JP3565692B2 - Manufacturing method of perforated floor panel - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a perforated floor panel.
[0002]
[Prior art]
As a perforated floor panel having a large number of small holes for ventilation laid on the floor surface of a clean room, office, computer room, etc., for example, a laminate obtained by laminating a finishing material on the upper surface of a floor panel body formed by casting Was known. Conventionally, the following two methods have been known as methods for manufacturing such a perforated floor panel.
{Circle around (1)} The floor panel body material is formed by casting (die casting), and then a finishing material is adhered to the upper surface of the floor panel body material. A method of forming holes.
{Circle around (2)} The floor panel body material is formed by casting (die-casting), and a small through hole is punched and formed in the upper surface wall. Furthermore, a position corresponding to the small through hole of the floor panel body material is formed as a separate finishing material. A method in which a small through hole is punched and formed, and then a finishing material is bonded to the upper surface of the floor panel body material so that the corresponding small through hole matches.
[0003]
[Problems to be solved by the invention]
However, in the above-mentioned method (1), since the material of the floor panel main body and the finishing material are different and the physical properties such as hardness are different, if the upper surface wall portion of the floor panel main body material and the finishing material are simultaneously punched, for example, However, there has been a problem that the periphery of the small through-hole of the finishing material is crushed to impair the appearance.
[0004]
In the above method (2), it is difficult to adhere the small through-holes of the floor panel main body and the small through-holes of the finishing material so that the small through-holes coincide with each other. In addition, the adhesive protrudes into the small through-hole at the time of bonding and hardens as it is, so that the appearance deteriorates and the small through-hole becomes narrow or closed.
[0005]
Then, the present invention solves the above-mentioned problems, and can easily, efficiently and beautifully form a large number of small through-holes, and furthermore, a perforated floor panel which can reduce the number of types of casting molds. The purpose is to provide a manufacturing method.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, a method for manufacturing a perforated floor panel according to the present invention comprises punching a large number of first small holes with a first punch having a plurality of punches in an upper wall portion of a metal floor panel body material. The floor panel body is formed by punching, and then a finishing material is adhered and adhered to the front surface of the floor panel body. A second punch is inserted into the finishing material to form a second small hole having substantially the same diameter as the first small hole. Then, when the second small hole portion is formed by punching, at least two of the guide punches, which are protruded by a predetermined dimension from the other punches, out of the plurality of punches of the second punching die, First, it is inserted into the first small hole.
[0007]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0008]
1 and 2 show a perforated floor panel 1 which is laid on the entire surface of a floor surface or a part thereof for dust prevention, air conditioning, etc. in a clean room, an office, a computer room, or the like. The floor panel body 2 is composed of a metal floor panel body 2 and a finishing material 4 laminated on the front surface 3 of the floor panel body 2. ) An upper wall portion 5 and a number of small through holes 6 penetrating the finishing material 4 are formed. The floor panel main body 2 includes an upper wall 5, peripheral walls 7, 8 protruding from the rear surface of the upper wall 5, and large and small ribs 9, 10, and is made of aluminum or aluminum alloy or other material. Of metal. The finishing material 4 is formed of a resin or a plate material containing the resin as a component.
[0009]
As shown in FIG. 3, the small through-holes 6 extend from the back surface 12 of the upper wall 5 to the middle of the wall thickness at the same time as the casting. A first small hole portion 13 formed by mechanical processing from the middle part to the surface 3 and having an inner dimension smaller than an inner dimension of the back side hole portion 11 in cross-sectional shape; 4 and a second small hole portion 15 formed by mechanical processing. In this case, the back hole 11 and the first small hole 13 are circular holes having a circular cross section, and the first small hole 13 has an inner diameter smaller than the inner diameter of the back hole 11.
