JP2019095060A - Machine screw reception structure and its process of manufacture - Google Patents

Abstract

To provide a machine screw reception structure applied to an adiabaticity water-proof pan or the like in low cost.SOLUTION: An annular machine screw member 18 is arranged to enclose an opening part 16 at an adiathermancy water-proof pan 1 for a bath-room including a foam layer 10a and an epidermal layer 10b laminated at its upper surface. This machine screw member 18 is buried at the upper surface of the foam layer 10a through insert foam molding work and covered by the epidermal layer 10b. The foam layer 10a is thermally melted to the epidermal layer 10b and the annular machine screw member. A supporting lid 30 of a tube lead-out structure 5 is installed to cover an opening part 16. A machine screw 39 passing through an insertion hole 31a at the supporting lid 30 and an insertion hole 10x at the epidermal layer 10b is screwed into a tapping hole 18x of the machine screw reception member 18 to cause the supporting lid 30 to be fixed to the machine screw reception member 18.SELECTED DRAWING: Figure 9

Description

  BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a screw receiving structure applicable to a waterproofing pan or the like having a heat insulating property and a method of manufacturing the same.

In a bathroom, piping such as a hot water supply pipe and a water supply pipe is passed between a bathroom waterproof pan and a floor slab, led out from the opening of the bathroom waterproof pan, and connected to the water supply / hot water tap May be adopted.
Patent Document 1 discloses a structure in which the above-mentioned piping is led upward from the opening of a bathroom waterproof pan. Briefly explaining, a rubber packing (supporting lid, mounting part) is watertightly attached to the opening of the bathroom waterproof pan by covering the opening with a screw. A tubular insertion portion is formed in the rubber packing, and the pipe is inserted in a watertight manner through the insertion portion.

  In recent years, various waterproof pans for a bathroom provided with a foam layer have been developed as lightweight waterproof pans having a heat insulating property. Since the foam layer has difficulty in water tightness and surface hardness, it is also devised to laminate a skin layer on the foam layer.

  The rubber packing can not be screwed directly to the periphery of the opening of the bathroom waterproof pan having the heat insulation property as described above. Therefore, it is necessary to fix an annular screw receiving member having a predetermined rigidity to the upper surface of the surface layer at the peripheral edge of the opening by adhesion or the like, and fix the rubber packing to the screw receiving member with a screw.

JP 10-152873 A

  As described above, the work of retrofitting the screw receiving member to the upper surface of the waterproofing pan of the bathroom having the heat insulating property takes time and effort. In addition, in order to ensure the water tightness between the surface layer and the screw receiving member, it is necessary to interpose a sealing material. As a result, costs are rising.

The present invention has been made to solve the above problems, and in a screw receiving structure, it is embedded in a foam layer, a skin layer laminated on the top surface of the foam layer, and the top surface of the foam layer. And a screw receiving member covered by the surface layer.
According to the above configuration, the screw receiving member does not need to be attached on the skin layer, and even if water tightness between the screw receiving member and the skin layer is required, there is no need to interpose the sealing material. The cost of the receiving structure can be reduced.

Preferably, the foam layer is heat-welded to the skin layer and the screw receiving member.
According to the above configuration, the screw receiving member can be firmly supported by the foam layer.

  Preferably, a recess is formed in the surface layer at a position corresponding to the screw receiving planned portion of the screw receiving member. According to the above configuration, the recess can be formed as a mark or a guide, whereby the tapping hole can be formed in the portion intended to receive the screw, and the insertion hole can be formed in the skin layer continuous with the tapping hole.

  An opening passing through the foam layer and the skin layer is formed, and the screw receiving member is disposed in an annular shape larger than the opening so as to surround the opening, and a mounting component for covering the opening An insertion hole is formed in the peripheral edge portion, and a screw passing through the insertion hole of the skin layer is screwed from the insertion hole into the tapping hole to fix the mounting component to the screw receiving member.

In a more specific aspect, a waterproof pan for a bathroom is configured by the foam layer and the skin layer, the opening is formed in the waterproof pan for the bathroom, a pipe passes through the opening, and the screw receiving member is In addition, as the mounting component, a support lid for inserting the pipe in a watertight manner is fixed.
Preferably, a plurality of the openings are formed in the waterproof pan for a bathroom, and the screw receiving member is disposed at the periphery of each of the plurality of openings, and the selected opening of the plurality of openings is selected. The piping passes through the portion and the support lid is attached. The screw receiving member of the non-selected opening is fixed, as the attachment component, a closing lid that closes the opening.

