JP7431037B2 - Manufacturing method for bathroom washing area floor components - Google Patents

Description

The present invention relates to a bathroom washing area floor member comprising a thermoplastic resin foam particle molded body and a frame member embedded in the thermoplastic resin foam particle molded body by insert molding.

Foamed plastic is sometimes used as a floor member for the washing area floor of a bathroom because of its excellent heat insulation properties (Patent Document 1).
High rigidity is required for the washing area floor member of the bathroom. As a method for improving the rigidity of foamed plastic, for example, a technique of embedding and integrating a frame member made of metal etc. inside a thermoplastic resin foamed particle molded product (hereinafter sometimes simply referred to as a foamed particle molded product) There is (Patent Document 2). In this case, the frame member embedded in the foamed particle molded body functions as a reinforcing material and a mounting material.

A composite molded product made by integrating such a foamed particle molded product and a frame member is produced by arranging the frame member at a predetermined position in a mold, filling it with thermoplastic resin foamed particles, heating it, and melting it. It is manufactured by so-called insert molding.

Japanese Patent Application Publication No. 2012-117257 Japanese Patent Application Publication No. 2002-225949

In recent years, the washing area floor members of bathrooms are sometimes required to have a plate-like shape with excellent surface smoothness. Furthermore, there is a growing demand for materials with even greater rigidity. One way to increase the rigidity of a bathroom washroom floor is to insert a thick frame member.

However, when a thick frame member is inserted into a plate-shaped foamed particle molded product, the part where the frame member is inserted will swell, and unevenness will occur on the surface between it and the non-inserted part, making it difficult to make the surface smooth. In some cases, sexuality was impaired. If surface irregularities occur on the surface of a bathroom washroom floor member, there is a risk of problems occurring when cushioning materials, skin materials, etc. are laminated onto the floor member.

The present invention has been made in view of the problems of the above-mentioned background art, and its purpose is to minimize surface irregularities even if it is a plate-shaped foamed particle molded product in which a thick frame member is inserted. An object of the present invention is to provide a bathroom washing area floor member having excellent surface smoothness.

In order to achieve the above object, the present invention provides a method for manufacturing a bathroom washing area floor member as described in the following [1] to [ 12 ].
[1] A bathroom washing area floor member consisting of a plate-shaped thermoplastic resin foamed particle molded body and a long frame member embedded in the foamed particle molded body is manufactured by insert molding of the frame member. In a method of manufacturing a washing area floor member ,
The thickness of the above frame member exceeds 8 mm,
A plurality of bottomed recesses are formed along the longitudinal direction of the embedded frame member on one plate surface of the foamed particle molded body, and a part of the frame member is exposed by the bottomed recess , and
A plurality of bottomed holes are formed in the same plate surface as the bottomed recess formed in the area adjacent to the part where the frame member is buried,
A method of manufacturing bathroom washing area floor components.
[ 2 ] The bathroom washing area according to [1] above, wherein the thickness of the frame member embedded in the foamed particle molded body is 20 to 60% of the thickness of the foamed particle molded body. Method for manufacturing floor components.
[ 3 ] The method for manufacturing a bathroom washing area floor member according to [1] or [2] above, wherein the frame member is embedded along the longitudinal direction of the foamed particle molded body.
[ 4 ] A plurality of the frame members are embedded in the foamed particle molded body, and at least one of the plurality of frame members is embedded along the longitudinal direction of the foamed particle molded body. The method for manufacturing a bathroom washing area floor member according to any one of [1] to [ 3 ] above.
[ 5 ] The method for manufacturing a bathroom washing area floor member according to any one of [1] to [ 4 ] above, wherein the foamed particle molded product is a plate-shaped body having a substantially rectangular shape in plan view.
[ 6 ] The bottomed recesses are formed along the frame member at intervals of 20 to 80 mm, and the bottomed recesses expose 50 to 80% of the area of the frame member in plan view. The method for manufacturing a bathroom washing area floor member according to any one of [1] to [ 5 ] above, characterized in that:
[ 7 ] Any one of [ 1 ] to [ 6 ] above, characterized in that the bottomed holes are formed at intervals of 20 to 80 mm in an area adjacent to the part where the frame member is buried. The method for manufacturing the bathroom washing area floor member described above.
[ 8 ] The bathroom according to any one of [ 1 ] to [ 7 ] above, wherein the bottomed hole is formed to a depth of 50 to 80% of the thickness of the expanded particle molded body. A manufacturing method for washing area floor components.
[ 9 ] The method for manufacturing a bathroom washing area floor member according to any one of [ 1 ] to [ 8 ] above, wherein the bottomed recess and the bottomed hole are arranged in a staggered manner. .
[ 10 ] The bathroom washing area floor member according to any one of [ 1 ] to [ 9 ] above, wherein the openings of the bottomed recess and the bottomed hole are each substantially circular in plan view. manufacturing method .
[ 11 ] Any one of [1] to [10] above, wherein the thermoplastic resin expanded particle molded product is flat plate-shaped with a length of 300 to 1800 mm, a width of 300 to 1800 mm, and a thickness of 15 to 100 mm. A method for manufacturing a bathroom washing area floor member as described in .
[ 12 ] The bathroom washing area floor member according to any one of [1] to [ 11 ] above, wherein the thermoplastic resin expanded particle molded product has an apparent density of 20 to 200 kg/m ³ . Production method .

