JPH0754469A - Production of floor slab - Google Patents

Abstract

PURPOSE:To provide a floor slab which brings out a high anti-rusting effect and hardly brings about shaking or creaking at the contact position between mutual floor slabs and between the floor slab and the floor frame where the floor slab is fixed, and even is there are some shaking or creaking positions, prevents sounds resulting from these causes on walking. CONSTITUTION:A base board 4 on which fitting nuts 6 are fixed at one side thereof is formed. A first elastic fluid 47 is poured in a molding frame 40. The base board 4 is placed on the poured first elastic fluid 47 layer. A second elastic fluid 48 is poured from the upper side of the base board 4. After the first and second elastic fluids have been solidified, they are removed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a floor board which is preferably used as a floor of a portion of a building such as a balcony, a veranda or an outer corridor attached to the outside of a building. In particular, the present invention relates to a method for manufacturing a floorboard body having a metal plate inside and entirely covered with an elastic material.

[0002]

2. Description of the Related Art As a floor board used for an outer corridor, there is, for example, one disclosed in Japanese Utility Model Laid-Open No. 63-104539. The floorboard body of this publication is formed of a steel plate having a pair of bent portions with opposite sides bent inward, a reinforcing member welded to the lower surface of the steel plate, and an elastic material attached to the upper surface of the steel plate. It has a soundproof layer.

[0003]

The floor base body described above is effective in reducing or muffling walking noise. However, since the surface of the steel sheet is exposed in portions other than the upper surface of the steel sheet, the rust prevention effect is low and deterioration due to rust occurs. Further, in this floor base, a plurality of floor bases are laid to form a floor surface, but since the side surfaces of the steel plates of the floor bases contact each other, the contact portions between the floor bases and the floor base are fixed. Rattling and squeaking easily occur in the contact area with the floor frame. The rattling and squeaking generate a squeaking sound when walking.

Therefore, an object of the present invention is to provide a high anticorrosive effect, and to prevent rattling and squeaking at the contact portions of the floor bases and the floor frame to which the floor bases are fixed. Provided is a method for manufacturing a floor base body capable of easily and quality producing a floor base body capable of preventing the generation of a sound during walking due to the rattling or squeaking.

[0005]

[Means for Solving the Problems] To achieve the above object, a step of producing a substrate having a mounting nut or a mounting bracket fixed to one surface of a rectangular metal plate, and a substrate formed larger than the substrate. A frame body forming a rectangular substrate housing portion, a first side surface forming member disposed on a bottom surface portion of the substrate housing portion over the entire length of the inner side surface of one side of the frame body, and the frame body The first frame is provided with a second side surface forming member which is arranged at a position spaced apart from the bottom surface of the substrate housing portion by a predetermined dimension over the entire length of the inner side surface of the other side facing the one side. The step of injecting the elastic material liquid material to a predetermined thickness, and before the first elastic material liquid material is solidified, the surface of the substrate on which the mounting nut or the mounting bracket is not provided is used as the lower surface. The elastic material liquid layer of 1 above The step of placing the plate, and if the substrate has a mounting nut, except for the threaded portion of the mounting nut, the first elastic material liquid material is contacted over the entire circumference of the substrate from above. The whole elastic material having a step of applying or injecting the elastic material liquid material of 2 and a step of releasing from the mold after the first and second elastic material liquid layers are solidified to a demoldable degree. Is a method for producing a floorboard body coated with.

After the step of placing the substrate on the upper surface of the first elastic material liquid material layer, the first elastic material liquid material layer is solidified to a demoldable degree and then removed from the mold. A step of removing the mold, and if the substrate has a mounting nut, the second elastic member is placed on the second substrate from above the substrate so that the entire circumference is in contact with the liquid material of the first elastic material except for the threaded portion of the mounting nut. It is also possible to manufacture a floor board as a step of applying a liquid material of an elastic material.

