Deck plate

Abstract

To provide a deck plate having high strength and rigidity and having reduced manufacturing costs.SOLUTION: A deck plate 10 includes: a flat portion 11 on one side of which concrete C is placed in a thickness direction Z; and a plurality of protruding portions protruding from the flat portion 11 to one side in the thickness direction Z. Each of the plurality of protruding portions is aligned in the first direction X and extends along the second direction Y. The plurality of protruding portions includes a first protruding portion 210 that protrudes from the flat portion 11 in the thickness direction Z to a first height T1, and a second protruding portion 220 that protrudes from the flat portion 11 in the thickness direction Z to a second height T2 that is lower than the first height T1.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a deck plate. [Background technology]

[0002] Known deck plates function solely as formwork for pouring concrete (see, for example, Patent Document 1). The deck plate described in Patent Document 1 includes a flat, planar portion and multiple protruding portions protruding from the flat portion, with concrete poured onto the flat portion on the side opposite the protruding portions. Such deck plates are sometimes called "flat decks."

[0003] Another type of deck plate is known that not only functions as a formwork but also serves the structural function of a concrete slab (see, for example, Patent Document 2). The deck plate described in Patent Document 2 has a shape in which peaks and valleys are alternately formed. Furthermore, minute grooves such as dovetail grooves and V-grooves, as well as minute irregularities, are formed in the peaks and valleys of the deck plate described in Patent Document 2. According to the deck plate described in Patent Document 2, the peaks, valleys, minute grooves (dovetail grooves, V-grooves), and minute irregularities integrate the deck plate and the concrete poured on it, forming a composite deck slab from the deck plate and the concrete. Such a deck plate is sometimes called a "composite deck." [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2023-112945 [Patent Document 2] Japanese Patent Application Publication No. 2016-037717 Summary of the Invention [Problem to be solved by the invention]

[0005] The flat deck and composite deck described above function as formwork, and therefore preferably have high rigidity to support the load of the concrete before it hardens. Furthermore, the composite deck becomes part of the concrete slab after the concrete hardens, and therefore preferably has high rigidity to fulfill the structural function of the concrete slab.

[0006] However, in order to strengthen the rigidity of flat decks or composite decks, previous knowledge required, for example, increasing the thickness of the deck plates or uniformly increasing the height of the deck plates, which resulted in, for example, an increase in the amount of material required for manufacturing, leading to increased costs.

[0007] The present invention has been made in consideration of the above points, and one of its objectives is to provide a deck plate that has high strength and rigidity and can be manufactured at reduced costs. [Means for solving the problem]

[0008] (1): The deck plate according to the present invention comprises a flat portion on one side of which concrete is poured in a thickness direction, and a plurality of protruding portions protruding from the flat portion to one side in the thickness direction, the plurality of protruding portions being aligned in a first direction perpendicular to the thickness direction and extending along a second direction perpendicular to the thickness direction and the first direction, the plurality of protruding portions including a first protruding portion protruding from the flat portion in the thickness direction to a first height, and a second protruding portion protruding from the flat portion in the thickness direction to a second height lower than the first height. Note that the flat portion may have a protruding stripe formed thereon.

[0009] In this specification, "perpendicular" also includes cases where the orientation is not perpendicular due to the range of error caused by manufacturing error or the like.

[0010] (2) In the deck plate of (1), the first protruding portions and the second protruding portions may be arranged alternately in the first direction.

[0011] (3) In the deck plate of (1) or (2), the second protrusions may be arranged at equal intervals in the first direction.

[0012] (4) In the deck plate of any one of (1) to (3), the top of the first protrusion may be parallel to the flat portion.

[0013] In this specification, "parallel" also includes cases where the objects are not parallel within the range of tolerances resulting from manufacturing tolerances and the like.

[0014] (5): In any of the deck plates (1) to (4), a recess may be formed at the top of the second protrusion along the second direction in which a reinforcing bar to be embedded in the concrete can be placed.

[0015] (6): In any of the deck plates (1) to (5), the flat portion is made of a single plate-like member, and each of the first protruding portion and the second protruding portion has a plate joint portion where the plate-like member is bent toward one side in the thickness direction so that parts of the plate-like members overlap in the first direction, a transition portion where the flat portion transitions to the plate joint portion, and a protruding portion main body connected to the end of the plate joint portion on the opposite side in the thickness direction to the transition portion, and the height of the plate joint portion of the second protruding portion in the thickness direction may be lower than the height of the plate joint portion of the first protruding portion.

[0016] (7): In the deck plate of (6), the height of the plate joint portion of the first protrusion in the thickness direction may be higher by a predetermined height than a reference height from the flat portion in the thickness direction, and the height of the plate joint portion of the second protrusion in the thickness direction may be lower by the same height as the predetermined height.

[0017] (8): In any of the deck plates (1) to (5), the flat portion may be made of a single plate-like member, and the first protrusion may have a plate joint portion where the plate-like member is bent toward one side in the thickness direction so that parts of the plate-like members overlap in the first direction, a transition portion that transitions from the flat portion to the plate joint portion, and a first protrusion main body that is connected to the end of the plate joint portion on the opposite side in the thickness direction to the transition portion, and the second protrusion may be composed of a second protrusion main body and a transition portion that transitions from the flat portion to the second protrusion main body.

[0018] (9): In any of the deck plates (1) to (5), each of the plurality of protrusions includes a top parallel to the flat portion and a pair of inclined portions that connect to the flat portion from both ends of the top in the first direction and incline away from each other in the first direction as they approach the flat portion, and the height from the flat portion to the top of the second protrusion in the thickness direction may be lower than the height from the flat portion to the top of the first protrusion.

