JPH1190563A - Manufacture of perforated floor panel and perforated floor panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently chamfer an opening inner peripheral edge of many small through holes in a perforated floor panel. SOLUTION: The perforated floor panel is composed of a metal made floor panel main body 2 and a finished material 4 which is laminated on a surface 3 of the floor panel main body 2. Chamfered parts 14 are formed by plastic deformation in the opening inner peripheral edge of a finished material side of many small through holes 6 which penetrate an upper surface wall part 5 of the floor panel main body 2 and the finished material 4. When a chamfering dimension of the chamfered parts 14 is shown by B, the chamfering dimension is set at 0.5 mm<=B<=< 2.0 mm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a perforated floor panel and a perforated floor panel.

[0002]

2. Description of the Related Art Perforated floor panels having a large number of small ventilation holes are generally or partially laid on the floor of a clean room, office, computer room, or the like. Conventionally, the following two production methods have been known as methods for producing such a perforated floor panel. The floor panel body material is formed by casting (die casting), and then a finishing material is adhered to the upper surface of the floor panel body material,
Thereafter, a substantially uniform thickness upper surface wall portion of the floor panel body material and the finishing material are simultaneously punched to form a small through-hole, and thereafter, the inner peripheral edge of the opening of the small through-hole is cut and chamfered with a tapered rotary cutting tool. Manufacturing method. The floor panel body material is formed by casting (die-casting), and a small through hole is punched and formed in the upper surface wall. In addition, a small through hole is formed at a position corresponding to the small through hole of the floor panel body material as a separate finishing material. Then, a finishing material is adhered to the upper surface of the floor panel body material so that the corresponding small through-holes coincide with each other, and then the inner peripheral edge of the opening of the small through-hole is cut with a tapered rotary cutting tool. The method of chamfering.

[0003]

However, in the above-mentioned manufacturing method, since the small through hole is chamfered with a rotary cutting tool, there is a problem that the working efficiency is poor.

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above-mentioned problems and to provide a method of manufacturing a perforated floor panel capable of efficiently chamfering the inner peripheral edge of a large number of small through holes.
Another object of the present invention is to solve the above-mentioned problems and to provide a light-lit floor panel capable of chamfering the inner peripheral edge of the opening of a large number of small through holes efficiently.

[0005]

In order to achieve the above-mentioned object, a method of manufacturing a perforated floor panel according to the present invention is to provide a method for manufacturing a small number of small-sized floor panels by mechanically processing the upper wall of a metal floor panel body material. A hole is formed, and thereafter, a plurality of pressing punches having a rounded or tapered pressing surface at the distal end are formed by a press-type pressing punch in which a plurality of pressing punches are provided. The periphery is pressed to form a chamfer by plastic deformation.

In the method of manufacturing a perforated floor panel according to the present invention, a large number of first small holes are formed in the upper wall of a metal floor panel main body material by mechanical processing to form a floor panel main body. Then, a finishing material is adhered to and adhered to the front surface of the floor panel body, and thereafter, the finishing material is mechanically processed into a second small hole having substantially the same diameter as the first small hole portion. Part, and thereafter, a pressing punch having a plurality of pressing punches having a round or tapered pressing surface at the tip end thereof is opened by the pressing punch having the front surface side opening of the second small hole portion. The inner peripheral edge is pressed to form a chamfer by plastic deformation.

Further, in the perforated floor panel according to the present invention, a large number of small through holes are formed in the upper wall portion of the metal floor panel main body, and the inner peripheral edge of the small through hole in the surface side opening is plastically deformed. A chamfer is formed. Further, the perforated floor panel according to the present invention is a perforated floor panel comprising a metal floor panel main body and a finishing material laminated on a front surface of the floor panel main body, wherein a top wall of the floor panel main body is provided. A plurality of small through-holes penetrating the portion and the finishing material are formed, and a chamfered portion is formed by plastic deformation on an inner peripheral edge of the opening of the small through-hole on the finishing material side. When the chamfer dimension of the chamfered portion is B, it is preferable to set 0.5 mm ≦ B ≦ 2.0 mm.

[0008]

Embodiments of the present invention will be described below in detail with reference to the drawings.

FIGS. 1 and 2 show a perforated floor panel 1 which can be entirely or completely disposed on a floor for dust prevention, air conditioning, etc. in a clean room, office, computer room, or the like. The floor panel body 2 is partially laid and used, and comprises a metal floor panel body 2 and a finishing material 4 laminated on the front surface 3 of the floor panel body 2. An upper surface wall 5 which forms the surface 3 and a number of small through holes 6 penetrating the finishing material 4 are formed. The floor panel main body 2 includes an upper wall 5, a peripheral wall 7, 8 protruding from the rear surface of the upper wall 5, and large and small ribs 9, 10, and aluminum or aluminum alloy or other material. Of metal. The finishing material 4 is formed of a resin or a plate material containing the resin as a component.

