JP2016135970A - Floor panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor panel that ensures both rigidity and weight saving in a simple structure and does not easily deteriorates when constructing an outdoor floor.SOLUTION: A floor panel 1 has a composite layer structure consisting of a core layer 2, which is a rectangular plate and has a porous structure, and a surface layer 3, which covers outer surfaces 2A, 2B, 2C of the core layer 2. The surface layer 3 is made by extending a thermoplastic resin into a sheet and forming and solidifying the sheet so as to cover the core layer 2. The floor panel 1 has a structure in which an upper inner surface 3Ab of the surface layer 3 is welded on the upper outer surface 2A of the core layer 2 and a lower inner surface 3Bb of the surface layer 3 is welded on the lower outer surface 2B of the core layer 2.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a floor panel laid outside or indoors such as a veranda, a balcony, a terrace, or a rooftop of a building.

  Conventionally, a floor panel that uses a material having a porous structure such as a foam of a synthetic resin to reduce the weight is known.

  The following Patent Document 1 has a center layer made of a wood resin foam molded body and an outer wall layer made of a thermoplastic resin, and is molded by co-extrusion (coextrusion) the center layer and the outer wall layer. A floor panel is disclosed.

  Further, in Patent Document 2 below, a plastic hollow plate having a three-layer structure in which a plastic sheet having a concavo-convex shape is sandwiched between flat plastic sheets is bonded to the upper and lower surfaces of a foam as a central layer, and A floor panel having a structure in which a metal plate is bonded to each outer surface is disclosed.

JP 2009-30390 A JP 2013-227817 A

  Each of the floor panels of Patent Documents 1 and 2 has an advantage that the weight can be reduced by using a foam as a central layer, but each has the following problems. ing.

  That is, since the floor panel of Patent Document 1 co-extrudes the center layer and the outer wall layer, the outer wall layer cannot be formed at both ends in the extrusion direction of the center layer, and particularly an outdoor floor is constructed. In such a case, there is a problem that rainwater or the like enters from both ends of the central layer and the central layer deteriorates.

  In addition, since the center layer is formed at the same time as the outer wall layer, it is not possible to perform a process such as forming a thinned portion, and it is difficult to further reduce the weight.

  The floor panel of the above-mentioned Patent Document 2 has a problem that the plastic hollow plate covering the central layer has a three-layer structure and has a complicated shape, and thus the work and cost of manufacturing the plastic hollow plate are burdened. Yes.

  In addition, there is no layer covering the side of the floor panel. In particular, when an outdoor floor is constructed, rainwater or the like enters the central layer from the exposed side and deteriorates.

  The present invention provides a floor panel that achieves both rigidity and light weight with a simple structure and does not easily deteriorate even when an outdoor floor is constructed.

  In short, the floor panel according to the present invention has a composite layer structure composed of a core layer having a rectangular plate shape and having a porous structure, and a surface layer covering the outer surface of the core layer. The formed thermoplastic resin is formed into a sheet shape and molded and solidified so as to cover the core layer. The upper inner surface of the surface layer is welded to the upper outer surface of the core layer, and the lower inner surface of the surface layer is bonded to the core. The core layer has a structure welded to the lower outer surface of the layer, and the core layer having the porous structure is reduced in weight, and the upper and lower parts of the core layer and the surface layer are resistant to compressive stress and tensile stress generated by walking load or the like. The upper and lower parts work together to ensure rigidity. Moreover, the whole floor panel can be made into a waterproof structure by the surface layer covering the outer surface (six surfaces) of the core layer.

  Preferably, by forming a gap between the outer side surface of the core layer and the inner surface of the side surface of the core layer, the surface layer side against deformation of the upper and lower surfaces of the surface layer and deformation of the core layer due to walking load or the like. The parts deform independently and respond appropriately.

  In addition, by forming a chamfered portion at the corner of the surface layer, the core layer can be covered soundly while maintaining the layer thickness at the same place.

