JP2010255199A - Method for manufacturing floor panel, and the floor panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To keep the amount of deformation of the whole floor panel small by suppressing the displacement between upper and lower plates when a load is imposed on them. <P>SOLUTION: The upper metal plate 3 and the lower metal plate 7 having a recess 5 provided on the side facing the upper plate 3 overlap each other; and a welded zone 27 is formed by applying spot welding to the flange 25 of the upper plate 3 and a flange 13 of the lower plate 7. After the spot welding, edge bending work is performed by bending an edge bending portion 23 on a leading end side with respect to the flange 25 of the upper plate 3 so as to make it overlap the flange 13 of the lower plate 7. In this case, the edge bending portion 23 covers the welded zone 27. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention includes a metal upper plate and a metal lower plate provided with a recess on the side facing the upper plate, and the outer peripheral edge portions are fixed by overlapping the upper plate and the lower plate. The present invention relates to a method of manufacturing a floor panel having a structure and a floor panel.

  In recent years, a double floor system has been adopted in response to an increase in the amount of power, telephone, and data. In this double floor system, for example, a large number of support legs are erected on a floor base material such as a concrete slab, and the floor panel is supported by the support legs, whereby a gap between the floor panel and the floor base material is obtained. Is used as a wiring space, and cables such as power lines and information lines are laid in the wiring space.

  As a floor panel used in such a double floor system, a flat plate-like upper plate and a lower plate having a concave portion for containing a filler such as mortar on the upper plate side are provided. The plates are stacked on top of each other to secure the outer peripheral edge. As a method for fixing the outer peripheral edge, there are edge bending and spot welding in which the outer peripheral edge of the upper plate is folded and fastened so as to overlap the outer peripheral edge of the lower plate (see Patent Document 1).

Japanese Patent Laid-Open No. 11-131767

  However, in the conventional floor panel described above, the outer peripheral edge portion of the upper plate is only bent and fastened to the outer peripheral edge portion of the lower plate, or spot welding or caulking joint fastening is used instead of the bending fastening. Since the joint strength is low, the upper plate and the lower plate are easily displaced from each other when the outer peripheral edge receives a particularly large load, and the deformation amount of the entire floor panel increases. .

  Therefore, an object of the present invention is to suppress the displacement between the upper plate and the lower plate when receiving a load, and to reduce the deformation amount of the entire floor panel.

  According to the first aspect of the present invention, a metal upper plate and a metal lower plate provided with a recess on the side facing the upper plate are overlapped with each other, and the outer peripheral portions of the upper plate and the lower plate are respectively overlapped. After the overlapping portions are welded and fixed, the protruding portion protruding from the outer peripheral edge portion of the lower plate at the outer peripheral edge portion of the upper plate is bent to cover the welded portion of the outer peripheral edge portion of the lower plate And the edge bending process is performed.

  Invention of Claim 2 is a manufacturing method of the floor panel of Claim 1, Comprising: The protrusion site | part of the outer-periphery edge part of the said upper board is a bending process toward the said lower board side before the said edge bending process. The overlapping portion is welded and fixed in a state where a gap is provided between the bent portion of the protruding upper plate and the tip of the outer peripheral edge of the lower plate.

  Invention of Claim 3 is a manufacturing method of the floor panel of Claim 1 or 2, Comprising: The said lower board is equipped with the protrusion which protrudes toward an upper board by denting the opposite side to the said upper board. When the tip of the projection and the upper plate are welded and fixed by spot welding, the overlapping portion is simultaneously welded and fixed by spot welding.

  According to a fourth aspect of the present invention, a metal upper plate and a metal lower plate having a recess on a side facing the upper plate are provided, and each of the outer peripheral portions of the upper plate and the lower plate is connected to each other. The overlapping portion is fixed by welding, and the protruding portion protruding from the outer peripheral edge portion of the lower plate at the outer peripheral edge portion of the upper plate is bent so as to cover the weld-fixed portion of the outer peripheral edge portion of the lower plate. It is characterized by being overlapped and edge bent.

  According to the invention of claim 1 or claim 4, since the outer peripheral edge portions of the upper plate and the lower plate of the portion to be edge bent are welded and fixed before the edge bending processing, the bonding strength of the outer peripheral edge portion Therefore, when the load is applied, the displacement between the upper plate and the lower plate can be suppressed, and the deformation amount of the entire floor panel can be suppressed to a small level, so that a high-quality floor panel can be obtained.

