JP2022048672A - Bathroom floor structure and bathroom unit - Google Patents

Abstract

To provide a bathroom floor structure which has excellent designability, and to provide a bathroom unit.SOLUTION: A bathroom floor structure 1 includes a base material 13 constituted by FRP and a floor panel 10 having designability, and is constituted in such a manner that the floor panel 10 is fixed on the base material 13. The floor panel 10 has: a resin-impregnated nonwoven fabric 101 having a nonwoven fabric on which printing is performed; and an SMC layer 104 constituted by FRP. The resin-impregnated nonwoven fabric 101 and the SMC layer 104 are integrally formed by press molding.SELECTED DRAWING: Figure 2

Description

The present disclosure relates to bathroom floor structures and bathroom units.

As a conventional bathroom floor material, various materials such as tile material, wood, stone material, resin material and FRP material are used depending on its functionality. Among them, FRP material has been widely used in recent years because it has high strength and high waterproofness. For example, Patent Document 1 discloses a molded product for a bathroom floor made of FRP, which has a hollow structure by containing a balloon material and has improved heat insulating performance.

Japanese Unexamined Patent Publication No. 2017-133319

When a resin material or FRP material is used as a bathroom floor material, the design is poor compared to wood, stone, and the like. Therefore, the resin material and the FRP material are painted. However, it is difficult to perform fine decoration that reproduces the wood grain of wood, for example.

The present disclosure provides a bathroom floor structure comprising a substrate composed of FRP and a floor panel having a design, wherein the floor panel is fixed and configured on the substrate.

It is a figure which shows the bathroom unit which concerns on one Embodiment of this disclosure. It is sectional drawing of the floor structure which concerns on one Embodiment of this disclosure. It is sectional drawing of the floor panel which concerns on one Embodiment of this disclosure. It is a figure which shows the floor structure which concerns on one Embodiment of this disclosure. It is a figure which shows the floor panel which concerns on one Embodiment of this disclosure. It is a figure which shows the state of manufacturing the resin impregnated nonwoven fabric which concerns on one Embodiment of this disclosure.

As shown in FIG. 1, the bathroom unit 100 of the present embodiment includes a substantially rectangular floor structure 1, a shower 2, a faucet 3, a bathtub 4, and a counter 5. Further, the floor structure 1 has a plurality of floor panels 10 having design, a drainage mass 11, a ridge line 12, and a base material 13. The plurality of floor panels 10 are fixed side by side on the base material 13 to form a bathroom floor surface.

The floor structure 1 has a plurality of inclined surfaces inclined toward the drainage mass 11, and a straight valley-shaped ridge line 12 is formed between the plurality of inclined surfaces. The plurality of inclined surfaces are inclined so as to guide the flow of water toward the drainage mass 11, and have good drainage property. The floor panel 10 may have water repellency on its inclined surface in order to improve drainage.

As shown in FIG. 2, the floor panel 10 is bonded and fixed on the base material 13 via the adhesive layer 14 to form a floor panel having a design on the surface in the floor structure 1. The method of fixing the floor panel 10 to the base material 13 is not particularly limited. In addition to gluing, it may be fixed by a mechanical fixing means such as screwing. A plurality of floor panels 10 are arranged side by side to form a floor surface, and joints 15 are formed in the gaps between the floor panels 10.

Further, as shown in FIG. 3, the floor panel 10 has a resin-impregnated nonwoven fabric 101 having a design property and an SMC (Sheet Molding Compound) layer 104 made of a thermosetting fiber reinforced material. The SMC layer 104 further includes a heat insulating layer 102 having a hollow structure inside and a reinforcing layer 103 having no hollow structure inside, and is composed of two layers. That is, the floor panel 10 is composed of three layers: a resin-impregnated nonwoven fabric 101 having a design property, a heat insulating layer 102, and a reinforcing layer 103. As a result, the floor panel 10 having design, heat insulation, and strength can be obtained.

