JPS6133113B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a prefabricated bathroom unit.

When assembling a conventional unit-type bathroom,
As shown in Fig. 1, the wall panel 1 is placed along the indoor side of the pillar material 2, and the wall panels 1 are connected to each other using the connecting fittings 3, 4, 5 and wood screws 6, and fixed to the pillar material 2. After that, the inner surfaces of the connecting fittings 3 and 4 were filled with synthetic resin joint material 7 and assembled. As a result, the waterproofness is incomplete, and the only part without the pillar material 2 is the wall panel 1, so the wall panel 1 needs to be rigid, and the connection fittings 3, 4, and 5 must also be thick and durable. Moreover, since the thick connecting fittings 3 and the synthetic resin joint material 7 appear on the inner surface, there is a drawback that the fittings are unsightly. Furthermore, in the past, there were completely waterproof bathroom units made of fiber-reinforced plastics (hereinafter referred to as "FRP"), but they had the disadvantage of not being comfortable in terms of design.

This invention uses tiles, decorative calcium silicate boards, aluminum polyethylene composite boards, etc. commonly used as bathroom interior materials to create a completely waterproof bathroom unit.

Next, one embodiment of this invention will be explained.
As shown in FIGS. 3 and 3, the floor surface of the bathroom unit has a width, and a peripheral edge rising part 10 is formed around the entire circumference, and the peripheral edge rising part 10 is bent further outward and upward from the upper edge. Then, a rectangular dish-shaped waterproof pan 8 with a bent overhang 13 formed with a hemmed upper edge is placed horizontally, and a column-shaped temporary frame is placed at the four inner corners of the waterproof pan 8 and at a suitable location between the rising edges 10. 9
are erected vertically with their lower parts abutting the peripheral edge rising portions 10 of the waterproof pans 8, and the support plates 11 are temporarily fixed between the inner sides of the temporary frames 9 to hold all the temporary frames 9 in a vertical state. Do it like this.

Next, a waterproof decorative wall panel 12 is placed between the outer sides of the temporary frame 9 with their side edges adjacent to each other, and the lower edge of the decorative wall panel 12 is made waterproof as shown in FIG. The decorative wall panel 12 is erected by falling between the inside of the bent overhang 13 of the pan 8 and the outside of the temporary frame 9. Then, as shown in FIG. 5, the water-resistant decorative ceiling panel 14 is placed with its edge along the upper edge of the decorative wall panel 12. Then, a corner metal fitting 16 shown in FIG. 5, the iron wire 15 is stretched along the outer upper surface of the decorative ceiling panel 14, and the iron wire 15 is also stretched between the diagonally located corner fittings 16, 16 to make it waterproof. Pan 8, decorative wall panel 12, and decorative ceiling panel 1
4 and tied up. A hole 17 through which the iron wire 15 is inserted is bored in the rim of the bent overhang 13 of the waterproof pan 8, as shown in FIGS. 2 to 4, and the corner fitting 16 shown in FIG. A hole 18 is bored through which the hole 15 is inserted.

In the embodiment shown in FIG. 5, two decorative ceiling panels 14 are joined by a joining plate 19, and the iron wire 15 can also be secured to the end of the joining plate 19. In FIG. 5, reference numeral 20 denotes an entrance, and the decorative wall panel 12 is not installed here.

After binding the waterproof pan 8, the decorative wall panel 2, and the decorative ceiling panel 14 with the iron wire 15 and the corner fittings 16, the decorative wall panel 12 and the decorative ceiling panel 1 are tied together.
FRP is laminated on the entire surface of 4, and the iron wire 15 and corner fittings 16 are embedded in the FRP. At this time, the fourth
As shown in the figure, the bending protrusion 13 of the waterproof pan 8 is also
It is embedded in FRP21.

After leaving it as it is to harden the FRP, remove the support plate 11 (see Figures 2 and 3) from the temporary frame 9, and attach the support plate 11 and the temporary frame 9 to the entrance part 20 (see Figure 5).
When the door 22 is attached to the entrance section 20 as shown in FIG.
The bathroom unit covered with 21 is completed.

FIG. 8 is an enlarged sectional view when an aluminum polyethylene composite board is used as the decorative wall panel 12, and 23 is used to protect the edges of the aluminum polyethylene composite board from chipping and to prevent the corners from being directly exposed inside. This is an aluminum edge decoration to make it look like this, and can be omitted.

FIG. 9 is an enlarged sectional view of the bathroom interior when the interior is tiled, and a base material 27 such as water-resistant plywood or calcium silicate board is used as the decorative wall panel 26.
Either the tiles 24 are placed on the inner surface of the waterproof pan 8 in advance and the tiles 24 are placed upright on the rising edge 10 of the waterproof pan 8, or the tiles 24 are placed after the FRP 21 has hardened.
Paste 4. 25 is joint cement.

