JPH05200925A - Production of floor panel - Google Patents

Abstract

PURPOSE:To produce a floor panel by certainly bonding a floor panel and a reinforcing material without generating a solvent crack in the floor panel main body. CONSTITUTION:A projection 11 is provided to the rear surface of a floor panel main body 1 at a desired position and a through-hole 21 is provided to a reinforcing material at the part corresponding to the projection. The reinforcing material is applied to the rear surface of the floor panel main body so that the projection faces to the through-hole and the leading end part of the projection protruding from the through-hole 21 is deformed by thermal deformation to prevent the detachment of the floor panel main body or the projection is inserted in the through-hole under pressure to be bonded thereto.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a floor panel used for forming a floor such as a balcony or a terrace.

[0002]

2. Description of the Related Art A floor panel 101 used for forming a floor such as a balcony or terrace as shown in FIGS. 11 and 12 is usually formed by vacuum molding a thermoplastic resin of acrylic modified polyvinyl chloride resin. As a result, the floor panel body 102 is formed. Since the floor panel body 102 alone cannot withstand a sufficient load,
A reinforcing plate 103 such as plywood is integrated with the back surface of the floor panel body 102 via an adhesive or an adhesive tape.

[0003]

However, in the method of adhering the reinforcing plate 103 from the back surface with an adhesive or an adhesive tape, there is a problem in durability of the floor panel body 102. That is, a solvent is contained in the adhesive or the adhesive tape, and these solvents corrode the resin forming the floor panel main body 102 over time, so-called solvent cracking occurs, and the floor panel 101 is exposed. When a person walks, the floor panel body 102 is cracked or cracked, and rainwater or the like leaks downstairs from this portion.

Particularly, in the case where the floor panel main body 102 is provided with a tile pattern by deep drawing or the like in order to enhance the cosmetic property, since a space is opened between the back surface of the tile portion 104 and the reinforcing material 103, this There is a strong tendency. In addition, the method of adhering with an adhesive has a problem that the adhesive strength varies due to uneven coating of the adhesive.

On the other hand, there is also a method of screwing a screw or the like into the reinforcing material from the floor panel body side to mechanically fix the reinforcing material.
According to this method, a screw insertion hole must be provided in the floor panel body. Therefore, if the insertion hole is not sufficiently sealed, rainwater or the like collected on the floor panel body may leak downstairs from this insertion hole. There is. In view of such a situation, the present invention is reinforced with the floor panel body without causing solvent cracking in the floor panel body and without providing holes reaching the front and back surfaces such as screw insertion holes in the floor panel body. It is an object of the present invention to provide a method for manufacturing a floor panel that can reliably bond to a material.

[0006]

In order to achieve such an object, a floor panel manufacturing method according to a first aspect of the present invention is a floor panel main body made of a thermoplastic resin having protrusions provided at desired positions on the back surface side. On the back surface of the protrusion, a reinforcing plate having a thickness smaller than the protrusion length of the protrusion and having a through hole formed at a position corresponding to the protrusion is pressed, and the tip portion of the protrusion is protruded from the through hole. The tip of the projection is pressed by a hot plate to thermally deform the tip so that the outer shape of the tip is larger than the through hole.

In the above construction, the protrusion may be solid or may be a bottomed cylinder having an opening on the front surface side of the floor panel body. When the projection has a cylindrical shape with a bottom, it is preferable to thermally deform the tip end of the projection and then close the opening with a cap or the like. On the other hand, in the floor panel manufacturing method according to claim 2, the floor panel main body made of a synthetic resin having protrusions projecting at desired positions on the back side has a position thinner than the length of the protrusions and corresponding to the protrusions. A reinforcing plate having a through hole smaller than the protrusion is pressed against the protrusion to press fit the protrusion into the through hole.

In the above structure, the protrusion may be solid or may be a bottomed cylinder having an opening on the surface side of the floor panel body. When the projection has a cylindrical shape with a bottom, the projection is press-fitted into the through hole, and then a wedge-shaped jig with a large diameter part larger than the inner diameter of the cylinder is driven into the cylindrical part from the opening. It is preferable that the wall of the groove is pushed outward. In addition, at this time, it is preferable to close the opening with a cap or the like.

Further, the inner wall surface of the through hole may be made of an elastic material. On the other hand, the floor panel manufacturing method according to claim 3, wherein a rectangular tubular portion having a substantially rectangular cross section is provided at a desired position on the back surface of the floor panel body made of a thermoplastic resin provided so as to project the bottom surface of the tube to the back surface side. A reinforcing plate having a through hole of substantially the same shape as the square tube portion is pressed against a portion corresponding to the square tube portion having a thickness smaller than the protruding length of the square tube portion, and the bottom portion of the square tube portion is penetrated through the through hole. After projecting from the jig, the jig is provided with a base portion having substantially the same shape as the internal shape of the square tubular portion and having a thickness approximately the same as the length of the protruding portion from the through hole of the square tubular portion with the base portion on the bottom side. It is configured to be inserted into the rectangular tube portion and horizontally rotated 90 ° near the bottom portion of the rectangular tube portion so as to plastically deform the short side wall near the bottom portion of the rectangular tube portion so as to bulge from the inside to the outside.

