WO2021085195A1 - Wet-area member and method for manufacturing wet-area member - Google Patents

Wet-area member and method for manufacturing wet-area member Download PDF

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Publication number
WO2021085195A1
WO2021085195A1 PCT/JP2020/039189 JP2020039189W WO2021085195A1 WO 2021085195 A1 WO2021085195 A1 WO 2021085195A1 JP 2020039189 W JP2020039189 W JP 2020039189W WO 2021085195 A1 WO2021085195 A1 WO 2021085195A1
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WO
WIPO (PCT)
Prior art keywords
water
floor pan
film
base material
decorative film
Prior art date
Application number
PCT/JP2020/039189
Other languages
French (fr)
Japanese (ja)
Inventor
亮太 喜多
浅地　正博
揖斐　秀実
功一 増川
真矢 植田
Original Assignee
パナソニックＩｐマネジメント株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by パナソニックＩｐマネジメント株式会社 filed Critical パナソニックＩｐマネジメント株式会社
Priority to JP2021553408A priority Critical patent/JP7253726B2/en
Publication of WO2021085195A1 publication Critical patent/WO2021085195A1/en
Priority to JP2023040492A priority patent/JP2023082019A/en
Priority to JP2023040493A priority patent/JP2023082020A/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/16—Lining or labelling
    • E—FIXED CONSTRUCTIONS
    • E03—WATER SUPPLY; SEWERAGE
    • E03C—DOMESTIC PLUMBING INSTALLATIONS FOR FRESH WATER OR WASTE WATER; SINKS
    • E03C1/00—Domestic plumbing installations for fresh water or waste water; Sinks
    • E03C1/12—Plumbing installations for waste water; Basins or fountains connected thereto; Sinks
    • E03C1/20—Connecting baths or bidets to the wastepipe
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/12—Small buildings or other erections for limited occupation, erected in the open air or arranged in buildings, e.g. kiosks, waiting shelters for bus stops or for filling stations, roofs for railway platforms, watchmen's huts or dressing cubicles

Definitions

  • the present disclosure relates to a water-related member and a method of manufacturing the water-related member, and more particularly to a water-related member and a method of manufacturing the water-related member in which a film having irregularities on the surface is decorated.
  • Patent Document 1 describes a bathroom washroom floor (for example, a water-related member such as a floor pan) provided with a base material and a surface material laminated on the surface side of the base material.
  • the surface of the surface material is formed with irregularities to prevent slipping.
  • the unevenness of the surface of the surface material may shrink and decrease due to the molding heat and tension.
  • An object of the present disclosure is to provide a water-related member and a method for manufacturing the water-related member, which easily form irregularities on the surface.
  • the water-related member includes a water-related base material having a plurality of convex portions on its surface, and a decorative film in close contact with the surface of the water-related base material.
  • the decorative film has a grain material having a diameter of 1 ⁇ m or more and 30 ⁇ m or less and having a softening temperature higher than that of other parts of the decorative film.
  • the method for manufacturing a water-related member includes a pressing step and a close contact step.
  • the pressing step is a step of pressing a decorative film softened by heating against the surface of a water-related base material having a plurality of convex portions on the surface.
  • the close contact step is a step of bringing the decorative film into close contact with the surface of the water-related base material by vacuum forming or vacuum forming.
  • the decorative film has a grain material having a diameter of 1 ⁇ m or more and 30 ⁇ m or less and having a softening temperature higher than that of other parts of the decorative film.
  • the method for manufacturing a water-related member includes a pressing step, a close contact step, and a coating step.
  • the pressing step is a step of pressing the film body softened by heating against the surface of the water-related base material having a plurality of convex portions on the surface.
  • the close contact step is a step of bringing the film body into close contact with the surface of the water-related base material by vacuum forming or vacuum forming.
  • the coating step is a step of applying a paint containing a granular material having a diameter of 1 ⁇ m or more and 30 ⁇ m or less on the surface of the film body that is in close contact with the water-related base material.
  • FIG. 1 is a perspective view showing a water-related member (floor pan) of the first embodiment.
  • FIG. 2A is an enlarged perspective view showing a portion A of FIG. 1
  • FIG. 2B is a schematic cross-sectional view showing a water circulation member (floor pan) of the same.
  • 3A to 3D are views schematically showing a method of manufacturing the same water-related member (floor pan).
  • FIG. 4 is a schematic cross-sectional view showing the water-related member (floor pan) of the second embodiment.
  • FIG. 5 is a schematic cross-sectional view showing the water-related member (floor pan) of the third embodiment.
  • FIG. 6 is an enlarged perspective view showing a part (a part corresponding to the part A in FIG. 1) of the water-related member (floor pan) of the fourth embodiment.
  • FIG. 7 is a perspective view showing the same water-related member (floor pan).
  • FIG. 8 is a perspective view showing a modified example of the water-related member (floor pan) of the above.
  • the water circulation member (floor pan 1) of the first embodiment shown in FIGS. 1, 2A and 2B includes a water circulation base material (floor pan base material 3) having a plurality of convex portions 2 on the surface 30 and a surface 30.
  • a decorative film 4 that is in close contact with the floor is provided.
  • the decorative film 4 has a grain material 5 having a diameter of 1 ⁇ m or more and 30 ⁇ m or less and having a softening temperature higher than that of other parts of the decorative film 4.
  • the grain material 5 tends to form irregularities on the surface of the decorative film 4, that is, the surface of the water-related member (floor pan 1).
  • the decorative film is used in the water-related member (floor pan 1) of the first embodiment.
  • the other part of 4 softens, but the grain material 5 does not soften. Therefore, in the water-related member (floor pan 1) of the first embodiment, unevenness due to the grain material 5 is likely to be formed on the surface of the decorative film 4, that is, the surface of the water-related member (floor pan 1).
  • the method for manufacturing the water-related member (floor pan 1) of the first embodiment includes a pressing step and a close contact step.
  • the pressing step is a step of pressing the decorative film 4 softened by heating against the surface 30 of the water-related base material (floor pan base material 3) having the plurality of convex portions 2 on the surface 30.
  • the adhesion step is a step of adhering the decorative film 4 to the surface 30 of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming.
  • the decorative film 4 has a grain material 5 having a diameter of 1 ⁇ m or more and 30 ⁇ m or less and having a softening temperature higher than that of other parts of the decorative film 4.
  • the water-related member will be described in detail using the floor pan 1 used for the washroom floor for the bathroom.
  • the floor pan base material 3 has a floor portion 31 having a plurality of convex portions 2 on the upper surface, and a plurality of rising portions 32 rising from the edge portions of the floor portion 31.
  • the plurality of rising portions 32 are continuous so that two adjacent rising portions 32 form a corner.
  • the floor portion 31 has a rectangular shape when viewed from above.
  • the plurality of rising portions 32 have four rising portions 32a, 32b, 32c, and 32d rising from each of the four end sides of the floor portion 31.
  • the four rising portions 32a, 32b, 32c, and 32d are continuous in a rectangular frame shape when viewed from above, and form four corners.
  • the rising portion 32a is a portion rising from the rear end side of the floor portion 31
  • the rising portion 32b is a portion rising from the front end side of the floor portion 31
  • the rising portions 32c and 32d are the floor portions. It is a part that rises from the left and right ends of 31.
  • the rising portions 32b, 32c, 32d have a common shape.
  • the rising portion 32d on the right side will be described in detail.
  • the rising portion 32d has a vertical plate portion 320 protruding upward from the end edge of the floor portion 31 (specifically, the right end edge) and the outer side in the horizontal direction (specifically, the upper end of the vertical plate portion 320). It has a horizontal plate portion 321 protruding to the right side).
  • the rising portion 32d further has a second vertical plate portion 322 protruding upward from the horizontal outer end portion (specifically, the right end portion) of the horizontal plate portion 321.
  • the rear rising portion 32a includes a vertical plate portion 323 protruding upward from the rear end side of the floor portion 31, a horizontal plate portion 324 protruding rearward from the upper end of the vertical plate portion 323, and a pair of left and right inclined plates. It has a part 325 and.
  • both left and right ends are inclined so as to be located downward toward the outer portion in the left-right direction.
  • the remaining portion of the upper end of the vertical plate portion 323 except for the left and right ends is parallel to the floor portion 31.
  • the horizontal plate portion 324 projects rearward from the remaining portion of the upper end of the vertical plate portion 323 except for the left and right end portions.
  • the pair of left and right inclined plate portions 325 project rearward from the left and right end portions of the upper end of the vertical plate portion 323.
  • the pair of left and right inclined plate portions 325 are located downward toward the outer portion in the left-right direction, and are inclined with respect to the horizontal plate portion 324.
  • the pair of left and right inclined plate portions 325 are continuous with both left and right ends of the horizontal plate portion 324.
  • the inclined plate portion 325 on the right side is continuous with the rear end portion of the horizontal plate portion 321 of the rising portion 32d on the right side.
  • the inclined plate portion 325 on the left side is continuous with the rear end portion of the horizontal plate portion 321 of the rising portion 32c on the left side.
  • the four rising portions 32a, 32b, 32c, and 32d are continuous with two adjacent vertical plate portions (vertical plate portions 320, 323 or vertical plate portions 320, 320) forming a corner.
  • Each of the plurality of convex portions 2 has a flat rectangular parallelepiped shape in the present embodiment.
  • Each of the plurality of convex portions 2 has a longitudinal direction parallel to the left-right direction, a lateral direction parallel to the front-rear direction, and a thickness direction parallel to the vertical direction.
  • the plurality of convex portions 2 have the same shape and dimensions.
  • the plurality of convex portions 2 are arranged in a row in the left-right direction and the front-rear direction so as to cover the entire surface (upper surface) of the floor portion 31 and are arranged in a matrix.
  • Each of the plurality of convex portions 2 has an upper surface 20 (tip surface in the protruding direction) and a side surface 21.
  • the upper surface 20 has a rectangular shape (specifically, a rectangular shape) when viewed from above, and the side surface 21 has a pair of rectangular surfaces facing in the front-rear direction and a pair of rectangular surfaces facing in the left-right direction. including.
  • the floor portion 31 has a groove portion 33 which is a portion of the upper surface of the floor portion 31 excluding a plurality of convex portions 2.
  • the groove portions 33 are in a grid pattern when viewed from above.
  • Each of the plurality of convex portions 2 is surrounded by a groove portion 33.
  • the outer peripheral portion (edge portion) of the upper surface of the floor portion 31 is composed of a groove portion 33.
  • the floor pan base material 3 further has a drainage recess 34 located at the center of the rear end of the floor 31 in the left-right direction.
  • the drainage recess 34 is a rectangular recess when viewed from above.
  • the drainage recess 34 has a bottom wall 341 having a rectangular shape in a plan view in which a drainage hole 340 is formed in the center, and three side walls 342 protruding upward from the front end side and the left and right end sides of the bottom wall 341. ..
  • the central portion of the vertical plate portion 323 of the rising portion 32a in the left-right direction projects upward from the rear end side of the bottom wall 341.
  • the three side walls 342 and the vertical plate portion 323 of the rising portion 32a are continuous with adjacent members forming a corner.
  • Each of the left and right side wall 342 has a support portion 343 parallel to the upper surface of the bottom wall 341 at the central portion in the vertical direction.
  • the support portion 343 is a portion that supports a lid that is detachably attached to the drainage recess 34.
  • the floor pan base material 3 is, for example, a resin molded product made of fiber reinforced plastic.
  • the floor pan base material 3 may be formed of an SMC (Sheet Molding Compound) material containing glass fibers, or may be formed of artificial marble containing acrylic or polyester as a main component.
  • SMC Sheet Molding Compound
  • a primer layer 35 formed by applying an isocyanate-based primer is laminated on the surface 30 of the floor pan base material 3.
  • the surface 30 of the floor pan base material 3 means the surface (upper surface) of the floor portion 31, the surfaces of the four rising portions 32a, 32b, 32c, 32d, and the surface of the drainage recess 34.
  • the surfaces of the four rising portions 32a, 32b, 32c, 32d are a surface facing upward of the front and rear rising portions 32a, 32b, a surface facing inward in the front-rear direction, and a surface facing upward of the left and right rising portions 32c, 32d. It means a surface facing inward in the left-right direction.
  • the surface of the drainage recess 34 means an upper surface of the bottom wall 341, a surface facing upward of the left and right side walls 342, a surface facing inward in the left-right direction, and a surface facing the rear side of the front side wall 342.
  • the decorative film 4 is a member that is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum pressure air forming or vacuum forming.
  • the decorative film 4 has a film body 40 having thermoplasticity.
  • the grain material 5 is mixed with the film body 40 and has a softening temperature higher than that of the film body 40.
  • the film body 40 includes a surface layer 41 constituting the surface thereof (that is, the surface of the decorative film 4) and a base layer 42 located on the back side of the surface layer 41.
  • the film body 40 further includes a printing layer 43 located between the surface layer 41 and the base layer 42, and an adhesive layer 44 located on the back side of the base layer 42.
  • the surface layer 41 is formed of, for example, a transparent PMMA (Polymethyl methyllate).
  • the thickness of the surface layer 41 is, for example, 30 ⁇ m or more and 100 ⁇ m or less, and in this embodiment, 50 ⁇ m.
  • the surface layer 41 is not limited to the transparent PMMA, and may be formed of a transparent PMMA containing or alloyed with fluorine, or may be formed of a transparent PVC (polyvinyl chloride). Further, the surface layer 41 may be formed of decorated PMMA, PVC, or ABS (Acrylonirile butadiene style). A plurality of granules 5 are mixed and dispersed in the surface layer 41 so that irregularities are formed on the surface of the surface layer 41.
  • the plurality of granules 5 are mixed only in the portion of the surface layer 41 that covers the floor portion 31 of the floor pan base material 3, and the portion that covers the plurality of rising portions 32 and the drainage recess 34. Is not a mixture of the plurality of granules 5.
  • the grain material 5 is formed of a material that does not deform or is not easily deformed at the heating temperature when the film body 40 is softened by heating.
  • the granule 5 is, for example, an inorganic filler such as silica.
  • the granule 5 is not limited to silica, and may be an inorganic filler such as calcium carbonate or aluminum hydroxide, an acrylic filler, or an organic filler. Further, the grain material 5 may be a combination of the above-mentioned various grain materials 5.
  • the diameter of the grain material 5 is 5 ⁇ m or more and 30 ⁇ m or less.
  • the diameter of the grain material 5 is smaller than 5 ⁇ m, the unevenness appearing on the surface of the film body 40 of the decorative film 4 is small, and the anti-slip function cannot be sufficiently obtained.
  • the diameter of the grain material 5 is larger than 30 ⁇ m, the surface roughness of the film body 40 of the decorative film 4 becomes too large, and the touch is deteriorated.
  • the diameter and amount of the granular material 5 mixed with the surface layer 41 are appropriately set according to the thickness of the surface layer 41 and the required anti-slip function.
  • the surface of the decorative film 4, that is, the surface of the floor pan 1 can be provided with a non-slip function, and the surface of the floor pan 1 can also be provided with pseudohydrophilicity. It is also possible to improve the drainage property of the surface of the floor pan 1.
  • the base layer 42 is made of, for example, hard PVC.
  • the thickness of the base layer 42 is, for example, 50 ⁇ m or more and 250 ⁇ m or less, and 110 ⁇ m in the present embodiment.
  • the base layer 42 is not limited to hard PVC, but may be formed of soft PVC or ABS.
  • the print layer 43 is a layer for displaying a pattern or a color on the surface of the decorative film 4.
  • the pattern and color of the print layer 43 pass through the surface layer 41 and are visible from the surface side of the decorative film 4.
  • the adhesive layer 44 is laminated on the back surface of the base layer 42.
  • the thickness of the adhesive layer 44 is, for example, 50 ⁇ m.
  • the adhesive layer 44 is formed of a PMMA-based adhesive that is difficult to hydrolyze.
  • the adhesive layer 44 is not limited to PMMA-based, and may be formed of an epoxy-based, urethane-based, cyanoacrylate-based, modified silicon-based, or polyester-based adhesive.
  • the above-mentioned decorative film 4 is attached to the surface 30 of the floor pan base material 3 via the primer layer 35 so as to be in close contact with the surface 30.
  • the decorative film 4 is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum forming or vacuum forming, which will be described later.
  • the floor pan 1 is formed by TOM (Three Generation Overlay Method) molding (in other words, vacuum pressure air molding) to bring the decorative film 4 into close contact with the surface 30 of the floor pan base material 3. Manufactured.
  • TOM Three Generation Overlay Method
  • the method for manufacturing the floor pan 1 includes a coating process, an installation process, a depressurizing process, a heating process, a pressing process, an adhesion process, a mold release process, and a cutting process.
  • the floor pan 1 is vacuum compressed air molded using, for example, the molding machines 100 shown in FIGS. 3A to 3C.
  • the molding machine 100 includes an upper chamber 101, a lower chamber 102, a heater 103, a pedestal 104, an elevating device 105, a vacuum tank, and a compressed air tank.
  • the vacuum tank is connected to each of the upper chamber 101 and the lower chamber 102, and the inside of the chambers 101 and 102 can be independently depressurized to a vacuum state.
  • the compressed air tank is connected to the upper chamber 101, and the inside of the upper chamber 101 can be compressed.
  • the upper chamber 101 can be moved between a position where the decorative film 4 is sandwiched between the upper chamber 101 and the lower chamber 102 and a position away from the lower chamber 102.
  • the upper chamber 101 has a box shape with an open lower surface.
  • a heater 103 is installed in the upper chamber 101. The heater 103 can heat the decorative film 4 to a temperature at which the decorative film 4 softens.
  • the lower chamber 102 is a box type with an open upper surface.
  • a pedestal 104 is installed in the lower chamber 102, and the pedestal 104 can be moved up and down by the elevating device 105.
  • a support base 106 that immovably supports the floor pan base material 3 in the horizontal direction is placed on the pedestal 104.
  • a primer is applied to the entire surface 30 of the floor pan base material 3 to form a primer layer 35.
  • the floor pan base material 3 is installed on the support base 106 on the pedestal 104 in the lower chamber 102, and the floor pan base material 3 is added so as to close the opening on the upper surface of the lower chamber 102.
  • the decorative film 4 is installed on the upper surface of the lower chamber 102.
  • the upper chamber 101 is lowered, and the decorative film 4 is sandwiched between the upper chamber 101 and the lower chamber 102. At this time, the insides of the chambers 101 and 102 are sealed.
  • the insides of the chambers 101 and 102 are decompressed by a vacuum tank to create a vacuum state.
  • the decorative film 4 is heated and softened by the heater 103.
  • the plurality of grain materials 5 are not softened, and it is possible to maintain a state in which irregularities due to the grain materials 5 are formed on the surface of the film body 40.
  • the pedestal 104 is raised by the elevating device 105, and the softened decorative film 4 is pressed against the surface 30 of the floor pan base material 3.
  • the inside of the upper chamber 101 is compressed by a compressed air tank.
  • the softened decorative film 4 is pressed against the entire surface 30 of the floor pan base material 3, and the decorative film 4 is deformed into the shape of the surface 30 of the floor pan base material 3 to decorate the floor pan base material 3.