According to the above-mentioned bathroom washing area floor member according to the present invention, even if the thick frame member is a flat foamed particle molded product embedded by insert molding, the surface has few irregularities and has excellent surface smoothness. This will be used as a bathroom washing area floor component with a board surface.

FIG. 1 is a conceptual longitudinal cross-sectional view of a typical molding device used for manufacturing the bathroom washing area floor member of the present invention. FIG. 2 is a plan view (design side) of a bathroom washing area floor member according to an embodiment of the present invention. FIG. 3 is a rear view (rear side) of the bathroom washing area floor member shown in FIG. 2; 4 is a cross-sectional view of a portion taken along the line AA in FIG. 3. FIG. FIG. 4 is a cross-sectional view of a portion taken along the line BB in FIG. 3; 1 is a diagram showing a bathroom washing area floor member of Example 1, (a) is a rear view, (b) is a cross-sectional view of a portion along the line AA in (a), and (c) is (a). It is a cross-sectional view of a portion along the BB gland in the figure. 3 is a diagram showing a bathroom washroom floor member in Example 2, (a) is a rear view, (b) is a cross-sectional view of a portion along the line AA in (a), and (c) is (a) It is a cross-sectional view of a portion along the BB gland in the figure. 3 is a diagram showing a bathroom washing area floor member of Example 3, (a) is a rear view, (b) is a cross-sectional view of a portion along the AA gland in (a), and (c) is (a) It is a cross-sectional view of a portion along the BB gland in the figure. It is a figure which showed the washing area floor member of the bathroom of Example 4, (a) is a back view, (b) is a sectional view of the part along the AA gland of (a), (c) is (a) It is a cross-sectional view of a portion along the BB gland in the figure. FIG. 3 is a diagram showing a bathroom washing area floor member of Example 5, (a) is a rear view, (b) is a cross-sectional view of a portion along the AA gland in (a), and (c) is (a). It is a cross-sectional view of a portion along the BB gland in the figure. 3 is a diagram showing a bathroom washing area floor member of Comparative Example 1, (a) is a rear view, (b) is a cross-sectional view of a portion along the AA gland in (a), and (c) is (a) It is a cross-sectional view of a portion along the BB gland in the figure. FIG. 2 is a diagram showing a washing area floor member of a bathroom in Comparative Example 2, (a) is a rear view, (b) is a cross-sectional view of a portion along the line AA in (a), and (c) is (a). It is a cross-sectional view of a portion along the BB gland in the figure.

Hereinafter, the bathroom washing area floor member according to the present invention will be explained in detail.

The bathroom washing area floor member (hereinafter sometimes simply referred to as a floor member) according to the present invention includes a plate-shaped thermoplastic resin foamed particle molded body and a long length of the foamed particle molded body embedded in the foamed particle molded body by insert molding. A bathroom washroom floor member consisting of a frame member, and even if the thick frame member is a flat foamed particle molded product embedded by insert molding, the board has less unevenness on the surface and has excellent surface smoothness. It is used as a washing area floor member in a bathroom with a surface.