Further, as shown in FIG.
The small through hole 6 has a back side hole 11 formed simultaneously with the casting from the back surface 12 of the upper surface wall portion 5 to a middle portion of the wall thickness, and a small through hole 6.
A first small hole portion 13 formed by mechanical processing from the middle part of the thickness to the surface 3 and having an inner size smaller than the inner size of the back side hole portion 11 in the cross-sectional shape; And a second small hole portion 15 formed in the finishing material 4 by mechanical processing. In this case, the back hole 11 and the first small hole 13 are circular in cross section, and the first small hole 13 has an inner diameter smaller than the inner diameter of the back hole 11.

Then, assuming that the thickness dimension of the upper surface wall portion 5 of the floor panel body 2 is T, 4.0 mm ≦ T ≦ 10.0 mm. In addition, assuming that the dimension in the thickness direction from the front surface 3 of the upper wall portion 5 to the edge of the opening on the back surface side of the first small hole portion 13 is t, 1.
Set 5mm ≤ t ≤ 3.5mm. The reason for setting this value is that if T <4.0 mm, the strength is insufficient and the heavy weight of a large computer or the like on the perforated floor panel 1 cannot withstand a large weight, and 10.0 mm <T. This is because it is difficult to form the first small holes 13 by mechanical processing. If t <1.5 mm, the strength is insufficient, and if 3.5 mm <t, it is difficult to form the first small hole portion 13 by mechanical processing, and the flow of molten metal during casting becomes poor. It is.

When the inside diameter of the back side hole 11 is A and the inside diameter of the first small hole 13 is a, (a + 1.0 mm
) Set A ≦ A ≦ (a + 5.0 mm). More preferably, (a + 1.5 mm) ≦ A ≦ (a + 3.0 mm).
(A + 1.0mm) ≦ A ≦ (a + 5.0mm)
If <(a + 1.0 mm), the back side hole 11 is too small, and it is difficult to make the first side hole 13 coincide with the back side hole 11 when the first side hole 13 is formed. If (a + 5.0 mm) <A, the back side hole 11 becomes too large and the strength of the upper wall 5 is insufficient.

A chamfered portion 14 is formed by plastic deformation on the inner peripheral edge of the opening of the small through hole 6 on the finishing material 4 side. When the chamfer dimension of the chamfered portion 14 is B, 0.5 mm ≦
Set B ≦ 2.0mm. Here, the chamfer dimension is defined as a vertical dimension of the chamfered portion 14. Also,
The reason for setting 0.5 mm ≦ B ≦ 2.0 mm is that if B <0.5 mm, dust (swarf) is generated when a person walks or a trolley runs on the perforated floor panel 1. <
If B, distortion, cracks, and the like occur in the chamfered portion 14 and its vicinity.

Next, a method for manufacturing the perforated floor panel will be described. First, as shown in FIG. 4 (in a state of being installed upside down), a floor panel body material 16 is formed by casting. At this time, concave recesses 17 are formed on the back surface of the upper surface wall portion 5 of the floor panel body material 16 at the positions where the holes are to be drilled at the same time as the casting.

Thereafter, as shown in FIGS. 5 and 6, a number of first small holes 13 are punched by a first punching die 19 having a plurality of punches 18 in the upper surface wall 5 of the floor panel body material 16. Die forming.
That is, many first small holes 13 are formed by mechanical processing (in this case, punching with the punch 18). Chips 22 formed by this punching are formed with holes 23 of receiving mold 21.
Is discharged from

As described above, the floor panel main body 2 shown in FIG. 7 is formed. The floor panel main body 2 has a back side hole 11 formed simultaneously with casting from the back surface 12 of the upper surface wall 5 to the middle of the thickness and a surface 3 from the middle of the thickness of the upper surface wall 5.
And a first small hole portion 13 having an inner dimension smaller than the inner dimension of the back side hole portion 11 in the cross-sectional shape.

Next, as shown in FIG.
The finishing material 4 is adhered to the surface 3 of the above. At this time, the adhesive 24 protrudes into the first small holes 13 of the floor panel main body 2 and hardens as it is.