  • the film 4 comes into close contact with the surface 30.
  • the decorative film 4 is cooled and cured.
  • the pressure inside the upper chamber 101 and the inside of the lower chamber 102 are set to atmospheric pressure, the upper chamber 101 is raised, and the decorative film 4 is brought into close contact with the surface 30 from the support base 106. Remove.
  • the decorative film 4 is in close contact with the entire surface 30 of the floor pan base material 3. Specifically, the decorative film 4 is in close contact with the entire upper surface 20 and side surface 21 of each of the plurality of convex portions 2 on the surface of the floor portion 31 of the floor pan base material 3, and is deformed along the upper surface 20 and the side surface 21. ing. Air does not intervene between the surface 30 of the floor pan base material 3 and the decorative film 4.
  • the upper surface of the bottom portion of the floor pan 1 (the upper surface of the decorative film 4 covering the floor portion 31) is provided with a non-slip function. Since the grain material 5 is a member that does not soften or is hard to soften at the heating temperature for heating the decorative film 4 during TOM molding, unevenness of a desired size can be formed on the upper surface of the bottom of the floor pan 1. ..
  • the floor pan 1 is not limited to TOM molding (vacuum pressure air molding), and the decorative film 4 may be adhered to the surface 30 of the floor pan base material 3 by vacuum forming.
  • the floor pan base material 3 is provided with a through hole penetrating from the front surface 30 to the back surface of the floor pan base material 3.
  • the decorative film 4 is evacuated to the floor pan base material 3 side through the through holes provided in the floor pan base material 3. As a result, the decorative film 4 is brought into close contact with the surface 30 of the floor pan base material 3.
  • the grain material 5 is not limited to the surface layer 41, but may be contained in both the surface layer 41 and the base layer 42, or may be contained in the printing layer 43 as well. Further, the grain material 5 is not limited to the portion of the surface layer 41 that covers the floor portion 31, and may be included in the entire surface layer 41.
  • the grain material 5 may be hollow as long as it is higher than the softening temperature of the film body 40, and is not limited to solid.
  • the floor pan base material 3 may have only the floor portion 31 of the floor portion 31 and the rising portion 32.
  • the shape and dimensions of the plurality of convex portions 2 do not have to be the same as each other, and those having various shapes and dimensions may be mixed.
  • the method for producing the floor pan 1 does not have to include all of the above-mentioned coating step, installation step, depressurizing step, heating step, pressing step, adhesion step, mold release step, and cutting step.
  • the floor pan base material Depending on the material of 3, the coating step can be omitted.
  • the decorative film 4 has a film main body 40 having thermoplasticity and a coating film 45 provided on the surface of the film main body 40.
  • the coating film 45 contains the granular material 5.
  • the diameter of the grain material 5 is 1 ⁇ m or more and 30 ⁇ m or less.
  • the coating film 45 is formed of, for example, a paint containing PMMA as a main component.
  • the grain material 5 is contained in the paint forming the coating film 45.
  • the coating film 45 is provided on the surface of the film body 40 by applying a paint containing a plurality of grain materials 5 to the surface of the surface layer 41 of the film body 40.
  • the thickness of the coating film 45 is, for example, 1 ⁇ m or more and 50 ⁇ m or less. In the present embodiment, the thickness of the coating film 45 is 5 ⁇ m, and the diameter of the grain material 5 is 10 ⁇ m.
  • the coating film 45 can be stretched during vacuum forming or vacuum forming.
  • the surface layer 41 of the film body 40 is formed of transparent PMMA.
  • the surface layer 41 does not contain the grain material 5.
  • a decorative film 4 in which a coating film 45 containing a grain material 5 is provided on the surface of the film body 40 is used.
  • Other steps are the same as the manufacturing method of the floor pan 1 of the first embodiment.
  • the surface of the decorative film 4 is formed with irregularities due to the plurality of grain materials 5, and the upper surface of the bottom of the floor pan 1 is formed.
  • the upper surface of the decorative film 4 covering the floor portion 31 can be provided with a non-slip function.
  • the floor pan 1 of the second embodiment and the manufacturing method thereof described above may be appropriately combined with a modified example of the floor pan 1 of the first embodiment and the manufacturing method thereof described above.
  • the decorative film 4 has a film main body 40 having thermoplasticity and a coating film 46 provided on the surface of the film main body 40.
  • the coating film 46 contains the granular material 5.
  • the diameter of the grain material 5 is 1 ⁇ m or more and 30 ⁇ m or less.
  • the coating film 46 is formed of, for example, a paint containing PMMA as a main component.
  • the grain material 5 is contained in the paint forming the coating film 46.
  • the coating film 46 is provided on the surface of the film body 40 by applying a paint containing the granular material 5 to the surface of the surface layer 41 of the film body 40 after vacuum forming or vacuum forming.
  • the thickness of the coating film 46 is, for example, 1 ⁇ m or more and 50 ⁇ m or less. In the present embodiment, the thickness of the coating film 46 is 5 ⁇ m, and the diameter of the grain material 5 is 10 ⁇ m. Since the coating film 46 is formed after vacuum forming or vacuum forming, it does not have to have the property of stretching during vacuum forming or vacuum forming.
  • the surface layer 41 of the film body 40 is formed of transparent PMMA.
  • the surface layer 41 does not contain the grain material 5.
  • the manufacturing method of the present embodiment includes a pressing step, a close contact step, and a coating step.
  • the pressing step the surface 30 of the floor pan base material 3 having a plurality of convex portions 2 on the surface 30 is softened by heating.
  • the film body 40 is pressed against the film body 40.
  • the close contact step the film body 40 is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum pressure air forming or vacuum forming.
  • a paint containing a granular material 5 having a diameter of 1 ⁇ m or more and 30 ⁇ m or less is applied to the surface of the film body 40 that is in close contact with the floor pan base material 3.
  • the manufacturing method of the present embodiment includes a contacting step in addition to the coating step, the setting step, the depressurizing step, the heating step, the pressing step, the adhesion step, the mold release step, and the cutting step of the manufacturing method of the first embodiment. It is provided with a coating step (hereinafter referred to as "second coating step") performed after that.
  • the film body 40 in which the coating film 46 is not formed on the surface is used in the installation process.
  • the depressurizing step, the heating step, the pressing step, the close contact step, the mold release step, and the cutting step are the same steps as each step of the manufacturing method of the first embodiment.
  • the film body 40 having no coating film 46 formed on the surface is also used in the depressurizing step, the heating step, the pressing step, the adhesion step, the mold release step, and the cutting step.
  • the second coating step is performed, for example, after the excision step.
  • a paint containing the granular material 5 is applied to the surface of the film body 40 which is in close contact with the surface 30 of the floor pan base material 3 and is deformed into the same shape as the surface 30.
  • a coating film 46 containing the granular material 5 is formed on the surface of the film body 40.
  • the floor pan 1 of the present embodiment is manufactured.
  • the surface of the decorative film 4 is formed with irregularities due to the plurality of granules 5, and the upper surface of the bottom of the floor pan 1 is formed.
  • the upper surface of the decorative film 4 covering the floor portion 31 can be provided with a non-slip function.
  • pseudo-hydrophilicity can be developed on the surface of the floor pan 1 due to the unevenness of the plurality of granules 5, and the drainage property of the surface of the floor pan 1 can be improved.
  • the floor pan 1 of the third embodiment and the manufacturing method thereof described above may be appropriately combined with a modified example of the floor pan 1 of the first embodiment and the manufacturing method thereof described above.
  • the floor pan 1 of the fourth embodiment is decorated with a floor pan base material 3 having a bent corner portion 6, a colored primer 7 applied to the surface of the corner portion 6, and a decoration in close contact with the surface 30 of the floor pan base material 3.
  • the film 4 and the like are provided.
  • the decorative film 4 has an elongated portion 47 that is thinner than the other portions in the portion that covers the corner portion 6. The elongated portion 47 is in close contact with the corner portion 6 via the colored primer 7.
  • the method for manufacturing the floor pan 1 of the fourth embodiment includes a coating step, a pressing step, and a close contact step.
  • the coating step is a step of applying the coloring primer 7 to the surface of the corner portion 6 of the floor pan base material 3 having the bent corner portion 6.
  • the pressing step is a step of pressing the decorative film 4 softened by heating against the surface 30 of the floor pan base material 3.
  • the adhesion step is a step of adhering the decorative film 4 to the surface 30 of the floor pan base material 3 by vacuum pressure air forming or vacuum forming.
  • the decorative film 4 has an elongated portion 47 which is formed in the close contact step and is thinner than the other parts of the decorative film 4. The elongated portion 47 is brought into close contact with the corner portion 6 via the colored primer 7.
  • the thin-walled elongated portion 47 of the decorative film 4 adheres to the corner portion 6 via the coloring primer 7, so that the adhesiveness between the corner portion 6 and the elongated portion 47 is maintained. It can be improved. Further, in the floor bread manufacturing method of the present embodiment, even if the stretched portion 47 is transparent, the colored primer 7 is displayed on the surface of the stretched portion 47, so that the floor pan base material 3 can be prevented from seeing through.
  • the floor pan base material 3 has four first corner portions 6a located at the four corners of the floor portion 31 and four second corner portions 6b located at the four corners of the bottom wall 341 of the drainage recess 34 as corner portions 6.
  • the first corner portion 6a is an inner corner portion formed by being surrounded by two adjacent rising portions 32 and a floor portion 31 among the four rising portions 32.
  • the second corner portion 6b is an inner corner portion formed by surrounding the three side walls 342 of the drainage recess 34, two adjacent members of the rear rising portion 32a, and the bottom wall 341.
  • the coloring primer 7 is applied to the surface of each corner portion 6 to form the coloring primer layer 36.
  • the colored primer layer 36 is formed on the surfaces of each of the four first corner portions 6a and its peripheral portions and the four second corner portions 6b and its peripheral portions.
  • the coloring primer 7 is colored by mixing a coloring agent such as a pigment with a synthetic resin primer such as urethane-based, acrylic-based, epoxy-based, or modified silicon-based.
  • the color of the coloring primer 7 is similar to the color of the other portion of the decorative film 4 excluding the elongated portion 47.
  • the color of the coloring primer 7 is, for example, the same color as the color of the other portion of the decorative film 4 excluding the elongated portion 47, or a color different only in color tone from the color of the other portion of the film 4.
  • the color of the coloring primer 7 can be appropriately selected so that the color displayed on the surface of the elongated portion 47 of the decorative film 4 looks the same as the other parts of the decorative film 4.
  • the color of the coloring primer 7 may be a color close to colorless as long as it looks the same as the other parts of the decorative film 4.
  • the colored primer layer 36 may be laminated directly on the surface of the corner portion 6 of the floor pan base material 3, or may be laminated on the surface of the primer layer 35 laminated on the surface of the corner portion 6.
  • the primer layer 35 laminated on the entire surface 30 of the floor pan base material 3 is formed of a primer that is not similar in color to the decorative film 4.
  • This primer is a synthetic resin primer such as urethane-based, acrylic-based, epoxy-based, and modified silicone-based.
  • the primer layer 35 may be formed of the colored primer 7.
  • the decorative film 4 is, for example, a rectangular sheet in a state before heating, and the thickness is constant throughout.
  • the decorative film 4 has the same color as a whole in the state before heating.
  • the decorative film 4 is formed in a color different from that of the floor pan base material 3.
  • the color of the decorative film 4 can be set as appropriate, but is, for example, a dark color such as brown.
  • the decorative film 4 is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum forming or vacuum forming, so that the portion covering the corner portion 6 is thinner than the other portions. 47 is formed.
  • the extension portion 47 is formed into a portion that covers each of the four first corner portions 6a and a portion that covers each of the four second corner portions 6b.
  • the stretched portion 47 is lighter in color than the other portion of the decorative film 4 excluding the stretched portion 47, and is translucent in the present embodiment.
  • the color of the portion on the back side thereof is displayed on the surface of the extension portion 47 through the extension portion 47.
  • the coloring primer 7 is applied to the corner portion 6 and the peripheral portion thereof, substantially the same color as the surface of the other portion of the decorative film 4 is displayed on the surface of the elongated portion 47. As a result, the same color is displayed on the entire surface of the decorative film 4.
  • the manufacturing method of the present embodiment includes a coating step, an installation step, a depressurizing step, a heating step, a pressing step, an adhesion step, a mold release step, and a cutting step, similarly to the manufacturing method of the first embodiment.
  • the coloring primer 7 is applied to the surface of the corner portion 6 of the floor pan base material 3 and the peripheral portion thereof to form the coloring primer layer 36.
  • the colored primer 7 is applied to each of the four first corners 6a and its peripheral portions at the four corners of the floor portion 31 and the four second corner portions 6b and its peripheral portions at the four corners of the drainage recess 34.
  • the colored primer layer 36 may be formed by applying a primer having a color similar to that of the decorative film 4 to the entire surface 30 of the floor pan base material 3 to form the primer layer 35, or the corners. It may be formed directly with respect to the part 6 without passing through the primer layer 35.
  • the softened decorative film 4 is pressed against the entire surface 30 of the floor pan base material 3, and the decorative film 4 is deformed into the shape of the surface 30 of the floor pan base material 3 and added.
  • the decorative film 4 comes into close contact with the surface 30.
  • the portion of the decorative film 4 that is in close contact with the corner portions 6a and 6b is extended to form a thin-walled elongated portion 47.
  • the decorative film 4 is in close contact with the entire surface 30 of the floor pan base material 3.
  • the color of the coloring primer 7 is displayed on the surface of each of the plurality of elongated portions 47 of the decorative film 4, whereby the same color is displayed on the entire surface of the floor pan 1.
  • the floor pan 1 of the fourth embodiment and the manufacturing method thereof described above can be appropriately combined with the floor pan 1 of the first embodiment and the modified example of the manufacturing method thereof. Further, the floor pan 1 of the fourth embodiment and the manufacturing method thereof can be combined with the floor pan 1 of the second and third embodiments and the manufacturing method thereof.
  • the floor pan base material 3 may have any bent corner portion 6, and may have only the floor portion 31 and the drainage recess 34 without the rising portion 32. Further, the floor pan base material 3 has a floor portion 31 and a rising portion 32, and does not have to have a drainage recess 34. Further, the floor pan base material 3 may have other portions forming the bent corner portion 6.
  • the drainage recess 34 is not limited to a rectangular shape in a plan view, and may have a shape in which the side wall 342 forms a corner and is not continuous, such as a circular shape in a plan view.
  • the coloring primer 7 is a corner portion formed by each of the plurality of rising portions 32 and the floor portion 31 and a peripheral portion thereof (that is, each end side of the floor portion 31 and its peripheral portion) as in the modified example of the floor pan 1 shown in FIG. Peripheral portion) may be further applied. Then, the colored primer 7 may be further applied to the corner portion formed by the portion above the support portion 343 of the left and right side wall 342 of the drainage recess 34 and the support portion 343 and the peripheral portion thereof.
  • the colored primer 7 may be further applied to the corner portion formed by each of the plurality of side walls 342 of the drainage recess 34 and the bottom wall 341 and its peripheral portion (that is, each end side of the bottom wall 341 and its peripheral portion).
  • the coloring primer 7 may be applied to all or a part of the floor pan base material 3 corresponding to the elongated portion 47 formed on the decorative film 4 in the adhesion step.
  • the coloring primer 7 may be applied not only to the corner portion of the floor pan base material 3 (the portion corresponding to the elongated portion 47) but also to the entire surface 30 of the floor pan base material 3.
  • the coloring primer 7 does not have to be the same color as the other portion of the decorative film 4 except for the stretched portion 47, and the color displayed on the surface of the stretched portion 47 is the surface of the other portion of the decorative film 4. It can be appropriately selected so that it is substantially the same as the color displayed in.
  • the floor pan 1 does not have to have the primer layer 35.
  • the remaining portion of the decorative film 4 excluding the stretched portion 47 is made of the floor pan base material 3 due to the adhesive force of the adhesive layer 44. It is directly adhered to the surface 30.
  • the water-related member (floor pan 1) of the first aspect has the following configuration.
  • the water-related member (floor pan 1) of the first aspect includes a water-related base material (floor pan base material 3) having a plurality of convex portions (2) on the surface (30) and a water-related base material (floor pan).
  • a decorative film (4) that is in close contact with the surface (30) of the base material 3) is provided.
  • the decorative film (4) has a grain material (5) having a diameter of 1 ⁇ m or more and 30 ⁇ m or less and having a softening temperature higher than that of other parts of the decorative film (4).
  • the grain material (5) forms irregularities on the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1).
  • Cheap In the water-related member (floor pan 1) of the first aspect, for example, when the decorative film (4) is heated and softened to be brought into close contact with the surface (30) of the water-related base material (floor pan base material 3). , The other part of the decorative film (4) is softened, but the grain material (5) is not softened. Therefore, in the water-related member (floor pan 1) of the first aspect, unevenness due to the grain material (5) is likely to be formed on the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1). ..
  • the water supply member (floor pan 1) of the second aspect has the following configuration in addition to the configuration of the water supply member (floor pan 1) of the first aspect. Is additionally provided.
  • the decorative film (4) has a film body (40) having thermoplasticity.
  • the grain material (5) is mixed with the film body (40) and has a higher softening temperature than the film body (40).
  • the decorative film (4) is heated and softened to be brought into close contact with the surface (30) of the water circulation base material (floor pan base material 3).
  • the film body (40) softens, but the grain material (5) does not soften. Therefore, in the floor pan (1) of the second aspect, unevenness due to the grain material (5) is likely to be formed on the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1).
  • the water supply member (floor pan 1) of the third aspect has the following configuration in addition to the configuration of the water supply member (floor pan 1) of the first aspect. Is additionally provided.
  • the decorative film (4) is a film body (40) having thermoplasticity and a coating film (45) provided on the surface of the film body (40). , 46) and.
  • the grain material (5) is contained in the coating film (45, 46).
  • the surface of the decorative film (4) that is, the water-related member ( Unevenness can be formed on the surface of the floor pan 1).
  • the water supply member (floor pan 1) of the fourth aspect is the water supply member (floor pan 1) of any one of the first to third aspects.
  • the following configuration is additionally provided.
  • the decorative film (4) is in close contact with the upper surface (20) and the side surface (21) of the plurality of convex portions (2), respectively. It is deformed along the upper surface (20) and the side surface (21) of the convex portion (2), respectively.
  • the water-related base material (floor pan base material) is placed on the surface of the decorative film (4), that is, on the surface of the water-related member (floor pan 1).
  • the shape of the plurality of convex portions (2) of 3) is likely to appear, and the anti-slip function of the plurality of convex portions (2) is likely to be exhibited.
  • the water supply member (floor pan 1) of the fifth aspect has the following configuration in addition to the configuration of the water supply member (floor pan 1) of the second aspect. Is additionally provided.
  • the film body (40) is located on the surface layer (41) constituting the surface of the film body (40) and the back side of the surface layer (41). Includes a base layer (42).
  • the grain material (5) is contained in the surface layer (41).
  • the water supply member (floor pan 1) of the sixth aspect is the water supply member (floor pan 1) of any one of the first to fifth aspects.
  • the following configuration is additionally provided.
