Floor structure

Abstract

To provide a floor structure suppressing swell of a surface thereof.SOLUTION: A floor structure 10 is provided with substrate layers 50, a surface layer 70, and a boding layer 60 arranged between the substrate layers 50 and the surface layer 70. The substrate layers 50 are formed to be aligned by abutting side surfaces 20T of a plurality of resin hollow plate members 20 to each other, and the hollow plate member 20 has linear expansion coefficient larger than that of the surface layer 70, and the substrate layers 50 are aligned so as to make gaps between the side surfaces 20T of the hollow plate members 20 adjacent to each other.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a floor structure provided in a building. [Background technology]

[0002] Hollow board materials are sometimes used as the internal structural material for flooring in buildings, such as gymnasiums, judo and kendo halls, fitness studios, rehabilitation facilities, etc. Hollow board materials with an internal hollow structure have appropriate rigidity and elasticity, as well as uniform hardness throughout, making them ideal for use in floor structures where various types of exercise are carried out.

[0003] Patent Document 1 describes a floor structure in which multiple rectangular hollow synthetic resin boards are fixed with adhesive onto the concrete of a building, and a synthetic resin flooring material is fixed with adhesive onto the hollow boards. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2022-94741 Summary of the Invention [Problem to be solved by the invention]

[0005] By the way, synthetic resin hollow boards have their own linear expansion coefficients depending on the material and structure. Similarly, synthetic resin flooring materials also have their own linear expansion coefficients depending on the material and structure. Therefore, the amount of deformation between the hollow boards and the flooring material may differ depending on the temperature change of the surrounding environment. In particular, when the linear expansion coefficient of multiple hollow boards arranged on the inner layer side is large, the amount of deformation of the hollow boards on the inner layer side is larger than the amount of deformation of the flooring material on the surface layer side, and the sides of the hollow boards press against each other under the flooring material. As a result, the butted parts of the sides of the hollow boards rise up, and partial rises are formed in the surface flooring material as well. This causes an undesirable situation in which the aesthetics of the floor structure are deteriorated. [Means for solving the problem]

[0006] In order to solve the above problems, the present invention provides a floor structure comprising a base layer, a surface layer, and an adhesive layer provided between the base layer and the surface layer, wherein the base layer is formed by arranging a plurality of resin hollow plate materials so that their sides face each other, the hollow plate materials having a larger linear expansion coefficient than the surface layer, and the base layer is formed by arranging the hollow plate materials so that there is a gap between the sides of adjacent hollow plate materials.

[0007] In the above configuration, it is preferable that the adhesive layer has a main adhesive portion provided between the base layer and the surface layer, and a side adhesive portion that penetrates into the gap. In the above configuration, it is preferable that the hollow plate material has a plurality of cells partitioned by side wall portions extending in the thickness direction, and the adhesive layer has an internal adhesive portion extending from the side adhesive portion and penetrating into the inside of the cell. Effect of the Invention

[0008] According to the present invention, it is possible to suppress the rise of the surface of the floor structure. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic cross-sectional view of the floor structure of this embodiment. [Diagram 2] FIG. 2 is an enlarged partial cross-sectional view of the floor structure. [Diagram 3] Fig. 3(a) is a plan view showing the arrangement of cushion material sheets, Fig. 3(b) is a plan view showing the arrangement of hollow boards, and Fig. 3(c) is a plan view showing the arrangement of floor material sheets. [Figure 4] 4(a) to 4(c) are diagrams illustrating the structure of the hollow plate material. [Diagram 5] 5(a) to 5(c) are diagrams illustrating a method for manufacturing a hollow plate material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] <About floor structure 10> Hereinafter, a floor structure 10 for forming the floor of a gymnasium will be described as one embodiment of the present invention. Note that the floor structure 10 in this embodiment means a structure formed on the ground and does not include the ground.

[0011] As shown in Fig. 1, the floor structure 10 of this embodiment is structured by stacking the following on the ground from the bottom: moisture-proof sheet 11, heat insulating material 12, concrete 13, adhesive layer 14, cushion layer 30, adhesive layer 40, base layer 50, adhesive layer 60, and surface layer 70. Note that Fig. 1 is a schematic cross-sectional view for explaining the stacked structure of each member, and the thickness of each member is not shown in detail. In addition, the sheet is not limited to a deformable sheet that can be rolled up, but also includes a sheet that is hard and does not deform or is difficult to deform.

[0012] The ground is made of soil having a certain area formed by digging into the ground to a certain depth, and the top surface is leveled to a certain degree. A moisture-proof sheet 11 is laid on the ground. The moisture-proof sheet 11 is laid on the ground to protect structures such as concrete 13 from moisture in the ground. As the moisture-proof sheet 11, a sheet having a known moisture-proof function, such as a polyethylene sheet, can be used. The thickness of the moisture-proof sheet 11 is not particularly limited as long as it can exhibit the moisture-proof function. A typical polyethylene sheet having a thickness of 0.1 to 2.0 mm can be used.

