JP2022039568A - Bathroom wash place floor - Google Patents

Abstract

To provide a bathroom wash place floor which can inhibit significant degradation of cushioning characteristics around the center of the bathroom wash place floor.SOLUTION: A bathroom wash place floor includes: a base material layer 21; a cushion layer 22 provided above the base material layer; a surface layer provided above the cushion layer and forming a surface of the bathroom wash place floor; and a drain port 10h for draining water flowing on a top face of the surface layer. The top face of the base material layer has a drain slope inclined downward toward the drain port. The cushion layer has a central part 22p including the center of the bathroom wash place floor, and an end part 22q located outside the central part in a top view. A thickness T1 of the central part is smaller than a thickness T2 of the end part.SELECTED DRAWING: Figure 4

Description

Aspects of the invention generally relate to bathroom wash floors.

It is known that a bathroom washing floor has a two-layer structure in which a cushion layer is provided on a base material layer. For example, Patent Document 1 proposes a bathroom washroom floor in which a polyurethane cushion layer is provided on a foamed resin base material layer.

Japanese Unexamined Patent Publication No. 2016-65391

When a person walks, sits on a chair, or kneels when cleaning on the bathroom floor, a downward load is applied to the bathroom floor. When a downward load is applied to the bathroom washroom floor, the cushion layer is compressed in the thickness direction. As a result, the cushion layer imparts cushioning properties to the bathroom washroom floor. Further, the cushion layer maintains the cushioning property by returning from the compressed state to the original shape when the downward load is not applied to the bathroom washing floor.

In the vicinity of the center of the bathroom washroom floor, which is frequently stepped on, the compression of the cushion layer is concentrated and repeatedly occurs. Therefore, in the vicinity of the center of the bathroom washroom floor, the cushion layer may not easily return to its original shape during use, and the cushioning property may be significantly deteriorated.

The present invention has been made based on the recognition of such a problem, and an object of the present invention is to provide a bathroom washing floor that can suppress a large decrease in cushioning property in the vicinity of the center of the bathroom washing floor.

The first invention comprises a base material layer, a cushion layer provided on the base material layer, a surface layer provided on the cushion layer and forming the surface of a bathroom washroom floor, and the surface layer. The base material layer is provided with a drainage port for draining water flowing on the upper surface, the upper surface of the base material layer has a drainage gradient inclined downward toward the drainage port, and the cushion layer is the center of the bathroom washroom floor. It is a bathroom washing floor having a central portion including the above portion and an end portion located outside the central portion in a top view, wherein the thickness of the central portion is smaller than the thickness of the end portion. ..

According to this bathroom washroom floor, by making the thickness of the central part of the cushion layer smaller than the thickness of the end part of the cushion layer, a downward load is repeatedly applied at the central part, and it is difficult for the cushion layer to return to its original shape. Even so, since the original thickness is small, it is possible to suppress a large decrease in cushioning property. Therefore, it is possible to prevent the cushioning property from being significantly reduced near the center of the bathroom washroom floor.

A second invention is a bathroom washroom floor, characterized in that, in the first invention, the density of the central portion is higher than the density of the end portion.

According to this bathroom washroom floor, by making the density of the central portion larger than the density of the edge portion, it is possible to increase the durability of the central portion of the cushion layer that the user frequently steps on. Therefore, it is possible to further suppress a large decrease in cushioning property near the center of the bathroom washroom floor.

A third aspect of the invention is the bathroom washroom floor according to the first or second aspect, wherein the cushion layer is an aggregate of foamed bead particles made of a thermoplastic resin.

According to this bathroom washroom floor, the thickness and density of the cushion layer can be finely controlled by forming the cushion layer as an aggregate of foamed bead particles made of a thermoplastic resin. Therefore, it is possible to provide the cushioning property required for the cushion layer.

In a fourth aspect of the invention, in the third aspect, the base material layer is an aggregate of first foamed bead particles made of a thermoplastic resin, and the cushion layer is made of a second foamed bead particle made of a thermoplastic resin. It is a bathroom washroom floor characterized by being an aggregate.

According to this bathroom washroom floor, the base material layer is an aggregate of first foamed bead particles made of thermoplastic resin, and the cushion layer is an aggregate of second foamed bead particles made of thermoplastic resin. The drainage gradient can be easily formed on the upper surface of the base material, and the base material layer and the cushion layer can have different characteristics. For example, the base material layer can be made strong, and the cushion layer can be made cushioned. Further, by forming both the base material layer and the cushion layer as an aggregate of foamed bead particles, the adhesion between the base material layer and the cushion layer can be improved.

According to the aspect of the present invention, it is possible to provide a bathroom washing floor that can suppress a large decrease in cushioning property near the center of the bathroom washing floor.

It is a perspective view schematically showing the bathroom unit provided with the bathroom washroom floor which concerns on embodiment. It is an exploded perspective view schematically showing the bathroom washroom floor which concerns on embodiment. It is a top view schematically showing the base material layer and the cushion layer of the bathroom washing place floor which concerns on embodiment. 4 (a) and 4 (b) are cross-sectional views schematically showing the base material layer and the cushion layer of the bathroom washroom floor according to the embodiment. It is sectional drawing which shows typically the base material layer and the cushion layer of the bathroom washing place floor which concerns on embodiment. It is sectional drawing which shows the part of the bathroom washing place floor which concerns on embodiment schematically. It is sectional drawing which shows typically the 1st foamed bead particle and the 2nd foamed bead particle which concerns on embodiment. It is sectional drawing which shows typically how to obtain the thickness of the base material layer and the thickness of the cushion layer of the bathroom washing place floor which concerns on embodiment. 9 (a) and 9 (b) are cross-sectional views schematically showing how to obtain the particle size of the first foamed bead particles and the particle size of the second foamed bead particles of the bathroom washroom floor according to the embodiment. .. 10 (a) to 10 (d) are explanatory views schematically showing a method for manufacturing a base material layer and a cushion layer of a bathroom washroom floor according to an embodiment.

Hereinafter, embodiments will be described with reference to the drawings. In each drawing, similar components are designated by the same reference numerals and detailed description thereof will be omitted as appropriate.
FIG. 1 is a perspective view schematically showing a bathroom unit provided with a bathroom washing floor according to the embodiment.
As shown in FIG. 1, the bathroom unit 2 includes a bathroom washroom floor 10, a bathtub 60, and wall panels 71a to 71f.

Support legs 61 are provided near the four corners on the back surface of the bottom of the bathtub 60, and the bathtub 60 is installed on the installation surface (for example, the floor of the building) 100 via the support legs 61. A bolt portion is provided on the tip end side (lower end side) of the support leg 61, and the height of the support leg 61 can be adjusted by rotating the bolt portion.

A bathroom washroom floor 10 is installed at the bottom of the space next to the bathtub 60. The surface 10a of the bathroom washing floor 10 has a waterproof property that prevents water from leaking to the outside of the bathroom. In the specification of the present application, the term "water" includes not only cold water but also heated hot water.