Further, a step of manufacturing a board having a mounting nut or a mounting bracket fixed to one surface of a rectangular metal plate, and a lower frame body forming a rectangular board housing portion formed larger than the board. A first frame disposed on the bottom surface of the substrate storage unit over the entire length of the inner side surface of one side of a form frame including an upper frame body that covers the substrate storage unit of the lower frame body and forms a required molding space. A side surface forming member and a second side surface forming member disposed at a position spaced apart by a predetermined dimension above the bottom surface of the substrate housing portion over the entire length of the inner side surface of the other side facing the one side. In the mold, a step of arranging the substrate in the molding space with a predetermined distance above the bottom surface of the mold, and in the case of the substrate having a mounting nut, the molding space is removed except for the screw part of the mounting nut. Inject liquid of elastic material into A method of manufacturing a flooring body, comprising: a step of encapsulating the entire substrate with the elastic material liquid material; and a step of releasing the elastic material liquid material layer from the mold after the elastic material liquid material layer is solidified to a demoldable degree. Can also be

Further, it is preferable that the mold frame has a pattern sheet that is laid inside the frame body and forms a bottom surface of the substrate housing portion. Further, it is preferable that the step of applying or injecting the second liquid material of elastic material is performed before the first liquid material of elastic material injected into the mold is solidified. It should be noted that it is also possible to form a recess over substantially the entire length of the side surface forming member on the upper surface of the first side surface forming member and / or the lower surface of the second side surface forming member. This makes it possible to form a ridge as a rainwater guide on the front surface side protruding piece and / or the back surface side protruding piece formed corresponding to the concave portion.

[0009]

EXAMPLES Now, a method for manufacturing a floor board according to the present invention will be described with reference to Examples. 1 is a perspective view of a floor panel manufactured according to an embodiment of the present invention, FIG. 2 is a sectional view taken along the line AA of FIG. 1, and FIG. 3 is a line taken along the line BB of FIG. FIG. 4 is a cross-sectional view, FIG. 4 is a top view of an example of a formwork used in the method for manufacturing the floorboard body of the present embodiment, and FIGS. 5 and 6 are methods for manufacturing the floorboard body of the present embodiment. It is a sectional view for explaining.

The floor board 1 manufactured according to this embodiment includes a metal plate 2 and a mounting nut 6 fixed to one side of the metal plate 2.
Excluding the threaded portion of the nut 6 and the substrate 4 consisting of
The elastic material coating layer 3 covers the entire surface of the substrate 4.

The manufacturing method of the floor board 1 according to this embodiment is as follows.
A substrate forming step, a step of injecting a first elastic material liquid material into the mold, a step of placing the substrate 4 on the injected elastic material liquid material, and a second elastic material from above the substrate 4. The method includes a step of injecting a liquid material material and a step of releasing the elastic material liquid material after solidifying.

The step of forming the substrate 4 is carried out by fixing a mounting nut 6 to the inner surface of one side of the rectangular metal plate 2 surrounded by a bent portion described later by welding or the like. Metal plate 2
In order to improve the flexural rigidity of the substrate, at least a pair of opposite sides, for example, as shown in FIG. 2, the long side surface of the rectangular metal plate 2 is bent inward to bend portions 2b and 2c.
To form. Further, as shown in FIG. 3, the short sides may be bent inward to form the bent portions 2d and 2e. In this embodiment, all four sides are bent inward. It is desirable that the bent portions 2b to 2e have the same length. Then, the fixing of the mounting nut 6 to the inner surface of the metal plate 2 is performed at a predetermined number and at a predetermined interval, as shown in FIGS. 1, 2 and 3. The mounting nut 6 is the floor board 1
Since it also functions as a supporting portion of the floor board 1, the number thereof is appropriately set depending on the size, rigidity, and the like of the floor board body 1 in consideration of deflection against a load and the like.

In the step of forming the substrate 4, the surface may be roughened by a method such as sandblasting in order to improve the adhesion between the substrate 4 and the liquid material of the first and second elastic materials described later. desirable. The roughening may be performed before or after the nut 6 is fixed and the bent portion is formed.