  Preferably, the upper outer surface or / and the lower outer surface of the core layer has an uneven shape, so that the upper inner surface of the surface layer and the upper outer surface of the core layer or / and the lower inner surface of the surface layer and the lower outer surface of the core layer are To ensure the welding of

  In addition, by forming a plurality of thinned portions on the lower outer surface of the core layer and forming the remaining portion of the lower portion of the core layer in a beam shape, further weight reduction can be achieved while securing rigidity.

  In addition, the upper outer surface of the surface layer is formed in a convex curved shape, so that rainwater can be appropriately released without being accumulated on the upper outer surface of the surface layer even when exposed to rainwater or the like outdoors.

  ADVANTAGE OF THE INVENTION According to this invention, although it is a simple structure, the floor panel which aimed at weight reduction, ensuring rigidity can be provided.

  In addition, when an outdoor floor is constructed, the surface layer covering all of the outer surface of the core layer can prevent rainwater and the like from entering the core layer, thereby suppressing deterioration of the core layer and thus the entire floor panel. .

The perspective view which cuts and shows the floor panel which concerns on this invention partially. The centerline sectional view of the floor panel of FIG. The perspective view which shows the example which engraved the groove | channel on the upper outer surface (lower outer surface) of the core layer, and provided the uneven | corrugated form. (A) is a perspective view showing an example in which a bottomed hole is formed on the upper outer surface (lower outer surface) of the core layer to give an uneven shape, and (B) shows a protrusion formed on the upper outer surface (lower outer surface) of the core layer. The perspective view which shows the example which provided the uneven | corrugated form. The expanded sectional view of the corner angle part of a core layer and a surface layer. The perspective view which shows the example which formed the hollow part in the lower outer surface of a core layer, and made the remaining part of the lower part of the core layer beam shape. The centerline sectional view which shows the example of the floor panel which included the core layer which formed the meat | fleshing part. The centerline sectional view which shows the example of the floor panel which formed the upper outer surface of the surface layer in the convex curve shape. The perspective view explaining the process of laying the floor panel which concerns on this invention on a floor foundation surface via a raising leg. The perspective view explaining the process of laying a finishing panel on the floor panel which concerns on this invention. Sectional drawing which shows the structure of the completed floor.

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

  As shown in FIGS. 1 and 2, a floor panel 1 according to the present invention includes a core layer 2 having a rectangular plate shape and a porous structure, and an upper outer surface 2A, a lower outer surface 2B, which are outer surfaces of the core layer 2, and It has a composite layer structure including the surface layer 3 covering the four outer side surfaces 2C.

<Configuration of core layer>
The core layer 2 is rectangular using a material having a porous structure that is lightweight and easy to mold, such as a foam that is foamed by using a known rubber sponge or a synthetic resin such as polystyrene or polyolefin alone or in combination. Mold into a plate. Preferably, the upper outer surface 2A and / or the lower outer surface 2B of the core layer 2 is provided with a concavo-convex form as follows in order to ensure welding with the upper inner surface 3Ab and / or the lower inner surface 3Bb of the surface layer 3. .

  That is, as shown in FIG. 2 and FIG. 3, the upper outer surface 2A and the lower outer surface 2B of the core layer 2 are provided with an uneven shape by engraving the vertical grooves 4A and the transverse grooves 4B that cut the respective surfaces vertically, Following the uneven form, plastic deformation of the constituent material of the surface layer 3 is promoted to obtain an anchor effect to ensure welding, and the rigidity of the entire floor panel 1 is ensured. Alternatively, a vertical groove 4A and a horizontal groove 4B are formed on either one of the upper outer surface 2A and the lower outer surface 2B to give an uneven shape. In addition, the cross-sectional shape of the said vertical groove | channel 4A and the said horizontal groove | channel 4B does not have limitation in particular, For example, it is arbitrary according to implementation to make a cross-sectional U-shape, a cross-sectional V-shape, and a cross-sectional U-shape.

  Alternatively, as shown in FIG. 4A, a plurality of bottomed holes 5 may be formed in the upper outer surface 2A and / or the lower outer surface 2B of the core layer 2 to give an uneven shape. Alternatively, as shown in FIG. 4B, a large number of protrusions 6 may be provided on the upper outer surface 2A and / or the lower outer surface 2B of the core layer 2 to give an uneven shape. The hole shape of the bottomed hole 5 and the protrusion shape of the protrusion 6 are not particularly limited as long as the anchor effect of the constituent material of the surface layer 3 can be obtained.

