JP7525279B2 - Floor panel and method for manufacturing the floor panel - Google Patents

Description

The present invention relates to floor panels used in constructing floors of buildings and a method for manufacturing floor panels.

The floors of large buildings such as high-rise buildings are constructed of concrete, while the floors of small buildings such as houses are constructed of wood materials. On the other hand, medium-sized buildings such as schools are often constructed of concrete for its strength and soundproofing properties. However, in recent years, since the Law on Promoting the Use of Wood in Public Buildings and Other Buildings came into force, there has been a growing movement to use wood, especially in public buildings, and there have been an increasing number of cases in which engineered wood such as CLT (Cross Laminated Timber) and wooden panels made from such wood are used for floors (see, for example, Patent Document 1).

JP 2019-190102 A

Floors constructed from wood materials have the advantage of being lightweight and being able to be constructed using dry construction methods, thereby shortening the construction period. However, they have the disadvantage of being inferior to floors constructed from concrete in terms of strength, fire resistance, livability, insulation, etc.
Floors constructed with concrete have the advantage of being superior in terms of strength performance and the like compared to floors constructed with wood materials, but they have disadvantages such as being heavy and being constructed using wet construction methods, which results in a longer construction period and more complicated on-site management.

The present invention was made in consideration of the above problems, and aims to provide a floor panel and a method for manufacturing the floor panel that can be constructed using dry construction methods while improving the strength performance, etc., compared to floors constructed using wood materials.

To solve the above problems, one aspect of the present invention is a floor panel that includes a metal plate having an uneven surface, and a wood part that is formed on at least one surface of the metal plate with a predetermined thickness and fits into the uneven surface.

It is also preferable that the metal plate is made of steel.

It is also preferable that the metal plate is a deck plate.

It is also preferable that the wood portion contains a solidifying material that has fluidity and solidifies after a predetermined time has elapsed, and wood chips that are mixed with the solidifying material.

The present invention relates to a method for manufacturing a floor panel, which includes the steps of: setting up a formwork so as to surround at least one side of a metal plate having an uneven surface; pouring a fluid solidification material mixed with wood chips into the set up formwork; solidifying the poured solidification material; and removing the formwork after the solidification material has solidified.

According to this aspect of the present invention, construction can be performed using dry construction methods while improving strength performance and other aspects compared to floors constructed using wood materials.

FIG. 2 is a perspective view of the floor panel according to the first embodiment. FIG. 2 is a front view of the floor panel according to the first embodiment, seen from the longitudinal direction. FIG. 2 is a perspective view of a deck plate according to the first embodiment. FIG. 11 is a perspective view of a floor panel according to a second embodiment. FIG. 11 is a front view of a floor panel according to a second embodiment, as viewed from the longitudinal direction. FIG. 11 is a perspective view of a deck plate according to a second embodiment. FIG. 11 is a front view of the deck plate according to the second embodiment as viewed from the longitudinal direction. FIG. 11 is a perspective view of a floor panel in a modified example.

A preferred embodiment of the present invention will be described with reference to the drawings. Note that the embodiment shown below is merely an example, and various embodiments are possible within the scope of the present invention.

[First embodiment]
<Floor panel>
A first embodiment of the floor panel will be described with reference to Figs. 1 to 3.
As shown in FIGS. 1 and 2 , the floor panel 1 includes a metal plate 2 and a wood portion 3 .
The metal plate 2 is formed, for example, from a steel deck plate 2. The deck plate 2 is used as part of a formwork for a wooden part 3 that is poured when constructing a floor structure (or a ceiling structure) of a building, and after the wooden part 3 has solidified, the deck plate 2 is used as a structural material together with the wooden part 3.

The deck plate 2 is formed from a thin steel plate that has been plated with zinc or other plating, or from a black steel material that has not been surface-treated. The deck plate 2 is manufactured, for example, by roll-forming a flat steel plate using a roll-forming machine. The deck plate 2 is bent at multiple locations by the roll-forming machine. Here, the thickness of the deck plate 2 is preferably 0.5 to 6.0 mm. The thickness of the deck plate 2 is, for example, 1.0 mm.