  • the grain material (5) is solid.
  • the decorative film (4) is heated and softened to be brought into close contact with the surface (30) of the water circulation base material (floor pan base material 3).
  • the surface (30) of the water circulation base material (floor pan base material 3) it is possible to prevent the size of the unevenness formed on the surface of the decorative film (4) from becoming smaller due to the grain material (5) being crushed or the like. Therefore, in the water-related member (floor pan 1) of the sixth aspect, unevenness of an intended size is likely to be formed on the surface of the decorative film (4) by the solid grain material (5).
  • the water supply member (floor pan 1) of the seventh aspect is the water supply member (floor pan 1) of any one of the first to sixth aspects.
  • the following configuration is additionally provided.
  • the water-related base material (floor pan base material 3) has a floor portion (31) having a plurality of convex portions (2) on the upper surface and a floor portion (floor portion (31)). It has a rising portion (32) rising from the edge portion of 31).
  • the decorative film (4) is in close contact with each of the upper surface of the floor portion (31) and the surface of the rising portion (32).
  • the method for manufacturing the water-related member (floor pan 1) of the eighth aspect has the following configuration.
  • the method for manufacturing the water-related member (floor pan 1) of the eighth aspect includes a pressing step and a close contact step.
  • the pressing step the decorative film (4) softened by heating is pressed against the surface (30) of the water-related base material (floor pan base material 3) having the plurality of convex portions (2) on the surface (30). It is a process.
  • the adhesion step is a step of adhering the decorative film (4) to the surface (30) of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming.
  • the decorative film (4) has a grain material (5) having a diameter of 1 ⁇ m or more and 30 ⁇ m or less and having a softening temperature higher than that of other parts of the decorative film (4).
  • the decorative film (4) is heated and softened to soften the surface (30) of the water-related base material (floor pan base material 3).
  • the other part of the decorative film (4) is softened, but the grain material (5) is not softened. Therefore, in the method for manufacturing the water-related member (floor pan 1) of the sixth aspect, the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1) is formed with irregularities due to the grain material (5).
  • Cheap is
  • the method for manufacturing the water-related member (floor pan 1) in the ninth aspect is the same as the method for producing the water-related member (floor pan 1) in the eighth aspect.
  • the following configuration is additionally provided.
  • the decorative film (4) has a film body (40) having thermoplasticity.
  • the grain material (5) is mixed with the film body (40) and has a higher softening temperature than the film body (40).
  • the decorative film (4) is heated and softened to soften the surface (30) of the water-related base material (floor pan base material 3).
  • the film body (40) softens, but the grain material (5) does not soften. Therefore, in the method for manufacturing the water-related member (floor pan 1) of the ninth aspect, the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1) is uneven due to the grain material (5). Easy to form.
  • the method for manufacturing the water-related member (floor pan 1) of the tenth aspect is the same as the method for producing the water-related member (floor pan 1) of the eighth aspect.
  • the following configuration is additionally provided.
  • the decorative film (4) is a film body (40) having thermoplasticity and a coating provided on the surfaces of the film body (40). It has a film (45) and. The grain material (5) is contained in the coating film (45).
  • the surface of the decorative film (4) that is, the water-related member is made of the grain material (5) contained in the coating film (45). Unevenness can be formed on the surface of (floor pan 1).
  • the method for manufacturing the water-related member (floor pan 1) of the eleventh aspect has the following configuration.
  • the method for manufacturing the water-related member (floor pan 1) of the eleventh aspect includes a pressing step, a close contact step, and a coating step.
  • the pressing step is a step of pressing the film body (40) softened by heating against the surface (30) of the water-related base material (floor pan base material 3) having a plurality of convex portions (2) on the surface (30).
  • the close contact step is a step of bringing the film body (40) into close contact with the surface (30) of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming.
  • the coating step is a step of applying a paint containing a granular material (5) having a diameter of 1 ⁇ m or more and 30 ⁇ m or less on the surface of the film body (40) that is in close contact with the water-related base material (floor pan base material 3).
  • the surface of the film body (40), that is, the water-related member (floor pan 1) is made of the grain material (5) contained in the paint. It is possible to form irregularities on the surface of the grain material (5).
  • the water-related member (floor pan 1) of the twelfth aspect has the following configuration.
  • the water circulation member (floor pan 1) of the twelfth aspect is applied to the surface of the water circulation base material (floor pan base material 3) having the bent corner portion (6) and the corner portion (6).
  • a coloring primer (7) and a decorative film (4) in close contact with the surface (30) of the water-related base material (floor pan base material 3) are provided.
  • the decorative film (4) has a stretched portion (47) thinner than the other portion in the portion covering the corner portion (6).
  • the elongated portion (47) is in close contact with the corner portion (6) via the colored primer (7).
  • the thin-walled stretched portion (47) of the decorative film (4) adheres to the corner portion (6) via the colored primer (7). Therefore, the adhesion between the corner portion (6) and the extension portion (47) can be improved. Further, in the floor pan (1) of the twelfth aspect, even if the stretched portion (47) is transparent, the color of the coloring primer (7) is displayed on the surface of the stretched portion (47). It is possible to prevent see-through of the floor pan base material 3).
  • the water circulation member (floor pan 1) of the thirteenth aspect has the following configuration in addition to the configuration of the water circulation member (floor pan 1) of the twelfth aspect.
  • the configuration of is additionally provided.
  • the water-related base material (floor pan base material 3) is a plurality of rising from the floor portion (31) and the edge portion of the floor portion (31). It has a rising portion (32) of the above.
  • the corner portion (6) includes a corner portion (first corner portion 6a) formed by two adjacent rising portions (32) and a floor portion (31) among the plurality of rising portions (32). A coloring primer (7) is applied to this corner portion.
  • a corner portion formed by two adjacent rising portions (32) and a floor portion (31) among a plurality of rising portions (32).
  • the water supply member (floor pan 1) of the fourteenth aspect has the configuration of the water supply member (floor pan 1) of the twelfth or thirteenth aspect.
  • the following configuration is additionally provided.
  • the water-related base material (floor pan base material 3) has a drainage recess (34) provided with a drainage hole (340).
  • the drainage recess (34) includes a bottom wall (341) and a plurality of side walls (342) rising from the edge of the bottom wall (341).
  • the corner portion (6) includes a corner portion (second corner portion 6b) formed by two adjacent side walls (342) and a bottom wall (341) among the plurality of side walls (342). A coloring primer (7) is applied to this corner portion.
  • the water supply member (floor pan 1) of the fifteenth aspect is the water supply member (floor pan 1) of any one of the twelfth to fourteenth aspects.
  • the following configuration is additionally provided.
  • the coloring primer (7) has the same color as the other portion of the decorative film (4) excluding the elongated portion (47).
  • the color displayed on the surface of the elongated portion (47) is the decorative film (4) excluding the elongated portion (47). It tends to be the same as the color displayed on the surface of the part.
  • the method for manufacturing the water-related member (floor pan 1) of the sixteenth aspect has the following configuration.
  • the method for manufacturing the water-related member (floor pan 1) of the sixteenth aspect includes a coating step, a pressing step, and a close contact step.
  • the coating step is a step of applying the coloring primer (7) to the surface of the corner portion (6) of the water-related base material (floor pan base material 3) having the bent corner portion (6).
  • the pressing step is a step of pressing the decorative film (4) softened by heating against the surface (30) of the water-related base material (floor pan base material 3).
  • the adhesion step is a step of adhering the decorative film (4) to the surface (30) of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming.
  • the decorative film (4) has an elongated portion (47) that is formed in the close contact process and is thinner than the other parts of the decorative film (4). The elongated portion (47) is brought into close contact with the corner portion (6) via the colored primer (7).
  • the thin-walled elongated portion (47) of the decorative film (4) is interposed at the corner portion (6) via the colored primer (7). Therefore, the adhesion between the corner portion (6) and the extension portion (47) can be improved. Further, in the method for manufacturing a floor pan according to the sixteenth aspect, even if the stretched portion (47) is transparent, the color of the coloring primer (7) is displayed on the surface of the stretched portion (47). It is possible to prevent see-through of the bread base material 3).
  • the water-related member is a floor pan
  • the water-related member is not limited to the floor pan, and is used, for example, in a wall panel forming a wall in a bathroom or in a kitchen. It may be a top plate or the like.

Abstract

The present invention addresses the problem of providing a wet-area member in which recesses and projections are readily formed on the surface thereof, and a method for manufacturing a wet-area member. A wet-area member (1) comprises a wet-area substrate (3) having a plurality of projections (2) on a surface (30) thereof, and a decorative film (4) which is bonded to the surface (30) of the wet-area substrate (3). The decorative film (4) has a granular material (5) which has a diameter of 1-30 µm inclusive and which has a higher softening temperature than the remaining portion of the decorative film (4). A method for manufacturing the wet-area member (1) comprises a pressing step and a bonding step. In the pressing step, the decorative film (4), softened by heating, is pressed against the surface (30) of the wet-area substrate (3). In the bonding step, the decorative film (4) is bonded to the surface (30) of the wet-area substrate (3) by vacuum/pressure molding or vacuum molding.

Description

水廻り部材及び水廻り部材の製造方法Water-related member and manufacturing method of water-related member
　本開示は、水廻り部材及び水廻り部材の製造方法に関し、詳しくは、表面に凹凸を有するフィルムが加飾された水廻り部材及び水廻り部材の製造方法に関する。 The present disclosure relates to a water-related member and a method of manufacturing the water-related member, and more particularly to a water-related member and a method of manufacturing the water-related member in which a film having irregularities on the surface is decorated.
　特許文献１には、基材と、基材の表面側に積層された表面材とを備える浴室用の洗い場床（例えば床パンなどの水廻り部材）が記載されている。表面材の表面には、滑り止め等のための凹凸が形成されている。 Patent Document 1 describes a bathroom washroom floor (for example, a water-related member such as a floor pan) provided with a base material and a surface material laminated on the surface side of the base material. The surface of the surface material is formed with irregularities to prevent slipping.
　ところで、特許文献１に記載の洗い場床では、基材と表面材との積層構造を得るにあたって、それらを一体に熱間成型することによって相互に溶着固定させている。 By the way, in the washroom floor described in Patent Document 1, in order to obtain a laminated structure of a base material and a surface material, they are integrally welded and fixed by hot molding.
　しかし、このように熱間成型する場合、表面材の表面の凹凸が、成形熱と引張により収縮して減少するおそれがある。 However, in the case of hot molding in this way, the unevenness of the surface of the surface material may shrink and decrease due to the molding heat and tension.
日本国公開特許公報２０１０－５９６５２号Japanese Patent Publication No. 2010-59652
　本開示は、表面に凹凸を形成しやすい水廻り部材及び水廻り部材の製造方法を提供することを、目的とする。 An object of the present disclosure is to provide a water-related member and a method for manufacturing the water-related member, which easily form irregularities on the surface.
　本開示の一態様に係る水廻り部材は、複数の凸部を表面に有する水廻り基材と、前記水廻り基材の前記表面に密着した加飾フィルムと、を備える。前記加飾フィルムは、直径が１μｍ以上３０μｍ以下であり、かつ前記加飾フィルムの他の部分よりも軟化温度が高い粒材を有する。 The water-related member according to one aspect of the present disclosure includes a water-related base material having a plurality of convex portions on its surface, and a decorative film in close contact with the surface of the water-related base material. The decorative film has a grain material having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film.
　本開示の一態様に係る水廻り部材の製造方法は、押圧工程と密着工程とを備える。前記押圧工程は、複数の凸部を表面に有する水廻り基材の前記表面に、加熱により軟化させた加飾フィルムを押し当てる工程である。前記密着工程は、真空圧空成形又は真空成形により前記加飾フィルムを前記水廻り基材の前記表面に密着させる工程である。前記加飾フィルムは、直径が１μｍ以上３０μｍ以下であり、かつ前記加飾フィルムの他の部分よりも軟化温度が高い粒材を有する。 The method for manufacturing a water-related member according to one aspect of the present disclosure includes a pressing step and a close contact step. The pressing step is a step of pressing a decorative film softened by heating against the surface of a water-related base material having a plurality of convex portions on the surface. The close contact step is a step of bringing the decorative film into close contact with the surface of the water-related base material by vacuum forming or vacuum forming. The decorative film has a grain material having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film.
　本開示の他の一態様に係る水廻り部材の製造方法は、押圧工程、密着工程、及び塗布工程を備える。前記押圧工程は、複数の凸部を表面に有する水廻り基材の前記表面に、加熱により軟化させたフィルム本体を押し当てる工程である。前記密着工程は、真空圧空成形又は真空成形により前記フィルム本体を前記水廻り基材の前記表面に密着させる工程である。前記塗布工程は、前記水廻り基材に密着した前記フィルム本体の表面に、直径が１μｍ以上３０μｍ以下の粒材を含む塗料を塗布する工程である。 The method for manufacturing a water-related member according to another aspect of the present disclosure includes a pressing step, a close contact step, and a coating step. The pressing step is a step of pressing the film body softened by heating against the surface of the water-related base material having a plurality of convex portions on the surface. The close contact step is a step of bringing the film body into close contact with the surface of the water-related base material by vacuum forming or vacuum forming. The coating step is a step of applying a paint containing a granular material having a diameter of 1 μm or more and 30 μm or less on the surface of the film body that is in close contact with the water-related base material.
図１は、実施形態１の水廻り部材（床パン）を示す斜視図である。FIG. 1 is a perspective view showing a water-related member (floor pan) of the first embodiment. 図２Ａは、図１のＡ部分を拡大して示す斜視図であり、図２Ｂは、同上の水廻り部材（床パン）を示す概略的な断面図である。FIG. 2A is an enlarged perspective view showing a portion A of FIG. 1, and FIG. 2B is a schematic cross-sectional view showing a water circulation member (floor pan) of the same. 図３Ａから図３Ｄは、同上の水廻り部材（床パン）を製造する方法を概略的に示す図である。3A to 3D are views schematically showing a method of manufacturing the same water-related member (floor pan). 図４は、実施形態２の水廻り部材（床パン）を示す概略的な断面図である。FIG. 4 is a schematic cross-sectional view showing the water-related member (floor pan) of the second embodiment. 図５は、実施形態３の水廻り部材（床パン）を示す概略的な断面図である。FIG. 5 is a schematic cross-sectional view showing the water-related member (floor pan) of the third embodiment. 図６は、実施形態４の水廻り部材（床パン）の一部（図１のＡ部分に対応する部分）を拡大して示す斜視図である。FIG. 6 is an enlarged perspective view showing a part (a part corresponding to the part A in FIG. 1) of the water-related member (floor pan) of the fourth embodiment. 図７は、同上の水廻り部材（床パン）を示す斜視図である。FIG. 7 is a perspective view showing the same water-related member (floor pan). 図８は、同上の水廻り部材（床パン）の変形例を示す斜視図である。FIG. 8 is a perspective view showing a modified example of the water-related member (floor pan) of the above.
　（実施形態１）
　１．概要
　図１、図２Ａ及び図２Ｂに示す実施形態１の水廻り部材（床パン１）は、複数の凸部２を表面３０に有する水廻り基材（床パン基材３）と、表面３０に密着した加飾フィルム４と、を備える。加飾フィルム４は、直径が１μｍ以上３０μｍ以下であり、かつ加飾フィルム４の他の部分よりも軟化温度が高い粒材５を有する。 (Embodiment 1)
1. 1. Outline The water circulation member (floor pan 1) of the first embodiment shown in FIGS. 1, 2A and 2B includes a water circulation base material (floor pan base material 3) having a plurality of convex portions 2 on the surface 30 and a surface 30. A decorative film 4 that is in close contact with the floor is provided. The decorative film 4 has a grain material 5 having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film 4.
　上記構成を備える実施形態１の水廻り部材（床パン１）では、粒材５によって加飾フィルム４の表面、つまり、水廻り部材（床パン１）の表面に凹凸を形成しやすい。実施形態１の水廻り部材（床パン１）では、例えば、加飾フィルム４を加熱して軟化させて水廻り基材（床パン基材３）の表面３０に密着させる場合に、加飾フィルム４の他の部分は軟化するものの、粒材５は軟化しない。そのため、実施形態１の水廻り部材（床パン１）では、加飾フィルム４の表面、つまり、水廻り部材（床パン１）の表面に、粒材５による凹凸を形成しやすい。 In the water-related member (floor pan 1) of the first embodiment having the above configuration, the grain material 5 tends to form irregularities on the surface of the decorative film 4, that is, the surface of the water-related member (floor pan 1). In the water-related member (floor pan 1) of the first embodiment, for example, when the decorative film 4 is heated and softened to be brought into close contact with the surface 30 of the water-related base material (floor pan base material 3), the decorative film is used. The other part of 4 softens, but the grain material 5 does not soften. Therefore, in the water-related member (floor pan 1) of the first embodiment, unevenness due to the grain material 5 is likely to be formed on the surface of the decorative film 4, that is, the surface of the water-related member (floor pan 1).
　また、実施形態１の水廻り部材（床パン１）の製造方法は、押圧工程と密着工程とを備える。押圧工程は、複数の凸部２を表面３０に有する水廻り基材（床パン基材３）の表面３０に、加熱により軟化させた加飾フィルム４を押し当てる工程である。密着工程は、真空圧空成形又は真空成形により加飾フィルム４を水廻り基材（床パン基材３）の表面３０に密着させる工程である。加飾フィルム４は、直径が１μｍ以上３０μｍ以下であり、かつ加飾フィルム４の他の部分よりも軟化温度が高い粒材５を有する。 Further, the method for manufacturing the water-related member (floor pan 1) of the first embodiment includes a pressing step and a close contact step. The pressing step is a step of pressing the decorative film 4 softened by heating against the surface 30 of the water-related base material (floor pan base material 3) having the plurality of convex portions 2 on the surface 30. The adhesion step is a step of adhering the decorative film 4 to the surface 30 of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming. The decorative film 4 has a grain material 5 having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film 4.
　上記構成を備える実施形態１の水廻り部材（床パン１）の製造方法では、加飾フィルム４を加熱して軟化させて水廻り基材（床パン基材３）の表面３０に密着させる際に、加飾フィルム４の他の部分は軟化するものの、粒材５は軟化しない。そのため、実施形態１の水廻り部材（床パン１）の製造方法では、加飾フィルム４の表面、つまり水廻り部材（床パン１）の表面に、粒材５による凹凸を形成しやすい。 In the method for manufacturing the water-related member (floor pan 1) of the first embodiment having the above configuration, when the decorative film 4 is heated and softened to be brought into close contact with the surface 30 of the water-related base material (floor pan base material 3). In addition, although the other part of the decorative film 4 is softened, the grain material 5 is not softened. Therefore, in the method for manufacturing the water-related member (floor pan 1) of the first embodiment, unevenness due to the grain material 5 is likely to be formed on the surface of the decorative film 4, that is, the surface of the water-related member (floor pan 1).
　２．詳細
　続いて、図１、図２Ａ及び図２Ｂに示す実施形態１の水廻り部材（床パン１）について更に詳しく説明する。以下では、図１に示す前後方向、左右方向及び上下方向を用いて、各構成について詳しく説明する。 2. Details Subsequently, the water-related member (floor pan 1) of the first embodiment shown in FIGS. 1, 2A and 2B will be described in more detail. In the following, each configuration will be described in detail using the front-rear direction, the left-right direction, and the up-down direction shown in FIG.