Another aspect of the present invention relates to a method for producing a screw receiving structure,
Bonding a screw receiving member made of an injection-molded article to a pre-formed skin layer;
Setting the skin layer on the foam mold so that the surface opposite to the screw receiving member faces the mold surface of the foam mold;
Foaming the foam layer in the foaming mold, and thermally welding the foam layer to the skin layer and the screw receiving member in the foam molding;
It is characterized by having.
According to the above method, in the foam molding step of the foam layer, the screw receiving member and the skin layer are set in the foaming mold and insert molding is performed, so that the screw receiving member need not be attached, and the screw receiving member and the skin layer Since it is not necessary to seal between them, the screw receiving structure can be manufactured at low cost. The adhesion between the skin layer and the screw receiving member is not strong and may be only temporary adhesion. This is because the screw receiving member and the skin layer are heat-welded by the heat of steam generated by foam molding.

Preferably, the skin layer and the screw receiving member are made of a styrenic resin containing any of polystyrene, HIPS, and ABS, and the foam layer is made of expanded polystyrene obtained by bead foam molding.
According to the above method, the foam layer and the skin layer and the screw receiving member can be reliably heat-welded.

Preferably, small protrusions are formed on the molding surface of the foaming mold at positions corresponding to the planned screw receiving portions of the screw receiving members, and in the step of the foam molding, the projections are dented in the skin by the protrusions Form
Furthermore, by tapping the skin layer and the foam layer at the position where the recess is formed, a tapping hole is formed in the screw receiving planned portion of the screw receiving member, and the tapping hole is formed in the skin layer. A step of forming a series of insertion holes is provided.
According to the above method, it is possible to reliably perform the drilling process of the tapping hole.

In a specific aspect, a waterproof pan for a bathroom is constituted by the foam layer and the skin layer, and an opening is formed in the skin layer prior to the foam molding step, and the screw receiving member is formed from the opening. It has a large annular shape and is adhered to the skin layer so as to surround the opening prior to the foam molding step,
In the foam molding step, the foam layer having an opening corresponding to the opening of the skin layer is molded.

  According to the present invention, it is possible to provide a low cost screw receiving structure despite having a foam layer.

It is a top view of the bathtub side waterproof pan to which the screw receptacle structure concerning one embodiment of the present invention was applied. It is sectional drawing in alignment with the II-II line in FIG. It is sectional drawing which decomposes | disassembles and shows the component of FIG. It is a top view expanding and showing one of a plurality of openings of the bathtub side waterproofing pan. It is a top view of the centering member installed in the opening part for piping derivation | leading-out. (A) is a top view of the support lid installed in the opening part for piping derivation | leading-out, (B) is sectional drawing in alignment with the BB line of FIG. 6 (A). (A) is a top view of the closure lid which closes the opening from which piping is not derived | led-out, (B) is sectional drawing in alignment with the BB line of FIG. 7 (A). It is a principal part expanded sectional view showing a forming process of a bathtub side waterproof pan in order, (A) shows a state where a skin layer and a screw receiving member are set to a foaming mold, (B) shows a state immediately after foam molding completion. . It is a principal part expanded sectional view showing a screwing process carried out in a bathroom construction site in order, (A) is a state before drilling processing of a foam-formed bathtub waterproof pan, (B) is a screw receiving member by drilling processing. The state which formed the tapping hole and formed the penetration hole in the outer_skin | epidermis layer, (C) shows the state which fixed the support lid of piping lead-out structure to a screw receiving member by a screw, respectively.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
As shown in FIG. 1, on the floor slab of the space in the building where the bathroom unit is to be stored or the foundation for the bathroom unit, the tub side waterproof pan 1 (waterproof pan for bathroom) and the washing side waterproof pan 2 (bathroom) A waterproof pan is installed, and the long sides adjacent to each other are connected.
The bathtub side waterproof pan 1 is provided with a bathtub (not shown). The bathtub side waterproof pan 1 is supported by a pedestal (not shown) having support legs, and the washroom side waterproof pan 2 is also supported by the support legs.