The form 40 shown in FIG. 4 has a surface plate 60.
And frame bodies 41a, 41b, 42a, which are provided on the surface plate 60 and which form a substrate housing portion slightly larger than the substrate 4.
42b, the first side surface forming member 44 disposed on the bottom surface portion of the substrate housing portion over the entire length of the inner side surface of the frame body 42b, and the entire length of the inner side surface of the frame body 42a facing the frame body 42b. The second side surface forming member 45 is provided at a position spaced apart from the bottom surface by a predetermined dimension. Frame 4
1a, 41b, 42a, 42b have the same height as a whole, and regulate the height of the floorboard body 1 to be manufactured.

As shown in FIGS. 4 and 5, the first side face forming member 44 and the second side face forming member 45 are made of square bars having a quadrangular cross section. Back side protruding piece 7 and front side protruding piece 8
Is formed. The both side surface forming members 44 and 45 are formed as separate members from the frame bodies 42a and 42b, but they may be formed integrally with these frame bodies. Frame 41a, 41
b, 42a, 42b can be disassembled by a known means.

The mold 40 may have a pattern sheet 43 on the surface plate 60, as shown in FIG. By using such a pattern sheet 43, the surface pattern can be formed simultaneously with the formation of the elastic material coating layer 3 without performing a special pattern forming operation after the floor board 1 is manufactured, and the designability is also improved. To do. The pattern sheet is not necessarily used and may be directly formed on the surface of the surface plate 60 if necessary.

When the floor board 1 is manufactured, the first liquid material 47 of elastic material is first injected into the mold 40 to a predetermined thickness.

The elastic material liquid material 47 is a material which shows elasticity to some extent after curing, and any liquid material can be used as long as it is liquid at the time of injecting the mold, for example, various rubber materials and synthetic resin elastomers. Can be used. For example, urethane rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, butyl rubber, synthetic rubber such as thermoplastic elastomer or synthetic resin elastomer, and natural rubber such as latex rubber can be preferably used. In particular, urethane rubber is preferable in terms of moldability, mechanical strength, wear resistance, heat resistance, weather resistance and the like. Urethane rubber is a rubber-like elastic body obtained by reacting a polyester or polyether polyol with an isocyanate compound. Urethane rubber is classified into polyether urethane rubber and polyester urethane rubber. Polyether urethane rubber is particularly suitable for use as the coating layer of the floorboard of the present invention in view of cold resistance, heat resistance and rubber elasticity. is there. Further, in consideration of workability, a room temperature effect type urethane rubber is preferable, and either one-pack type or two-pack type may be used.

The elastic material liquid material 47 is shown in FIG.
As shown in (1), the liquid is injected to have the same height as the upper surface of the first side surface forming member 44 and the lower surface of the second side surface forming member 45 to form a first elastic material liquid material layer.

Next, the outer surface of the substrate 4 is placed on the upper surface of the first elastic material liquid material 47 before the first elastic material liquid material 47 is solidified. This step is performed by the first elastic material liquid material 47.
Although it may be performed by the weight of the substrate 4 placed on the layer,
As shown in FIG. 6, by applying pressure from the upper side of the substrate 4 by using an appropriate substrate pressing device 50 to which a plurality of bolts 51 screwed with the mounting nut 6 of the substrate 4 are attached. Is desirable.

Further, the substrate 4 is replaced by the first elastic liquid material 4
Before being placed on the 7th layer, it is desirable that the surface of the substrate 4 be coated with a liquid containing an adhesion improving substance in order to improve the adhesion to the first liquid material of the elastic material. As such a liquid, for example, a so-called adhesive or a thin liquid of the above-mentioned first elastic material liquid material 47 can be used.

Then, the second elastic material liquid material 48 is placed on the substrate so that the entire circumference of the mounting nut 6 of the board 4 is in contact with the first elastic material liquid material layer 47 except for the threaded portion. inject. It is desirable that the step of injecting the second elastic material liquid material is performed before the first elastic material liquid material 47 layer is solidified. Then, the pressing plate 49 is placed on the second elastic material liquid material 48 layer and pressed, so that a recessed portion is formed on the inner surface of the floor base 1 after molding. This state is the state shown in FIG. At the time of the injection and the pressing, it is desirable that the end surface of the second elastic material liquid material 48 layer does not overflow from the upper surface of the frame body 40. As the second elastic material liquid material 48, a material having adhesiveness to the first elastic material liquid material 47 is used, and the same material or the same material is particularly preferable. Further, the second elastic material liquid material 48 may be applied not only by the above injection but also by using so-called spray or the like, as long as it can prevent the substrate 4 from rusting.