　なお、本実施の形態において水廻り部材は、浴室用の洗い場床に使用される床パン１を用いて詳細に説明する。 In the present embodiment, the water-related member will be described in detail using the floor pan 1 used for the washroom floor for the bathroom.
　２－１．水廻り基材（床パン基材）
　床パン基材３は、複数の凸部２を上面に有する床部３１と、床部３１の端縁部から立ち上がった複数の立ち上がり部３２と、を有する。複数の立ち上がり部３２は、隣接する二つの立ち上がり部３２が角をなすように連続している。 2-1. Water-related base material (floor pan base material)
The floor pan base material 3 has a floor portion 31 having a plurality of convex portions 2 on the upper surface, and a plurality of rising portions 32 rising from the edge portions of the floor portion 31. The plurality of rising portions 32 are continuous so that two adjacent rising portions 32 form a corner.
　本実施形態では、床部３１は、上方から見て、矩形状である。複数の立ち上がり部３２は、床部３１の四つの端辺のそれぞれから立ち上がった四つの立ち上がり部３２ａ，３２ｂ，３２ｃ，３２ｄを有する。四つの立ち上がり部３２ａ，３２ｂ，３２ｃ，３２ｄは、上方から見て矩形枠状に連続しており、四つの角を形成している。 In the present embodiment, the floor portion 31 has a rectangular shape when viewed from above. The plurality of rising portions 32 have four rising portions 32a, 32b, 32c, and 32d rising from each of the four end sides of the floor portion 31. The four rising portions 32a, 32b, 32c, and 32d are continuous in a rectangular frame shape when viewed from above, and form four corners.
　立ち上がり部３２ａは、床部３１の後側の端辺から立ち上がった部分であり、立ち上がり部３２ｂは、床部３１の前側の端辺から立ち上がった部分であり、立ち上がり部３２ｃ，３２ｄは、床部３１の左右の端辺から立ち上がった部分である。 The rising portion 32a is a portion rising from the rear end side of the floor portion 31, the rising portion 32b is a portion rising from the front end side of the floor portion 31, and the rising portions 32c and 32d are the floor portions. It is a part that rises from the left and right ends of 31.
　立ち上がり部３２ｂ，３２ｃ，３２ｄは、形状が共通している。以下では、右側の立ち上がり部３２ｄについて詳しく説明する。図２Ａに示すように、立ち上がり部３２ｄは、床部３１の端辺（詳しくは右側の端辺）から上方に突出した縦板部３２０と、縦板部３２０の上端から水平方向外側（詳しくは右側）に突出した横板部３２１とを有する。立ち上がり部３２ｄは更に、横板部３２１の水平方向外側の端部（詳しくは右端部）から上方に突出した第二縦板部３２２を有する。 The rising portions 32b, 32c, 32d have a common shape. Hereinafter, the rising portion 32d on the right side will be described in detail. As shown in FIG. 2A, the rising portion 32d has a vertical plate portion 320 protruding upward from the end edge of the floor portion 31 (specifically, the right end edge) and the outer side in the horizontal direction (specifically, the upper end of the vertical plate portion 320). It has a horizontal plate portion 321 protruding to the right side). The rising portion 32d further has a second vertical plate portion 322 protruding upward from the horizontal outer end portion (specifically, the right end portion) of the horizontal plate portion 321.
　後側の立ち上がり部３２ａは、床部３１の後側の端辺から上方に突出した縦板部３２３と、縦板部３２３の上端から後側に突出した横板部３２４及び左右一対の傾斜板部３２５と、を有する。 The rear rising portion 32a includes a vertical plate portion 323 protruding upward from the rear end side of the floor portion 31, a horizontal plate portion 324 protruding rearward from the upper end of the vertical plate portion 323, and a pair of left and right inclined plates. It has a part 325 and.
　縦板部３２３の上端のうち左右両端部は、左右方向外側の部分ほど下方に位置するように傾いている。縦板部３２３の上端のうち左右両端部を除く残りの部分は、床部３１に対して平行である。横板部３２４は、縦板部３２３の上端のうち、左右両端部を除く残りの部分から後方に突出している。左右一対の傾斜板部３２５は、縦板部３２３の上端のうち左右両端部から後方に突出している。左右一対の傾斜板部３２５は、左右方向外側の部分ほど下方に位置しており、横板部３２４に対して傾いている。左右一対の傾斜板部３２５は、横板部３２４の左右両端に連続している。 Of the upper ends of the vertical plate portion 323, both left and right ends are inclined so as to be located downward toward the outer portion in the left-right direction. The remaining portion of the upper end of the vertical plate portion 323 except for the left and right ends is parallel to the floor portion 31. The horizontal plate portion 324 projects rearward from the remaining portion of the upper end of the vertical plate portion 323 except for the left and right end portions. The pair of left and right inclined plate portions 325 project rearward from the left and right end portions of the upper end of the vertical plate portion 323. The pair of left and right inclined plate portions 325 are located downward toward the outer portion in the left-right direction, and are inclined with respect to the horizontal plate portion 324. The pair of left and right inclined plate portions 325 are continuous with both left and right ends of the horizontal plate portion 324.
　右側の傾斜板部３２５は、右側の立ち上がり部３２ｄの横板部３２１の後端部と連続している。左側の傾斜板部３２５は、左側の立ち上がり部３２ｃの横板部３２１の後端部と連続している。 The inclined plate portion 325 on the right side is continuous with the rear end portion of the horizontal plate portion 321 of the rising portion 32d on the right side. The inclined plate portion 325 on the left side is continuous with the rear end portion of the horizontal plate portion 321 of the rising portion 32c on the left side.
　四つの立ち上がり部３２ａ，３２ｂ，３２ｃ，３２ｄは、隣接する二つの縦板部同士（縦板部３２０，３２３又は縦板部３２０，３２０）が角を形成して連続している。 The four rising portions 32a, 32b, 32c, and 32d are continuous with two adjacent vertical plate portions ( vertical plate portions 320, 323 or vertical plate portions 320, 320) forming a corner.
　複数の凸部２のそれぞれは、本実施形態では、扁平な直方体状である。複数の凸部２のそれぞれは、左右方向に対して平行な長手方向と、前後方向に対して平行な短手方向と、上下方向に対して平行な厚み方向と、を有する。複数の凸部２は、形状及び寸法が互いに同じである。複数の凸部２は、床部３１の表面（上面）の全体にわたるように、左右方向及び前後方向に列をなして並んで、マトリクス状に配置されている。 Each of the plurality of convex portions 2 has a flat rectangular parallelepiped shape in the present embodiment. Each of the plurality of convex portions 2 has a longitudinal direction parallel to the left-right direction, a lateral direction parallel to the front-rear direction, and a thickness direction parallel to the vertical direction. The plurality of convex portions 2 have the same shape and dimensions. The plurality of convex portions 2 are arranged in a row in the left-right direction and the front-rear direction so as to cover the entire surface (upper surface) of the floor portion 31 and are arranged in a matrix.
　複数の凸部２のそれぞれは、上面２０（突出方向の先端面）と側面２１とを有する。上面２０は、本実施形態では、上方から見て矩形状（詳しくは長方形）であり、側面２１は、前後方向を向く一対の矩形状の面と、左右方向を向く一対の矩形状の面とを含む。 Each of the plurality of convex portions 2 has an upper surface 20 (tip surface in the protruding direction) and a side surface 21. In the present embodiment, the upper surface 20 has a rectangular shape (specifically, a rectangular shape) when viewed from above, and the side surface 21 has a pair of rectangular surfaces facing in the front-rear direction and a pair of rectangular surfaces facing in the left-right direction. including.
　床部３１は、床部３１の上面のうち複数の凸部２を除く部分である溝部３３を有する。本実施形態では、溝部３３は、上方から見て格子状である。複数の凸部２のそれぞれは、溝部３３によって囲まれている。床部３１の上面の外周部（端縁部）は、溝部３３で構成されている。 The floor portion 31 has a groove portion 33 which is a portion of the upper surface of the floor portion 31 excluding a plurality of convex portions 2. In the present embodiment, the groove portions 33 are in a grid pattern when viewed from above. Each of the plurality of convex portions 2 is surrounded by a groove portion 33. The outer peripheral portion (edge portion) of the upper surface of the floor portion 31 is composed of a groove portion 33.
　床パン基材３は、図１に示すように、床部３１の後端部の左右方向の中央部に位置する排水凹部３４を更に有する。排水凹部３４は、上方から見て矩形状の凹みである。排水凹部３４は、中央に排水孔３４０が形成された平面視矩形状の底壁３４１と、底壁３４１の前側の端辺及び左右の端辺から上方に突出した三つの側壁３４２と、を有する。立ち上がり部３２ａの縦板部３２３のうち左右方向の中央部は、底壁３４１の後側の端辺から上方に突出している。三つの側壁３４２と立ち上がり部３２ａの縦板部３２３とは、隣接する部材同士が角をなして連続している。 As shown in FIG. 1, the floor pan base material 3 further has a drainage recess 34 located at the center of the rear end of the floor 31 in the left-right direction. The drainage recess 34 is a rectangular recess when viewed from above. The drainage recess 34 has a bottom wall 341 having a rectangular shape in a plan view in which a drainage hole 340 is formed in the center, and three side walls 342 protruding upward from the front end side and the left and right end sides of the bottom wall 341. .. The central portion of the vertical plate portion 323 of the rising portion 32a in the left-right direction projects upward from the rear end side of the bottom wall 341. The three side walls 342 and the vertical plate portion 323 of the rising portion 32a are continuous with adjacent members forming a corner.
　左右の側壁３４２のそれぞれは、上下方向の中央部に、底壁３４１の上面に対して平行な支持部３４３を有する。支持部３４３は、排水凹部３４に着脱可能に取り付けられる蓋を支持する部分である。 Each of the left and right side wall 342 has a support portion 343 parallel to the upper surface of the bottom wall 341 at the central portion in the vertical direction. The support portion 343 is a portion that supports a lid that is detachably attached to the drainage recess 34.
　床パン基材３は、例えば、繊維強化プラスチックで形成される樹脂成型品である。床パン基材３は、ガラス繊維を含有するＳＭＣ（Ｓｈｅｅｔ　Ｍｏｌｄｉｎｇ　Ｃｏｍｐｏｕｎｄ）材料から形成されてもよいし、アクリル又はポリエステルなどを主成分として含む人工大理石で形成されてもよい。 The floor pan base material 3 is, for example, a resin molded product made of fiber reinforced plastic. The floor pan base material 3 may be formed of an SMC (Sheet Molding Compound) material containing glass fibers, or may be formed of artificial marble containing acrylic or polyester as a main component.
　床パン基材３の表面３０には、図２Ｂに示すように、イソシアネート系のプライマーを塗布して形成されるプライマー層３５が積層される。床パン基材３の表面３０は、床部３１の表面（上面）、四つの立ち上がり部３２ａ，３２ｂ，３２ｃ，３２ｄの表面、及び排水凹部３４の表面を意味する。 As shown in FIG. 2B, a primer layer 35 formed by applying an isocyanate-based primer is laminated on the surface 30 of the floor pan base material 3. The surface 30 of the floor pan base material 3 means the surface (upper surface) of the floor portion 31, the surfaces of the four rising portions 32a, 32b, 32c, 32d, and the surface of the drainage recess 34.
　四つの立ち上がり部３２ａ，３２ｂ，３２ｃ，３２ｄの表面とは、前後の立ち上がり部３２ａ，３２ｂの上方を向く面と前後方向内側を向く面と、左右の立ち上がり部３２ｃ，３２ｄの上方を向く面と左右方向内側を向く面とを意味する。排水凹部３４の表面とは、底壁３４１の上面と、左右の側壁３４２の上方を向く面と左右方向内側を向く面と、前側の側壁３４２の後側を向く面とを意味する。 The surfaces of the four rising portions 32a, 32b, 32c, 32d are a surface facing upward of the front and rear rising portions 32a, 32b, a surface facing inward in the front-rear direction, and a surface facing upward of the left and right rising portions 32c, 32d. It means a surface facing inward in the left-right direction. The surface of the drainage recess 34 means an upper surface of the bottom wall 341, a surface facing upward of the left and right side walls 342, a surface facing inward in the left-right direction, and a surface facing the rear side of the front side wall 342.
　２－２．加飾フィルム
　加飾フィルム４は、真空圧空成形又は真空成形によって床パン基材３の表面３０に密着される部材である。本実施形態では、加飾フィルム４は、熱可塑性を有するフィルム本体４０を有する。粒材５は、フィルム本体４０に混合し、フィルム本体４０よりも軟化温度が高い。 2-2. Decorative film The decorative film 4 is a member that is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum pressure air forming or vacuum forming. In the present embodiment, the decorative film 4 has a film body 40 having thermoplasticity. The grain material 5 is mixed with the film body 40 and has a softening temperature higher than that of the film body 40.
　フィルム本体４０は、その表面（つまり加飾フィルム４の表面）を構成する表面層４１と、表面層４１の裏側に位置するベース層４２と、を含む。フィルム本体４０は更に、表面層４１とベース層４２との間に位置する印刷層４３と、ベース層４２の裏側に位置する接着層４４とを含む。 The film body 40 includes a surface layer 41 constituting the surface thereof (that is, the surface of the decorative film 4) and a base layer 42 located on the back side of the surface layer 41. The film body 40 further includes a printing layer 43 located between the surface layer 41 and the base layer 42, and an adhesive layer 44 located on the back side of the base layer 42.
　表面層４１は、例えば、透明なＰＭＭＡ（Ｐｏｌｙｍｅｔｈｙｌ　ｍｅｔｈａｃｒｙｌａｔｅ）で形成される。表面層４１の厚みは、例えば、３０μｍ以上１００μｍ以下であり、本実施形態では、５０μｍである。表面層４１は、透明なＰＭＭＡに限らず、フッ素が含有又はアロイされた透明なＰＭＭＡで形成されてもよいし、透明なＰＶＣ（ｐｏｌｙｖｉｎｙｌ　ｃｈｌｏｒｉｄｅ）で形成されてもよい。また、表面層４１は、加飾されたＰＭＭＡ、ＰＶＣ、ＡＢＳ（Ａｃｒｙｌｏｎｉｔｒｉｌｅ　ｂｕｔａｄｉｅｎｅ　ｓｔｙｒｅｎｅ）で形成されてもよい。表面層４１には、表面層４１の表面に凹凸が形成されるように、複数の粒材５が混合されて分散している。本実施形態では、表面層４１のうち、床パン基材３の床部３１を覆う部分にのみ、複数の粒材５が混合されており、複数の立ち上がり部３２及び排水凹部３４を覆う部分には、複数の粒材５が混合されていない。 The surface layer 41 is formed of, for example, a transparent PMMA (Polymethyl methyllate). The thickness of the surface layer 41 is, for example, 30 μm or more and 100 μm or less, and in this embodiment, 50 μm. The surface layer 41 is not limited to the transparent PMMA, and may be formed of a transparent PMMA containing or alloyed with fluorine, or may be formed of a transparent PVC (polyvinyl chloride). Further, the surface layer 41 may be formed of decorated PMMA, PVC, or ABS (Acrylonirile butadiene style). A plurality of granules 5 are mixed and dispersed in the surface layer 41 so that irregularities are formed on the surface of the surface layer 41. In the present embodiment, the plurality of granules 5 are mixed only in the portion of the surface layer 41 that covers the floor portion 31 of the floor pan base material 3, and the portion that covers the plurality of rising portions 32 and the drainage recess 34. Is not a mixture of the plurality of granules 5.
　粒材５は、フィルム本体４０を加熱により軟化させるときの加熱温度で熱変形しない、又は熱変形しにくい材料で形成される。粒材５は、例えば、シリカ等の無機系フィラーである。粒材５は、シリカに限らず、炭酸カルシウム、水酸化アルミニウム等の無機系フィラーであってもよいし、アクリル系フィラー、又は有機系フィラーであってもよい。また、粒材５は、上記の各種の粒材５の組み合わせであってもよい。 The grain material 5 is formed of a material that does not deform or is not easily deformed at the heating temperature when the film body 40 is softened by heating. The granule 5 is, for example, an inorganic filler such as silica. The granule 5 is not limited to silica, and may be an inorganic filler such as calcium carbonate or aluminum hydroxide, an acrylic filler, or an organic filler. Further, the grain material 5 may be a combination of the above-mentioned various grain materials 5.
　粒材５の直径は、５μｍ以上３０μｍ以下である。粒材５の直径が５μｍより小さい場合には、加飾フィルム４のフィルム本体４０の表面に表れる凹凸が小さくて、滑り止めの機能が十分に得ることができない。また、粒材５の直径が３０μｍより大きい場合には、加飾フィルム４のフィルム本体４０の表面粗さが大きくなり過ぎて、肌触りが悪化する。表面層４１に混合される粒材５の直径及び量は、表面層４１の厚みや必要な滑り止め機能に応じて、適宜設定される。粒材５の直径が、上記範囲の場合、加飾フィルム４の表面、つまり床パン１の表面に滑り止め機能を付与できる他、床パン１の表面に疑似親水も発現させることができて、床パン１の表面の水はけ性の向上を図ることもできる。 The diameter of the grain material 5 is 5 μm or more and 30 μm or less. When the diameter of the grain material 5 is smaller than 5 μm, the unevenness appearing on the surface of the film body 40 of the decorative film 4 is small, and the anti-slip function cannot be sufficiently obtained. Further, when the diameter of the grain material 5 is larger than 30 μm, the surface roughness of the film body 40 of the decorative film 4 becomes too large, and the touch is deteriorated. The diameter and amount of the granular material 5 mixed with the surface layer 41 are appropriately set according to the thickness of the surface layer 41 and the required anti-slip function. When the diameter of the grain material 5 is in the above range, the surface of the decorative film 4, that is, the surface of the floor pan 1 can be provided with a non-slip function, and the surface of the floor pan 1 can also be provided with pseudohydrophilicity. It is also possible to improve the drainage property of the surface of the floor pan 1.
　ベース層４２は、例えば、硬質ＰＶＣで形成される。ベース層４２の厚みは、例えば、５０μｍ以上２５０μｍ以下であり、本実施形態では、１１０μｍである。ベース層４２は、硬質ＰＶＣに限らず、軟質ＰＶＣやＡＢＳで形成されてもよい。 The base layer 42 is made of, for example, hard PVC. The thickness of the base layer 42 is, for example, 50 μm or more and 250 μm or less, and 110 μm in the present embodiment. The base layer 42 is not limited to hard PVC, but may be formed of soft PVC or ABS.
　印刷層４３は、加飾フィルム４の表面に柄や色を表示させるための層である。印刷層４３の柄や色は、表面層４１を透過して加飾フィルム４の表面側から見える。 The print layer 43 is a layer for displaying a pattern or a color on the surface of the decorative film 4. The pattern and color of the print layer 43 pass through the surface layer 41 and are visible from the surface side of the decorative film 4.