[0013] The heat insulating material 12 is laid on the moisture-proof sheet 11. The heat insulating material 12 is laid above the ground to prevent heat from the ground from directly acting on structures such as concrete 13. As the heat insulating material 12, a known heat insulating material 12 such as a sheet-shaped material or a panel-shaped material such as expanded polystyrene can be used. The thickness of the heat insulating material 12 is not particularly limited and may be determined according to the material used. In the case of expanded polystyrene, a material having a thickness of 10 to 100 mm can be used.

[0014] Concrete 13 is formed on top of the heat insulating material 12. Concrete 13 is composed of floor concrete 13a and leveling material 13b formed on top of it. Note that although reinforcing bars are arranged inside the floor concrete 13a poured on the gymnasium floor, reinforcing structures such as reinforcing bars are not shown in FIG. 1. Floor concrete 13a is a type of floor concrete that is generally used as a base for finishing floors in gymnasiums. The thickness of floor concrete 13a can be in the range of 12 to 30 cm, and preferably about 15 to 20 cm.

[0015] A leveling material 13b is layered on the top surface of the concrete floor 13a. Generally, when the concrete floor 13a is poured, the top surface becomes uneven, and it is difficult to ensure the levelness and smoothness of the top surface with the concrete floor 13a alone. Therefore, a highly fluid leveling material 13b is poured into the top surface of the concrete floor 13a to a certain thickness, and is integrated with the concrete floor 13a to achieve the levelness and smoothness of the top surface.

[0016] The leveling material 13b used is not particularly limited, and any known self-leveling material 13b such as cement or mortar can be used. The thickness of the leveling material 13b is not particularly limited, but can be in the range of 1 to 3 cm to achieve levelness and smoothness on the concrete floor 13a. The leveling material 13b makes the top surface of the concrete 13 horizontal and smooth.

[0017] The adhesive layer 14 is a layer that bonds and fixes the concrete 13 and the cushion layer 30. The material of the adhesive that forms the adhesive layer 14 is not particularly limited as long as it can bond and fix the two together. For example, a urethane adhesive, an epoxy adhesive, a silicone adhesive, a vinyl adhesive, a rubber adhesive, an acrylic adhesive, etc. can be used. The adhesive layer 14 may be applied and attached in a manner similar to double-sided tape, in which the material that constitutes the adhesive is disposed on both sides of the base material.

[0018] The cushion layer 30 is a layer that imparts elasticity to the floor structure 10. The thickness of the cushion layer 30 (the length in the vertical direction in FIG. 1) is not particularly specified, but a thickness of 5 mm or more is preferable in order to impart cushioning properties. The cushion layer 30 refers to a porous body in which air is formed inside the structure. A resin foam can be used as the cushion layer 30. Polyurethane foam is preferable as the resin foam. In particular, from the standpoint of cost, chip urethane foam, which is a recycled product made by crushing and remolding polyurethane foam scraps, is preferable, and the cushion layer 30 of this embodiment is formed from chip urethane foam.

[0019] As shown in Fig. 3(a), the cushion layer 30 is composed of a plurality of cushion material sheets 30S. Each cushion material sheet 30S is a rectangular plate with a long side of 2000 mm, a short side of 1200 mm, and a thickness of 8 mm. As shown in Fig. 1 and Fig. 3(a), the plurality of cushion material sheets 30S are laid on the concrete 13 with the side surfaces 30T of adjacent cushion material sheets 30S butting against each other.

[0020] The adhesive layer 40 is a layer that bonds and fixes the cushion layer 30 and the base layer 50 together. The material of the adhesive that forms the adhesive layer 40 is not particularly limited as long as it can bond and fix the two together, and examples of the material include the same materials as those of the adhesive layer 14. The material of the adhesive that forms the adhesive layer 40 is preferably one that is elastic in a solidified state. The adhesive layer 40 is formed by applying an adhesive onto the cushion layer 30. There is no particular limit to the method of applying the adhesive.

[0021] The base layer 50 is formed of a hollow plate material 20 made of a thermoplastic resin, as shown in Fig. 4. The hollow plate material 20 is a hollow structure having a plurality of cells S arranged side by side inside. The structure of the hollow plate material 20 will be described later.

[0022] The base layer 50 of this embodiment is composed of a plurality of hollow plate materials 20. Each hollow plate material 20 has a rectangular plate shape with long sides of 1800 mm, short sides of 900 mm, and a thickness of 3 to 30 mm.

[0023] As shown in Figs. 1, 2 and 4(b), the hollow plate materials 20 constituting the base layer 50 are laid on the cushion layer 30 with the side surfaces 20T of adjacent hollow plate materials 20 butted against each other. The hollow plate materials 20 are laid so that gaps G are formed between the side surfaces 20T of adjacent hollow plate materials 20. The base layer 50 of this embodiment is formed in such a manner that the gaps G intersect in a cross shape when the floor structure 10 is viewed from above. The width of the gaps G is smaller than the thickness of the hollow plate materials 20, about 2 mm. The gaps G are formed at approximately the same intervals in the thickness direction of the base layer 50 so as to extend in the thickness direction of the base layer 50.