As shown in FIG. 3 , the deck plate 2 has a lower surface portion 21 , an inclined portion 22 , and an upper surface portion 23 .
The lower surface portions 21 and upper surface portions 23 are alternately formed parallel to each other in the width direction B of the deck plate 2. The upper surface portions 23 are formed higher in the thickness direction of the deck plate 2 than the lower surface portions 21, and the distance between the lower surface portions 21 and the upper surface portions 23 is the height of the deck plate 2. The ends of the adjacent lower surface portions 21 and upper surface portions 23 are connected by inclined portions 22.

A groove (one of the uneven portions) 24 that protrudes toward the upper surface portion is formed on the surface (upper surface portion 23 side) of a portion of the lower surface portion 21. The groove 24 is formed to extend along the longitudinal direction L of the deck plate 2. At the connection portion between the lower surface portion 21 and the inclined portion 22, a curved portion (dovetail groove, one of the uneven portions) 25 that is greatly curved is formed on the front and back surfaces of the deck plate 2.
Convex portions (one of the concave and convex portions) 26 that protrude toward the upper surface portion are formed on the surface (upper surface portion 23 side) of the inclined portion 22. The convex portions 26 are formed at regular intervals along the longitudinal direction L of the deck plate 2.
A groove (one of the uneven portions) 27 that is recessed toward the lower surface portion 21 is formed on the surface of the upper surface portion 23. The groove 27 is formed near the center in the width direction of the upper surface portion 23 so as to extend along the longitudinal direction L of the deck plate 2.

As shown in Figures 1 and 2, the wooden part 3 is provided with a predetermined thickness on the surface of the deck plate 2, and is fitted into the grooves 24, 27, the convex parts 26, and the curved parts 25, which are the uneven parts of the deck plate 2, to form a composite structure and constitute the floor panel 1 that is strong against compressive and tensile forces. The wooden part 3 has a solidifying material and wood chips. The wooden part 3 is made by mixing the wood chips with a fluid solidifying material, pouring it onto the surface of the deck plate 2, and then curing it for a predetermined time or by hot pressing it to solidify it.

The solidification material may be an adhesive or cement, such as a phenol-based or isocyanurate-based adhesive, or Portland cement.
Examples of wood chips include wood wool and wood chips of hardwood and softwood.
If necessary, fireproofing agents and insect repellents may be added. For example, fireproofing agents include boron-based, phosphoric acid-based, and halogen-based agents, and insect repellents include cyphenothrin, bifenthrin, and fenitrothion.
In addition, other materials that enhance the deodorizing and moisture-regulating properties may be mixed into the solidifying material.

<Floor panel manufacturing method>
Next, a manufacturing method of the floor panel 1 will be described.
First, a formwork is installed so as to surround the periphery of the surface of the deck plate 2.
Next, a fluid solidification material mixed with wood chips is poured into a formwork installed around the deck plate 2. After the solidification material has been poured onto the surface of the deck plate 2, it is left to cure or hot pressed until it hardens. When the solidification material hardens, the wooden part 3 integrated with the deck plate 2 is constructed.
After the solidification material has solidified, the formwork is removed to construct a composite floor panel 1 comprising a deck plate 2 and a wooden portion 3.

As described above, the floor panel 1 is a composite structure panel including the deck plate 2 formed from a metal plate and having uneven portions (curved portion 25, grooves 24, 27, convex portion 26) on the surface, and the wood portion 3 formed on the surface of the deck plate 2 and fitting into the uneven portions (curved portion 25, grooves 24, 27, convex portion 26) of the deck plate 2, and can be constructed by a dry construction method while improving strength performance and the like compared to floors constructed from wood materials. That is, by providing the deck plate 2, strength performance and the like can be improved compared to floors constructed from wood materials, and further, since concrete is not used, it can be manufactured in a factory as a precast floor panel, and can be constructed by a dry construction method, shortening the construction period and facilitating on-site management. In addition, since the wood portion 3 is provided instead of concrete, the weight of the floor panel 1 can be reduced. Furthermore, by changing the density of the wood portion 3 (type of solidification material, type and amount of wood chips), the floor panel 1 can be manufactured with a weight according to the required performance.
Thus, it is possible to manufacture a floor panel 1 that combines the advantages of both a floor constructed of wood materials and a floor made of concrete.

