JP2013204259A - Wash place floor pan - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wash place floor pan capable of holding a drainage slope by suppressing a variation in the position of one member relative to the other even when using a foam formed of a thermoplastic resin.SOLUTION: The wash place floor pan includes a floor base material having higher strength than the thermoplastic resin foam, a floor surface material having an opening for a drain port, supported upward by the floor base material, and formed of the thermoplastic resin foam so that the drainage slope inclined downward toward the opening is formed on the surface, a flexible surface material provided above the floor surface material for covering the upper face of the floor surface material, and a non-water-permeable drainage pit which is mounted in the opening to form at least part of the drain port, which has a flange at the upper end in contact with the lower face of the surface material, and whose hardness is higher than that of the surface material. A joint member joining the flange to the lower face of the surface material is mounted in the opening.

Description

  Aspects of the present invention generally relate to washroom floor pans used in bathrooms, shower stalls, and the like.

  The present inventor, for example, is a foam formed of a thermoplastic resin for the purpose of reducing carbon dioxide emissions by reducing recycling, reducing the burden on the environment, reducing mold costs, etc. We are investigating a laundry floor pan using sushi.

  Here, for example, there is a bathroom floor pan using a thermosetting resin such as fiber reinforced plastic (FRP) (Patent Document 1). In the bathroom washroom floor pan described in Patent Document 1, the base material has a drain outlet formed integrally with the base material itself.

  On the other hand, in a washing floor floor pan using a foam formed of a thermoplastic resin, a surface material and a drain outlet that are separate from the foam are formed from the viewpoint of design or securing waterproofness. A drainage pit is required. Therefore, the wash floor floor pan has a multi-layer structure. Then, in the manufacturing process of the washing floor floor pan, the relative position of the foam, the surface material, and the drainage pit may vary. If variations occur in the relative positions of the foam, the surface material, and the drainage pits, for example, there may be a problem that the drainage gradient formed on the wash floor pan cannot be maintained.

JP 2010-229790 A

  The present invention has been made based on recognition of such a problem, and even when a foam formed of a thermoplastic resin is used, variation in relative position between members is suppressed, and a drainage gradient is maintained. An object is to provide a washing floor bread that can be washed.

  1st invention has the floor base material which has higher intensity | strength than a thermoplastic foamed resin, and the opening part for drain outlets, it is supported by the said floor base material from the downward direction, and is formed with the thermoplastic foamed resin, and the said A flooring material having a drainage slope inclined downward toward the opening, a surface material having flexibility and covering the upper surface of the flooring material provided above the flooring material, and water-impermeable Drainage having a hardness higher than the hardness of the surface material, having a flange that is attached to the opening to form at least a part of the drainage port and has a flange that contacts the lower surface of the surface material at the upper end. It is a washing ground floor bread | pan characterized by including the pit and the joining member which joined the said flange and the lower surface of the said surface material was mounted | worn with the said opening part.

  According to this washing ground floor pan, the joining member obtained by joining the drainage pit and the surface material is attached to the opening of the floor surface material to manufacture the washing ground floor pan. At this time, since the drainage pit is formed of a resin having a hardness higher than that of the surface material, it has a function as a member that determines the horizontal position of the joining member with respect to the opening of the floor surface material. And the position of a joining member should just be determined on the basis of the center of the opening part of a floor surface material. Thereby, workability and productivity can be improved.

  Moreover, the drainage pit has non-water permeability. Therefore, it is possible to suppress the discharged water from penetrating into the drain pit. Moreover, it can suppress that a water leaks or penetrate | invades into the back side of a drainage pit. Therefore, even if the drainage pit is provided as a separate component from the floor base material, the floor surface material, and the surface material, it is possible to provide a wash floor floor pan with excellent waterproofness.

  According to a second aspect of the present invention, in the first aspect, the horizontal position of the drainage pit is determined by positioning means for positioning the drainage pit at a predetermined position inside the opening. It is a washing floor floor pan.

  According to this washing place floor pan, since the positioning means can determine and fix the horizontal position of the drainage pit to a predetermined position, the relative positions of the floor material, the surface material, and the drainage pit vary. This can be suppressed. Therefore, even if the drain pit is connected to the drain trap, it is possible to suppress the occurrence of problems such as wrinkles on the surface material.

