Floor panel

Abstract

To provide a floor panel capable of suppressing cracking at corners of a covering member even when a thickness of the covering member is reduced.SOLUTION: A floor panel 1 comprises a plate-shaped panel material 30 having a top surface 31 and a bottom surface 32; a first covering member 10 covering the top surface 31; a second covering member 20 covering the bottom surface 32; a plurality of wall portions (second wall portions 22A, 22B, 23) provided around a peripheral edge of at least one of the first covering member 10 and the second covering member 20 so as to rise up along a thickness direction of the panel material 30, respectively, with one wall portion (second wall portion 22A, 22B) and the other wall portion (second wall portion 23) adjacent to the one wall portion in a peripheral edge direction PD; a corner portion (second corner portion 26A) formed by the one wall portion and the other wall portion; and an opposing portion (second opposing portion 25A) provided in the corner portion and formed by opposing an end edge 22B1 on a side of the other wall portion in the one wall portion and an end edge 23A on a side of the one wall portion in the other wall portion.SELECTED DRAWING: Figure 8

Description

[Technical field]

[0001] The present disclosure relates to a floor panel. [Background technology]

[0002] Conventionally, there is known a technique for forming a double floor structure by connecting multiple floor panels. The floor panel comprises a panel material, which is an internal component, and a covering material that covers the panel material. The covering material is usually in the shape of a box having a bottom and multiple walls rising from the bottom. In addition, since the panel material of the floor panel has corners (i.e., corner portions), the covering member that covers the panel material also has corners.

[0003] The corners of the box-shaped covering member can be formed by combining a bottom portion and wall portions adjacent to each other in the peripheral direction along the direction in which the peripheral edge of the bottom portion extends. As a method for manufacturing a box-shaped covering member having corners, as disclosed in Patent Document 1, a drawing press process is known in which a single flat blank is partially deformed by applying pressure thereto. In this specification, the blank refers to a plate-shaped member that is prepared in advance for subsequent operations such as pressing and bending. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6121206 Summary of the Invention [Problem to be solved by the invention]

[0005] However, when the corners of the blank are manufactured by drawing press processing, the amount of deformation is relatively large, and therefore, if the thickness of the blank is made relatively thin, the amount of tension in the corners increases, making them more likely to crack.

[0006] The present disclosure has been made in consideration of the above, and provides a floor panel that can suppress cracks at the corners of a covering member even if the plate thickness of the covering member is thin. [Means for solving the problem]

[0007] A first aspect of the present disclosure is a floor panel comprising: a plate-shaped panel material having a top surface and a bottom surface; a first covering member covering the top surface; a second covering member covering the bottom surface; a plurality of wall portions each provided on the periphery of at least one of the first covering member and the second covering member so as to rise along the thickness direction of the panel material, the plurality of wall portions having one wall portion and another wall portion adjacent to the one wall portion in the periphery direction; a corner portion formed by the one wall portion and the other wall portion; and an opposing portion provided at the corner portion, formed by an edge of the one wall portion facing the other wall portion and an edge of the other wall portion on the side of the one wall portion opposing each other.

[0008] In the first aspect, a plurality of walls are provided on the periphery of at least one of the first covering member and the second covering member so as to rise along the thickness direction of the panel material. A corner is formed by one wall of the plurality of walls and the other wall adjacent to the one wall. That is, for example, a blank having a flat plate shape is cut in a predetermined pattern so that excess material not required for forming the corner is removed, thereby forming a portion constituting the bottom and a plurality of pieces continuing from the portion constituting the bottom and constituting the wall portions.

[0009] The corners of the covering member can be formed by bending each of the formed pieces so that they rise from the portion that constitutes the bottom. As a result, at the corners, an edge of one wall portion facing the other wall portion faces an edge of the other wall portion facing the one wall portion, thereby forming an opposing portion. Therefore, there is no need to use a drawing press process to form the corners of the covering member, and cracks in the corners of the floor panel can be suppressed.

[0010] A second aspect of the present disclosure is a floor panel according to the first aspect, wherein an edge of at least one of the one wall portion and the other wall portion has a first curved portion that is positioned outwardly of the end face corresponding to the edge in the circumferential direction.

[0011] In the second aspect, a first curved portion is formed on the edge of the wall portion, which is located outside the end face corresponding to the edge in the circumferential direction. Therefore, even if the end face of the wall portion is a cut end face formed by cutting a blank during the manufacture of the floor panel, when a worker handles the floor panel during transportation, installation, etc., the worker is likely to come into contact with the first curved portion, but contact with the cut end face is reduced. As a result, safety when handling the floor panel can be improved.