[0024] The adhesive layer 60 is a layer that bonds and fixes the base layer 50 and the surface layer 70. The material of the adhesive forming the adhesive layer 60 is not particularly limited as long as it can bond and fix the two together, and examples of the adhesive include the same materials as those of the adhesive layers 14 and 40. The adhesive material forming the adhesive layer 60 is preferably elastic in a solidified state, similar to the adhesive layer 40. The adhesive layer 60 is formed by applying an adhesive onto the base layer 50. There is no particular limit to the method of applying the adhesive.

[0025] As shown in FIG. 2, the adhesive layer 60 has an adhesive main body 61, a side adhesive portion 62, and an internal adhesive portion 63. The adhesive main body 61 is a portion provided between the base layer 50 and the surface layer 70. The side adhesive portion 62 is a portion that enters the gap G and bonds the side surfaces 20T of adjacent hollow plate materials 20 together. The internal adhesive portion 63 is a portion that enters the inside of the cell S that constitutes the hollow plate material 20. The side adhesive portion 62 extends from the adhesive main body 61 and is formed integrally with the adhesive main body 61. Moreover, the internal adhesive portion 63 extends from the side adhesive portion 62 and is formed integrally with the side adhesive portion 62.

[0026] The surface layer 70 is a layer located on the top surface of the floor structure 10 and serves as a design surface. The material of the surface layer 70 is not particularly limited. It can be made of synthetic resin, which is generally used as a floor material for indoor sports facilities, or a multi-layered version of such a material. The surface layer 70 of this embodiment is composed of multiple flooring sheets 70S. The flooring sheet 70S has a multi-layered structure mainly composed of polyvinyl chloride sheets. Specifically, it is formed as a composite sheet layer including a polyvinyl chloride sheet, a urethane coating layer on the front side of the polyvinyl chloride sheet, and a high-density sponge layer on the back side of the polyvinyl chloride sheet. The flooring sheet 70S is long with a long side of 1800 mm, a short side of 150 mm, and a thickness of 10 to 20 mm.

[0027] As shown in FIG. 3(c), the multiple flooring sheets 70S constituting the surface layer 70 are laid out in a lattice or staggered pattern on the base layer 50 with the sides 70T of adjacent flooring sheets 70S butted against each other.

[0028] The linear expansion coefficient of the flooring sheet 70S constituting the surface layer 70 is smaller than the linear expansion coefficient of the hollow board material 20 constituting the base layer 50. <About the hollow plate material 20> Next, the hollow plate material 20 that forms the base layer 50 of the floor structure 10 will be described.

[0029] 4(a), the hollow plate material 20 of this embodiment includes a core layer 21 having a plurality of cells S arranged side by side therein, a skin layer 22 joined to an upper surface 21a of the core layer 21, and a skin layer 23 joined to a lower surface 21b of the core layer 21. In the following description, the hollow plate material 20 and the core layer 21 will be described with the side to which the skin layer 22 is joined as the upper side and the side to which the skin layer 23 is joined as the lower side.

[0030] As shown in Fig. 4(b), Fig. 4(c), and Fig. 5, the core layer 21 is formed by folding one sheet material 100 obtained by forming a thermoplastic resin sheet into a predetermined shape. The core layer 21 is composed of an upper wall portion 24, a lower wall portion 25, and a side wall portion 26 that is erected between the upper wall portion 24 and the lower wall portion 25 and forms a hexagonal cylindrical wall portion. The upper wall portion 24, the lower wall portion 25, and the side wall portion 26 define and form hexagonal columnar cells S inside the core layer 21. As described below, the upper wall portion 24 and the lower wall portion 25 of the core layer 21 have a structure in which a one-layer structure and a two-layer structure are mixed, but in Fig. 4(a), the upper wall portion 24 and the lower wall portion 25 of the core layer 21 are shown as a one-layer structure.

[0031] As shown in Figures 4(b) and 4(c), the cells S partitioned and formed inside the core layer 21 include a first cell S1 and a second cell S2 having different structures. As shown in Figure 4(b), in the first cell S1, a two-layered upper wall portion 24 is provided on the upper part of the side wall portion 26. The layers of this two-layered upper wall portion 24 are bonded to each other. In addition, an opening (not shown) is formed in the two-layered upper wall portion 24 due to thermal contraction of the thermoplastic resin during molding of the core layer 21. In the first cell S1, a one-layered lower wall portion 25 is provided on the lower part of the side wall portion 26.

[0032] On the other hand, as shown in Fig. 4(c), in the second cell S2, a single-layered upper wall 24 is provided on the upper part of the side wall 26. In the second cell S2, a two-layered lower wall 25 is provided on the lower part of the side wall 26. The layers of the two-layered lower wall 25 are bonded to each other. An opening (not shown) is formed in the two-layered lower wall 25 due to thermal contraction of the thermoplastic resin when the core layer 21 is molded.

[0033] 4(b) and 4(c), adjacent first cells S1 and adjacent second cells S2 are partitioned by sidewalls 26 having a two-layer structure. The two-layer sidewalls 26 have portions that are not heat-welded to each other in the center in the thickness direction of the core layer 21. Therefore, the internal space of each cell S of the core layer 21 communicates with the internal spaces of the other cells S through the two-layer sidewalls 26.

