JP2805121B2 - Floor bread and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a waterproof floor pan constituting a floor surface of a unit bathroom or the like and a method of manufacturing the floor pan.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 4, a floor pan 1 of this kind has a surface layer 2 formed of a floor plate 3 made of reinforced plastic (FRP) and edges 4 around its four sides. A receiving portion 5 having a substantially L-shaped cross section is formed at the upper end, a resin concrete layer 6 is integrally formed on the lower surface of the floor plate 3 of the surface layer 2, and a thin resin concrete layer 6 is formed on the lower surface side of the resin concrete layer 6. A reinforcing member 7 in which a square pipe made of a steel plate or the like is framed in a grid by welding means is additionally provided, and furthermore, the outer periphery of the resin concrete layer 6 and the reinforcing member 7 are wrapped from the edge 4 of the surface layer 2 as shown in the figure. An outer peripheral layer 8 is formed of reinforced plastic, and a bottom substrate 10 is formed of reinforced plastic with a hollow portion 9 interposed between the outer peripheral layer 8 and a substantial part of the floorboard 3. The floor pan 1 thus formed is provided with adjusting bolts 11 at a plurality of locations of the reinforcing member 7.
Was attached and laid on the floor F.

The floor pan 1 is molded as follows. First, a mold is prepared and a mold release agent is applied to a molding surface. Then, a gel coat is applied to the molding surface. And before this gel coat hardens, a reinforced plastic is laminated (surface layer 2). Then, the reinforced plastic is subjected to a defoaming treatment, and a resin concrete layer 6 is cast before being hardened. Then, the reinforcing member 7 is attached, and further, the reinforced plastic is laminated, and the reinforcing member 7 is wrapped to form the outer peripheral layer 8.
Are formed, the hollow portion 9 is molded, the bottom substrate 10 is formed by a defoaming process with reinforced plastic, a hardening process is performed, and the mold is removed to form the floor pan 1. Further, as another method, there has been a configuration using a plywood instead of the reinforcing member 7.

[0004]

However, there is a problem in that the molding by the conventional method requires a lot of man-hours and is costly. Further, since the reinforcing member is a thin steel plate, the weight is heavy and the handling is easy. In addition, if the reinforcing member is made of a thin steel plate and framed by a welding means in the form of a girder, it will be warped and the surface layer will be warped. There is a problem that the quality is deteriorated.

The present invention has been made to solve the above-mentioned conventional problems, and has as its object to provide a lightweight and high-quality floor pan and a method for producing the same.

[0006]

SUMMARY OF THE INVENTION In order to solve the above-mentioned technical problems, the present invention relates to a floor pan mold comprising a lower mold and an upper mold, wherein the lower mold is formed with a surface layer of a floor pan. Forming a convex portion to be formed, and, in the upper mold, forming a concave portion for forming a floor substrate of a floor pan,
A reinforcing plastic is laminated on the molding convex portion of the lower molding die, and in the curing process, glass fiber is laminated on the bottom plate portion of the surface layer, the glass fiber is implanted and cured, and the molding concave portion of the upper molding die is formed. Glass fiber is attached to the bottom, the upper mold is closed on the upper surface of the convex part of the lower mold, and the urethane is injected and foamed into the space with an overpack to raise and lower the urethane. It is a method of manufacturing a floor pan that is configured to be impregnated with glass fiber, and further molded into a substantially dish-shaped cross-section having edges on the four sides of the bottom plate with reinforced plastic and protruding on the lower surface side of the bottom plate of the upper surface layer. In a floor pan formed with a bottom substrate, the bottom substrate is composed of a urethane material as a main body, and an intermediate reinforcing layer and an outer peripheral reinforcing layer in which glass fiber is impregnated on the back surface of the bottom plate of the top layer and the bottom of the bottom substrate to form a lightweight structure. Floor floor It is.

[0007]

According to the above construction, two reinforcing layers can be formed vertically on the lower surface side of the floor pan mainly using urethane, and the weight can be reduced.

[0008]

FIG. 1 is a cross-sectional view of a molding die 21 for forming a floor pan 35, and FIG. 2 is a cross-sectional view of the bottom of the floor pan 35. ,
The mold 21 includes a lower mold 22 and an upper mold 26.

The lower mold 22 forms the surface layer 36 of the floor pan 35 as shown in FIGS. 1 and 3, and the upper surface portion 24 for molding the floor plate 37 of the surface layer 36 as in the prior art.
In addition, a convex shaped convex portion 23 having an edge portion 38 and a side surface portion 25 forming a receiving portion 39 is formed on four sides thereof. The formed convex portion 2 of the lower forming die 22 thus formed
3, first, a gel coat 30 is applied to a predetermined thickness, heat of, for example, about 40 ° C. is applied, and before the curing, a reinforced plastic material 31 mixed with glass fiber and polyester resin is sprayed (surface layer 36). ) Laminated.
The reinforced plastic material 31 is subjected to a defoaming process by a roll and is molded along the molding surface 23. Then, the reinforced plastic material 31 is cured by applying heat of about 80 to 90 ° C. Immediately before the reinforced plastic 31 is hardened, the glass fiber mat or chop 32 is hardened with a glass fiber mat or chop 32 uniformly spread on the portion to be the molding bottom 31a.
Is planted in the reinforced plastic 31.