[0012] Aspect 3 of the present disclosure is a floor panel of aspect 2, wherein the first curved portion is formed in each of the one wall portion and the other wall portion, and the first curved portion of the one wall portion and the first curved portion of the other wall portion are butted together in the thickness direction.

[0013] In the third aspect, the first curved portion is formed on each of the one wall portion and the other wall portion, so safety can be improved compared to when the first curved portion is formed on only one side. Also, the first curved portions are butted against each other in the thickness direction, so safety can be improved. Also, the gap between adjacent wall portions is covered by the first curved portion in the thickness direction, so that the joint portion of the panel material is prevented from being exposed through the gap. This improves the aesthetic appearance of the panel material.

[0014] A fourth aspect of the present disclosure is a floor panel according to any one of aspects 1 to 3, wherein the first covering member has a first wall portion as the wall portion, and the second covering member has a second wall portion as the wall portion at a position corresponding to the first wall portion in the thickness direction, the first wall portion and the second wall portion are overlapped with each other in an inward / outward direction perpendicular to the wall surfaces of the wall portions, and an end portion in the peripheral direction of the first wall portion and the second wall portion which is positioned on the outside in the inward / outward direction is folded back to the back side of the wall portion and overlapped with the wall portion of the first wall portion and the second wall portion which is positioned on the inside in the inward / outward direction. In the fourth embodiment, the integrity of the first covering member and the second covering member is improved, so that the strength can be improved.

[0015] A fifth aspect of the present disclosure is a floor panel as described in a fourth aspect, wherein the edge of the first wall portion and the second wall portion, whichever is positioned outward in the inward / outward direction, has a second curved portion formed thereon, the second curved portion being positioned outward in the circumferential direction than the end face corresponding to the edge. In the fifth aspect, safety when handling the floor panel can be further improved.

[0016] A sixth aspect of the present disclosure is a floor panel according to the fourth or fifth aspect, wherein an end portion in the thickness direction of one of the first and second wall portions which is positioned on the outside in the inward / outward direction is folded back and overlapped on the other wall portion which is positioned on the inside in the inward / outward direction. In the sixth aspect, the strength of the floor panel can be further improved.

[0017] A seventh aspect of the present disclosure is a floor panel according to any one of aspects 4 to 6, wherein the edge of the first wall portion and the second wall portion, whichever is located on the outside in the inward / outward direction, has a third curved portion located on the edge in the thickness direction.

[0018] In the seventh aspect, safety when handling the floor panel can be further improved. Effect of the Invention

[0019] According to the present disclosure, even if the plate thickness of the covering member is reduced, cracks at the corners of the covering member can be suppressed. [Brief description of the drawings]

[0020] [Figure 1] 1 is a perspective view illustrating a floor panel according to an embodiment of the present invention, viewed from above. [Diagram 2] FIG. 2 is an enlarged view of part A in FIG. [Diagram 3] 1 is a perspective view illustrating a corner portion of a floor panel according to an embodiment of the present invention, viewed from below. [Figure 4] This is an oblique view illustrating the first covering member of the corner portion of the floor panel before assembly in this embodiment, viewed from above, from the outside to the inside. [Diagram 5] This is an oblique view illustrating the second covering member for the corner portion of the floor panel before assembly in this embodiment, viewed from above, from the inside to the outside. [Figure 6] 6 is a cross-sectional view illustrating the floor panel according to the present embodiment, taken along a plane that includes line 6-6 in FIG. 3 and is perpendicular to the wall surface of the second wall portion. [Figure 7] 7 is a cross-sectional view illustrating the floor panel according to the present embodiment, taken along a plane that includes line 7-7 in FIG. 3 and is perpendicular to the wall surface of the second wall portion. [Figure 8] 8 is a cross-sectional view taken along line 8-8 in FIG. 7. [Figure 9] This is an oblique view illustrating the second covering member of the corner portion of the floor panel in this embodiment, viewed from above, from the outside to the inside. [Figure 10] 8 is a cross-sectional view illustrating a floor panel according to a modified example taken along the same position as line 8-8 in FIG. 7. [Figure 11] An oblique view illustrating a second covering member for a corner of a floor panel relating to a modified example, viewed from above, from the outside to the inside. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The present embodiment will be described below. In the following description of the drawings, the same or similar parts are given the same or similar symbols. However, the drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each device and each member, etc. may differ from the actual ones. Therefore, the specific thickness and dimensions should be determined by taking into consideration the following description. In addition, there may be parts with different dimensional relationships and ratios between the drawings. In addition, unless otherwise specified in the specification, the number of each component of the present disclosure is not limited to one, and there may be more than one.