The reason why the floor member of the present invention has excellent surface smoothness is not clear, but it is thought to be as follows.
When a frame member is inserted into a foamed particle molded body and molded, the foamed particles and the frame member are simultaneously heated in a heating step, and then the expanded particles are cooled in a cooling step. At this time, since the frame member is buried inside the foamed particle molded body, it is difficult to cool down and is in a high temperature state. Therefore, it is thought that the foamed particles around the insert member undergo tertiary foaming due to the heat of the frame member, and as a result, bulges occur on the surface and the surface smoothness is impaired.
According to the floor member of the present invention, a plurality of bottomed recesses are formed along the longitudinal direction of the embedded frame member on one plate surface (sometimes referred to as the back surface in this specification) of the foamed particle molded body. In addition, since a part of the frame member is exposed by the bottomed recess, the frame member is efficiently cooled in the cooling process, and tertiary foaming of foamed particles around the insert member can be suppressed. It is considered that the surface (sometimes referred to as a design surface in this specification) opposite to the plate surface on which the bottomed recess is formed has excellent surface smoothness.

The thermoplastic resin constituting the foamed particle molded article can be selected as appropriate, but examples include polyolefin resins such as polystyrene resins, polyethylene resins, and polypropylene resins, polybutylene succinate, polyethylene terephthalate, polylactic acid, etc. Examples include polyester resins, polycarbonate resins, and the like. Other examples include composite resins of polystyrene resins and polyolefin resins, mixtures of two or more of the above resins, and the like. Among these, polyolefin resins and composite resins of polystyrene resins and polyolefin resins are preferred from the viewpoint of lightness and strength. Among these, polyethylene resins and polypropylene resins are preferred, and polypropylene resins are more preferred. Further, since a foamed particle molded body made of a thermoplastic resin containing a crystalline resin such as polyethylene or polypropylene has a large shrinkage rate after molding, it is easier to obtain the effects of the present invention.

The foamed particle molded article can be manufactured by molding the foamed particles of the thermoplastic resin in a mold. Expanded particles can be manufactured by a known method for manufacturing this type of expanded particles. For example, if necessary, a dispersant such as a surfactant or an inorganic powder is added to the required amount of dispersion medium (usually water) in a pressurized airtight container such as an autoclave, and then the thermoplastic resin particles are prepared. After dispersion, the blowing agent is press-fitted and stirred under heating to impregnate the resin particles with the blowing agent. After a predetermined period of time, the resin particles impregnated with the blowing agent are transferred together with the dispersion medium from the container under high temperature and high pressure conditions to a low pressure area. It is produced by a method such as releasing the foam into the air (usually under atmospheric pressure) and foaming it to obtain foamed particles. The foamed particles that have been foamed in advance in this way are filled into a mold and then molded in the mold by introducing heated steam.The foamed particles undergo secondary foaming, and the surfaces of the foamed particles melt and become integrated, resulting in foaming. A particle molded body can be obtained.

The frame member used in the present invention has a thickness of more than 8 mm. Since the frame member is a thick frame member having a thickness exceeding 8 mm, the floor member has excellent rigidity. The thickness of the frame member is preferably 9 to 30 mm, more preferably 10 to 25 mm, from the viewpoint of rigidity, lightness, etc.
Conventionally, thick frame members exceeding 8 mm in thickness have a large heat capacity and are difficult to cool, so foamed particle molded bodies in which such frame members are embedded by insert molding are likely to have unevenness on the surface. According to the present invention, even when a thick frame member is inserted, the frame member is efficiently cooled, so that a floor member with excellent surface smoothness can be obtained.
Note that the thickness of the frame member is the thickness (height) in the thickness direction of the plate-shaped expanded particle molded body to be embedded.

The material of the frame member is not particularly limited as long as it is normally used as a frame member for flooring members, and examples include metal frame members made of iron, aluminum, copper, etc., engineering plastics, glass fiber reinforced resin, etc. Examples include resin frame members made of. Among these, those made of metal are preferred from the viewpoint of strength and the like. Moreover, the frame member can be used by processing a long member of any shape, such as a rod shape, a tube shape, a plate shape, or the like. Among these, plate-shaped ones are preferable from the viewpoint of further improving strength.

When using a plate-like frame member, from the viewpoint of improving strength, it is preferably rectangular in top view with dimensions of 250 to 1750 mm in length, 8 to 60 mm in width, and over 8 mm in thickness, and has a length of 450 mm. More preferably, the width is 15 to 40 mm, and the thickness is 9 to 30 mm.

The floor member of the present invention is formed from a foamed particle molded body in which the frame member is integrally molded with the foamed particles, and the frame member is embedded.
Below, the forming process of the floor member of the present invention will be explained using FIG. 1.