The resin-impregnated non-woven fabric 101 is a non-woven fabric obtained by gravure-printing a design such as wood or stone, impregnated with resin and cured. By printing on the non-woven fabric, it is possible to express a finer design on the bathroom floor surface than by painting on a resin material or the like, and the design of the bathroom floor structure 1 is greatly improved. As the non-woven fabric, it is preferable to use a polyester non-woven fabric having antifungal properties. The resin impregnated in the resin-impregnated nonwoven fabric 101 is not particularly limited. In the present embodiment, the resin-impregnated nonwoven fabric 101 is impregnated with an acrylic resin. If it is an acrylic resin, the surface of the floor panel 10 can have a high design property.

The imparting of design to the floor panel 10 of the present disclosure is not limited to the gravure printing on the non-woven fabric. For example, a non-woven fabric or other material that has been painted or inkjet printed may be coated with an acrylic resin or other resin, or a floor panel having a design can be obtained by wrapping a decorative sheet having an adhesive on one side. 10 may be configured.

The heat insulating layer 102 has a hollow structure inside. As a result, the heat insulating performance of the bathroom floor surface is improved, and the user can comfortably use the bathroom unit 100. From the viewpoint of strength and durability, the heat insulating layer 102 is preferably made of FRP having a hollow structure. For example, a hollow structure can be obtained by containing a hollow filler when the FRP is cured.

The reinforcing layer 103 is a layer made of FRP and having no hollow structure inside. Since there is no hollow structure, it is configured to have higher strength than the heat insulating layer 102. Therefore, by having the reinforcing layer 103 in addition to the heat insulating layer 102, the strength of the floor panel 10 can be further reinforced. The heat insulating layer 102 and the reinforcing layer 103 may be formed by using the same FRP material.

The hollow filler preferably has closed cells inside, and can be either inorganic or organic. Examples of the inorganic material include glass balloons, silica balloons, and fly ash balloons. Silica balloons, alumina balloons, ceramic balloons and the like can be used. As the organic system, urethane balloons, phenol balloons, polyamide balloons and the like can be used. Inorganic and organic ones can be used together. Further, two or more kinds of hollow fillers having different particle sizes can be used in combination.

The drainage mass 11 is a concave recess formed in the floor structure 1 and drains used water through a drainage port provided inside. The drainage mass 11 is covered with a drainage plate, and the water flowing on the surface of the floor panel 10 is drained by flowing into the gap between the drainage mass 11 and the lid. The upper surface of the lid has a unified appearance with the surface of the floor panel 10, and forms a part of the floor structure 1. As a result, the design is improved while maintaining the drainage property.

The drainage mass 11 is arranged near the midpoint of the side of the bathtub 4 side in the substantially rectangular floor structure 1. The drainage mass 11 is preferably arranged on the side far from the entrance of the bathroom. If a drainage ditch is placed at the position where the user passes through the bathroom when he / she enters the bathroom, where dirty water and hair after washing are collected, the cleanliness will be reduced and the user will feel a bad odor. This is to cause discomfort.

As shown in FIG. 4, the ridge line 12 is formed by arranging and connecting a plurality of floor panels 10 having a valley shape. That is, the floor panel 10 having a part of the ridge line 12 as shown in FIG. 5 is manufactured in advance and arranged in a predetermined place to complete the ridge line 12 extending to the drainage mass 11.

The number of ridge lines 12 is preferably about two. If the number of formed a plurality of inclined surfaces is large, the drainage property is high by having the inclinations along the path to the drainage ditch. However, if the number of divisions of the floor surface is large, the number of ridge lines 12 increases and it becomes difficult to secure a wide flat surface portion. In this respect, if there are about two, a wide flat surface can be secured while maintaining good drainage. However, there may be three or more ridge lines 12 constituting the floor structure 1 of the present disclosure.