[0022] <Floor panel structure> The structure of the floor panel according to this embodiment will be described with reference to Figures 1 to 9. As shown in Figure 1, a plurality of floor panels 1 according to this embodiment are arranged side by side on, for example, a slab 41 of a building. As shown in Figure 2, the corners of the plurality of floor panels 1 are supported by support legs 42 while butting against each other.

[0023] The floor panel 1 and the support legs 42 are fixed by fasteners 43. A double floor structure can be formed by connecting multiple floor panels 1 by the support legs 42 and fasteners 43. Note that, as shown in Fig. 1, an interior material such as a carpet 44 may be laid on top of the multiple floor panels 1 arranged side by side.

[0024] 2 to 4, the floor panel 1 according to this embodiment includes a panel material 30, a first covering member 10, a second covering member 20, and a plurality of wall portions WH, WS. The floor panel 1 also includes first corner portions 16A, 16B and second corner portions 26A, 26B, first opposing portions 15A, 15B (see FIG. 3) and second opposing portions 25A, 25B (see FIG. 8).

[0025] (Panel material) The panel material 30 is a plate-like member having a top surface 31, a bottom surface 32 (see FIG. 6), and a side surface 33 (see FIG. 4). In this embodiment, the shape of the plate-like panel material 30 is substantially rectangular, but this is not limited to this in the present disclosure. In the present disclosure, the shape of the panel material 30 may be, for example, a triangle, a hexagon, or any other geometric shape. The material of the panel material 30 may also be any material, such as wood, metal, or resin.

[0026] As shown in Fig. 4, in this embodiment, the four corners of the panel material 30 are chamfered to form corner surfaces 34 between adjacent side surfaces 33. In addition, sloped surfaces 35 are formed at the four corners of the top surface 31 of the panel material 30.

[0027] (Covering material) In this embodiment, the covering member includes a first covering member 10 and a second covering member 20. As shown in Fig. 4, the first covering member 10 covers the top surface 31 of the panel material 30. Note that, although the number of first covering members 10 covering the top surface 31 is one in this embodiment, this is not limited to this in the present disclosure. In the present disclosure, one first covering member may be composed of two or more covering members.

[0028] 5 and 6, the second covering member 20 covers the bottom surface 32 of the panel material 30. In the present embodiment, the number of second covering members 20 covering the bottom surface 32 is one, but this is not limited to this in the present disclosure. In the present disclosure, one second covering member may be composed of two or more covering members.

[0029] (First wall portion and second wall portion) 4 and 6, in this embodiment, the first covering member 10 has a rectangular first bottom 11 corresponding to the top surface of the panel material 30, and a plurality of first walls 12A, 12B, 13. The first walls 12A, 12B are provided as four walls WH in the floor panel 1, rising along the thickness direction TD of the panel material 30 on the four sides of the first bottom 11. The first walls 13 are provided as four walls WS, rising along the thickness direction TD of the panel material 30 on the four corners of the first bottom 11.

[0030] 5 and 6, the second covering member 20 similarly has a rectangular second bottom 21 corresponding to the bottom surface of the panel material 30, and a plurality of second walls 22A, 22B, 23. The second walls 22A, 22B are provided as four walls WH in the floor panel 1 so as to rise along the thickness direction TD of the panel material 30 on the four sides of the second bottom 21.

[0031] The second wall portions 23 are provided as four wall portions WS of the floor panel 1, rising along the thickness direction TD of the panel material 30 at the four corners of the second bottom portion 21. In the present disclosure, the multiple wall portions may be formed by at least one of the first covering member 10 and the second covering member 20.

[0032] As shown in Fig. 3, the lower end of the first wall portion 12A and the upper end of the second wall portion 22A, which correspond to each other in the thickness direction TD, are folded in a state where they overlap at the height of the upper part of the floor panel 1. Similarly, the lower end of the first wall portion 12B and the upper end of the second wall portion 22B, which correspond to each other in the thickness direction TD, are folded in a state where they overlap at the height of the upper part of the floor panel 1. Fig. 6 illustrates an example in which the lower end of the first wall portion 12B and the upper end of the second wall portion 22B are folded in a state where they overlap at the height of the upper part of the floor panel 1.

[0033] 7, the lower end of the first wall portion 13 and the upper end of the second wall portion 23, which correspond to each other in the thickness direction TD, are folded in an overlapping state at the height of the upper portion of the floor panel 1. FIG. 7 illustrates a state in which the base folded piece X1 as the lower end of the first wall portion 13, the central folded piece X3, and the folded piece X4 as the upper end of the second wall portion 23 are folded.