  In addition, as shown in FIG. 5, chamfered portions 7 are formed at the corner portions of the core layer 2. The chamfered portion 7 facilitates plastic deformation of the constituent material (thermoplastic resin) of the surface layer 3 in the corner portion of the core layer 2 and secures the surface layer thickness after molding in the same place, so that the entire floor panel 1 is formed. Contributes to securing rigidity. In the figure, reference numeral 8 denotes a chamfered portion formed on the surface layer 3 after molding and solidification.

  Preferably, as shown in FIG. 6 and FIG. 7, a plurality of lightening portions 11 are formed on the lower outer surface 2B of the core layer 2, and the remaining portion of the lower portion of the core layer 2 is formed into a beam shape while ensuring rigidity. Further weight reduction can be achieved. In this case, it is needless to say that a concavo-convex shape can be given to the remaining lower outer surface 2B. In the figure, reference numeral 13 denotes a beam formed by the thinned portion 11.

  Further, as shown in FIG. 8, the upper outer surface 2A of the core layer 2 can be formed in a convex curved shape having the central portion as a top portion. In this case, the surface layer 3 is formed following the convex curved surface shape of the upper outer surface 2A of the core layer 2, and the upper outer surface 3Aa of the surface layer 3 can be formed into a convex curved surface shape. Can properly collect the accumulated water from rain water or the like from the upper outer surface 3Aa of the surface layer 3.

<Configuration of surface layer 3>
The surface layer 3 is formed by extending a plasticized thermoplastic resin into a sheet shape, and forming and solidifying the preformed core layer 2 having the above-described structure as shown in FIG.

  For example, a pair of plasticized thermoplastic resin sheets are respectively addressed from the upper side and the lower side of the core layer 2, the thermoplastic resin sheets are pressed against each other with a pair of molds, and the upper outer surface 2 A of the core layer 2 is The inner surface of the other thermoplastic resin sheet is welded to the lower outer surface 2B, and the edges of both thermoplastic resin sheets are welded on the side of the core layer 2 And then solidified to form.

  As the thermoplastic resin, a known thermoplastic resin such as polypropylene, polyethylene, or polystyrene is used. Depending on the implementation, it is optional to add a reinforcing material such as talc powder or synthetic resin fiber to the thermoplastic resin in order to increase rigidity.

  At the time of the welding, as shown in FIGS. 2 and 5, the thermoplastic resin that is a constituent material of the surface layer 3 follows the uneven shape of the upper outer surface 2A and / or the lower outer surface 2B of the core layer 2. The surface layer 3 is formed by molding and solidifying in a state in which the anchor effect is obtained by plastic deformation.

  Further, when the thinned portion 11 is formed on the lower outer surface 2B of the core layer 2, the thermoplastic resin as the constituent material of the surface layer 3 rises along the opening edge of the thinned portion 11 as shown in FIG. The protrusion ribs 12 are formed on the lower inner surface 3Bb of the surface layer 3 after being solidified. As shown in FIG. 7, the projecting rib 12 holds the free end of the beam 13, that is, the lower outer surface 2 B of the remaining core layer 2, and cooperates with the beam 13 on the lower side of the core layer 2. Ensure rigidity.

  As described above, the surface layer 3 has a structure in which the upper inner surface 3Ab of the surface layer 3 is welded to the upper outer surface 2A of the core layer 2 and the lower inner surface 3Bb of the surface layer 3 is welded to the lower outer surface 2B of the core layer 2. Have. With this structure, when the floor panel 1 receives a walking load, the core layer 2 and the surface layer 3 can act in cooperation on the upper side of the floor panel 1 where compressive stress occurs and the lower side where tensile stress occurs. Ensure adequate rigidity.

  Further, as described above, a chamfered portion 8 is formed along the chamfered portion 7 formed at the projected corner portion of the core layer 2 at a portion covering the projected corner portion of the core layer 2. The thickness of the floor panel 1 is maintained and the rigidity of the entire floor panel 1 is secured while properly covering the protruding corners of the floor.

