Floor panels

Abstract

This invention provides a floor panel that is lightweight and thin while maintaining rigidity and strength, despite having a simple structure. [Solution] The floor panel according to the present invention is a rectangular plate-shaped floor panel comprising a first member made of synthetic resin having a surface panel portion and a second member made of synthetic resin having a back panel portion, wherein the first member has a first side wall portion vertically installed along the lower edge of the surface panel portion and at least one pair of vertical and horizontal first rib walls vertically installed connecting opposing portions of the first side wall portion, the second member has a second side wall portion erected along the upper edge of the back panel portion and at least one pair of vertical and horizontal second rib walls erected connecting opposing portions of the second side wall portion, the first side wall portion and the second side wall portion are welded together to form a side wall portion, and the first rib wall and the second rib wall facing the first rib wall are welded together to provide reinforcement.

Description

[[Technical Field]]

[0001] The present invention relates to a floor panel laid indoors or outdoors such as balconies, terraces, and rooftops of buildings. [[Background Art]]

[0002] In this type of floor panel, it is required to achieve both of the two effects that tend to be in a trade-off relationship: ensuring rigidity and reducing weight.

[0003] Therefore, conventionally, a floor panel having a structure in which a core layer is formed of a material having a porous structure such as a synthetic resin foam, and part or all of the core layer is covered with a surface layer is known. Weight reduction is achieved by the core layer, and rigidity is ensured by the cooperation of the core layer and the surface layer.

[0004] In particular, the floor panel disclosed in the following Patent Document 1 has a structure in which the outer surface (six surfaces) of the core layer is covered with a surface layer, the upper inner surface of the surface layer is welded to the upper outer surface of the core layer, and the lower inner surface of the surface layer is welded to the lower outer surface of the core layer. Rigidity can be ensured by the cooperative action of the upper and lower parts of the core layer and the upper and lower parts of the surface layer against compressive stress and tensile stress generated by walking load or the like. [[Prior Art Documents]] [[Patent Documents]]

[0005] [[Patent Document 1]] Japanese Patent No. 6114318 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0006] As described above, the floor panel of Patent Document 1 can achieve both rigidity assurance and weight reduction with a simple structure. In addition, the floor panel of Patent Document 1 can appropriately prevent rainwater or the like from entering the core layer due to the structure in which the entire outer surface of the core layer is covered with the surface layer.

[0007] However, in the above-mentioned Patent Document 1, if holes are made in the surface layer when the floor panels are fastened with screws, water may seep in through these holes, which could cause deterioration of the porous structural material such as expanded polystyrene that constitutes the core layer.

[0008] Furthermore, if the porous structural material constituting the core layer is soft, it may give the user the feeling of sinking in more than necessary when walking, potentially causing anxiety or discomfort.

[0009] Furthermore, the structure in which the surface layer covers the core layer presented the problem of difficulty in thinning the material while maintaining rigidity. [Means for solving the problem]

[0010] This invention fundamentally changes the structure of conventional floor panels, providing a floor panel that achieves both rigidity and weight reduction with a simple structure, while possessing the desired strength and being compatible with screw fastening. In addition, it provides a floor panel that can be made thinner while maintaining rigidity and strength.

[0011] In summary, the floor panel according to the present invention is a rectangular plate-shaped floor panel formed by welding together a first member made of synthetic resin having a surface panel portion and a second member made of synthetic resin having a back panel portion. The first member has a first side wall portion vertically attached along the lower edge of the surface panel portion, and at least one pair of vertical and horizontal first rib walls vertically attached to connect opposing portions of the first side wall portion. The second member has a second side wall portion erected along the upper edge of the back panel portion, and at least one pair of vertical and horizontal second rib walls erected to connect opposing portions of the second side wall portion. The first side wall portion and the second side wall portion are welded together to form a side wall portion, and the first rib wall and the second rib wall facing the first rib wall are welded together to reinforce it, thereby ensuring both rigidity and weight reduction while also ensuring walking strength.

[0012] Furthermore, since rigidity and strength can be ensured solely by the surface and back panel sections, the first and second side walls, and the first and second rib walls, the panel itself can be made as thin as possible. In addition, by creating holes in the surface panel section and the back panel section, there is no risk of deterioration even if water penetrates the interior.

