Stiffness reinforced floor panel for a raised floor system

Abstract

A floor panel for a raised floor system is provided, where the floor panel includes a plate member with at least one longitudinal groove and a reinforcing member at least a portion of which is inserted into the longitudinal groove. The longitudinal groove is formed on the plate member of the floor panel for a raised floor system, and a stick type reinforcing member and/or a plate type reinforcing member is inserted into the longitudinal groove. Thereby, a thickness of the floor panel can be reduced and at the same time high stiffness and light weight of the floor panel can be achieved, and so a better walking feeling can be obtained and wider spacing of pedestals can be achieved. By coating the plate with a waterproof composition, it is possible to overcome drawbacks of a size and strength thereof being changed and deteriorated by being exposed to moisture.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2005-0015683 filed in the Korean Intellectual Property Office on Feb. 25, 2005, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a floor panel for a raised dry-floor system. More particularly, the present invention relates to a floor panel for a raised floor system having enhanced strength as well as small thickness by inserting a reinforcing member into a longitudinal groove of a plate type member.

(b) Description of the Related Art

A typical interior room of a house, an office, a computer room, and a factory for using IT-related electronic products, etc., therein, is applied with a raised floor system in which, for accommodating cables, pipes, etc., floor panels are arranged on equally spaced pedestals such that an under-floor space corresponding to a height and spacing of the pedestals may become available.

A typical raised floor system scheme involves a relatively heavy material such as a steel support and mineral panel such that it may endure a heavy load, and a disposing distance of the supports is about 500×500 mm or 600×600 mm and so the speed and quality of installation depends much on the skill of a worker.

In the case of Japan, raised floor systems are commonly applied to apartment buildings. However, the principal purpose for this is to provide room for under-floor pipes and to reduce light floor impact noises. That is, the reduction capability for heavy floor impact noises is minimal, and depending on the structure of the building, the reduction of impact noise is sometimes deteriorated. Further, soft rubber is adopted in order to maximize the reduction of floor impact noise, but this causes a wave when a person walks on the raised floor system. Such a wave causes an uneasy feeling to people who are accustomed to a hard and rigid floor, such as a cement mortar floor.

According to a conventional Japanese sound insulation raised dry-floor system, a plurality of pedestals are arranged on a concrete slab floor, and a plurality of floor panels are laid on the pedestals. In this case, when the spacing between pedestals is greater (i.e., when the number of pedestals is smaller), the number of trials for horizontal leveling is reduced, installation speed is enhanced, and a cost of the pedestals is reduced. However, when the spacing between pedestals is greater (that is, when each floor panel is larger), stiffness of the floor panels for a raised floor system is decreased and the wave phenomenon caused by walking, as well as a sagging problem, may occur. Due to such drawbacks, the spacing between pedestals for a conventional raised floor system (i.e., a size of the floor panel) has been realized as 600×455 mm, at best.

In addition, conventional floor panels are usually made of a single integral plate of particle board such that it may have a drawback of low absorption of floor impact noise. Furthermore, the high weight of such a floor panel produces a big load on the pedestals.

In manufacturing a floor panel of a raised floor system, a thickness of the floor panel must be generally increased in order to obtain a sufficient strength. This may cause a disadvantage in that a height of the raised floor system is limited. In addition, the feel when walking on the panels is one of the important criteria for a material for a raised floor system. When the stiffness of a floor panel is insufficient, the floor panel may wave due to walking thereon, and a person may feel uneasy or uncomfortable. In order to prevent such a phenomenon, the spacing between pedestals may be decreased. However, in this case, installation cost is increased since the number of pedestals required is increased.

Waterproof material is used to provide waterproof characteristics, and the kind of waterproof material can be divided into a material filling an empty space and a material forming an insoluble material by reacting with glass lime generated within concrete, and, as examples, there are various waterproof materials such as a waterproof cloth obtained by impregnating cotton cloth or hemp cloth with asphalt, an asphalt roofing such as a concrete block, a material providing a waterproof characteristic by being pasted on surfaces of mortar, concrete, cloth, paper, or fabric, and a material mixed with mortar or concrete to increase waterproof characteristics.

A particle board is used for commercial and residential raised floor systems since it has advantages of having enhanced strength and manufacturing ease compared to its low price, but it also has drawbacks in that a size and strength thereof may be changed and deteriorated by being exposed to moisture.

In order to solve problems of the particle board used for a floor panel of a raised floor system caused by moisture, various methods such as adding a waterproof sheet onto a surface of the particle board, spraying a waterproof material thereon, and forming a waterproof coating layer thereon can be considered.

Although there is a particle board formed with a waterproof sheet, it is expensive and has only a little increase of waterproof performance, about 40%. Further, most conventional waterproof coating liquid products are for blocking moisture in cement floors, outer surfaces of a building, and underground structures, and there is no product among conventional waterproof coating liquid products for a waterproof coating material for a particle board.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

SUMMARY OF THE INVENTION

The present invention has been made in an effort to provide a floor panel for a raised floor system having advantages of slim thickness, high stiffness, and light weight so as to provide a stable feel when walking and a wide spacing of pedestals.