  The surface layer 3 is formed so that the side outer surface 3Ca slightly bulges outward to form a bulging portion 9, and a gap is formed between the side inner surface 3Cb and the side outer surface 2C of the core layer 2. 10 is defined. That is, the edge portions of the pair of thermoplastic resin sheets are fused slightly apart from the side outer surface 2C of the core layer 2 to form the bulging portion 9 and the gap 10.

  Therefore, even if the upper part of the floor panel 1 (upper part of the core layer 2 and the surface layer 3) and the lower part (lower part of the core layer 2 and the surface layer 3) are deformed due to the compressive stress or tensile stress generated by walking load, etc. The side part of the surface layer 3 having the protruding part 9 corresponds appropriately in an independent state.

  In addition, when a floor is constructed by laying a large number of floor panels 1 according to the present invention, as will be described later, upper and lower parts are formed between the side parts of adjacent floor panels 1 by the bulging part 9 and the gap 10. In this way, it is possible to form a gap 14 that expands and to release rainwater and the like through the gap 14. In particular, as shown in FIG. 8, when the upper outer surface 2A of the core layer 2 and the upper outer surface 3Aa of the surface layer 3 are formed in a convex curve shape, the rainwater etc. that has escaped from the upper outer surface 3Aa of the surface layer 3 is allowed to pass through the clearance 14. It can escape smoothly downward.

<Example of floor construction>
Next, an example in which a floor is constructed using the floor panel 1 according to the present invention will be described. Here, an example in which an outdoor floor is constructed on an outdoor floor ground surface G such as a veranda or a balcony will be described.

  When constructing the outdoor floor, first, a plurality of raised legs L that can be adjusted in height are installed on the floor base surface G at predetermined intervals while adjusting the level and inclination of the support base La, as shown in FIG. A large number of floor panels 1 are laid in a single plane while receiving the four corners 1a of the four floor panels 1 adjacent to the support base La of the raising leg L together. Depending on the implementation, it is optional to support the portions other than the corners 1a of the floor panel 1 with the raised legs L.

  In this case, for example, as shown in FIG. 9, a raised leg Lb provided on the support base La is used, and a gap is provided between the side portions of the floor panel 1 adjacent to the ruler Lb. Laying while forming.

  Further, as indicated by 1 'in FIG. 9, it is a matter of course that a floor panel processed according to the size and shape of the end portion is laid at the end portion of the floor base surface G.

  Next, as shown in FIG. 10, a large number of finishing panels (decoration panels) F are laid out on the floor panel 1 laid on one plane as described above, and the construction of the outdoor floor is completed. To do.

  In the constructed outdoor floor, as shown in FIG. 11, a gap 14 is formed between the side portions of the adjacent floor panels 1, but in the floor panel 1 according to the present invention, that side By the bulging part 9 formed in the part (side part of the surface layer 3), the shape of the play 14 can be formed into a shape in which the upper opening and the lower opening are expanded.

  Therefore, rainwater or the like drooping through the finishing panel F can be appropriately released downward through the gap 14.

  As described above, when the upper outer surface 3Aa of the surface layer 3 is formed in a convex curve shape, rainwater or the like can be drained more smoothly.

  As described above, the floor panel 1 according to the present invention has a composite layer structure including the core layer 2 having a porous structure and the surface layer 3 covering the outer surfaces 2A, 2B, and 2C of the core layer 2, Weight reduction is achieved by molding the core layer 2 with a porous structural material.

  Further, the surface layer 3 is formed by extending a plasticized thermoplastic resin into a sheet shape and molding and solidifying the core layer 2 so that the upper inner surface 3Ab of the surface layer 3 is formed on the upper outer surface 2A of the core layer 2. It has a structure in which the lower inner surface 3Bb of the surface layer 3 is welded to the lower outer surface 2B of the core layer 2 while being welded. In addition, the side portion of the surface layer 3 has a structure in which a bulging portion 9 is formed and separated from the side portion of the core layer 2 through a gap 10.