[0034] (First corner and second corner) As shown in Fig. 3, the first covering member 10 has first corners 16A, 16B. The second covering member 20 has second corners 26A, 26B. The first corners 16A, 16B are formed by one of the first wall portions 22A, 22B, 23 adjacent to each other in the circumferential direction PD and the other first wall portion adjacent to the one first wall portion in the circumferential direction PD (for example, one first wall portion 12A and the other first wall portion 13). In other words, the circumferential direction PD is a direction along the side edge of the rectangular floor panel 1 when the plate surface of the rectangular floor panel 1 is viewed from the front.

[0035] 3 illustrates a first corner 16A formed by the first wall portion 13 and the first wall portion 12A adjacent to the right side of the first wall portion 13 in the circumferential direction PD. Also, FIG 3 illustrates a first corner 16B formed by the first wall portion 13 and the first wall portion 12B adjacent to the left side of the first wall portion 13 in the circumferential direction PD.

[0036] As shown in Figures 8 and 9, the second corner portions 26A, 26B are formed by one of the multiple second wall portions 22A, 22B, 23 adjacent to each other in the circumferential direction PD and the other second wall portion adjacent to the one second wall portion in the circumferential direction PD.

[0037] 8 illustrates a second corner portion 26A formed by the second wall portion 23 as one second wall portion and the second wall portion 22A as the other second wall portion adjacent to the left side of the second wall portion 23 in the circumferential direction PD. Also, FIG 8 illustrates a second corner portion 26B formed by the second wall portion 23 as one second wall portion and the second wall portion 22B as the other second wall portion adjacent to the right side of the second wall portion 23 in the circumferential direction PD.

[0038] (First opposing portion and second opposing portion) As shown in Fig. 3, first opposing portions 15A, 15B are provided at first corners 16A, 16B of the first covering member 10. As shown in Fig. 8, second opposing portions 25A, 25B are provided at second corners 26A, 26B of the second covering member 20. Note that in this embodiment, "opposing" includes, for example, a state in which the edges are closely arranged with a gap therebetween, a state in which the edges are in partial or total contact with each other in the thickness direction TD, a state in which the edges overlap with each other in the inward-outward direction SD, and the like.

[0039] In this embodiment, in the in-plane direction of the surface of the rectangular floor panel 1, the side where the intersection of the diagonal lines inside the rectangle is located is the "inner side IS," and the side away from the intersection along the in-plane direction is the "outer side OS." The in-outer direction SD is the direction extending between the inner side IS and the outer side OS.

[0040] As shown in FIG. 3, the first opposing portions 15A, 15B are formed by the edge of one first wall portion 12A facing the other first wall portion 12B and the edge of the other first wall portion 12B facing the one first wall portion 12A, among the multiple first wall portions 12A, 12B.

[0041] Figure 3 illustrates a first opposing portion 15A formed by the opposing edge 13F of the first wall portion 13 on the right side of the first wall portion 12A and the edge 12A1 of the first wall portion 12A on the first wall portion 13 side.

[0042] FIG. 3 also illustrates a first opposing portion 15B formed by the opposing edge 13G of the first wall portion 13 on the left side of the first wall portion 12B and the edge 12B1 of the first wall portion 12B on the first wall portion 13 side.

[0043] The second opposing portions 25A, 25B are formed by an opposing edge of one second wall portion 22A facing the other second wall portion 22B and an opposing edge of the other second wall portion 22B facing the one second wall portion 22A.

[0044] Figure 8 illustrates a second opposing portion 25A formed by the opposing edge 23A of the second wall portion 23 on the left side of the second wall portion 22A and the edge 22A1 of the second wall portion 22A on the second wall portion 23 side.

[0045] Figure 8 also illustrates a second opposing portion 25B formed by the opposing edge 23B on the right side of the second wall portion 22B of the second wall portion 23 and the edge 22B1 on the second wall portion 23 side of the second wall portion 22B.

[0046] (cut end surface) In the present embodiment, in both the first covering member 10 and the second covering member 20, a pair of wall portions forming the first corners 16A, 16B and the second corners 26A, 26B each have a cut end surface corresponding to an edge in the circumferential direction PD in Fig. 8 as an end surface in the present disclosure. Note that in the present disclosure, in at least one of the first covering member 10 and the second covering member 20, each of the pair of wall portions forming a corner may have a cut end surface corresponding to an edge in the circumferential direction PD in Fig. 8.