On the back side (lower side) of the bathroom washing place floor 10, a drainage pipe 62 is provided near the boundary with the bathtub 60. In the bathroom washing place floor 10, for example, a drainage port 10h communicating with the drainage pipe 62 is formed in the vicinity of the boundary portion with the bathtub 60. The drainage port 10h may be closed with, for example, a removable lid. The portion where the drainage port 10h is provided is recessed downward, and the surface 10a of the bathroom washing place floor 10 is provided with a drainage gradient inclined downward toward the drainage port 10h. Further, a drainage port (not shown) provided at the bottom of the bathtub 60 is also connected to the drainage pipe 62.

As shown by the two-dot chain line in FIG. 1, wall panels 71a to 71c are installed on the rim of the bathtub 60. Further, wall panels 71d to 71f are installed on the peripheral edge of the bathroom washing floor 10. Further, a door is attached to the wall panel 71f via a door attachment frame (not shown).

At the boundary between the bathtub 60 and the bathroom washroom floor 10, a bath apron 67 that covers the side surface of the bathtub 60 on the bathroom washroom floor 10 side is provided. Depending on the structure of the bathtub 60, the bath apron 67 may not be provided.

Further, a small panel 65b is provided between one end side of the bath apron 67 in the longitudinal direction and the wall panel 71d. Further, a small panel 65a is provided between the other end side of the bus apron 67 in the longitudinal direction and the wall panel 71f. The small panels 65a and 65b are provided as needed and can be omitted.

FIG. 2 is an exploded perspective view schematically showing the bathroom washing floor according to the embodiment.
As shown in FIG. 2, the bathroom washing floor 10 includes a floor body 20 and a frame body 30.

The frame body 30 is provided under the floor body 20 and supports the floor body 20 from below. The frame body 30 has an outer frame 31, a grid portion 32, and support legs 33. The outer frame 31, the grid portion 32, and the support legs 33 are each made of metal.

The outer frame 31 forms the outer shape (outline) of the frame body 30. The grid portion 32 partitions the inside of the outer frame 31 in a grid pattern. The lattice portion 32 supports, for example, a portion inside the outer frame 31 of the floor body 20. The support legs 33 are provided on the lower surface of the lattice portion 32. The support legs 33 extend downward (installation surface side) from the lower surface of the lattice portion 32. The support legs 33 may be provided on the lower surface of the outer frame 31. In this example, four support legs 33 are provided, but the number of support legs 33 may be five or more.

The frame body 30 is installed on the installation surface 100 via each support leg 33. A bolt portion is provided on the tip end side (lower end side) of each support leg 33, and the height of each support leg 33 can be adjusted by rotating the bolt portion. By adjusting the height of each support leg 33, the installation height and levelness of the floor body 20 supported on the frame body 30 are adjusted.

The frame body 30 has an opening 30h provided at a position corresponding to the drainage port 10h. The opening 30h is formed in a plate provided in the lattice portion 32, and penetrates the plate in the vertical direction.

The floor body 20 is placed on the frame body 30 and supported by the frame body 30. The floor body 20 has a base material layer 21, a cushion layer 22, and a surface layer 23. Each layer is provided in the order of the base material layer 21, the cushion layer 22, and the surface layer 23 from the lower side.

The base material layer 21 is located at the bottom of the floor body 20 and supports the cushion layer 22 and the surface layer 23. The base material layer 21 is formed in a shallow-bottomed vessel shape (bread shape) with a peripheral portion bent upward.

The base material layer 21 has an opening 21h provided at a position corresponding to the drainage port 10h. The opening 21h is provided in a concave shape that is recessed downward. Further, on the upper surface of the base material layer 21, a drainage gradient inclined downward toward the opening 21h (drainage port 10h) is formed.

By providing the base material layer 21, the strength of the bathroom washing floor 10 (floor body 20) can be increased. The base material layer 21 will be described later.

The cushion layer 22 is provided above the base material layer 21 and below the surface layer 23. That is, the cushion layer 22 is provided between the base material layer 21 and the surface layer 23. The cushion layer 22 is provided inside the peripheral portion of the base material layer 21.

The cushion layer 22 has an opening 22h provided at a position corresponding to the drainage port 10h. The opening 22h penetrates the cushion layer 22 in the vertical direction and communicates with the opening 21h of the base material layer 21. Further, a drainage gradient reflecting the drainage gradient of the upper surface of the base material layer 21 is formed on the upper surface of the cushion layer 22. That is, a drainage gradient inclined downward toward the opening 22h (drainage port 10h) is formed on the upper surface of the cushion layer 22.

By providing the cushion layer 22, it is possible to give the user a soft feeling of use (treading comfort) on the floor surface. By changing the hardness (softness) of the cushion layer 22, the specifications of the hardness (softness) of the floor surface can be changed. The cushion layer 22 will be described later.

The surface layer 23 is provided on the cushion layer 22. In other words, the surface layer 23 is provided on the base material layer 21 via the cushion layer 22. The surface layer 23 covers the base material layer 21 and the cushion layer 22 and forms the surface 10a of the bathroom washing floor 10 (floor body 20). The surface layer 23 imparts appearance design and waterproofness to the surface 10a of the bathroom washing floor 10.

The surface layer 23 has an opening 23h provided at a position corresponding to the drainage port 10h. The opening 23h penetrates the surface layer 23 in the vertical direction and communicates with the opening 22h of the cushion layer 22 and the opening 21h of the base material layer 21. Further, a drainage gradient reflecting the drainage gradient of the upper surface of the cushion layer 22 (drainage gradient of the upper surface of the base material layer 21) is formed on the upper surface of the surface layer 23. That is, a drainage gradient inclined downward toward the opening 23h (drainage port 10h) is formed on the upper surface of the surface layer 23. As a result, a drainage gradient inclined downward toward the drainage port 10h is formed on the surface 10a of the bathroom washing place floor 10 (floor body 20), and water flowing on the upper surface of the surface layer 23 can be discharged from the drainage port 10h. can.

For the surface layer 23, for example, a soft resin sheet material having waterproofness and flexibility is used. The upper surface (surface) of the surface layer 23 may be processed to provide irregularities or patterns in order to improve the design and drainage of the surface 10a of the bathroom washing floor 10.

The frame body 30, the base material layer 21, the cushion layer 22, and the surface layer 23 are overlapped so that the openings 30h, 21h, 22h, and 23h, respectively, are aligned with each other. A drainage pit is provided inside each of the openings 30h, 21h, 22h, and 23h. The drainage pit is made of resin and has impermeable property. A drainage port 10h is provided inside the drainage pit. The drainage port 10h is connected to the drainage pipe 62. As a result, the water flowing on the surface 10a of the bathroom washing place floor 10 (floor body 20) is drained to the drain pipe 62 through the drain pit or the like.

FIG. 3 is a plan view schematically showing the base material layer and the cushion layer of the bathroom washroom floor according to the embodiment.
4 (a), 4 (b), and 5 are cross-sectional views schematically showing the base material layer and the cushion layer of the bathroom washing floor according to the embodiment.
FIG. 4A is a cross-sectional view taken along the line A1-A2 shown in FIG.
FIG. 4B is a cross-sectional view taken along the line B1-B2 shown in FIG.
FIG. 5 is a cross-sectional view taken along the line C1-C2 shown in FIG.
As shown in FIG. 3, the cushion layer 22 has a central portion 22p and an end portion 22q. The central portion 22p is a portion including the central CP of the bathroom washing floor 10. The end portion 22q is a portion located outside the central portion 22p in a top view. The end portion 22q includes, for example, a peripheral portion 22e of the cushion layer 22. For example, the inside of the region connecting the central CP of the bathroom washing floor 10 and the peripheral point 22e of the cushion layer 22 can be regarded as the central portion 22p.