[0019] (10): In the deck plate of (9), the height from the flat portion to the top of the first protrusion may be higher than the reference height from the flat portion in the thickness direction by a predetermined height, and the height from the flat portion to the top of the second protrusion may be lower by a length equal to the predetermined length. [Effects of the Invention]

[0020] According to the present invention, a deck plate having high strength and rigidity and having reduced manufacturing costs is provided. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a cross-sectional view schematically showing a portion of a concrete slab having a deck plate according to a first embodiment of the present invention. [Figure 2] 2 is a table showing the cross-sectional properties of the deck plate shown in FIG. 1. [Figure 3]2 is a cross-sectional view schematically showing a portion of a concrete slab having a deck plate according to a modified example of the deck plate shown in FIG. 1. FIG. [Figure 4] FIG. 6 is a cross-sectional view schematically showing a portion of a concrete slab having a deck plate according to a second embodiment of the present invention. [Figure 5] FIG. 5 is a diagram for explaining a deck plate for verifying the cross-sectional performance of the deck plate shown in FIG. 4. [Figure 6] 6 is a table showing the cross-sectional properties of the deck plate shown in FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0022] Below, embodiments for implementing a deck plate according to the present invention are illustrated with reference to the accompanying drawings. The embodiments illustrated below are intended to facilitate understanding of the present invention and are not intended to limit the present invention. The present invention can be modified or improved from the following embodiments without departing from the spirit of the present invention. In addition, in the accompanying drawings, the dimensions of each component may be exaggerated or reduced, and hatching may be omitted, in order to facilitate understanding.

[0023] (First embodiment) Fig. 1 is a cross-sectional view showing a part of a concrete slab according to this embodiment. As shown in Fig. 1, the concrete slab 1 according to this embodiment mainly comprises concrete C, a deck plate 10, an upper reinforcing bar group 120, and a lower reinforcing bar group 130.

[0024] The deck plate 10 is a member formed by bending a single metal plate (plate-shaped member) and includes a flat portion 11 and multiple protrusions (hereinafter, the multiple protrusions may be collectively referred to as a "protrusion group 20"). The flat portion 11 is a flat portion extending in a first direction X and a second direction Y perpendicular to the first direction X. The thickness direction Z is a direction perpendicular to the first direction X and the second direction Y. The protrusion group 20 protrudes from the flat portion 11 to one side (upper side) in the thickness direction Z. No protrusion group 20 is present on the other side (lower side) of the flat portion 11. Therefore, the lower surface 11B of the concrete slab 1 (i.e., the lower surface 11B of the deck plate 10) is substantially flat. Note that the lower surface 11B may be embossed or ridged for the purpose of improving rigidity, etc. Meanwhile, concrete C is poured onto an upper surface 11U, which is one surface of the flat portion 11 in the thickness direction Z. Therefore, the projection group 20 is embedded in the concrete C.

[0025] The protrusions constituting the protrusion group 20 are arranged at intervals (equally spaced in this embodiment) in the first direction X and extend along the second direction Y. In this embodiment, the protrusion group 20 includes a plurality of first protrusions 210 and a plurality of second protrusions 220. In the thickness direction Z, each of the plurality of first protrusions 210 protrudes from the flat portion 11 to a first height T1, and each of the plurality of second protrusions 220 protrudes from the flat portion 11 to a second height T2. The second height T2 is smaller than the first height T1. In this embodiment, the first protrusions 210 and the second protrusions 220 are arranged alternately in the first direction X. Furthermore, in this embodiment, the plurality of second protrusions 220 are arranged at equal intervals D in the first direction X.

[0026] It is not necessary that the first protrusions 210 and the second protrusions 220 are alternately arranged in the first direction X. Furthermore, it is not necessary that the multiple protrusions constituting the protrusion group 20 are arranged at equal intervals in the first direction X, and furthermore, it is not necessary that the multiple second protrusions 220 are arranged at equal intervals D.

[0027] Each of the multiple first protrusions 210 has a plate joint portion 213 where the plate-like members constituting the flat portion 11 are bent upward so that parts of the plate-like members overlap in the first direction X, a transition portion 21 that transitions from the flat portion 11 to the plate joint portion 213, and a protrusion main body 211 that is connected to the end (upper end) of the plate joint portion 213 on the opposite side (upper side) to the transition portion 21 side in the thickness direction Z. Parts of the plate-like members (two overlapping portions) that form the plate joint portion 213 may be in contact with each other, or may be integrated by processing such as caulking.

[0028] The transition portion 21 is a pair of rounded portions formed at the boundary between the board joining portion 213 and the flat portion 11 in the process of forming the board joining portion 213 by overlapping parts of the plate-like members. Specifically, the transition portion 21 includes an rounded portion on one side that connects the plate portion on one side in the first direction X of the board joining portion 213 to the flat portion 11 on one side in the first direction X of the board joining portion 213, and an rounded portion on the other side that connects the plate portion on the other side in the first direction X of the board joining portion 213 to the flat portion 11 on the other side in the first direction X of the board joining portion 213. The distance from the upper end of the transition portion 21 to the upper end of the board joining portion 213 is the height T3 of the board joining portion 213.