  Therefore, the integrated upper part of the core layer 2 and the upper part of the surface layer 3 cooperate to ensure rigidity, and the side part of the surface layer 3 that is separated from the side part of the core layer 2 is independent, and the walking load Even when the upper and lower portions of the surface layer 3 and the core layer 2 are deformed due to the above or the like, it can be appropriately handled. Further, the swollen portion 9 on the side of the surface layer 3 forms a gap 14 that expands vertically between the side portions of the adjacent floor panels 1 so that rainwater or the like can be appropriately released.

  Moreover, since the floor panel 1 according to the present invention forms the surface layer 3 with respect to the core layer 2 formed in advance, as described above, the core layer 2 is provided with a concavo-convex shape (vertical groove 4A / horizontal groove). 4B engraving, bottomed hole 5 drilling, protrusion 6 projecting), forming the above-mentioned hollow portion 11, and making the upper outer surface 2A into a convex curved surface shape, ensuring rigidity and further weight reduction The core layer 2 can be processed for this purpose.

  Furthermore, it is also possible to process a mold used when the surface layer 3 is formed, and to provide the upper outer surface 3Aa of the surface layer 3 with an uneven form for preventing the finish panel F from slipping.

  DESCRIPTION OF SYMBOLS 1,1 '... Floor panel, 1a ... Corner | angular part, 2 ... Core layer, 2A ... Upper outer surface, 2B ... Lower outer surface, 2C ... Side part outer surface, 3 ... Surface layer, 3Aa ... Upper outer surface, 3Ab ... Upper inner surface, 3Ba ... Lower outer surface, 3Bb ... Lower inner surface, 3Ca ... Side outer surface, 3Cb ... Side inner surface, 4A ... Vertical groove, 4B ... Lateral groove, 5 ... Bottomed hole, 6 ... Projection, 7 ... Chamfered portion of core layer, 8 ... Surface layer Chamfered portion, 9 ... bulging portion, 10 ... gap, 11 ... meat removal portion, 12 ... ribs, 13 ... beam, 14 ... play space, G ... floor surface, L ... raised leg, La ... support base, Lb ... ruler part, F ... finishing panel.

When Yojutsu, floor panels according to the present invention includes a core layer having a porous structure has a rectangular plate shape, the composite layer structure composed of a surface layer that envelope the outer surface of the core layer, the surface layer heat made of a plastic resin, the upper inner surface of the surface layer lower inner surface of the welded structure and the surface layer on the upper outer surface of the core layer and having a welded structure in the lower outer surface of the core layer, the surface layer of the side inner face and the have a structure in which voids formed between the outside lateral surface of the core layer, the upper and lower of the porous with weight reduction by the core layer having a structure, the core layer with respect to compressive stress and tensile stress generated by the walking load etc. And the upper and lower portions of the surface layer work in cooperation to ensure rigidity, and the side portions of the surface layer against the deformation of the upper and lower portions of the surface layer and the deformation of the core layer due to walking loads, etc. Transform independently and respond appropriately. Moreover, the whole floor panel can be made into a waterproof structure by the surface layer covering the outer surface (six surfaces) of the core layer.

Claims (6)

  It has a composite layer structure comprising a core layer having a rectangular plate shape and a porous structure, and a surface layer covering the outer surface of the core layer, and the surface layer is formed by extending a plasticized thermoplastic resin into a sheet shape. Forming and solidifying so as to enclose a layer, and having a structure in which the upper inner surface of the surface layer is welded to the upper outer surface of the core layer and the lower inner surface of the surface layer is welded to the lower outer surface of the core layer. Characteristic floor panel.   The floor panel according to claim 1, wherein a gap is formed between an outer surface of the side portion of the core layer and an inner surface of the side portion of the surface layer.   The floor panel according to claim 1, wherein a chamfered portion is formed at a protruding corner portion of the surface layer.   The floor panel according to any one of claims 1 to 3, wherein the upper outer surface and / or the lower outer surface of the core layer has an uneven shape.   The floor panel according to any one of claims 1 to 4, wherein a plurality of thinned portions are formed on a lower outer surface of the core layer, and a remaining portion of the lower portion of the core layer is formed in a beam shape.   The floor panel according to any one of claims 1 to 5, wherein an upper outer surface of the surface layer is formed in a convex curved shape.

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