As shown in FIG. 2 and FIG. 3, the bathtub side waterproof pan 1 is composed of a thermoplastic resin foam layer 10a and a thermoplastic resin skin layer 10b laminated on the upper surface of the foam layer 10a. There is. Details will be described later.
Although the washroom-side waterproof pan 2 also has a foam layer, it has a different layer structure from the bathtub-side waterproof pan 1 in the present embodiment.

  The bathtub side waterproof pan 1 has a bottom portion 11, rising portions 12 and 13 formed on the long side of the peripheral edge, and a rising portion 14 formed on the short side. A drainage port 11a is formed in the bottom portion 11 near the washroom-side waterproof pan 2, and a drainage unit (not shown) is attached to the drainage port 11a.

A rising portion 12 corresponding to one long side of the bathtub side waterproof pan 1 is connected to the washing side waterproof pan 2.
Two wall panels (not shown) are installed at the rising portion 13 corresponding to the other long side of the bathtub side waterproof pan 1, and one wall panel is installed at each rising portion 14 of the two short sides. . Two wall panels are installed on the long side away from the bathtub side waterproof pan 1 at the periphery of the washroom side waterproof pan 2, one wall panel is installed on one short side, and the door on the other short side Is installed. The wall panels and the door enclose the bathroom.

  A shelf 15 of an intermediate height is formed between the bottom 11 and the rising portion 14 on the short side of the bathtub side waterproof pan 1, and two openings 16 are formed in each shelf 15. They are formed apart from one another. The opening 16 has a flat oval shape, and vertically penetrates the foam layer 10a and the skin layer 10b.

The screw receiving structure of the present invention is applied to the bathtub side waterproof pan 1. The details will be described below.
As shown in FIGS. 2 to 4, in the shelf portion 15 of the bathtub side waterproof pan 1, an annular thermoplastic resin screw receiving member 18 surrounding the upper end peripheral edge of the opening 16 is disposed.
The screw receiving member 18 is embedded in the upper surface of the foam layer 10a and covered by the skin layer 10b. The screw receiving member 18 has an oval shape and is larger than the opening 16, and has a plurality of, for example, four screw receiving scheduled portions 18a projecting outward in the radial direction. The screw receiving planned portion 18a is thicker than other portions and protrudes downward.

A method of forming the bathtub side waterproof pan 1 as described above will be described with reference to FIG.
First, a skin layer 10b corresponding to the upper surface shape of the bathtub side waterproof pan 1 described above is obtained by vacuum forming a styrene resin sheet such as polystyrene (PS), HIPS, or ABS as a thermoplastic resin. Further, an opening 16 'which is a part of the opening 16 is formed in the skin layer 10b. The thickness of the skin layer 10b is, for example, 1 to 4 mm, preferably 1 to 3 mm, and more preferably 1 to 2 mm.

  Next, as shown in FIG. 8A, a screw receiving member 18 made of an injection-molded product of a styrenic resin similar to the skin layer 10b is formed on the back surface of the skin layer 10b so as to surround the opening 16 '. Bond (temporary bonding).

  Next, the skin layer 10b is set in the foaming mold 100 with the surface on the front side (the surface on the opposite side to the screw receiving member 18) facing the mold surface of the foaming mold 100. Four small protrusions 101 are formed on the mold surface of the foaming mold 100, and the center position of the screw receiving scheduled portion 18a of the screw receiving member 18 coincides with the protrusions 101 in the set state.

In the above set state, as shown in FIG. 8 (B), a foam layer 10a having an opening 16 ′ ′ made of expanded polystyrene (EPS) is obtained by bead foam molding. In the process of this foam molding, the foam layer 10a It is thermally welded and integrated with the skin layer 10b and the screw receiving member 18. At this time, the screw receiving member 18 and the skin layer 10b are also thermally welded by the heat of the foam molding. As a result, the skin layer 10 b is pressed against the mold surface having the projections 101, so that the depressions 10 z corresponding to the projections 101 are formed in the skin layer 10 b.
The opening 16 of the bathtub side waterproof pan 1 is completed by the opening 16 ′ ′ of the foam layer 10a and the opening 16 ′ of the skin layer 10b.

  By the above-mentioned insert molding, the screw receiving member 18 is embedded in the foam layer 10a and covered with the skin layer 10b. The inner periphery of the screw receiving member 18 is also covered by the foam layer 10a.

