Floor panel

Abstract

To provide a floor panel that solves the problem of a conventional floor panel, is easily manufactured, excellent in workability, and has a sufficient sound insulation property, and further excellent in recyclability.SOLUTION: A floor panel according to the present invention comprises a metallic upper plate at a top, and a metallic bottom plate with a marginal part erected upward around its periphery at a bottom, a side wall that is formed by a marginal part of the bottom plate by joining peripheries of the upper plate and the bottom plate, and an internal space that is formed between the upper plate and the bottom plate. In the floor panel, a plaster board with a thickness corresponding to height of the internal space is arranged in the internal space. Preferably, a buffer member to fill a clearance may be provided in the clearance between a periphery of the plaster board arranged in the internal space and a marginal part inner surface of the bottom plate.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] In particular, the present invention relates to an improvement in floor panels used in a double floor structure. [Background technology]

[0002] Conventionally, a double floor structure has been used in which support legs are provided on a floor frame and floor panels are placed on the support legs in order to make effective use of indoor space by accommodating piping and wiring under the floor. The floor panel used here is a floor panel formed by joining the periphery of a steel upper plate and a bottom plate, and there is known such a floor panel in which mortar is filled inside, i.e., between the upper plate and the bottom plate (see Patent Document 1, especially Figures 1 and 2). In a floor panel configured in this way, the mortar filled inside serves as the core material of the floor panel. Also known is a floor panel that uses plywood made by stacking a plurality of veneers as a core material (see Patent Document 2, especially Figures 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-280242 [Patent Document 2] JP 2011-140856 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, the conventional floor panels filled with mortar as described above have the advantage that the filled mortar functions as a core material, so that it is possible to secure sufficient rigidity and sound insulation, but they have the problem that it takes a long time to manufacture because mortar must be filled in. In particular, after filling with mortar, it is necessary to wait until it hardens, and during that time, the curing cannot be removed, which results in a long curing period. Furthermore, since the mortar is integrated with the top and bottom panels of the floor panel after filling with mortar, dismantling is very difficult when discarding the panel, which also poses the problem of poor recyclability. Furthermore, floor panels that use plywood, made by layering multiple veneers, as the core material have the advantages of being lighter in weight and easier to recycle than floor panels that use mortar as the core material, but they have the problem of lower sound insulation performance than floor panels that use mortar as the core material. An object of the present invention is to solve the above-mentioned problems of conventional floor panels and to provide a floor panel which is easy to manufacture, has good workability, has sufficient sound insulation properties, and is also easily recyclable. [Means for solving the problem]

[0005] In order to achieve the above-mentioned object, the floor panel of the present invention is characterized in that a metal upper plate and a metal bottom plate having a peripheral portion rising upward around the periphery are arranged one above the other, and by joining the periphery of the upper plate and the bottom plate, the peripheral portion of the bottom plate forms a side wall, and an internal space is formed between the upper plate and the bottom plate, and a gypsum board having a thickness corresponding to the height of the internal space is arranged in the internal space. Preferably, a buffer member may be provided in a gap between the periphery of the gypsum board disposed in the internal space and the inner surface of the peripheral edge of the bottom plate to fill the gap. The buffer member may be separate from the top plate and the bottom plate, or may be formed integrally with the top plate, or may be formed integrally with the bottom plate. Furthermore, if necessary, an adhesive sheet that adheres to the upper plate and / or the bottom plate may be provided on the upper surface and / or the bottom surface of the gypsum board. Effect of the Invention