During this time, an upper mold 26 is prepared. The upper molding die 26 is for molding the bottom substrate 40 of the floor pan 35, and is formed with a concave molding concave portion 27 corresponding to the molding convex portion 23 of the lower molding die 22. The material 29 is adhered to the upper surface 24 of the lower mold 22.
It is formed so as to contact the side. A glass mat or glass chop 32 is attached to the bottom surface 27a of the formed concave portion 27 of the upper forming die 26 formed as described above, for example, using a double-sided tape. Then, the upper mold 26 is placed on the molding protrusion 23 of the lower mold 22 and
Although not shown, the members 2 and 26 are firmly fixed by fastening members. The upper mold 26 of the two molded molds 22 and 26 thus fastened.
(Not shown) from the edge 28 side of the foaming agent 3 such as urethane
3 for example, foaming pressure of 100 to 300 kg / m ³ , thickness of 20 to ³
Inject and foam at 0 mm. After curing, the floor pan 35 is formed by removing the mold.

The surface layer 36 of the floor pan 35 thus formed has a rising edge 38 formed on the four sides of the floor plate 37 and a receiving portion 39 formed at the upper end thereof. Urethane 3 is provided on the lower surface side of the floor plate 37 of the surface layer 36.
3 is formed integrally with the bottom substrate 40.

The floor plate 3 of the floor pan 35 thus formed
As shown in FIG. 2, the cross-sectional shape of the floor substrate 40 formed on the lower surface side of
It is formed to a thickness of about 3 mm, and 0.3 to
A layer of a corrugate 30 having a gloss of about 0.4 mm is formed, and the lower surface of the floor plate 37 is cured by placing a glass mat or chop 32 in a scattered shape before curing. Most of the fibers are in a state of being hardened while piercing the back side of the reinforced plastic 31 constituting the floor plate 37, and the urethane 33 is provided in this portion.
Since the glass mat or the chop 32 is impregnated with urethane 33, a reinforced plastic 31, glass fiber 32 and urethane 33 are interposed between the back surface of the floor plate 37 and the urethane 33. An intermediate reinforcing layer 41 having a considerable strength is integrally formed with a predetermined thickness by the foaming pressure of the urethane 33, and the urethane 3 is added to the glass fibers 32 on the lower surface of the floor substrate 40.
3 is impregnated by the foaming pressure, and an outer peripheral reinforcing layer 42 having a considerable strength is integrally formed with a predetermined thickness.

The floor pan 35 thus formed is different from the conventional one in which the reinforcing member 7 made of a steel plate is internally provided, and the floor substrate 40 mainly made of urethane 33 is provided.
Therefore, it becomes extremely lightweight and its handling becomes easy. Further, since the intermediate reinforcing layer 41 and the outer peripheral reinforcing layer 42 having strength are formed above and below the floor substrate 40, the floor plate 37 is not deformed unlike the related art, and the intermediate reinforcing layer 41 is made of glass fiber. Since they are connected by 32, they do not peel off or the like, so that the quality can be improved, and the step of welding the reinforcing members 7 in a cross-girder shape as in the related art can be omitted, and the cost can be reduced. Can be.

[0014]

According to the present invention, as described above, unlike a structure in which a reinforcing member made of a steel plate material is internally provided, the present invention is extremely lightweight because it is a floor substrate mainly made of urethane. Handling becomes easy. In addition, since an intermediate reinforcing layer having strength and an outer peripheral reinforcing layer are formed above and below the floor substrate, the floorboard is not deformed as in the related art, and the intermediate reinforcing layer is connected by glass fibers. Therefore, since there is no peeling or the like, the quality can be improved, and the step of welding the reinforcing member in a cross-girder shape as in the related art can be omitted, and the cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a sectional view of a floor bread mold.

FIG. 2 is a sectional view of a floor substrate.

FIG. 3 is a mounting state diagram of a floor pan.

FIG. 4 is a sectional view of a conventional floor pan.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 21 Mold 22 Lower mold 23 Mold convex part 24 Upper surface part 26 Upper mold part 27 Mold concave part 27a Bottom part 31 Reinforced plastic 32 Glass fiber (glass mat, glass chip) 33 Urethane 35 Floor pan 36 Surface layer 37 Floor plate 40 Floor substrate 41 Intermediate reinforcement layer 42 Outer periphery reinforcement layer

Claims (2)

(57) [Claims] 1. A floor pan forming die 21 comprising a lower forming die 22 and an upper forming die 26, wherein the lower forming die 22 is provided with a forming projection 23 for forming a surface layer 36 of the floor pan.
A molding recess 27 for molding the floor substrate 40 of the floor pan is formed in the upper molding die 26, and a reinforced plastic 31 is laminated on the molding projection 23 of the lower molding die. The glass fiber 32 is laminated on the bottom plate portion, the glass fiber 32 is planted and hardened, and the glass fiber 32 is attached to the bottom of the molding recess 27 of the upper molding die, and the upper molding die 26 is attached to the lower molding die. Molded convex part 23
A method of manufacturing a floor pan in which the molded concave portion 27 is hermetically sealed on the upper surface of the substrate and urethane 33 is injected and foamed into the space by an overpack to impregnate the upper and lower glass fibers 32, 32 with the urethane 33. 2. A floor pan in which a bottom plate 40 is formed in a substantially dish-shaped cross section in which edges 38 are formed on the four sides of the bottom plate 37 and made of reinforced plastic to form a bottom substrate 40 on the lower surface side of the bottom plate 37 of the upper layer. The bottom substrate 40 is a floor pan made of urethane material as a main component and formed with an intermediate reinforcing layer 41 impregnated with glass fiber and an outer peripheral reinforcing layer 42 at the bottom surface of the bottom plate 37 and the bottom of the bottom substrate 40.