[0013] Preferably, by providing a recess in one of the welded portions of the first side wall and the second side wall, and a corresponding protrusion in the other, the protrusions and recesses can be fitted together and welded, allowing the side wall to be constructed firmly and ensuring the rigidity and strength of the entire floor panel.

[0014] Furthermore, by arranging the first rib wall in a grid pattern when viewed from below, and the second rib wall in a grid pattern when viewed from above, the structure can be reinforced in a well-balanced manner.

[0015] Furthermore, by pre-drilling holes in the surface panel and / or the back panel, screw fastening can be facilitated, and in particular, drilling holes in the back panel allows water that has seeped inside to drain out.

[0016] Furthermore, by molding the first and second components using different types of synthetic resins, it is possible to adjust the balance of rigidity and strength, and also contribute to cost reduction. [Effects of the Invention]

[0017] According to the present invention, it is possible to provide a floor panel that is lightweight and thin while ensuring rigidity and strength, despite having a simple structure. Therefore, the thinning, in particular, makes it easy to realize a double floor structure or a structure that accommodates beams protruding from below.

[0018] Furthermore, it is possible to provide floor panels that do not deteriorate even if water penetrates the interior. [Brief explanation of the drawing]

[0019] [Figure 1]It is an exploded perspective view showing a part of the first member cut away among the first member and the second member constituting the floor panel according to the present invention. [Figure 2] It is a cross-sectional view of the first member and the second member before welding. [Figure 3] It is an enlarged view of part A in FIG. 2. [Figure 4] It is a plan view of the floor panel according to the present invention. [Figure 5] It is a bottom view of the floor panel according to the present invention. [Figure 6] It is a cross-sectional view taken along line B-B of FIG. 5, and is a cross-sectional view of the floor panel according to the present invention, which is configured by welding the first member and the second member. [Figure 7] It is an enlarged view of part C in FIG. 6. [Figure 8] It is a bottom view showing an example in which an extremely thin portion is formed in the floor panel according to the present invention. [Figure 9] It is a cross-sectional view taken along line D-D of FIG. 8. [Figure 10] It is a perspective view for explaining the step of laying the floor panel according to the present invention on a floor substrate surface via raising legs. [Figure 11] It is a perspective view for explaining the step of laying a finishing panel on the floor panel according to the present invention. MODE FOR CARRYING OUT THE INVENTION

[0020] Hereinafter, embodiments of the present invention will be described based on FIG. 1 to FIG. 11.

[0021] As shown in FIG. 1 and FIG. 2, the floor panel 1 according to the present invention is a rectangular plate-shaped floor panel, which is formed by welding two members: a synthetic resin first member 2 having a surface panel portion 2a constituting the surface of the floor panel 1, and a synthetic resin second member 3 having a back panel portion 3a constituting the back surface of the floor panel 1. The floor panel 1 according to the present invention does not have a multi-layer structure like conventional floor panels, and can ensure rigidity and strength as well as achieve weight reduction only with synthetic resin members.

[0022] <Configuration of First Member> As shown in Figures 1, 2, and 4, the first member 2 has a first side wall portion 2b vertically installed along the entire circumference of the lower edge of the rectangular surface panel portion 2a, and at least one pair of first rib walls 2c vertically installed to connect opposing portions of the first side wall portion 2b. In other words, the first member 2 has a structure in which the first rib walls 2c are provided in a cross shape or grid shape inside the rectangular tray composed of the surface panel portion 2a and the first side wall portion 2b, thereby ensuring rigidity and strength.

[0023] Furthermore, since the first member 2 is composed only of synthetic resin panels consisting of a surface panel portion 2a, a first side wall portion 2b, and a first rib wall portion 2c, it is inherently lightweight. However, by adjusting the thickness of the surface panel portion 2a, the thickness of the first side wall portion 2b, and the number, thickness, and pitch of the first rib wall portion 2c, it is possible to further reduce the weight while ensuring rigidity and strength.

[0024] Furthermore, since the first component 2 does not contain any internal components that would deteriorate due to the intrusion of water such as rainwater, holes can be pre-drilled in the surface panel portion 2a that is exposed as the outer surface. For example, as shown in Figures 2 and 3, countersunk holes 2d for screw fastening can be provided.