  According to the invention of claim 2, even when the outer peripheral edge of the lower plate expands and extends due to thermal deformation when the overlapping portion is fixed by welding, the tip of the outer peripheral edge of the extended lower plate is Interference with the protruding portion of the bent upper plate can be avoided, and the strength of the welded portion can be ensured.

  According to the invention of claim 3, since the welding operation of the overlapping portion at the outer peripheral edge portion can be performed in the same process as the welding operation of the protrusion of the lower plate and the upper plate, the work efficiency can be improved.

It is a perspective view of the floor panel which shows one Embodiment of this invention. It is the bottom view seen from the lower-plate side of the floor panel of FIG. (A) is sectional drawing which expands and shows the outer-periphery edge part of the floor panel of FIG. 1, (b) is an effect explanatory drawing which shows the state which is carrying out the spot welding of the flange weld part of an upper board, and the flange part of a lower board. It is. (A) is explanatory drawing which shows the state which is coating with respect to the floor panel of FIG. 1, (b) is an enlarged view of the outer periphery part vicinity of the floor panel at the time of coating. It is explanatory drawing which shows the operation | movement which lifts the floor panel which is not edge-bending the outer peripheral edge part of an upper board.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  A floor panel 1 shown as a perspective view in FIG. 1 is made of a steel plate provided with a flat steel plate upper plate 3 that is substantially square as a whole, and a recess 5 (see FIG. 3) on the side facing the upper plate 3. A lower plate 7 is provided. As shown in FIG. 2, the lower plate 7 has a substantially square shape as with the upper plate 3, and the lower plate 7 includes a bottom plate portion 9 and side walls that rise substantially vertically from the four sides around the bottom plate portion 9. Part 11 and a flange part 13 extending from the end of the side wall part 11 opposite to the bottom plate part 9 to the outside substantially parallel to the bottom plate part 9.

  The flange portion 13 of the lower plate 7 described above has continuous four sides at the corners (four corners), and the overall outer shape of the continuous flange portion 13 substantially matches the outer shape of the upper plate 3. ing.

  Further, the bottom plate portion 9 of the lower plate 7 is formed with dimples 15 which are recessed from the opposite side to the upper plate 3, and the projections 17 projecting toward the upper plate 3 corresponding to the dimples 15. Are provided. As shown in FIG. 2, the dimples 15 (protrusions 17) are continuously arranged in one direction and at equal intervals in the longitudinal direction and the lateral direction orthogonal to each other over almost the entire area of the bottom plate portion 7.

  Such a lower plate 7 is manufactured by press molding so as to be in the state shown in FIG. 3B. The bottom portion of the dimple 15 (corresponding to the tip of the protrusion 17) of the press-molded lower plate 7 and the upper plate 3 The dimple welded portion 19 is set to fix the contacted portion by spot welding.

  On the other hand, the upper plate 3 has a substantially square upper plate body 21 having substantially the same shape as the outer peripheral flange portions 13 of the lower plate 7 and a periphery excluding the corners (four corners) of the upper plate body 21. An edge bending portion 23 is provided that bends a protruding portion that protrudes outward from the flange portion 13 serving as the outer peripheral edge portion of the lower plate 7 from the four side portions.

  Further, a welded portion 27 by spot welding is set between the flange portion 13 of the lower plate 7 and the flange portion 25 which is the outer peripheral edge portion of the upper plate 3 superimposed on the flange portion 13. The flange portions 13 and 25 are fixed to each other by welding. And the above-mentioned edge bending part 23 is overlapped and bent on the flange part 13 of the lower board 7 so that the welding part 27 may be covered, as shown to Fig.3 (a).

  Next, the manufacturing method of the above floor panel will be described. In the upper plate 3 located at the lower part in FIG. 3B, the edge bent portion 23 is bent to the lower plate 7 side at a substantially right angle to the flange portion 25 by pressing before the edge bending process. is there. A gap 29 is provided between the inner surface 23 a of the edge bending portion 23 that is the protruding portion of the pressed upper plate 3 and the front end of the flange portion 13 that is the outer peripheral edge portion of the lower plate 7.

  In this state, the overlapping portions of the flange portion 25 of the upper plate 3 and the flange portion 13 of the lower plate 7 are fixed by welding. At that time, the upper plate 3 is placed on the electrode plate 31 as the lower side in the vertical direction with respect to the lower plate 7, and the rod-shaped electrode 33 is brought into contact with the flange portion 13 between the electrodes 31, 33. By energizing, a welded portion 27 is formed by spot welding.