Then, as shown in FIGS. 9 and 10, the punches 26 of the second punching die 25 are inserted into the first small holes 13 of the floor panel main body 2 from the back surface 12 side. Specifically, of the plurality of punches 26 of the second die 25, the predetermined dimension E is larger than that of the other punches 26b.
At least two guide / punches 26a protruding only
Are inserted into the first small holes 13 before the other punches 26b. As a result, another punch is used by the guide dual-purpose punch 26a.
26b can be guided so as to be smoothly inserted into the plurality of first small holes 13.

Here, the predetermined dimension E is set to 1 mm ≦ E ≦ F, where F is the thickness dimension of the finishing material 4. This is because if E <1 mm, the guide effect of the guide / punch 26a is hardly obtained, and the other punches 26b... This is because the punch 26b may be damaged.
If <E, the predetermined dimension E is too large and the punch 26
This is because the up-and-down stroke becomes large.

The state shown in FIG. 11 is continuously (instantly) obtained from FIG. 10, and as shown in FIG.
The second small holes 15 having substantially the same diameter as 13 are formed by punching. At this time, the plurality of second small holes 15 are punched and formed almost simultaneously with the plurality of punches 26. At the same time as this punching, the first small hole 13
The adhesive 24 that has protruded (after curing) is removed. Then, the adhesive 24 and the dust 27 are discharged from the holes 29 of the receiving mold 28. It is preferable that the interval between at least two guide / punches 26a is large, as shown in FIGS.
Here, only one of the guide and punches 26a is shown. The punch 26 for punching and forming the second small hole portion 15 and the punch 18 for punching and forming the first small hole portion 13 are:
Preferably they are separate, but it is also possible to use the same ones.

Next, as shown in FIGS. 12 and 13, the pressing punches 31 having a plurality of pressing punches 31 having a tapered pressing surface 30 at the tip end are finished by a pressing punch 31. The inner peripheral edge 33 of the surface side opening of the second small hole portion 15 of the material 4 is pressed to form the chamfered portion 14 by plastic deformation. The chamfered portion 14 is a straight inclined surface. Thus, the perforated floor panel 1 shown in FIGS. 1 to 3 is formed.

Thus, according to the perforated floor panel manufacturing method, the first small hole portion 13 of the floor panel main body 2 and the second small hole portion 15 of the finishing material 4 can be accurately matched. In addition, the work of bonding the finishing material 4 to the floor panel body 2 can be performed easily and
It can be carried out quickly and obtains a stable and large adhesive force. In addition, the adhesive 24 protruding into the small through-hole 6 can be reliably removed at the same time as the formation of the second small hole 15. Further, the chamfered portion 14 can be efficiently formed. Also, punches 18 and 26 corresponding to the material of the floor panel body material 16 and the material of the finishing material 4 can be used.
The first and second small holes 13 and 15 can be beautifully formed while the life of the first and second small holes 8 and 26 is extended. By changing the number of the punches 18 and 26 and the pressing punches 31, the number of small through holes 6 can be easily increased / decreased / changed.

Further, even if the thickness of the upper wall 5 of the floor panel main body 2 is increased, the thickness of the bottom wall 20 of the recess 17 becomes relatively small. It can be formed easily and efficiently by processing (mechanical processing). Therefore,
The load bearing capacity of the perforated panel 1 can be significantly increased. Further, for example, among the concave recesses 17 of the floor panel main body material 16, those which do not need to form the small through-holes 6 can be closed as they are without making holes, so that the load bearing capacity can be increased. Can be further increased. In addition, a mold for forming the floor panel body material 16 can be shared, and the number of types of molds can be reduced.

Further, the perforated floor panel 1 comprises a floor panel main body 2.
By increasing the thickness dimension T of the top wall 5 of the above, a large strength enough to withstand the large weight of a large computer or the like can be obtained, and the first small holes 13 can be easily formed by punching. It can be formed by processing. Further, the small through-hole 6 becomes beautiful in appearance. In addition, even if a person walks on the finishing material 4 or a trolley or the like travels, the inner peripheral edge of the opening of the small through hole 6 is not shaved, and no dust is generated. Therefore, it is most suitable for floors such as clean rooms and computer rooms.

Next, FIG. 14 shows another embodiment of the perforated floor panel 1 which comprises only a metal floor panel main body 2. That is, a large number of small through holes 6 are formed in the upper surface wall 5 of the metal floor panel main body 2, and the small through holes 6 are formed simultaneously with the casting from the rear surface 12 of the upper surface wall 5 to the middle part of the thickness. An inner shape that is formed by mechanical processing from the middle part of the thickness of the upper surface wall 5 to the back surface 11 and from the middle portion of the upper surface wall 5 and that is smaller than the inner size of the rear surface hole 11 in the cross-sectional shape. A small hole 34 having dimensions. The back side hole 11 and the small hole 34 are circular. Other configurations are the same as those in FIGS.