For example, as shown in FIG. 3, the portion represented by the diagonal line can be regarded as the central portion 22p. Specifically, in the bathroom washroom floor 10, two regions including the central CP divided into four equal parts in the longitudinal direction and two regions including the central CP divided into four equal parts in the lateral direction intersect. The range (the range shown by diagonal lines in FIG. 3) can be regarded as the central portion 22p. Considering the actions such as entering and exiting the bathroom, washing the body, washing hair, and the layout of doors, faucet fittings, shower units, washbasin counters, etc. (not shown), the above parts should be regarded as parts that are frequently loaded by humans. Can be done.

As shown in FIGS. 4A, 4B, and 5, the thickness T1 of the central portion 22p is smaller than the thickness T2 of the end portion 22q. As a result, even if a downward load is repeatedly applied to the central portion 22p and it becomes difficult for the cushion layer 22 to return to its original shape, the original thickness is small, so that it is possible to prevent the cushioning property from being significantly reduced. Therefore, it is possible to prevent the cushioning property from being significantly reduced near the center of the bathroom washing floor 10. The method of obtaining the thickness T1 of the central portion 22p and the thickness T2 of the end portion 22q will be described later.

The thickness T1 of the central portion 22p is preferably 2 mm or more and 7.75 mm or less, and more preferably 3 mm or more and 5.5 mm or less. The thickness T2 of the end portion 22q is preferably 2.25 mm or more and 8 mm or less, and more preferably 3.5 mm or more and 6 mm or less. The difference between the thickness T1 of the central portion 22p and the thickness T2 of the end portion 22q is preferably 0.25 mm or more and 6 mm or less, and more preferably 0.5 mm or more and 3 mm or less.

In the embodiment, the thickness of at least one point of the central portion 22p may be smaller than the thickness of at least one point of the end portion 22q. That is, the minimum thickness of the central portion 22p may be smaller than the maximum thickness of the end portion 22q. The thickness of the cushion layer 22 at the central CP of the bathroom washing floor 10 is preferably smaller than the thickness of the peripheral portion 22e of the cushion layer 22. Further, it is preferable that the average value of the thicknesses of the plurality of locations of the central portion 22p is smaller than the average value of the thicknesses of the plurality of locations of the end portions 22q.

As shown in FIGS. 4 (a), 4 (b), and 5, in this example, the thickness of the cushion layer 22 gradually decreases from the end portion 22q toward the central portion 22p. For example, either the thickness T1 of the central portion 22p or the thickness T2 of the end portion 22q may be constant. Further, the central portion 22p and the end portion 22q may each have a portion having a constant thickness and a portion having a variable thickness.

In FIG. 4A, the thickness of the cushion layer 22 gradually decreases from the end portion 22q toward the central portion 22p. That is, the thickness T2 of the end portion 22q gradually decreases toward the central portion 22p, and the thickness T1 of the central portion 22p gradually decreases toward the drain port 10h. In FIGS. 4B and 5, the thickness T2 of the end portion 22q gradually decreases toward the central portion 22p, and the thickness T1 of the central portion 22p is smaller than the thickness T2 of the end portion 22q and has a constant thickness. Is.

FIG. 6 is a cross-sectional view schematically showing a part of the bathroom washing floor according to the embodiment.
As shown in FIG. 6, the cushion layer 22 is preferably in contact with the base material layer 21. That is, it is preferable that the base material layer 21 and the cushion layer 22 are directly joined. In other words, it is preferable that the upper surface 21a of the base material layer 21 and the lower surface 22b of the cushion layer 22 form an interface between the base material layer 21 and the cushion layer 22. The base material layer 21 and the cushion layer 22 may be indirectly joined via an adhesive layer or the like.

The surface layer 23 is preferably adhered onto the cushion layer 22 via the adhesive layer 24. That is, it is preferable that the surface layer 23 is not in contact with the cushion layer 22. In other words, it is preferable that the surface layer 23 and the cushion layer 22 are indirectly joined via the adhesive layer 24. The adhesive layer 24 is provided as needed and can be omitted. That is, the surface layer 23 and the cushion layer 22 may be directly bonded to each other without the adhesive layer 24. When the surface layer 23 and the cushion layer 22 are directly joined, they can be joined by heat fusion or the like.

The adhesive layer 24 is a layer for adhering the surface layer 23 and the cushion layer 22. The surface layer 23 and the cushion layer 22 are preferably bonded using an adhesive. Adhesives include synthetic resin adhesives, rubber adhesives, emulsion adhesives, water-based adhesives, reactive acrylic adhesives, UV curable adhesives, hot melt adhesives, double-sided tapes, and film adhesives. , One or more selected from the sealing materials can be used. As the adhesive, it is preferable to use a hot melt type adhesive or double-sided tape.

Further, it is preferable that the base material layer 21 and the cushion layer 22 are joined in a non-linear manner in a cross section. That is, it is preferable that the interface between the base material layer 21 and the cushion layer 22 has irregularities. In other words, it is preferable that the upper surface 21a of the base material layer 21 and the lower surface 22b of the cushion layer 22 have irregularities. The unevenness referred to here is a displacement in the stacking direction (vertical direction). It is preferable that the base material layer 21 and the cushion layer 22 are joined so as to bite into each other. The base material layer 21 and the cushion layer 22 preferably have irregularities over the entire interface. In this way, the base material layer 21 and the cushion layer 22 are joined in a non-linear manner in the cross section, so that the base material layer 21 and the cushion layer 22 are joined in a linear shape in the cross section. The contact area between the material layer 21 and the cushion layer 22 becomes large, and the bonding strength (adhesion) between the base material layer 21 and the cushion layer 22 can be improved.

On the other hand, it is preferable that the surface layer 23 and the adhesive layer 24 are joined in a straight line in a cross section. Further, it is preferable that the adhesive layer 24 and the cushion layer 22 are joined in a straight line in a cross section. In this way, the surface layer 23 and the adhesive layer 24 are joined linearly in the cross section, and the adhesive layer 24 and the cushion layer 22 are joined linearly in the cross section, so that the surface layer 23 and the adhesive layer 24 are joined together. The bonding strength (adhesiveness) and the bonding strength (adhesiveness) between the adhesive layer 24 and the cushion layer 22 can be made smaller than the bonding strength (adhesiveness) between the base material layer 21 and the cushion layer 22. Therefore, the surface layer 23 can be easily peeled off from the cushion layer 22.

Hereinafter, the base material layer 21 and the cushion layer 22 will be described in more detail with reference to FIGS. 6 and 7.
FIG. 7 is a cross-sectional view schematically showing the first foamed bead particles and the second foamed bead particles according to the embodiment.