[0029] As described above, the protrusion main body 211 is connected to the upper end of the plate joint portion 213. The protrusion main body 211 is formed so that its cross section along the thickness direction Z is triangular (for example, an isosceles triangle). The protrusion main body 211 is formed so that it widens in the first direction X as it moves upward from the upper end of the plate joint portion 213. In this embodiment, the upper surface of the protrusion main body 211 (hereinafter referred to as the "top 211T") is parallel to the flat portion 11. The first height T1, which is the height of the first protrusion 210, is the length in the thickness direction from the upper side surface 11U of the flat portion 11 to the top 211T.

[0030] The cross-sectional shape of the protrusion main body 211 is not limited to a triangular shape. The top 211T of the protrusion main body 211 does not have to be parallel to the flat portion 11. Although not shown, the end of each of the multiple first protrusions 210 in the second direction Y may be end-closed.

[0031] Each of the plurality of second protrusions 220 has a plate joint portion 223 where the plate-like members constituting the flat portion 11 are bent upward so that parts of the plate-like members overlap in the first direction X, a transition portion 21 that transitions from the flat portion 11 to the plate joint portion 223, and a protrusion main body 221 that is connected to the end portion (upper end) of the plate joint portion 223 on the opposite side (upper side) to the transition portion 21 in the thickness direction Z. Parts of the plate-like members (two overlapping portions) that form the plate joint portion 223 may be in contact with each other, or may be integrated by processing such as caulking.

[0032] The transition portion 21 has the same configuration as the transition portion 21 of the first protruding portion 210, as indicated by the same reference numerals as those of the transition portion 21 described in the first protruding portion 210. The distance from the upper end of the transition portion 21 to the upper end of the board joint portion 223 is the height T4 of the board joint portion 223. In this embodiment, the height T4 of the board joint portion 223 of the second protruding portion 220 is shorter than the height T3 of the board joint portion 213 of the first protruding portion 210.

[0033] As described above, the protrusion main body 221 is connected to the upper end of the plate joint portion 223. The protrusion main body 221 is formed so that its cross section along the thickness direction Z is triangular (for example, an isosceles triangle). The protrusion main body 221 is formed so that it widens in the first direction X as it moves upward from the upper end of the plate joint portion 223. In this embodiment, the upper surface of the protrusion main body 221 (hereinafter referred to as the "top 221T") is parallel to the flat portion 11. The second height T2, which is the height of the second protrusion 220, is the length in the thickness direction from the upper side surface 11U of the flat portion 11 to the top 221T.

[0034] The cross-sectional shape of the protrusion main body 221 is not limited to a triangular shape. The apex 221T does not have to be parallel to the flat portion 11. Although not shown, the end of each of the multiple second protrusions 220 in the second direction Y may be end-closed.

[0035] In this embodiment, a recess 221R is formed along the second direction Y, for example near the center in the first direction X of the top 221T of the protrusion main body 221. This recess 221R is formed so that its cross section along the thickness direction Z is, for example, semicircular, and is formed so that reinforcing bars, which will be described later and which form the lower reinforcing bar group 130, can be placed therein. Note that the recess 221R does not necessarily have to be formed in the top 221T. Also, a recess similar to the recess 221R may be formed in the top 211T of the first protrusion 210.

[0036] In this embodiment, the width (length in the first direction X) of the protrusion main body 211 is the same as the width of the protrusion main body 221. Furthermore, the height (length in the thickness direction Z) of the protrusion main body 211 is the same as the height of the protrusion main body 221. Therefore, in this embodiment, the difference between the first height T1 of the first protrusion 210 and the second height T2 of the second protrusion 220 is equal to the difference between the height T3 of the board joining portion 213 of the first protrusion 210 and the height T4 of the board joining portion 223 of the second protrusion 220.

[0037] As shown in FIG. 1 , the upper reinforcing bar group 120 is embedded in concrete C and reinforces, for example, the bearing capacity and rigidity of a concrete slab 1. The upper reinforcing bar group 120 includes a plurality of main reinforcements 121 extending along the second direction Y and a plurality of distribution reinforcements 122 extending along the first direction X. The main reinforcements 121 are located above the distribution reinforcements 122 and are fixed to the distribution reinforcements 122 by, for example, binding wires. That is, the upper reinforcing bar group 120 can be considered as a lattice-shaped reinforcing bar member consisting of the main reinforcements 121 and the distribution reinforcements 122, or as a wire mesh-shaped member in which the main reinforcements 121 and the distribution reinforcements 122 are joined to each other by welding or the like. As described above, the top 211T of the first protrusion 210 is parallel to the flat portion 11. Therefore, by placing a plurality of reinforcing bars 122 on each of the apexes 211T of the plurality of first protrusions 210, the upper reinforcing bar group 120 can be arranged without tilting relative to the flat portion 11. That is, in this embodiment, the first protrusions 210 function as spacers for arranging the upper reinforcing bar group 120.

[0038] The upper reinforcing bar group 120 may be disposed above the top portion 211T (that is, at a position away from the top portion 211T).