[0010]
Then, assuming that the thickness dimension of the upper surface wall portion 5 of the floor panel body 2 is T, 4.0 mm ≦ T ≦ 10.0 mm is set. In addition, when the dimension in the thickness direction from the front surface 3 of the upper surface wall portion 5 to the edge of the opening on the back surface side of the first small hole portion 13 is t, 1.5 mm ≦ t ≦ 3.5 mm is set. The reason for setting in this way is that if T <4.0 mm, the strength is insufficient and the large weight of a large computer or the like on the holed floor panel 1 cannot withstand a large weight. This is because it is difficult to form the first small holes 13 by mechanical processing. If t <1.5 mm, the strength is insufficient, and if 3.5 mm <t, it is difficult to form the first small holes 13 by mechanical processing, and the molten metal flows during casting. Is worse.
[0011]
Further, when the inner diameter of the back side hole 11 is A and the inner diameter of the first small hole 13 is a, (a + 1.0 mm) ≦ A ≦ (a + 5.0 mm) is set. More preferably, (a + 1.5 mm 2) ≦ A ≦ (a + 3.0 mm 2). The reason for (a + 1.0 mm) ≦ A ≦ (a + 5.0 mm) is that if A <(a + 1.0 mm), the back side hole 11 is too small and the back side hole 11 is formed when the first small hole 13 is formed. This is because it is difficult to make the first small hole portion 13 coincide with the portion 11. If (a + 5.0 mm 2) <A, the back side hole portion 11 becomes too large and the strength of the upper surface wall portion 5 is insufficient.
[0012]
A chamfered portion 14 is formed by plastic deformation on the inner peripheral edge of the opening of the small through hole 6 on the finishing material 4 side. Then, when the chamfer dimension of the chamfered portion 14 is B, 0.5 mm ≦ B ≦ 2.0 mm is set. Here, the chamfer dimension is defined as a vertical dimension of the chamfered portion 14. Further, the reason for setting 0.5 mm ≦ B ≦ 2.0 mm is that if B <0.5 mm, dust (swarf) is generated when a person walks on the holed floor panel 1 or a trolley runs. This is because, if 2.0 mm <B, distortion, cracks, and the like occur near the chamfered portion 14.
[0013]
Next, a method for producing the perforated floor panel will be described. First, as shown in FIG. 4 (in a state of being installed upside down), a floor panel main body material 16 is formed by casting. At this time, concave recesses 17 are formed on the back surface of the upper surface wall portion 5 of the floor panel main body material 16 at the positions where the holes are to be drilled at the same time as the casting.
[0014]
Then, as shown in FIGS. 5 and 6, a large number of first small holes 13 are punched and formed by a first punching die 19 having a plurality of punches 18 in the upper surface wall 5 of the floor panel body material 16. . Chips 22 generated by the punching are discharged from the holes 23 of the receiving die 21.
[0015]
As described above, the floor panel main body 2 shown in FIG. 7 is formed. The floor panel main body 2 has a rear side hole 11 formed simultaneously with casting from the rear surface 12 of the upper surface wall portion 5 to the middle portion of the wall thickness, and mechanically extends from the middle thickness portion of the upper surface wall portion 5 to the surface 3. And a first small hole portion 13 formed by processing and having an inner size smaller than the inner size of the back side hole portion 11 in the cross-sectional shape.
[0016]
Next, as shown in FIG. 8, a finishing material 4 is adhered to the front surface 3 of the floor panel main body 2 and adhered thereto. At this time, the adhesive 24 protrudes into the first small holes 13 of the floor panel main body 2 and hardens as it is.
[0017]
Then, as shown in FIGS. 9 and 10, the punches 26 of the second die 25 are inserted into the first small holes 13 of the floor panel main body 2 from the back surface 12 side. Specifically, of the plurality of punches 26 of the second punching die 25, at least two guide / combination punches 26a projecting by a predetermined dimension E from the other punches 26b are provided before the other punches 26b. It is inserted into the first small hole portion 13. Thereby, the guide punches 26a can guide the other punches 26b so as to be smoothly inserted into the plurality of first small holes 13.