As shown in FIG. 6, the base material layer 21 is preferably an aggregate of the first foamed bead particles 41 made of a thermoplastic resin. That is, the base material layer 21 is a bead foam layer made of a thermoplastic resin, and is preferably a layer made of foamed bead particles obtained by foaming a plurality of raw material beads made of a thermoplastic resin. In the base material layer 21, the first foamed bead particles 41 are preferably bonded by melting each other. The plurality of first foamed bead particles 41 are joined by melting with each other to form an aggregate. By forming the base material layer 21 as an aggregate of the first foamed bead particles 41 made of a thermoplastic resin, the thickness and density of the base material layer 21 can be finely controlled. Therefore, it is possible to give the base material layer 21 the strength and rigidity required for it. Further, a drainage gradient can be easily formed on the upper surface 21a of the base material layer 21.

As shown in FIG. 7, the first foamed bead particles 41 have a dense portion 41a covering the outer periphery and a sparse portion 41b provided inside the dense portion 41a, respectively. The dense portion 41a is a resin film (shell). The sparse portion 41b is a porous body having a cavity. Each hole of the sparse portion 41b is formed by generating (foaming) bubbles inside the resin, and the holes are basically independent of each other. That is, each hole of the sparse portion 41b is not continuous.

The density of the sparse portion 41b is preferably smaller than the density of the dense portion 41a. That is, each of the first foamed bead particles 41 has a structure in which a dense portion 41a having a high density is formed on the outside of a sparse portion 41b having a low density. The density of the sparse portion 41b is smaller than the density of the non-foamed molded product (solid molded product) made of the same material, and is preferably 300 g / L or less, for example. The base material layer 21 is preferably bonded by gathering such first foamed bead particles 41 and melting the dense portions 41a with each other. The density here is a value obtained by JIS K 7222: 2005.

The raw material of the base material layer 21 (first foamed bead particles 41) is selected according to the properties (strength, heat insulating property, durability, etc.) required for the base material layer 21. The first foamed bead particles 41 contain a thermoplastic resin. As the thermoplastic resin, expanded polyolefin (expanded polypropylene, expanded polyethylene), expanded polystyrene, expanded polyurethane, expanded polyamide, expanded polyester and the like can be used. The first expanded bead particles 41 may be expanded bead particles containing two or more of these thermoplastic resins. Further, the base material layer 21 may contain additives such as a colorant, an antibacterial agent, a weather resistant agent, a pigment, a filler, a cross-linking agent, and a foaming agent. The base material layer 21 preferably contains foamed polyolefin. Foamed polyolefin has excellent water resistance and chemical resistance. Therefore, even if water infiltrates into the bathroom washing floor 10, deterioration of the base material layer 21 can be suppressed.

The particle size R1 of the first foamed bead particles 41 is preferably 0.5 mm or more and 3.5 mm or less, and more preferably 1 mm or more and 3 mm or less. As a result, the first foamed bead particles 41 are sufficiently fused with each other to increase the bonding strength between the first foamed bead particles 41, and the base material layer 21 is provided with sufficient strength and durability. Can be done. The method of obtaining the particle size R1 of the first foamed bead particles 41 will be described later.

In the base material layer 21, it is preferable that a plurality of first foamed bead particles 41 are laminated in the thickness direction (that is, the vertical direction) of the layer. The base material layer 21 is preferably an aggregate of the first foamed bead particles 41 in which a plurality of first foamed bead particles 41 are laminated in the thickness direction. The number of the first foamed bead particles 41 laminated in the thickness direction of the base material layer 21 is preferably 2 or more and 30 or less, and more preferably 3 or more and 20 or less. As a result, the base material layer 21 can be formed by the aggregate of the first foamed bead particles 41, and the base material layer 21 can have the strength and rigidity required for the base material layer 21.

The thickness of the base material layer 21 is preferably 5 mm or more and 40 mm or less, and more preferably 10 mm or more and 30 mm or less. The thickness of the base material layer 21 is the length of the base material layer 21 in the vertical direction. This makes it possible to give the base material layer 21 the strength required for it. The method of determining the thickness of the base material layer 21 will be described later.

The density of the base material layer 21 is preferably 90 g / L or more and 300 g / L or less, and more preferably 100 g / L or more and 200 g / L or less. This makes it possible to give the base material layer 21 the strength and rigidity required for it. The density of the base material layer 21 is a value obtained by cutting out only the base material layer 21 from the bathroom washing floor 10 and using JIS K 7222: 2005.

The compressive stress (at the time of 10% strain) of the base material layer 21 is preferably 0.1 MPa or more and 2.0 MPa or less, and more preferably 0.2 MPa or more and 1.5 MPa or less. This makes it possible to give the base material layer 21 the strength required for it. Here, "compressive stress (at the time of 10% strain)" refers to the compressive stress when compressed by 10% with respect to the thickness. The compressive stress (at the time of 10% strain) of the base material layer 21 is a value obtained by cutting out only the base material layer 21 from the bathroom washing floor 10 and JIS K 6767: 1999.

The bending strength of the base material layer 21 is preferably 0.5 MPa or more and 5 MPa or less, and more preferably 1 MPa or more and 3.5 MPa or less. This makes it possible to give the base material layer 21 the strength required for it. The bending strength of the base material layer 21 is a value obtained by cutting out only the base material layer 21 from the bathroom washing floor 10 and JIS K 7221-1: 2006.

As shown in FIG. 6, the cushion layer 22 is preferably an aggregate of the second foamed bead particles 42 made of a thermoplastic resin. That is, the cushion layer 22 is a bead foam layer made of a thermoplastic resin, and is preferably a layer made of foamed bead particles obtained by foaming a plurality of raw material beads made of a thermoplastic resin. In the cushion layer 22, the second foamed bead particles 42 are preferably bonded by melting each other. It is preferable that the plurality of second foamed bead particles 42 are joined by melting with each other to form an aggregate. By forming the cushion layer 22 as an aggregate of the second foamed bead particles 42 made of a thermoplastic resin, the thickness and density of the cushion layer 22 can be finely controlled. Therefore, the cushion layer 22 can be provided with the cushioning property required for the cushion layer 22.

The base material layer 21 and the cushion layer 22 are both made into an aggregate of foamed bead particles, and more preferably, the base material layer 21 and the cushion layer 22 are provided so as to be in contact with the base material layer. Adhesion with the cushion layer can be improved. On the other hand, by forming the base material layer 21 and the cushion layer 22 as aggregates of different foamed bead particles, the base material layer 21 and the cushion layer 22 can have different characteristics. For example, the base material layer 21 can be provided with strength and rigidity, and the cushion layer 22 can be provided with cushioning properties. Thereby, the bathroom washing floor 10 can have a good balance of strength, rigidity and cushioning property.

The structure of the second foamed bead particles 42 is the same as the structure of the first foamed bead particles 41. That is, as shown in FIG. 7, each of the second foamed bead particles 42 has a structure in which a dense portion 42a having a high density is formed on the outside of a sparse portion 42b having a low density. The density of the sparse portion 42b is smaller than the density of the non-foamed molded product (solid molded product) made of the same material, and is preferably 300 g / L or less, for example. The cushion layer 22 is preferably bonded by gathering such second foamed bead particles 42 and melting the dense portions 42a with each other. The density here is a value obtained by JIS K 7222: 2005.