[0039] As shown in FIG. 1 , the lower reinforcing bar group 130 is located below the upper reinforcing bar group 120, specifically, below the apex 211T of the first protrusion 210. The lower reinforcing bar group 130 includes a plurality of independent reinforcing bars 110. Each of the plurality of reinforcing bars 110 extends in the second direction Y and is embedded in concrete C, thereby enhancing the strength and rigidity of, for example, the concrete slab 1. As described above, the apex 221T of the second protrusion 220 has a recess 221R formed therein. Therefore, by arranging one reinforcing bar 110 in a one-to-one correspondence with the recess 221R of one apex 221T, the lower reinforcing bar group 130 can be placed on a plurality of second protrusions 220. In this manner, in this embodiment, the second protrusion 220 functions as a spacer for arranging the lower reinforcing bar group 130. Furthermore, by placing the reinforcing bars 110 in the recesses 221R, the reinforcing bars 110 are prevented from moving on the tops 221T, allowing the reinforcing bars 110 to be positioned appropriately. Furthermore, in this embodiment, the multiple second protrusions 220 are arranged at equal intervals D, allowing the reinforcing bars 110 to be positioned at equal intervals. Note that the position at which the lower reinforcing bar group 130 is placed is not limited to on the tops 221T of the second protrusions 220. For example, in the thickness direction Z, the lower reinforcing bar group 130 may be placed between the tops 211T of the first protrusions 210 and the tops 221T of the second protrusions 220, or may be placed between the tops 221T of the second protrusions 220 and the flat portion 11.

[0040] As described above, the deck plate 10 of this embodiment has a flat portion 11 on one side surface (upper surface 11U) in the thickness direction Z onto which concrete C is poured, and a plurality of protrusions (protrusion group 20) protruding from the flat portion 11 to one side (upper side) in the thickness direction Z. In the deck plate 10, each of the plurality of protrusions is aligned in a first direction X perpendicular to the thickness direction Z and extends along a second direction Y perpendicular to the thickness direction Z and the first direction X. The plurality of protrusions include a first protrusion 210 protruding from the flat portion 11 in the thickness direction Z to a first height T1, and a second protrusion 220 protruding from the flat portion 11 in the thickness direction Z to a second height T2 lower than the first height T1.

[0041] When flat decks are used for concrete slabs, concrete can be poured evenly on the upper surface of the flat portion (the surface opposite the protruding portion), enabling rational design of versatile reinforced concrete slabs. Furthermore, the strength and rigidity of the slab can be enhanced, which can be advantageous in terms of improving the building's vibration performance, sound insulation, and other aspects of livability. For this reason, flat decks are widely used as useful building components. However, when using such flat decks, for example, when connecting to parting walls, the construction site may require the time and effort of filling the ribs with non-combustible materials, or in other cases, the time and effort of removing the ribs.

[0042] In contrast, when using the deck plate 10 according to this embodiment, the protrusion group 20 of the deck plate 10 faces upward (the side where the concrete C is poured), and the flat lower surface 11B of the flat portion 11 of the deck plate 10 faces downward (the side opposite to the side where the concrete C is poured). In other words, in this embodiment, the vertically lower surface (bottom surface) of the concrete slab 1 is flat, so that the parting walls of the building can be joined to the concrete slab 1 without gaps. Therefore, with the deck plate 10 according to this embodiment, it is possible to address gaps between parting walls and partition walls without cutting out the protrusion group 20 or filling the spaces between adjacent protrusions or the internal spaces of the protrusion bodies 211 with a non-combustible material or other injection material, making it easy to address gaps in the partition walls.

[0043] Furthermore, according to the concrete slab 1 using the deck plate 10 of this embodiment, the group of protrusions 20 do not protrude downward in the vertical direction, which prevents the group of protrusions 20 from interfering with ensuring the interior height, making it easier to ensure the interior height and reducing the overall height of the building.

[0044] Furthermore, in the concrete slab 1 using the deck plate 10 according to this embodiment, the group of protrusions 20 extending in the second direction Y are embedded inside the concrete C, so that the deck plate and concrete can be integrated to function as a composite deck slab. In this case, the concrete slab 1 has unidirectional properties in the second direction Y. This allows the group of protrusions 20 to bear loads. Therefore, the deck plate 10 can be used not only as a formwork material but also as a structural material.

[0045] The deck plate 10 can also be used as a formwork material. When the deck plate 10 is used as a formwork material, the concrete slab 1 is treated as a reinforced concrete structural floor with high design versatility, and therefore is less subject to the design conditions of the concrete slab 1, such as the structural design specifications for deck composite slabs and the fire resistance certification specifications for deck composite slabs, compared to when the deck plate 10 is used as a structural material. Therefore, the deck plate 10 can achieve high design convenience.

[0046] Furthermore, because the deck plate 10 is not a reinforced deck plate with complicated rebar trusses attached to the walking side, it is possible to prevent difficulty in walking on the deck plate 10 and prevent work equipment cords from becoming tangled in the main reinforcement at the construction site once the deck plate 10 is installed. In this way, the deck plate 10 also contributes to good workability at construction sites.

[0047] Furthermore, since the deck plate 10 of this embodiment has a group of protrusions 20 composed of first protrusions 210 and second protrusions 220 of different heights, it has higher cross-sectional performance than a deck plate having a group of protrusions composed of protrusions of the same height, for reasons described below.

[0048] The inventors have verified the cross-sectional performance of the deck plate 10 according to this embodiment as follows.

[0049] Specifically, a deck plate having the same configuration as deck plate 10 except that the first height T1 and the second height T2 were the same was designated as the deck plate of Comparative Example 1. The improvement rate of the cross-sectional performance of deck plate 10 (Examples 1 to 8) relative to the cross-sectional performance of the deck plate of Comparative Example 1 was calculated using computer-aided design (CAD) software. The second moment of area I when the entire cross section is effective and the section modulus Z when the entire cross section is effective were used as indicators of cross-sectional performance.

[0050] FIG. 2 shows the results of verifying the cross-sectional performance of the deck plate of Comparative Example 1 and the cross-sectional performance of each of the deck plates 10 of Examples 1 to 8.