[0047] The cut end surface is a cut mark of a blank, which is a material for a coated member. In this embodiment, the "cut end surface" includes not only an end surface where the base material of the blank is exposed on the surface, but also an end surface having a surface coated with a coating paint or the like.

[0048] 8, cut end faces 13C and 13D are formed at both ends in the circumferential direction PD of the first wall portion 13. Also, the first wall portion 13 is bent at positions closer to the center in the circumferential direction PD than the respective cut end faces 13C and 13D, so that the cut end faces 13C and 13D are located inside the outermost positions in the circumferential direction PD, thereby forming edges 13A and 13B at the bending positions.

[0049] (song section) Next, a description will be given of the curved portions of the first covering member 10 and the second covering member 20 of this embodiment. First, the first curved portion CV1 of the second covering member 20 will be described.

[0050] (Bent portion of second covering member: first curved portion) 8, in this embodiment, the first curved portion CV1 in the second covering member 20 is formed on each of the edge 22A1 of the second wall portion 22A, the edge 22B1 of the second wall portion 22B, and the edge 23A of the second wall portion 23. Note that in the present disclosure, it is sufficient that the first curved portion CV1 is formed on the edge of at least one of the second wall portion 22A, the second wall portion 22B, and the second wall portion 23, and is positioned outward from the cut end surface corresponding to the edge in the circumferential direction PD.

[0051] The first curved portion CV1 has a curved surface facing the outside OS in the inward-outward direction SD, as shown in Figures 8 and 9. The first curved portion CV1 can be formed, for example, by partially folding back a region including the cut end surface of the blank to the inside IS. As a folding method, for example, drawing press processing can be used, but other known folding methods may also be used.

[0052] In this embodiment, the first curved portion CV1 of the second wall portion 22A and the first curved portion CV1 of the second wall portion 23 are butted against each other in the thickness direction TD (the up-down direction in FIG. 5). Similarly, the first curved portion CV1 of the second wall portion 22B and the first curved portion CV1 of the second wall portion 23 are butted together in the thickness direction TD (the up-down direction in FIG. 5). Note that in the present disclosure, it is not essential that the first curved portions CV1 are butted together throughout the entire thickness direction TD. For example, only the root portions of the first curved portions CV1 in the thickness direction TD may be connected together.

[0053] (Bend of first covering member) Next, the second curved portion CV2 and the third curved portion CV3 of the first covering member 10 will be described. Here, in this embodiment, as shown in Fig. 8, the second covering member 20 has a second wall portion 23 at a position in the thickness direction TD corresponding to the first wall portion 13 of the first covering member 10. The first wall portion 13 and the second wall portion 23 are overlapped with each other in the inner / outer direction SD perpendicular to the wall surface of the wall portion. Hereinafter, the second curved portion CV2 and the third curved portion CV3 will be described using the first wall portion 13 and the second wall portion 23 as an example.

[0054] (Second song part) As shown in FIG. 3, in this embodiment, between the first corner 16A on the right side and the first corner 16B on the left side, the first wall 13 and the second wall 23 are disposed on the outer side OS in the inward-outward direction SD. As shown in FIG. 8, the first wall 13 has a trapezoidal base bent piece X1, a pair of end bent pieces X2, and a central bent piece X3 at the lower end in the thickness direction TD. In addition, as shown in FIG. 5, the second wall 23 has a trapezoidal bent piece X4 at the upper end in the thickness direction TD. The bent piece X4 of the second wall 23 is formed at a position corresponding to the base bent piece X1, the pair of end bent pieces X2, and the central bent piece X3 of the first wall 13.

[0055] As shown in Fig. 2, the outer surface of the base bent piece X1 faces the fixing device 43. As shown in Fig. 4, the end bent piece X2 extends downwardly continuous with the hypotenuse portion of the trapezoid of the base bent piece X1, and the central bent piece X3 extends downwardly continuous with the lower base portion of the trapezoid of the base bent piece X1. As shown in Fig. 4, a cut end surface 13H extending approximately horizontally is formed at the lower edge of the central bent piece X3.

[0056] As shown in Figures 3 and 8, the end portion of the first wall portion 13 in the circumferential direction PD is folded back to the back side of the first wall portion 13 as an end folding piece X2, and is overlapped with the second wall portion 23 that is positioned on the inner side IS in the inward-outward direction SD, out of the first wall portion 13 and the second wall portion 23.

[0057] As shown in Figure 8, in this embodiment, the end edges 13A, 13B of the first wall portion 13 located on the outer side OS in the inward-outward direction SD have a second curved portion CV2 that is located outside the cut end faces 13C, 13D corresponding to the ends 13A, 13B in the circumferential direction PD.