At the interface between the base material layer 21 and the cushion layer 22, the first foamed bead particles 41 and the second foamed beads 42 are preferably adjacent to each other. It is preferable that the first foamed bead particles 41 and the second foamed bead particles 42 that are adjacent to each other are joined by melting each other. More specifically, it is preferable that the dense portion 41a of the adjacent first foamed bead particles 41 and the dense portion 42a of the second foamed bead particles 42 are joined by melting with each other. As a result, it is preferable that the base material layer 21 and the cushion layer 22 are joined in a non-linear manner in the cross section. That is, it is preferable that the unevenness of the interface between the base material layer 21 and the cushion layer 22 is formed by the bonding surface of the first foamed bead particles 41 and the second foamed bead particles 42.

The base material layer 21 and the cushion layer 22 are joined by melting the first foamed bead particles 41 contained in the base material layer 21 and the second foamed bead particles 42 contained in the cushion layer 22. Therefore, the adhesion between the base material layer 21 and the cushion layer 22 can be improved.

The raw material of the cushion layer 22 (second foamed bead particles 42) is selected according to the properties required for the cushion layer 22 (cushion property, durability, adhesion to the base material layer 21, etc.). The second foamed bead particles 42 contain a thermoplastic resin. As the thermoplastic resin, foamed polyurethane, foamed polyolefin (expanded polypropylene, foamed polyethylene), foamed thermoplastic elastomer (polyolefin (polypropylene, polyethylene), polyurethane, polystyrene, polyester, polyamide, etc.), foamed (crosslinked) polyethylene, or the like is used. be able to. The second foamed bead particles 42 may be foamed bead particles containing two or more of these thermoplastic resins. Further, the cushion layer 22 may contain additives such as a colorant, an antibacterial agent, a weather resistant agent, a pigment, a filler, a cross-linking agent, and a foaming agent. The cushion layer 22 preferably contains a foamed polyolefin. Foamed polyolefin has excellent water resistance and chemical resistance. Therefore, even if water infiltrates into the bathroom washing floor 10, deterioration of the cushion layer 22 can be suppressed.

The particle size R2 of the second foamed bead particles 42 is preferably 1 mm or more and 4 mm or less, and more preferably 1.5 mm or more and 3.5 mm or less. As a result, the second foamed bead particles 42 are sufficiently fused with each other to increase the bonding strength between the second foamed bead particles 42, and the cushion layer 22 is provided with sufficient cushioning property and durability. Can be done. The particle size R2 of the second expanded bead particles 42 is preferably larger than the particle size R1 of the first expanded bead particles 41. The method of obtaining the particle size R2 of the second foamed bead particles 42 will be described later.

The ratio R2 / R1 of the particle size R2 of the second expanded bead particles 42 to the particle size R1 of the first expanded bead particles 41 is preferably 0.5 or more and 5 or less, and more preferably 0.75 or more and 4 or less. As a result, the strength and cushioning properties required for the bathroom washroom floor 10 can be achieved in a more balanced manner.

In the cushion layer 22, it is preferable that a plurality of second foamed bead particles 42 are laminated in the thickness direction (that is, the vertical direction) of the layer. The number of the second foamed bead particles 42 laminated in the thickness direction of the cushion layer 22 is preferably 2 or more and 10 or less, and more preferably 3 or more and 8 or less. As a result, the cushion layer 22 can be formed by the aggregate of the second foamed bead particles 42, and the cushion layer 22 can have the cushioning property required for the cushion layer 22. Further, even if the cushion layer 22 is dented (sunk) when the user steps on the bathroom washroom floor 10, it can be easily restored, so that the cushioning property can be maintained for a long period of time. The number of the second foamed bead particles 42 laminated in the thickness direction of the cushion layer 22 is preferably smaller than the number of the first foamed bead particles 41 laminated in the thickness direction of the base material layer 21.

The thickness of the cushion layer 22 is preferably 2 mm or more and 8 mm or less, and more preferably 3 mm or more and 6 mm or less. The thickness of the cushion layer 22 is the length of the cushion layer 22 in the vertical direction. As a result, the cushion layer 22 can be provided with the cushioning property required for the cushion layer 22. Further, even if the cushion layer 22 is dented (sunk) when the user steps on the bathroom washroom floor 10, it can be easily restored, so that the cushioning property can be maintained for a long period of time. The thickness of the cushion layer 22 is preferably smaller than the thickness of the base material layer 21. How to obtain the thickness of the cushion layer 22 will be described later. The thickness of the cushion layer 22 referred to here is an average value of the thickness T1 of the central portion 22p of the cushion layer 22 and the thickness T2 of the end portion 22q.

The density of the cushion layer 22 is preferably 90 g / L or more and 300 g / L or less, and more preferably 100 g / L or more and 200 g / L or less. As a result, the cushion layer 22 can be provided with the cushioning property required for the cushion layer 22. Further, even if the cushion layer 22 is dented (sunk) when the user steps on the bathroom washroom floor 10, it can be easily restored, so that the cushioning property can be maintained for a long period of time. The density of the cushion layer 22 referred to here is an average value of the density of the central portion 22p and the density of the end portion 22q of the cushion layer 22.

The density of the central portion 22p of the cushion layer 22 is preferably higher than the density of the end portion 22q of the cushion layer 22. This makes it possible to increase the durability of the central portion 22p of the cushion layer 22 that the user frequently steps on. Therefore, it is possible to further suppress a large decrease in cushioning property in the vicinity of the center of the bathroom washing floor 10.

The density of the central portion 22p is preferably 95 g / L or more and 300 g / L or less, and preferably 110 g / L or more and 200 g / L or less. The density of the end portion 22q is preferably 90 g / L or more and 295 g / L or less, and more preferably 100 g / L or more and 190 g / L or less. The difference between the density of the central portion 22p and the density of the end portion 22q is preferably 5 g / L or more and 100 g / L or less, and more preferably 10 g / L or more and 90 g / L. The density of the central portion 22p and the density of the end portion 22q are the values obtained by cutting out only the central portion 22p or the end portion 22q of the cushion layer 22 from the bathroom washing floor 10 and using JIS K 7222: 2005.

The hardness of the base material layer 21 is preferably higher than the hardness of the cushion layer 22. As an index of hardness, either compressive stress (at 50% strain), Duro A hardness, or Duro CS hardness is used. As an index of hardness, it is preferable to use compressive stress (at 50% strain). That is, it is preferable that the compressive stress (at the time of 50% strain) of the base material layer 21 is higher than the compressive stress (at the time of 50% strain) of the cushion layer 22. Here, "compressive stress (at the time of 50% strain)" refers to the compressive stress when compressed by 50% with respect to the thickness of each layer.

The compressive stress (at the time of 50% strain) of the base material layer 21 is preferably 0.5 MPa or more and 4 MPa or less, and more preferably 0.5 MPa or more and 3 MPa or less. The compressive stress (at the time of 50% strain) of the cushion layer 22 is preferably 0.02 MPa or more and 0.45 MPa or less, and more preferably 0.1 MPa or more and 0.4 MPa or less.