[0034] As shown in Fig. 4(a), the first cells S1 are arranged in a row along the X direction. Similarly, the second cells S2 are arranged in a row along the X direction. The rows of the first cells S1 and the rows of the second cells S2 are alternately arranged in the Y direction perpendicular to the X direction. The first cells S1 and the second cells S2 form a honeycomb structure as a whole in the core layer 21.

[0035] In the hollow plate material 20 of this embodiment, the core layer 21 and the skin layers 22, 23 are all made of only a thermoplastic resin. The thermoplastic resin may be any conventionally known thermoplastic resin, such as polypropylene resin, polyamide resin, polyethylene resin, acrylonitrile-butadiene-styrene copolymer resin, acrylic resin, polybutylene terephthalate resin, etc. In this embodiment, the core layer 21 and the skin layers 22, 23 are made of polypropylene resin. In other words, the hollow plate material 20 of this embodiment, i.e., the base layer 50, is made of polypropylene resin.

[0036] The thermoplastic resin constituting the core layer 21 and the thermoplastic resin constituting the skin layers 22, 23 are preferably the same material. In addition, the thickness of the skin layers 22, 23 is preferably greater than the thickness of the sheet material 100 forming the core layer 21. The thickness of the skin layers 22 and 23 is preferably the same.

[0037] <Regarding the manufacturing method of the hollow plate material 20> Next, a method for manufacturing the hollow plate material 20 will be described. As shown in FIG. 5, the hollow plate material 20 is manufactured by forming a core layer 21 from one sheet material 100 and bonding skin layers 22 and 23 to the core layer 21.

[0038] As shown in FIG. 5(a), the sheet material 100 is formed by molding one thermoplastic resin sheet into a predetermined shape. The sheet material 100 has band-shaped planar regions 110 and bulging regions 120 arranged alternately in the longitudinal direction (Z1 direction) of the sheet material 100. In the bulging region 120, a first bulging portion 121 having a cross section of a downward groove shape consisting of an upper surface and a pair of side surfaces is formed over the entire extension direction (Z2 direction) of the bulging region 120. Note that the angle between the upper surface and the side surface of the first bulging portion 121 is preferably 90 degrees, and as a result, the cross section of the first bulging portion 121 is a downward U-shape. The width of the first bulging portion 121 (the length of the short side of the upper surface) is set to be equal to the width of the planar region 110 and twice the length of the bulging height of the first bulging portion 121 (the length of the short side of the side surface).

[0039] In addition, in the bulging region 120, a plurality of second bulging portions 122, each of which has a cross-sectional shape that is a trapezoid obtained by bisecting a regular hexagon at its longest diagonal, are formed so as to be perpendicular to the first bulging portion 121. The bulging height of the second bulging portion 122 is set to be equal to the bulging height of the first bulging portion 121. In addition, the interval between adjacent second bulging portions 122 is equal to the width of the upper surface of the second bulging portion 122.

[0040] The first bulging portion 121 and the second bulging portion 122 are formed by partially bulging the sheet upwards by utilizing the plasticity of the sheet. The sheet material 100 can be formed from a single sheet by a known forming method such as vacuum forming or compression forming.

[0041] As shown in Fig. 5(a) and Fig. 5(b), the sheet material 100 configured as described above is folded along the boundary lines P and Q to form the core layer 21. Specifically, the sheet material 100 is valley-folded at the boundary line P between the flat area 110 and the bulging area 120, and mountain-folded at the boundary line Q between the top surface and side surface of the first bulging portion 121 to compress in the Z1 direction. Then, as shown in Fig. 5(b) and Fig. 5(c), the top surface and side surface of the first bulging portion 121 are folded over, and the end surface of the second bulging portion 122 and the flat area 110 are folded over, thereby forming one rectangular column-shaped partition 130 extending in the Z2 direction for one bulging area 120. Such partitions 130 are continuously formed in the Z1 direction to form the hollow plate-shaped core layer 21.

[0042] When the sheet material 100 is compressed as described above, the upper wall portion 24 of the core layer 21 is formed by the upper surface and side surface of the first bulge portion 121, and the lower wall portion 25 of the core layer 21 is formed by the end surface of the second bulge portion 122 and the flat region 110. As shown in Fig. 5(c), the portion of the upper wall portion 24 where the upper surface and side surface of the first bulge portion 121 are folded over to form a two-layer structure, and the portion of the lower wall portion 25 where the end surface of the second bulge portion 122 and the flat region 110 are folded over to form a two-layer structure are overlapping portions 131.

[0043] Moreover, a hexagonal columnar region formed by folding the second bulging portion 122 becomes the second cell S2, and a hexagonal columnar region formed between a pair of adjacent partitions 130 becomes the first cell S1. In this embodiment, the upper surface and side surface of the second bulging portion 122 form the side wall portion 26 of the second cell S2, and the side surface of the second bulging portion 122 and a flat portion located between the second bulging portions 122 in the bulging region 120 form the side wall portion 26 of the first cell S1. The contact portion between the upper surfaces of the second bulging portions 122 and the contact portion between the flat portions in the bulging region 120 form the side wall portion 26 having a two-layer structure. Note that, when carrying out such a folding process, it is preferable to heat-treat the sheet material 100 so as to soften it.