FIG. 1 shows a typical molding apparatus used for manufacturing the floor member of the present invention. The molding device 1 is composed of a pair of molds 2 for molding a floor member and a steam chamber 3. The mold 2 is equipped with a filling device 4 for filling foamed particles, and a heated steam A core vent 5 is provided for permeation of air and discharge of air. The mold 2 is made of metal with good thermal conductivity, such as iron, aluminum, or the like.

The manufacturing process of the floor member includes the steps of placing the frame member 20 in the mold 2, filling the foam particles P, heating, cooling, and releasing the mold.
First, as for the arrangement of the frame member 20, the frame member 20 is arranged on one side of the mold 2 and the mold is clamped. Next, foamed particles P are filled into the mold 2 from the filling device 4 .
In this state, heated steam H is supplied into the steam chamber 3 and introduced into the mold 2 through the core vent 5 of the mold 2 to cause secondary foaming of the foamed particles P, thereby creating voids between the foamed particles. bury them and fuse them together. Through this heating process, a foamed bead molded body is formed within the mold 2, and the frame member 20 is fused and integrated with the foamed bead molded body embedded therein.
Next, after cooling the mold 2 by a method such as supplying cooling water W, the mold is released and taken out from the mold 2 to obtain a molded floor member.

The shape of the floor member (expanded particle molded product) of the present invention is preferably a plate-like shape that is approximately rectangular in plan view, as shown in FIGS. 2 to 5. In this case, the dimensions of the floor member (expanded particle molded body) 10 are preferably flat plate-like, with a length of 300 to 2000 mm, a width of 300 to 1800 mm, and a thickness of 15 to 100 mm; , it is more preferable to have a flat plate shape with a thickness of 20 to 70 mm. In the illustrated embodiment, the floor member (foamed particle molded body) 10 is formed into a flat plate shape with a length of 500 mm, a width of 300 mm, and a thickness of 30 mm.

It is preferable that the frame member 20 is embedded along the longitudinal direction of the floor member (foamed particle molded body) 10, and furthermore, a plurality of frame members are embedded in the floor member, and the plurality of frame members More preferably, at least one of them is embedded along the longitudinal direction of the expanded particle molded body. In this case, it is preferable that the frame member 20 is embedded within a range of at least 50 to 99%, and preferably 70 to 99%, when the length in the longitudinal direction of the floor member (expanded particle molded body) 10 is taken as 100%. It is more preferable that the amount of embedding is within a range of 10%. In the illustrated embodiment, two frame members 20 each having a length of 450 mm are buried in parallel along the longitudinal direction of a floor member (foamed particle molded body: length 500 mm) 10, ) A frame member 20 is embedded in an area covering 90% of the length of the frame 10 in the longitudinal direction.

Further, the buried frame member 20 preferably has a thickness that accounts for 20 to 60%, and preferably 30 to 50%, when the thickness of the floor member (expanded particle molded body) 10 is 100%. It is more preferable that there be. When such a thick frame member 20 is inserted, surface irregularities tend to occur, and the effects of the present invention are noticeable. In the illustrated embodiment, a frame member 20 with a thickness of 12 mm is embedded in a floor member (foamed particle molded body: 30 mm thick) 10, and the frame member 20 has a thickness that accounts for 40% of the thickness of the foamed particle molded body 10. It is buried.

It is preferable that the frame member 20 is embedded in the center of the expanded particle molded body 10 in the thickness direction. In this case, the frame member can be reliably embedded in the foamed particle molded body, resulting in better strength from the viewpoint of strength. Furthermore, surface irregularities can be further suppressed.

The floor member (foamed particle molded product) 10 according to the present invention has a plurality of bottomed recesses 30 formed on one plate surface (back surface) of the foamed particle molded product along the embedded frame member 20. A portion of the frame member 20 is exposed through the bottom recess 30. This bottomed recess 30 is formed by the protrusion 6 formed on the mold 2 in the manufacturing process described above, and since the frame member 20 is exposed by the bottomed recess 30, it is difficult to use in the cooling process. Since the cooling is strengthened and tertiary foaming of the foamed particles is suppressed, the molded body has reduced surface irregularities even though the thick frame member 20 is inserted.