  As shown in FIGS. 1 and 2, a plurality of welds 27 are formed along each side of the peripheral four sides. Further, the welded portion 27 is set corresponding to the arrangement direction of the plurality of dimples 15 formed in the bottom plate portion 9 of the lower plate 7 in the vertical and horizontal directions. That is, each welded portion 27 is located on an extension line in the arrangement direction of the plurality of dimples 15.

  Here, the spot welding operation between the dimples 15 and the upper plate 3 is performed by applying a plurality of spot welding electrodes 33 so that one row in the vertical direction or the horizontal direction in FIG. Using the electrode holding frame provided in the row, the floor panel 1 as a work is sequentially moved relative to the electrode holding frame in the direction orthogonal to the arrangement direction of the electrodes 33, and the row is performed one row at a time.

  At this time, spot welding is simultaneously performed on, for example, the overlapping portions of the outer peripheral edge portions on the left and right sides in FIG. 2 which are located on the extended line in the arrangement direction for one row of the plurality of dimples 15. That is, in this case, the number of the electrode 33 for spot welding, which corresponds to the plurality of dimples 15 for one row and the one corresponding to the pair of left and right overlapping portions, is attached to the electrode holding frame. I will leave.

  That is, the lower plate 7 includes a protrusion 17 that protrudes toward the upper plate 3 by denting the side opposite to the upper plate 3, and when the tip of the protrusion 17 and the upper plate 3 are welded and fixed by spot welding. In addition, the overlapping portion of the outer peripheral edge is simultaneously welded and fixed by spot welding.

  Thereby, since the welding operation of the overlapping portion at the outer peripheral edge portion can be performed in the same process as the welding operation of the protrusion 15 of the lower plate 7 and the upper plate 3, in order to perform the welding operation on the overlapping portion. It is not necessary to add a new work process separately, and work efficiency can be improved.

  As described above, when performing a welding operation simultaneously on the pair of overlapping portions on both the left and right sides in FIG. 2 and the plurality of dimples 15 for one row arranged in the left-right direction in FIG. As for the other pair of overlapping portions located on both the upper and lower sides in FIG. 2, only a plurality of the overlapping portions are simultaneously performed.

  At this time, since the gap 29 is provided between the inner surface 23a of the edge bending portion 23 of the upper plate 3 and the tip of the flange portion 13 of the lower plate 7, the overlapping portion between the flange portions 13 and 25 is provided. Even when the flange portion 13 which is the outer peripheral edge portion of the lower plate 7 expands and extends due to thermal deformation when welding and fixing, the tip of the outer peripheral edge portion of the extended lower plate 7 is the edge of the upper plate 3. Interference with the inner surface 23a of the bent portion 23 can be avoided, and thereby the strength of the welded portion 27 can be ensured.

  After forming the welded portion 27 as shown in FIG. 3B, the edge bent portion 23 is bent so as to overlap the flange portion 13 of the lower plate 7 as shown in FIG. Hemming) processing. At this time, the bent edge bending portion 23 covers the welded portion 27, thereby avoiding exposure of the welded portion 27 to the lower plate 7 side.

  Thus, in the present embodiment, the flange portion 25 of the upper plate 3 and the flange portion 13 of the lower plate 7 are welded and fixed as the welded portion 27 by spot welding, and the edge bent portion 23 of the upper plate 3 is fixed to the lower plate 7. The edge is bent so as to be superimposed on the flange portion 13.

  For this reason, compared with the case where the outer peripheral edge portions of the upper plate 3 and the lower plate 7 are simply fixed by welding or the case where the outer peripheral edge portion is simply subjected to edge bending processing, the bond strength at the outer peripheral edge portion is increased and the load is increased. The shift between the upper plate 3 and the lower plate 7 when received can be more reliably suppressed, the deformation amount of the entire floor panel 1 can be suppressed small, and the high-quality floor panel 1 can be obtained.

  Moreover, it becomes possible to reduce the plate thickness of the upper plate 3 and the lower plate 7 by increasing the bonding strength at the outer peripheral edge portion, so that the cost can be reduced, and when the floor panel 1 is constructed, The rigidity of the support legs that support the floor panel 1 can be set lower, which can also reduce the cost. As a result, cost reduction and weight reduction of the entire floor system using the floor panel 1 can be achieved.

  Furthermore, by reducing the amount of material used for reducing the thickness of the upper plate 3 and the lower plate 7 as described above, it is possible to contribute to the reduction of carbon dioxide, the effect of reducing the transportation cost due to the weight reduction, and the It can also be expected to reduce carbon dioxide.