Then, after the first and second liquid layers of the elastic material are solidified to such a degree that they can be demolded, they are demolded from the mold. The demolding is performed by disassembling the mold 40.

In this way, as shown in FIGS. 1 to 3, the substrate 4 including the rectangular metal plate 2 and the mounting nut 6 fixed to one surface thereof and at least the screw portion of the mounting nut 6 are removed. Elastic material coating layer 3 for encapsulating the entire surface of the substrate
A floorboard is formed by and. Further, the floor base 1 is formed continuously with the outer surface of the coating layer 3 and has a thickness smaller than the height of the floor base 1, and the outer side is formed over almost the entire length of one side of the floor base 1. Of the front surface side protruding piece 8 and the upper surface of the other side which is formed so that the upper surface thereof is at the same position as or below the extension line of the lower surface of the front surface side protruding piece 8 and which opposes the one side of the floorboard 1. The rear surface side protruding piece 7 which protrudes outward over substantially the entire length of the side is integrally formed.

Next, a method of attaching the floorboard 1 of this embodiment will be described with reference to FIGS. 7 and 8. First, a steel material 13 having a U-shaped cross section is bridged between a pillar (not shown) for forming a balcony, an outer corridor, etc. and the wall side of the building, and attached by welding or bolts. Next, the horizontal members 12a to 12d are fixed between the steel members 13 by welding or bolts to manufacture the floor frame 10. The horizontal members 12a to 12d are provided with bolt holes 15 formed in advance or formed after the floor frame is assembled. This bolt hole 15 is used for mounting nut 6 of floor board 1.
It corresponds to. Then, as shown in FIG. 7, the floor board 1 is placed on the floor frame 10, and the floor board 1 is tightly connected to the floor frame 10 using the mounting bolts 16. A cushioning sheet material (for example, a washer made of soft synthetic resin) is interposed between the mounting nut 6 and the horizontal members 12a to 12d, if necessary. As shown in FIG. 8, the laying of the required number of floor board bodies 1 is performed so that the front surface side protruding pieces 8 are positioned on the back surface side protruding pieces 7 of the fixed floor board body 1 as shown in FIG. 1 is placed on the floor frame, and the floor board 1 is tightly connected with the bolts 16. By repeating this work by repeatedly laying the number of floor boards, a floor structure is formed.

Next, a method of manufacturing a floorboard body according to another embodiment of the present invention shown in FIGS. 9 to 11 will be described.

FIG. 9 is a perspective view of a floor board manufactured according to another embodiment of the present invention, FIG. 10 is a sectional view taken along the line CC of FIG. 9, and FIG. 11 is this embodiment. FIG. 6 is a cross-sectional view for explaining the method of manufacturing the floor board body of FIG.

As shown in FIG. 9, the floorboard body 71 manufactured by this embodiment is the same as the floorboard body 1 of the above-described embodiment except that it has the protrusions 5 formed on the upper surfaces of the projecting pieces 7. Is the same.

Then, as shown in FIG. 11, a concave portion 44a is formed over the entire length of the upper surface of the first side surface forming member 44 of the frame body 40. Therefore, a part of the second liquid material of elastic material flows into the recess 44a, and as shown in FIG. 9 and FIG. 10, the protrusion 5 protruding over the entire length is integrally formed on the upper surface of the back side protruding piece 7. Form. This ridge 5 is
A groove for the rainwater guide is formed in the connection portion between the floor boards to prevent rainwater from dripping below the floor boards.

Further, the lower surface of the second side surface forming member 45 having a recess formed over its entire length may be used. As a result, the projecting ridge 5 integrally formed is formed so as to project over the entire length of the front surface side protruding piece 8. Furthermore, a recess may be formed over the entire length of both the first side surface forming member 44 and the second side surface forming member 45. As a result, integrally formed protrusions that project over the entire length of the front surface side protruding piece 8 and the back surface side protruding piece 7 are formed.