[0044] Next, the skin layer 22 is superimposed on the upper surface of the core layer 21, and the skin layer 23 is superimposed on the lower surface of the core layer 21. The skin layers 22, 23 are preferably softened by heat treatment. By heat treating the skin layers 22, 23, the adhesive layer of thermoplastic resin coated on the skin layers 22, 23 is partially thermally melted. Therefore, the skin layers 22, 23 superimposed on the core layer 21 are positioned in a state where they are temporarily bonded to the core layer 21. The adhesive layer solidifies due to a decrease in temperature of the core layer 21 and the skin layers 22, 23, and the skin layers 22, 23 are bonded to the core layer 21 to form the hollow plate material 20.

[0045] When the hollow board material 20 is used as the base layer 50 of the floor structure 10, the long hollow board material 20 thus manufactured can be cut to a predetermined length and width and then used. <About the construction method of floor structure 10> Next, a construction method for the floor structure 10 will be described. Here, a method for laminating the cushion layer 30, the base layer 50, and the surface layer 70 on the concrete 13 will be described. In the following description, the up-down direction of each layer in FIG. 1 may be referred to based on the up-down direction in FIG.

[0046] The construction method of the floor structure 10 includes a preparation step, a first adhesion step, a second adhesion step, and a third adhesion step. The preparation step is a step of cutting out a hollow plate material 20 of a predetermined shape. The first adhesion step is a step of applying an adhesive to the concrete 13 and adhering and fixing a cushion material sheet 30S onto the concrete 13 to form an adhesive layer 14 and a cushion layer 30. The second adhesion step is a step of applying an adhesive to the cushion layer 30 and adhering and fixing the hollow plate material 20 onto the cushion layer 30 to form an adhesive layer 40 and a base layer 50. The third adhesion step is a step of applying an adhesive to the base layer 50 and adhering and fixing a floor material sheet 70S onto the base layer 50 to form an adhesive layer 60 and a surface layer 70.

[0047] In the preparation step, the hollow board material 20 described in the above manufacturing method is cut into a rectangular shape with long sides of 1800 mm and short sides of 900 mm. In addition, a cushion material sheet 30S that will become the cushion layer 30 is prepared with long sides of 2000 mm, short sides of 1200 mm, and a thickness of 8 mm. A floor material sheet 70S that will become the surface layer 70 is prepared with long sides of 1800 mm, short sides of 150 mm, and a thickness of 10 to 20 mm.

[0048] In the first adhesion step, an adhesive that will become the adhesive layer 14 is applied to the entire upper surface of the concrete 13. Next, as shown in FIG. 3(a), the cushion material sheets 30S are laid on the concrete 13 on which the adhesive has been applied, with the side surfaces 30T of the cushion material sheets 30S butting against each other. Adjacent cushion material sheets 30S are arranged such that the side surfaces 30T of the cushion material sheets 30S are in contact with each other and no gaps are formed between the side surfaces 30T. As the adhesive hardens, an adhesive layer 14 is formed, and the cushion layer 30 made of the cushion material sheets 30S is adhered and fixed to the upper surface of the concrete 13.

[0049] In the second adhesion step, an adhesive that will become the adhesive layer 40 is applied to the entire upper surface of the cushion layer 30. Next, as shown in FIG. 3(b), the cut hollow plate material 20 is placed on the cushion layer 30 on which the adhesive has been applied. At this time, the hollow plate materials 20 are placed so that a gap G of about 2 mm is formed between adjacent hollow plate materials 20. Also, as shown in FIG. 1, the hollow plate materials 20 are placed so that the positions of the side surfaces 20T of the hollow plate materials 20 and the side surfaces 30T of the cushion material sheet 30S do not overlap each other in a plan view. When the adhesive solidifies, an adhesive layer 40 is formed, and the base layer 50 made of the hollow plate material 20 is adhered and fixed to the upper surface of the cushion layer 30.

[0050] 2, the internal spaces of the cells S that make up the hollow plate material 20 are exposed on the side surface 20T of the cut-out hollow plate material 20. Also, on a part of the side surface 20T, the side wall portion 26 of the core layer 21 of the hollow plate material 20 is inclined. In the part where the side wall portion 26 is inclined, the cell S on the side surface 20T side and the inner cell S adjacent to that cell S are in communication with each other via the opening 26a at the end of the side wall portion 26 formed by the inclination of the side wall portion 26.

[0051] In the third bonding step, an adhesive that will become the adhesive layer 60 is applied to the entire upper surface of the base layer 50. Next, as shown in FIG. 3(c), the flooring sheets 70S are laid on the adhesive-applied base layer 50 with their sides 70T facing each other. Adjacent flooring sheets 70S are arranged in a state in which their sides 70T are in contact with each other and no gaps are formed between the sides 70T. Also, as shown in FIG. 1, the flooring sheets 70S are arranged so that the positions of the sides 70T of the flooring sheets 70S do not overlap the positions of the sides 20T of the hollow board 20 and the sides 30T of the cushioning sheets 30S in a plan view. The adhesive solidifies to form an adhesive layer 60, and the surface layer 70 made of the flooring sheets 70S is adhered and fixed to the upper surface of the base layer 50.