  In a third aspect based on the second aspect, the positioning means is a fastener for fastening the drainage pit and the floor surface material from below the floor surface material. It is.

  According to this washroom floor pan, since the fastener only positions the drainage pit and the flooring material from below the flooring material, the drainage pit is positioned. Therefore, between the opening of the flooring material and the drainage pit, It can suppress that a clearance gap arises. Further, since only a fastener for fastening the drainage pit and the floor surface material is used, cost reduction can be achieved.

  According to a fourth aspect of the present invention, in the second or third aspect, the drainage pit is joined to the surface material by bonding or welding the flange and the lower surface of the surface material. It is bread.

  According to this washroom floor pan, since the joining of the flange portion and the lower surface of the surface material is performed by a cheaper and more reliable method, the surface material and the drain pit are separated when positioning the drain pit. That can be suppressed.

  According to a fifth aspect of the present invention, in the fourth aspect of the invention, the flange is sandwiched between the surface material and the floor surface material.

  According to this washroom floor pan, since the lower surface of the flange portion of the drain pit is supported by the floor material supported by the floor base material, the strength in the vicinity of the opening of the floor material is increased, and the surface material and the drain pit It can suppress that a junction part with is damaged.

  According to the aspect of the present invention, even when a foam formed of a thermoplastic resin is used, it is possible to provide a washing floor floor pan that can maintain a drainage gradient while suppressing variation in relative position between members. The

It is a typical exploded view showing the washing ground floor bread concerning an embodiment of the invention. It is a typical top view showing the washing ground floor bread concerning this embodiment. It is a typical sectional view showing the washing ground floor bread concerning this embodiment. It is typical sectional drawing explaining the positioning method of the joining member with respect to an opening part. It is typical sectional drawing explaining the positioning method of the joining member with respect to an opening part. It is the typical top view to which the vicinity of the drainage pit of the washing floor floor pan concerning this embodiment was expanded. It is a typical side view showing the drainage pit of this embodiment. It is a schematic diagram showing the positioning means of this embodiment.

Embodiments of the present invention will be described below with reference to the drawings. In addition, in each drawing, the same code | symbol is attached | subjected to the same component and detailed description is abbreviate | omitted suitably.
FIG. 1 is a schematic exploded view showing a washing ground floor pan according to an embodiment of the present invention.
FIG. 2 is a schematic plan view showing a washing floor floor pan according to the present embodiment.
Moreover, FIG. 3 is typical sectional drawing showing the washing-room floor bread concerning this embodiment.
FIG. 3 is a schematic cross-sectional view taken along the cutting plane AA shown in FIG.

  The washing floor floor pan 100 shown in FIG. 1 includes a floor base material 110, a floor surface material 130, a cushion material 140, a surface material 150, and a drainage pit 160. The washing floor pan 100 is formed in a shallow vessel shape (bread shape) with its peripheral edge bent upward, and has a waterproof property that prevents water from leaking out of a sanitary equipment room such as a bathroom or a shower room. In the present specification, the term “water” includes not only cold water but also warm hot water.

  The floor base material 110 includes support legs 111, a support frame 113, and a receiving plate 115. The support frame 113 includes, for example, four first frames 113a whose longitudinal direction is arranged in the first direction and four fourth frames arranged in the second direction whose longitudinal direction is orthogonal to the first direction. 2 frames 113b. The support legs 111 are provided at the four corners of the support frame 113. The support leg 111 has a bolt part, and has a structure whose height can be adjusted by rotation of the bolt part.

  The floor base 110 receives a load applied to the upper surface of the washing floor floor pan 100 in a limited space such as a bathroom, and maintains its position. Therefore, the floor base 110 needs to have sufficient strength. For example, the floor substrate 110 has a strength higher than that of a thermoplastic foam resin. Therefore, as an example of obtaining this sufficient strength, steel material is used for the floor base material 110 in the present embodiment.

  The floor base material 110 is placed on an installation surface such as a bathroom (for example, the floor of a building), and the height is appropriately adjusted by the rotation of the bolt portion of the support leg 111. Thereby, the horizontal surface of the washroom floor pan 100 is secured. The support legs 111 and the support frame 113 support the receiving plate 115 from below. In other words, the receiving plate 115 is placed on the support leg 111 and the support frame 113. The receiving plate 115 is fixed to the support frame 113 by a fastening member such as a screw.

