Method for manufacturing floor panels and floor panels

Abstract

This invention relates to a method for manufacturing floor panels and to floor panels themselves. [Solution] A method for manufacturing a floor panel, comprising: a first step of drilling multiple through holes in an upper panel and a lower panel; a second step of forming protrusions on the upper and lower surfaces of a resin plate material that can be inserted into the through holes and have a height that protrudes from the through holes; a third step of arranging the upper panel and the lower panel on the upper and lower surfaces of the resin plate material and inserting the protrusions into the through holes of the upper panel and the lower panel; a fourth step of heating the protrusions of the resin plate material that protrude from the through holes of the upper panel and the lower panel to generate molten resin; a fifth step of pressing the upper panel and the lower panel and deforming the molten resin into the through holes and the depressions around the through holes; a sixth step of filling the through holes and the depressions around the through holes with the molten resin that has been introduced to form a joint and smooth the surfaces of the upper panel and the lower panel; and a seventh step of processing and finishing the ends of the upper panel and the lower panel.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a floor panel, particularly a floor panel constituting a double floor such as an OA floor, and to the floor panel.

Background Art

[0002] In recent years, a double floor structure for housing wiring and the like under the floor, called an OA floor, has become widespread, and there are a variety of floor materials constituting the double floor, which are selected and used according to the purpose of use and environmental conditions. For example, there are concrete-based floor materials with high durability, sound absorption, and fire resistance, aluminum or steel floor materials with high strength, and inexpensive and lightweight resin-based floor materials. In particular, a mortar-filled panel is a widely adopted floor material. The mortar-filled panel is easy to walk on, has high load-bearing capacity, is incombustible, and can reduce weight increase by adopting lightweight mortar, and can sufficiently meet the needs of OA floors. Also, a floor material using a highly sound-insulating gypsum board as a core material and bonding a metal panel to the surface of the core material has high durability and has been conventionally used. Furthermore, various floor materials have been developed to add more performance.

[0003] For example, Japanese Patent Application Laid-Open No. 2023-119513 discloses a method for manufacturing a metal sandwich panel in which a plurality of plate materials are bonded to each other to form a core material, a first metal material is bonded to the surface of the core material, and a second metal material is bonded to the back surface. The metal sandwich panel has a core material made of a plurality of boards in multiple layers, and by combining boards with different characteristics, it can be a panel with arbitrary performance added.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The metal sandwich panel disclosed in Patent Document 1 is constructed by applying adhesive to the surface of each of the multiple boards that make up the core material and bonding them together, and also by bonding and joining metal materials to the front and back surfaces of the core material with adhesive. Therefore, although it has a high degree of unity, it has the problem that it is difficult to separate during repair or disposal, and processing becomes complicated.

[0006] Furthermore, in the case of the mortar-filled panels, a curing period is required after filling the space between the upper and lower panels, which presents problems in terms of both time and cost until completion.

[0007] This invention solves these problems by providing a floor panel that can be manufactured in a short time, does not require a curing period, is easy to separate during renovation or disposal, and is environmentally friendly, by arranging a resin plate as a core material between the upper and lower panels and joining them together. [Means for solving the problem]

[0008] The following are examples of a method for manufacturing a floor panel and a floor panel configuration according to the present invention to achieve the above objective. In this document, to aid in understanding the present invention, the main components constituting the solution are denoted by the same reference numerals used in the drawings of the embodiments described later. However, the present invention is not limited to the means specified by these reference numerals, and it goes without saying that various modifications can be made within the scope of the technical concept of the present invention.

[0009] [1] A method for manufacturing a floor panel, comprising placing a core material made of resin plate material between an upper panel and a lower panel, and integrally joining the core material to the upper panel and the lower panel, comprising: a first step of drilling a plurality of through holes with recesses around the periphery in the upper panel and the lower panel; a second step of forming protrusions on the upper and lower surfaces of the resin plate material at positions corresponding to the through holes drilled in the upper and lower panels, which are insertable into the through holes and have a height that protrudes from the through holes; and placing the upper panel and the lower panel on the upper and lower surfaces of the resin plate material, respectively, and forming on the upper and lower surfaces of the resin plate material The method is characterized by comprising: a third step of inserting the protruding portion into the through-holes of the upper and lower panels; a fourth step of heating the protruding portion of the resin plate material protruding from the through-holes of the upper and lower panels to generate molten resin; a fifth step of pressing the upper and lower panels together to deform and allow the molten resin to flow into the through-holes and the depressions around the through-holes; a sixth step of filling the through-holes and the depressions around the through-holes with the flowed molten resin to form a joint and smooth the surfaces of the upper and lower panels; and a seventh step of processing and finishing the edges of the upper and lower panels.