[0052] 2, when the adhesive is applied in the third bonding step, part of the adhesive enters the gap G of the lower hollow plate material 20. In addition, part of the adhesive that has entered the gap G enters the internal space of the cell S located inward from the opening 26a at the end of the side wall portion 26.

[0053] As shown in Fig. 2, the adhesive layer 60 formed by solidifying the adhesive has an adhesive main body portion 61 provided between the base layer 50 and the surface layer 70. It also has a side adhesive portion 62 that enters the gap G and bonds the side surfaces 20T of adjacent hollow plate materials 20 together. The side adhesive portion 62 is formed integrally with the adhesive main body portion 61. It also has an internal adhesive portion 63 that enters the internal space of the cell S. The internal adhesive portion 63 is formed integrally with the side adhesive portion 62.

[0054] The side adhesive portion 62 is formed in some parts over the entire thickness direction of the base layer 50 in the gap G, and in other parts only in a part (upper part) in the thickness direction. There are also parts in the gap G where the side adhesive portion 62 is not formed. This is because in the third bonding step, the amount of adhesive that enters the gap G varies depending on the application amount, viscosity, etc. of the adhesive that becomes the adhesive layer 60.

[0055] 2 is bonded to the top wall 24 and side wall 26 constituting the core layer 21 inside the cell S. The internal adhesive portion 63 is not limited to this, and may have a portion bonded only to the top wall 24, a portion bonded only to the side wall 26, or a portion not bonded to the top wall 24 or the side wall 26. A portion of the internal adhesive portion 63 reaches the bottom wall 25. This is because the amount of adhesive that enters the internal space of the cell S varies depending on the application amount, viscosity, etc. of the adhesive that becomes the adhesive layer 60 in the third bonding step.

[0056] As shown in FIG. 1, the side surface 30T of the cushion material sheet 30S, the side surface 20T of the hollow plate 20, and the side surface 70T of the floor material sheet 70S are arranged so as not to overlap one another in a plan view.

[0057] Through each of the above steps, the floor structure 10 is constructed. <About the function of floor structure 10> In the floor structure 10 of this embodiment, a surface layer 70 is bonded and fixed onto a base layer 50 via an adhesive layer 60. The surface layer 70 is formed as a layer with a smaller linear expansion coefficient than the hollow plate materials 20 that constitute the base layer 50. Therefore, the amount of deformation of the base layer 50 made of the hollow plate materials 20 with a large linear expansion coefficient increases due to heat trapped under the floor when constructing the floor structure 10 and temperature changes around the gymnasium after construction.

[0058] A gap G of approximately 2 mm is formed between the multiple hollow plate materials 20 constituting the base layer 50. Therefore, the difference in the amount of deformation between the base layer 50 and the surface layer 70 is absorbed by the gap G. The phenomenon in which the surface of the surface layer 70 rises along the opposing side surfaces 20T of two adjacent hollow plate materials 20 is suppressed.

[0059] The adhesive applied in the third bonding step forms an adhesive layer 60 that bonds and fixes the base layer 50 and the surface layer 70. The adhesive layer 60 has an adhesive main body 61 provided between the base layer 50 and the surface layer 70, and a side adhesive portion 62 that enters the gap G and bonds the opposing side surfaces 20T of adjacent hollow plate materials 20. The adhesive used for forming the adhesive layer 60 is elastic in a solidified state. Therefore, the side adhesive portion 62 acts to disperse stress when the hollow plate material 20 expands and contracts.

[0060] The adhesive layer 60 also has an internal adhesive portion 63 that extends from the side adhesive portion 62 and enters the internal space of the cell S of the hollow plate material 20. The internal adhesive portion 63 enters from the cell S located at the edge on the side surface 20T side of the hollow plate material 20 into the internal space of the adjacent cell S on the inside. Therefore, the solidified internal adhesive portion 63 increases the adhesion area between the base layer 50 and the adhesive layer 60. The anchor effect of the internal adhesive portion 63 improves the bonding strength.

[0061] The cushion layer 30 of this embodiment is formed of chip urethane foam. Therefore, its elasticity gives the floor structure 10 a sense of elasticity. Even if the adjacent cushion material sheets 30S are arranged in a state where no gap is formed between the side surfaces 30T, the elasticity absorbs the deformation of the base layer 50. In addition, since it is a foam material, it is possible to absorb the deformation of the hollow plate material 20 constituting the base layer 50.

[0062] The floor structure 10 of this embodiment provides the following effects. (1) The floor structure 10 of this embodiment includes a base layer 50 composed of hollow plate materials 20, a surface layer 70, and an adhesive layer 60 provided between the base layer 50 and the surface layer 70. The base layer 50 is formed by arranging a plurality of resin hollow plate materials 20 so that their side surfaces 20T face each other. A gap G is formed between the side surfaces 20T of adjacent hollow plate materials 20.