In addition, the present invention has been made in an effort to provide a floor panel for a raised floor system having the advantage of overcoming drawbacks of a size and strength thereof being changed and deteriorated by exposure to moisture.

An exemplary floor panel for a raised floor system according to an embodiment of the present invention includes a plate member with at least one longitudinal groove, and a reinforcing member at least a portion of which is inserted into the longitudinal groove.

The plate member may include an upper plate member and a lower plate member, and the at least one longitudinal groove may be formed on at least one of a lower surface of the upper plate member and an upper surface of the lower plate member.

The reinforcing member may include a stick type reinforcing member having the same sectional shape as the longitudinal groove.

The reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove, and a bent portion of the plate type reinforcing member may be inserted into the longitudinal groove.

The reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove and a stick type reinforcing member having the same sectional shape as the longitudinal groove, and a bent portion of the plate type reinforcing member may be inserted into the longitudinal groove. The stick type reinforcing member may be inserted into the bent portion of the plate type reinforcing member.

At least one longitudinal groove may be formed on each of a lower surface of the upper plate member and an upper surface of the lower plate member, and the reinforcing member may include a stick type reinforcing member having the same sectional shape as a coupling longitudinal groove formed by a combination of the upper plate and the lower plate, and the stick type reinforcing member is inserted into the coupling longitudinal groove.

At least one longitudinal groove may be formed on each of a lower surface of the upper plate and an upper surface of the lower plate, and the reinforcing member may include at least one plate type reinforcing member bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper plate and the lower plate. A bent portion of the plate type reinforcing member may be inserted into the coupling longitudinal groove.

At least one longitudinal groove may be formed on each of a lower surface of the upper plate and an upper surface of the lower plate, and the reinforcing member may include at least one plate type reinforcing member bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper plate and the lower plate and a stick type reinforcing member having the same sectional shape as the coupling longitudinal groove. The plate type reinforcing member may be inserted into the longitudinal groove, and the stick type reinforcing member may be inserted into a bent portion of the plate type reinforcing member.

The plate member may be formed as a single plate, and the at least one longitudinal groove may be formed on a lower surface of the plate member.

The reinforcing member may include a stick type reinforcing member having the same sectional shape as the longitudinal groove.

The reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove, and a bent portion of the plate type reinforcing member may be inserted into the longitudinal groove.

In another embodiment, the reinforcing member may include a plate type reinforcing member bent corresponding to a shape of the longitudinal groove and a stick type reinforcing member having the same sectional shape as the longitudinal groove. The plate type reinforcing member may be inserted into the longitudinal groove, and the stick type reinforcing member may be inserted into a bent portion of the plate type reinforcing member.

Sectional shapes of the longitudinal groove and the reinforcing member may be a tetragon, a circle, an ellipse, or a triangle.

The stick type reinforcing member may be an aluminum bar, a steel bar, or a high strength plastic bar.

The plate type reinforcing member may be a zinc-coated steel plate or a general steel plate.

The plate member may be a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.

The plate member may be coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.

A diameter of a particle of the acrylic resin may be between 0.1 to 0.5 μm.

The acrylic resin may be at least one selected from the group consisting of water-soluble acrylic resin, Styrene Maleic Anhydride copolymer (SMA), acrylic hybrid emulsion, and urethane hybrid resin.

The water repellent agent may be at least one selected from the group consisting of polyethylene wax, polypropylene wax, paraffin wax, fluorine-based water repellent agent, and silicone-based water repellent agent.

The hydrogenated rosin may be at least one selected from the group consisting of ester gum rosin, terpene phenol, petroleum resin, hydrocarbon, and synthetic resin emulsion.

The penetrating agent may be at least one negative ionic surfactant selected from the group consisting of sodium alkyl ester, naphthalene sulphonate, phosphate-based surfactant, and nonyl phenyl alkyl-based surfactant.

The high-boiling-point solvent may be at least one selected from the group consisting of ethylene glycol, propylene glycol, and diethylene glycol.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a raised floor system having a floor panel according to an exemplary embodiment of the present invention.

FIG. 2 is a partially cut-away top plan view of a floor panel for a raised floor system according to an exemplary embodiment of the present invention.

FIG. 3 is a partially cut-away top plan view of a floor panel for a raised floor system according to another exemplary embodiment of the present invention.

FIG. 4 to FIG. 20 are cross-sectional views of floor panels according to various exemplary embodiments of the present invention.

FIG. 21A to 21F illustrate cross-sectional views of stick type reinforcing members having various structures applied to a floor panel for a raised floor system according to an exemplary embodiment of the present invention.

FIG. 22 is a graph comparatively showing load tolerance performances of a floor panel according to an exemplary embodiment of the present invention and a conventional floor panel.