  At the bathroom construction site, a hole is drilled with a drill using the recess 10z of the surface layer 10b shown in FIG. 9A as a guide or a guide. As a result, as shown in FIG. 9B, the insertion hole 10x is formed in the surface layer 10b, and the tapping hole 18x is formed in the screw receiving scheduled portion 18a of the screw receiving member 18.

  The resin water supply pipe P1 (piping) and the hot water supply pipe P2 (piping) disposed in the space under the bathtub side waterproof pan 1 are selected one of the four openings 16 (in the present embodiment) Through the lower right opening portion 16), it is led out to the upper side of the bathtub side waterproof pan 1, and its tip is connected to a water supply / hot water tap (not shown).

  Next, the pipe lead-out structure 5 at the selected opening 16 will be described with reference to FIGS. 2 and 3. The pipe lead-out structure 5 includes a centering member 20, a support lid 30 (mounting component), an elastic member 40 made of rubber, a fixing ring 50, and a tightening band 60. The centering member 20, the support lid 30, and the fixing ring 50 are made of a resin injection-molded product and have rigidity.

  As shown in FIGS. 3 and 5, the centering member 20 is formed in two places of a bottom wall 21 having an oval shape, a peripheral wall 22 rising from the periphery of the bottom wall 21, and a bottom wall 21. A support cylindrical portion 23 stands vertically from the periphery of the hole, and a rib 24 connecting the bottom wall 21, the peripheral wall 22 and the support cylindrical portion 23.

  The centering member 20 is installed in the opening 16 as shown in FIG. 2 by press-fitting the opening 16 from above. The tapered outer periphery of the peripheral wall 22 of the centering member 20 is in contact with the tapered inner periphery of the opening 16.

  As shown in FIG. 3 and FIG. 6, the support lid 30 has a lid plate portion 31 having a flat rectangular shape, and a pair of mounting cylinder portions 32 vertically projecting upward from the lid plate portion 31. The peripheral edge portion of the cover plate portion 31 is lower than other portions, and an annular support groove 33 is formed on the lower surface thereof, and a packing 38 is fitted in the support groove 33. Insertion holes 31 a are formed at four corners of the lid plate portion 31 on the inner side of the support groove 33.

  As shown in FIG. 2, the cover plate portion 31 is put on the opening portion 16 of the bathtub side waterproof pan 1, and as shown in FIG. 9C, the screw 39 is inserted into the insertion hole 31a of the cover plate portion 31 and the surface 10b. The support lid 30 is fixed to the screw receiving member 18 by screwing it through the insertion hole 10 x and tapping into the tapping hole 18 x of the screw receiving member 18 embedded in the foam layer 10 a while tapping. In this state, the compressed packing 38 ensures water tightness between the support lid 30 and the skin layer 10 b of the bathtub side waterproof pan 1.

  The elastic member 40 having a tubular shape is attached to each of the two attachment cylindrical portions 32 of the support lid 30 by means of the fixing ring 50 in a watertight manner.

  The water supply pipe P <b> 1 and the hot water supply pipe P <b> 2 are drawn out above the bathtub side waterproof pan 1 through the pipe lead-out structure 5 described above. More specifically, the water supply pipe P1 and the hot water supply pipe P2 are bent upward, pass through the support cylindrical portion 23 of the centering member 20 disposed in the opening 16, and are drawn upward through the elastic member 40. The upper end portion of the elastic member 40 forms a minimum diameter portion, and by tightening the upper end portion with a tightening band 60, water tightness between the elastic member 40 and the water supply pipe P1 and the hot water supply pipe P2 is secured.

  The other openings 16 not selected for leading the water supply pipe P1 and the hot water supply pipe P2 are closed by the closing lid 80 (attachment component) shown in FIG. FIG. 1 shows a state in which the lower left opening 16 of the three non-selected openings 16 is closed by the closing lid 80, but the other two openings 16 are also closed in the same manner. .

  Similar to the support lid 30, the closure lid 80 is formed with a support groove 81 at its peripheral edge, and has insertion holes 82 at its four corners. A packing 88 is attached to the support groove 81. The fixing of the closing lid 80 to the screw receiving member 18 by the screw 39 is the same as that of the supporting lid 30, and thus the detailed description thereof is omitted.