A method of manufacturing the perforated floor panel will now be described. First, as shown in FIG. 15, a floor panel main body material 16 is formed by casting. At this time, concave recesses 17 are formed on the back surface of the upper surface wall portion 5 of the floor panel body material 16 at the positions where the holes are to be drilled at the same time as the casting.

Thereafter, as shown in FIGS. 16 and 17, a large number of small holes 34 are punched and formed by a first punching die 19 having a plurality of punches 18 in the upper wall 5 of the floor panel body material 16. I do. That is, the small hole portion 34 penetrating the bottom wall portion 20 is formed in the bottom wall portion 20 of the concave recess portion 17 by mechanical processing (in this case, punching with the punch 18). Chips generated by this punching 22
Are discharged from the holes 23 of the receiving mold 21. As described above, as shown in FIG. 18, the small holes 34 are formed in the floor panel main body material 16.

Next, as shown in FIGS. 19 and 20, the pressing punches 31 having a plurality of pressing punches 31 each having a tapered pressing surface 30 at the tip end are pressed by a pressing punch 31. Hole 34 ...
Are pressed, and the chamfered portions 14 are formed by plastic deformation. The chamfered portion 14 is a straight inclined surface. Thus, the perforated floor panel 1 shown in FIG. 14 is formed.

According to the perforated floor panel manufacturing method and perforated floor panel, the perforated floor panel can be manufactured more efficiently. In particular, the chamfered portion 14 can be formed efficiently. Further, since no finishing material is used, it can be applied to painting, plating, or other surface treatments. And floor panel body material
16 can also be used for floor panels without small through holes. In that case, the recesses 17 may be left closed. Also, when casting the floor panel body material 16,
(Because the small through-holes 6 are not formed at the same time), the molten metal easily flows in the casting mold, so that casting is easy and the occurrence rate of defective products is reduced.

The pressing surfaces 30 of the pressing punches 31 are preferably not only tapered but also rounded as shown in FIG. Specifically, FIG. 21A shows the pressing surface 30
Has a concave round shape, and the chamfered portion 14 has a mountain-shaped round surface. In FIG. 21B, the pressing surface 30 has a convex round shape, and the chamfered portion 14 has a concave round surface. As a method of forming the small holes 34 by mechanical processing, a punch is used.
In addition to the punching by 18, drilling by a drill may be used in some cases.

The shape of the small through hole 6 is not limited to a circle, but may be an ellipse, an ellipse, a square, a rectangle as shown in FIGS. 22 (a), (b), (c), (d) and (e). , A cross shape, or any other shape. In that case, the cross-sectional shapes of the punches 18 and 26 and the pressing punch 31 may be set to desired shapes.

[0032]

Since the present invention is configured as described above, the following effects can be obtained.

According to the method of manufacturing a perforated floor panel according to the first aspect, a large number of small holes 34 in the upper wall 5 of the floor panel body material 16.
In addition, the chamfered portions 14 can be efficiently formed (the chamfered portions 14 can be simultaneously formed in many small holes 34). Therefore, the working efficiency is improved, and the processing time can be greatly reduced, so that the perforated floor panel can be mass-produced. Further, since no dust (swarf) is generated, equipment and products are less likely to become dirty, and maintenance of the equipment becomes easier. According to the method for manufacturing a perforated floor panel according to the second aspect, the chamfered portion 14 can be efficiently formed in the second small hole portion 15 of the finishing material 4 on the front surface 3 side of the floor panel body 2 (many). The chamfered portion 14 can be simultaneously formed in the second small hole portion 15). Therefore, the working efficiency is improved, and the processing time can be greatly reduced, so that the perforated floor panel can be mass-produced. Further, since no dust (swarf) is generated, equipment and products are less likely to become dirty, and maintenance of the equipment becomes easier.

According to the perforated floor panel of the third aspect, the chamfered portion is formed by plastic deformation.
And the vicinity thereof become hard, so that even if a person walks or a trolley runs on the perforated floor panel, the inner peripheral edges of the small through holes 6 are hardly worn, and no dust (scrapings) is generated. Therefore, it is most suitable for floors of clean rooms, computer rooms, offices and the like. According to the perforated floor panel according to claim 4, since the chamfered portion 14 is formed by plastic deformation, the chamfered portion 14 and its vicinity are hardened, and even when a person walks or a bogie runs on the perforated floor panel. The inner peripheral edge of the opening of the small through hole 6 is hardly worn, and no dust (shavings) is generated. Therefore, it is most suitable for floors of clean rooms, computer rooms, offices and the like. Further, since the finishing material 4 is exposed on the floor surface, the appearance is beautiful.