Next, a method of manufacturing the floor board according to another embodiment of the present invention will be described. The floor board manufacturing method of this embodiment includes a substrate forming step, a step of injecting a first elastic material liquid material, and a substrate 4 on the injected elastic material liquid material.
The step of placing the first elastic liquid material on the surface having the mounting nut of the substrate 4 and the first elastic liquid material on the surface having the mounting nut of the first elastic material. And a step of applying the material liquid material layer by spraying or the like so that the entire circumference is in contact with the liquid material layer.

The difference between the manufacturing method of this embodiment and the manufacturing method described above is that demolding is performed before the first elastic liquid material is solidified to some extent and before the second elastic liquid material is applied. The other points are the same as those of the above-described embodiment.

Next, a method of manufacturing the floor board according to another embodiment of the present invention will be described. In this example,
The form frame is composed of an upper frame body and a lower frame body, and the frame body forming the substrate housing portion in each of the above-described embodiments is used as a lower frame body, and an upper frame body such as a so-called lid is provided on the upper surface of the lower frame body. By arranging the above, the above-mentioned substrate storage section is used as a molding space.

The floor board can be manufactured by placing a substrate in the molding space of the mold, then pouring and filling the liquid material of the elastic material into the molding space to solidify, and then removing the mold. . The positioning of the board in the molding space can be performed, for example, by connecting a nut for mounting the board and a support bolt inserted from the upper frame side or the lower frame side.

The difference between this embodiment and each of the above-mentioned embodiments is that the injection of the liquid material of the elastic material is performed once and after the substrate is placed in the form frame composed of the upper frame body and the lower frame body. . Others are the same as those in the above-described embodiment.

Further, in the above description, an example in which the mounting nut 6 is fixed to one surface of the metal plate 2 in the step of forming the substrate 4 has been described, but instead of the nut 6, an angle member or the like is used. It is also possible to fix the bracket.
In the case of this bracket, the entire substrate including the bracket may be covered with the elastic material coating layer 3 and tightly connected to the floor frame 10 with appropriate bolts and nuts. Although the metal plate 2 is provided with the bent portion 2b and the like on the opposite side, it may be used as a simple flat plate as long as the metal plate 2 has a sufficient thickness.

[0037]

According to the method of manufacturing a floor board of the present invention, a metal plate and a substrate composed of a mounting nut or a mounting bracket fixed to one surface of the metal plate, and the entire surface of the substrate is covered. It is possible to easily and with good quality manufacture a floorboard body including an elastic material coating layer. In addition, the formed floor board has substantially no exposed metal plate surface, and can be attached to the floor frame from the lower surface side without penetrating the floor board, so that it has a high rust prevention effect. .

Further, the cushioning effect of the coating layer on the front surface side of the floorboard provides a comfortable walking feeling and prevents the generation of noise when walking or when transporting an object or the like.

Further, since the entire surface of the floor board is covered with the elastic material, rattling and squeaking hardly occur at the contact portion with the adjacent floor board and floor frame.
Further, even if there is some rattling or squeaking, it is possible to prevent the generation of a sound at the time of walking due to the rattling or squeaking.

[Brief description of drawings]

FIG. 1 is a perspective view of an example of a floor board manufactured by a manufacturing method of the present invention.

FIG. 2 is a sectional view taken along the line AA of FIG.

FIG. 3 is a sectional view taken along line BB of FIG.

FIG. 4 is a top view of an example of a mold used in the method for manufacturing a floor board of the present invention.

FIG. 5 is a cross-sectional view for explaining a step of injecting a first liquid material of elastic material in the method for manufacturing a floor board of the present invention.

FIG. 6 is a cross-sectional view for explaining the method for manufacturing a floor board of the present invention.

FIG. 7 is a perspective view for explaining a configuration of a floor by the floor board obtained by the manufacturing method of the present invention.

FIG. 8 is a cross-sectional view illustrating an assembled state of FIG.

FIG. 9 is a perspective view of an example of a floor board manufactured by a manufacturing method according to another embodiment of the present invention.

10 is a cross-sectional view taken along the line CC of FIG.