DESCRIPTION OF REFERENCE NUMERALS INDICATING PRIMARY ELEMENTS IN THE DRAWINGS

10: raised floor system

20: floor panel

21: upper plate type member

22: lower plate type member

23: stick type reinforcing member

24: upper plate type reinforcing member

25: lower plate type reinforcing member

30: pedestal

DETAILED DESCRIPTION OF THE EMBODIMENTS

Exemplary embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings.

FIG. 1 shows a raised floor system 10 adopting a floor panel 20 according to an exemplary embodiment of the present invention, and the raised floor system 10 includes a plurality of pedestals 30 that are equally spaced and an upper plate 20 placed on the pedestals 30.

In an exemplary embodiment of the present invention, a high strength sandwich panel is used for the floor panel 20, and thus the pedestals 30 may be arranged with a spacing of at least 400×400 mm (for example, 600×600 mm, 900×900 mm, 800×1,200 mm, 1,200×1,200 mm, or 1,200×1,800 mm). Therefore, installation speed thereof may be enhanced, and the installation cost may be reduced by a reduction of the number of required pedestals 30.

A pedestal 30 used in the raised floor system 10 is generally composed of a head, a height adjustment bolt, and a supporting rubber. In more detail, it may include a plate shaped head, a bolt, and a supporting rubber. The plate shaped head includes a nut disposed at a center thereof and it supports the floor panel 20 of the raised floor system 10. The bolt has a slot-shaped or cross-shaped groove at its top end and is engaged with the nut, such that the vertical position of the head may be adjusted. The supporting rubber is provided with a bolt supporting recess that supports the bolt while permitting rotation of the bolt.

In order to absorb an impact incident on the floor and to reduce vibration of the floor, the supporting rubber may be made of a vibration-damping rubber material. The supporting rubber may be formed in various shapes, for example, in a cylindrical shape that is advantageous against a heavy load, in an inverse trapezoidal sectional shape for providing stability, or in an embossed structure for obtaining better performance of floor impact noise reduction.

FIG. 2 is a partially cut-away top plan view of a floor panel 20 for a raised floor system according to an exemplary embodiment of the present invention, and the floor panel 20 includes an upper plate member 21, a lower plate member 22, and a stick type reinforcing member 23 disposed between the upper and lower plate members 21 and 22. The stick type reinforcing member 23 is inserted into tetragonal longitudinal grooves formed on a lower surface of the upper plate member 21 and an upper surface of the lower plate member 22.

For light weight of the floor panel 20, the stick type reinforcing member 23 may be formed as an aluminum bar having at least one hollow space at its interior or a recess portion on an outer surface thereof. For high stiffness of the floor panel 20, the stick type reinforcing member 23 may have at least one rib formed in its interior in a length direction thereof.

FIG. 3 is a partially cut-away top plan view of a floor panel for a raised floor system according to another exemplary embodiment of the present invention, wherein one additional stick type reinforcing member is provided to the structure of FIG. 2, in which three stick type reinforcing members 23 are provided.

FIG. 4 to FIG. 20 show cross-sectional views of floor panels according to various exemplary embodiments of the present invention.

In the floor panel 20a of FIG. 4, a tetragonal longitudinal groove is respectively formed on a lower surface of an upper plate 21a and an upper surface of a lower plate 22a, and a tetragonal stick type reinforcing member 23a is inserted into a coupling longitudinal groove formed by a combination of the upper and lower plates 21a and 22a. The stick type reinforcing member 23a has the same sectional shape as the coupling longitudinal groove. Although in FIG. 4 four longitudinal grooves in each of the lower and upper surfaces forming four coupling longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto. The number of longitudinal grooves and stick type reinforcing members can be varied within the scope of the present invention. The upper and lower plates 21a and 22a are disposed to symmetrically face each other such that the longitudinal grooves face each other, and the stick type reinforcing members 23a are equally disposed into both of the facing longitudinal grooves.

In the floor panel of FIG. 5, a longitudinal groove is not formed in a lower surface of the upper plate 21b, but a tetragonal longitudinal groove is formed only in the upper surface of the lower plate 22b. A tetragonal stick type reinforcing member 23a having the same sectional shape as the tetragonal longitudinal groove is inserted into the tetragonal longitudinal groove. Although in FIG. 5 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

The floor panel 20c of FIG. 6 is formed with a single plate, and a tetragonal longitudinal groove is formed on a lower surface of the single plate. A tetragonal stick type reinforcing member 23a having the same sectional shape as the tetragonal longitudinal groove is inserted into the tetragonal longitudinal groove. Although in FIG. 6 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20d of FIG. 7, a semicircular longitudinal groove is respectively formed on a lower surface of the upper plate 21d and an upper surface of the lower plate 22d. A circular stick type reinforcing member 23d is inserted into a circular coupling longitudinal groove formed by a combination of the upper and lower plates 21d and 22d. The stick type reinforcing member 23d has the same sectional shape as the coupling longitudinal groove. Although in FIG. 7 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto. The upper and lower plates 21d and 22d are disposed to symmetrically face each other such that the longitudinal grooves face each other, and the circular stick type reinforcing members 23a are equally disposed into both of the facing semicircular longitudinal grooves.