The bottomed recesses 30 are formed at intervals of 10 to 80 mm along the frame member 20, and when the total area of the frame member 20 in a plan view due to the bottomed recesses 30 is taken as 100%, Preferably, 50 to 80% of the frame member 20 is exposed in plan view. By forming the bottomed recess 30 within the above range, the frame member 20 can be efficiently cooled while maintaining the strength of the floor member (foamed particle molded product) 10, and surface irregularities can be more easily suppressed. Become. From this point of view, the bottomed recesses 30 are formed along the frame member 20 at intervals of 20 to 70 mm, and the total area of the frame member 20 in plan view is made 100% by the bottomed recesses 30. In some cases, it is more preferable that 55 to 70% of the frame member 20 is exposed in plan view. The interval between the bottomed recesses 30 is the distance between the end of the bottomed recess 30 and the end of the bottomed recess 30 located closest to the bottomed recess 30 on the bottomed recess side. d ₁ (see Figure 3).

Moreover, it is preferable that the opening of the bottomed recess 30 to be formed is approximately circular in plan view from the viewpoints of filling properties, mechanical strength, moldability, etc. of the expanded particles. In the illustrated embodiment, seven bottomed recesses 30 having circular openings with a diameter of 40 mm are formed at intervals of 20 mm along the buried frame member 20, and occupy 67% of the frame member 20 in plan view. Parts are exposed.

The bottomed concave portion 30 is bottomed from the viewpoint of obtaining the floor member (foamed particle molded product) 10 with excellent surface smoothness in the design surface. In addition, the depth is preferably 5 to 90 mm, more preferably 10 to 60 mm, from the viewpoint of the relationship with the thickness of the frame member, strength, filling properties of expanded particles, moldability, etc.

The floor member (foamed particle molded product) 10 according to the present invention is located on the same board surface (back surface) as the board surface in which the bottomed recess 30 is formed, and in an area adjacent to the part where the frame member 20 is buried. , it is preferable that a plurality of bottomed holes 40 are formed. This bottomed hole 40 is formed by the convex portion 6 formed on the mold 2 in the manufacturing process described above. By forming the bottomed hole 40 in the non-insert part adjacent to the frame member, shrinkage of the foamed particle molded product in that part is suppressed, surface irregularities on the design surface are further reduced, and the design is more excellent. It becomes a molded body.
Note that the area adjacent to the part where the frame member is buried refers to the area up to 40 mm lateral to the buried part of the frame member. In the region adjacent to the part where the frame member is buried, at least a part of the bottomed hole may be formed in a region up to 40 mm lateral to the end of the frame member.

The reason why the floor member (expanded particle molded product) 10 of the present invention has even better surface smoothness by having the bottomed holes 40 is not clear, but it is thought to be as follows.
When molding a frame member by inserting it into a foamed particle molded product, the thickness of the molded product at the top of the frame member (the thickness of the part from the design surface of the molded product to the frame member) is equal to or smaller than the area adjacent to the embedded part of the frame member. It is thinner than the thickness of the non-insert portion (total thickness of the molded body). The shrinkage rate of a foamed particle molded object is determined by the base resin, so it is a constant value regardless of the thickness of the molded object, but the amount of shrinkage of a foamed particle molded object increases as the thickness of the molded object increases. . Therefore, the amount of shrinkage in the non-insert portion is large, and sink marks are likely to occur in the molded product. In particular, when a thick frame member is inserted, the difference in the amount of shrinkage between the non-inserted part and the inserted part becomes large, so it is thought that the surface smoothness is more likely to be impaired.
When the floor member of the present invention has the above-mentioned bottomed hole, the thickness of the non-insert part is thin, and the difference between the thickness of the non-insert part and the thickness of the molded body on the upper part of the frame member is small. Therefore, it is thought that shrinkage of the expanded particle molded product is suppressed and surface irregularities on the designed surface are further reduced.

It is preferable that the bottomed holes 40 have an opening area of 500 to 3000 mm ² and are formed at intervals of 10 to 80 mm in a region adjacent to the part where the frame member 20 is buried. By forming the bottomed holes 40 in the above range, the strength of the floor member (expanded particle molded product) 10 is maintained, shrinkage of the non-insert portion is suppressed, and the floor member has a plate surface with better surface smoothness. becomes. From this point of view, it is more preferable that the bottomed holes 40 have an opening area of 800 to 2000 mm ² and are formed at intervals of 20 to 70 mm in a region adjacent to the part where the frame member is buried.
The distance between the bottomed holes is the distance between the end of the bottomed hole and the end of the bottomed hole located closest to the bottomed hole on the bottomed hole side.