FIG. 11 is a cross-sectional view for explaining a method for manufacturing a floorboard body according to another embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Floor board 2 Metal plate 3 Elastic material coating layer 4 Substrate 5 Projection 6 Mounting nut 7 Back side protruding piece 8 Front side protruding piece 40 Form 43 43 Pattern sheet 44 First side forming member 45 Second side forming Member 47 First elastic material liquid material 48 Second elastic material liquid material

Claims (4)

[Claims] 1. A step of producing a substrate having a mounting nut or a mounting bracket fixed to one surface of a rectangular metal plate, and a frame body forming a rectangular substrate housing formed to be larger than the substrate. A first side surface forming member disposed on a bottom surface portion of the substrate housing portion along the entire length of the inner side surface of one side of the frame body, and an inner side surface of the other side opposite to the one side side of the frame body A step of injecting the first elastic material liquid material with a predetermined thickness into a mold having a second side surface forming member arranged at a position spaced apart from the bottom surface of the substrate housing portion by a predetermined dimension over the entire length of Before the first liquid material of the elastic material is solidified, the substrate is provided on the upper surface of the first liquid material layer of elastic material with the surface of the substrate on which the mounting nut or the mounting bracket is not provided as the lower surface. The step of placing the When the second nut includes a mounting nut, a step of applying or injecting the second liquid material of elastic material from above the substrate so that the entire liquid contact with the first liquid material of elastic material except for the threaded portion of the mounting nut. And a step of removing the mold from the mold after the first and second liquid layers of the elastic material are solidified to the extent that they can be removed from the mold, and the floorboard body entirely covered with the elastic material. Manufacturing method. 2. A step of producing a substrate having a mounting nut or a mounting bracket fixed to one surface of a rectangular metal plate, and a frame body forming a rectangular substrate housing formed to be larger than the substrate. A first side surface forming member disposed on a bottom surface portion of the substrate housing portion along the entire length of the inner side surface of one side of the frame body, and an inner side surface of the other side opposite to the one side side of the frame body A step of injecting the first elastic material liquid material with a predetermined thickness into a mold having a second side surface forming member arranged at a position spaced apart from the bottom surface of the substrate housing portion by a predetermined dimension over the entire length of Before the first liquid material of the elastic material is solidified, the substrate is provided on the upper surface of the first liquid material layer of elastic material with the surface of the substrate on which the mounting nut or the mounting bracket is not provided as the lower surface. Mounting the first elastic material A step of releasing from the mold after the liquid material layer is solidified to a degree capable of releasing, and the first elastic material liquid material except the threaded portion of the mounting nut when the substrate has a mounting nut. A step of applying a second liquid material of the elastic material from above the substrate so that the entire circumference is in contact with the substrate, and a method for manufacturing a floorboard body entirely covered with the elastic material. 3. A step of producing a substrate having a mounting nut or a mounting bracket fixed to one surface of a rectangular metal plate, and a lower frame body forming a rectangular substrate housing formed to be larger than the substrate. A first frame disposed on the bottom surface of the substrate storage unit over the entire length of the inner side surface of one side of a form frame including an upper frame body that covers the substrate storage unit of the lower frame body and forms a required molding space. A side surface forming member and a second side surface forming member disposed at a position spaced apart by a predetermined dimension above the bottom surface of the substrate housing portion over the entire length of the inner side surface of the other side facing the one side. A step of arranging the substrate in the molding space in the mold so as to be spaced apart from the bottom surface of the mold by a predetermined distance above the molding space; and when the substrate has a mounting nut, the molding space except for the threaded portion of the mounting nut. Inject the elastic material liquid into the
An elastic material comprising: a step of encapsulating the entire substrate with the liquid material of elastic material; and a step of releasing from the mold after the liquid material layer of elastic material is solidified to a degree such that it can be released. A method for manufacturing a floorboard body entirely covered with. 4. A recess is formed on at least the upper surface of the first side surface forming member over the entire length of the side surface forming member, and a protrusion is formed over at least the entire length of the back surface side protruding piece formed on the floor base body. The method for manufacturing a floorboard body according to claim 1, wherein the floorboard body is manufactured.