[0058] In the present disclosure, the second wall portion 23 may be disposed on the outer side OS in the inward-outward direction SD. That is, the second curved portion CV2 may be formed on the edge of the wall portion that is disposed on the outer side OS in the inward-outward direction SD, out of the first wall portion and the second wall portion, and is disposed on the outer side of the cut end surface corresponding to the edge in the circumferential direction PD.

[0059] The second curved portion CV2 has a curved surface facing the outside OS in the inward / outward direction SD, as shown in Fig. 8. The second curved portion CV2 of this embodiment can be formed using a drawing press process or the like, similar to the case of the first curved portion CV1.

[0060] (Third song part) As shown in Figures 3 and 4, in this embodiment, the end portion of the first wall portion 13 in the thickness direction TD is folded back to the back side as a central folded piece X3 and overlapped with the second wall portion 23 located on the inner side IS in the inward-outward direction SD.

[0061] As shown in Fig. 7, a third curved portion CV3 is formed at an edge 13E in the thickness direction TD at the edge of the first wall portion 13. The curved surface of the third curved portion CV3 faces downward in the thickness direction TD. The third curved portion CV3 in this embodiment can be formed, for example, by bending the first wall portion 13 at the position of the edge 13E using a bending process. In this embodiment, the cut end surface 13H of the central bent piece X3 is sandwiched by the second bottom portion 21 as shown in Fig. 7.

[0062] As shown in Fig. 3, in this embodiment, the second curved portion CV2 and the third curved portion CV3 are continuous in both the circumferential direction PD and the thickness direction TD. This further improves safety when handling the floor panel 1. Note that in the present disclosure, it is not essential that the second curved portion CV2 and the third curved portion CV3 are continuous in both the circumferential direction PD and the thickness direction TD. For example, the second curved portion CV2 and the third curved portion CV3 may be separated from each other.

[0063] (Action and effect) In the floor panel 1 according to this embodiment, a plurality of first walls 12A, 12B, 13 are provided on the periphery of the first covering member 10 so as to rise along the thickness direction TD of the panel material 30. Among the plurality of first walls 12A, 12B, 13, the first wall 12A and the first wall 13 form a first corner 16A. In addition, the first wall 12B and the first wall 13 form a first corner 16B.

[0064] Further, a plurality of second walls 22A, 22B, 23 are provided on the periphery of the second covering member 20 so as to rise along the thickness direction TD of the panel material 30. The second wall 22A and the second wall 23 of the plurality of second walls 22A, 22B, 23 form a second corner 26A. The second wall 22B and the second wall 23 of the plurality of second walls 22A, 22B, 23 form a second corner 26B.

[0065] That is, for example, a flat blank is cut in a predetermined pattern so that excess material not necessary for forming the first corner portions 16A, 16B and the second corner portions 26A, 26B is removed, thereby forming a portion that constitutes the bottom and a number of pieces that are continuous with the portion that constitutes the bottom and each constitute a wall portion.

[0066] The first corners 16A, 16B of the first covering member 10 and the second corners 26A, 26B of the second covering member 20 can be formed by bending each of the formed pieces so as to rise from the portion constituting the bottom. As a result, in the first corner 16A, an edge 12A1 of the first wall portion 12A on the side of the first wall portion 13 faces an edge 13F of the first wall portion 13 on the side of the first wall portion 12A, forming a first opposing portion 15A. In addition, in the first corner 16B, an edge 12B1 of the first wall portion 12B on the side of the first wall portion 13 faces an edge 13G of the first wall portion 13 on the side of the first wall portion 12B, forming a first opposing portion 15B.

[0067] At the second corner 26A, an edge 22A1 of the second wall portion 22A on the second wall portion 23 side faces an edge 23A of the second wall portion 23 on the second wall portion 22A side, thereby forming a second opposing portion 25A. At the second corner 26B, an edge 22B1 of the second wall portion 22B on the second wall portion 23 side faces an edge 23B of the second wall portion 23 on the second wall portion 22B side, thereby forming a second opposing portion 25B.

[0068] Therefore, there is no need to use drawing press processing to form the first corners 16A, 16B of the first covering member 10 and the second corners 26A, 26B of the second covering member 20. As a result, even if the plate thicknesses of the first covering member 10 and the second covering member 20 are made thin, cracks in the first corners 16A, 16B and the second corners 26A, 26B of the floor panel 1 can be suppressed.

