JP3038171B2 - Floor panel - 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 panel capable of effectively reducing vibration noise.

[0002]

2. Description of the Related Art A floor panel forming a floor of a prefabricated building, for example, has conventionally been provided with a framework in which a joist b is arranged in a four-peripheral frame in which frame members a are joined as shown in FIG. Is filled with a resin foam material c to be a heat insulating layer.

[0003]

However, such a conventional floor panel has a structure in which the lower end of the joist b is exposed from the resin foam material c. The vibration generated on the floor and transmitted to the joist material b is not sufficiently attenuated by the resin foam material c, and the vibration noise due to the vibration cannot be sufficiently absorbed, so that the vibration noise increases, which tends to impair the quietness. It is.

Further, since the lower end of the joist b is in direct contact with air, if the joist b is formed of a shaped steel material, rust is easily generated, and the joist b serves as a thermal bridge to provide heat insulation performance. Tends to decrease.

It is an object of the present invention to provide a floor panel that can effectively reduce vibration noise, improve rust prevention performance, and help prevent a thermal bridge.

[0006]

SUMMARY OF THE INVENTION According to the present invention, a floor material attached to the upper surface of a four-circle frame is received on an upper surface between four frame members facing each other in which the frame material is joined in a rectangular shape, and the lower surface is formed on the lower surface of the four-circle frame. A floor panel in which a resin foam material is filled by burying the lower surface of the joist material inside a framework formed by bridging a higher joist material .

[0007] The joist material may be made of a shaped steel material.
Can be.

[0008] The frame member is made of a shaped steel material provided with a lower flange at least at a lower end of a vertical web, and forms a raised portion which is raised upward by drawing on the lower flange. It is preferable that the bottom surface of the joist material is supported, and the resin foam material is filled to a position where the lower surface is aligned with the lower surface of the four-sided frame .

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. The floor panel 1 of the present invention includes a floor member 6 attached to the upper surface 2a of the four-peripheral frame 2 between the facing frame members 5 and 5 of the four-peripheral frame 2 in which the frame members 5 are joined in a rectangular shape.
And a resin foam material 9 is filled in a frame 4 formed by bridging a joist 3 whose lower surface 3b is higher than the lower surface 2b of the four-circle frame 2 by burying the lower surface 3b of the joist 3. I have.

The frame member 5 is, as shown in FIGS.
The vertical web 5a is formed of a U-shaped steel member having a horizontal upper flange 5b and a lower flange 5c provided at least at the lower end, in this example, the upper and lower ends thereof, and the grooves are opposed to each other and are rectangularly joined by welding or the like. Thereby, the four-peripheral frame 2 in which the upper surface 2a and the lower surface 2b are horizontal is manufactured.

In addition, among the frame members 5, a rectangular four-circle frame 2
Each of the lower flanges 5c of the frame members 5A and 5A forming the long side of
One or more arbitrary numbers, in this example, two upwardly raised ridges 10, 10 are formed by drawing.

The raised portion 10 has a plate-shaped raised piece 10A parallel to the upper flange 5b of the frame member 5A.

The frame member 5 facing the four-circle frame 2
A, 5A, between the frame members 5B, 5
In parallel with B, one or a plurality of arbitrary numbers, in this example, two joists 3 are bridged.

The raised piece 10A of the raised portion 10 is
The length along the length direction of the frame member 5A may be equal to or longer than the width of the joist material 3.
Is preferred from the viewpoint of reliably supporting.

In the case where one joist 3 is supported by one protruding portion 10, the number of the protruding portions 10 of each frame member 5A and the number of joists 3 are made to match each other. Is preferably minimized from the viewpoint that the productivity of the floor panel 1 can be increased, but the raised portion 10 may be formed extra.

It is also possible to support a plurality of joists 3 spaced apart by one protruding portion 10. In such a case, the number of protruding portions 10 of each frame member 5A is made larger than the number of joists 3 It can be reduced.

The joist 3 is made of a steel member having a U-shaped cross section provided with a horizontal upper piece 16 and a lower piece 17 at the upper and lower ends of a vertical standing piece 15, and has drawn portions 19, 19 formed at both ends. The frame member 5B is fitted between the raised piece 10A of the raised portion 10 of each frame member 5A and the upper flange 5b and fixed by welding or the like.
The frame 4 is manufactured in such a manner as to be stretched between the frame members 5A and 5A in parallel with the above.