In addition, since the wooden part 3 is made by mixing wood chips with a fluid solidifying material and solidifying it (for example, engineered wood such as OSB), when the solidifying material is poured onto the surface of the deck plate 2, the solidifying material containing the wood chips, etc. penetrates into the uneven parts of the deck plate 2 (the curved parts 25, grooves 24, 27, and convex parts 26) and solidifies, it is possible to enhance the sense of unity between the deck plate 2 and the wooden part 3, and the floor panel 1 with a composite structure can exhibit high strength performance, etc.
In addition, since the solidification material has fire resistance, the fire resistance of the floor panel 1 can be improved.
In addition, since the solidification material has insect-repellent properties, the insect-repellent performance of the floor panel 1 can be improved.

[Second embodiment]
A second embodiment of the floor panel will be described with reference to Figures 4 to 7. The floor panel 1a in the second embodiment differs from the floor panel 1 in the first embodiment in the configuration of the metal plate 4, and therefore the metal plate 4 will be described in detail.

As shown in FIGS. 4 and 5 , the floor panel 1 a includes a metal plate 4 and a wood portion 5 .
The metal plate 4 is formed, for example, from a steel deck plate 4. The deck plate 4 is used as a part of a formwork for a wooden part 5 that is poured when constructing a floor structure (or a ceiling structure) of a building, and after the wooden part 5 has solidified, the deck plate 4 is used as a structural material together with the wooden part 5.

The deck plate 4 is formed from a thin steel plate that has been plated with zinc or other plating, or from a black steel material that has not been surface-treated. The deck plate 4 is manufactured, for example, by roll-forming a flat steel plate using a roll-forming machine. The deck plate 4 is bent at multiple locations by the roll-forming machine. Here, the thickness of the deck plate 4 is preferably 0.5 to 2.3 mm. The thickness of the deck plate 4 is, for example, 0.8 mm.

As shown in FIGS. 4 to 7, the deck plate 4 has a rib 41, a surface portion 42, a locking portion 43, and an end closed portion 44.
7, the rib (one of the concave and convex portions) 41 is formed by bending a steel plate by a roll forming machine. The rib 41 has a curved portion 41a bent toward one surface of the steel plate, a straight portion 41b continuing from the curved portion 41a and extending in a direction perpendicular to the surface portion 42, a folded portion 41c continuing from the straight portion 41b and curved and folded back multiple times, a straight portion 41d continuing from the folded portion 41c and extending in a direction parallel to the straight portion 41b, and a curved portion 41e continuing from the straight portion 41d and folded toward the surface portion 42.
The straight line portion 41b and the straight line portion 41d are formed so that their surfaces abut against each other, and are connected by, for example, crimping, etc. This improves the effect of connecting the straight line portion 41b and the straight line portion 41d so that they do not separate.
The folded portion 41c is formed in a generally triangular shape in cross section, and is folded back so that the start point and the end point are adjacent to each other and the straight portion 41b and the straight portion 41d abut against each other.

The surface portions 42 are primarily portions of the deck plate 4 where the ribs 41 are not formed, and are portions into which a solidifying material mixed with wood chips and the like is poured. A plurality of surface portions 42 are formed in the width direction B of the deck plate 4, with the ribs 41 interposed between them. That is, the ribs 41 and the surface portions 42 are formed alternately in the width direction B of the deck plate 4. Each surface portion 42 is formed in a generally rectangular shape in a plan view, and is formed on the same plane.
The surface portion 42 has an embossment (one of the uneven portions) 42a formed on the upper surface side (the surface opposite the rib 41), for example, which protrudes on the side opposite the rib 41. The embossment 42a is formed so as to extend along the width direction B of the deck plate 4. A plurality of embossments 42a are formed at predetermined intervals along the length direction L of the deck plate 4. Here, the deck plate 4 may have a protrusion portion formed extending in the longitudinal direction of the deck plate 4 instead of the embossment, or may have both an embossment and a protrusion portion formed.
In addition, the deck plate 4 is formed with three ribs 41 and three surface portions 42 .