[0069] In this embodiment, in the plurality of walls WH and WS, the edge 22A1 of the second wall 22A is formed with a first curved portion CV1 disposed outside the cut end surface 22D corresponding to the edge 22A1 in the circumferential direction PD. In the plurality of walls WH and WS, the edge 22B1 of the second wall 22B is formed with a first curved portion CV1 disposed outside the cut end surface 22C corresponding to the edge 22B1 in the circumferential direction PD. In the plurality of walls WH and WS, the edges 23A and 23B of the second wall 23 are formed with a first curved portion CV1 disposed outside the cut end surfaces 23C and 23D corresponding to the edges 23A and 23B in the circumferential direction PD.

[0070] For this reason, even if the end faces of the multiple second wall portions 22A, 22B, 23 are cut end faces 22D, 22C, 23C, 23D formed by cutting a blank during the manufacture of the floor panel 1, when a worker handles the floor panel 1 during transportation, installation, etc., the worker is likely to come into contact with the first curved portion CV1. On the other hand, contact with the cut end faces 22D, 22C, 23C, 23D is reduced. As a result, safety when handling the floor panel 1 can be improved.

[0071] In this embodiment, in the multiple wall portions WH, WS, the first curved portion CV1 is formed in each of the adjacent second wall portions 22A and 23 among the multiple second wall portions 22A, 22B, 23. In the multiple wall portions WH, WS, the first curved portion CV1 is formed in each of the adjacent second wall portions 22B and 23 among the multiple second wall portions 22A, 22B, 23.

[0072] Therefore, safety can be improved compared to when the first curved portion CV1 is formed in only one of the adjacent second wall portions 22A, 22B, 23. Also, since the first curved portions CV1 are butted against each other in the thickness direction TD, safety can be improved. Also, since the gaps between the adjacent second wall portions 22A, 22B, 23 are covered by the first curved portion CV1 in the thickness direction TD, exposure of the joint portions of the panel material 30 from the gaps is suppressed. This improves the aesthetic appearance of the panel material 30.

[0073] In the present embodiment, the first wall portions 12A, 12B, 13 and the second wall portions 22A, 22B, 23 corresponding to each other in the multiple wall portions WH, WS are overlapped with each other in the inward-outward direction SD perpendicular to the wall surfaces of the multiple wall portions WH, WS. The end portions in the circumferential direction PD of the first wall portions 12A, 12B, 13 arranged on the outer side OS in the inward-outward direction SD are folded back to the back side of the first wall portions 12A, 12B, 13 and overlap with the second wall portions 22A, 22B, 23 arranged on the inner side IS in the inward-outward direction SD. This improves the integrity of the first covering member 10 and the second covering member 20, thereby improving the strength.

[0074] In this embodiment, in the four wall portions WS, the first wall portion 13 disposed on the outer side OS in the inward / outward direction SD has two edges 13A, 13B in the circumferential direction PD formed with second curved portions CV2 disposed outside the cut end faces 13C, 13D corresponding to the edges 13A, 13B in the circumferential direction PD. This further improves safety when handling the floor panel 1.

[0075] In this embodiment, in the plurality of walls WH, WS, the ends in the thickness direction TD of the first walls 12A, 12B, 13 arranged on the outer side OS in the inward / outward direction SD are folded back and overlapped with the second walls 22A, 22B, 23 arranged on the inner side IS in the inward / outward direction SD. This further improves the strength of the floor panel 1.

[0076] In this embodiment, the third curved portion CV3 is formed at the edge 13E in the thickness direction TD of the first wall portion 13 disposed on the outer side OS in the inward / outward direction SD of the four wall portions WS. This further improves safety when handling the floor panel 1.

[0077] <Other embodiments> Although the present disclosure has been described by the above disclosed embodiments, the descriptions and drawings forming a part of this disclosure should not be understood as limiting the present disclosure. It should be considered that various alternative embodiments, examples and operating techniques will become apparent to those skilled in the art from the present disclosure.

[0078] (Modification) 10 and 11, in a floor panel 1A according to a modified example, the end portions in the circumferential direction PD of the second wall portions 22A, 22B, 23 of the second covering member 20A are bent. In the modified example, the first curved portion CV1 is formed by bending, not by drawing press processing.

[0079] 10 illustrates a state in which the left end of the central second wall portion 23 is bent so that the corresponding cut end surface 23C is located inside the left end edge 23A in the medial-lateral direction SD. Also, a state in which the right end of the central second wall portion 23 is bent so that the corresponding cut end surface 23D is located inside the right end edge 23B in the medial-lateral direction SD. A first curved portion CV1 is formed between the left end edge 23A and the right end edge 23B of the central second wall portion 23 in FIG. 10.