  The upper surface of the receiving plate 115 serves as a vertical reference position, that is, a horizontal reference surface, of each member included in the washing floor pan 100. The receiving plate 115 supports the floor material 130 from below and receives a load from a member placed on the receiving plate 115. Therefore, the receiving plate 115 is preferably a flat plate material having relatively high strength and rigidity. As an example, for example, a steel deck plate or a sandwich panel may be used. The strength of the floor base material 110 is higher than the strength of the floor surface material 130 formed of a thermoplastic foam resin described later.

A floor material 130 is placed on the floor substrate 110. The floor surface material 130 is formed of a thermoplastic foam resin and is supported from below by the floor base material 110. Examples of the thermoplastic foamed resin include foamed polypropylene, foamed polystyrene, foamed polyethylene, and foamed polyurethane. In this embodiment, foamed polypropylene is used as an example. Since the thermoplastic foamed resin is recyclable, the use of this makes it possible to reduce the CO ₂ emission accompanying the production and disposal of the floor covering 130 and provide an environmentally friendly product. Moreover, since the mold used for foam molding can be manufactured at a lower cost than molds produced by other molding methods, the manufacturing cost of the washing floor pan 100 can be kept low.

  As shown in FIG. 1, an opening 131 for a drain outlet communicating with the drain trap 210 shown in FIG. 3 is formed in the vicinity of the outer periphery of the floor material 130, for example, on the long side. The portion provided with the opening 131 has a concave shape. In addition, a drainage gradient inclined downward toward the opening 131 is formed on the surface of the floor member 130.

  A surface material 150 is provided on the floor material 130 via a cushion material 140. The cushion material 140 and the surface material 150 are for improving the sensory performance such as the appearance design and feeling of use of the floor surface of the washing floor floor pan 100 and the functions that are inevitably required for the washing floor floor pan 100 such as waterproofness. It is used for.

  That is, the cushion material 140 obtains the softness of the floor surface given to the user. As a material of the cushion material 140, for example, a soft material such as foamed polyurethane is used. By changing the hardness (softness) of the cushion material 140, the specification of the hardness (softness) of the floor surface can be changed.

  The surface material 150 covers the upper surface of the floor surface material 130 and forms the surface of the washing floor pan 100. The surface material 150 has flexibility. As the material of the surface material 150, a flexible soft sheet material having waterproofness is used. In order to improve the design and drainage of the surface of the washing floor floor pan 100, the surface material 150 may be subjected to uneven processing or a pattern.

The drain pit 160 is formed of a resin having a hardness higher than the hardness of the floor surface material 130 and has a water-impermeable property. In other words, the drain pit 160 is formed of a resin having a foaming rate lower than that of the thermoplastic foamed resin of the floor material 130. Specifically, the drain pit 160 is formed of a non-foaming resin.
Here, in this specification, “hardness” refers to the hardness (hardness) determined by either the “Rockwell hardness” test method or the “Shore hardness” test method.

  As shown in FIGS. 2 and 3, the drain pit 160 is attached to the opening 131 of the floor surface material 130. Further, as shown in FIG. 2, the drainage pit 160 has an opening 165 and forms at least a part of the drainage port. As shown in FIG. 3, the drain pit 160 has a flange portion 161 at the upper end portion. The flange portion 161 is in contact with the lower surface of the surface material 150 and is joined to the lower surface of the surface material 150 by, for example, vibration welding, adhesion using an adhesive, or adhesion using IH (induction heating).

  As shown in FIG. 3, the flange 161 of the drain pit 160 is sandwiched between the surface material 150 and the floor member 130 in a state where the drain pit 160 is attached to the opening 131 of the floor member 130. Has been. According to this, since the lower surface of the flange portion 161 of the drain pit 160 is supported by the floor surface material 130 supported by the floor base material 110, the strength in the vicinity of the opening 131 of the floor surface material 130 is increased, and the surface material It can suppress that the junction part of 150 and the drain pit 160 is damaged.