[0063] If the base layer 50 is formed by laying the hollow boards 20 closely together, and if the linear expansion coefficient of the hollow boards 20 is greater than that of the surface layer 70, the amount of deformation of the hollow boards 20 will be greater than that of the surface layer 70, and a bulge will appear on the surface of the surface layer 70 where the side surfaces 20T are butted together. In this regard, in the floor structure 10 of this embodiment, the gaps G are formed, so that the amount of deformation of the hollow boards 20 is absorbed by the gaps G. The bulge on the surface of the floor structure 10 due to the deformation of the hollow boards 20 is suppressed, and undesirable situations such as a deterioration in the aesthetic appearance of the surface of the floor structure 10 can be suppressed.

[0064] (2) The adhesive layer 60 has an adhesive main body 61 provided between the base layer 50 and the surface layer 70, and a side adhesive portion 62 that penetrates into the gap G between the side surfaces 20T of adjacent hollow plate materials 20. The adhesive used for forming the adhesive layer 60 is elastic in a solidified state. Therefore, the side adhesive portion 62 of the adhesive layer 60 can disperse stress caused when the hollow plate material 20 expands and contracts.

[0065] (3) The adhesive layer 60 has internal adhesive portions 63 that extend from the side adhesive portions 62 and penetrate into the internal spaces of the cells S of the hollow plate material 20. Therefore, the internal adhesive portions 63 exert an anchor effect, and the bonding strength between the adhesive layer 60 and the base layer 50 can be improved.

[0066] (4) The floor structure 10 has a cushion layer 30 made of chip urethane foam. This gives the floor a sense of elasticity. In addition, it can absorb deformation of the base layer 50, which has a large linear expansion coefficient.

[0067] The above embodiment can be modified as follows: The above embodiment and the following modified examples can be applied in combination with each other to the extent that there is no technical contradiction. The floor structure 10 of the above embodiment has been described as having a thermoplastic resin hollow plate 20 laminated as the base layer 50 and a polyvinyl chloride composite sheet laminated as the surface layer 70, but the layer configuration of the floor structure 10 is not limited to this. As long as the hollow plate 20 constituting the base layer 50 has a linear expansion coefficient larger than that of the surface layer 70, the hollow plate 20 and the surface layer 70 can be appropriately selected. For example, the surface layer 70 may not be a polyvinyl chloride composite sheet, but may be a sheet made of other resin. It may also be a thin wooden plate. When the surface layer 70 is made of wood, it is heavier than the polyvinyl chloride composite sheet. Therefore, when the surface layer 70 is joined in the third bonding step, the adhesive constituting the adhesive layer 60 is also pressed by the weight of the surface layer 70, and is likely to enter the gap G of the hollow plate 20.

[0068] The adhesive layer 60 is where the side adhesive portion 62 that penetrates into the gap G between adjacent hollow plate materials 20 is formed, but the adhesive layer 40 that bonds and fixes the cushion layer 30 and the base layer 50 may also have a portion similar to the side adhesive portion 62 that penetrates into the gap G. This portion is formed when the hollow plate material 20 is placed on the upper surface of the cushion layer 30 in the second bonding step, and the weight of the hollow plate material 20 causes adhesive to penetrate into the gap G between adjacent hollow plate materials 20. The portion that extends from the adhesive layer 40 and penetrates into the gap G is smaller than the side adhesive portion 62. This is because the amount of adhesive that penetrates into the gap G from above due to gravity is greater than the amount of adhesive that penetrates into the gap G from below.

[0069] The adhesive layer 40 that bonds and fixes the cushion layer 30 and the base layer 50 may also have a portion similar to the internal adhesive portion 63 extending from a portion similar to the side adhesive portion 62 that enters into the gap G. This portion occurs because, when the hollow plate material 20 is placed on the cushion layer 30 in the second bonding step, part of the adhesive enters the gap G due to the weight of the hollow plate material 20 and further enters the internal space of the cells S located inward from the openings 26a at the lower ends of the side walls 26. The portion that enters from the openings 26a at the lower ends of the side walls 26 is smaller than the internal adhesive portion 63.

[0070] The layer configuration of the floor structure 10 can be changed as appropriate. At least one of the moisture-proof sheet 11, the heat insulating material 12, the concrete 13, the adhesive layer 14, the cushion layer 30, and the adhesive layer 40 may be omitted. Also, in addition to the moisture-proof sheet 11, the heat insulating material 12, the concrete 13, the adhesive layer 14, the cushion layer 30, the adhesive layer 40, the base layer 50, the adhesive layer 60, and the surface layer 70, another layer may be further included. For example, the surface of the surface layer 70 may have an antifouling layer, a clear coat layer, or the like.

[0071] The thickness of each layer of the floor structure 10 can be changed as desired. The size and shape of the cushioning sheet 30S, the hollow plate 20, and the flooring sheet 70S can be changed as desired.

[0072] The base layer 50 in the above embodiment is formed by laying a plurality of hollow plate materials 20 in such a manner that the gaps G intersect in a cross shape when the floor structure 10 is viewed from above. The method of laying the hollow plate materials 20 is not limited to this. For example, they may be laid in a lattice or staggered pattern, like the floor material sheet 70S constituting the surface layer 70.