[0018]
Here, the predetermined dimension E is set to 1 mm ≦ E ≦ F, where F is the thickness dimension of the finishing material 4. This is because if E <1 mm, the guide effect of the guide / punch 26a is hardly obtained, and the other punches 26b contact the inner peripheral edge of the opening of the first small hole 13 to deform the first small hole 13 and to perform other operations. This is because there is a possibility that the punch 26b may be damaged, and if F <E, the predetermined dimension E is too large, and the vertical stroke of the punch 26.
[0019]
11 continuously (instantly) from the state shown in FIG. 10, and as shown in FIG. 11, the second small holes 15 having substantially the same diameter as the first small holes 13 are formed in the finishing material 4. Die forming. At this time, the plurality of second small holes 15 are punched and formed almost simultaneously with the plurality of punches 26. At the same time as this punching, the (cured) adhesive 24 that has protruded into the first small holes 13 is removed. Then, the adhesive 24 and the dust 27 are discharged from the holes 29 of the receiving mold 28. It is preferable that at least two guide / punches 26a have a large mutual interval, and FIGS. 9, 10 and 11 show only one of the guide / punches 26a. The punch 26 for punching and forming the second small hole portion 15 and the punch 18 for punching and forming the first small hole portion 13 are preferably separate bodies. Is also possible.
[0020]
Next, as shown in FIGS. 12 and 13, the finishing material 4 is formed by a pressing punch 31 of a press die 32 having a plurality of pressing punches 31 each having a tapered pressing surface 30 at the distal end. The inner peripheral edge 33 of the surface side opening of the second small hole portion 15 is pressed, and the chamfered portion 14 is formed by plastic deformation. The chamfered portion 14 becomes a linear inclined surface. Thus, the perforated floor panel 1 shown in FIGS. 1 to 3 is formed.
[0021]
Thus, according to the method for manufacturing a perforated floor panel, the first small holes 13 of the floor panel main body 2 and the second small holes 15 of the finishing material 4 can be accurately matched. In addition, the work of bonding the finishing material 4 to the floor panel main body 2 can be performed easily and quickly, and a stable large adhesive force can be obtained. Moreover, the adhesive 24 protruding into the small through-hole 6 can be reliably removed at the same time as the formation of the second small hole 15. In addition, the punches 18 and 26 can be used according to the material of the floor panel body material and the material of the finishing material 4, so that the life of the punches 18 and 26 is extended, and the first small hole portion 13 and the second small hole portion are used. 15 can be formed beautifully. Further, by changing the number of the punches 18, 26 and the pressing punches 31, the number of the small through holes 6 can be easily increased / decreased / changed. In addition, the mold for forming the floor panel body material 16 can be shared, and the number of molds can be reduced.
[0022]
The perforated floor panel 1 has a large strength T that can sufficiently withstand the large weight of a large computer or the like by increasing the thickness dimension T of the upper surface wall portion 5 of the floor panel main body 2. It can be easily punched (ie, formed by mechanical processing). Further, the small through-hole 6 becomes beautiful in appearance. In addition, even if a person walks or a trolley or the like travels on the finishing material 4, the inner peripheral edge of the opening of the small through hole 6 is not shaved, and no dust is generated. Therefore, it is most suitable for floors such as clean rooms and computer rooms.
[0023]
In some cases, the concave portion 17 of the floor panel body material 16 may be omitted. By doing so, the number, position, and cross-sectional shape of the small through holes 6 can be easily increased / decreased / changed by merely changing the number, position, and cross-sectional shape of the punches 18 and 26 and the pressing punch 31. The number of types of molds for forming the floor panel body material 16 can be further reduced.
[0024]
The pressing surface 30 of the pressing punches 31 is preferably not only a tapered shape but also a round shape as shown in FIG. 14A, the pressing surface 30 has a concave round shape, and the chamfered portion 14 has a mountain-shaped round surface. 14B, the pressing surface 30 has a convex round shape, and the chamfered portion 14 has a concave round surface.
[0025]
Further, the shape of the small through-hole 6 is not limited to a circle as shown in FIG. 1, but may be an oval or elliptical as shown in (a), (b), (c), (d), and (e) of FIG. , A square, a rectangle, a cross, or any other shape. In that case, the cross-sectional shapes of the punches 18 and 26 and the pressing punch 31 may be any desired shapes.