  As shown in FIG. 3, a drain trap 210 fixed to the floor base 110 is provided below the opening 131. The drain trap 210 includes a drain trap body 211, a water seal cylinder 213, and a mounting flange 215. The drain trap 210 forms sealed water by the drain trap body 211 and the sealing cylinder 213, and prevents odors, pests and the like on the downstream side of the drain trap 210 from flowing into the bathroom.

  A female screw is provided at the upper end of the inner peripheral portion of the drain trap body 211. On the other hand, a male screw is provided at the lower end of the outer peripheral portion of the mounting flange 215. Then, the mounting flange 215 is screwed into the drain trap body 211 and tightened while the bottom surface portion 163 of the drain pit 160 is sandwiched between the upper surface of the drain trap body 211 and the lower surface of the mounting flange 215. Thereby, the drain trap 210 can be attached to the bottom surface portion 163 of the drain pit 160. Further, the bottom surface portion 163 of the drainage pit 160 can be fixed.

  Here, as described above, the washing floor floor pan 100 according to the present embodiment includes the floor base material 110, the floor surface material 130, the cushion material 140, the surface material 150, and the drainage pit 160, and a plurality of them. It has a layer structure. Therefore, in the manufacturing process of the washing ground floor pan 100, there may be variations in the relative positions of the floor material 130, the surface material 150, and the drainage pit 160. If the relative positions of the floor surface material 130, the surface material 150, and the drain pit 160 vary, for example, the drainage gradient formed on the floor surface material 130 may not be maintained.

  On the other hand, in the washing floor pan 100 according to the present embodiment, a joining member obtained by joining the drain pit 160 and the lower surface of the surface material 150 is attached to the opening 131 of the floor surface material 130. At this time, a bonding member is attached and bonded to the opening 131 of the floor member 130 in a state where the horizontal position of the drain pit 160 is positioned at a predetermined position inside the opening 131 of the floor member 130. Specifically, the joining member is attached to the opening 131 of the floor covering 130 in a state where the center of the opening 131 of the floor covering 130 and the center of the opening 165 of the drain pit 160 are aligned. Glue. In addition, in a state where the installation height of the drainage pit 160 is pulled down to a predetermined installation height, a bonding member is attached and bonded to the opening 131 of the floor surface material 130.

  According to this embodiment, the joining member obtained by joining the drainage pit 160 and the surface material 150 is attached to the opening 131 of the floor surface material 130, and the washing floor pan 100 is manufactured. At this time, since the drain pit 160 is formed of a resin having a hardness higher than that of the surface material 150, the drain pit 160 has a function as a member that determines the horizontal position of the joining member with respect to the opening 131 of the floor surface material 130. . Then, the position of the joining member may be determined by combining the positions of the center of the opening 131 of the floor material 130 and the center of the opening 165 of the drainage pit 160. Thereby, workability and productivity can be improved.

  Further, as described above, the drain pit 160 has non-water permeability. Therefore, it is possible to suppress the discharged water from penetrating into the drain pit 160. In addition, it is possible to prevent water from leaking or entering the back side of the drainage pit 160. Therefore, even if the drain pit 160 is provided as a separate component from the floor base material 110, the floor surface material 130, and the surface material 150, it is possible to provide the wash floor pan 100 having excellent waterproofness.

Next, a method for assembling the washing ground floor pan 100 according to the present embodiment will be described with reference to the drawings.
4 and 5 are schematic cross-sectional views illustrating a method for positioning the joining member with respect to the opening.
FIG. 6 is an enlarged schematic plan view of the vicinity of the drainage pit of the washing floor floor pan according to the present embodiment.
FIG. 7 is a schematic side view showing the drain pit of the present embodiment.
FIG. 8 is a schematic diagram showing the positioning means of this embodiment.

FIG. 4 is a schematic cross-sectional view taken along the cutting plane BB shown in FIG. FIG. 5 is a schematic cross-sectional view taken along the cutting plane CC shown in FIG.
FIG. 7B is a schematic diagram in which the region A1 shown in FIG. 7A is enlarged.
FIG. 8B is a schematic cross-sectional view taken along the cutting plane DD shown in FIG.