In the floor panel 20e of FIG. 8, a longitudinal groove is not formed on a lower surface of the upper plate 21b, but a circular longitudinal groove is formed only on an upper surface of the lower plate 22e. A circular stick type reinforcing member 23d having the same sectional shape with the circular longitudinal groove is inserted into the circular longitudinal groove. Although in FIG. 8 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

The floor panel 20f of FIG. 9 is formed with a single plate, and a circular longitudinal groove is formed on a lower surface of the plate. A circular stick type reinforcing member 23f having the same sectional shape as the circular longitudinal groove is inserted into the circular longitudinal groove. Although in FIG. 9 three longitudinal grooves and three stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20g of FIG. 10, a semi-elliptical longitudinal groove is respectively formed on a lower surface of the upper plate 21g and an upper surface of the lower plate 22g. An elliptical stick type reinforcing member 23g is inserted into an elliptical coupling longitudinal groove formed by a combination of the upper and lower plates 21g and 22g. The stick type reinforcing member 23g has the same sectional shape as the coupling longitudinal groove. Although in FIG. 10 three longitudinal grooves and three stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto. The upper and lower plates 21g and 22g are disposed to symmetrically face each other such that the longitudinal grooves face each other, and the elliptical stick type reinforcing members 23a are equally disposed into both of the facing semi-elliptical longitudinal grooves.

In the floor panel 20h of FIG. 11, a triangular longitudinal groove is formed on a lower surface of the upper plate 21h, and a trapezoidal longitudinal groove is formed on an upper surface of the lower plate 22h. A triangular stick type reinforcing member 23h is inserted into a triangular coupling longitudinal groove formed by a combination of the upper and lower plates 21h and 22h. The stick type reinforcing member 23h has the same sectional shape as the coupling longitudinal groove. Although in FIG. 11 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

The floor panel 20i of FIG. 12 is formed with a single plate, and a triangular longitudinal groove is formed on a lower surface of the plate. A triangular stick type reinforcing member 23i having the same sectional shape as the triangular longitudinal groove is inserted into the triangular longitudinal groove. Although in FIG. 12 three longitudinal grooves and three stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20j of FIG. 13, a tetragonal longitudinal groove is respectively formed on a lower surface of the upper plate 21a and an upper surface of the lower plate 22a, and upper and lower plate type reinforcing members 24j and 25j, bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper and lower plates 21a and 22a, are disposed between the upper and lower plates 21a and 22a. Tetragonal bent portions of the plate type reinforcing members 24j and 25j are inserted into the tetragonal coupling longitudinal groove, and a tetragonal stick type reinforcing member 23a, having the same sectional shape as the tetragonal coupling longitudinal groove, is inserted into the tetragonal bent portions of the upper and lower plate type reinforcing members 24j and 25j. Although in FIG. 13 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto. The upper and lower plates 21a and 22a are disposed to symmetrically face each other such that the longitudinal grooves face each other, and the stick type reinforcing members 23a are equally disposed into both of the facing tetragonal bent portions of the plate type reinforcing members 24j and 25j.

In the floor panel 20k of FIG. 14, a tetragonal longitudinal groove is formed on a lower surface of the upper plate 21k, but a longitudinal groove is not formed on the lower plate 22k. An upper plate type reinforcing member 24k bent corresponding to a shape of the tetragonal longitudinal groove is inserted between the upper and lower plates 21k and 22k. A tetragonal bent portion of the upper plate type reinforcing member 24k is inserted into the tetragonal longitudinal groove, and a stick type reinforcing member 23a having the same sectional shape as the tetragonal longitudinal groove is inserted into the tetragonal bent portion of the upper plate type reinforcing member 24k. Although in FIG. 14 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20l of FIG. 15, a tetragonal longitudinal groove is formed on a lower surface of the upper plate 21k, but a longitudinal groove is not formed on the lower plate 22k. An upper plate type reinforcing member 24k bent corresponding to a shape of the tetragonal longitudinal groove is inserted between the upper and lower plates 21k and 22k. A tetragonal bent portion of the upper plate type reinforcing member 24k is inserted into the tetragonal longitudinal groove, and in this embodiment, a stick type reinforcing member is not included. Although in FIG. 15 four longitudinal grooves are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20m of FIG. 16, a semicircular longitudinal groove is respectively formed on a lower surface of the upper plate 21m and an upper surface of the lower plate 22m, and upper and lower plate type reinforcing members 24m and 25m bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper and lower plates 21m and 22m are disposed between the upper and lower plates 21m and 22m. Semicircular bent portions of the plate type reinforcing members 24m and 25m are respectively inserted into the semicircular longitudinal grooves, and a circular stick type reinforcing member 23d having the same sectional shape as the circular coupling longitudinal groove is inserted into the semicircular bent portions of the upper and lower plate type reinforcing members 24m and 25m. Although in FIG. 16 three longitudinal grooves and three stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto. The upper and lower plates 21m and 22m are disposed to symmetrically face each other such that the longitudinal grooves face each other, and the stick type reinforcing members 23d are equally disposed into both of the facing semicircular bent portions of the plate type reinforcing members 24m and 25m.