[0010] [2] The resin plate material is characterized by having multiple holes formed in it for weight reduction.

[0011] [3] The joint between the upper panel and the lower panel and the resin plate material formed by molten resin filling the through holes in the upper panel and the recesses around them is characterized in that the total area of ​​the joint between the upper panel and the resin plate material is 5 to 20% of the surface area of ​​the upper panel and the lower panel.

[0012] [4] The resin plate material is characterized in that it is made of thermoplastic resin.

[0013] [5] A floor panel in which a core material made of a resin plate is placed between an upper panel and a lower panel, wherein the upper panel and the lower panel have a number of through holes with recesses around their periphery, the resin plate has protrusions formed at positions corresponding to the through holes drilled in the upper panel and the lower panel, the protrusions formed on the resin plate are inserted into the number of drilled through holes so that their upper parts protrude from the through holes, the protruding parts of the protrusions are heated to become molten resin, which flows into the through holes and the recesses around the through holes, and the resin plate is integrally joined to the upper panel and the lower panel. [Effects of the Invention]

[0014] The manufacturing method and floor panel according to the present invention comprises: a first step of drilling a plurality of through holes with recesses around the periphery in an upper panel and a lower panel; a second step of forming protrusions on the upper and lower surfaces of the resin plate material at positions corresponding to the through holes drilled in the upper and lower panels, which are insertable into the through holes and have a height that protrudes from the through holes; a third step of arranging the upper panel and the lower panel on the upper and lower surfaces of the resin plate material, respectively, and inserting the protrusions formed on the upper and lower surfaces of the resin plate material into the through holes of the upper panel and the lower panel; a fourth step of heating the protrusions of the resin plate material protruding from the through holes of the upper panel and the lower panel to generate molten resin; and the upper panel The manufacturing process involves a fifth step of pressing the lower panel and deforming and flowing molten resin into the through-holes and the depressions around the through-holes, a sixth step of filling the through-holes and the depressions around the through-holes with the flowing molten resin to form a joint and smoothing the surfaces of the upper and lower panels, and a seventh step of processing and finishing the edges of the upper and lower panels. As a result, the upper and lower panels and the resin plate are joined at the joint formed by the through-holes and the depressions around them of the upper and lower panels, making it easy to separate the upper and lower panels from the resin plate, and eliminating the need for bonding with adhesives or curing for mortar hardening, thus enabling the manufacture of floor panels that are time-consuming and costly to produce. [Brief explanation of the drawing]

[0015] [Figure 1] Perspective view for explaining an embodiment of a floor panel manufactured by the method for manufacturing a floor panel according to the present invention, [Figure 2] Drawings for explaining an embodiment of the method for manufacturing a floor panel according to the present invention [Figure 3-1] Drawings for explaining the method for manufacturing a floor panel according to the present invention, [Figure 3-2] Drawings for explaining the method for manufacturing a floor panel according to the present invention,

Mode for Carrying Out the Invention

[0016] Hereinafter, the method for manufacturing a floor panel and embodiments of the floor panel according to the present invention will be described in detail with reference to the drawings showing examples.

[0017] FIG. 1 is a perspective view for explaining an embodiment of a floor panel manufactured by the method for manufacturing a floor panel according to the present invention, FIG. 2 is a drawing for explaining an embodiment of the method for manufacturing a floor panel according to the present invention, and FIG. 3 is a drawing for explaining the method for manufacturing a floor panel according to the present invention. In the drawings, 1 is a floor panel, 2 is an upper panel, 3 is a lower panel, and 4 is a resin-made plate material. Further, 21 is a through hole, 22 is a depression, 31 is a through hole, 32 is a depression, 41 is a convex portion, and 42 is a joint portion.

[0018] The floor panel 1 according to the present invention is formed by inserting the convex portions 41 formed on the resin-made plate material 4 into a large number of through holes 21 formed in the upper panel 2 and the lower panel 3, heating the convex portions 41 to molten resin, and causing the molten resin to flow into the through holes 21, 31 and the depressions 22, 32 around the through holes of the upper panel 2 and the lower panel 3, and being integrally joined to the resin-made plate material 4, the upper panel 2 and the lower panel 3.