[0073] The size of the gap G is not limited to 2 mm and can be adjusted as appropriate. It may be set in consideration of the linear expansion coefficient of the underlayer 50 and the linear expansion coefficient of the surface layer 70. The size of the gap G does not have to be uniform. For example, a gap wider than 2 mm or narrower than 2 mm may be formed between adjacent hollow plate materials 20. If it is not necessary to make the size of the gap G uniform, there is no need to use a jig or the like to accurately measure the gap G during construction, which improves work efficiency during construction.

[0074] The adhesive layer 60 may have only the adhesive main body portion 61, and may not have the side adhesive portion 62 and the internal adhesive portion 63. Also, the adhesive layer 60 may have the adhesive main body portion 61 and the side adhesive portion 62, and may not have the internal adhesive portion 63.

[0075] The adhesive layer 40 and the adhesive layer 60 may be made of different materials. Also, the coating amount may be changed to change the thickness. Although the floor structure 10 in the above embodiment has been described as an on-site construction type floor structure 10, it may be a plate-shaped floor panel. In this case, for example, it may be a rectangular plate-shaped floor panel including a cushion layer 30, an adhesive layer 40, a base layer 50, an adhesive layer 60, and a surface layer 70, which may be laid on a concrete base at the site.

[0076] The core layer 21 of the hollow plate material 20 does not have to be formed by folding the sheet material 100 . The hollow plate material 20 can be any hollow structure known in the art.

[0077] In the hollow plate material 20 of the above embodiment, the cells S having a hexagonal prism shape are defined and formed inside the core layer 21, but the shape of the cells S is not limited to this. For example, the cells S may have a polygonal prism shape such as a square prism or an octagonal prism, or a cylindrical shape.

[0078] At least one of the skin layers 22, 23 joined to the hollow board 20 may have a multi-layer structure instead of a single layer structure. For example, it may have a multi-layer structure including a low melting point film layer, a decorative layer with a printed pattern, a nonwoven fabric layer, etc.

[0079] The skin layer 23 may be omitted. The material constituting the core layer 21 and the skin layers 22 and 23 may contain a thermoplastic resin, but may contain a material other than a thermoplastic resin.

[0080] The thermoplastic resin constituting the core layer 21 and the skin layers 22, 23 may contain various functional resins. For example, flame retardancy can be improved by adding a flame retardant resin to the thermoplastic resin. It is also possible to use thermoplastic resins containing various functional resins for all of the core layer 21 and the skin layers 22, 23, or to use a thermoplastic resin for at least one of the core layer 21 and the skin layers 22, 23.

[0081] The technical concepts that can be understood from the above embodiment and each of the modified examples will be described below. (i) A floor panel comprising a cushion layer, a base layer, a surface layer, a first adhesive layer provided between the cushion layer and the base layer, and a second adhesive layer provided between the base layer and the surface layer, wherein the base layer is formed by arranging a plurality of resin hollow boards so that their sides face each other, the hollow boards having a larger linear expansion coefficient than the surface layer, and the base layer is formed by arranging the hollow boards so that there is a gap between the sides of adjacent hollow boards.

[0082] (b) The floor panel described in (a) above, characterized in that the second adhesive layer has a second adhesive main body portion provided between the base layer and the surface layer, and a second side adhesive portion that penetrates into the gap.

[0083] (c) The floor panel described in (b) above, characterized in that the hollow board has a plurality of cells partitioned by side wall portions extending in the thickness direction, and the second adhesive layer has a second internal adhesive portion extending from the second side adhesive portion and penetrating into the interior of the cell.

[0084] (ii) A floor panel described in any one of (i) to (iii), characterized in that the first adhesive layer has a first adhesive main body portion provided between the cushion layer and the base layer, and a first side adhesive portion that penetrates into the gap.

[0085] (e) The floor panel described in (ii) above, characterized in that the hollow board material has a plurality of cells partitioned by side wall portions extending in the thickness direction, and the first adhesive layer has a first internal adhesive portion extending from the first side adhesive portion and penetrating into the interior of the cell. [Explanation of symbols]

[0086] G…Gap S: Cell 10…Floor structure 20…Hollow plate material 20T…side 26…Side wall 30…Cushion layer 40, 60...adhesive layer 50…base layer 61…Adhesive body part 62...Side adhesive part 63…Internal adhesive part 70…Surface layer

Claims

1. A floor structure comprising a base layer, a surface layer, and an adhesive layer provided between the base layer and the surface layer, The base layer is formed by arranging a plurality of hollow resin plate materials so that their side surfaces face each other, the hollow plate material has a linear expansion coefficient greater than that of the surface layer, A floor structure characterized in that the base layer is formed by arranging the hollow plate members so that there is a gap between the side surfaces of adjacent hollow plate members.

2. The floor structure according to claim 1, characterized in that the adhesive layer has an adhesive main body portion provided between the base layer and the surface layer, and a side adhesive portion that penetrates into the gap.

3. The hollow plate material has a plurality of cells defined by side walls extending in a thickness direction, 3. The floor structure according to claim 2, wherein the adhesive layer has an internal adhesive portion extending from the side adhesive portion into the interior of the cell.

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