　接着層４４は、ベース層４２の裏面に積層している。接着層４４の厚みは、例えば、５０μｍである。接着層４４は、加水分解しにくいＰＭＭＡ系接着剤で形成される。接着層４４は、ＰＭＭＡ系に限らず、エポキシ系、ウレタン系、シアノアクリレート系、変形シリコン系、又はポリエステル系の接着剤で形成されてもよい。 The adhesive layer 44 is laminated on the back surface of the base layer 42. The thickness of the adhesive layer 44 is, for example, 50 μm. The adhesive layer 44 is formed of a PMMA-based adhesive that is difficult to hydrolyze. The adhesive layer 44 is not limited to PMMA-based, and may be formed of an epoxy-based, urethane-based, cyanoacrylate-based, modified silicon-based, or polyester-based adhesive.
　上述した加飾フィルム４は、プライマー層３５を介して床パン基材３の表面３０に密着するように貼り合わされる。床パン基材３の表面３０への加飾フィルム４の密着は、後述する真空圧空成形又は真空成形により行われる。 The above-mentioned decorative film 4 is attached to the surface 30 of the floor pan base material 3 via the primer layer 35 so as to be in close contact with the surface 30. The decorative film 4 is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum forming or vacuum forming, which will be described later.
　３．水廻り部材（床パン）の製造方法
　床パン１は、ＴＯＭ（Ｔｈｒｅｅ　Ｄｅｍｅｎｓｉｏｎ　Ｏｖｅｒｌａｙ　Ｍｅｔｈｏｄ）成形（言い換えると真空圧空成形）によって、加飾フィルム４を床パン基材３の表面３０に密着させることで製造される。 3. 3. Manufacturing method of water-related member (floor pan) The floor pan 1 is formed by TOM (Three Generation Overlay Method) molding (in other words, vacuum pressure air molding) to bring the decorative film 4 into close contact with the surface 30 of the floor pan base material 3. Manufactured.
　詳しくは、床パン１の製造方法は、塗布工程、設置工程、減圧工程、加熱工程、押圧工程、密着工程、離型工程、及び切除工程を備える。 Specifically, the method for manufacturing the floor pan 1 includes a coating process, an installation process, a depressurizing process, a heating process, a pressing process, an adhesion process, a mold release process, and a cutting process.
　床パン１は、例えば、図３Ａから図３Ｃに示す成形機１００を用いて真空圧空成形される。成形機１００は、上チャンバー１０１、下チャンバー１０２、ヒーター１０３、台座１０４、昇降装置１０５、真空タンク、及び圧空タンクを備える。 The floor pan 1 is vacuum compressed air molded using, for example, the molding machines 100 shown in FIGS. 3A to 3C. The molding machine 100 includes an upper chamber 101, a lower chamber 102, a heater 103, a pedestal 104, an elevating device 105, a vacuum tank, and a compressed air tank.
　真空タンクは、上チャンバー１０１と下チャンバー１０２のそれぞれに接続されており、チャンバー１０１，１０２内をそれぞれ独立して真空状態まで減圧することができる。圧空タンクは、上チャンバー１０１に接続されており、上チャンバー１０１内を圧空することができる。 The vacuum tank is connected to each of the upper chamber 101 and the lower chamber 102, and the inside of the chambers 101 and 102 can be independently depressurized to a vacuum state. The compressed air tank is connected to the upper chamber 101, and the inside of the upper chamber 101 can be compressed.
　上チャンバー１０１は、下チャンバー１０２との間に加飾フィルム４を挟み込む位置と、下チャンバー１０２から離れた位置との間で移動可能である。上チャンバー１０１は、下面が開口した箱型である。上チャンバー１０１内には、ヒーター１０３が設置されている。ヒーター１０３は、加飾フィルム４が軟化する温度まで、加飾フィルム４を加熱することができる。 The upper chamber 101 can be moved between a position where the decorative film 4 is sandwiched between the upper chamber 101 and the lower chamber 102 and a position away from the lower chamber 102. The upper chamber 101 has a box shape with an open lower surface. A heater 103 is installed in the upper chamber 101. The heater 103 can heat the decorative film 4 to a temperature at which the decorative film 4 softens.
　下チャンバー１０２は、上面が開口した箱型である。下チャンバー１０２内には、台座１０４が設置されており、台座１０４は昇降装置１０５によって上下に移動可能である。台座１０４上には、床パン基材３を水平方向に移動不可に支持する支持台１０６が載置される。 The lower chamber 102 is a box type with an open upper surface. A pedestal 104 is installed in the lower chamber 102, and the pedestal 104 can be moved up and down by the elevating device 105. A support base 106 that immovably supports the floor pan base material 3 in the horizontal direction is placed on the pedestal 104.
　続いて、床パン１の製造方法の各工程について詳しく説明する。 Next, each process of the manufacturing method of the floor pan 1 will be described in detail.
　塗布工程では、床パン基材３の表面３０の全体に、プライマーを塗布してプライマー層３５を形成する。 In the coating step, a primer is applied to the entire surface 30 of the floor pan base material 3 to form a primer layer 35.
　次いで、設置工程では、図３Ａに示すように、下チャンバー１０２内の台座１０４上の支持台１０６の上に床パン基材３を設置し、下チャンバー１０２の上面の開口を塞ぐように、加飾フィルム４を下チャンバー１０２の上面に設置する。次いで、上チャンバー１０１を降下させて、上チャンバー１０１と下チャンバー１０２とで加飾フィルム４を挟み込む。このとき、チャンバー１０１，１０２内は密閉状態となる。 Next, in the installation step, as shown in FIG. 3A, the floor pan base material 3 is installed on the support base 106 on the pedestal 104 in the lower chamber 102, and the floor pan base material 3 is added so as to close the opening on the upper surface of the lower chamber 102. The decorative film 4 is installed on the upper surface of the lower chamber 102. Next, the upper chamber 101 is lowered, and the decorative film 4 is sandwiched between the upper chamber 101 and the lower chamber 102. At this time, the insides of the chambers 101 and 102 are sealed.
　次いで、減圧工程では、図３Ｂに示すように、真空タンクによってチャンバー１０１，１０２内をそれぞれ減圧して真空状態とする。 Next, in the depressurization step, as shown in FIG. 3B, the insides of the chambers 101 and 102 are decompressed by a vacuum tank to create a vacuum state.
　次いで、加熱工程では、ヒーター１０３によって、加飾フィルム４を加熱し、軟化させる。このとき、加飾フィルム４では、フィルム本体４０が軟化するものの、複数の粒材５は軟化せず、フィルム本体４０の表面に粒材５による凹凸が形成された状態を維持することができる。 Next, in the heating step, the decorative film 4 is heated and softened by the heater 103. At this time, in the decorative film 4, although the film body 40 is softened, the plurality of grain materials 5 are not softened, and it is possible to maintain a state in which irregularities due to the grain materials 5 are formed on the surface of the film body 40.
　次いで、押圧工程では、図３Ｃに示すように、昇降装置１０５によって台座１０４を上昇させて、床パン基材３の表面３０に軟化した状態の加飾フィルム４を押し当てる。 Next, in the pressing step, as shown in FIG. 3C, the pedestal 104 is raised by the elevating device 105, and the softened decorative film 4 is pressed against the surface 30 of the floor pan base material 3.
　次いで、密着工程では、圧空タンクによって上チャンバー１０１内を圧空する。これにより、床パン基材３の表面３０の全体に、軟化した状態の加飾フィルム４が押し当てられて、床パン基材３の表面３０の形状に加飾フィルム４が変形し、加飾フィルム４が表面３０に密着する。次いで、加飾フィルム４を冷却して硬化させる。 Next, in the close contact process, the inside of the upper chamber 101 is compressed by a compressed air tank. As a result, the softened decorative film 4 is pressed against the entire surface 30 of the floor pan base material 3, and the decorative film 4 is deformed into the shape of the surface 30 of the floor pan base material 3 to decorate the floor pan base material 3. The film 4 comes into close contact with the surface 30. Next, the decorative film 4 is cooled and cured.
　次いで、離型工程では、上チャンバー１０１内及び下チャンバー１０２内をそれぞれ大気圧にし、上チャンバー１０１を上昇させて、支持台１０６から、加飾フィルム４が表面３０に密着した床パン基材３を取り外す。 Next, in the mold release step, the pressure inside the upper chamber 101 and the inside of the lower chamber 102 are set to atmospheric pressure, the upper chamber 101 is raised, and the decorative film 4 is brought into close contact with the surface 30 from the support base 106. Remove.
　次いで、切除工程では、図３Ｄに示すように、加飾フィルム４のうち、床パン基材３の表面３０からはみ出した部分を切除する。これにより、床パン１が形成される。 Next, in the excision step, as shown in FIG. 3D, the portion of the decorative film 4 that protrudes from the surface 30 of the floor pan base material 3 is excised. As a result, the floor pan 1 is formed.
　上記の各工程を経て製造された床パン１では、床パン基材３の表面３０の全体に加飾フィルム４が密着している。詳しくは、加飾フィルム４は、床パン基材３の床部３１の表面の複数の凸部２のそれぞれの上面２０及び側面２１の全体に密着し、上面２０及び側面２１に沿って変形している。床パン基材３の表面３０と加飾フィルム４との間には空気が介在しない。 In the floor pan 1 manufactured through each of the above steps, the decorative film 4 is in close contact with the entire surface 30 of the floor pan base material 3. Specifically, the decorative film 4 is in close contact with the entire upper surface 20 and side surface 21 of each of the plurality of convex portions 2 on the surface of the floor portion 31 of the floor pan base material 3, and is deformed along the upper surface 20 and the side surface 21. ing. Air does not intervene between the surface 30 of the floor pan base material 3 and the decorative film 4.
　床パン１では、加飾フィルム４の表面に複数の粒材５による凹凸が形成されている。これにより、床パン１の底部の上面（床部３１を覆う加飾フィルム４の上面）には、滑り止め機能が付与されている。粒材５は、ＴＯＭ成形時の加飾フィルム４を加熱する加熱温度では軟化しない又は軟化しにくい部材であるため、床パン１の底部の上面に所望の大きさの凹凸を形成することができる。 In the floor pan 1, unevenness due to a plurality of grain materials 5 is formed on the surface of the decorative film 4. As a result, the upper surface of the bottom portion of the floor pan 1 (the upper surface of the decorative film 4 covering the floor portion 31) is provided with a non-slip function. Since the grain material 5 is a member that does not soften or is hard to soften at the heating temperature for heating the decorative film 4 during TOM molding, unevenness of a desired size can be formed on the upper surface of the bottom of the floor pan 1. ..
　４．変形例
　以上説明した本実施形態の床パン１及びその製造方法の変形例について説明する。 4. Modification Example A modification of the floor pan 1 of the present embodiment described above and the method of manufacturing the same will be described.
　床パン１は、ＴＯＭ成形（真空圧空成形）に限らず、真空成形によって床パン基材３の表面３０に加飾フィルム４が密着されたものであってもよい。この場合、床パン基材３には、床パン基材３の表面３０から裏面にわたって貫通する貫通孔が設けられる。そして、床パン１の製造工程のうち、密着工程では、床パン基材３に設けた貫通孔を通じて、加飾フィルム４を床パン基材３側に真空引きする。これにより、加飾フィルム４は、床パン基材３の表面３０に密着される。 The floor pan 1 is not limited to TOM molding (vacuum pressure air molding), and the decorative film 4 may be adhered to the surface 30 of the floor pan base material 3 by vacuum forming. In this case, the floor pan base material 3 is provided with a through hole penetrating from the front surface 30 to the back surface of the floor pan base material 3. Then, in the adhesion step of the manufacturing process of the floor pan 1, the decorative film 4 is evacuated to the floor pan base material 3 side through the through holes provided in the floor pan base material 3. As a result, the decorative film 4 is brought into close contact with the surface 30 of the floor pan base material 3.
　粒材５は、表面層４１のみに限らず、表面層４１とベース層４２の両方に含まれていてもよいし、また、印刷層４３にも含まれていてもよい。また、粒材５は、表面層４１のうち床部３１を覆う部分のみに限らず、表面層４１の全体に含まれてもよい。 The grain material 5 is not limited to the surface layer 41, but may be contained in both the surface layer 41 and the base layer 42, or may be contained in the printing layer 43 as well. Further, the grain material 5 is not limited to the portion of the surface layer 41 that covers the floor portion 31, and may be included in the entire surface layer 41.
　粒材５は、フィルム本体４０の軟化温度よりも高ければよく、中実に限らず、中空であってもよい。 The grain material 5 may be hollow as long as it is higher than the softening temperature of the film body 40, and is not limited to solid.
　床パン基材３は、床部３１と立ち上がり部３２のうち、床部３１のみを有してもよい。 The floor pan base material 3 may have only the floor portion 31 of the floor portion 31 and the rising portion 32.
　複数の凸部２は、形状及び寸法が互いに同じでなくてもよく、種々の形状や寸法のものが混在していてもよい。 The shape and dimensions of the plurality of convex portions 2 do not have to be the same as each other, and those having various shapes and dimensions may be mixed.
　床パン１の製造方法は、上述した塗布工程、設置工程、減圧工程、加熱工程、押圧工程、密着工程、離型工程、及び切除工程の全てを備えなくてもよく、例えば、床パン基材３の材質によっては、塗布工程は省略可能である。 The method for producing the floor pan 1 does not have to include all of the above-mentioned coating step, installation step, depressurizing step, heating step, pressing step, adhesion step, mold release step, and cutting step. For example, the floor pan base material Depending on the material of 3, the coating step can be omitted.
　（実施形態２）
　続いて、図４に示す実施形態２の床パン１及びその製造方法について説明する。以下では、実施形態２の床パン１及びその製造方法について、実施形態１の床パン１及びその製造方法と共通する構成については図中に同じ符号を付して説明を省略し、実施形態１の床パン１及びその製造方法とは異なる構成については詳しく説明する。 (Embodiment 2)
Subsequently, the floor pan 1 of the second embodiment shown in FIG. 4 and a method for manufacturing the same will be described. In the following, the floor pan 1 of the second embodiment and the method for manufacturing the floor pan 1 and the structure common to the floor pan 1 of the first embodiment and the manufacturing method thereof are designated by the same reference numerals in the drawings, and the description thereof will be omitted. The floor pan 1 and the configuration different from the manufacturing method thereof will be described in detail.
　実施形態２の床パン１では、加飾フィルム４は、熱可塑性を有するフィルム本体４０と、フィルム本体４０の表面に設けられた塗膜４５と、を有する。塗膜４５に粒材５が含まれている。粒材５の直径は、１μｍ以上３０μｍ以下である。 In the floor pan 1 of the second embodiment, the decorative film 4 has a film main body 40 having thermoplasticity and a coating film 45 provided on the surface of the film main body 40. The coating film 45 contains the granular material 5. The diameter of the grain material 5 is 1 μm or more and 30 μm or less.
　塗膜４５は、例えばＰＭＭＡを主成分とする塗料で形成される。粒材５は、塗膜４５を形成する塗料に含まれている。塗膜４５は、複数の粒材５を含む塗料をフィルム本体４０の表面層４１の表面に塗布することで、フィルム本体４０の表面に設けられる。 The coating film 45 is formed of, for example, a paint containing PMMA as a main component. The grain material 5 is contained in the paint forming the coating film 45. The coating film 45 is provided on the surface of the film body 40 by applying a paint containing a plurality of grain materials 5 to the surface of the surface layer 41 of the film body 40.
　塗膜４５の厚みは、例えば、１μｍ以上５０μｍ以下である。本実施形態では、塗膜４５の厚みは５μｍであり、粒材５の直径は１０μｍである。塗膜４５は、真空圧空成形又は真空成形時に伸びることができる。 The thickness of the coating film 45 is, for example, 1 μm or more and 50 μm or less. In the present embodiment, the thickness of the coating film 45 is 5 μm, and the diameter of the grain material 5 is 10 μm. The coating film 45 can be stretched during vacuum forming or vacuum forming.
　フィルム本体４０の表面層４１は、透明なＰＭＭＡで形成される。表面層４１は、粒材５を含まない。 The surface layer 41 of the film body 40 is formed of transparent PMMA. The surface layer 41 does not contain the grain material 5.
　続いて、本実施形態の床パン１の製造方法について詳しく説明する。 Subsequently, the manufacturing method of the floor pan 1 of the present embodiment will be described in detail.
　本実施形態の製造方法では、設置工程において、フィルム本体４０の表面に粒材５を含んだ塗膜４５が設けられた加飾フィルム４を用いる。その他の工程については、実施形態１の床パン１の製造方法と同じである。 In the manufacturing method of the present embodiment, in the installation process, a decorative film 4 in which a coating film 45 containing a grain material 5 is provided on the surface of the film body 40 is used. Other steps are the same as the manufacturing method of the floor pan 1 of the first embodiment.
　以上説明した実施形態２の床パン１においても、実施形態１の床パン１と同様に、加飾フィルム４の表面に複数の粒材５による凹凸が形成されて、床パン１の底部の上面（床部３１を覆う加飾フィルム４の上面）に、滑り止め機能を付与することができる。 In the floor pan 1 of the second embodiment described above, similarly to the floor pan 1 of the first embodiment, the surface of the decorative film 4 is formed with irregularities due to the plurality of grain materials 5, and the upper surface of the bottom of the floor pan 1 is formed. (The upper surface of the decorative film 4 covering the floor portion 31) can be provided with a non-slip function.
　以上説明した実施形態２の床パン１及びその製造方法は、上述した実施形態１の床パン１及びその製造方法の変形例を適宜組み合わせてもよい。 The floor pan 1 of the second embodiment and the manufacturing method thereof described above may be appropriately combined with a modified example of the floor pan 1 of the first embodiment and the manufacturing method thereof described above.
　（実施形態３）
　続いて、図５に示す実施形態３の床パン１及びその製造方法について説明する。以下では、実施形態３の床パン１及びその製造方法について、実施形態１の床パン１及びその製造方法と共通する構成については図中に同じ符号を付して説明を省略し、実施形態１の床パン１及びその製造方法とは異なる構成については詳しく説明する。 (Embodiment 3)
Subsequently, the floor pan 1 of the third embodiment shown in FIG. 5 and a method for manufacturing the same will be described. In the following, the floor pan 1 of the third embodiment and the method for manufacturing the floor pan 1 and the structure common to the floor pan 1 of the first embodiment and the manufacturing method thereof are designated by the same reference numerals in the drawings, and the description thereof will be omitted. The floor pan 1 and the configuration different from the manufacturing method thereof will be described in detail.
　実施形態３の床パン１では、加飾フィルム４は、熱可塑性を有するフィルム本体４０と、フィルム本体４０の表面に設けられた塗膜４６と、を有する。塗膜４６に粒材５が含まれている。粒材５の直径は、１μｍ以上３０μｍ以下である。 In the floor pan 1 of the third embodiment, the decorative film 4 has a film main body 40 having thermoplasticity and a coating film 46 provided on the surface of the film main body 40. The coating film 46 contains the granular material 5. The diameter of the grain material 5 is 1 μm or more and 30 μm or less.