[0051] The thickness Td (see FIG. 1) of each of the deck plate of Comparative Example 1 and the deck plate 10 (Examples 1 to 8) was set to 0.8 mm. The thickness Td is the length in the thickness direction Z from the lower surface 11B of the flat portion 11 to the upper surface 11U. The height of the protruding portion of the deck plate of Comparative Example 1 (T1 = T2 = T) was set to 74.0 mm. That is, the height from the lower surface 11B of the deck plate of Comparative Example 1 to the top of the protruding portion (hereinafter referred to as the "reference height") was 74.8 mm (T + Td). The height of the plank joint of the deck plate of Comparative Example 1 (T3 = T4) was set to 8.77 mm.

[0052] The deck plate 10 of Example 1 has a protrusion group 20 composed of a first protrusion 210 having a height (T+Td+1=75.8 (mm)) that is 1 mm (predetermined height) higher than the reference height, and a second protrusion 220 having a height (T+Td-1=73.8 (mm)) that is 1 mm (predetermined height) lower than the reference height. Furthermore, the plate joint 213 of the first protrusion 210 of Example 1 has a height T3 that is 1 mm higher than the plate joint of Comparative Example 1, and the plate joint 223 of the second protrusion 220 of Example 1 has a height T4 that is 1 mm lower than the plate joint of Comparative Example 1.

[0053] The deck plates 10 of Examples 2 to 7, where the example number is N (N is a natural number between 2 and 7), have a protrusion group 20 made up of a first protrusion 210 having a height (T+Td+N) that is N mm (a predetermined height) higher than the reference height (T+Td), and a second protrusion 220 having a height (T+Td-N) that is N mm (a predetermined height) lower than the reference height. Furthermore, the plate joint 213 of the first protrusion 210 of Examples 2 to 7 has a height T3 that is N mm higher than the plate joint of Comparative Example 1, and the plate joint 223 of the second protrusion 220 of Example 1 has a height T4 that is N mm lower than the plate joint of Comparative Example 1.

[0054] The deck plate 10 of Example 8 has a protrusion group 20 composed of a first protrusion 210 having a height (T + Td + 8 = 82.8 mm) that is 8 mm (predetermined height) higher than the reference height and a second protrusion 220 having a height (T + Td - 8 = 66.8 mm) that is 8 mm (predetermined height) lower than the reference height. Furthermore, the plate joint 213 of the first protrusion 210 of Example 8 has a height T3 that is 8 mm higher than the plate joint of Comparative Example 1. Meanwhile, since the plate joint height of Comparative Example 1 is 8.77 mm as described above, the plate joint 223 of the second protrusion 220 of Example 8 is 0.77 mm. However, this (plate joint height = 0.77 mm) is small enough to be considered a manufacturing error compared to the 8 mm plate joint height of Comparative Example 1, and is negligibly small. Therefore, the second protrusion 220 of Example 8 does not substantially have a plate joint 223. That is, as shown in Figure 3, in the deck plate 10A of Example 8, the first protrusion 210 is composed of a board joint portion 213, a transition portion 21, and a protrusion main body 211 (first protrusion main body), whereas the second protrusion 220A is composed of a protrusion main body 221 (second protrusion main body) and a transition portion 21 that transitions from the flat portion 11 to the protrusion main body 221 (second protrusion main body).

[0055] As shown in Figure 2, compared to the deck plate of Comparative Example 1, in which the protrusions constituting the protrusion group 20 have the same height (T = 74.0 mm), the deck plates 10 of Examples 1 to 7 and the deck plate 10A of Example 8 each include a first protrusion 210 having a first height T1 and a second protrusion 220 having a second height T2 that is lower than the first height T1. It was found that the cross-sectional performance was improved in each of these deck plates. For example, focusing on Example 6, it can be seen that the second moment of area I of Example 6 is improved by 1.72% and the section modulus Z of Example 6 is improved by 1.33% compared to Comparative Example 1. Furthermore, focusing on Example 8 (deck plate 10A), it can be seen that the second moment of area I of Example 8 is improved by 3.06% and the section modulus Z of Example 8 is improved by 2.35% compared to Comparative Example 1.

[0056] Furthermore, as shown in Figure 2, it was found that the greater the difference between the first height T1 and the second height T2, the more improved the cross-sectional performance of the deck plate 10. In other words, it was found that the cross-sectional performance of the deck plate 10A according to Example 8 shown in Figure 3 was the best among the deck plates of Examples 1 to 8. Note that even if the thickness Td of the deck plate 10 is different from 0.8 mm, the greater the difference between the first height T1 and the second height T2, the more improved the cross-sectional performance of the deck plate 10.

[0057] As described above, according to the first embodiment, by manufacturing a deck plate 10 with protrusions of different heights using the same amount of material as would be used to manufacture a deck plate having a group of protrusions made up of protrusions of the same height, a deck plate with high strength and rigidity can be provided despite the same material cost as a deck plate having a group of protrusions made up of protrusions of the same height.

[0058] In the above-described embodiment and example, the width of protrusion main body 211 and the width of protrusion main body 221 are the same, and the height of protrusion main body 211 and the height of protrusion main body 221 are the same (for convenience, this configuration will be referred to as "Configuration A"), and therefore the difference between first height T1 of first protrusion 210 and second height T2 of second protrusion 220 is equal to the difference between height T3 of board joint portion 213 of first protrusion 210 and height T4 of board joint portion 223 of second protrusion 220. However, as long as second height T2 of second protrusion 220 is lower than first height T1 of first protrusion 210, the configuration does not have to be Configuration A.

