JP2547420Y2 - Floor structure - Google Patents

Description

[Detailed description of the invention]

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor structure, and more particularly to a floor structure suitable for a floor of a vehicle such as a vehicle or a ship.

[0002]

2. Description of the Related Art As a prior art relating to a floor structure, a floor structure of a vehicle will be described. As an example, a kaolinite-based lightweight aggregate is mixed with an epoxy resin or a lightweight aggregate is mixed with cement. Is applied on a floor metal plate to form an intermediate coating layer, and an epoxy-based synthetic resin elastic layer is formed on the intermediate coating layer to form a floor.

[0003] For example, Japanese Patent Publication No. 54-951
It belongs to the above-mentioned prior art series, and according to the description of the claims, an undercoating in which an epoxy-based or urethane-based synthetic resin elastic layer is formed in a sheet shape on a floor metal plate of a vehicle, a ship or the like. The surface of the porous agglomerate, such as a porous agglomerate formed by firing a kaolinite-based viscous mineral at a high temperature, is mixed on the layer so that the epoxy-based or urethane-based synthetic resin elastic body is coated as described above. On the intermediate coating layer, furthermore, the above-mentioned fired porous material powder, plastic cement mortar in which glass fibers are used alone or in combination with a mixture of synthetic rubber latex and cement, or the above-mentioned epoxy-based or urethane-based synthetic resin elastic material and It is constituted integrally with an overcoat layer coated with a fire-resistant resin mortar composition composed of a single substance of a porous substance powder or a mixture thereof in combination.

FIG. 3 shows an example of a conventional system in which the above-mentioned kaolinite-based lightweight mortar is applied on a floor metal plate called a keystone plate.
Is coated with a primer 2, a light-weight mortar 3 is applied thereon as an intermediate coat, an epoxy lining 4 is provided on the upper surface, and the surface is covered with a rubber sheet 5. Table 2 shows the results of the actually measured weight and strength tests performed on the test piece (X-1) having the conventional structure.

[0005]

[Table 2] The weight in the table indicates the weight per 1 m ² with respect to the total thickness including the keystone 1 and the topcoat and the rubber sheet.

The high heel strength described in the table is
It is usually used as an index for comparing the strength against pressing of painted surfaces and the like. At the tip of the jig, the projected shape equivalent to the “high heel bottom” of women's shoes (vertical / horizontal approx.
A tip with m. 8.5 mm horseshoe shape is attached, and the surface of the test specimen (painted floor in this case) via floor covering
And the load when a permanent deformation occurs on the surface of the test specimen. As shown in FIG. 3, when the floor metal plate is a keystone plate, there is a difference in the thickness of the coating material due to the unevenness of the surface. I do. Table 2
According to the high heel strength of the convex portion is 82 kg, the high heel strength of the concave portion is 315 kg, the numerical value of the concave portion is considerably higher than that of the convex portion, which depends on the thickness of the concave portion, This is considered to be the result of a large capacity for elastically supporting the load.

[0007]

[Problems to be Solved by the Invention] As described above, in the conventional floor structure mainly composed of lightweight mortar, traces of efforts to reduce the weight by the development of a kaolinite-based lightweight aggregate are apparent. However, as in the case of the present invention, when the target of application is a vehicle, especially when it comes to vehicles,
The weight reduction of the floor structure, which has a considerable effect on the overall weight,
As an important issue closely related to the speeding up of vehicles, it had to be solved immediately.

Conventionally, aluminum honeycombs have been used for certain types of panel bodies for the purpose of weight reduction.
Furthermore, a paper honeycomb impregnated with a phenol resin has been adopted from the viewpoint of economy.

As a paper honeycomb conventionally used in view of the above economical efficiency, "Birchcell Paper Honeycomb (registered trademark)" manufactured by Birchcell of the United States is famous.