The upper surface 3a of the joist 3 other than the squeezed portion 19 is aligned with the upper surface 2a of the four-circle frame 2, and the lower surface 3b of the joist 3 other than the squeezed portion 19 is formed of the raised portion 10a.
Of the raised piece 10A.

Further, a floor material 6 such as a particle board is attached to the upper surface 2a of the four-peripheral frame 2 by a fixing means such as a screw, a nail, or an adhesive.

Therefore, the joist 3 has an upper surface 3a in contact with the floor 6 so as to carry a load applied to the floor 6, and a lower surface 3b is higher than a lower surface 2b of the four-round frame 2.

In addition, a resin foam material 9 is provided inside the frame 4.
Are filled with almost no gap. To this end, the framework 4 is transported by the transport device with the floor material 6 down, and is filled with an unfoamed resin foam material by a coating device (both not shown). The resin foam material 9 is cured and foamed by a curing device 25 (schematically shown in FIG. 7). After the curing, if necessary, a face material 21 (indicated by a dashed line in FIG. 2) may be attached to the lower surface of the framework 4, but the presence or absence of the face material 21 is optional.

As the resin foam material, for example, a foaming agent capable of forming the resin foam material 9 by foaming, a phenol resin containing a curing catalyst, a urethane resin, or the like can be used. In this example, the phenolic resin and Freon R-11, R-113,
A foaming agent using methylene chloride or the like alone or in combination of two or more is employed. As the curing catalyst, sulfuric acid, hydrochloric acid, phosphoric acid, etc. can be used as an inorganic acid, and benzenesulfonic acid, toluenesulfonic acid, phenolsulfonic acid, etc. can be used as an organic acid. In addition, a foam stabilizer, a flame retardant, and the like can be added as needed. The mixing ratio can be selected depending on the reactivity and the foaming conditions.

Such a resin foam material may be correctly referred to as the "upper surface" because the frame 4 is turned upside down during filling, although the lower surface of the resin foam material 9 is correct by later curing. In consideration of the up and down, the “lower surface” is applied in an amount appropriate for filling to a position aligned with the lower surface 2 b of the four-peripheral frame 2, and inside the resin foam material 9, The joist material 3 is buried including the lower surface 3b.

That is, the lower part 9A of the resin foam material 9 below the joist material 3 is formed continuously below the lower surface 3b of the resin joist material 3 without interruption and in close contact with the lower surface 3b.

A resin foam material is also applied to the lower part of the raised portion 10, and the lower surface 2b of the four-peripheral frame 2 is formed by the subsequent foaming.
The resin foam material 9 is filled up to a position where the resin foam material 9 is aligned, and the lower portion 9B of the raised portion of the resin foam material 9 is continuously formed without interruption with the surroundings.

The frame 4 filled with an unfoamed resin foam material is carried into the curing device 25 by an appropriate transport device 23 as shown in FIG.

The curing device 25 has a heating device 26 fixed below an intermediate frame 27 which can be raised and lowered by means of a lifting device such as a cylinder.

The heating device 26 includes a vertical member 2 made of steel.
A frame 32 made of a steel member having a substantially U-shaped cross section and having a horizontal bottom plate portion 30 between 9 and 29 and connected by horizontal members 31... Arranged side by side, and the upper surface of the bottom plate portion 30 of the frame body 32 And a plurality of heating means 33 such as plate heaters provided at right angles to the vertical member 29.

A Teflon-based non-adhesive tape 34 is adhered to the lower surfaces of the bottom plates 30 to prevent the resin foam material from sticking and to secure the releasability. Instead of the non-adhesive tape 34, an appropriate release means such as Teflon coating may be applied to the lower surface of the bottom plate portions 30.

The heating device 26 descends together with the intermediate frame 27 descended by the elevating means such as the cylinder or the like, and clamps the stopped frame assembly 4 with the transfer device 23. Bottom plate part 30... The resin foam material is heated on the lower surface to fill the resin foam material 9, and non-flat portions such as partially convex portions are flattened, and the lower surface of the resin foam material 9 is Align with the lower surface 2b.