[0059] (Second embodiment) Next, a deck plate according to a second embodiment will be described.

[0060] Fig. 4 is a cross-sectional view schematically showing a portion of a concrete slab according to this embodiment. As shown in Fig. 4, the concrete slab 2 according to this embodiment mainly comprises concrete C, a deck plate 310, an upper reinforcing bar group 120, and a lower reinforcing bar group 130 (a plurality of reinforcing bars 110). The upper reinforcing bar group 120 and the lower reinforcing bar group 130 have the same configurations as the upper reinforcing bar group 120 and the lower reinforcing bar group 130 according to the first embodiment.

[0061] The deck plate 310 is a corrugated steel plate formed by bending a single metal plate (plate-shaped member), and includes a flat portion 301 and multiple protrusions (hereinafter, the multiple protrusions may be collectively referred to as a "protrusion group 320"). The flat portion 11 is a flat part extending in the first direction X and the second direction Y, and forms valleys between the multiple protrusions that make up the protrusion group 320. The protrusion group 320 protrudes upward from the flat portion 11 to form peaks and extends in the second direction Y. In this embodiment, the multiple protrusions that make up the protrusion group 320 are arranged at equal intervals in the first direction X. Concrete C is poured on an upper surface 301U of the flat portion 301. Therefore, the protrusion group 320 is embedded in the concrete C. In this way, the deck plate 310 has a configuration in which the peaks (the protrusions constituting the protrusion group 320) and the valleys (the flat portions 301) are arranged alternately in the first direction X.

[0062] The protrusion group 320 includes a plurality of first protrusions 311 and a plurality of second protrusions 321. In the thickness direction Z, each of the plurality of first protrusions 311 protrudes from the flat portion 301 to a first height T11, and each of the plurality of second protrusions 321 protrudes from the flat portion 301 to a second height T12. The second height T12 is smaller than the first height T11. In this embodiment, the first protrusions 311 and the second protrusions 321 are alternately arranged in the first direction X. In addition, in this embodiment, the plurality of second protrusions 321 are arranged at equal intervals in the first direction X.

[0063] It should be noted that the first protrusions 311 and the second protrusions 321 do not have to be arranged alternately in the first direction X. Furthermore, it does not matter that the multiple protrusions constituting the protrusion group 320 are not arranged at equal intervals in the first direction X, and furthermore, it does not matter that the multiple second protrusions 321 are not arranged at equal intervals.

[0064] Each of the multiple first protrusions 311 includes an apex 311T parallel to the flat portion 301 and a pair of inclined portions 312, 312 that are inclined from both ends of the apex 311T in the first direction X so as to move away from each other in the first direction X as they approach the flat portion 301 and connect to the flat portion 301. The length of the inclined portion 312 in the thickness direction Z is a first height T11. A recess 311R is formed in the apex 311T, for example, near the center in the first direction X. Note that the recess 311R does not necessarily have to be formed. Furthermore, a protrusion 311P that protrudes toward the concrete C is formed in the inclined portion 312 near the boundary with the flat portion 301. Note that the protrusion 311P does not necessarily have to be formed.

[0065] Each of the multiple second protrusions 321 includes an apex 321T parallel to the flat portion 301 and a pair of inclined portions 322, 322 that are inclined from both ends of the apex 321T in the first direction X so as to move away from each other in the first direction X as they approach the flat portion 301 and connect to the flat portion 301. The length of the inclined portion 322 in the thickness direction Z is a second height T12. A recess 321R is formed in the apex 321T, for example, near the center in the first direction X. This recess 321R is formed so that its cross section along the thickness direction Z is, for example, semicircular, and is formed so that the reinforcing bars 110 that form the lower reinforcing bar group 130 can be placed therein. Note that the recess 321R does not necessarily have to be formed. Furthermore, a protrusion 321P that protrudes toward the concrete C is formed in the inclined portion 322 near the boundary with the flat portion 301. Note that the protrusion 321P does not necessarily have to be formed.

[0066] Furthermore, in this embodiment, a convex portion 301P is formed near the center of the flat portion 301 in the first direction X, protruding upward, i.e., toward the concrete C. The height of the convex portion 301P (the length from the flat portion 301 to the apex 301Pt of the convex portion 301P) is smaller than the height T11 of the first protrusion 311 and the height T12 of the second protrusion 321. For example, the apex 310Pt of the convex portion 301P may be located at a position in the thickness direction Z of the convex portion 311P formed on the inclined portion 312 or at a position in the thickness direction Z of the convex portion 321P formed on the inclined portion 322. The height of the convex portion 301P may be 5 mm or less. That is, the height T12 of the second protrusion 321 may be greater than the height of the convex portion 301P, for example, greater than 5 mm. Note that the formation of the convex portion 301P is not essential.

[0067] As shown in Fig. 4, the upper reinforcing bar group 120 is embedded in the concrete C, and in this embodiment, it is arranged above the top 311T of the first protrusion 311 (i.e., at a position away from the top 311T). However, the upper reinforcing bar group 120 may be placed on the top 311T. When the upper reinforcing bar group 120 is placed on the top 311T, the top 311T functions as a spacer for placing the upper reinforcing bar group 120.