The birch cell paper honeycomb has features such as high mechanical strength, excellent flame retardancy and moisture resistance, and resistance to pests and fungi.
In addition to solving the problem of corrosiveness, which was a problem when using the conventional aluminum honeycomb, and the problem of economical efficiency, the birch cell honeycomb is formed by alternately stacking a plate-shaped member and a wave-shaped member. The plate-shaped member works as an aggregate (alternative to conventional SUS, steel) to increase the load strength as a panel, and to a door with a secondary curved surface etc. Can be easily adopted by bending the honeycomb core itself. Therefore, conventionally, the above-mentioned birch cell paper honeycomb has been considered to be economical, light in weight, and satisfactory in terms of corrosion resistance.

However, in order to use the above-mentioned birch cell paper honeycomb as it is as a vehicle floor structure, a kaolinite-based lightweight mortar is still used as a main component because of its poor heat insulation performance and sound insulation performance. Is used as a vehicle floor structure.

The present invention has been made to solve the above-mentioned conventional problems in the floor structure, and uses a kraft paper honeycomb structure instead of the lightweight mortar used in the conventional floor structure. By reinforcing the object itself and the joint between the structure and the adjacent structural member, the compressive strength and the bending strength required for the floor surface are increased, and the height required for the floor surface is improved. It is an object of the present invention to provide a floor structure capable of improving the heat insulation performance and the soundproofing performance of a vehicle and achieving a significant weight reduction.

[0013]

In order to achieve the above object, in the floor structure of the present invention, a foamable phenolic resin composite in which a foamable phenolic resin is adhered to at least one surface of a plate-like mat-like fiber material is provided. And a kraft paper honeycomb structure as a core material impregnated with phenolic resin,
The foamable phenolic resin adhering to the mat-like fiber material enters the cells of the kraft paper honeycomb structure, and is laminated and molded in an arrangement in which the inside of the cells is filled with the foamable phenolic resin, and molded to form a foamed phenolic resin composite. A molded article is formed, and the foamed phenolic resin composite molded article is cut into a shape corresponding to the surface shape of the metal sheet for the floor facing the metal sheet for a floor, and the both sides are joined with an adhesive. It is what was covered with.

The kraft paper honeycomb structure is formed by alternately stacking plate-like members and wave-like members so that the direction of the plate-like members is parallel to the direction of the groove of the floor metal plate. It is desirable to combine them.

Alternatively, the directions of the plate members constituting the kraft paper honeycomb structure may be combined so as to be orthogonal to the direction of the groove of the floor metal plate.

[0016]

The foamed phenolic resin composite molded article is formed, for example, in the form of a plate, and an organic mat-like or inorganic mat-like fiber formed by heating and fusing an expandable phenolic resin to one side thereof, and is in opposing contact with one side thereof. And a kraft paper honeycomb structure placed in a related position, which are stacked and placed in a mold, and are subjected to molding processing by appropriate heating and pressing using a press. Thereby, the foamable phenol resin fused to the mat-like fiber material penetrates into the cells of the kraft paper honeycomb structure located on the surface opposed thereto,
It foams and becomes filled.

Next, the molded foamed phenolic resin composite molded article is cut in accordance with the surface shape of the floor metal plate, and the two are tightly bonded to each other using an adhesive on the upper surface of the floor metal plate. Join.

According to this configuration, each cell of the kraft paper honeycomb structure is filled with the foamable phenol resin penetrating from the mat-like fiber material, and the air in the cell is sealed. Without this, the heat insulation is improved as a result. Further, even if a space is formed in the cell without being completely filled, the convection of air is hindered and the heat insulating property is improved because both ends of the cell are closed. At the same time, the sound insulation performance is improved due to the above configuration.

The above-mentioned kraft paper honeycomb structure is formed by alternately stacking plate members and corrugated members. When this is combined with a floor metal plate, the direction of the plate member is the same as that of the floor metal plate. It is possible to increase the strength of the floor in a specific direction by combining it in a relationship parallel to the direction of the groove or in a relationship perpendicular to the direction of the groove in the floor metal plate. .