The locking portion 43 is formed at one end of the deck plate 4 in the width direction B. The locking portion 43 is formed along the height direction of the rib 41 so as to extend approximately perpendicular to the surface direction of the surface portion 42. Note that the deck plate 4 does not necessarily have to have the locking portion 43, and for example, a deck plate with a part cut off may be used as the metal plate 4, as a special accessory.

The end-closed portions 44 are formed at both ends in the longitudinal direction L of the deck plate 4. The end-closed portions 44 are formed by crushing both ends of the rib 41 at right angles to the surface of the deck plate 4. As a result, the rib 41 is formed with a cross section in which the end-closed portions 44 at both ends are crushed, and the other portion sandwiched between the end-closed portions 44 is formed in a roughly triangular cross section. With this configuration, both ends of the rib 41 are formed flat, so that it can be placed on the upper surface of the flange portion of the beam. The end-closed portions 44 are formed so that the length along the extension direction of the rib 41 is longer than the length at which it is placed on the upper surface of the flange portion of the beam.

As shown in Figures 4 and 5, the wooden part 5 is provided with a predetermined thickness on the surface of the deck plate 4, and is integrated with the uneven parts of the deck plate 4, such as the ribs 41 and embossments 42a, to form a composite structure and constitute the floor panel 1a that is resistant to compressive and tensile forces. The wooden part 5 has a solidifying material and wood chips. The wooden part 5 is made by mixing the wood chips with a fluid solidifying material, pouring it onto the back surface of the deck plate 4 (the surface where the ribs 41 are present), and then curing it for a predetermined time or by hot pressing it to solidify it.

The solidification material may be an adhesive or cement, such as a phenol-based or isocyanurate-based adhesive, or Portland cement.
Examples of wood chips include wood wool and wood chips of hardwood and softwood.
If necessary, fireproofing agents and insect repellents may be added. For example, fireproofing agents include boron-based, phosphoric acid-based, and halogen-based agents, and insect repellents include cyphenothrin, bifenthrin, and fenitrothion. In addition, materials that enhance deodorizing and moisture-regulating properties may be mixed into the solidifying material.

<Floor panel manufacturing method>
Next, a manufacturing method of the floor panel 1a will be described.
First, a formwork is placed so as to surround the rear surface of the deck plate 4 (the surface on which the ribs 41 are formed).
Next, a fluid solidification material mixed with wood chips is poured into a formwork installed around the deck plate 4. After the solidification material has been poured onto the surface of the deck plate 4, it is left to cure or hot pressed until it hardens. When the solidification material hardens, a wooden part 5 integrated with the deck plate 4 is constructed.
After the solidification material has solidified, the formwork is removed to construct a composite floor panel 1a comprising a deck plate 4 and a wooden portion 5.

As described above, the floor panel 1a is a composite structure panel including the deck plate 4 formed from a metal plate and having uneven portions (ribs 41, embossments 42a) on the surface, and the wood part 5 formed on the surface of the deck plate 4 and fitting into the uneven portions (ribs 41, embossments 42a) of the deck plate 4, and can be constructed by a dry construction method while improving the strength performance and the like compared to floors constructed from wooden materials. That is, by providing the deck plate 4, the strength performance and the like can be improved compared to floors constructed from wooden materials, and further, since concrete is not used, it can be manufactured in a factory as a precast floor panel, and can be constructed by a dry construction method, shortening the construction period and facilitating on-site management. In addition, since the wood part 5 is provided instead of concrete, the weight of the floor panel 1a can be reduced. Furthermore, by changing the density of the wood part 5 (type of solidification material, type and amount of wood chips), the floor panel 1a can be manufactured with a weight according to the required performance.
Therefore, it is possible to manufacture a floor panel 1a that combines the advantages of both a floor constructed of wood materials and a floor made of concrete.