　塗膜４６は、例えばＰＭＭＡを主成分とする塗料で形成される。粒材５は、塗膜４６を形成する塗料に含まれている。塗膜４６は、真空成形又は真空圧空成形の後に、粒材５を含む塗料をフィルム本体４０の表面層４１の表面に塗布することで、フィルム本体４０の表面に設けられる。 The coating film 46 is formed of, for example, a paint containing PMMA as a main component. The grain material 5 is contained in the paint forming the coating film 46. The coating film 46 is provided on the surface of the film body 40 by applying a paint containing the granular material 5 to the surface of the surface layer 41 of the film body 40 after vacuum forming or vacuum forming.
　塗膜４６の厚みは、例えば、１μｍ以上５０μｍ以下である。本実施形態では、塗膜４６の厚みは５μｍであり、粒材５の直径は１０μｍである。塗膜４６は、真空圧空成形又は真空成形後に、形成されるものであるため、真空圧空成形又は真空成形時に伸びる性質を有さなくてもよい。 The thickness of the coating film 46 is, for example, 1 μm or more and 50 μm or less. In the present embodiment, the thickness of the coating film 46 is 5 μm, and the diameter of the grain material 5 is 10 μm. Since the coating film 46 is formed after vacuum forming or vacuum forming, it does not have to have the property of stretching during vacuum forming or vacuum forming.
　フィルム本体４０の表面層４１は、透明なＰＭＭＡで形成される。表面層４１は、粒材５を含まない。 The surface layer 41 of the film body 40 is formed of transparent PMMA. The surface layer 41 does not contain the grain material 5.
　続いて、本実施形態の床パン１の製造方法について詳しく説明する。 Subsequently, the manufacturing method of the floor pan 1 of the present embodiment will be described in detail.
　本実施形態の製造方法は、押圧工程と、密着工程と、塗布工程と、を備える、押圧工程では、複数の凸部２を表面３０に有する床パン基材３の表面３０に、加熱により軟化させたフィルム本体４０を押し当てる。密着工程では、真空圧空成形又は真空成形によりフィルム本体４０を床パン基材３の表面３０に密着させる。塗布工程では、床パン基材３に密着したフィルム本体４０の表面に、直径が１μｍ以上３０μｍ以下の粒材５を含む塗料を塗布する。 The manufacturing method of the present embodiment includes a pressing step, a close contact step, and a coating step. In the pressing step, the surface 30 of the floor pan base material 3 having a plurality of convex portions 2 on the surface 30 is softened by heating. The film body 40 is pressed against the film body 40. In the close contact step, the film body 40 is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum pressure air forming or vacuum forming. In the coating step, a paint containing a granular material 5 having a diameter of 1 μm or more and 30 μm or less is applied to the surface of the film body 40 that is in close contact with the floor pan base material 3.
　詳しくは、本実施形態の製造方法は、実施形態１の製造方法の、塗布工程、設置工程、減圧工程、加熱工程、押圧工程、密着工程、離型工程、及び切除工程に加えて、密着工程よりも後に行われる塗布工程（以下「第二塗布工程」という）を備える。 Specifically, the manufacturing method of the present embodiment includes a contacting step in addition to the coating step, the setting step, the depressurizing step, the heating step, the pressing step, the adhesion step, the mold release step, and the cutting step of the manufacturing method of the first embodiment. It is provided with a coating step (hereinafter referred to as "second coating step") performed after that.
　本実施形態の製造方法では、設置工程において、表面に塗膜４６が形成されていないフィルム本体４０を用いる。減圧工程、加熱工程、押圧工程、密着工程、離型工程、及び切除工程は、実施形態１の製造方法の各工程と同様の工程である。減圧工程、加熱工程、押圧工程、密着工程、離型工程、及び切除工程においても、表面に塗膜４６が形成されていないフィルム本体４０を用いる。 In the manufacturing method of the present embodiment, the film body 40 in which the coating film 46 is not formed on the surface is used in the installation process. The depressurizing step, the heating step, the pressing step, the close contact step, the mold release step, and the cutting step are the same steps as each step of the manufacturing method of the first embodiment. The film body 40 having no coating film 46 formed on the surface is also used in the depressurizing step, the heating step, the pressing step, the adhesion step, the mold release step, and the cutting step.
　第二塗布工程は、例えば、切除工程の後に行う。第二塗布工程では、床パン基材３の表面３０に密着し、表面３０と同形状に変形したフィルム本体４０の表面に、粒材５を含む塗料を塗布する。塗布した塗料を硬化させることで、フィルム本体４０の表面に粒材５を含む塗膜４６が形成される。これにより、本実施形態の床パン１が製造される。 The second coating step is performed, for example, after the excision step. In the second coating step, a paint containing the granular material 5 is applied to the surface of the film body 40 which is in close contact with the surface 30 of the floor pan base material 3 and is deformed into the same shape as the surface 30. By curing the applied paint, a coating film 46 containing the granular material 5 is formed on the surface of the film body 40. As a result, the floor pan 1 of the present embodiment is manufactured.
　以上説明した実施形態３の床パン１においても、実施形態１の床パン１と同様に、加飾フィルム４の表面に複数の粒材５による凹凸が形成されて、床パン１の底部の上面（床部３１を覆う加飾フィルム４の上面）に、滑り止め機能を付与することができる。また、複数の粒材５による凹凸によって床パン１の表面に疑似親水も発現させることができて、床パン１の表面の水はけ性の向上を図ることもできる。 In the floor pan 1 of the third embodiment described above, similarly to the floor pan 1 of the first embodiment, the surface of the decorative film 4 is formed with irregularities due to the plurality of granules 5, and the upper surface of the bottom of the floor pan 1 is formed. (The upper surface of the decorative film 4 covering the floor portion 31) can be provided with a non-slip function. Further, pseudo-hydrophilicity can be developed on the surface of the floor pan 1 due to the unevenness of the plurality of granules 5, and the drainage property of the surface of the floor pan 1 can be improved.
　以上説明した実施形態３の床パン１及びその製造方法は、上述した実施形態１の床パン１及びその製造方法の変形例を適宜組み合わせてもよい。 The floor pan 1 of the third embodiment and the manufacturing method thereof described above may be appropriately combined with a modified example of the floor pan 1 of the first embodiment and the manufacturing method thereof described above.
　（実施形態４）
　続いて、図６及び図７に示す実施形態４の床パン１及びその製造方法について説明する。以下では、実施形態４の床パン１及びその製造方法について、実施形態１の床パン１及びその製造方法と共通する構成については図中に同じ符号を付して説明を省略し、実施形態１の床パン１及びその製造方法とは異なる構成については詳しく説明する。 (Embodiment 4)
Subsequently, the floor pan 1 of the fourth embodiment shown in FIGS. 6 and 7 and a method for manufacturing the floor pan 1 will be described. In the following, the floor pan 1 of the fourth embodiment and the method for manufacturing the floor pan 1 and the structure common to the floor pan 1 of the first embodiment and the manufacturing method thereof are designated by the same reference numerals in the drawings, and the description thereof will be omitted. The floor pan 1 and the configuration different from the manufacturing method thereof will be described in detail.
　実施形態４の床パン１は、屈曲したコーナー部６を有する床パン基材３と、コーナー部６の表面に塗布された着色プライマー７と、床パン基材３の表面３０に密着した加飾フィルム４と、を備える。加飾フィルム４は、コーナー部６を覆う部分に他の部分よりも薄肉の伸び部４７を有する。伸び部４７は、着色プライマー７を介してコーナー部６に密着している。 The floor pan 1 of the fourth embodiment is decorated with a floor pan base material 3 having a bent corner portion 6, a colored primer 7 applied to the surface of the corner portion 6, and a decoration in close contact with the surface 30 of the floor pan base material 3. The film 4 and the like are provided. The decorative film 4 has an elongated portion 47 that is thinner than the other portions in the portion that covers the corner portion 6. The elongated portion 47 is in close contact with the corner portion 6 via the colored primer 7.
　実施形態４の床パン１の製造方法は、塗布工程、押圧工程、及び密着工程を備える。塗布工程は、屈曲したコーナー部６を有する床パン基材３のコーナー部６の表面に、着色プライマー７を塗布する工程である。押圧工程は、床パン基材３の表面３０に、加熱により軟化させた加飾フィルム４を押し当てる工程である。密着工程は、真空圧空成形又は真空成形により加飾フィルム４を床パン基材３の表面３０に密着させる工程である。加飾フィルム４は、密着工程において形成され、加飾フィルム４の他の部分よりも薄肉である伸び部４７を有する。伸び部４７は、着色プライマー７を介してコーナー部６に密着される。 The method for manufacturing the floor pan 1 of the fourth embodiment includes a coating step, a pressing step, and a close contact step. The coating step is a step of applying the coloring primer 7 to the surface of the corner portion 6 of the floor pan base material 3 having the bent corner portion 6. The pressing step is a step of pressing the decorative film 4 softened by heating against the surface 30 of the floor pan base material 3. The adhesion step is a step of adhering the decorative film 4 to the surface 30 of the floor pan base material 3 by vacuum pressure air forming or vacuum forming. The decorative film 4 has an elongated portion 47 which is formed in the close contact step and is thinner than the other parts of the decorative film 4. The elongated portion 47 is brought into close contact with the corner portion 6 via the colored primer 7.
　本実施形態の床パン１及びその製造方法では、加飾フィルム４の薄肉の伸び部４７が着色プライマー７を介してコーナー部６に密着するため、コーナー部６と伸び部４７との密着性の向上が図れる。また、本実施形態の床パンの製造方法では、伸び部４７が透けても着色プライマー７が伸び部４７の表面に表示されるため、床パン基材３の透け防止を図ることができる。 In the floor pan 1 of the present embodiment and the manufacturing method thereof, the thin-walled elongated portion 47 of the decorative film 4 adheres to the corner portion 6 via the coloring primer 7, so that the adhesiveness between the corner portion 6 and the elongated portion 47 is maintained. It can be improved. Further, in the floor bread manufacturing method of the present embodiment, even if the stretched portion 47 is transparent, the colored primer 7 is displayed on the surface of the stretched portion 47, so that the floor pan base material 3 can be prevented from seeing through.
　以下では、本実施形態の床パン１及びその製造方法について更に詳しく説明する。 Hereinafter, the floor pan 1 of the present embodiment and the manufacturing method thereof will be described in more detail.
　床パン基材３は、コーナー部６として、床部３１の四隅に位置する四つの第一コーナー部６ａと、排水凹部３４の底壁３４１の四隅に位置する四つの第二コーナー部６ｂとを有する。第一コーナー部６ａは、四つの立ち上がり部３２のうちの隣接する二つの立ち上がり部３２と床部３１とで囲んで形成される内隅部分である。第二コーナー部６ｂは、排水凹部３４の三つの側壁３４２と後側の立ち上がり部３２ａのうちの隣接する二つの部材と底壁３４１とで囲んで形成される内隅部分である。 The floor pan base material 3 has four first corner portions 6a located at the four corners of the floor portion 31 and four second corner portions 6b located at the four corners of the bottom wall 341 of the drainage recess 34 as corner portions 6. Have. The first corner portion 6a is an inner corner portion formed by being surrounded by two adjacent rising portions 32 and a floor portion 31 among the four rising portions 32. The second corner portion 6b is an inner corner portion formed by surrounding the three side walls 342 of the drainage recess 34, two adjacent members of the rear rising portion 32a, and the bottom wall 341.
　本実施形態では、各コーナー部６の表面には、着色プライマー７が塗布されて着色プライマー層３６が形成される。本実施形態では、着色プライマー層３６は、四つの第一コーナー部６ａ及びその周辺部分と、四つの第二コーナー部６ｂ及びその周辺部分のそれぞれの表面に、形成されている。 In the present embodiment, the coloring primer 7 is applied to the surface of each corner portion 6 to form the coloring primer layer 36. In the present embodiment, the colored primer layer 36 is formed on the surfaces of each of the four first corner portions 6a and its peripheral portions and the four second corner portions 6b and its peripheral portions.
　着色プライマー７は、ウレタン系、アクリル系、エポキシ系、変形シリコン系などの合成樹脂プライマーに顔料等の着色剤を混ぜて、着色したものである。着色プライマー７の色は、加飾フィルム４のうち伸び部４７を除いた他の部分の色と同系色である。着色プライマー７の色は、例えば、加飾フィルム４のうち伸び部４７を除いた他の部分の色と同色、又は、コの他の部分の色に対して色調のみ異なる色である。着色プライマー７の色は、加飾フィルム４の伸び部４７の表面に表示される色が、加飾フィルム４の他の部分と同色に見えるように、適宜選択可能である。なお、着色プライマー７の色は、加飾フィルム４の他の部分と同色に見えるような色であれば、無色に近い色であってもよい。 The coloring primer 7 is colored by mixing a coloring agent such as a pigment with a synthetic resin primer such as urethane-based, acrylic-based, epoxy-based, or modified silicon-based. The color of the coloring primer 7 is similar to the color of the other portion of the decorative film 4 excluding the elongated portion 47. The color of the coloring primer 7 is, for example, the same color as the color of the other portion of the decorative film 4 excluding the elongated portion 47, or a color different only in color tone from the color of the other portion of the film 4. The color of the coloring primer 7 can be appropriately selected so that the color displayed on the surface of the elongated portion 47 of the decorative film 4 looks the same as the other parts of the decorative film 4. The color of the coloring primer 7 may be a color close to colorless as long as it looks the same as the other parts of the decorative film 4.
　着色プライマー層３６は、床パン基材３のコーナー部６の表面に直接積層されてもよいし、コーナー部６の表面に積層されたプライマー層３５の表面に積層されてもよい。 The colored primer layer 36 may be laminated directly on the surface of the corner portion 6 of the floor pan base material 3, or may be laminated on the surface of the primer layer 35 laminated on the surface of the corner portion 6.
　本実施形態では、床パン基材３の表面３０の全体に積層されたプライマー層３５は、加飾フィルム４と同系色ではないプライマーで形成される。このプライマーは、ウレタン系、アクリル系、エポキシ系、変形シリコン系などの合成樹脂プライマーである。プライマー層３５は、着色プライマー７で形成されてもよい。 In the present embodiment, the primer layer 35 laminated on the entire surface 30 of the floor pan base material 3 is formed of a primer that is not similar in color to the decorative film 4. This primer is a synthetic resin primer such as urethane-based, acrylic-based, epoxy-based, and modified silicone-based. The primer layer 35 may be formed of the colored primer 7.
　本実施形態では、加飾フィルム４は、加熱前の状態では、例えば矩形状の１枚のシートであり、全体にわたって厚みが一定である。加飾フィルム４は、加熱前の状態では、全体にわたって色が同じである。加飾フィルム４は、床パン基材３とは異なる色で形成されている。加飾フィルム４の色は、適宜設定可能であるが、例えば、茶色等の濃色である。 In the present embodiment, the decorative film 4 is, for example, a rectangular sheet in a state before heating, and the thickness is constant throughout. The decorative film 4 has the same color as a whole in the state before heating. The decorative film 4 is formed in a color different from that of the floor pan base material 3. The color of the decorative film 4 can be set as appropriate, but is, for example, a dark color such as brown.
　加飾フィルム４は、加熱により軟化した状態において、真空圧空成形又は真空成形によって床パン基材３の表面３０に密着されることで、コーナー部６を覆う部分に他の部分より薄肉の伸び部４７が形成される。伸び部４７は、四つの第一コーナー部６ａのそれぞれを覆う部分と、四つの第二コーナー部６ｂのそれぞれを覆う部分とに形成される。 In a state of being softened by heating, the decorative film 4 is brought into close contact with the surface 30 of the floor pan base material 3 by vacuum forming or vacuum forming, so that the portion covering the corner portion 6 is thinner than the other portions. 47 is formed. The extension portion 47 is formed into a portion that covers each of the four first corner portions 6a and a portion that covers each of the four second corner portions 6b.
　伸び部４７は、加飾フィルム４のうち伸び部４７を除いた他の部分よりも色が薄く、本実施形態では、透光可能である。伸び部４７を通じてその裏側の部分の色が伸び部４７の表面に表示される。本実施形態では、コーナー部６及びその周辺部分に着色プライマー７が塗布されているため、伸び部４７の表面には加飾フィルム４の他の部分の表面と略同じ色が表示される。これにより、加飾フィルム４の表面全体に、同じ色が表示される。 The stretched portion 47 is lighter in color than the other portion of the decorative film 4 excluding the stretched portion 47, and is translucent in the present embodiment. The color of the portion on the back side thereof is displayed on the surface of the extension portion 47 through the extension portion 47. In the present embodiment, since the coloring primer 7 is applied to the corner portion 6 and the peripheral portion thereof, substantially the same color as the surface of the other portion of the decorative film 4 is displayed on the surface of the elongated portion 47. As a result, the same color is displayed on the entire surface of the decorative film 4.
　続いて、本実施形態の床パン１の製造方法について説明する。 Subsequently, the manufacturing method of the floor pan 1 of the present embodiment will be described.
　本実施形態の製造方法は、実施形態１の製造方法と同様に、塗布工程、設置工程、減圧工程、加熱工程、押圧工程、密着工程、離型工程、及び切除工程を備える。 The manufacturing method of the present embodiment includes a coating step, an installation step, a depressurizing step, a heating step, a pressing step, an adhesion step, a mold release step, and a cutting step, similarly to the manufacturing method of the first embodiment.
　塗布工程において、床パン基材３のコーナー部６及びその周辺部分の表面に、着色プライマー７を塗布して着色プライマー層３６を形成する。本実施形態では、床部３１の四隅の四つの第一コーナー部６ａ及びその周辺部分と、排水凹部３４の四隅の四つの第二コーナー部６ｂ及びその周辺部分のそれぞれに、着色プライマー７を塗布して着色プライマー層３６を形成する。着色プライマー層３６の形成は、床パン基材３の表面３０の全体に、加飾フィルム４とは非同系色のプライマーを塗布してプライマー層３５を形成したうえで行ってもよいし、コーナー部６に対してプライマー層３５を介さずに直接形成してもよい。 In the coating step, the coloring primer 7 is applied to the surface of the corner portion 6 of the floor pan base material 3 and the peripheral portion thereof to form the coloring primer layer 36. In the present embodiment, the colored primer 7 is applied to each of the four first corners 6a and its peripheral portions at the four corners of the floor portion 31 and the four second corner portions 6b and its peripheral portions at the four corners of the drainage recess 34. To form the colored primer layer 36. The colored primer layer 36 may be formed by applying a primer having a color similar to that of the decorative film 4 to the entire surface 30 of the floor pan base material 3 to form the primer layer 35, or the corners. It may be formed directly with respect to the part 6 without passing through the primer layer 35.
　密着工程において、床パン基材３の表面３０の全体に、軟化した状態の加飾フィルム４が押し当てられて、床パン基材３の表面３０の形状に加飾フィルム４が変形し、加飾フィルム４が表面３０に密着する。このとき、加飾フィルム４のうち、コーナー部６ａ，６ｂに密着する部分が延びて薄肉の伸び部４７が形成される。 In the adhesion step, the softened decorative film 4 is pressed against the entire surface 30 of the floor pan base material 3, and the decorative film 4 is deformed into the shape of the surface 30 of the floor pan base material 3 and added. The decorative film 4 comes into close contact with the surface 30. At this time, the portion of the decorative film 4 that is in close contact with the corner portions 6a and 6b is extended to form a thin-walled elongated portion 47.