In the above structure, the jig may be made of a metal material such as iron, and the thermoplastic resin forming the floor panel body is thermally deformed before the wall near the bottom of the rectangular tube is plastically deformed. It is preferably heated to a temperature possible. As a heating method, the jig is heated in advance to a predetermined temperature by a heating means such as a burner, or +/- electrode terminals are provided at both ends of the base, and a voltage is applied between these terminals to generate heat. And the like.

As a method of rotating the jig, for example, a method may be mentioned in which a knob is provided vertically on the base and the knob is rotated while being sandwiched by a tool such as pliers. Further, after rotating the jig, it is preferable to close the opening of the rectangular tube portion with a cap or the like.

[0012]

According to the structure of claim 1, the floor panel main body having the protrusion on the back surface side and the reinforcing member having the through hole at the portion corresponding to the protrusion are prepared, and the protrusion is provided at the corresponding through hole. Press the reinforcing material against the back side of the floor panel body so that it faces.
Since the reinforcing material is thinner than the length of the protrusion,
When the reinforcing material is brought into close contact with the back surface of the floor panel body, the tip of the protrusion projects from the through hole. A hot plate or the like is pressed against the protruding portion to be crushed, and is expanded to have an outer shape larger than the through hole to form a barb.

By this return, the reinforcing material is prevented from separating from the floor panel body, and the floor panel body and the reinforcing material can be joined without using an adhesive. On the other hand, according to the second aspect of the invention, the floor panel main body having the protrusion on the back surface side and the reinforcing member having the through hole having a diameter slightly smaller than the protrusion at the portion corresponding to the protrusion are prepared. Then, a reinforcing material is arranged on the back side of the floor panel main body so that the projection faces the corresponding through hole, and when the reinforcing material is pressed toward the floor panel main body side, the projection is press-fitted into the through hole. By this press-fitting, the outer peripheral surface of the protrusion and the inner wall surface of the through hole are pressed against each other, and the detachment of the reinforcing material from the floor panel body is prevented. That is, the floor panel body and the reinforcing material can be joined without using an adhesive.

On the other hand, according to the third aspect of the present invention, the floor panel main body is provided on the back surface side with the square tube portion projecting the bottom portion thereof, and the square tube portion is substantially provided at the portion corresponding to the square tube portion. A reinforcing material having through holes having the same cross-sectional shape is prepared. Then, the reinforcing material is pressed against the back side of the floor panel main body so that the square tubular portion faces the corresponding through hole. Since the reinforcing material has a thickness smaller than the length of the square tubular portion, when the reinforcing material is brought into close contact with the back surface of the floor panel body, the tip portion of the square tubular portion, that is, the vicinity of the bottom portion projects from the through hole.

Next, a jig is inserted into the rectangular tube so that the table reaches the bottom of the rectangular tube, and the table is moved to 90 by pliers or the like.
When rotated horizontally, the short side wall near the bottom of the square tube bulges outward by the difference between the longitudinal width and the short width of the base, and the width becomes wider than the short width of the through hole. Therefore, the bulging portion is returned to prevent the reinforcing material from being separated from the floor panel body. That is, the floor panel body and the reinforcing material can be joined without using an adhesive.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the drawings showing the embodiments thereof. (Embodiment 1) As shown in FIG. 1, a floor panel body 1 is formed by vacuum-molding an acrylic modified polyvinyl chloride resin material, and a plurality of protrusions 11 are provided at predetermined positions on the back side. There is. The protrusion 11 has a bottomed tubular shape having an opening 12 on the front surface side of the floor panel body 1.

The reinforcing plate 2 is formed of a plywood having a thickness smaller than the length of the protrusion 11, and a through hole 21 having a diameter slightly larger than that of the protrusion 11 is formed in a portion corresponding to the protrusion 11.
The cap 3 is provided with a fitting insertion portion 32 on the back surface of an umbrella-shaped cap body 31. The fitting insertion portion 32 is a locking portion 32a whose tip portion is slightly larger in diameter than the middle portion and is tapered, and is locked by inserting the fitting insertion portion 32 into the cylinder of the projection 11 from the opening 12. The portion 32a is engaged with the ridge 13 provided in the cylinder to prevent the cap 3 from coming off.