As shown in FIG. 8, the heating device 26 of the curing device 25 is in contact with the lower surface 2b of the four-peripheral frame 2 of the frame 4 transported by the transport device 23, and
A device having a wide belt 36 that circulates in synchronization with the belt may be used.

The heating device 26 spans both ends of a horizontal frame 39 which connects vertical members 37, 37 parallel to the conveying direction of the conveying device 23 with joining members 43. The wide belt 36 is wound around 40 and 40. The wide belt 36 is formed by using a non-adhesive material such as a fluororesin or by coating the non-adhesive material, and has heat resistance. In addition, the pulley 40 is appropriately synchronized with the conveying device 23 and the wide belt 36 is
Is driven at a speed to orbit.

In the frame 39 of the heating device 26, a heating means 41 such as a plate heater or an aluminum cast heater is provided between the joint members 43, 43 to heat the wide belt 36.

Therefore, it is possible to cure the frame 4 while moving it while lowering the heating device 26 and holding the frame 4 with the transport device 23,
The resin foam material is foamed and the resin foam material 9 is filled. or,
Non-flat portions such as partially convex portions generated in the resin foam material 9 can be flattened.

It should be noted that the unfoamed resin foamed material is
Instead of coating the inside, the foamed resin foam material 9 may be filled in the framework 4.

As described above, since the resin foam material 9 is formed from the lower surface of the flooring material 6 to a position below the lower surface 3b of the joist material 3 to form a lower portion 9A of the joist material and is filled into the framework 4 with almost no gap. That is, since the joist 3 abutting on the lower surface of the floor 6 is completely buried in the resin foam material 9, the lower surface 3b of the joist 3 is not exposed, and for example, an upper floor is formed by the floor panel 1. Even if the vibration caused by walking, jumping, and the like generated on the upper floor is transmitted to the joist 3, the vibration noise due to the vibration is caused by the lower part 9A and the lower part 9B of the resin foam material 9, particularly the joist material. The vibration of the joist 3 itself is absorbed and attenuated by being restrained by the resin foam material 9, and the vibration noise due to the vibration of the upper floor can be effectively reduced, and the floor panel 1 excellent in sound insulation performance can be provided.

The expression "with almost no gap" means that a small amount of voids that does not impair the sound insulation performance, heat insulation performance, and the like of the resin foam material 9 is allowed.

Further, since the joist 3 is covered with the flooring 6 and the resin foam material 9 and does not come into contact with the air, even if the joist 3 is formed of a shaped steel material, rust can be prevented from being generated. In addition, the rust prevention performance can be improved, and the joist 3 made of a shaped steel material is buried in the resin foam 9 so that the joist 3 can be improved.
Can be prevented from dissipating hot and cold heat of the living space as a thermal bridge, and the heat insulation performance can be improved.

The effect of preventing the thermal bridge becomes remarkable especially when the first floor is formed by the floor panel 1 which easily dissipates heat in the underfloor space.

Also, the lower surface 3b of the joist 3 and more precisely the lower surface of the narrowed portion 19 are supported by the raised portion 10 formed by drawing the lower flange 5c of the frame member 5, so that the raised portion 10 According to the height dimension, the joist 3 can be reliably buried inside the resin foam material 9 by a predetermined size. For example, even if the upper floor vibration is transmitted to the joist 3, the vibration noise caused by this vibration is more increased. The vibration noise from the upper floor vibration can be reduced in addition to the effect of reliably absorbing the resin foam material 9 and suppressing the vibration of the joist 3 itself by the resin foam material 9.

As shown in FIGS. 3 and 4, the frame 5
B over substantially the entire length of the lower flange 5 except for both ends.
c to form a raised portion 10 raised upward by drawing,
The raised portions 10 may support one or more arbitrary number of lower surfaces 3b of the joists 3 and also fill the resin foam material 9 by embedding the lower surfaces 3b of the joists 3.

As shown in FIGS . 5 and 6 , the joist 3 whose height is smaller than that of the frame 5 is formed without forming the raised portion 10, and the lower surface of the floor 6 is brought into contact with the upper surface 3a. The lower surface 3b of the joist 3 can be made higher than the lower surface 2b of the four-round frame 2 by bridging the frame members 5 facing each other.
However, in this case, a mounting bracket 13 for connecting the joist 3 and the frame 5 such as an L-shaped bracket is required, which is not preferable.
No.