[0080] 10 illustrates a state in which the right end portion of the second wall portion 22A on the left side is bent so that the corresponding cut end surface 22D is located inside the right edge 22A1 in the medial-lateral direction SD. Also, in FIG. 10 illustrates a state in which the left end portion of the second wall portion 22B on the right side is bent so that the corresponding cut end surface 22C is located inside the left edge 22B1 in the medial-lateral direction SD.

[0081] The bending angle of the end of the central second wall portion 23 in Fig. 10 is different from the bending angle of the end of each of the left and right second wall portions 22A, 22B in Fig. 10. As in the modified example, in this disclosure, the bending angle of the end can be changed as appropriate. The other structure of the floor panel 1A according to the modified example is similar to the structure of this embodiment described using Figs. 1 to 9, so a duplicated description will be omitted.

[0082] (Action and effect) In the modified example, as in the present embodiment, even if the plate thickness of the covering member is reduced, cracks in the corners of the floor panel 1 can be suppressed. Other effects of the modified example are the same as those of the present embodiment.

[0083] In addition, the present disclosure may be configured by partially combining the configurations illustrated in the drawings attached to this specification. As described above, the present disclosure includes various embodiments not described above, and the technical scope of the present disclosure is defined only by the invention-specifying matters in the claims that are appropriate from the above description. [Explanation of symbols]

[0084] 1, 1A... Floor panel 10... First covering member 11... First bottom 12A,12B...First wall part 12A1,12B1...Edge 13...First wall part 13A, 13B, 13E, 13F, 13G... Edge 13C, 13D, 13H...Cut end surface 15A, 15B...First opposing part 16A, 16B...First corner 20,20A...Second covering member 21...Second bottom part 22A,22B...Second wall part 22A1,22B1...Edge 22C,22D...Cut end surface 23...Second wall part 23A, 23B...Edge 23C, 23D...Cut end surface 25A,25B...Second opposing part 26A,26B...Second corner part 30 Panel material 31 Top surface 32 Bottom surface 33 Side surface 34... Corner section 35... Slope section 41... Slab 42... Support leg 43... Fixture 44... Interior material CV1... First curved section CV2...Second song part CV3...Third song part IS...Inside OS: Outside PD: Circumferential direction SD: Inside-out direction TD: Thickness direction X1···base folded piece X2···end folded piece X3···center folded piece X4···Bending piece

Claims

1. a plate-shaped panel material having a top surface and a bottom surface; A first covering member covering the top surface; A second covering member covering the bottom surface; A plurality of wall portions each provided on a periphery of at least one of the first covering member and the second covering member so as to rise along a thickness direction of the panel material, the plurality of wall portions having one wall portion and another wall portion adjacent to the one wall portion in the periphery direction; a corner portion formed by the one wall portion and the other wall portion; a facing portion provided at the corner portion and formed by an edge of the one wall portion on the side of the other wall portion facing an edge of the other wall portion on the side of the one wall portion; A floor panel equipped with

2. a first curved portion is formed on the edge of at least one of the one wall portion and the other wall portion, the first curved portion being disposed on the outer side of an end surface corresponding to the edge in the circumferential direction; The floor panel according to claim 1 .

3. The first curved portion is formed in each of the one wall portion and the other wall portion, The first curved portion of the one wall portion and the first curved portion of the other wall portion are butted against each other in the thickness direction. The floor panel according to claim 2.

4. The first covering member has a first wall portion as the wall portion, The second covering member has a second wall portion as the wall portion at a position corresponding to the first wall portion in the thickness direction, The first wall portion and the second wall portion are overlapped with each other in an inner-outer direction perpendicular to a wall surface of the wall portion, An end portion in the circumferential direction of one of the first wall portion and the second wall portion that is disposed on the outer side in the inward / outward direction is folded back to the back side of the wall portion and overlapped with the other of the first wall portion and the second wall portion that is disposed on the inner side in the inward / outward direction. The floor panel according to claim 1 .

5. a second curved portion is formed on the edge of the wall portion that is disposed on the outer side in the inward / outward direction out of the first wall portion and the second wall portion, the second curved portion being disposed on the outer side of an end surface corresponding to the edge in the circumferential direction; The floor panel according to claim 4.

6. An end portion in the thickness direction of the first wall portion and the second wall portion that is disposed on the outer side in the inward / outward direction is folded back and overlapped with the wall portion that is disposed on the inner side in the inward / outward direction. The floor panel according to claim 5.

7. A third curved portion is formed on an edge of the first wall portion or the second wall portion that is disposed on the outer side in the inward / outward direction, the third curved portion being disposed on an edge in the thickness direction. The floor panel according to claim 6.

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