First, the drainage pit 160 of this embodiment will be described.
As shown in FIG. 7, an engaging portion 167 having a convex shape is provided on the outer peripheral portion of the drainage pit 160 of the present embodiment. In the plan view shown in FIG. 7A and FIG. 7B, the engaging portion 167 has an inclined surface 167a having a shape that rises to the right. In the drainage pit 160 of the present embodiment, for example, four engagement portions 167 are provided on the outer peripheral portion at substantially equal intervals. However, the installation number or installation location of the engaging portion 167 is not limited to this.

  Here, when the joining member obtained by joining the drainage pit 160 and the surface material 150 is attached to the opening 131 of the floor surface material 130, the positioning means (fastener) 310 as shown in FIG. 8 is used. As shown in FIG. 8A, the positioning means 310 of the present embodiment has a circular shape and has a through hole 311 in the center. Further, as shown in FIG. 8B, an engaging portion 313 that protrudes toward the central portion is provided at the upper end portion of the inner peripheral portion of the through hole 311. In the positioning means 310 of the present embodiment, for example, four engaging portions 313 are provided at substantially equal intervals on the inner peripheral portion of the through hole 311. However, the number of installation portions or the installation locations of the engaging portions 313 are not limited to this.

  When assembling the washing ground floor pan 100 according to the present embodiment, first, the relative position between the floor surface material 130 and the positioning means 310 is appropriately determined. Specifically, alignment between the center of the opening 131 of the floor surface material 130 and the center of the through hole 311 of the positioning means 310 is performed. The positioning of the relative position between the floor material 130 and the positioning means 310 may be performed by the positioning portions provided on the floor material 130 and the positioning means 310, or the floor material 130 and the positioning means 310. It may be performed by another jig different from the above.

  Subsequently, a joining member obtained by joining the drain pit 160 and the lower surface of the surface material 150 in advance is attached to the opening 131 of the floor surface material 130. Specifically, the bottom surface portion 163 (see FIG. 3) of the drainage pit 160 is inserted into the opening 131 of the floor surface material 130 and the through hole 311 of the positioning means 310. Subsequently, the positioning means 310 is rotated in a state where the bottom surface portion 163 of the drainage pit 160 is inserted into the opening 131 of the floor surface material 130 and the through hole 311 of the positioning means 310.

  Then, as shown in FIGS. 4 and 5, the engaging portion 313 of the positioning means 310 engages with the engaging portion 167 of the drainage pit 160. Accordingly, the horizontal position of the drain pit 160, that is, the horizontal position of the joining member that joins the drain pit 160 and the surface material 150 is positioned at a predetermined position inside the opening 131 of the floor member 130. . Specifically, alignment between the center of the opening 165 of the drain pit 160 and the center of the through hole 311 of the positioning means 310 is performed. Here, as described above, the center of the opening 131 of the floor material 130 and the center of the through hole 311 of the positioning means 310 are aligned. Therefore, the positioning means 310 brings the center of the opening 165 of the drain pit 160 and the center of the opening 131 of the floor surface material 130 into alignment.

  According to this, since the positioning means 310 can determine and fix the horizontal position of the drainage pit 160 to a predetermined position, the positioning means 310 can be positioned at the relative positions of the floor material 130, the surface material 150, and the drainage pit 160. The occurrence of variations can be suppressed. Therefore, even if the drain trap 210 (see FIG. 3) and the drain pit 160 are connected, it is possible to suppress the occurrence of problems such as wrinkles on the surface material 150. As described above with reference to FIGS. 1 to 3, the flange 161 and the surface material 150 of the drain pit 160 are joined by a cheaper and more reliable method. It is possible to prevent the surface material 150 and the drain pit 160 from being divided.

  Further, when the engaging portion 313 of the positioning means 310 engages with the engaging portion 167 of the drain pit 160 as indicated by an arrow A11 shown in FIG. The inclined surface 167a of the engaging portion 167 slides relatively upward. As described above, the engaging portion 167 of the drainage pit 160 has the inclined surface 167a having a right upward shape, so that the engaging portion 313 of the positioning means 310 makes the inclined surface 167a of the engaging portion 167 of the drainage pit 160 relatively Thus, as it slides upward (in the direction of arrow A11 shown in FIG. 7), it receives a downward force. Therefore, the drain pit 160 is fixed in a state where it is drawn downward by the positioning means 310. Thus, the positioning means 310 of the present embodiment fastens the drain pit 160 and the floor surface material 130 from below the floor surface material 130.