According to the perforated floor panel according to the fifth aspect, generation of dust (swarf) due to walking of a person or running of a bogie is prevented.
Can be effectively prevented. In addition, no distortion, crack, or the like occurs in the chamfered portion 14 and its vicinity, and the appearance is further improved.

[Brief description of the drawings]

FIG. 1 is a plan view showing an embodiment of a perforated floor panel of the present invention.

FIG. 2 is an enlarged sectional view of a main part.

FIG. 3 is a sectional view further enlarged.

FIG. 4 is an enlarged sectional view of a main part of a floor panel body material.

FIG. 5 is a cross-sectional view just before punching out a small hole.

FIG. 6 is a cross-sectional view immediately after punching out a small hole.

FIG. 7 is an enlarged sectional view of a main part of the floor panel main body.

FIG. 8 is a cross-sectional view showing a state in which a finishing material is adhered to the holed floor panel main body.

FIG. 9 is a cross-sectional view just before punching and forming a second small hole portion in a finishing material.

FIG. 10 is a cross-sectional view of a state where a guide / punch is inserted into the small hole.

FIG. 11 is a cross-sectional view immediately after a second small hole is punched and formed in the finishing material.

FIG. 12 is a cross-sectional view immediately before forming a chamfer.

FIG. 13 is a cross-sectional view illustrating a state in which a chamfer is formed.

FIG. 14 is a plan view showing another embodiment of the perforated floor panel of the present invention.

FIG. 15 is an enlarged sectional view of a main part of a floor panel body material.

FIG. 16 is a cross-sectional view immediately before punching out a small hole.

FIG. 17 is a cross-sectional view immediately after punching out a small hole.

FIG. 18 is a cross-sectional view showing a state where punching of a small hole portion is completed.

FIG. 19 is a cross-sectional view immediately before forming a chamfer.

FIG. 20 is a cross-sectional view of a state where a chamfer is formed.

FIG. 21 is a cross-sectional view illustrating a modification of the pressing punch and the chamfer.

FIG. 22 is an enlarged plan view showing a modification of the small through hole.

[Explanation of symbols]

 2 Floor panel body 3 Front surface 4 Finishing material 5 Top wall 6 Small through hole 13 First small hole 14 Chamfered part 15 Second small hole 16 Floor panel body material 30 Press surface 31 Press punch 32 Press mold 33 Inner edge of front opening 34 Small hole 35 Front inner edge of opening B B chamfer dimension

Claims (5)

[Claims] An upper wall portion of a metal floor panel body material.
, A large number of small holes 34 are formed by mechanical processing, and thereafter, a plurality of pressing punches 31 having a round or tapered pressing surface 30 at the distal end thereof are provided with a plurality of pressing dies 31. With the pressing punches 31, the inner peripheral edge of the opening on the surface side of the small holes 34.
A method for manufacturing a light-perforated floor panel, characterized in that a chamfered portion 14 is formed by plastic deformation by pressing 35. 2. The upper wall portion 5 of the metal floor panel body material 16.
Then, a large number of first small holes 13 are formed by mechanical processing to form the floor panel main body 2, and then the finishing material 4 is adhered to the front surface 3 of the floor panel main body 2. After that, a second small hole portion 15 having substantially the same diameter as the first small hole portion 13 is formed in the finishing material 4 by mechanical processing, and then a round or tapered pressing surface 30 is formed. The pressing punches 31 of the press die 32 having a plurality of pressing punches 31... Provided at the distal end thereof press the inner peripheral edge 33 of the surface side opening of the second small hole portion 15 to be plastically deformed. A method for producing a light-perforated floor panel, wherein a chamfered portion 14 is formed. 3. An upper wall portion 5 of a metal floor panel main body 2,
A plurality of small through-holes 6 are formed, and a chamfered portion 14 is formed by plastic deformation on the inner peripheral edge of the front side opening of the small through-hole 6. 4. A perforated floor panel comprising a metal floor panel main body 2 and a finishing material 4 laminated on a front surface 3 of the floor panel main body 2, wherein a top wall portion of the floor panel main body 2 is provided. 5 and a number of small through-holes 6 penetrating the finishing material 4,
A perforated floor panel in which a chamfered portion 14 is formed by plastic deformation on the inner peripheral edge of the finishing material side opening of the small through hole 6. 5. The perforated floor panel according to claim 3, wherein 0.5 mm ≦ B ≦ 2.0 mm when the chamfer dimension of the chamfered portion 14 is B.