The base material 13 is made of a hand-laid-up molded FRP material, and has a plurality of inclined surfaces and ridges inclined toward the drainage mass 11. As shown in FIG. 4, the positions of the plurality of inclined surfaces and ridge lines of the base material 13 correspond to the inclined surfaces and ridge lines 12 on the bathroom floor surface formed after arranging the floor panels 10. That is, by arranging the floor panels 10 according to the inclined surface of the base material 13, it is not necessary to incline the thickness of the floor panel 10 itself, and the floor panel 10 can be manufactured to have a uniform thickness. can. This improves the strength and production efficiency of the floor panel 10.

The adhesive layer 14 is a layer composed of an adhesive for adhering and fixing the floor panel 10 to the base material 13. As the adhesive constituting the adhesive layer 14, a modified silicone resin-based elastic adhesive or the like can be used. In the present embodiment, the adhesive layer 14 is configured to have gaps at regular intervals as shown in FIG. 3 instead of applying the adhesive to the entire surfaces of the base material 13 and the floor panel 10. As a result, air can be retained in the adhesive layer 14, so that the heat insulating property of the floor structure 1 is further improved.

The joint 15 is configured to fill the space between the plurality of floor panels 10. As the material constituting the joint 15, for example, an epoxy resin can be used. Since the floor structure 1 has the joints 15, it is possible to reduce the discomfort felt by the user due to the surface step between the plurality of floor panels 10.

The surface step between the plurality of floor panels 10 is preferably 2 mm or less, and more preferably 1 mm or less. Within this range, since the plurality of floor panels are arranged so as to be substantially flush with each other, it is possible to reduce the discomfort felt by the user due to the surface step between the plurality of floor panels 10. That is, in the present disclosure, substantially flush means that the surface step is 2 mm or less.

Further, the floor panel 10 preferably has rounded edges and chamfered edges. It is possible to improve the feel when the user touches the floor panel 10.

Next, the manufacturing method of the floor structure 1 of this embodiment will be described.

As shown in FIG. 6, the resin-impregnated nonwoven fabric 101 is produced by impregnating a nonwoven fabric with an acrylic resin, drying it, and curing it. Specifically, the nonwoven fabric sent out from the nonwoven fabric roll 91 is carried by the other rollers 92 and immersed in the resin impregnation tank 93 in which the liquid acrylic resin is stored. The nonwoven fabric immersed in the resin impregnated tank 93 and impregnated with the acrylic resin is further carried by the rollers 92, and is dried and cured by passing through the dryer 94 to produce the resin impregnated nonwoven fabric 101. The resin-impregnated nonwoven fabric 101 is then cut by the cutting machine 95 or wound up on the product roll 96.

In addition to the acrylic resin, the resin impregnation tank 93 may contain an inorganic filler, acetone, a curing agent, an internal mold release agent, and a wearing agent.

The floor panel 10 is integrally molded by laminating the acrylic resin-containing nonwoven fabric 101 and the SMC layer 104 composed of FRP and hot-press molding at 110 ° C to 295 ° C. Each layer is thermocompression bonded by press molding and has high adhesive strength. As the press forming pressure, a pressure of 3.0 to 15.0 MPa is applied depending on the size and shape of the floor panel 10.

By arranging the floor panel 10 manufactured in this manner on the upper surface of the base material 13 manufactured by hand lay-up molding, the floor structure 1 having excellent designability can be manufactured. At this time, the corresponding floor panel 10 can be easily identified by the ridge line formed on the surface of the base material 13.

As described above, according to the bathroom floor structure 1 of the present embodiment, the following effects are achieved.

The floor structure 1 of the bathroom of the present embodiment has a base material 13 made of FRP and a floor panel 10 having a design property, and the floor panel 10 is fixed and configured on the base material 13. As a result, the bathroom floor can be given a design according to the taste, and the design can be improved.

An adhesive layer 14 for adhering both layers is provided between the base material 13 and the floor panel 10. As a result, the base material 13 and the floor panel 10 are well adhered to each other.