Compressive stress (at 50% strain) is measured by performing a compression test in accordance with JIS K 6767: 1999. More specifically, first, only the layer to be measured (that is, only the base material layer 21 and only the cushion layer 22) is taken out from the bathroom washroom floor 10. At this time, using a band saw or the like, care is taken not to allow other layers to adhere to the surface of each layer or to peel off in the layer, and cut out so that the surface becomes a flat surface. Next, a test piece having a size of 50 mm in length and 50 mm in width is prepared from each of the removed layers. Then, each thickness of this test piece is measured with a dial gauge. Next, the test speed is set to 50% of the thickness per minute (for example, the speed is 5 mm / min when the thickness is 10 mm), and the compression test is performed according to JIS K 6767: 1999. The test force when compressed by 50% with respect to the thickness is converted into the stress per unit area, and the compressive stress (at the time of 50% strain) is obtained.

Further, the Duro A hardness of the base material layer 21 is preferably higher than the Duro A hardness of the cushion layer 22. The Duro A hardness of the base material layer 21 is preferably 55 or more and 99 or less, and more preferably 60 or more and 99 or less. The Duro A hardness of the cushion layer 22 is preferably 5 or more and 50 or less, and more preferably 10 or more and 40 or less.

The Duro A hardness is measured using a hardness tester such as an Asker rubber hardness tester type A (manufactured by Polymer Meter Co., Ltd.) in accordance with JIS K 6253-3: 2012. More specifically, first, only the layer to be measured (that is, only the base material layer 21 and only the cushion layer 22) is taken out from the bathroom washroom floor 10. At this time, each layer is cut out in the same manner as described above, taking care not to deform each layer. Next, a test piece having a size of 100 mm in length and 100 mm in width is prepared from each of the removed layers. Then, this test piece is placed on a flat and hard surface, and the hardness is measured with an Asker rubber hardness tester A type. At this time, the pressure plate of the hardness tester is maintained parallel to the surface of the test piece, and the hardness tester is held so that the push needle is perpendicular to the surface of the test piece so as not to give an impact. In contact with the test piece. Read the value about 3 seconds after contact. The hardness is measured at 5 points on one test piece, and the average value is taken as Duro A hardness.

Further, the Duro CS hardness of the base material layer 21 is preferably higher than the Duro CS hardness of the cushion layer 22. The Duro CS hardness of the base material layer 21 is preferably 70 or more and 99 or less, and more preferably 80 or more and 99 or less. The Duro CS hardness of the cushion layer 22 is preferably 10 or more and 70 or less, and more preferably 20 or more and 60 or less.

The Duro CS hardness can be obtained by the same method as the above-mentioned method for obtaining "Duro A hardness" except that an Asker rubber hardness tester CS type (manufactured by Polymer Meter Co., Ltd.) is used instead of the Asker rubber hardness tester A type. can.

By making the hardness of the base material layer 21 higher than the hardness of the cushion layer 22, that is, by making the hardness of the cushion layer 22 lower than the hardness of the base material layer 21, the base material layer 21 is the bathroom washroom floor 10. It is possible to demonstrate the rigidity required for. Further, the cushion layer 22 can exhibit flexibility and durability. Therefore, it is possible to achieve and maintain the strength and cushioning properties required for the bathroom washroom floor 10 in a well-balanced manner.

As described above, the base material layer 21 is an aggregate of the first foamed bead particles 41 made of a thermoplastic resin, and the cushion layer 22 is an aggregate of the second foamed bead particles 42 made of a thermoplastic resin. By making the hardness higher than the hardness of the cushion layer 22, it is possible to achieve the rigidity and cushioning properties required for the bathroom washing floor 10 in a well-balanced manner.

As described above, the base material layer 21 is required to have strength and rigidity, and the cushion layer 22 is required to have cushioning properties. That is, the properties required for the base material layer 21 are different from the properties required for the cushion layer 22. Therefore, it is preferable that the thermoplastic resin contained in the first expanded bead particles 41 constituting the base material layer 21 is different from the thermoplastic resin contained in the second expanded bead particles 42 constituting the cushion layer 22. Thereby, the physical characteristics of the base material layer 21 and the physical characteristics of the cushion layer 22 can be made different. That is, for the first foamed bead particles 41, a thermoplastic resin suitable for the base material layer 21 (that is, excellent in strength) was selected, and for the second foamed bead particles 42, the cushion layer 22 was suitable (that is, that is). By selecting a thermoplastic resin (which has excellent cushioning properties), strength and cushioning properties can be achieved in a more balanced manner.

Further, it is preferable that the thermoplastic resin contained in the first foamed bead particles 41 and the thermoplastic resin contained in the second foamed bead particles 42 have similar structures. For example, it is preferable that the thermoplastic resin contained in the first expanded bead particles 41 and the thermoplastic resin contained in the second expanded bead particles 42 are each polyolefin. As described above, by allowing the thermoplastic resin contained in the first foamed bead particles 41 and the thermoplastic resin contained in the second foamed bead particles 42 to have similar structures, the base material layer 21 and the cushion layer 22 are formed. Adhesion with can be improved.

Further, the color of the cushion layer 22 is preferably different from the color of the base material layer 21. More specifically, it is preferable that the base material layer 21 and the cushion layer 22 are different in at least one of hue, saturation, and lightness. It is preferable that the raw material beads of the base material layer 21 and the raw material beads of the cushion layer 22 can be visually or visually distinguished. Thereby, the base material layer 21 and the cushion layer 22 can be easily distinguished. Therefore, even if the raw material beads of each layer are mixed at the time of production, they can be easily identified.

Hereinafter, how to obtain the thickness of the base material layer 21 and the thickness of the cushion layer 22 will be described.
FIG. 8 is a cross-sectional view schematically showing how to obtain the thickness of the base material layer and the thickness of the cushion layer of the bathroom washroom floor according to the embodiment.
When determining the thickness of each layer, first, as shown in FIG. 8, the bathroom washing floor 10 is cut so that the cross section can be observed, and the bathroom washing floor is used with an optical microscope, a scanning electron microscope (SEM), or the like. 10 cross-sectional images are obtained. If the surface 10a of the bathroom washroom floor 10 is provided with a drainage gradient that goes downward toward the drainage port 10h, the bathroom washroom floor 10 is cut so as not to straddle the ridge line 23a of the surface layer 23. .. At this time, the cross-sectional image is acquired so as to include the lower surface 21b (lower end) of the base material layer 21 and the upper surface 22a (upper end) of the cushion layer 22. That is, the cross-sectional image is acquired so as to include the entire base material layer 21 and the cushion layer 22 in the vertical direction. In FIG. 8, the surface layer 23 and the adhesive layer 24 are omitted, and only the cross sections of the base material layer 21 and the cushion layer 22 are shown.

Next, in the cross-sectional image, the first reference line RL1 is drawn at the position of the lower surface 21b of the base material layer 21, and the second reference line RL2 is drawn at the position of the upper surface 22a of the cushion layer 22. Next, in the cross-sectional image, a straight line orthogonal to the first reference line RL1 is drawn from any 10 points on the first reference line RL1 toward the second reference line RL2, and the points intersect with the first reference line RL1 of each straight line. The lengths L1 to L10 between and the point where the second reference line RL2 intersects are measured. Then, the average value of the lengths L1 to L10 is calculated, and this is used as the thickness Ta of the two layers. The thickness Ta of the two layers is an average value of the total thickness of the base material layer 21 and the cushion layer 22.