In the floor panel 20n of FIG. 17, a semicircular longitudinal groove is respectively formed on a lower surface of the upper plate 21m and an upper surface of the lower plate 22m, and an upper plate type reinforcing member 24m bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper and lower plates 21m and 22m is disposed between the upper and lower plates 21m and 22m. A semicircular bent portion of the plate type reinforcing member 24m is inserted into the circular coupling longitudinal groove, and a circular stick type reinforcing member 23d having the same sectional shape as the circular coupling longitudinal groove is inserted into the semicircular bent portion of the upper plate type reinforcing member 24m. Although in FIG. 17 three longitudinal grooves and three stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20o of FIG. 18, a semicircular longitudinal groove is respectively formed on a lower surface of the upper plate 21m and an upper surface of the lower plate 22m, and an upper plate type reinforcing member 24m bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper and lower plates 21m and 22m is disposed between the upper and lower plates 21m and 22m. A semicircular bent portion of the plate type reinforcing member 24m is inserted into the circular coupling longitudinal groove, and in this embodiment, a circular stick type reinforcing member is not included. Although in FIG. 18 three longitudinal grooves are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20p of FIG. 19, a triangular longitudinal groove is formed on a lower surface of an upper plate 21h, and a trapezoidal longitudinal groove is formed on an upper surface of a lower plate 22h. An upper plate type reinforcing member 24p bent corresponding to a shape of a triangular coupling longitudinal groove formed by a combination of the upper and lower plates 21h and 22h is disposed between the upper and lower plates 21h and 22h. A triangular bent portion of the plate type reinforcing member 24p is inserted into the triangular coupling longitudinal groove, and a triangular stick type reinforcing member 23h having the same sectional shape as the triangular coupling longitudinal groove is inserted into the triangular bent portion of the upper plate 24p and the trapezoidal groove of the lower plate 22h. Although in FIG. 19 four longitudinal grooves and four stick type reinforcing members are provided, it should not be understood that the scope of the present invention is limited thereto.

In the floor panel 20q of FIG. 20, a triangular longitudinal groove is formed on a lower surface of the upper plate 21h, and a longitudinal groove is not formed in the lower plate 22k. An upper plate type reinforcing member 24p bent corresponding to a shape of a triangular groove is disposed between the upper and lower plates 21h and 22k. A triangular bent portion of the upper plate reinforcing member 24p is inserted into the triangular longitudinal groove, and in this embodiment, a stick type reinforcing member is not included. Although in FIG. 20 four longitudinal grooves are provided, it should not be understood that the scope of the present invention is limited thereto.

In addition, although in the drawings the shapes of the longitudinal groove and the stick type reinforcing member are shown as a tetragon, a triangle, a circle, or an ellipse, the shapes thereof can be variously changed, and a combination of these shapes is also possible.

FIG. 21A to 21F illustrate cross-sectional views of stick type reinforcing members having various structures applied to a floor panel for a raised floor system according to an exemplary embodiment of the present invention.

According to an exemplary embodiment of the present invention, for light weight of a floor panel, the stick type reinforcing member may be formed as a bar having a hollow space at its interior, and for high stiffness, it may have at least one rib formed in its interior in a length direction thereof.

The rib may be formed, in a cross-sectional view cut in a width direction thereof, by two triangular or semicircular members elongated in the width direction facing each and connected to a center vertical member, or by a long vertical member having a constant width.

In another exemplary embodiment of the present invention, the stick type reinforcing member may be an aluminum bar having a hollow space in its interior, and the hollow space may be arranged in a single layer structure or in a plurality of layers structure having the shape of an ellipse, a semi circle, a circle, or a tetragon.

In still another exemplary embodiment, the stick type reinforcing member may be an aluminum bar having at least one recess portion at an outer surface thereof.

In the embodiments of the present invention, the stick type reinforcing member may be an aluminum bar, a steel bar, or a high strength plastic bar.

In the embodiments of the present invention, the plate type reinforcing member may be a zinc-coated steel plate or a general steel plate.

In the embodiments of the present invention, the plate member may be a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.

A total thickness of a floor panel including an upper plate member, a lower plate member, and a reinforcing member may be between 20 to 70 mm, and a thickness of the reinforcing member may be 3 to 20 mm. If a thickness of the floor panel and the reinforcing member is too thin, a desired strength cannot be obtained. On the other hand, if a thickness of the floor panel and the reinforcing member is too thick, weight and manufacturing cost increase.