[0068] As shown in FIG. 4 , the lower reinforcing bar group 130 is located below the upper reinforcing bar group 120, specifically, below the top 311T of the first protrusion 311. The lower reinforcing bar group 130 is embedded in concrete C. As described above, a recess 321R is formed in the top 321T of the second protrusion 321. Therefore, by placing one reinforcing bar 110 in a one-to-one correspondence with the recess 321R of one top 321T, the lower reinforcing bar group 130 can be placed on multiple second protrusions 321. In this way, in this embodiment, the second protrusion 321 functions as a spacer for placing the lower reinforcing bar group 130. Furthermore, by placing the reinforcing bar 110 in the recess 321R, the reinforcing bar 110 is prevented from moving on the top 321T, allowing the reinforcing bar 110 to be properly placed. Furthermore, in this embodiment, since the multiple second protrusions 321 are arranged at equal intervals, the reinforcing bars 110 can be arranged at equal intervals. The position at which the lower reinforcing bar group 130 is arranged is not limited to on the tops 321T of the second protrusions 321. For example, in the thickness direction Z, the lower reinforcing bar group 130 may be arranged between the tops 311T of the first protrusions 311 and the tops 321T of the second protrusions 321.

[0069] The deck plate 310 includes flat portions 301 as valleys and protruding portions 320 as peaks, and the first uneven structure formed by the flat portions 301 and the protruding portions 320 combines and integrates the deck plate 310 and the concrete C. This allows the deck plate 310 to function as a composite deck. Furthermore, in addition to the first uneven structure, the deck plate 310 also has a second uneven structure (a minute uneven structure) formed by protruding portions 301P, protruding portions 311P, and recessed portions 311R, etc., which further integrates the deck plate 310 and the concrete C. The second uneven structure need not be provided on the deck plate 310.

[0070] As described above, the deck plate 310 of this embodiment has a flat portion 301 on one side surface (upper surface 301U) in the thickness direction Z onto which concrete C is poured, and a plurality of protrusions (protrusion group 320) protruding from the flat portion 301 to one side (upper side) in the thickness direction Z. In the deck plate 310, each of the plurality of protrusions is aligned in a first direction X perpendicular to the thickness direction Z and extends along a second direction Y perpendicular to the thickness direction Z and the first direction X. The plurality of protrusions include a first protrusion 311 protruding from the flat portion 301 in the thickness direction Z to a first height T11, and a second protrusion 321 protruding from the flat portion 301 in the thickness direction Z to a second height T12 that is lower than the first height T11.

[0071] As such, the deck plate 310 of this embodiment has a group of protrusions 320 composed of first protrusions 311 and second protrusions 321 of different heights, and therefore has higher cross-sectional performance than a composite deck having a group of protrusions composed of protrusions of the same height, for reasons described below.

[0072] The inventors verified the cross-sectional performance of the deck plate 310 according to this embodiment as follows.

[0073] Specifically, the above verification was performed based on a deck plate 310A as shown in Figure 5. This deck plate 310A has a similar configuration to deck plate 310, except that the portions corresponding to inclined portions 312, 322 are not inclined but are portions 312A, 322A that are parallel to thickness direction Z, and that it does not have a second uneven structure formed by convex portions 301P, convex portions 311P, concave portions 311R, etc. Therefore, the cross-sectional performance of deck plate 310 according to the second embodiment also tends to be similar to the cross-sectional performance of deck plate 310A.

[0074] In this verification, a deck plate (composite deck) having a configuration similar to deck plate 310A except that the first height T11 and second height T12 were the same was used as the deck plate of Comparative Example 2. The improvement rate of the cross-sectional performance of deck plate 310A (Examples 9 to 17) relative to the cross-sectional performance of the deck plate of Comparative Example 2 was calculated using computer-aided design (CAD) software. The second moment of area I when the entire cross section is effective and the section modulus Z when the entire cross section is effective were used as indicators of cross-sectional performance.

[0075] FIG. 6 shows the results of verifying the cross-sectional performance of the deck plate of Comparative Example 2 and the cross-sectional performance of each of the deck plates 310A of Examples 9 to 17.

[0076] The thickness Td (see FIG. 5) of each of the deck plate of Comparative Example 2 and deck plate 310A (Examples 9 to 17) was set to 1.0 mm. The height of the protruding portion of the deck plate of Comparative Example 2 (T11 = T12 = T) was set to 75 mm. The height of the protruding portion of the deck plate of Comparative Example 2 (hereinafter referred to as the "reference height") is the height from the upper side surface 301U of the flat portion 301 of the deck plate of Comparative Example 2 to the top of the protruding portion.

[0077] The deck plate 310A of Example 9 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+1 = 76 (mm)) that is 1 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-1 = 74 (mm)) that is 1 mm (predetermined height) lower than the reference height.

[0078] The deck plate 310A of Example 10 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+2=77 (mm)) that is 2 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-2=73 mm) that is 2 mm (predetermined height) lower than the reference height.

[0079] The deck plate 310A of Example 11 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+3=78 (mm)) that is 3 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-3=72 (mm)) that is 3 mm (predetermined height) lower than the reference height.

[0080] The deck plate 310A of Example 12 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+4=79 (mm)) that is 4 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-4=71 (mm)) that is 4 mm (predetermined height) lower than the reference height.

[0081] The deck plate 310A of Example 13 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+5=80 (mm)) that is 5 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-5=70 (mm)) that is 5 mm (predetermined height) lower than the reference height.

[0082] The deck plate 310A of Example 14 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+10=85 (mm)) that is 10 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-10=65 (mm)) that is 10 mm (predetermined height) lower than the reference height.

[0083] The deck plate 310A of Example 15 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+20=95 (mm)) that is 20 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-20=55 (mm)) that is 20 mm (predetermined height) lower than the reference height.