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. In FIGS. 1 (a) and 1 (b), a mat-like fiber material 6 formed in a plate shape is provided on one side thereof. The foamable phenol resin is adhered to form the foamable phenol resin composite 7. The foamable phenolic resin composite 7 and the kraft paper honeycomb structure 8 as a core material impregnated with the phenolic resin are mixed in the cells 9 of the kraft paper honeycomb structure 8 with the foamable phenolic resin adhered to the mat-like fiber material 6. The foamed phenolic resin composite 7 and the kraft paper honeycomb structure 8 are integrally formed by laminating in an arrangement where the inside of the cell 9 is filled with the foamable phenolic resin and performing heat molding. Thus, the foamed phenolic resin composite molded article 10 is obtained. That is,
The foamable phenolic resin 11 attached to the mat-like fiber material 6 by heating is intruded into the cell 9 and foams, and becomes a filled state. As a result, the mat-like fiber material 6 and the kraft paper honeycomb structure are formed. 8 is firmly integrated. The thickness of the integrated foamed phenolic resin composite molded product 10 is generally about 18 to 20 mm for a vehicle, for example.

The kraft paper honeycomb structure 8 is shown in FIG.
As shown in FIG. 1B, a plate-like member 17 and a wave-like member 18 are alternately overlapped and bonded. FIG. 1A shows an example in which the direction of the plate-like member 17 is combined so as to be parallel to the direction of the groove of the keystone 1, and FIG.
It is shown in (b).

In the foamed phenolic resin composite molded article 10 obtained by heat molding, the lower surface 12 is cut into a shape conforming to the surface shape of the keystone 1, and an adhesive 13 is applied between both surfaces.
Join with. An epoxy-based synthetic resin elastic layer 14 is mounted on the upper surface of the mat-like fiber material 6, and the upper surface thereof is further covered with a topcoat paste 15 and an elastic sheet 16. The amount of the phenol resin impregnated in the kraft paper honeycomb structure 8 is typically 10 to 10 with respect to the finished weight of the structure 8.
It is desirable to set the ratio to 20%, up to 35%.

In the illustrated example, a foamable phenolic resin composite 7 in which a foamable phenolic resin is adhered to one surface of a mat-like fiber material 6 is applied to only one surface of a kraft paper honeycomb structure 8 impregnated with phenolic resin. Although an example of lamination and molding is shown, two foamable phenolic resin composites 7 may be prepared, and the kraft paper honeycomb structure 8 may be laminated and molded from both sides, in which case the strength, heat insulation and soundproofing are obtained. In each aspect, further improvement in performance is expected.

A test sample (X-6) according to one embodiment of the floor structure of the present invention having the above-described configuration was prepared, and the measured results are shown in Table 1.

[0025]

[Table 1] Comparing the values in Table 1 with the values in Table 2 for the conventional floor structure, the weight with keystone is about 1/2,
It can be seen that significant weight reduction can be achieved with this configuration.

Next, the high heel strength shows a large increase in the convex portion, but rather a considerable decrease in the concave portion. However, when considering the strength of the floor surface, what is necessary is to determine the numerical value of the minimum strength through the convex and concave parts. The lowest value of the high heel strength in Table 1 is 130 kg for the convex portion, while the lowest value in Table 2 is 82 kg for the convex portion, and the lowest value in Table 1 is
This is about 1.6 times that of the floor of the present invention, and it can be seen that the compressive strength of the floor of the present invention is remarkably excellent.

FIG. 2 is a graph showing the amount of deflection of the floor structure of the present invention and the conventional floor structure with respect to the load. The floor structure having a certain size is supported from the lower surface in the manner shown in FIG. 5 shows a change in the amount of deflection when a load is applied to the.

As shown in the figure, the deflection amount of the floor structure of the present invention is always smaller than the deflection amount of the conventional floor structure. For example, when the load is 600 kg, the deflection amount of the conventional floor structure is 10.3 mm. On the other hand, the deflection amount of the floor structure of the present invention is 9.3 mm, which indicates that the bending strength of the present invention is superior to that of the conventional one.