In addition, in the embodiments of the present invention, the plate may be coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.

Vinyl acetate-based emulsion is known as a waterproof agent, and it includes a copolymer such as vinyl acetate homo-polymer, vinyl acetate acryl, vinyl acetate-based adhesive, ethylene vinyl acetate, and the like. Such conventional waterproof agents have good adhesive characteristics and water tolerance characteristics because they do not use a surfactant. However, since they use a water-soluble polymer they have high viscosity, and so it is difficult to coat such waterproof agents. In addition, since a size of the particles of such conventional waterproof agents is relatively large water molecules can easily move between the particles, and so water easily permeates such a waterproof agent. Therefore, when such a conventional waterproof agent is exposed to water for a long time, there may be a problem in that water may permeate. For this reason, such a conventional waterproof agent is generally used for internal structures of buildings, and it is not suitable for being used for a plate member such as a particle board.

In the embodiments of the present invention, in order to solve the problem of the conventional waterproof agent, a waterproof composition using a resin having a small particle size, wax, and various additives is coated on the plate member, thereby obtaining stabilization of the plate member. The plate member coated by the waterproof composition has good durability and a small twisting phenomenon, and in addition, emission of formalin during manufacturing of the plate member can be prevented.

At this time, a diameter of a particle of the acrylic resin may be between 0.1 to 0.5 μm. The particle diameter of acrylic resin is generally between about 0.1 to 1.5 μm. If the particle diameter of acrylic resin is greater than 1.0 μm, the amount of coating material remaining on a coated surface is larger than the amount of coating material penetrating. On the other hand, if the particle diameter of the acrylic resin is less than 0.1 μm, the opposite phenomenon may occur.

Furthermore, the acrylic resin may be at least one selected from the group consisting of a water-soluble acrylic resin, a Styrene Maleic Anhydride copolymer (SMA), an acrylic hybrid emulsion, and a urethane hybrid resin. Since water-tolerance of a water-soluble acrylic resin increases depending on evaporation of moisture, a water-soluble acrylic resin may be preferable.

The water repellent agent may be at least one selected from the group consisting of polyethylene wax, polypropylene wax, paraffin wax, a fluorine-based water repellent agent, and a silicone-based water repellent agent. In the case of paraffin wax or polyethylene wax, if a softening point is low, stability in a coated surface or in an interior of a coated surface may deteriorate. Thus, it is preferable to use wax at a temperature at which a softening point is relatively high, and a preferable temperature range of a softening point is about 80 to 110° C.

The hydrogenated rosin may be at least one selected from the group consisting of ester gum rosin, terpene phenol, petroleum resin, hydrocarbon, and synthetic resin emulsion.

The penetrating agent may be at least one negative ionic surfactant selected from the group consisting of sodium alkyl ester, naphthalene sulphonate, phosphate-based surfactant, and nonyl phenyl alkyl-based surfactant.

The high-boiling-point solvent may be at least one selected from the group consisting of ethylene glycol, propylene glycol, and diethylene glycol.

The additive agent may be a leveling agent, a wetting and dispersion agent, or the like. BYK-348 (BYK Chemie) can be used as the leveling agent, and BYK-190 (BYK Chemie) and Dispers 610S (TegoChemie) can be used as the wetting and dispersion agent.

In order to manufacture an adhesive material or a coating material, a material having various components is needed, and each component may have an effect on the physical or chemical characteristics of the resultant material. In the embodiments of the present invention, the weight % of acrylic resin, the water repellent agent, the hydrogenated rosin, the penetrating agent, the additive agent, and the high-boiling-point solvent form the optimal range for such effects.

Hereinafter, experimental examples for checking effects of a floor panel according to an exemplary embodiment of the present invention will be described.

A floor panel of an experimental example is manufactured in the structure shown in FIG. 1 according to an exemplary embodiment of the present invention. In the floor panel of this experimental example, a particle board in a thickness of 18 mm is used as the upper and lower plates 21 and 22, and four tetragonal aluminum bars having a rib structure of the specification (unit: mm) shown in FIG. 21 are used as the stick type reinforcing members 23.

At first, four tetragonal grooves are respectively formed on a lower surface of the upper plate 21 and an upper surface of the lower plate 22 in a length direction of a shorter side, and the aluminum bar is inserted into each tetragonal groove. Then, they are glued to each other and pressed to form the floor panel 20 in a thickness of 36 mm.

Table 1 and FIG. 22 comparatively show a sagging amount of the above-mentioned experimental example and a comparison example in which a reinforcing member is simply disposed between upper and lower plates without forming grooves in the upper and lower plates. The sagging amount is measured by a method in which a weight of 100 kg having a circular pressure area with a diameter of 80 mm is laid on a central portion of the floor panel and the sagging amount is measured from below the floor panel.