[0019] In the present invention, the upper panel 2 and the lower panel 3 are made of metal, and examples thereof include metal materials such as iron, steel, titanium, magnesium, copper, aluminum, and stainless steel. The floor panel manufactured in the present invention is, for example, used as a floor material for a double floor of an OA floor, and a steel plate is preferably used in consideration of durability, sound insulation, fire resistance, etc.

[0020] Then, a plurality of through holes 21 provided with depressions 22 around are formed in the upper panel 2 and the lower panel 3. The through holes 21 are formed at positions corresponding to the positions of the convex portions 41 so that the convex portions formed on the upper and lower surfaces of the resin plate material 4 can be inserted. And, around the through holes 21, depressions having a depth and size suitable for the molten resin to flow in and form a joint are formed. The molten resin is generated by melting the convex portions 41 of the resin plate material 4 by heating, flows into and fills the gaps of the through holes 21 into which the convex portions 41 are inserted, and also flows into the depressions 22 around the through holes 21. And after the molten resin is cured, the resin filled in the through holes 21 and the depressions 22 becomes a shape like a screw, and the resin cured in the depression 22 portion serves as a retaining means to form a joint, and the resin plate material 4, the upper panel 2 and the lower panel 3 are firmly joined.

[0021] In addition, the joint formed after the curing of the molten resin forms a resin area having a size approximately the same as that of the depression 22 on the surfaces of the upper panel 2 and the lower panel 3. The resin area is the area occupied by the joint. When it is small with respect to the surface areas of the upper panel 2 and the lower panel 3, the joint is weak, and when it is large, it inhibits the characteristics of the upper panel 2 and the lower panel 3. In the present invention, the sizes of the depressions 22 and 32 are adjusted so that the total area occupied by the joints is about 5 to 20% with respect to the surface areas of the upper panel 2 and the lower panel 3.

[0022] The floor panel 1 according to the present invention has a structure in which a resin plate material 4 is used as a core material and the core material is sandwiched between the upper panel 2 and the lower panel 3 and integrally joined. The resin plate material 4 is provided with convex portions 41 having a size that can be inserted into the through holes 21 and 31 of the upper panel 2 and the lower panel 3, respectively, at positions corresponding to the through holes 21 and 31 formed in the upper panel 2 and the lower panel 3 on its upper and lower surfaces. The protrusion 41 is made of the same material as the resin plate 4 and is configured to protrude from the through holes 21 and 31 of the upper panel 2 and the lower panel 3 when inserted into the through holes 21 and 31. The portion protruding from the through holes 21 and 31 is then heated and becomes molten resin, forming a joint. Therefore, the amount of protrusion (height h) of the protrusion 41 is adjusted considering the amount of molten resin generated by heating.

[0023] The resin plate material 4 is formed by heating the upper part of the protrusion 41 to generate molten resin, and is composed of a thermoplastic resin. Examples of thermoplastic resins include polyethylene, polypropylene, polyamide, polyvinyl chloride, PET (polyethylene terephthalate), and PP (polypropylene). However, polypropylene is preferably used in this embodiment because it has the function of being a core material for the floor panel and the function of joining the upper panel 2 and the lower panel 3.

[0024] In this embodiment, the resin plate material 4 has multiple holes 42 formed therein. These are formed to reduce the weight of the resin plate material 4 and are balanced throughout the material so as not to affect its strength. However, if weight reduction is not necessary, the holes 42 may be omitted.

[0025] Next, the method for manufacturing a floor panel according to the present invention will be explained based on the explanatory drawing of Figure 3, which shows the method for manufacturing a floor panel according to the present invention. First, multiple through holes 21 and 31 with recesses around their perimeters are drilled in the upper panel 2 and the lower panel 3. (Step 1) (Figure 3-1(1)) In addition, protrusions 41 are formed on the upper and lower surfaces of the resin plate material 4 at positions corresponding to the through holes 21 and 31 drilled in the upper panel 2 and lower panel 3, respectively. These protrusions are insertable into the through holes 21 and 31 and have a height that extends beyond the through holes 21 and 31. (Second step) (Figure 3-1(2))

[0026] Then, the upper panel 2 and the lower panel 3 are placed on the upper and lower surfaces of the resin plate material 4, respectively (Figure 3-1(3)), and the protrusions 41 formed on the upper and lower surfaces of the resin plate material 4 are inserted into the through holes 21 and 31 of the upper panel 2 and the lower panel 3 (third step) (Figure 3-1(4)). In this case, the protrusions 41 inserted into the through holes 21 and 31 have a length such that their upper ends protrude from the through holes 21 and 31. In the figure, the height of the protrusion is denoted as h.