In addition, since the wooden part 5 is made by mixing wood chips with a fluid solidifying material and solidifying it (for example, engineered wood such as OSB), when the solidifying material is poured onto the surface of the deck plate 4, the solidifying material containing the wood chips, etc. penetrates into the uneven parts of the deck plate 4 (the ribs 41, the embossments 42a, etc.) and solidifies, it is possible to enhance the sense of unity between the deck plate 4 and the wooden part 5 and to exhibit high strength performance as a composite structure floor panel 1a.
In addition, since the solidification material has fire resistance, the fire resistance of the floor panel 1a can be improved.
In addition, since the solidification material has insect-repellent properties, the insect-repellent performance of the floor panel 1a can be improved.

＜Other＞
Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above-mentioned embodiments, and includes all aspects included in the concept of the present invention and the scope of the claims. In addition, each configuration may be appropriately and selectively combined so as to achieve at least a part of the above-mentioned problems and effects. In addition, for example, the shape, material, arrangement, size, etc. of each component in the above-mentioned embodiments may be appropriately changed depending on the specific use mode of the present invention.

For example, as shown in FIG. 8, the metal plate is not limited to a deck plate, but may be a floor panel including a metal plate other than a deck plate and a wooden portion.
Specifically, the floor panel 1b includes a metal plate 6 and a wood portion 7. The metal plate 6 is bent at predetermined intervals in the width direction B to form fitting portions (uneven portions) 61. Between adjacent fitting portions 61, flat planar portions 62 are formed along the width direction B.

The fitting portion 61 has a vertical portion 61a extending from the planar portion 62 in a direction perpendicular to the width direction B, a horizontal portion 61b extending along a direction perpendicular to the vertical portion 61a (direction B), a vertical portion 61c extending along a direction perpendicular to the horizontal portion 61b, a horizontal portion 61d extending along a direction perpendicular to the vertical portion 61c (direction B), a vertical portion 61e extending along a direction perpendicular to the horizontal portion 61b, a horizontal portion 61f extending along a direction perpendicular to the vertical portion 61e (direction B), and a vertical portion 61g extending along a direction perpendicular to the horizontal portion 61f.
Here, the vertical portions 61a and 61g face each other in the width direction B, and the vertical portions 61c and 61e face each other in the width direction B. The horizontal portion 61d faces the horizontal portions 61b and 61f, respectively, in a direction perpendicular to the width direction B. Therefore, the fitting portion 61 is formed by being bent so as to trace the outline of a substantially T-shape when viewed from the front.

Even with this configuration, when the solidifying material is poured onto the surface of the metal plate 6, the solidifying material containing wood chips, etc. penetrates into the uneven parts of the metal plate 6 (the fitting parts 61, etc.) and solidifies, thereby enhancing the sense of unity between the metal plate 6 and the wood part 7, and allowing the composite structure floor panel 1b to exhibit high strength performance, etc.
The shape of the fitting portion 61 is not important as long as it fits with the wood portion 7 to enhance the sense of unity and construct a composite structure.

1, 1a, 1b Floor panel 2, 4 Deck plate (metal plate)
3, 5, 7 Wooden part 6 Metal plate 24, 27 Groove (uneven part)
25 Curved portion (uneven portion)
26 Convex portion (concave-convex portion)
41 Rib (uneven part)
42a Embossed (concave and convex)
61 Fitting part 62 Plane part

Claims (5)

A deck plate having an uneven surface;
A wooden portion is formed on at least one surface of the deck plate with a predetermined thickness and fitted into the uneven portion .
The woody part is
A solidification material that has fluidity and solidifies after a predetermined time has elapsed;
Wood chips to be mixed with the solidification material;
A floor panel comprising : 2. The floor panel of claim 1, wherein the deck plate is formed from steel. 3. The floor panel according to claim 1 or 2, wherein the solidifying material is an adhesive or cement. 4. The floor panel according to claim 3, wherein the solidifying agent is a phenol-based or isocyanurate-based adhesive. A step of installing a formwork so as to surround at least one surface of a deck plate having an uneven surface;
A step of pouring a fluidized solidification material mixed with wood chips into the installed formwork;
A step of solidifying the poured solidification material;
removing the formwork after the solidification material has solidified;
A method for manufacturing a floor panel, comprising the steps of:

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