  According to this, the positioning means 310 can fix the installation height of the drain pit 160 to a predetermined installation height. That is, by rotating the positioning means 310 below the floor material 130 and tightening from below, the drain pit 160 can be drawn downward, and the vertical position of the drain pit 160 can be fixed at a predetermined position. Therefore, it is possible to suppress the occurrence of a gap between the opening 131 of the floor material 130 and the drain pit 160. Further, the drainage gradient formed on the floor material 130 can be maintained.

  In this way, the joining member that joins the drainage pit 160 and the surface material 150 in a state where the horizontal and vertical positions of the drainage pit 160 are fixed at predetermined positions is the opening 131 of the floor surface material 130. Attached to and bonded to. Positioning means 310 until the adhesive applied between floor surface material 130 and drainage pit 160 and the adhesive applied between floor surface material 130 and surface material 150 are cured. The drainage pit 160 and the floor surface material 130 remain fastened. For example, the positioning means 310 keeps the drain pit 160 and the floor covering 130 fastened until the joining member is attached to the opening 131 of the floor covering 130 and bonded to the construction site.

Subsequently, the positioning means 310 is removed at the construction site. Subsequently, as described above with reference to FIG. 3, the drain trap 210 is fixed by the mounting flange 215 to the opening 131 of the floor material 130 or the bottom surface 163 of the drain pit 160. The positioning means 310 removed at the construction site is reused as a member for fixing the horizontal and vertical positions of the drain pits 160 to predetermined positions, for example, in a manufacturing factory or an assembly factory.
According to this, since the positioning means 310 fastens the drain pit 160 and the floor surface material 130 and is reused, the cost can be reduced.

The embodiment of the present invention has been described above. However, the present invention is not limited to these descriptions. As long as the features of the present invention are provided, those skilled in the art appropriately modified the design of the above-described embodiments are also included in the scope of the present invention. For example, the shape, size, material, arrangement, etc. of each element provided in the floor surface material 130, the surface material 150, the drainage pit 160, the positioning means 310, and the like, and the engaging portion 167 of the drainage pit 160 and the engaging portion of the positioning means 310 The installation form of 313 is not limited to those illustrated, but can be changed as appropriate.
Moreover, each element with which each embodiment mentioned above is provided can be combined as long as technically possible, and the combination of these is also included in the scope of the present invention as long as it includes the features of the present invention.

  100 wash floor pan, 110 floor base material, 111 support leg, 113 support frame, 113a first frame, 113b second frame, 115 backing plate, 130 floor surface material, 131 opening, 140 cushion material, 150 surface material , 160 Drain pit, 161 Flange, 163 Bottom, 165 Opening, 167 Engagement, 167a Inclined surface, 210 Drain trap, 211 Drain trap body, 213 Sealing cylinder, 215 Mounting flange, 310 Positioning means, 311 Through hole 313 engagement part

Claims (5)

A floor base material having higher strength than a thermoplastic foam resin;
A flooring material having an opening for a drain outlet, supported from below by the floor base material, formed of a thermoplastic foam resin and having a drainage gradient inclined downward toward the opening; ,
A surface material provided above the floor material and having flexibility to cover the upper surface of the floor material;
Hardness that is higher than the hardness of the surface material, has a non-water permeability and has a flange that is attached to the opening to form at least a part of the drainage port and that contacts the lower surface of the surface material at the upper end. A drain pit having
With
A washing floor floor pan, wherein a joining member joining the flange and the lower surface of the surface material is attached to the opening.   The washing ground floor pan according to claim 1, wherein the horizontal position of the drainage pit is determined by positioning means for positioning the drainage pit at a predetermined position inside the opening.   The washing place floor pan according to claim 2, wherein the positioning means is a fastener that fastens the drain pit and the floor surface material from below the floor surface material.   The washing ground floor pan according to claim 2 or 3, wherein the drain pit is joined to the surface material by adhesion or welding between the flange and a lower surface of the surface material.   The washing floor floor pan according to claim 4, wherein the flange is sandwiched between the surface material and the floor material.

Images