Next, in the cross-sectional image, the unevenness of the interface between the base material layer 21 and the cushion layer 22 is confirmed. Here, the concave portion is a portion where the base material layer 21 is recessed downward due to the cushion layer 22 biting into the base material layer 21. The convex portion is a portion where the base material layer 21 bites into the cushion layer 22 and the base material layer 21 projects upward. Next, the lengths L11 to L20 between the bottoms of 10 randomly selected recesses and the second reference line RL2 are measured. In addition, the lengths L21 to L30 between the vertices of 10 randomly selected convex portions and the second reference line RL2 are measured. Then, the average value of the lengths L11 to L30 is calculated, and this is used as the thickness Tb of the cushion layer 22. The value obtained by subtracting the thickness Tb of the cushion layer 22 from the thickness Ta of the two layers is defined as the thickness Tc of the base material layer 21 (Tc = Ta—Tb). From the above, the thickness Tb of the cushion layer 22 and the thickness Tc of the base material layer 21 can be obtained.

By obtaining the thickness of the central portion 22p and the end portion 22q of the cushion layer 22 as described above, the thickness T1 of the central portion 22p and the thickness T2 of the end portion 22q can be obtained. Further, the thickness of the cushion layer 22 can be obtained from the thickness T1 of the central portion 22p and the thickness T2 of the end portion 22q.

Hereinafter, a method for obtaining the particle size R1 of the first expanded bead particles 41 constituting the base material layer 21 and the particle size R2 of the second expanded bead particles 42 constituting the cushion layer 22 will be described.
9 (a) and 9 (b) are cross-sectional views schematically showing how to obtain the particle size of the first foamed bead particles and the particle size of the second foamed bead particles of the bathroom washroom floor according to the embodiment. ..
When determining the particle size of each foamed bead particle, first, as shown in FIGS. 9 (a) and 9 (b), the bathroom washroom floor 10 is cut so that the cross section can be observed, and an optical microscope or scanning is performed. A cross-sectional image of the bathroom washroom floor 10 is obtained using a scanning electron microscope (SEM) or the like. At this time, the cross-sectional image is acquired so as to include the lower surface 21b (lower end) of the base material layer 21 and the upper surface 22a (upper end) of the cushion layer 22. That is, the cross-sectional image is acquired so as to include the entire base material layer 21 and the cushion layer 22 in the vertical direction. In FIGS. 9 (a) and 9 (b), the surface layer 23 and the adhesive layer 24 are omitted, and only the cross sections of the base material layer 21 and the cushion layer 22 are shown.

Next, as shown in FIG. 9A, in the cross-sectional image, the first reference line RL1 is drawn at the position of the lower surface 21b of the base material layer 21, and the second reference line RL2 is drawn at the position of the upper surface 22a of the cushion layer 22. pull. Next, in the base material layer 21, three or more straight lines parallel to the first reference line RL1 and having a length of d1 (mm) are drawn. In the cushion layer 22, three or more straight lines parallel to the second reference line RL2 and having a length of d1 (mm) are drawn. Here, d1 is an arbitrary length. In this example, straight lines X1 to X3 are drawn on the base material layer 21, and straight lines X4 to X6 are drawn on the cushion layer 22. The start point and end point of each straight line are drawn so as to overlap the grain boundaries of the foamed bead particles.

Next, in each straight line X1 to X6, the number of foamed bead particles existing on the line is counted. That is, in the straight lines X1 to X3, the number of the first foamed bead particles 41 existing on the line is counted, and in the straight lines X4 to X6, the number of the second foamed bead particles 42 existing on the line is counted. Next, in each of the straight lines X1 to X3, the particle size of the first foamed bead particles 41 in the X direction is calculated by the following formula (1). Further, in each of the straight lines X4 to X6, the particle size of the second foamed bead particles 42 in the X direction is calculated by the following formula (2). The "X direction" here is a direction parallel to the first reference line RL1.
Particle size (mm) in the X direction of the first foamed bead particles = length d1 (mm) of a straight line ÷ number of first foamed bead particles existing on the line ... Equation (1)
Particle size (mm) in the X direction of the second foamed bead particles = length d1 (mm) of a straight line ÷ number of second foamed bead particles existing on the line ... Equation (2)

Next, in each layer, the average value of the particle size in the X direction is calculated, and this is taken as the average particle size Rx (mm) in the X direction of the foamed bead particles contained in each layer. In this example, the average value of the particle size of the first foamed bead particles 41 in the X direction in the straight lines X1 to X3 is defined as the average particle size Rx1 of the first foamed bead particles 41 in the X direction. Further, in this example, the average value of the particle size of the second foamed bead particles 42 in the X direction in the straight lines X4 to X6 is defined as the average particle size Rx2 of the second foamed bead particles 42 in the X direction.

Next, as shown in FIG. 9B, in the cross-sectional image, three or more straight lines perpendicular to the first reference line RL1 and having a length of d2 (mm) are drawn so as to straddle each layer. Here, d2 is an arbitrary length. In this example, straight lines Y1 to Y5 straddling the base material layer 21 and the cushion layer 22 are drawn. The start point and end point of each straight line are drawn so as to overlap the grain boundaries of the foamed bead particles. Of the straight lines Y1 to Y5, the length of the portion overlapping the base material layer 21 is d3 (mm), and the length of the portion overlapping the cushion layer 22 is d4 (mm) (d3 + d4 = d2). The length d3 and the length d4 may be different for each straight line.

Next, in each straight line Y1 to Y5, the number of foamed bead particles existing on the line is counted. At this time, the number of foamed bead particles existing on the line is counted for each layer. That is, in the straight lines Y1 to Y5, the number of the first foamed bead particles 41 existing on the line and the number of the second foamed bead particles 42 existing on the line are counted separately. Next, in each of the straight lines Y1 to Y5, the particle size of the first foamed bead particles 41 in the Y direction is calculated by the following formula (3). Further, in each of the straight lines Y1 to Y5, the particle size of the second foamed bead particles 42 in the Y direction is calculated by the following formula (4). The "Y direction" here is a direction perpendicular to the first reference line RL1.
Particle size (mm) in the Y direction of the first foamed bead particles = length d3 (mm) of a straight line ÷ number of first foamed bead particles existing on the line ... Equation (3)
Particle size (mm) in the Y direction of the second foamed bead particles = length d4 (mm) of a straight line ÷ number of second foamed bead particles existing on the line ... Equation (4)

Next, in each layer, the average value of the particle size in the Y direction is calculated, and this is taken as the average particle size Ry (mm) in the Y direction of the foamed bead particles contained in each layer. In this example, the average value of the particle size of the first expanded bead particles 41 in the Y direction in the straight lines Y1 to Y5 is defined as the average particle size Ry1 of the first expanded bead particles 41 in the Y direction. Further, in this example, the average value of the particle size of the second foamed bead particles 42 in the Y direction in the straight lines Y1 to Y5 is defined as the average particle size Ry2 of the second foamed bead particles 42 in the Y direction.