The floor panel 10 has a resin-impregnated nonwoven fabric 101 having a colored nonwoven fabric and an SMC layer 104 composed of FRP, and the resin-impregnated nonwoven fabric 101 and the SMC layer 104 are integrally molded by press molding. .. As a result, fine printing can be applied to the non-woven fabric, so that excellent designability can be imparted to the floor panel 10, and the designability of the floor panel 10 is greatly improved. Since the resin-impregnated nonwoven fabric 101 and the SMC layer 104 made of a high-strength FRP material are bonded with high adhesive strength, a high-strength floor panel 1 can be manufactured.

The SMC layer 104 is composed of FRP formed in a sheet shape, and has a heat insulating structure 102 in which a hollow portion is non-uniformly formed. As a result, the heat insulating performance of the floor panel 10 is improved, and the user's comfort is improved.

The resin-impregnated nonwoven fabric 101 is impregnated with an acrylic resin. As a result, the surface of the floor panel 10 has a high degree of design.

The floor panel 10 is configured by arranging a plurality of panels substantially flush with each other. As a result, it is possible to reduce the discomfort felt by the user due to the surface step between the plurality of floor panels 10.

A joint 15 is formed between the plurality of panels. As a result, it is possible to further reduce the discomfort felt by the user due to the surface step between the plurality of floor panels 10.

The bathroom unit 100 of the present embodiment includes a floor structure 1. Thereby, it is possible to provide the bathroom unit 100 having excellent design.

In the present embodiment, the resin-impregnated nonwoven fabric 101 and the SMC layer 104 are integrally molded by press molding under the conditions of 110 ° C. to 295 ° C. and 3.0 to 15.0 MPa. As a result, each layer is thermocompression bonded by press molding and has high adhesive strength.

The embodiment of the bathroom unit having the floor structure of the present disclosure is not limited to the type in which the bathtub 4 and the shower are integrated as shown in FIG. 1, and the bathroom without the bathtub 4 and only the shower is provided independently. It may be a unit.

The embodiments according to the present disclosure have been described above. The present disclosure is not limited to the above-described embodiment, and improvements and modifications thereof are also included in the present disclosure.

1 ... Floor structure, 2 ... Shower, 3 ... Faucet, 4 ... Bathtub, 5 ... Counter, 10 ... Floor panel, 101 ... Resin impregnated non-woven fabric, 102 ... Insulation layer, 103 ... Reinforcing layer, 104 ... SMC layer, 11 ... Drainage mass, 12 ... Ridge line, 13 ... Base material, 14 ... Adhesive layer, 15 ... Joint, 9 ... Resin impregnated non-woven fabric manufacturing equipment, 91 ... Nonwoven fabric roll, 92 ... Roller, 93 ... Resin impregnated tank, 94 ... Dryer, 95 … Cutting machine, 96… Product roll, 100… Bathroom unit

Claims (9)

It has a base material made of FRP and a floor panel with design.
The floor structure of the bathroom is configured by fixing the floor panel on the base material. The bathroom floor structure according to claim 1, further comprising an adhesive layer for adhering both layers between the base material and the floor panel. The floor panel has a resin-impregnated nonwoven fabric having a colored nonwoven fabric and an SMC layer composed of FRP.
The bathroom floor structure according to claim 1 or 2, wherein the resin-impregnated nonwoven fabric and the SMC layer are integrally molded by press molding. The bathroom floor structure according to claim 3, wherein the SMC layer is composed of FRP molded into a sheet shape and has a heat insulating structure in which hollow portions are non-uniformly formed. The bathroom floor structure according to claim 3 or 4, wherein the resin-impregnated nonwoven fabric is impregnated with an acrylic resin. The bathroom floor structure according to any one of claims 1 to 5, wherein the floor panel is configured by arranging a plurality of panels substantially flush with each other. The bathroom floor structure according to claim 6, wherein joints are formed between the plurality of panels. A bathroom unit comprising the bathroom floor structure according to any one of claims 1 to 7. The method for manufacturing a bathroom floor structure according to claim 3 or 4.
A method for manufacturing a bathroom floor structure, wherein the resin-impregnated nonwoven fabric and the SMC layer are integrally molded by press molding under the conditions of 110 ° C. to 295 ° C. and 3.0 to 15.0 MPa.

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