In this embodiment, the floor panel can be manufactured as follows. That is, as shown in FIG. 2, after the through hole 21 corresponding to the protrusion 11 is exposed and the reinforcing plate 2 is pressed from the back surface of the floor panel body 1, the tip portion 11 a of the protrusion 11 protruding from the through hole 21 is pressed. Then, the heat plate 16 is pressed against and pressed in the direction of the reinforcing plate 2. As a result of this pressing, as shown in FIG. 3, the tip portion 11 a is crushed and the rebound 14 which is wider than the hole diameter of the through hole 21 is formed.

Then, by covering the opening 12 with the cap 3, the floor panel A as shown in FIG. 3 can be manufactured. In this floor panel A, as described above, the reinforcing plate 3 is prevented from coming off by the barb 14, and the floor panel main body 1 and the reinforcing plate 2 are joined and integrated without using an adhesive, and the floor panel by the solvent is used. Since the problem of solvent cracking of the main body 1 is eliminated, and the mechanical fixing is performed, the joining becomes firm and the durability of the floor panel itself is improved. Further, since the floor panel main body 2 is not provided with any screw insertion holes or the like at all, the sealability is good and rainwater or the like does not leak downstairs. (Embodiment 2) As shown in FIG. 4, the floor panel body 4 is formed by vacuum forming an acrylic modified polyvinyl chloride resin material, and a plurality of protrusions 41 are provided at predetermined positions on the back surface side. There is. The protrusion 41 has a bottomed tubular shape having an opening 42 on the front surface side of the floor panel body 4.

The reinforcing plate 5 is fitted integrally with a reinforcing plate body 51 formed of a plywood having a thickness smaller than the length of the protrusion 41 and a hole 51a provided in a portion of the reinforcing plate body 51 corresponding to the protrusion 41. It is composed of a rubber cylinder 52. The through hole 52a of the rubber tube 52 has a diameter slightly smaller than the outer diameter of the protrusion 41. And in this Example, a floor panel can be manufactured as follows. That is, FIG.
As shown in FIG. 5, the through hole 52a corresponding to the protrusion 41 is exposed, and the reinforcing material 5 is pressed from the back surface of the floor panel body 4 to be press-fitted into the through hole 52a. The floor panel B can be manufactured by covering the opening 42 with the cap 61.

This floor panel B has a projection 41 and a through hole 52.
By press-fitting and fitting into a, the outer peripheral surface of the protrusion 41 is pressed against the inner wall surface of the through hole 52a, and the frictional force prevents the reinforcing plate 5 from coming off the floor panel body 4. That is, the floor panel main body 4 and the reinforcing member 5 are joined and integrated without using an adhesive, the problem of solvent cracking of the floor panel main body 4 due to a solvent is eliminated, and since the mechanical fixing is performed, the joining is also performed. It becomes solid and the durability of the floor panel itself is improved. Further, since the floor panel main body 4 is not provided with any screw insertion holes or the like at all, it has a good sealing property, and rainwater and the like do not leak downstairs.

Before closing the opening 42 with the cap 61, a wedge-shaped member 62 as shown in FIG. 6 is driven into the cylinder through the opening 42 and the wall of the cylindrical portion is pushed outward by the wedge-shaped member 62. The reinforcing plate 5 may be more firmly integrated by increasing the pressure contact force of the through hole 52a to the inner wall surface. (Embodiment 3) As shown in FIG. 7, the floor panel main body 7 is formed by vacuum forming an acrylic modified polyvinyl chloride resin material, and an opening 73 is formed on the front surface side of the floor panel main body 7 and its cross section is shown. A rectangular tube-shaped portion 71 having a substantially rectangular shape is provided at a predetermined position so that a bottom portion 72 of the rectangular tubular portion 71 projects from the back surface side.

The reinforcing plate 8 is formed of a plywood having a thickness smaller than the length of the rectangular tubular portion 71, and a portion corresponding to the rectangular tubular portion 71 has a through hole 81 having a substantially rectangular cross section larger than the rectangular tubular portion 71.
Has been drilled. The jig (screw) 9 is made of iron and includes a base portion 91 having substantially the same shape as the inner cross-sectional shape of the rectangular tubular portion 71, and a knob 92 suspended from the base portion 91. The base 91 is formed to be slightly thinner than the length of the rectangular tubular portion 71 minus the thickness of the reinforcing plate 8.

