 where the peak portions 73a and the valley portions 73b appear alternately. It is a rod-shaped member having a rectangular cross section which is H2.
When the floor base panel 70 is manufactured, the end fitting members 74 and 75 are placed at predetermined positions on the upper flat plate 72 in which an adhesive is applied to the application surface serving as the lower surface. Further, an adhesive is applied to the surfaces 74b and 75b of the end fitting members 74 and 75 that do not contact the flat plate, and the end portions 73c and d are aligned with the surfaces 74b and 75b, and the corrugated plate member 73 is placed on the upper flat plate. To do. Further, the lower flat plate 71 in which an adhesive is applied to the upper application surface is placed on the corrugated member 73 and the end fitting members 74 and 75.
When a pressing force is applied in the vertical direction to the pair of flat plates 71 and 72 with the press machine in the above arrangement state, the members 71 to 75 are bonded to each other by the adhesive, and the floor base panel 70 is formed.

Furthermore, as shown in FIG. 9, the present invention is also applied to a floor panel 120 in which a plurality of corrugated plate members 123 are arranged in a horizontal direction with adjacent end portions 123 c and d between a pair of flat plates 121 and 122. Is possible. In the present floor panel, each corrugated plate member 123 is disposed between a pair of flat plates 121 and 122 with the peak portion 123a in contact with the upper flat plate 122 and the valley portion 123b in contact with the lower flat plate 121, and the entire floor panel is arranged. An outer end member 124 is arranged so that the left end 123c of the left corrugated member 123 is sandwiched between the lower flat plate 121 at the left end, and the right corrugated shape at the right end of the entire floor panel. The outer end member 125 is disposed so as to sandwich the right end portion 123d of the member 123 with the lower flat plate 121, and both the end portions 123c and d of the corrugated plate members adjacent to each other on the inner side in the horizontal direction of the entire floor panel. Is arranged between the lower flat plate 121 and the inner end member 126. With this arrangement, the corrugated plate members 123 and 123 and the end members 124, 125, and 126 are bonded and fixed between the pair of flat plates 121 and 122 to form the floor panel 120.
Note that the end members 124 to 126 are respectively provided along the direction in which the peak portion 123a and the valley portion 123b extend, and are formed in a bar shape so that the height in the above arrangement is the same. Further, a sandwiching portion 126a for sandwiching the end 123d of the left corrugated member 123 with the lower flat plate 121 is formed below the left edge, and the right corrugated plate is formed below the right edge. A clamping part 126 a that clamps the end 123 c of the member 123 with the lower flat plate 121 is formed.

In the floor panel 120, a wide floor panel can be easily formed by arranging a plurality of corrugated members, and both ends of adjacent corrugated members are securely bonded to a flat plate, so It is possible to improve the strength of the floor panel while obtaining good sound insulation.
It should be noted that the floor panel provided with an inner end member that sandwiches the end portions of the adjacent corrugated members between the upper flat plate and one end portion between the lower flat plate and the other end portion. Even if it is a floor panel which provided the inner side end member which clamps between upper side flat plates, and the floor panel which provided only the inner side end member without providing an outer side end member, the said effect is acquired.

  As described above, according to the present invention, the manufacturing efficiency of the floor panel can be improved and the strength of the floor panel can be improved while obtaining good sound insulation, according to various aspects.

The vertical sectional view showing the sound insulation floor using the floor panel of the present invention. The disassembled perspective view which shows a mode that a floor foundation panel is formed. The front view which shows the floor base panel after a member assembly | attachment seeing from the A1 direction of FIG. The front view which shows the modification of an end fitting member seeing from the same position as FIG. The perspective view which shows a mode that an adhesive agent is apply | coated on a flat plate. The front view which shows a mode when the edge part of a corrugated member is not clamped by the end fitting member. The front view which shows the modification of a floor foundation panel. The front view which shows the modification of a floor foundation panel. The front view which shows the modification of a floor foundation panel. The perspective view explaining the manufacturing method of the conventional floor foundation panel.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Sound insulation floor 12 ... Slab 14 ... Anti-vibration support leg 16 ... Finishing material 20, 50, 60, 70, 120 ... Floor base panel (floor panel)
21, 51, 61, 71, 121 ... lower flat plates 21a, 22a ... coating surfaces 22, 52, 62, 72, 122 ... upper flat plates 23, 53, 63, 73 ... corrugated plate members 23a, 53a, 63a, 73a , 123a ... mountain parts 23b, 53b, 63b, 73b, 123b ... valley parts 23c, 23d, 53c, 53d, 63c, 63d, 73c, 73d, 123c, 123d ... end parts 23e ... inclined parts 24, 25, 34, 35 , 44, 45, 54, 55, 64, 65, 124, 125, 126 ... end fitting member (end member)
24a, 25a, 34c, 35c, 44c, 45c, 54a, 55a, 64a, 65a, 126a, 126b ... sandwiching portions 26, 27 ... trapezoidal cavities 34a, 35a ... outer end members 34b, 35b ... inner end members 44a, 45a ... Base end members 44b, 45b ... Spacers (laminated members)