Referring to table 1 and FIG. 22, the floor panel of the experimental example has a smaller thickness than the comparison example, but has higher stiffness.

TABLE 1
Item               Sagging Amount(mm)
Comparison example 1.98
Experiment example 1.68
Comparison example: upper plate 15 mm + lower plate 15 mm + aluminum bar 8 mm = total 38 mm
Experiment example: upper plate 18 mm + lower plate 18 mm (aluminum bar 8 mm) = total 36 mm

Furthermore, by an application of a high stiffness floor panel 20, spacing between the pedestals 30 can be enhanced up to 800×1,200 mm for a raised floor system as shown in FIG. 1. Performance of reducing a floor impact noise (for example, according to a measurement method of KS F 2810-2 and a rating method of KS F 2863-2 of the Korean Standard) is 45 dB(A), which is a satisfactory value.

In addition, in the case that the waterproof composition is formed in accordance with Table 2 and the particle board is coated by the formed waterproof composition, an expansion rate of absorption thickness is decreased from 10.13% before coating to 4.34% after coating, that is, water tolerance has been increased.

TABLE 2
                            Amount
Components                  (weight %)
Water-soluble acrylic resin 54
(diameter of particle: 0.3-0.5 μm)
TC-400W                     20
(PE/Paraffin Wax Emulsion)
Eastotac H-100W emulsion    18
(hydrogenated rosin)
DO-113                      1
(penetrating agent)
BYK-348/Dispes 610S         2
(leveling agent/wetting and dispersion agent)
CS-12(Taxanol)              5
(high boiling point solvent)

TABLE 3
Suction Thickness
Expansion Rate
Before coating     10.13%
Comparison example 7.83%
(conventional Japanese waterproof coating
liquid)
Experiment example 4.34%
(after coating the waterproof composition
according to the present invention)
Measure standard: KS F 3104

As above stated, in the present invention, by forming a longitudinal groove in the plate of a floor panel of a raised floor system and by inserting a stick type reinforcing member and/or a plate type reinforcing member into the longitudinal groove, a thickness of a floor panel can be reduced and at the same time high stiffness and light weight of the floor panel can be achieved. Therefore, a better walking feeling can be obtained, and a wider spacing of pedestals can be achieved.

In addition, by achieving a light weight of the floor panel and a wider spacing of pedestals, installation speed may be enhanced, and installation cost may be reduced. Furthermore, floor impact noise can be substantially decreased.

In addition, by coating the plate with a waterproof composition, it is possible to overcome drawbacks of a size and strength thereof being changed and deteriorated by exposure to moisture.

While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A floor panel for a raised floor system, comprising:

a plate member with at least one longitudinal groove; and

a reinforcing member, at least a portion of which is inserted into the longitudinal groove.

2. The floor panel of claim 1, wherein:

the plate member comprises an upper plate member and a lower plate member; and

the at least one longitudinal groove is formed on at least one of a lower surface of the upper plate member and an upper surface of the lower plate member.

3. The floor panel of claim 2, wherein:

the reinforcing member comprises a stick type reinforcing member having the same sectional shape as the longitudinal groove.

4. The floor panel of claim 2, wherein:

the reinforcing member comprises a plate type reinforcing member bent corresponding to a shape of the longitudinal groove; and

a bent portion of the plate type reinforcing member is inserted into the longitudinal groove.

5. The floor panel of claim 2, wherein:

the reinforcing member comprises a plate type reinforcing member bent corresponding to a shape of the longitudinal groove and a stick type reinforcing member having the same sectional shape as the longitudinal groove;

a bent portion of the plate type reinforcing member is inserted into the longitudinal groove; and

the stick type reinforcing member is inserted into the bent portion of the plate type reinforcing member.

6. The floor panel of claim 2, wherein:

at least one longitudinal groove is formed on each of a lower surface of the upper plate member and an upper surface of the lower plate member; and

the reinforcing member includes a stick type reinforcing member having the same sectional shape as a coupling longitudinal groove formed by a combination of the upper plate and the lower plate, and the stick type reinforcing member is inserted into the coupling longitudinal groove.

7. The floor panel of claim 2, wherein:

at least one longitudinal groove is formed on each of a lower surface of the upper plate and an upper surface of the lower plate;

the reinforcing member includes at least one plate type reinforcing member bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper plate and the lower plate; and

a bent portion of the plate type reinforcing member is inserted into the coupling longitudinal groove.

8. The floor panel of claim 2, wherein:

at least one longitudinal groove is formed on each of a lower surface of the upper plate and an upper surface of the lower plate;

the reinforcing member includes at least one plate type reinforcing member bent corresponding to a shape of a coupling longitudinal groove formed by a combination of the upper plate and the lower plate and a stick type reinforcing member having the same sectional shape as the coupling longitudinal groove;

the plate type reinforcing member is inserted into the longitudinal groove; and

the stick type reinforcing member is inserted into a bent portion of the plate type reinforcing member.