[0084] The deck plate 310A of Example 16 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+40=115 (mm)) that is 40 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-40=35 (mm)) that is 40 mm (predetermined height) lower than the reference height.

[0085] The deck plate 310A of Example 17 has a protrusion group 320 consisting of a first protrusion 311 having a first height T11 (T+60=135 (mm)) that is 60 mm (predetermined height) higher than the reference height, and a second protrusion 321 having a second height T12 (T-60=15 (mm)) that is 60 mm (predetermined height) lower than the reference height.

[0086] As shown in Figure 6, compared to the deck plate of Comparative Example 2, in which the protrusions constituting protrusion group 320 have the same height (T = 75 mm), the deck plates 310A of Examples 9 to 17, which include first protrusion 311 having a first height T11 and second protrusion 321 having a second height T12 that is shorter than first height T11, exhibit improved cross-sectional performance. For example, focusing on Example 14, it can be seen that the second moment of area I of Example 14 is improved by 4.57% and the section modulus Z of Example 14 is improved by 3.96% compared to Comparative Example 2. Furthermore, focusing on Example 17, it can be seen that the second moment of area I of Example 17 is improved by 158.70% and the section modulus Z of Example 17 is improved by 113.71% compared to Comparative Example 2.

[0087] 6, it was found that the greater the difference between the first height T11 and the second height T12, the more the cross-sectional performance of the deck plate 310A improves. Note that even if the thickness Td of the deck plate 310A is different from 1.0 mm, the greater the difference between the first height T11 and the second height T12, the more the cross-sectional performance of the deck plate 310A improves.

[0088] As described above, according to the second embodiment, by manufacturing the deck plate 310 so that the protrusions have different heights using the same amount of material as would be used to manufacture a composite deck having a group of protrusions made up of protrusions of the same height, a composite deck with high strength and rigidity can be provided despite the same material cost as a composite deck having a group of protrusions made up of protrusions of the same height.

[0089] Although the present invention has been described above using the above-mentioned embodiment as an example, the present invention is not limited thereto. Those skilled in the art can appropriately modify the deck plate of the present invention in accordance with conventional knowledge. As long as such modifications still comprise the configuration of the present invention, they are of course included in the scope of the present invention. [Explanation of symbols]

[0090] 10, 10A, 310... deck plate, 11, 301... flat portion, 21... transition portion, 110... reinforcing bar, 210, 311... first protrusion, 211, 221... protrusion body, 211T, 311T, 321T... top, 220, 220A, 321... second protrusion, 221R, 321R... recess, 312, 322... inclined portion, C... concrete

Claims

1. A flat portion on one side of which concrete is poured in the thickness direction; a plurality of protruding portions protruding from the flat portion to one side in the thickness direction; Equipped with the plurality of protrusions are aligned in a first direction perpendicular to the thickness direction and extend along a second direction perpendicular to the thickness direction and the first direction, The plurality of protrusions are a first protruding portion protruding from the flat portion in the thickness direction to a first height; a second protruding portion protruding from the flat portion in the thickness direction to a second height that is lower than the first height; Including deck plate.

2. The deck plate according to claim 1 , wherein the first protrusions and the second protrusions are arranged alternately in the first direction.

3. The deck plate according to claim 1 or 2, wherein the second protrusions are arranged at equal intervals in the first direction.

4. The deck plate according to claim 1 or 2, wherein a top of the first protrusion is parallel to the flat portion.

5. 3. The deck plate according to claim 1, wherein a recess, into which a reinforcing bar to be embedded in the concrete can be placed, is formed at a top of the second protrusion along the second direction.

6. the flat portion is made of a single plate-like member, Each of the first protrusion and the second protrusion is a plate joining portion in which the plate-like members are bent toward one side in the thickness direction so that parts of the plate-like members overlap each other in the first direction; A transition portion that transitions from the flat portion to the plate joining portion; a protrusion main body connected to an end portion of the plate joining portion opposite to the transition portion in the thickness direction; and The deck plate according to claim 1 or 2, wherein a height of the plate joint portion of the second protruding portion in the thickness direction is lower than a height of the plate joint portion of the first protruding portion.

7. 7. The deck plate according to claim 6, wherein a height of the plate joint portion of the first protruding portion in the thickness direction is higher by a predetermined height than a reference height from the flat portion in the thickness direction, and a height of the plate joint portion of the second protruding portion in the thickness direction is lower by the same height as the predetermined height.

8. the flat portion is made of a single plate-like member, The first protrusion is a plate joining portion in which the plate-like members are bent toward one side in the thickness direction so that parts of the plate-like members overlap each other in the first direction; A transition portion that transitions from the flat portion to the plate joining portion; a first protrusion body connected to an end portion of the plate joining portion opposite to the transition portion in the thickness direction; and The deck plate according to claim 1 or 2, wherein the second protrusion is constituted by a second protrusion main body and a transition portion that transitions from the flat portion to the second protrusion main body.

9. Each of the plurality of protrusions is a top portion parallel to the flat portion; a pair of inclined portions inclined from both ends of the top portion in the first direction so as to move away from each other in the first direction as they approach the flat portion and connect to the flat portion; Including, 3. The deck plate according to claim 1, wherein a height from the flat portion to the top of the second protruding portion in the thickness direction is lower than a height from the flat portion to the top of the first protruding portion.

10. 10. The deck plate according to claim 9, wherein a height from the flat portion to the top of the first protruding portion is higher by a predetermined height than a reference height from the flat portion in the thickness direction, and a height from the flat portion to the top of the second protruding portion is lower by a length equal to the predetermined length.

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