Further, the bottomed hole 40 is preferably formed to have a depth of 50 to 80% when the thickness of the floor member (expanded particle molded body) 10 is 100%. By forming the bottomed holes 40 in the above range, while maintaining the strength of the floor member (foamed particle molded product) 10, the amount of shrinkage in the non-insert part is suppressed well, and the thickness of the non-insert part and the frame Since the difference in thickness from the molded body on the upper part of the member can be reduced, this combined with the effect of the bottomed recess 30 results in a floor member having a plate surface with better surface smoothness. Furthermore, even when the expanded particle molded product is thick, surface irregularities due to shrinkage can be suppressed well. From this point of view, it is more preferable that the bottomed hole 40 is formed to have a depth of 55 to 70% when the thickness of the floor member (expanded particle molded body) 10 is 100%.
From the same point of view, when inserting and molding the frame member 20 into the foamed particle molded body 10, the thickness D _i of the molded body at the upper part of the frame member (thickness of the portion from the design surface of the molded body to the frame member), The ratio (D _n /D _i ) of the molded body above the bottomed hole formed in the region adjacent to the buried part of the frame member to the thickness D _n (see FIG. 4) is 0.5 to 1.5. It is preferably from 0.8 to 1.2.

Further, it is preferable that the opening of the bottomed hole 40 to be formed has a substantially circular shape in plan view from the viewpoint of fillability, moldability, etc. of the expanded particles. In the illustrated embodiment, eight bottomed holes 40 each having a circular opening with a diameter of 40 mm and a depth of 19 mm are provided in an area of 20 mm on both sides of the buried portion of the frame member 20 in parallel with the frame member 20. They are formed at intervals, and are formed at a depth of 63% of the thickness of the floor member (foamed particle molded body) 10.

The bottomed holes 40 are bottomed from the viewpoint of obtaining the floor member (foamed particle molded product) 10 with excellent surface smoothness in the design surface. Further, the depth is preferably 5 to 90 mm, and preferably 10 to 60 mm, from the viewpoint of the relationship with the thickness of the molded body on the upper part of the frame member, strength, foamed particle filling property, moldability, etc. More preferred.

The bottomed recesses 30 and the bottomed holes 40 formed on one plate surface (back surface) of the floor member (foamed particle molded body) 10 are arranged in a staggered manner to maintain the strength of the floor member. It is preferable from the viewpoint of improving the smoothness of the designed surface. A preferred staggered range is a straight line connecting the midpoints of any bottomed recess 30 and the bottomed hole 40 disposed closest to the bottomed recess 30, and the center of either one. The angle θ (see FIG. 3) between the embedded frame member 20 passing through the point and a straight line perpendicular to the longitudinal direction is 10 to 45 degrees, more preferably 15 to 40 degrees. In the illustrated embodiment, the bottomed recesses 30 and the bottomed holes 40 are arranged in a staggered manner with the angle θ of 30°.

The floor member of the present invention may be provided with thinning, ribs, etc. in areas other than the bottomed recesses and bottomed holes for the purpose of attachment to other members, increased rigidity, weight reduction, etc., but the floor member has excellent surface smoothness. From the viewpoint of obtaining a floor member having a design surface, it is preferable not to provide anything that penetrates the molded body in the thickness direction.

The apparent density of the expanded particle molded product is preferably 20 to 200 kg/m ³ , more preferably 50 to 170 kg/m 3 , and more preferably 70 to 170 kg/m ³ from the viewpoint of providing a floor member with excellent strength and light weight. More preferably, it is 150 kg/m ³ . In the case of a foamed particle molded article made of polyolefin resin, the weight is preferably 80 to 140 kg/m ³ , more preferably 90 to 130 kg/m ³ . Further, a plurality of foamed bead molded bodies having different apparent densities may be combined to form one foamed bead molded body. In this case, it is sufficient that the average apparent density of the entire expanded particle molded product is within the above range. The apparent density of the foamed bead molded product can be determined by a submersion method in which the foamed bead molded product is submerged in water and measured.
Generally, the lower the apparent density of a foamed particle molded product, the greater the shrinkage of the molded product. According to the present invention, sink marks can be suppressed even in a foamed particle molded product having a low apparent density, resulting in a floor member that is excellent in lightness, mechanical strength, and surface smoothness.