[0025] The lower end (free end) of the first side wall portion 2b is a welding portion for welding to the second side wall portion 3b, which will be described later, and preferably a recess 4 is provided in this welding portion. This is to firmly integrate the first side wall portion 2b and the second side wall portion 3b by welding them together while fitting with a protrusion 5 provided on the second side wall portion 3b. Preferably the recess 4 is provided along the entire length of the welding portion of the first side wall portion 2b. Furthermore, the shape of the recess is not particularly limited and can be appropriately changed to match the corresponding protrusion shape.

[0026] Furthermore, it is preferable that the lower end (free end) of the first side wall portion 2b and the lower end (free end) of the first rib wall 2c, that is, the welded portion between the second side wall portion 3b and the second rib wall 3c, respectively, be at the same level throughout the entire area. This is for the purpose of tight welding.

[0027] As the synthetic resin constituting the first component 2, virgin or recycled materials of known thermoplastic synthetic resins such as polypropylene and polyethylene can be used, taking into consideration rigidity, strength, weight, etc.

[0028] In Figures 1 and 4, the part labeled 2e is a non-slip portion protruding from the surface panel portion 2a, and is provided to prevent misalignment of decorative panels and other items placed on the floor panel 1.

[0029] <Configuration of the second component> As shown in Figures 1, 2, and 5, the second member 3 has a second side wall portion 3b erected along the upper edge of the rectangular back panel portion 3a, and at least one pair of second rib walls 3c erected vertically and horizontally to connect opposing portions of the second side wall portion 3b. In other words, the second member 3 is configured to ensure rigidity and strength by providing the second rib walls 3c in a cross shape or grid pattern inside the rectangular tray formed by the back panel portion 3a and the second side wall portion 3b.

[0030] Furthermore, the second member 3, like the first member 2, is composed only of synthetic resin panels consisting of a back panel 3a, a second side wall 3b, and a second rib wall 3c, and is therefore inherently lightweight. However, by adjusting the thickness of the back panel 3a, the thickness of the second side wall 3b, and the number, thickness, and pitch of the second rib wall 3c, it is possible to further reduce weight while ensuring rigidity and strength.

[0031] Furthermore, since the second member 3, like the first member 2, does not contain any internal components that deteriorate due to the intrusion of water such as rainwater, holes can be pre-drilled in the back panel portion 3a that is exposed as the outer surface. For example, as shown in Figures 2 and 3, through holes 3d can be provided for drainage or screw fastening.

[0032] The upper end (free end) of the second side wall portion 3b is a welding portion for welding to the first side wall portion 2b described above, and preferably a protrusion 5 is provided on this welding portion. This is to firmly integrate the first side wall portion 2b and the second side wall portion 3b by welding while fitting into a recess 4 provided on the first side wall portion 2b. Preferably the protrusion 5 is provided along the entire length of the welding portion of the second side wall portion 2b. The shape of the protrusion is not particularly limited and can be appropriately changed to match the corresponding recess shape.

[0033] Furthermore, it is preferable that the upper end (free end) of the second side wall 3b and the upper end (free end) of the second rib wall 3c, that is, the welded portion between the first side wall 2b and the first rib wall 2c, be at the same level throughout their entire length. This is for the purpose of tight welding.

[0034] As the synthetic resin constituting the second component 3, virgin or recycled materials of known thermoplastic synthetic resins such as polypropylene and polyethylene can be used, taking into consideration rigidity, strength, weight, etc.

[0035] <Floor panel configuration> The floor panel 1 according to the present invention can be constructed by welding the first member 2 and the second member 3 described above together to form a single unit. Specifically, as shown in Figures 6 and 7, the side wall portion is constructed by welding the welded portion (lower end) of the first side wall portion 2b of the first member 2 to the welded portion (upper end) of the second side wall portion 3b of the second member 3, and reinforcement is provided by welding the welded portion (lower end) of the first rib wall 2c of the first member 2 to the welded portion (upper end) of the second rib wall 3c of the second member 3 facing the first rib wall 2c.

[0036] The ratio of the height h1 of the first side wall 2b to the height h2 of the second side wall 3b is not particularly limited, but can be adjusted as appropriate considering the desired rigidity, strength, relationship with the synthetic resin used, cost, etc. Furthermore, as described above, it is desirable that the lower end of the first side wall 2b and the lower end of the first rib wall 2c be flush, and the upper end of the second side wall 3b and the upper end of the second rib wall 3c be flush. Therefore, the ratio of the height h1 of the first side wall 2b to the height h2 of the second side wall 3b is the same as the ratio of the height of the first rib wall 2c to the height of the second rib wall 3c.