Next, the average value of the average particle size Rx1 in the X direction of the first expanded bead particles 41 and the average particle size Ry1 in the Y direction of the first expanded bead particles 41 is obtained, and this is the particle size of the first expanded bead particles 41. Let it be R1. Similarly, the average value of the average particle size Rx2 in the X direction of the second foamed bead particles 42 and the average particle size Ry2 in the Y direction of the second foamed bead particles 42 is obtained, and this is the particle size of the second foamed bead particles 42. Let it be R2. From the above, the particle size R1 of the first expanded bead particles 41 and the particle size R2 of the second expanded bead particles 42 can be obtained.

Hereinafter, a method for manufacturing the bathroom washing floor 10 of the present invention will be described. The bathroom washing floor 10 of the present invention can be manufactured by using a known method. First, a method for manufacturing the base material layer 21 and the cushion layer 22 will be described. A base material layer 21 having a drainage gradient inclined downward toward the drainage port 10h on the upper surface, a central portion 22p including the central CP of the bathroom washroom floor 10, and an end portion 22q located outside the central portion 22p in the top view. A cushion layer 22 having a thickness of the central portion 22p smaller than the thickness of the end portion 22q is prepared, and by joining these, a laminated body in which the base material layer 21 and the cushion layer 22 are laminated can be obtained. Examples of the joining method include an adhesive and heat fusion. Moreover, the following method can be used as a preferable method.

10 (a) to 10 (d) are explanatory views schematically showing a method for manufacturing a base material layer and a cushion layer of a bathroom washroom floor according to an embodiment.
As shown in FIGS. 10 (a) to 10 (d), the base material layer 21 and the cushion layer 22 are each made by heating and foaming raw beads made of a thermoplastic resin in a mold M, and foamed bead particles. It is manufactured by forming an aggregate of. The base material layer 21 and the cushion layer 22 are each formed by so-called bead foaming.

More specifically, first, as shown in FIG. 10A, the first raw material beads 46, which is the raw material of the first foamed bead particles 41, are accommodated in the mold M (first accommodating step). As the first raw material beads 46, it is preferable to use pre-foamed beads.

Next, as shown in FIG. 10B, the mold M is closed, the first raw material beads 46 are heated by steam, and the first raw material beads 46 housed in the mold M are fused (fused). Process).

Next, as shown in FIG. 10 (c), the mold M is opened, and the second raw material beads 47, which is the raw material of the second foamed bead particles 42, are accommodated on the first raw material beads 46 (second accommodation). Process). As the second raw material beads 47, it is preferable to use pre-foamed beads.

Next, as shown in FIG. 10D, the first raw material beads 46 and the second raw material beads 47 are foamed by closing the mold M and raising the temperature inside the mold M (foaming step). Then, the laminated body is cooled (cooling step). As a cooling method, a known method such as air cooling can be used. As a result, it is possible to obtain a laminated body in which the base material layer 21 made of the aggregate of the first foamed bead particles 41 and the cushion layer 22 made of the aggregate of the second foamed bead particles 42 are fused.

For example, the drainage gradient can be imparted to the base material layer 21 by changing the inclination of the surface S in contact with the first raw material beads 46 of the mold M used in the fusion step. Further, for example, the cushion layer is formed by changing the amount of the second raw material beads 47 to be accommodated in the mold M in the second accommodating step and the shape of the surface S in contact with the second raw material beads 47 of the mold M used in the foaming step. The thickness of 22 can be changed. That is, the thickness T1 of the central portion 22p of the cushion layer 22 and the thickness T2 of the end portion 22q can be changed.

The surface layer 23 is laminated on the surface of the cushion layer 22 of the laminate obtained as described above. Specifically, in the cushion layer 22, the surface layer 23 is arranged on the surface on the side where the base material layer 21 is not laminated to obtain a laminated body in which the base material layer 21, the cushion layer 22 and the surface layer 23 are laminated. be able to. When the surface layer 23 and the cushion layer 22 are joined using an adhesive, the adhesive is placed on the surface of the cushion layer 22. After that, the surface layer 23 is laminated on the adhesive. Then, if necessary, heating or the like is performed. From the above, it is possible to manufacture the bathroom washing floor 10 in which the surface layer 23, the cushion layer 22 and the base material layer 21 are laminated. When an adhesive is used, it is preferable to use a hot melt type adhesive or double-sided tape as the adhesive.

As described above, it is preferable to use a resin sheet as the surface layer 23. A resin sheet having a desired function can be used. Specifically, a resin sheet having functions such as flexibility, waterproofness, and hydrophilicity can be used.

As described above, according to the embodiment, there is provided a bathroom washing floor that can suppress a large decrease in cushioning property in the vicinity of the center of the bathroom washing floor.

The embodiment of the present invention has been described above. However, the present invention is not limited to these descriptions. The above-mentioned embodiments which have been appropriately designed by those skilled in the art are also included in the scope of the present invention as long as they have the features of the present invention. For example, the shape, dimensions, material, arrangement, and the like of each element provided in the bathroom washroom floor and the like are not limited to those exemplified, and can be appropriately changed.
Further, the elements included in each of the above-described embodiments can be combined as long as technically possible, and the combination thereof is also included in the scope of the present invention as long as the features of the present invention are included.

2 Bathroom unit, 10 Bathroom washroom floor, 10a surface, 10h drainage port, 20 floor body, 21 base material layer, 21a upper surface, 21b lower surface, 21h opening, 22 cushion layer, 22a upper surface, 22b lower surface, 22e peripheral part, 22h Opening, 22p center, 22q end, 23 surface layer, 23a ridge, 23h opening, 24 adhesive layer, 30 frame body, 30h opening, 31 outer frame, 32 grid, 33 support legs, 41, 42nd 1, 2nd foam bead particles, 41a, 42a dense part, 41b, 42b sparse part, 46, 47 1st, 2nd raw material beads, 60 bathtub, 61 support legs, 62 drainage pipe, 65a, 65b small panel, 67 bath Apron, 71a-71f wall panel, 100 installation surface, CP center, M type, S surface, RL1, RL2 1st and 2nd reference lines, X1 to X6, Y1 to Y5 straight

Claims (4)

Substrate layer and
A cushion layer provided on the base material layer and
A surface layer provided on the cushion layer and forming the surface of the bathroom washroom floor,
A drainage port for draining water flowing on the upper surface of the surface layer,
Equipped with
The upper surface of the base material layer has a drainage gradient that slopes downward toward the drainage port.
The cushion layer has a central portion including the center of the bathroom washroom floor and an end portion located outside the central portion in a top view.
The bathroom washroom floor is characterized in that the thickness of the central portion is smaller than the thickness of the end portion. The bathroom washing floor according to claim 1, wherein the density of the central portion is higher than the density of the end portion. The bathroom washing floor according to claim 1 or 2, wherein the cushion layer is an aggregate of foamed bead particles made of a thermoplastic resin. The base material layer is an aggregate of first foamed bead particles made of a thermoplastic resin.
The bathroom washing floor according to claim 3, wherein the cushion layer is an aggregate of second foamed bead particles made of a thermoplastic resin.

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