In FIG. 5, a joist 3 made of a steel member having a U-shaped cross section and a joist 3 having an H-shaped cross section as its binding material are shown.
A is shown, but as shown in FIG. 6, a joist 3 made of a shaped steel member having an L-shaped cross section, a joist 3B having a T-shaped cross section as a binding material thereof, and the like without departing from the spirit of the present invention. Various shapes of joists can be employed.

FIGS. 5 and 6 are comparative examples in which the raised portions 10 are not formed by drawing .

[0045]

According to the present invention, in the floor panel according to the first aspect of the present invention, the floor material attached to the upper surface of the four-peripheral frame is provided between the facing frame materials of the four-peripheral frame formed by joining the frame members in a rectangular shape. Since the resin foam material is filled inside the frame formed by bridging the joists having the lower surface higher than the lower surface of the four-peripheral frame so that the lower surface of the joists is embedded, the load from the floor material is supported. The joists are buried inside the resin foam material and the lower surface of the joists is not exposed, and even if vibrations caused by walking, jumping, etc. occurring on the upper floor are transmitted to the joists, the vibration noise due to this vibration is generated by the resin foam. The vibration of the joist material itself is absorbed by the material, and the vibration of the joist material itself is restrained and attenuated by the resin foam material, so that the vibration sound due to the vibration of the upper floor can be effectively reduced.

Further , the frame material is made of a shaped steel material, and
At the raised part formed by drawing on the lower flange, the joist
The lower surface is supported, and the resin foam is
Filled up to the position aligned with the lower surface of the four-round frame,
Depending on the height, that is, the thickness of the drawing process,
It can be reliably buried inside the foam material to the specified size.
For example, even if upper floor vibration is transmitted to joists,
The vibration noise caused by the resin is reliably absorbed by the resin foam,
In addition to the effect of suppressing the vibration of the joist itself by the fat foam material,
Vibration noise from upper floor vibration can be reduced.

In the case where the joist is made of a shaped steel,
Is the joist that supports the load from the flooring material inside the resin foam
And buried in the floor and covered with resin foam
Because it does not touch, it can prevent rust and improve rust prevention performance.
The joist made of shaped steel can be used as resin foam
Buried in the ground, especially when used on the first floor,
Thick wood acts as a thermal bridge to dissipate the heat and cold of the living space
Can be effectively prevented, and the heat insulation performance can be enhanced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of an embodiment of the present invention.

FIG. 2 is a partial sectional view thereof.

FIG. 3 is a perspective view showing another embodiment of the present invention.

FIG. 4 is a partial sectional view thereof.

FIG. 5 is a partial sectional view showing a comparative example of the present invention.

FIG. 6 is a partial sectional view showing a comparative example of the present invention.

FIG. 7 is a partial perspective view illustrating a curing device.

FIG. 8 is a partial perspective view illustrating a curing device.

FIG. 9 is a partial cross-sectional view for explaining a conventional technique.

[Explanation of symbols]

 Reference Signs List 1 floor panel 2 four-sided frame 3, 3A, 3B joist 4 framing 5, 5A, 5B frame 6 flooring 9 resin foam 10 ridge

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-7-292831 (JP, A) JP-A-5-248021 (JP, A) JP-A-7-158188 (JP, A) 113607 (JP, U) JP 3-17016 (JP, B2) JP 3-39293 (JP, Y2) JP 7-22414 (JP, Y2) (58) Fields surveyed (Int. Cl. ⁷ , DB name) E04B 5/02 E04B 5/43 E04B 1/76-1/90 E04B 9/06

Claims (2)

(57) [Claims] 1. A floor member attached to the upper surface of a four-circle frame is received on the upper surface, and a joist having a lower surface higher than the lower surface of the four-circle frame is placed between facing frame members of a four-circle frame formed by joining the frame members in a rectangular shape. A resin foam material is filled into the inside of the frame formed by burying the lower surface of the joist material , and the frame material is provided at least at a lower end of a vertical web with a lower flange.
Made of shaped steel material provided with
A raised portion is formed by processing, and the raised portion supports the lower surface of the joist material and forms the resin.
The foam material is filled until the lower surface is aligned with the lower surface of the four-sided frame.
A floor panel , characterized in that: 2. The floor panel according to claim 1, wherein said joist is made of a shaped steel material.