[0037] The welding method is not particularly limited as long as it can reliably integrate the first side wall portion 2b and the second side wall portion 3b, and the first rib wall portion 2c and the second rib wall portion 3c, as described later. However, heat welding, especially hot plate welding, is preferred because it can reliably integrate the parts regardless of their shape.

[0038] In the present invention, preferably, recesses 4 and protrusions 5 are provided in the welded portion of the first side wall portion 2b and the second side wall portion 3b, as described above, to ensure reliable welding and rigidity and strength after welding. The recesses 4 and protrusions 5 are fitted together and integrated securely, while being partially deformed by welding, as schematically shown as 4' and 5' in Figure 7. Furthermore, by fitting them together in this manner, burrs generated during welding can be suppressed. In this embodiment, a recess 4 is provided in the welded portion of the first side wall portion 2b and a protrusion 5 is provided in the welded portion of the second side wall portion 3b, but the present invention is not limited to this, and a protrusion 5 may be provided in the welded portion of the first side wall portion 2b and a recess 4 may be provided in the welded portion of the second side wall portion 3b.

[0039] Furthermore, as shown in Figure 7, in the present invention, the welded portion of the first rib wall 2c becomes a deformed end 6 that is wider than before welding, and the welded portion of the second rib wall 3c also becomes a deformed end 7 that is wider than before welding. These deformed ends 6 and 7 allow the first member 2 and the second member 3 to be firmly integrated.

[0040] The synthetic resin constituting the first component 2 and the synthetic resin constituting the second component 3 may be the same or different. If they are the same, reliable integration can be achieved, and if they are different, combinations that take into account the differences between the materials can be made. For example, in this embodiment, the first component 2 is made of virgin polypropylene, and the second component 3 is made of recycled polypropylene. Recycled material can reduce costs, but it is difficult to make it a light color such as white. Therefore, the first component 2, which constitutes the surface side involved in heat absorption due to sunlight, is made of virgin material and is white, and the second component 3, which constitutes the back side not involved in heat absorption, is made of recycled material and is black. Furthermore, in order to reduce costs, the second component 3 is made thicker than the first component 2, that is, the height h2 of the second side wall 3b is greater than the height h1 of the first side wall 2b.

[0041] Furthermore, Figures 8 and 9 show modified examples of the floor panel 1 according to the present invention. As shown in these modified examples, the floor panel 1 according to the present invention can also be configured with sections of different thicknesses by providing a stepped section 3e on the back panel section 3a of the second member 3. For example, it can be used in locations where a larger space, such as a water passage space, is desired on the back side. Also, as shown in Figure 9, the second rib wall 3c can be omitted in the back panel section 3a portion that is at a higher level due to the stepped section 3e.

[0042] In the above modified example, as shown in Figure 8, the stepped portion 3e is provided in an L-shape, and an example is shown in which two adjacent sides on the back side of the rectangular plate-shaped floor panel 1 are partially made extremely thin. However, the present invention is not limited to this, and it is also possible to provide the stepped portion 3e in a straight line, making only one side on the back side of the floor panel 1 partially extremely thin, or to provide two straight stepped portions 3e, making two opposite sides on the back side of the floor panel 1 partially extremely thin, depending on the implementation. Furthermore, although Figures 8 and 9 show an example in which the stepped portion is provided on the back panel portion 3a of the second member 3, the present invention does not exclude the provision of the stepped portion on the front panel portion 2a side of the first member 2.

[0043] <Example of floor construction> Next, we will describe an example of constructing a floor using the floor panel 1 according to the present invention. Here, we will describe an example of constructing an outdoor floor on the ground surface G beneath an outdoor floor, such as a veranda or balcony.

[0044] When constructing an outdoor floor, as shown in Figure 10, first, multiple height-adjustable risers L are installed on the ground surface G below the floor at predetermined intervals, adjusting the level and inclination of their support bases La. Then, the four opposing corners of the four floor panels 1 adjacent to the support bases La of each riser leg L are supported together, and multiple floor panels 1 are laid out to form a single plane. Depending on the implementation, it is also optional to support parts of the floor panels 1 other than the corners 1a with the riser legs L.