In FIG. 7, 94 is a synthetic resin cap for closing the opening 73, and 95 is a cap 94 for the opening 73.
Is a leg portion that faces the inside of the rectangular tubular portion 71 when it is closed, and elastically contacts the inner wall surface thereof to prevent the cap 94 from coming off. And in this Example, a floor panel can be manufactured as follows. That is, as shown in FIG. 8, the reinforcing member 8 is pressed from the back surface of the floor panel main body 7 with the through holes 81 corresponding to the rectangular tubular portion 71 facing, and then the rectangular tubular portion 7 is pressed.
The jig 9 heated from the first opening 73 is inserted into the tubular portion 71 until the base portion 91 reaches the vicinity of the bottom portion 72 of the rectangular tubular portion 71 while sandwiching the knob 92 with pliers (not shown). Next, as shown in FIG. 9, use the pliers to move the knob 92 to the bottom portion 7.
Rotate 90 ° horizontally along 2. By this rotation, as shown by the broken line in FIG. 9, the short side wall surface near the bottom of the rectangular tubular portion 71 is thermoplastically deformed and bulges outward to form the protruding portion 74.

The floor panel C as shown in FIG. 10 can be manufactured by press-fitting the leg portion 95 from the opening portion 73 into the rectangular tubular portion 71 and closing the opening portion 73 with the cap 94. In this floor panel C, the jig 9 inserted into the rectangular tubular portion 71 is rotated to plastically deform the tip portion of the rectangular tubular portion 71 to form a return-shaped protruding portion 74.
4 prevents the reinforcing plate 8 from coming off, and the floor panel body 7 and the reinforcing material 8 are joined and integrated without using an adhesive, so that the problem of solvent cracking of the floor panel body 7 due to a solvent is eliminated, and Since it is fixed mechanically, the joining is also firm and the durability of the floor panel itself is improved. Further, since the floor panel main body 7 is not provided with any screw insertion holes or the like at all, the sealability is good and rainwater or the like does not leak downstairs.

[0026]

According to the floor panel manufacturing method of the present invention as described above, the floor panel main body and the reinforcing member can be firmly connected without using an adhesive, so that the floor panel main body can be solvent cracked. Does not occur, and
Even if the floor panel body is not provided with a hole such as a screw insertion hole that reaches the front and back surfaces, the floor panel body and the reinforcing material can be reliably joined.

Therefore, the durability of the floor panel is improved.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing components of a floor panel used for carrying out the invention of claim 1. FIG.

FIG. 2 is a cross-sectional view showing a state during the manufacturing thereof.

FIG. 3 is a sectional view showing the completed state.

FIG. 4 is a perspective view showing the components of a floor panel used for carrying out the invention of claim 2 in an exploded manner.

FIG. 5 is a cross-sectional view showing the completed state.

FIG. 6 is a perspective view showing a wedge-shaped member used in this manufacturing.

FIG. 7 is an exploded perspective view showing components of a floor panel used for carrying out the invention of claim 3;

FIG. 8 is a cross-sectional view showing a condition partway through the manufacturing.

FIG. 9 is a diagram for explaining how the jig is rotated as viewed from above.

FIG. 10 is a sectional view showing the completed state.

FIG. 11 is a plan view of a conventional floor panel.

FIG. 12 is a sectional view taken along the line AA.

[Explanation of symbols]

 1 Floor panel main body 2 Reinforcement plate 3 Heat plate 4 Floor panel main body 5 Reinforcement plate 7 Floor panel main body 8 Reinforcement plate 9 Jig 11 Protrusion 21 Through hole 41 Protrusion 52a Through hole 71 Square tube 81 Through hole 91 Stand A Floor panel B floor panel C floor panel

Claims (3)

[Claims] 1. A back panel of a floor panel body made of a thermoplastic resin having a projection protruding at a desired position on the back surface, and a through hole having a thickness smaller than the projection length of the projection and corresponding to the projection. After pressing the stiffened reinforcing plate to project the tip of the protrusion from the through hole, heat the tip of the protrusion with a hot plate so that the outer shape of the tip becomes larger than the through hole. A method for manufacturing a floor panel, which comprises deforming. 2. A through hole smaller in thickness than the length of the protrusion and smaller than the protrusion at a position corresponding to the protrusion is formed on the rear face of the floor panel body made of a synthetic resin in which the protrusion is provided at a desired position on the back side. A method for manufacturing a floor panel, comprising: pressing a provided reinforcing plate to press-fit the protrusion into the through hole. 3. A rectangular panel having a substantially rectangular cross section at a desired position is provided on the back surface of a floor panel body made of a thermoplastic resin so as to prevent the bottom surface of the tube from projecting to the back surface side, and After pressing a reinforcing plate having a through hole of substantially the same shape as the square tube portion into the portion having a small thickness and corresponding to the square tube portion, the bottom portion of the square tube portion is projected from the through hole, and then the square Insert a jig with a base that is approximately the same as the internal shape of the cylinder and that has a thickness that is approximately the same as the length of the protrusion from the through-hole of the square cylinder into the square cylinder with the base at the bottom. A method for manufacturing a floor panel, which comprises horizontally rotating 90 ° near the bottom of the tubular portion and plastically deforming the short side wall near the bottom of the rectangular tubular portion so as to bulge from the inside to the outside.