  In addition, since the upper plate 3 and the lower plate 7 are in close contact with each other at the joint portion at the outer peripheral edge, the mortar stain when the concave portion 5 between the upper plate 3 and the lower plate 7 is filled with mortar. As a result, the floor panel 1 can be made more high-quality.

  Further, when painting is performed on the floor panel 1 after the upper plate 3 and the lower plate 7 are joined, as shown in FIG. The paint 39 is sprayed from the spray nozzle 37 installed on the side of the floor panel 1 in a state of being hung and hung on one part of the floor panel 1 and powder-coated. For this reason, as shown in an enlarged view in FIG. 4B, the sprayed paint 39a is easily applied to the boundary portion 41 between the tip of the edge bending portion 23 and the flange portion 13, and the filling 39a allows the filling to be performed. When doing so, the mortar exudation phenomenon can be suppressed more reliably.

  Separately from this embodiment, when the outer peripheral edge portion of the upper plate 3 is not provided with the edge bending portion 23 and is a flange portion having the same shape as the flange portion 13 of the lower plate 7, the boundary portion between the flange portions. Is positioned on the side with respect to the spraying direction of the paint 39, the paint 39 is difficult to paste and the mortar oozes out easily.

  When mortar seepage occurs, red rust is generated, and it is necessary to partially paint the red rust part, but in this embodiment, since mortar seepage is suppressed, red rust generation is also suppressed and red rust is generated. The complicated work of partial painting by can be abolished.

  By the way, when constructing the floor panel 1, when the packaging of the panel housing box containing a plurality of floor panels 1 is unpacked and taken out one by one at the construction site, the edge-bending portion of the outer peripheral edge portion Lift with both fingers. At this time, anti-slip rubber is attached to the lower surface of the panel, assuming container transportation.

  For this reason, unlike the floor panel 1A of the comparative example shown in FIG. 5, the edge bending (hemming) processing is not performed, and the bent portion 23A on the outer peripheral side of the upper plate 3A is formed as in the state of FIG. When it is only bent 90 degrees with respect to the upper plate body 21A, it is necessary to peel off the floor panels that are in close contact with rubber, and a considerable burden is applied to the fingertips, resulting in extremely deteriorated workability. It will be a thing. In addition, the code | symbol 7A in FIG. 5 is a lower board.

  On the other hand, in the present embodiment, the edge bending portion 23 is edge bent as shown in FIG. 3A from the state of FIG. 3B, so that the burden on the fingertip can be reduced and workability is improved. It can contribute to improvement.

1 Floor panel 3 Upper plate 5 Lower plate recess 7 Lower plate 13 Lower plate flange (outer peripheral edge of lower plate)
17 Lower plate protrusion 23 Upper plate edge bend (upper plate protrusion)
23a Inner surface of the edge bent portion of the upper plate (inner surface of the protruding portion of the upper plate)
25 Upper plate flange (outer peripheral edge of upper plate)
27 Welded portion 29 Gap between flange of lower plate and edge bent portion of upper plate

Claims (4)

  A metal upper plate and a metal lower plate having a recess on the side facing the upper plate are overlapped with each other, and the overlapping portions of the upper and lower plates are welded to each other at the outer peripheral edge. After fixing, the protruding portion protruding from the outer peripheral edge portion of the lower plate at the outer peripheral edge portion of the upper plate is folded and overlapped so as to cover the weld-fixed portion of the outer peripheral edge portion of the lower plate. A method of manufacturing a floor panel, characterized by processing.   The protruding portion of the outer peripheral edge of the upper plate is bent toward the lower plate before the edge bending, and the protruding portion of the bent upper plate and the outer peripheral edge of the lower plate The method for manufacturing a floor panel according to claim 1, wherein the overlapping portion is fixed by welding in a state where a gap is provided between the front end of the floor panel.   The lower plate is provided with a protrusion that protrudes toward the upper plate by denting the opposite side of the upper plate, and when the tip of the protrusion and the upper plate are welded and fixed by spot welding, the overlapping is performed. The method for manufacturing a floor panel according to claim 1 or 2, wherein the portions are welded and fixed simultaneously by spot welding.   A metal upper plate and a metal lower plate provided with a recess on the side facing the upper plate, and the overlapping portions of the upper plate and the lower plate at their outer peripheral edge portions are fixed by welding. In addition, the protruding portion protruding from the outer peripheral edge portion of the lower plate at the outer peripheral edge portion of the upper plate is bent and overlapped so as to cover the welded portion of the outer peripheral edge portion of the lower plate. Floor panel characterized by being processed.

Images