[0027] Next, the protrusions 41 of the resin plate material 4 that protrude from the through holes 21 and 31 of the upper panel 2 and lower panel 3 are heated to generate molten resin. (Fourth step) (Figure 3-2(5)) The protrusion 41 may be heated by ultrasonic heating or by hot pressing in conjunction with the next step.

[0028] Then, the upper panel 2 and the lower panel 3 are pressed together, and molten resin is deformed and allowed to flow into the through holes 21 and 31 and the depressions 22 and 32 around the through holes. (Fifth step) (Figure 3-2(6)). The molten resin introduced is used to fill the gaps between the through-holes 21 and 31 and the depressions 22 and 32 around the through-holes to form the joint 5, and the surfaces of the upper panel 2 and the lower panel 3 are smoothed. (Step 6) (Figure 3-2(7)) Finally, the edges of the upper panel 2 and lower panel 3 are processed and finished. (Step 7) (Figure 3-2(8))

[0029] As described above, the manufacturing method and floor panel according to the present invention use a resin plate material 4 as a core material, and the upper panel 2 and lower panel 3 are joined to both sides of the core material with resin to form an integral structure. Therefore, there is no need for a curing period, the manufacturing time is short, and costs can be reduced. Furthermore, since the upper panel 2 and lower panel 3 and the resin plate material 4 are joined only at the joint 42, they can be easily separated, making repair and disposal easy, and resulting in an environmentally friendly floor panel.

[0030] Although this invention has been described in the context of floor panels, the manufacturing method of this invention can also be used for ceiling panels, wall panels, and the like. [Explanation of symbols]

[0031] 1 Floor panel 2. Top panel 21 Through hole 22. Indentation 3. Bottom panel 31 Through hole 32 indentations 4. Resin sheet material 41 Convex part 42 Joint

Claims

1. A method for manufacturing a floor panel, comprising placing a core material made of resin plate material between an upper panel and a lower panel, and integrally joining the core material to the upper panel and the lower panel, The first step involves drilling multiple through holes with recesses around their periphery in the upper and lower panels, A second step involves forming protrusions on the upper and lower surfaces of the resin plate material at positions corresponding to through holes drilled in the upper and lower panels, where the protrusions are insertable into the through holes and have a height that extends outward from the through holes. The third step involves placing an upper panel and a lower panel on the upper and lower surfaces of the resin plate, respectively, and inserting the protrusions formed on the upper and lower surfaces of the resin plate into through holes in the upper and lower panels. A fourth step involves heating the protrusions of the resin plate material that protrude from the through holes of the upper and lower panels to generate molten resin, A fifth step involves pressing the upper and lower panels together and deforming the molten resin into the through-holes and the depressions around the through-holes, A sixth step involves filling the through-hole and the depression around the through-hole with the molten resin that has been introduced to form a joint, and smoothing the surfaces of the upper panel and the lower panel. The seventh step involves processing and finishing the edges of the upper and lower panels. A method for manufacturing a floor panel, characterized by comprising the following:

2. The method for manufacturing a floor panel according to claim 1, characterized in that the resin plate material has a plurality of holes formed therein for weight reduction.

3. The method for manufacturing a floor panel according to claim 1, characterized in that the total area of ​​the joint between the upper panel and the lower panel, formed by molten resin filling the through holes in the upper panel and the recesses around them, is 5 to 20% of the surface area of ​​the upper panel or the lower panel.

4. The method for manufacturing a floor panel according to claim 1, characterized in that the resin plate material is made of a thermoplastic resin.

5. A floor panel in which a core material made of resin plate material is placed between the upper panel and the lower panel, The upper and lower panels are provided with numerous through-holes with recesses around their periphery. The resin plate material has protrusions formed at positions corresponding to the through holes drilled in the upper and lower panels. A floor panel characterized in that protrusions formed on the resin plate are inserted into the numerous through holes drilled in the resin plate so that their upper parts protrude from the through holes, the protruding parts of the protrusions are heated to molten resin, which is then flowed into the through holes and the depressions around the through holes, thereby integrally joining the resin plate with the upper and lower panels.

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