9. The floor panel of claim 1, wherein:

the plate member is formed as a single plate; and

the at least one longitudinal groove is formed on a lower surface of the plate member.

10. The floor panel of claim 9, wherein the reinforcing member comprises a stick type reinforcing member having the same sectional shape as the longitudinal groove.

11. The floor panel of claim 9, wherein:

the reinforcing member comprises a plate type reinforcing member bent corresponding to a shape of the longitudinal groove; and

a bent portion of the plate type reinforcing member is inserted into the longitudinal groove.

12. The floor panel of claim 9, wherein:

the reinforcing member comprises a plate type reinforcing member bent corresponding to a shape of the longitudinal groove and a stick type reinforcing member having the same sectional shape as the longitudinal groove;

the plate type reinforcing member is inserted into the longitudinal groove; and

the stick type reinforcing member is inserted into a bent portion of the plate type reinforcing member.

13. The floor panel of claim 1, wherein sectional shapes of the longitudinal groove and the reinforcing member are a tetragon, a circle, an ellipse, or a triangle.

14. The floor panel of claim 2, wherein sectional shapes of the longitudinal groove and the reinforcing member are a tetragon, a circle, an ellipse, or a triangle.

15. The floor panel of claim 9, wherein sectional shapes of the longitudinal groove and the reinforcing member are a tetragon, a circle, an ellipse, or a triangle.

16. The floor panel of claim 3, wherein the stick type reinforcing member is an aluminum bar, a steel bar, or a high strength plastic bar.

17. The floor panel of claim 5, wherein the stick type reinforcing member is an aluminum bar, a steel bar, or a high strength plastic bar.

18. The floor panel of claim 6, wherein the stick type reinforcing member is an aluminum bar, a steel bar, or a high strength plastic bar.

19. The floor panel of claim 8, wherein the stick type reinforcing member is an aluminum bar, a steel bar, or a high strength plastic bar.

20. The floor panel of claim 10, wherein the stick type reinforcing member is an aluminum bar, a steel bar, or a high strength plastic bar.

21. The floor panel of claim 12, wherein the stick type reinforcing member is an aluminum bar, a steel bar, or a high strength plastic bar.

22. The floor panel of claim 4, wherein the plate type reinforcing member is a zinc-coated steel plate or a general steel plate.

23. The floor panel of claim 5, wherein the plate type reinforcing member is a zinc-coated steel plate or a general steel plate.

24. The floor panel of claim 7, wherein the plate type reinforcing member is a zinc-coated steel plate or a general steel plate.

25. The floor panel of claim 8, wherein the plate type reinforcing member is a zinc-coated steel plate or a general steel plate.

26. The floor panel of claim 11, wherein the plate type reinforcing member is a zinc-coated steel plate or a general steel plate.

27. The floor panel of claim 12; wherein the plate type reinforcing member is a zinc-coated steel plate or a general steel plate.

28. The floor panel of claim 1, wherein the plate member is a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.

29. The floor panel of claim 2, wherein the plate member is a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.

30. The floor panel of claim 9, wherein the plate member is a particle board (PB), a plywood, a medium density fiberboard (MDF), a high density fiberboard (HDF), an oriented strand board (OSB), a wood wool cement board, or a concrete cement plate.

31. The floor panel of claim 28, wherein the plate member is coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.

32. The floor panel of claim 29, wherein the plate is coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.

33. The floor panel of claim 30, wherein the plate is coated by a waterproof composition comprising 22 to 60 weight % of an acrylic resin, 5 to 30 weight % of a water repellent agent, 3 to 20% of a hydrogenated rosin, 0.5 to 5 weight % of a penetrating agent, 2 to 8 weight % of an additive agent, and 1 to 15 weight % of a high-boiling-point solvent.

34. The floor panel of claim 31, wherein a diameter of a particle of the acrylic resin is between 0.1 to 0.5 μm.

35. The floor panel of claim 31, wherein the acrylic resin is at least one selected from the group consisting of water-soluble acrylic resin, Styrene Maleic Anhydride copolymer (SMA), acrylic hybrid emulsion, and urethane hybrid resin.

36. The floor panel of claim 31, wherein the water repellent agent is at least one selected from the group consisting of polyethylene wax, polypropylene wax, paraffin wax, fluorine-based water repellent agent, and silicone-based water repellent agent.

37. The floor panel of claim 31, wherein the hydrogenated rosin is at least one selected from the group consisting of ester gum rosin, terpene phenol, petroleum resin, hydrocarbon, and synthetic resin emulsion.

38. The floor panel of claim 31, wherein the penetrating agent is at least one negative ionic surfactant selected from the group consisting of sodium alkyl ester, naphthalene sulphonate, phosphate-based surfactant, and nonyl phenyl alkyl-based surfactant.

39. The floor panel of claim 31, wherein the high-boiling-point solvent is at least one selected from the group consisting of ethylene glycol, propylene glycol, and diethylene glycol.