According to the floor member (foamed particle molded product) 10 according to the present invention described above, a plurality of bottomed recesses 30 are formed along the frame member 20 embedded in one plate surface of the foamed particle molded product, Since a part of the frame member 20 is exposed by the bottomed recess 30, the cooling of the frame member 20 in the cooling process is strengthened and tertiary foaming of foamed particles is suppressed, so that the thick frame member 20 is Even though it is inserted, the molded product has reduced surface irregularities.
Further, in the case where a plurality of bottomed holes 40 are formed in the same plate surface as the bottomed recess 30 and adjacent to the area where the frame member 20 is buried. In this case, the shrinkage of the expanded particle molded product in the non-insert portion of the frame member 20 is suppressed, and in combination with the effect of the bottomed recess 30, the molded product has an excellent design with further reduced surface irregularities.

Examples of the floor member according to the present invention will be described below together with comparative examples, but the present invention is not limited to these examples in any way.

In the molding apparatus 1 shown in FIG. 1, a frame member (iron hollow frame member, length 450 mm, width 25 mm, thickness 12 mm, wall thickness 1.2 mm) 20 is placed in a pair of molds 2, the molds are clamped, and foaming is performed. Particles (polypropylene resin foamed particles, apparent density 90 kg/m ³ , expanded particle diameter approximately 1.5 mm) P were filled into the mold 2 from the filling device 4 . Subsequently, heated steam H is supplied into the steam chamber 3 and introduced into the mold 2 through the core vent 5 of the mold 2 to cause secondary foaming of the foamed particles P and to close the voids between the foamed particles. In-mold molding was performed using steam heating to bury and fuse each other.
The heating method is to preheat (exhaust process) by supplying heated steam H for 5 seconds with the drain valves of both sides of the mold open, and then reduce the molding steam pressure (usually 0.3 MPa (G)) to 0. After heating while supplying heating steam H at a pressure lower than 0.08 MPa (G), and further heating while supplying heating steam H from the opposite direction at a pressure lower than the molding steam pressure by 0.04 MPa (G), Main heating was performed for 3 seconds by supplying heating steam H from both sides at the molding steam pressure.
After heating, the pressure was released, cooling water W was supplied, water cooling was performed for 60 seconds, and then air cooling was performed for 5 seconds to obtain a floor member made of a polypropylene resin foam particle molding in which the frame member 20 was embedded. In addition, the mold 2 was provided with various convex parts 6, and a floor member 10 was obtained in which various bottomed recesses 30 and bottomed holes 40 were formed on one plate surface of the foamed particle molded body.
Next, the floor member taken out from the mold and having various bottomed recesses and bottomed holes formed on one plate surface was dried and cured in an atmosphere at 60° C. for 12 hours.

Each of the obtained floor members had dimensions of 500 mm in length, 300 mm in width, and 30 mm in thickness, an apparent density of the foamed particle molded product of 105 kg/m ³ , and a ratio of 67% to the thickness of the molded product of the frame member. , seven types (Examples 1 to 5, comparative Examples 1 and 2).
In Table 1, the value shown in the "distance" column for the bottomed hole means the distance between the end of the bottomed hole and the end of the frame member located closest to the bottomed hole.

For each floor member (Examples 1 to 5, Comparative Examples 1 and 2), calculate the dimensional error at each point a to e of the AA cross section and BB cross section shown in Figures 6 to 12, and calculate the dimensional error. The values are listed in Table 2.
In addition, the above-mentioned dimensional error was determined by the following procedure.
The dimensional error was determined by three-dimensionally measuring the floor member and measuring the amount of positional deviation from the CAD drawing. Three-dimensional measurement was performed using ATOS CORE500 manufactured by GOM. The measured value (unit: mm) was defined as a positive value (surface convexity) when it was thicker than the CAD drawing dimension, and a negative value (surface concaveness) when it was thinner than the CAD drawing dimension.

The dimensional error values were evaluated according to the following criteria for each positive value and negative value, and the evaluations were written together with each dimensional error value.
Plus value ◎: ~0.15mm
○:0.16mm~0.20mm
△:0.21mm~0.30mm
×: 0.31mm~
Negative value ◎: ~-0.09mm
○:-0.10mm~0.15mm
△:-0.16mm~0.20mm
×: -0.21mm~
Note that a negative value means that sink marks have occurred in the molded product. In areas where sink marks occur, air bubbles tend to collapse easily, and there is a strong possibility that the compressive strength will decrease, so strict evaluation criteria were set.