The manufacturing method of the present invention has the following effects.

(1) The outer surface is covered with FRP, making it completely waterproof.

(2) Because decorative wall panels and decorative ceiling panels are assembled and fixed using temporary frames, iron wire, and corner metal fittings, there is no need to use unsightly connecting metal fittings at the joints of decorative wall panels and decorative ceiling panels. Even if you use a corner, it should be something with a narrow width that is mainly used for decoration.

(3) To cover the outer surface with FRP and harden it,
The stiffness of the decorative wall panel and the decorative ceiling panel itself may be small.

(4) Since the iron wires and corner fittings that bind the bent overhang of the waterproof pan and the outer four corners of the decorative wall panel and decorative ceiling panel are buried in fiber-reinforced plastic, the strength of the fiber-reinforced plastic is improved. It also becomes more expensive.

(5) Since waterproof fiber-reinforced plastics are laminated on the outer surface, good-looking materials such as tiles, decorative calcium silicate boards, and aluminum-polyethylene composite boards are used as decorative wall panels and decorative materials for bathroom interiors. It can be used as a ceiling panel in a wide range of widths, allowing for a comfortable design.

(6) Assembling decorative wall panels and decorative ceiling panels using temporary frames and support plates, and laminating fiber-reinforced plastics on their outer surfaces, it is necessary to fasten the joints of decorative wall panels and decorative ceiling panels with connecting metal fittings. Since there are no holes, assembly man-hours are reduced.

(7) Since the decorative wall panels and decorative ceiling panels are assembled and held using the temporary frame and support plate, and the fiber-reinforced plastics are laminated and cured directly on the outer surface, a mold for molding the fiber-reinforced plastics is not required. , can be manufactured at low cost.

[Brief explanation of the drawing]

Fig. 1 is a partial cross-sectional plan view of a conventional bathroom unit, Fig. 2 is a plan view of the present invention with the decorative wall panel erected, and Fig. 3 is a partial perspective view of the temporary frame erected. Figure 4 is a vertical sectional view showing the relationship between the lower part of the decorative wall panel and the edge of the waterproof pan, Figure 5 is a perspective view showing the state in which it is tied up with a tightening tool, and Figure 6 is a vertical sectional view showing the relationship between the lower part of the decorative wall panel and the edge of the waterproof pan.
The figure is a perspective view of a corner fitting, FIG. 7 is a perspective view showing an example of a bathroom unit completed by the manufacturing method of the present invention, and FIGS. 8 and 9 are A-A in FIG.
FIG. 8... Waterproof pan, 9... Temporary frame, 10... Peripheral rising portion, 11... Support plate, 12, 26... Decorative wall panel, 13... Bent overhang, 14... Decorative ceiling panel, 15 ... Iron wire, 16 ... Corner fitting, 2
1...Fiber reinforced plastics (FRP).

Claims (1)

[Claims] 1. A rectangular dish-shaped waterproofing unit that has the floor area of a bathroom unit, has a rising edge around its entire circumference, and has a bent overhang extending outward and upward from the upper edge of the rising edge. Place the pan horizontally, place a column-shaped temporary frame vertically at the four inner corners of the waterproof pan and the middle of the rising edge of the pan, with the lower part of the frame in contact with the rising edge of the outer edge, and place between the inner sides of the temporary frames. All temporary frames are held vertically by temporarily fixing the support plates, and water-resistant decorative wall panels are placed between the outer sides of the temporary frames with their side edges adjacent to each other, and the decorative wall panels are The lower end edge of the waterproof pan is placed between the inside of the bent overhang and the outside of the temporary frame, and the water-resistant decorative ceiling panel is horizontally placed along the upper end edge of the decorative wall panel. corner metal fittings are applied to the outside of the four corners of the decorative wall panel and the decorative ceiling panel, and a steel wire is stretched diagonally between the corner metal fittings and the bent overhang, and the outside of the decorative ceiling panel is The waterproof pan, the decorative wall panel, and the decorative ceiling panel are tied together by stretching iron wire between the corner fittings located diagonally along the upper surface, and the bent overhang of the waterproof pan, the decorative wall panel, and the decorative ceiling are connected. Laminating and curing fiber-reinforced plastic so that the iron wire and corner fittings are embedded in the entire outer surface of the panel,
A method of manufacturing a bathroom unit, comprising removing the support plate and the temporary frame after the fiber-reinforced plastic is cured.