　上記の各工程を経て製造された床パン１では、床パン基材３の表面３０の全体に加飾フィルム４が密着している。加飾フィルム４の複数の伸び部４７のそれぞれの表面には、着色プライマー７の色が表示され、これにより、床パン１の表面全体には、同じ色が表示される。 In the floor pan 1 manufactured through each of the above steps, the decorative film 4 is in close contact with the entire surface 30 of the floor pan base material 3. The color of the coloring primer 7 is displayed on the surface of each of the plurality of elongated portions 47 of the decorative film 4, whereby the same color is displayed on the entire surface of the floor pan 1.
　以上説明した実施形態４の床パン１及びその製造方法は、上述した実施形態１の床パン１及びその製造方法の変形例と適宜組み合わせ可能である。また、実施形態４の床パン１及びその製造方法は、実施形態２，３の床パン１及びその製造方法と組み合わせ可能である。 The floor pan 1 of the fourth embodiment and the manufacturing method thereof described above can be appropriately combined with the floor pan 1 of the first embodiment and the modified example of the manufacturing method thereof. Further, the floor pan 1 of the fourth embodiment and the manufacturing method thereof can be combined with the floor pan 1 of the second and third embodiments and the manufacturing method thereof.
　また、床パン基材３は、屈曲したコーナー部６を有するものであればよく、立ち上がり部３２を有さず、床部３１と排水凹部３４のみを有してもよい。また、床パン基材３は、床部３１と立ち上がり部３２とを有し、排水凹部３４を有さなくてもよい。また、床パン基材３は、屈曲したコーナー部６を形成するその他の部分を有してもよい。 Further, the floor pan base material 3 may have any bent corner portion 6, and may have only the floor portion 31 and the drainage recess 34 without the rising portion 32. Further, the floor pan base material 3 has a floor portion 31 and a rising portion 32, and does not have to have a drainage recess 34. Further, the floor pan base material 3 may have other portions forming the bent corner portion 6.
　排水凹部３４は、平面視矩形状に限らず、平面視円形状等の、側壁３４２が角を形成して連続しない形状であってもよい。 The drainage recess 34 is not limited to a rectangular shape in a plan view, and may have a shape in which the side wall 342 forms a corner and is not continuous, such as a circular shape in a plan view.
　着色プライマー７は、図８に示す床パン１の変形例のように、複数の立ち上がり部３２のそれぞれと床部３１とがなす角部分及びその周辺部分（つまり床部３１の各端辺及びその周辺部分）に更に塗布されてもよい。そして、着色プライマー７は、排水凹部３４の左右の側壁３４２の支持部３４３よりも上方の部分と支持部３４３とがなす角部分及びその周辺部分に更に塗布されてもよい。 The coloring primer 7 is a corner portion formed by each of the plurality of rising portions 32 and the floor portion 31 and a peripheral portion thereof (that is, each end side of the floor portion 31 and its peripheral portion) as in the modified example of the floor pan 1 shown in FIG. Peripheral portion) may be further applied. Then, the colored primer 7 may be further applied to the corner portion formed by the portion above the support portion 343 of the left and right side wall 342 of the drainage recess 34 and the support portion 343 and the peripheral portion thereof.
　また、着色プライマー７は、排水凹部３４の複数の側壁３４２のそれぞれと底壁３４１とがなす角部分及びその周辺部分（つまり底壁３４１の各端辺及びその周辺部分）に更に塗布されてもよい。つまり、着色プライマー７は、床パン基材３のうち、密着工程において加飾フィルム４に形成される伸び部４７に対応する箇所の全体又はその一部に、塗布されてもよい。着色プライマー７は、床パン基材３の角部分（伸び部４７に対応する箇所）に限らず、床パン基材３の表面３０の全体に塗布されてもよい。 Further, the colored primer 7 may be further applied to the corner portion formed by each of the plurality of side walls 342 of the drainage recess 34 and the bottom wall 341 and its peripheral portion (that is, each end side of the bottom wall 341 and its peripheral portion). Good. That is, the coloring primer 7 may be applied to all or a part of the floor pan base material 3 corresponding to the elongated portion 47 formed on the decorative film 4 in the adhesion step. The coloring primer 7 may be applied not only to the corner portion of the floor pan base material 3 (the portion corresponding to the elongated portion 47) but also to the entire surface 30 of the floor pan base material 3.
　着色プライマー７は、加飾フィルム４のうち伸び部４７を除いた他の部分と同系色でなくてもよく、伸び部４７の表面に表示される色が加飾フィルム４の他の部分の表面に表示される色と略同じとなるように、適宜選択可能である。 The coloring primer 7 does not have to be the same color as the other portion of the decorative film 4 except for the stretched portion 47, and the color displayed on the surface of the stretched portion 47 is the surface of the other portion of the decorative film 4. It can be appropriately selected so that it is substantially the same as the color displayed in.
　床パン１は、プライマー層３５を有さなくてもよく、この場合、加飾フィルム４のうち伸び部４７を除いた残りの部分は、接着層４４の接着力によって、床パン基材３の表面３０に直接接着される。 The floor pan 1 does not have to have the primer layer 35. In this case, the remaining portion of the decorative film 4 excluding the stretched portion 47 is made of the floor pan base material 3 due to the adhesive force of the adhesive layer 44. It is directly adhered to the surface 30.
　（まとめ）
　以上説明した各実施形態及びその変形例のように、第一態様の水廻り部材（床パン１）は、下記の構成を備える。 (Summary)
As in each of the above-described embodiments and modifications thereof, the water-related member (floor pan 1) of the first aspect has the following configuration.
　すなわち、第一態様の水廻り部材（床パン１）は、複数の凸部（２）を表面（３０）に有する水廻り基材（床パン基材３）と、水廻り基材（床パン基材３）の表面（３０）に密着した加飾フィルム（４）と、を備える。加飾フィルム（４）は、直径が１μｍ以上３０μｍ以下であり、かつ加飾フィルム（４）の他の部分よりも軟化温度が高い粒材（５）を有する。 That is, the water-related member (floor pan 1) of the first aspect includes a water-related base material (floor pan base material 3) having a plurality of convex portions (2) on the surface (30) and a water-related base material (floor pan). A decorative film (4) that is in close contact with the surface (30) of the base material 3) is provided. The decorative film (4) has a grain material (5) having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film (4).
　上記構成を備える第一態様の水廻り部材（床パン１）では、粒材（５）によって加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に凹凸を形成しやすい。第一態様の水廻り部材（床パン１）では、例えば、加飾フィルム（４）を加熱して軟化させて水廻り基材（床パン基材３）の表面（３０）に密着させる場合に、加飾フィルム（４）の他の部分は軟化するものの、粒材（５）は軟化しない。そのため、第一態様の水廻り部材（床パン１）では、加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に、粒材（５）による凹凸を形成しやすい。 In the water-related member (floor pan 1) of the first aspect having the above configuration, the grain material (5) forms irregularities on the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1). Cheap. In the water-related member (floor pan 1) of the first aspect, for example, when the decorative film (4) is heated and softened to be brought into close contact with the surface (30) of the water-related base material (floor pan base material 3). , The other part of the decorative film (4) is softened, but the grain material (5) is not softened. Therefore, in the water-related member (floor pan 1) of the first aspect, unevenness due to the grain material (5) is likely to be formed on the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1). ..
　また、上述した各実施形態及びその変形例のように、第二態様の水廻り部材（床パン１）は、第一態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the second aspect has the following configuration in addition to the configuration of the water supply member (floor pan 1) of the first aspect. Is additionally provided.
　すなわち、第二態様の水廻り部材（床パン１）では、加飾フィルム（４）は、熱可塑性を有するフィルム本体（４０）を有する。粒材（５）は、フィルム本体（４０）に混合し、フィルム本体（４０）より軟化温度が高い。 That is, in the water-related member (floor pan 1) of the second aspect, the decorative film (4) has a film body (40) having thermoplasticity. The grain material (5) is mixed with the film body (40) and has a higher softening temperature than the film body (40).
　上記構成を備える第二態様の水廻り部材（床パン１）では、加飾フィルム（４）を加熱して軟化させて水廻り基材（床パン基材３）の表面（３０）に密着させる場合に、フィルム本体（４０）は軟化するものの、粒材（５）は軟化しない。そのため、第二態様の床パン（１）では、加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に、粒材（５）による凹凸を形成しやすい。 In the second aspect of the water circulation member (floor pan 1) having the above configuration, the decorative film (4) is heated and softened to be brought into close contact with the surface (30) of the water circulation base material (floor pan base material 3). In this case, the film body (40) softens, but the grain material (5) does not soften. Therefore, in the floor pan (1) of the second aspect, unevenness due to the grain material (5) is likely to be formed on the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1).
　また、上述した各実施形態及びその変形例のように、第三態様の水廻り部材（床パン１）は、第一態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the third aspect has the following configuration in addition to the configuration of the water supply member (floor pan 1) of the first aspect. Is additionally provided.
　すなわち、第三態様の水廻り部材（床パン１）では、加飾フィルム（４）は、熱可塑性を有するフィルム本体（４０）と、フィルム本体（４０）の表面に設けられた塗膜（４５，４６）と、を有する。粒材（５）は、塗膜（４５，４６）に含まれている。 That is, in the water-related member (floor pan 1) of the third aspect, the decorative film (4) is a film body (40) having thermoplasticity and a coating film (45) provided on the surface of the film body (40). , 46) and. The grain material (5) is contained in the coating film (45, 46).
　上記構成を備える第三態様の水廻り部材（床パン１）では、塗膜（４５，４６）に含まれる粒材（５）によって、加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に、凹凸を形成することができる。 In the water-related member (floor pan 1) of the third aspect having the above configuration, the surface of the decorative film (4), that is, the water-related member ( Unevenness can be formed on the surface of the floor pan 1).
　また、上述した各実施形態及びその変形例のように、第四態様の水廻り部材（床パン１）は、第一から第三のいずれか一つの態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the fourth aspect is the water supply member (floor pan 1) of any one of the first to third aspects. In addition to the configuration, the following configuration is additionally provided.
　すなわち、第四態様の水廻り部材（床パン１）では、加飾フィルム（４）は、複数の凸部（２）のそれぞれの上面（２０）及び側面（２１）に密着して、複数の凸部（２）のそれぞれの上面（２０）及び側面（２１）に沿うように変形している。 That is, in the water-related member (floor pan 1) of the fourth aspect, the decorative film (4) is in close contact with the upper surface (20) and the side surface (21) of the plurality of convex portions (2), respectively. It is deformed along the upper surface (20) and the side surface (21) of the convex portion (2), respectively.
　上記構成を備える第四態様の水廻り部材（床パン１）では、加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に、水廻り基材（床パン基材３）の複数の凸部（２）の形状が表れやすくて、複数の凸部（２）による滑り止め機能を発揮しやすい。 In the fourth aspect of the water-related member (floor pan 1) having the above configuration, the water-related base material (floor pan base material) is placed on the surface of the decorative film (4), that is, on the surface of the water-related member (floor pan 1). The shape of the plurality of convex portions (2) of 3) is likely to appear, and the anti-slip function of the plurality of convex portions (2) is likely to be exhibited.
　また、上述した各実施形態及びその変形例のように、第五態様の水廻り部材（床パン１）は、第二態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the fifth aspect has the following configuration in addition to the configuration of the water supply member (floor pan 1) of the second aspect. Is additionally provided.
　すなわち、第五態様の水廻り部材（床パン１）では、フィルム本体（４０）は、フィルム本体（４０）の表面を構成する表面層（４１）と、表面層（４１）の裏側に位置するベース層（４２）と、を含む。粒材（５）は、表面層（４１）に含まれている。 That is, in the water-related member (floor pan 1) of the fifth aspect, the film body (40) is located on the surface layer (41) constituting the surface of the film body (40) and the back side of the surface layer (41). Includes a base layer (42). The grain material (5) is contained in the surface layer (41).
　上記構成を備える第五態様の水廻り部材（床パン１）では、フィルム本体（４０）の表面に粒材（５）による凹凸を形成しやすく、また、フィルム本体（４０）の表面に凹凸を形成するために必要な粒材（５）の量を抑えることができる。 In the fifth aspect of the water circulation member (floor pan 1) having the above configuration, unevenness due to the grain material (5) is likely to be formed on the surface of the film body (40), and unevenness is formed on the surface of the film body (40). The amount of the granular material (5) required for forming can be suppressed.
　また、上述した各実施形態及びその変形例のように、第六態様の水廻り部材（床パン１）は、第一から第五のいずれか一つの態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the sixth aspect is the water supply member (floor pan 1) of any one of the first to fifth aspects. In addition to the configuration, the following configuration is additionally provided.
　すなわち、第六態様の水廻り部材（床パン１）では、粒材（５）は、中実である。 That is, in the water-related member (floor pan 1) of the sixth aspect, the grain material (5) is solid.
　上記構成を備える第六態様の水廻り部材（床パン１）では、加飾フィルム（４）を加熱して軟化させて水廻り基材（床パン基材３）の表面（３０）に密着させる場合に、粒材（５）が潰れる等して加飾フィルム（４）の表面に形成される凹凸の大きさが小さくなることを防ぐことができる。そのため、第六態様の水廻り部材（床パン１）では、中実の粒材（５）によって加飾フィルム（４）の表面に意図した大きさの凹凸を形成しやすい。 In the sixth aspect of the water circulation member (floor pan 1) having the above configuration, the decorative film (4) is heated and softened to be brought into close contact with the surface (30) of the water circulation base material (floor pan base material 3). In this case, it is possible to prevent the size of the unevenness formed on the surface of the decorative film (4) from becoming smaller due to the grain material (5) being crushed or the like. Therefore, in the water-related member (floor pan 1) of the sixth aspect, unevenness of an intended size is likely to be formed on the surface of the decorative film (4) by the solid grain material (5).
　また、上述した各実施形態及びその変形例のように、第七態様の水廻り部材（床パン１）は、第一から第六のいずれか一つの態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the seventh aspect is the water supply member (floor pan 1) of any one of the first to sixth aspects. In addition to the configuration, the following configuration is additionally provided.
　すなわち、第七態様の水廻り部材（床パン１）では、水廻り基材（床パン基材３）は、複数の凸部（２）を上面に有する床部（３１）と、床部（３１）の端縁部から立ち上がった立ち上がり部（３２）と、を有する。加飾フィルム（４）は、床部（３１）の上面と立ち上がり部（３２）の表面のそれぞれに、密着している。 That is, in the water-related member (floor pan 1) of the seventh aspect, the water-related base material (floor pan base material 3) has a floor portion (31) having a plurality of convex portions (2) on the upper surface and a floor portion (floor portion (31)). It has a rising portion (32) rising from the edge portion of 31). The decorative film (4) is in close contact with each of the upper surface of the floor portion (31) and the surface of the rising portion (32).
　上記構成を備える第七態様の水廻り部材（床パン１）では、水廻り基材（床パン基材３）のうち、床部（３１）の表面に対応する部分だけでなく、立ち上がり部（３２）の表面に対応する部分にも、粒材（５）による凹凸を形成することができる。 In the water-related member (floor pan 1) of the seventh aspect having the above configuration, not only the portion of the water-related base material (floor pan base material 3) corresponding to the surface of the floor portion (31) but also the rising portion (floor pan 1) Concavities and convexities due to the grain material (5) can also be formed on the portion corresponding to the surface of 32).
　また、上述した各実施形態及びその変形例のように、第八態様の水廻り部材（床パン１）の製造方法は、下記の構成を備える。 Further, as in each of the above-described embodiments and modifications thereof, the method for manufacturing the water-related member (floor pan 1) of the eighth aspect has the following configuration.
　すなわち、第八態様の水廻り部材（床パン１）の製造方法は、押圧工程と密着工程とを備える。押圧工程は、複数の凸部（２）を表面（３０）に有する水廻り基材（床パン基材３）の表面（３０）に、加熱により軟化させた加飾フィルム（４）を押し当てる工程である。密着工程は、真空圧空成形又は真空成形により加飾フィルム（４）を水廻り基材（床パン基材３）の表面（３０）に密着させる工程である。加飾フィルム（４）は、直径が１μｍ以上３０μｍ以下であり、かつ加飾フィルム（４）の他の部分よりも軟化温度が高い粒材（５）を有する。 That is, the method for manufacturing the water-related member (floor pan 1) of the eighth aspect includes a pressing step and a close contact step. In the pressing step, the decorative film (4) softened by heating is pressed against the surface (30) of the water-related base material (floor pan base material 3) having the plurality of convex portions (2) on the surface (30). It is a process. The adhesion step is a step of adhering the decorative film (4) to the surface (30) of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming. The decorative film (4) has a grain material (5) having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film (4).
　上記構成を備える第八態様の水廻り部材（床パン１）の製造方法では、加飾フィルム（４）を加熱して軟化させて水廻り基材（床パン基材３）の表面（３０）に密着させる際に、加飾フィルム（４）の他の部分は軟化するものの、粒材（５）は軟化しない。そのため、第六態様の水廻り部材（床パン１）の製造方法では、加飾フィルム（４）の表面、つまり水廻り部材（床パン１）の表面に粒材（５）による凹凸を形成しやすい。 In the method for manufacturing the water-related member (floor pan 1) of the eighth aspect having the above configuration, the decorative film (4) is heated and softened to soften the surface (30) of the water-related base material (floor pan base material 3). The other part of the decorative film (4) is softened, but the grain material (5) is not softened. Therefore, in the method for manufacturing the water-related member (floor pan 1) of the sixth aspect, the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1) is formed with irregularities due to the grain material (5). Cheap.
　また、上述した各実施形態及びその変形例のように、第九態様の水廻り部材（床パン１）の製造方法は、第八態様の水廻り部材（床パン１）の製造方法の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the method for manufacturing the water-related member (floor pan 1) in the ninth aspect is the same as the method for producing the water-related member (floor pan 1) in the eighth aspect. In addition, the following configuration is additionally provided.
　すなわち、第九態様の水廻り部材（床パン１）の製造方法は、加飾フィルム（４）は、熱可塑性を有するフィルム本体（４０）を有する。粒材（５）は、フィルム本体（４０）に混合し、フィルム本体（４０）よりも軟化温度が高い。 That is, in the method for manufacturing the water-related member (floor pan 1) of the ninth aspect, the decorative film (4) has a film body (40) having thermoplasticity. The grain material (5) is mixed with the film body (40) and has a higher softening temperature than the film body (40).
　上記構成を備える第九態様の水廻り部材（床パン１）の製造方法では、加飾フィルム（４）を加熱して軟化させて水廻り基材（床パン基材３）の表面（３０）に密着させる際に、フィルム本体（４０）は軟化するものの、粒材（５）は軟化しない。そのため、第九態様の水廻り部材（床パン１）の製造方法では、加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に、粒材（５）による凹凸を形成しやすい。 In the method for manufacturing the water-related member (floor pan 1) of the ninth aspect having the above configuration, the decorative film (4) is heated and softened to soften the surface (30) of the water-related base material (floor pan base material 3). The film body (40) softens, but the grain material (5) does not soften. Therefore, in the method for manufacturing the water-related member (floor pan 1) of the ninth aspect, the surface of the decorative film (4), that is, the surface of the water-related member (floor pan 1) is uneven due to the grain material (5). Easy to form.