Furthermore, the appearance of each floor member (Examples 1 to 5, Comparative Examples 1 and 2) was evaluated using the following criteria, and the evaluations are listed in Table 2.
○: Surface irregularities cannot be recognized when observing the appearance of the molded product. ×: Surface irregularities can be recognized when observing the appearance of the molded product.

From Table 1, it can be seen that Examples 1 to 5 in which the bottomed recesses 30 were formed had superior surface smoothness and better appearance than Comparative Examples 1 and 2 in which the bottomed recesses were not formed.
Further, it can be seen that Examples 1 to 4 in which the bottomed hole 40 was formed in addition to the bottomed recess 30 had better surface smoothness.

The bathroom washing area floor member according to the present invention has a plate surface with few surface irregularities and excellent surface smoothness even if it is a flat foamed particle molded product in which a thick frame member is embedded by insert molding. It becomes a floor component. Therefore, the bathroom washing area floor member of the present invention can be suitably used as a floor material in a bathroom structure, and a cushioning material or a skin material can be satisfactorily laminated on the board surface (design surface).

1 Molding device 2 Mold 3 Steam chamber 4 Filler 5 Core vent 6 Convex portion 10 Bathroom washing area floor member (foam particle molded product)
20 Frame member 30 Bottomed recess 40 Bottomed hole P Foamed particles H Heating steam W Cooling water

Claims (12)

A bathroom washing area floor member comprising a plate-shaped thermoplastic resin foam particle molded body and a long frame member embedded in the foamed particle molded body , which is manufactured by insert molding of the frame member. In the manufacturing method of
The thickness of the above frame member exceeds 8 mm,
A plurality of bottomed recesses are formed along the longitudinal direction of the embedded frame member on one plate surface of the foamed particle molded body, and a part of the frame member is exposed by the bottomed recess , and
A plurality of bottomed holes are formed in the same plate surface as the bottomed recess formed in the area adjacent to the part where the frame member is buried,
A method of manufacturing bathroom washing area floor components. The production of a bathroom washing area floor member according to claim 1, wherein the thickness of the frame member embedded in the foamed particle molded body is 20 to 60% of the thickness of the foamed particle molded body. Method . 3. The method of manufacturing a bathroom washing area floor member according to claim 1 , wherein the frame member is embedded along the longitudinal direction of the foamed particle molded body . A plurality of the frame members are embedded in the foamed particle molded body, and at least one of the plurality of frame members is embedded along the longitudinal direction of the foamed particle molded body. Item 3. A method for manufacturing a bathroom washing area floor member according to any one of Items 1 to 3. The method for manufacturing a bathroom washing area floor member according to any one of claims 1 to 4 , wherein the foamed particle molded body is a plate-like body having a substantially rectangular shape in plan view . The bottomed recesses are formed along the frame member at intervals of 10 to 80 mm, and the bottomed recesses expose 50 to 80% of the area of the frame member in plan view. The method for manufacturing a bathroom washing area floor member according to any one of claims 1 to 5, characterized by: The bathroom washing floor according to any one of claims 1 to 6 , wherein the bottomed holes are formed at intervals of 10 to 80 mm in a region adjacent to a region where the frame member is buried. Method of manufacturing parts. Manufacturing a bathroom washing area floor member according to any one of claims 1 to 7 , wherein the bottomed hole is formed to a depth of 50 to 80% of the thickness of the foamed particle molded body . Method . 9. The method of manufacturing a bathroom washing area floor member according to claim 1 , wherein the bottomed recess and the bottomed hole are arranged in a staggered manner . 10. The method for manufacturing a bathroom washing area floor member according to claim 1 , wherein the openings of the bottomed recess and the bottomed hole are each substantially circular in plan view . A bathroom washing area according to any one of claims 1 to 10, characterized in that the thermoplastic resin foamed particle molded product has a flat plate shape with a length of 300 to 1800 mm, a width of 300 to 1800 mm, and a thickness of 15 to 100 mm. Method for manufacturing floor components. The method for manufacturing a bathroom washing area floor member according to any one of claims 1 to 11 , wherein the thermoplastic resin expanded particle molded product has an apparent density of 20 to 200 kg/m ³ .

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