The present invention is not limited to the above embodiment, and various forms can be adopted.
In the above embodiment, the opening portion and the screw receiving structure are provided in the bathtub side waterproof pan, but may be provided in the washroom side waterproof pan.
The bathroom in the present application also includes a bathroom (shower room) which can only have a shower.
The present invention is not limited to a waterproof pan for a bathroom, and can be applied to any structure having a foam layer and a skin layer and fixing a mounting component with a screw.

  The present invention is applicable to a screw receiving structure such as a waterproof pan for a bathroom having heat insulation.

1 Bathtub side waterproof pan (waterproof pan for bathroom)
2 washroom side waterproof pan (waterproof pan for bathroom)
DESCRIPTION OF SYMBOLS 10a Foam layer 10b Skin layer 10x Insertion hole 16, 16 ', 16''Opening 18 Screw receiving member 18a Screw receiving scheduled portion 18x Tapping hole 39 Screw 30 Support lid (attachment parts)
31a insertion hole 80 closed lid (mounted parts)
82 Insertion hole

Claims (11)

  A screw comprising: a foam layer, a skin layer laminated on the top surface of the foam layer, and a screw receiving member embedded on the top surface of the foam layer and covered by the skin layer Receiving structure.   The screw receiving structure according to claim 1, wherein the foam layer is heat-welded to the skin layer and the screw receiving member.   The screw receptacle structure according to claim 1 or 2, wherein a dent is formed in the skin layer at a position corresponding to the screw receptacle planned portion of the screw receptacle member.   The screw according to claim 1 or 2, wherein a tapping hole is formed in the screw receiving scheduled portion of the screw receiving member, and an insertion hole connected to the tapping hole is formed in the skin layer. Receiving structure. An opening is formed through the foam layer and the skin layer,
The screw receiving member is arranged to surround the opening in an annular shape larger than the opening.
An insertion hole is formed in the peripheral portion of the mounting component covering the opening, and a screw passing through the insertion hole of the skin layer is screwed from the insertion hole into the tapping hole, whereby the mounting component receives the screw. The screw receiving structure according to claim 4, wherein the screw receiving structure is fixed to a member. The foam layer and the skin layer constitute a waterproof pan for a bathroom, the waterproof pan for a bathroom is formed with the opening, and the opening passes through a pipe,
The screw receiving structure according to claim 5, wherein a support lid through which the pipe is inserted in a watertight manner is fixed as the mounting component to the screw receiving member.   A plurality of the openings are formed in the waterproof pan for a bathroom, the screw receiving member is disposed at the peripheral edge of each of the plurality of openings, and the selected opening of the plurality of openings is the above 7. The apparatus according to claim 6, wherein the support lid is mounted while the pipe passes, and a closure lid which closes the opening is fixed as the mounting component to the screw receiving member of the non-selected opening. The screw receptacle structure described in. Bonding a screw receiving member made of an injection-molded article to a pre-formed skin layer;
Setting the skin layer on the foam mold so that the surface opposite to the screw receiving member faces the mold surface of the foam mold;
Foaming the foam layer in the foaming mold, and thermally welding the foam layer to the skin layer and the screw receiving member in the foam molding;
A method of manufacturing a screw receiving structure comprising:   The screw receiver according to claim 8, characterized in that the skin layer and the screw receiving member are made of a styrenic resin containing any of polystyrene, HIPS, and ABS, and the foam layer is made of expanded polystyrene obtained by bead foam molding. Manufacturing method of structure. Small projections are formed on the molding surface of the foaming mold at positions corresponding to the intended parts for receiving the screws of the screw receiving member, and in the step of the foam molding, the projections form recesses in the skin,
Furthermore, by tapping the skin layer and the foam layer at the position where the recess is formed, a tapping hole is formed in the screw receiving planned portion of the screw receiving member, and the tapping hole is formed in the skin layer. The method for manufacturing a screw receptacle structure according to claim 8 or 9, further comprising the step of forming a continuous through hole. A waterproof pan for a bathroom is constituted by the foam layer and the skin layer,
Prior to the foam molding step, an opening is formed in the skin layer,
The screw receiving member has an annular shape larger than the opening, and is adhered to the skin layer so as to surround the opening prior to the foam molding step,
The method for manufacturing a screw receptacle structure according to any one of claims 8 to 10, wherein the foam layer having an opening corresponding to the opening of the skin layer is formed in the foam molding step.

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