[0045] In this case, for example, a support base La with a ruler portion Lb protruding from it, such as the raising leg L shown in Figure 10, is used, and the floor panels are laid while creating a gap between the sides of adjacent floor panels 1 using the ruler portion Lb.

[0046] Furthermore, as shown by 1' in Figure 10, it is essential to lay floor panels that have been processed to match the dimensions and shape of the edges of the subfloor surface G.

[0047] Next, as shown in Figure 11, numerous finishing panels (decorative panels) F are laid on top of the floor panels 1 that have been laid out on a single plane as described above, so as to form a single plane, and the construction of the outdoor floor is completed.

[0048] As described above, the floor panel 1 according to the present invention has a simple structure, yet it can ensure both rigidity and lightness while also ensuring walking strength.

[0049] Furthermore, since rigidity and strength can be ensured using only the surface and back panel sections 2a and 3a, the first and second side wall sections 2b and 3b, and the first and second rib walls 2c and 3c, the panel itself can be made as thin as possible.

[0050] Furthermore, by providing a recess in one of the welded portions of the first side wall portion 2b and the second side wall portion 3b that constitute the side wall portion of the floor panel 1, and providing a corresponding protrusion in the other, the recessed and protruding portions can be fitted together and welded, thereby constructing the side wall portion firmly and ensuring the rigidity and strength of the entire floor panel 1.

[0051] Furthermore, by arranging the first rib wall 2c in a grid pattern when viewed from below and the second rib wall 3c in a grid pattern when viewed from above, balanced reinforcement can be achieved. Also, by arranging the first rib wall 2c in a cross pattern when viewed from below and the second rib wall 3c in a cross pattern when viewed from above, balanced reinforcement can be achieved.

[0052] Furthermore, by pre-drilling holes in the surface panel portion 2a and / or the back panel portion 3a, screw fastening can be facilitated, and in particular, drilling holes in the back panel portion 3a allows water that has seeped inside to drain out. Since the floor panel 1 according to the present invention is made only of synthetic resin, there is no risk of deterioration or other problems even if water seeps inside through the holes drilled in the surface panel portion 2a or the back panel portion 3a.

[0053] Furthermore, by adjusting the synthetic resins used in the first component 2 and the second component 3, it is possible to balance rigidity and strength, cost, and take advantage of the characteristics of the synthetic resins used. [Explanation of symbols]

[0054] 1...Floor panel, 1'...Dimensionally adjusted floor panel, 2...First member, 2a...Surface panel section, 2b...First side wall section, 2c...First rib wall, 2d...Counterbore hole, 2e...Anti-slip section, 3...Second member, 3a...Back panel part, 3b...Second side wall part, 3c...Second rib wall, 3d...Through hole, 3e...Step part, 4... recess, 4'... deformed recess, 5...convex part, 5'...deformed convex part, 6...Deformed end, 7…Deformed end, G...Underfloor surface, L...Raising legs, La...Support base, Lb...Ruler section, F...Finishing panel h1...height of the first side wall, h2...height of the second side wall

Claims

1. A floor panel having a rectangular plate shape, comprising a first member made of synthetic resin having a surface panel portion and a second member made of synthetic resin having a back panel portion, wherein the first member has a first side wall portion vertically attached along the lower edge of the surface panel portion and at least one pair of vertical and horizontal first rib walls vertically attached to connect opposing portions of the first side wall portion, the second member has a second side wall portion erected along the upper edge of the back panel portion and at least one pair of vertical and horizontal second rib walls erected to connect opposing portions of the second side wall portion, the first side wall portion and the second side wall portion are welded together to form a side wall portion, and the first rib wall and the second rib wall facing the first rib wall are welded together to provide reinforcement.

2. The floor panel according to claim 1, characterized in that a recess is provided in one of the welded portions of the first side wall and the welded portion of the second side wall, and a protrusion corresponding to the recess is provided in the other.

3. The floor panel according to claim 1, characterized in that the first rib wall is provided in a grid pattern when viewed from the bottom, and the second rib wall is provided in a grid pattern when viewed from above.

4. The floor panel according to claim 1, characterized in that holes are pre-drilled in the surface panel portion and / or the back panel portion.

5. The floor panel according to claim 1, characterized in that the first member and the second member are molded from different types of synthetic resins.

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