[0006] The floor panel of the present invention comprises a metal upper plate and a metal bottom plate having a peripheral portion rising upward around the periphery thereof, which are arranged one above the other, and the peripheral portion of the bottom plate forms a side wall by joining the periphery of the metal upper plate and the metal bottom plate, and an internal space is formed between the upper plate and the bottom plate.Since a plasterboard having a thickness corresponding to the height of the internal space is arranged in the internal space, no work is required to fill it with mortar, and no hardening time is required, making it easy to install, and it has sufficient sound insulation.Furthermore, since it consists of an upper plate, a bottom plate, and a plasterboard, it is easy to disassemble and has high recyclability. In addition, by providing a cushioning material to fill the gap between the periphery of the gypsum board placed in the internal space and the inner surface of the peripheral portion of the bottom plate, the gypsum board does not move within the floor panel, making manufacturing easy. Furthermore, by constructing the buffer member as a separate body from the top plate and bottom plate, it becomes possible to easily apply the buffer member to existing mortar-filled floor panels. Furthermore, by forming the buffer member integrally with the top plate or bottom plate, gaps in the internal gypsum board can be filled in during the process of assembling the top plate and bottom plate, making manufacturing extremely easy. Furthermore, by providing an adhesive sheet on the top and / or bottom surface of the gypsum board that adheres to the top plate and / or bottom plate, the gypsum board does not move during manufacturing, making manufacturing easier. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1(a) is a plan view of a floor panel according to the present invention, and FIG. 1(b) is a cross-sectional view taken along line AA of FIG. [Diagram 2] FIG. 1(b) is an enlarged view of a portion indicated by a circle X in FIG. [Figure 3(a)] 3 is an enlarged cross-sectional view corresponding to FIG. 2, illustrating an assembly process of the floor panel shown in FIG. 1. [Figure 3(b)] 3 is an enlarged cross-sectional view corresponding to FIG. 2, illustrating an assembly process of the floor panel shown in FIG. 1. [Figure 3(c)] 3 is an enlarged cross-sectional view corresponding to FIG. 2, illustrating an assembly process of the floor panel shown in FIG. 1. [Figure 3(d)] 3 is an enlarged cross-sectional view corresponding to FIG. 2, illustrating an assembly process of the floor panel shown in FIG. 1. [Figure 3(e)] 3 is an enlarged cross-sectional view corresponding to FIG. 2, illustrating an assembly process of the floor panel shown in FIG. 1. [Figure 4(a)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a second embodiment of the floor panel according to the present invention. [Figure 4(b)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a second embodiment of the floor panel according to the present invention. [Figure 4(c)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a second embodiment of the floor panel according to the present invention. [Figure 4(d)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a second embodiment of the floor panel according to the present invention. [Figure 5(a)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a third embodiment of a floor panel according to the present invention. [Figure 5(b)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a third embodiment of a floor panel according to the present invention. [Figure 5(c)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a third embodiment of a floor panel according to the present invention. [Figure 5(d)] 3 is an enlarged cross-sectional view corresponding to FIG. 2 showing an assembly process of a third embodiment of a floor panel according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, an embodiment of a floor panel according to the present invention will be described with reference to the accompanying drawings. FIG. 1(a) is a plan view of a floor panel according to the present invention, FIG. 1(b) is a cross-sectional view taken along line AA of FIG. 1(a), and FIG. 2 is an enlarged view of a portion of circle X in FIG. 1(b). In the drawings, reference numeral 1 denotes a floor panel, which includes a metal upper plate 2, a metal bottom plate 3, a plaster board 4, and a buffer member 5. Although not shown in Figs. 1 and 2, adhesive sheets 6 and 7 (see Fig. 3) are provided on the top and bottom surfaces of the plaster board 4, respectively. 2, the bottom plate 3 has a peripheral edge 3a rising upward on its outer periphery and a flange 3b extending substantially horizontally outward from the upper end of the peripheral edge 3a. The peripheral edge 3a forms the side wall of the completed floor panel 1. The buffer member 5 has a buffer portion 5a that fills the gap S between the inner surface of the peripheral portion 3a of the bottom plate 3 and the side surface of the gypsum board 4, and a flange portion 5b that extends substantially horizontally outward so as to overlap with the flange portion 3b of the bottom plate 3. The buffer portion 5a is configured by bending it into a U-shaped cross section, and its end portion is bent outward to form a guide portion 5c when the gypsum board 4 is placed. The upper plate 2 has a dimension at least larger outward than the flange portion 3b of the bottom plate 3, and is bent so as to cover the flange portion 3b of the bottom plate 3 and secured by crimping. Hereinafter, the assembly process of the floor panel shown in FIGS. 1 and 2 will be described with reference to FIG. First, the cushioning member 5 is placed inside the bottom plate 3 so that the cushioning portion 5a is along the inner periphery of the peripheral portion 3a and the flange portion 5b is placed on the flange portion 3b of the bottom plate 3 (FIGS. 3(a) and (b)). Next, with the adhesive sheets 6 and 7 placed on the top and bottom surfaces, the gypsum board 4 is placed inside the buffer member 5 (see Figs. 3(b) and (c)). At this time, because the end of the buffer portion 5a in the buffer member 5 forms the guide portion 5c, the gypsum board 4 is naturally guided to an appropriate position by the guide portion 5c when the gypsum board 4 is placed. In addition, because the buffer portion 5a is configured by bending it into a U-shaped cross section, it can be deformed appropriately according to the size of the gypsum board 4, and slight dimensional differences due to manufacturing errors in the gypsum board 4 can be absorbed by the deformation of the buffer portion 5a. Finally, the upper plate 2 is placed on top of the plaster boat 4 (adhesive sheet 6) and the flange portion 5b of the cushioning member 5 (Figures 3(c) and (d)), and then the outer periphery of the upper plate 2 is folded so as to sandwich the flange portion 5b of the cushioning member 5 and the flange portion 3b of the bottom plate 3, and crimped to complete the floor panel 1 (see Figures 3(d) and (e)). According to the floor panel 1 configured as described above, the gypsum board 4 arranged in the internal space S between the upper plate 2 and the bottom plate 3 is held down by the buffer member 5, thereby achieving the effect of making it possible to manufacture the floor panel 1 without any special processing or steps, and without the gypsum board 4 moving in the internal space S. Furthermore, by using the gypsum board 4 as the core material, all of the problems associated with filling with mortar are resolved, making it possible to obtain sufficient strength and sound insulation. According to this embodiment, the gypsum board 4 does not move during manufacturing because the cushioning member 5 can hold down the gypsum board 4. Therefore, the adhesive sheets 6 and 7 are used supplementarily and are not essential.