Claims (8)

A pair of flat plates composed of a lower flat plate and an upper flat plate, a corrugated plate member that is disposed between the pair of flat plates and in which peaks and troughs are alternately and repeatedly formed, and an end portion of the corrugated plate member The end members disposed on the floor panel are fixed to each other and disposed above the slab,
Between the pair of flat plates, the corrugated plate member is disposed with the peak portion in contact with the upper flat plate and the valley portion in contact with the lower flat plate, and the end portions of the corrugated plate member are the same. The end member is disposed so as to be sandwiched between one of the pair of flat plates, and the corrugated plate member and the same end member are bonded and fixed between the same pair of flat plates in the arrangement. Characteristic floor panel. The corrugated member is formed such that the peaks and valleys alternately extend in parallel,
The end member is provided in both ends of the corrugated plate member in a direction in which the crests and troughs are alternately and repeatedly formed along the extending direction of the crests and troughs, and is formed in a rod shape. The floor panel according to claim 1, wherein heights in the arrangement are the same.   2. The clamping member according to claim 1, wherein the end member is formed with a clamping portion that clamps an end portion of the corrugated plate member between one of the pair of flat plates on the corrugated plate member side. The floor panel according to claim 2.   The corrugated plate-shaped member is shaped so as to form a trapezoidal cavity in a vertical section with respect to the direction in which the crests and troughs are alternately and repeatedly arranged between the pair of flat plates. The floor panel according to any one of claims 1 to 3, wherein the floor panel is provided.   A plurality of the corrugated plate-like members are arranged in the horizontal direction with the end portions adjacent to each other between the pair of flat plates, and the end member has both ends of the adjacent corrugated plate-like members as one of the pair of flat plates. The floor panel according to any one of claims 1 to 4, wherein the floor panel is disposed so as to be sandwiched between the floor panel and the floor panel. A pair of flat plates composed of a lower flat plate and an upper flat plate, a corrugated plate member that is disposed between the pair of flat plates and in which crests and troughs are alternately and repeatedly formed, and an end of the corrugated plate member And an end member disposed on the floor panel, the floor member being fixed to each other and disposed above the slab,
Between the pair of flat plates, the corrugated portion is placed in contact with the upper flat plate, the valley portion is brought into contact with the lower flat plate, and the corrugated plate member is disposed, and the end portions of the corrugated plate members are placed in the same pair. The above-mentioned end member is arranged so as to be sandwiched between one flat plate, and the corrugated plate-like member and the same end member are bonded and fixed between the same pair of flat plates in the arrangement. The manufacturing method of the floor panel characterized by manufacturing.   The adhesive is applied to the mutually opposing surfaces of the pair of flat plates, and the corrugated plate member is placed with the adhesive-applied surface of one of the pair of flat plates facing upward. The end member is placed so that the end portion is sandwiched between one of the pair of flat plates, and the other flat plate is placed on the end member, so that the same corrugated plate shape is formed between the same pair of flat plates. The method for manufacturing a floor panel according to claim 6, wherein the member and the end member are bonded and fixed. The corrugated member is formed such that the peaks and valleys alternately extend in parallel,
When the adhesive is applied to the pair of flat plates, a roller for adhering the adhesive and using the roller having irregularities formed at the positions where the crests and troughs of the corrugated plate member are in contact with each other is used. The method for manufacturing a floor panel according to claim 7, wherein an adhesive is applied to the flat plate in accordance with the positions of the part and the valley part.

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