[0026]
【The invention's effect】
Since the present invention is configured as described above, the following effects can be obtained.
[0027]
According to the method for manufacturing a perforated floor panel according to the first aspect, a perforated floor panel having improved work efficiency, can be manufactured in a short time, and is beautiful in appearance and excellent in air permeability can be formed. That is, the first small holes 13 of the floor panel body 2 and the second small holes 15 of the finishing material 4 can be efficiently punched and formed. Moreover, the punches 18 and 26 can be used in accordance with the material of the floor panel body material and the material of the finishing material 4, and can be widely used from a material having a high hardness to a material having a small hardness. In addition, the first small holes 13 and the second small holes 15 can be formed beautifully. Further, the first small hole portion 13 and the second small hole portion 15 can be accurately matched. In addition, the work of bonding the finishing material 4 to the floor panel main body 2 can be performed easily and quickly, and a stable large adhesive force can be obtained. Further, the adhesive 24 protruding into the small through-hole 6 can be reliably removed at the same time as the formation of the second small hole 15. Further, the number, position, shape, etc. of the small through holes 6 can be easily increased / decreased / changed. Moreover, the number of types of molds for forming the floor panel body material 16 can be reduced.
[0028]
According to the manufacturing method of the perforated floor panel according to the second aspect, when the second small hole portion 15 is formed by punching, the other punches 26b are connected to the plurality of first small hole portions 13 by the guide / punch 26a. Guides can be smoothly inserted, and small through holes 6 can be formed more reliably and efficiently.
[Brief description of the drawings]
FIG. 1 is a plan view of an apertured floor panel.
FIG. 2 is an enlarged sectional view of a main part.
FIG. 3 is a further enlarged sectional view.
FIG. 4 is an enlarged sectional view of a main part of a floor panel body material.
FIG. 5 is a cross-sectional view immediately before forming a first small hole by punching.
FIG. 6 is a cross-sectional view immediately after a first small hole is formed by punching.
FIG. 7 is an enlarged sectional view of a main part of the floor panel main body.
FIG. 8 is a cross-sectional view showing a state in which a finishing material is adhered to the holed floor panel main body.
FIG. 9 is a cross-sectional view immediately before forming a second small hole by punching.
FIG. 10 is a cross-sectional view showing a state where a guide / punch is inserted into the first small hole portion.
FIG. 11 is a cross-sectional view immediately after a second small hole is formed by punching.
FIG. 12 is a cross-sectional view just before forming a chamfer.
FIG. 13 is a cross-sectional view showing a state where a chamfer is formed.
FIG. 14 is a cross-sectional view showing a modification of the pressing punch and the chamfer.
FIG. 15 is an enlarged plan view showing a modification of the small through hole.
[Explanation of symbols]
2 Floor panel body 3 Front surface 4 Finishing material 5 Top wall 12 Back 13 First small hole 15 Second small hole 16 Floor panel body material 18 Punch 19 First die 25 Second die 26 Punch 26a Guide / punch 26b Other punch E predetermined dimensions

Claims (2)

A plurality of first small holes 13 are punched and formed by a first punching die 19 having a plurality of punches 18 in the upper wall portion 5 of the metal floor panel body material 16 to form the floor panel body 2. Then, a finishing material 4 is adhered and attached to the front surface 3 of the floor panel body 2, and then a punch of a second punching die 25 is inserted into the first small holes 13. 26. A method for manufacturing a perforated floor panel, wherein the second small holes 15 having substantially the same diameter as the first small holes 13 are punched into the finishing material 4 by inserting 26. When the second small holes 15 are formed by punching, at least two of the punches 26a of the second punching die 25 projecting from the other punches 26b by a predetermined dimension E are used. The method for manufacturing a perforated floor panel according to claim 1, wherein the panel is inserted into the first small hole portion (13) before the other punch (26b).

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