[0009] Next, a second embodiment of the floor panel according to the present invention will be described with reference to FIG. 4(a) to (d) are enlarged cross-sectional views corresponding to FIG. 2 of the first embodiment, illustrating the assembly process of a second embodiment of a floor panel according to the present invention. In particular, as shown in FIG. 4(a), in this second embodiment, the buffer member 15 is formed integrally with the bottom plate 13. As shown in FIG. 4(d), in this second embodiment, the floor panel 10 includes an upper plate 12, a bottom plate 13 with which a buffer member 15 is integrally formed, and a plaster board 14. The cushioning member 15 has an outer peripheral portion of the bottom plate 13 folded back along the flange portion 13b of the bottom plate 13 and the upwardly rising peripheral edge portion 13a, and further has a cushioning portion 15a with a U-shaped cross section that rises upward from the peripheral edge portion 13a inward at a predetermined interval, and a guide portion 15c is formed at the end of the cushioning portion 15a, as in the first embodiment. According to the floor panel 10 of the second embodiment configured as described above, the plaster board 14 is placed inside the buffer member 15 of the bottom plate 13 (Figures 4(a) and (b)), then the upper plate 12 is placed on top of the plaster board 14 and the bottom plate 13 (Figures 4(b) and (c)), and finally, the outer periphery of the upper plate 12 is folded so as to sandwich the flange portion 13b of the bottom plate 13 and crimped to complete the assembly (Figures 4(c) and (d)). According to the floor panel 10 of the second embodiment described above, in addition to the effects obtained with the floor panel 1 of the first embodiment, since the cushioning member 15 is formed integrally with the bottom plate 13, the number of steps for positioning the cushioning member 15 is reduced and the number of parts is also reduced, resulting in easier manufacturing.

[0010] Finally, with reference to FIG. 5, a third embodiment of the floor panel according to the present invention will be described. 5(a) to (d) are enlarged cross-sectional views corresponding to FIG. 2 of the first embodiment, illustrating the assembly process of a third embodiment of a floor panel according to the present invention. In particular, as shown in FIG. 5(b), in this third embodiment, the buffer member 25 is formed integrally with the upper plate 22. As shown in FIG. 5(d), in this third embodiment, the floor panel 20 includes an upper plate 22 with a buffer member 25 integrally formed therewith, a bottom plate 23, and a plaster board 24. The cushioning member 25 has a cushioning portion 25a that is formed with a U-shaped cross section so as to rise along the bottom surface and peripheral portion 23a of the bottom plate 23 during assembly, after the outer circumferential portion of the upper plate 22 is folded inward and then downward. According to the floor panel 20 of the third embodiment configured as described above, a plaster board 24 is placed on the bottom plate 23 (Figures 5(a) and (b)), then the upper plate 22 is placed on top of the plaster board 24 and the bottom plate 23 so that its buffer portion 25a fits between the outer periphery of the plaster board 24 and the inner surface of the peripheral portion 23a of the bottom plate 23 (Figures 5(b) and (c)), and finally, the outer periphery of the upper plate 22 is folded so as to sandwich the flange portion 23b of the bottom plate 23 and crimped to complete the structure (Figures 5(c) and (d)). According to the floor panel 20 of the third embodiment described above, in addition to the effects obtained with the floor panel 1 of the first embodiment, since the cushioning member 25 is formed integrally with the upper plate 23, the number of steps for positioning the cushioning member 25 is reduced and the number of parts is also reduced, resulting in easier manufacture. [Explanation of symbols]

[0011] 1 Floor Panel 2. Top plate 3 Bottom plate 3a Periphery 3b Flange part 4. Gypsum board 5. Cushioning materials 5a Buffer 5b Flange part 5c Guide section 10 Floor Panel 12 Upper Plate 13 Bottom plate 13a Periphery 13b Flange part 14. Gypsum board 15 Cushioning material 15a Buffer section 15c Guide section 20 Floor Panel 22 Upper Board 23 Bottom plate 23a Periphery 23b Flange part 24. Gypsum board 25 Cushioning material 25a Buffer section

Claims

1. A floor panel in which a metal upper plate and a metal bottom plate having a peripheral portion rising upward from the periphery thereof are arranged one above the other, and the peripheral portions of the metal upper plate and the metal bottom plate are joined together, so that the peripheral portion of the bottom plate forms a side wall and an internal space is formed between the upper plate and the bottom plate, A gypsum board having a thickness corresponding to the height of the internal space was placed in the internal space. A floor panel characterized by:

2. A buffer member is provided in the gap between the periphery of the gypsum board arranged in the internal space and the inner surface of the peripheral portion of the bottom plate to fill the gap.

2. A floor panel according to claim 1.

3. 3. The floor panel according to claim 2, wherein the cushioning member is separate from the upper plate and the bottom plate.

4. 3. The floor panel according to claim 2, wherein the cushioning member is formed integrally with the upper plate.

5. 3. The floor panel according to claim 2, wherein the cushioning member is formed integrally with the bottom plate.

6. 2. The floor panel according to claim 1, wherein an adhesive sheet is provided on the top and / or bottom surface of the gypsum board for adhering to the top plate and / or bottom plate.

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