The structure of the kraft paper honeycomb structure 8 applied to the floor structure of the present invention is shown in FIGS.
As shown in (b), the plate-like member 17 and the wave-like member 18 have a structure in which the plate-like member 17 is alternately overlapped and bonded, and the plate-like member 17 is an aggregate (instead of conventional SUS, steel). The reason for this is that by acting as a panel, the load strength of the panel is increased.

[0030]

[Effects of the Invention] The floor structure of the vehicle of the present invention is constructed as described above, and has the following excellent effects. 1. Since the conventional kraft paper honeycomb structure is used as the core material, the floor structure can be significantly reduced in weight.

2. The mat-like fiber material to which the foamable phenolic resin is adhered and the kraft paper honeycomb structure as a core material impregnated with the phenolic resin are laminated and molded. The structure is such that the mat-like fibrous material and the kraft paper honeycomb structure are firmly integrated because they enter the cells of the paper honeycomb structure and become filled, increasing the compressive strength and bending strength of the floor structure. Is realized.

Further, by the configuration in which the foamable phenol resin enters the cells of the honeycomb structure and enters a filled state, each cell of the kraft paper honeycomb structure is filled with the foamable phenol resin penetrated from the mat-like fiber material. Since the inside is filled and the air in the cell is confined, the air does not generate convection due to heat, and as a result, the heat insulating property is improved. Also, even if a space is formed in the cell without being completely filled, the convection of air is hindered because both ends of the cell are closed, resulting in improved heat insulation, Due to the above configuration, the soundproof performance is improved.

3. Since the kraft paper honeycomb structure as the core material is impregnated with the phenolic resin, the foamable phenolic resin composite has a good affinity with the foamable phenolic resin, and more firm adhesion is realized.

4. Since the surface of the foamed phenolic resin composite molded article facing the floor metal plate was cut into a shape that matches the surface shape of the metal plate, and both surfaces were joined with an adhesive,
Strong integration between the composite molded article and the floor metal plate is achieved, and the strength and durability as a vehicle floor are further improved.

5. According to the floor structure of the second or third aspect, when the kraft paper honeycomb structure is combined with a floor metal plate, the strength of the floor in a specific direction is increased by appropriately selecting the combination direction. be able to.

[Brief description of the drawings]

1 is a cutaway perspective view of a vehicle floor structure according to an embodiment of the present invention, wherein FIG. 1A shows a first embodiment of the floor structure, and FIG. Two examples are shown.

FIG. 2 is a curve diagram showing respective characteristics of the floor structure of the present invention and a conventional floor structure.

FIG. 3 is a sectional view of a conventional vehicle floor structure.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 keystone 6 mat-like fiber material 7 foamable phenolic resin composite 8 kraft paper honeycomb structure 9 cell 10 foamed phenolic resin composite molded product 11 foamable phenolic resin 12 lower surface 13 adhesive 14 epoxy synthetic resin elastic layer 15 top coating paste 16 Elastic sheet

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location B32B 27/12 B32B 27/12 27/42 101 27/42 101 B61D 17/10 B61D 17/10

Claims (3)

(57) [Scope of request for utility model registration] 1. A foamable phenolic resin composite in which foamable phenolic resin is adhered to at least one surface of a plate-like mat-like fibrous material, and a kraft paper honeycomb structure as a core material impregnated with phenolic resin. The foamable phenol resin adhering to the mat-like fiber material enters the cells of the kraft paper honeycomb structure, and the cells are laminated and molded in an arrangement in which the interior of the cells is filled with the foamable phenol resin. The composite molded article is formed, and the foamed phenolic resin composite molded article is cut into a shape that matches the surface shape of the metal plate for the floor, and the two surfaces are joined with an adhesive, and the upper surface is overcoated. A floor structure characterized by being coated with a layer. 2. The kraft paper honeycomb structure according to claim 1, wherein a plate-like member and a wave-like member are alternately overlapped, and the direction of the plate-like member is parallel to the direction of the groove of the floor metal plate. The floor structure according to claim 1, wherein the floor structure is combined as described in (1). 3. The floor structure according to claim 1, wherein the directions of the plate members constituting the kraft paper honeycomb structure are combined so as to be orthogonal to the direction of the groove of the floor metal plate.