　また、上述した各実施形態及びその変形例のように、第十態様の水廻り部材（床パン１）の製造方法は、第八態様の水廻り部材（床パン１）の製造方法の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the method for manufacturing the water-related member (floor pan 1) of the tenth aspect is the same as the method for producing the water-related member (floor pan 1) of the eighth aspect. In addition, the following configuration is additionally provided.
　すなわち、第十態様の水廻り部材（床パン１）の製造方法では、加飾フィルム（４）は、熱可塑性を有するフィルム本体（４０）と、フィルム本体（４０）の表面に設けられた塗膜（４５）と、を有する。粒材（５）は、塗膜（４５）に含まれている。 That is, in the method for manufacturing the water-related member (floor pan 1) of the tenth aspect, the decorative film (4) is a film body (40) having thermoplasticity and a coating provided on the surfaces of the film body (40). It has a film (45) and. The grain material (5) is contained in the coating film (45).
　上記構成を備える第十態様の水廻り部材（床パン１）の製造方法では、塗膜（４５）に含まれる粒材（５）によって、加飾フィルム（４）の表面、つまり、水廻り部材（床パン１）の表面に、凹凸を形成することができる。 In the method for manufacturing the water-related member (floor pan 1) of the tenth aspect having the above configuration, the surface of the decorative film (4), that is, the water-related member is made of the grain material (5) contained in the coating film (45). Unevenness can be formed on the surface of (floor pan 1).
　また、上述した各実施形態及びその変形例のように、第十一態様の水廻り部材（床パン１）の製造方法は、下記の構成を備える。 Further, as in each of the above-described embodiments and modifications thereof, the method for manufacturing the water-related member (floor pan 1) of the eleventh aspect has the following configuration.
　すなわち、第十一態様の水廻り部材（床パン１）の製造方法は、押圧工程と密着工程と塗布工程とを備える。押圧工程は、複数の凸部（２）を表面（３０）に有する水廻り基材（床パン基材３）の表面（３０）に、加熱により軟化させたフィルム本体（４０）を押し当てる工程である。密着工程は、真空圧空成形又は真空成形によりフィルム本体（４０）を水廻り基材（床パン基材３）の表面（３０）に密着させる工程である。塗布工程は、水廻り基材（床パン基材３）に密着したフィルム本体（４０）の表面に、直径が１μｍ以上３０μｍ以下の粒材（５）を含む塗料を塗布する工程である。 That is, the method for manufacturing the water-related member (floor pan 1) of the eleventh aspect includes a pressing step, a close contact step, and a coating step. The pressing step is a step of pressing the film body (40) softened by heating against the surface (30) of the water-related base material (floor pan base material 3) having a plurality of convex portions (2) on the surface (30). Is. The close contact step is a step of bringing the film body (40) into close contact with the surface (30) of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming. The coating step is a step of applying a paint containing a granular material (5) having a diameter of 1 μm or more and 30 μm or less on the surface of the film body (40) that is in close contact with the water-related base material (floor pan base material 3).
　上記構成を備える第十一態様の水廻り部材（床パン１）の製造方法では、塗料に含まれる粒材（５）によって、フィルム本体（４０）の表面、つまり水廻り部材（床パン１）の表面に粒材（５）による凹凸を形成することができる。 In the method for manufacturing the water-related member (floor pan 1) of the eleventh aspect having the above configuration, the surface of the film body (40), that is, the water-related member (floor pan 1) is made of the grain material (5) contained in the paint. It is possible to form irregularities on the surface of the grain material (5).
　（その他）
　また、上述した各実施形態及びその変形例のように、第十二態様の水廻り部材（床パン１）は、下記の構成を備える。 (Other)
Further, as in each of the above-described embodiments and modifications thereof, the water-related member (floor pan 1) of the twelfth aspect has the following configuration.
　すなわち、第十二態様の水廻り部材（床パン１）は、屈曲したコーナー部（６）を有する水廻り基材（床パン基材３）と、コーナー部（６）の表面に塗布された着色プライマー（７）と、水廻り基材（床パン基材３）の表面（３０）に密着した加飾フィルム（４）と、を備える。加飾フィルム（４）は、コーナー部（６）を覆う部分に他の部分よりも薄肉の伸び部（４７）を有する。伸び部（４７）は、着色プライマー（７）を介してコーナー部（６）に密着している。 That is, the water circulation member (floor pan 1) of the twelfth aspect is applied to the surface of the water circulation base material (floor pan base material 3) having the bent corner portion (6) and the corner portion (6). A coloring primer (7) and a decorative film (4) in close contact with the surface (30) of the water-related base material (floor pan base material 3) are provided. The decorative film (4) has a stretched portion (47) thinner than the other portion in the portion covering the corner portion (6). The elongated portion (47) is in close contact with the corner portion (6) via the colored primer (7).
　上記構成を備える第十二態様の水廻り部材（床パン１）では、加飾フィルム（４）の薄肉の伸び部（４７）が着色プライマー（７）を介してコーナー部（６）に密着するため、コーナー部（６）と伸び部（４７）との密着性の向上が図れる。また、第十二態様の床パン（１）では、伸び部（４７）が透けていても着色プライマー（７）の色が伸び部（４７）の表面に表示されるため、水廻り基材（床パン基材３）の透け防止を図ることができる。 In the water-related member (floor pan 1) of the twelfth aspect having the above configuration, the thin-walled stretched portion (47) of the decorative film (4) adheres to the corner portion (6) via the colored primer (7). Therefore, the adhesion between the corner portion (6) and the extension portion (47) can be improved. Further, in the floor pan (1) of the twelfth aspect, even if the stretched portion (47) is transparent, the color of the coloring primer (7) is displayed on the surface of the stretched portion (47). It is possible to prevent see-through of the floor pan base material 3).
　また、上述した各実施形態及びその変形例のように、第十三態様の水廻り部材（床パン１）は、第十二態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water circulation member (floor pan 1) of the thirteenth aspect has the following configuration in addition to the configuration of the water circulation member (floor pan 1) of the twelfth aspect. The configuration of is additionally provided.
　すなわち、第十三態様の水廻り部材（床パン１）では、水廻り基材（床パン基材３）は、床部（３１）と、床部（３１）の端縁部から立ち上がった複数の立ち上がり部（３２）と、を有する。コーナー部（６）は、複数の立ち上がり部（３２）のうち隣接する二つの立ち上がり部（３２）と床部（３１）とで形成される角部分（第一コーナー部６ａ）を含む。この角部分に、着色プライマー（７）が塗布されている。 That is, in the water-related member (floor pan 1) of the thirteenth aspect, the water-related base material (floor pan base material 3) is a plurality of rising from the floor portion (31) and the edge portion of the floor portion (31). It has a rising portion (32) of the above. The corner portion (6) includes a corner portion (first corner portion 6a) formed by two adjacent rising portions (32) and a floor portion (31) among the plurality of rising portions (32). A coloring primer (7) is applied to this corner portion.
　上記構成を備える第十三態様の水廻り部材（床パン１）では、複数の立ち上がり部（３２）のうち隣接する二つの立ち上がり部（３２）と床部（３１）とで形成される角部分において、伸び部（４７）との密着性の向上や、水廻り基材（床パン基材３）の透け防止を図ることができる。 In the water circulation member (floor pan 1) of the thirteenth aspect having the above configuration, a corner portion formed by two adjacent rising portions (32) and a floor portion (31) among a plurality of rising portions (32). In the above, it is possible to improve the adhesion to the stretched portion (47) and prevent the water-related base material (floor pan base material 3) from seeping through.
　また、上述した各実施形態及びその変形例のように、第十四態様の水廻り部材（床パン１）は、第十二又は第十三態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the fourteenth aspect has the configuration of the water supply member (floor pan 1) of the twelfth or thirteenth aspect. In addition, the following configuration is additionally provided.
　すなわち、第十四態様の水廻り部材（床パン１）では、水廻り基材（床パン基材３）は、排水孔（３４０）が設けられた排水凹部（３４）を有する。排水凹部（３４）は、底壁（３４１）と、底壁（３４１）の端縁部から立ち上がった複数の側壁（３４２）と、を含む。コーナー部（６）は、複数の側壁（３４２）のうち隣接する二つの側壁（３４２）と底壁（３４１）とで形成される角部分（第二コーナー部６ｂ）を含む。この角部分に、着色プライマー（７）が塗布されている。 That is, in the water-related member (floor pan 1) of the fourteenth aspect, the water-related base material (floor pan base material 3) has a drainage recess (34) provided with a drainage hole (340). The drainage recess (34) includes a bottom wall (341) and a plurality of side walls (342) rising from the edge of the bottom wall (341). The corner portion (6) includes a corner portion (second corner portion 6b) formed by two adjacent side walls (342) and a bottom wall (341) among the plurality of side walls (342). A coloring primer (7) is applied to this corner portion.
　上記構成を備える第十四態様の水廻り部材（床パン１）では、複数の側壁（３４２）のうち隣接する二つの側壁（３４２）と底壁（３４１）とで形成される角部分において、伸び部（４７）との密着性の向上や、水廻り基材（床パン基材３）の透け防止を図ることができる。 In the water circulation member (floor pan 1) of the fourteenth aspect having the above configuration, at the corner portion formed by the two adjacent side walls (342) and the bottom wall (341) of the plurality of side walls (342), It is possible to improve the adhesion to the stretched portion (47) and prevent see-through of the water-related base material (floor pan base material 3).
　また、上述した各実施形態及びその変形例のように、第十五態様の水廻り部材（床パン１）は、第十二から第十四のいずれか一つの態様の水廻り部材（床パン１）の構成に加えて、下記の構成を付加的に備える。 Further, as in each of the above-described embodiments and modifications thereof, the water supply member (floor pan 1) of the fifteenth aspect is the water supply member (floor pan 1) of any one of the twelfth to fourteenth aspects. In addition to the configuration of 1), the following configuration is additionally provided.
　すなわち、第十五態様の水廻り部材（床パン１）では、着色プライマー（７）は、加飾フィルム（４）のうち、伸び部（４７）を除いた他の部分と同系色である。 That is, in the water-related member (floor pan 1) of the fifteenth aspect, the coloring primer (7) has the same color as the other portion of the decorative film (4) excluding the elongated portion (47).
　上記構成を備える第十五態様の水廻り部材（床パン１）では、伸び部（４７）の表面に表示される色が、加飾フィルム（４）のうち伸び部（４７）を除いた他の部分の表面に表示される色と同じとなりやすい。 In the water-related member (floor pan 1) of the fifteenth aspect having the above configuration, the color displayed on the surface of the elongated portion (47) is the decorative film (4) excluding the elongated portion (47). It tends to be the same as the color displayed on the surface of the part.
　また、上述した各実施形態及びその変形例のように、第十六態様の水廻り部材（床パン１）の製造方法は、下記の構成を備える。 Further, as in each of the above-described embodiments and modifications thereof, the method for manufacturing the water-related member (floor pan 1) of the sixteenth aspect has the following configuration.
　すなわち、第十六態様の水廻り部材（床パン１）の製造方法は、塗布工程、押圧工程、及び密着工程を備える。塗布工程は、屈曲したコーナー部（６）を有する水廻り基材（床パン基材３）のコーナー部（６）の表面に、着色プライマー（７）を塗布する工程である。押圧工程は、水廻り基材（床パン基材３）の表面（３０）に、加熱により軟化させた加飾フィルム（４）を押し当てる工程である。密着工程は、真空圧空成形又は真空成形により加飾フィルム（４）を水廻り基材（床パン基材３）の表面（３０）に密着させる工程である。加飾フィルム（４）は、密着工程において形成され、加飾フィルム（４）の他の部分よりも薄肉である伸び部（４７）を有する。伸び部（４７）は、着色プライマー（７）を介してコーナー部（６）に密着される。 That is, the method for manufacturing the water-related member (floor pan 1) of the sixteenth aspect includes a coating step, a pressing step, and a close contact step. The coating step is a step of applying the coloring primer (7) to the surface of the corner portion (6) of the water-related base material (floor pan base material 3) having the bent corner portion (6). The pressing step is a step of pressing the decorative film (4) softened by heating against the surface (30) of the water-related base material (floor pan base material 3). The adhesion step is a step of adhering the decorative film (4) to the surface (30) of the water-related base material (floor pan base material 3) by vacuum pressure air forming or vacuum forming. The decorative film (4) has an elongated portion (47) that is formed in the close contact process and is thinner than the other parts of the decorative film (4). The elongated portion (47) is brought into close contact with the corner portion (6) via the colored primer (7).
　上記構成を備える第十六態様の水廻り部材（床パン１）の製造方法では、加飾フィルム（４）の薄肉の伸び部（４７）が着色プライマー（７）を介してコーナー部（６）に密着されるため、コーナー部（６）と伸び部（４７）との密着性の向上が図れる。また、第十六態様の床パンの製造方法では、伸び部（４７）が透けても着色プライマー（７）の色が伸び部（４７）の表面に表示されるため、水廻り基材（床パン基材３）の透け防止を図ることができる。 In the method for manufacturing the water-related member (floor pan 1) of the sixteenth aspect having the above configuration, the thin-walled elongated portion (47) of the decorative film (4) is interposed at the corner portion (6) via the colored primer (7). Therefore, the adhesion between the corner portion (6) and the extension portion (47) can be improved. Further, in the method for manufacturing a floor pan according to the sixteenth aspect, even if the stretched portion (47) is transparent, the color of the coloring primer (7) is displayed on the surface of the stretched portion (47). It is possible to prevent see-through of the bread base material 3).
　以上、本開示を添付図面に示す実施形態に基づいて説明したが、本開示は上記の各実施形態に限定されるものではなく、本開示の意図する範囲内であれば、適宜の設計変更が可能である。 Although the present disclosure has been described above based on the embodiments shown in the accompanying drawings, the present disclosure is not limited to each of the above embodiments, and appropriate design changes can be made within the scope of the present disclosure. It is possible.
　以上説明した本開示においては、水廻り部材が床パンである場合について説明したが、水廻り部材は、床パンに限らず、例えば、浴室内の壁を形成する壁パネルや、キッチンに用いられる天板などであってもよい。 In the present disclosure described above, the case where the water-related member is a floor pan has been described, but the water-related member is not limited to the floor pan, and is used, for example, in a wall panel forming a wall in a bathroom or in a kitchen. It may be a top plate or the like.
１　　　床パン
２　　　凸部
２０　　上面
２１　　側面
３　　　床パン基材
３０　　表面
３１　　床部
３２　　立ち上がり部
４　　　加飾フィルム
４０　　フィルム本体
４１　　表面層
４２　　ベース層
４５　　塗膜
４６　　塗膜
５　　　粒材 1 Floor pan 2 Convex part 20 Top surface 21 Side surface 3 Floor pan base material 30 Surface 31 Floor part 32 Rising part 4 Decorative film 40 Film body 41 Surface layer 42 Base layer 45 Coating film 46 Coating film 5 Granules

Claims (11)

  1. 　複数の凸部を表面に有する水廻り基材と、
    　前記水廻り基材の前記表面に密着した加飾フィルムと、を備え、
    　前記加飾フィルムは、直径が１μｍ以上３０μｍ以下であり、かつ前記加飾フィルムの他の部分よりも軟化温度が高い粒材を有する、
    　水廻り部材。     A water-related base material having multiple protrusions on its surface,
    A decorative film that adheres to the surface of the water-related base material is provided.
    The decorative film has a grain material having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film.
    Water around member.
  2. 　前記加飾フィルムは、熱可塑性を有するフィルム本体を有し、
    　前記粒材は、前記フィルム本体に混合し、前記フィルム本体よりも軟化温度が高い、
    　請求項１に記載の水廻り部材。     The decorative film has a film body having thermoplasticity, and has a film body.
    The granules are mixed with the film body and have a higher softening temperature than the film body.
    The water-related member according to claim 1.
  3. 　前記加飾フィルムは、熱可塑性を有するフィルム本体と、
    　前記フィルム本体の表面に設けられた塗膜と、を有し、
    　前記粒材は、前記塗膜に含まれている、
    　請求項１に記載の水廻り部材。     The decorative film includes a film body having thermoplasticity and
    It has a coating film provided on the surface of the film body, and has
    The granules are contained in the coating film.
    The water-related member according to claim 1.
  4. 　前記加飾フィルムは、前記複数の凸部のそれぞれの上面及び側面に密着して、前記複数の凸部のそれぞれの上面及び側面に沿うように変形している、
    　請求項１から３のいずれか一項に記載の水廻り部材。     The decorative film is in close contact with the upper surface and the side surface of each of the plurality of convex portions, and is deformed along the upper surface and the side surface of each of the plurality of convex portions.
    The water-related member according to any one of claims 1 to 3.
  5. 　前記フィルム本体は、
    　前記フィルム本体の表面を構成する表面層と、前記表面層の裏側に位置するベース層と、を含み、
    　前記粒材は、前記表面層に含まれている、
    　請求項２に記載の水廻り部材。     The film body
    A surface layer constituting the surface of the film body and a base layer located on the back side of the surface layer are included.
    The granules are contained in the surface layer,
    The water-related member according to claim 2.
  6. 　前記粒材は、中実である、
    　請求項１から５のいずれか一項に記載の水廻り部材。     The granules are solid,
    The water-related member according to any one of claims 1 to 5.
  7. 　前記水廻り基材は、
    　前記複数の凸部を上面に有する床部と、
    　前記床部の端縁部から立ち上がった立ち上がり部と、を有し、
    　前記加飾フィルムは、前記床部の上面と前記立ち上がり部の表面のそれぞれに、密着している、
    　請求項１から６のいずれか一項に記載の水廻り部材。     The water-related base material is
    A floor portion having the plurality of convex portions on the upper surface, and a floor portion.
    It has a rising portion that rises from the edge portion of the floor portion, and has.
    The decorative film is in close contact with each of the upper surface of the floor portion and the surface of the rising portion.
    The water-related member according to any one of claims 1 to 6.
  8. 　複数の凸部を表面に有する水廻り基材の前記表面に、加熱により軟化させた加飾フィルムを押し当てる押圧工程と、
    　真空圧空成形又は真空成形により前記加飾フィルムを前記水廻り基材の前記表面に密着させる密着工程とを備え、
    　前記加飾フィルムは、直径が１μｍ以上３０μｍ以下であり、かつ前記加飾フィルムの他の部分よりも軟化温度が高い粒材を有する、
    　水廻り部材の製造方法。     A pressing step of pressing a decorative film softened by heating against the surface of a water-related base material having a plurality of convex portions on the surface.
    A close contact step of bringing the decorative film into close contact with the surface of the water-related base material by vacuum pressure air forming or vacuum forming is provided.
    The decorative film has a grain material having a diameter of 1 μm or more and 30 μm or less and having a softening temperature higher than that of other parts of the decorative film.
    Manufacturing method of water-related members.
  9. 　前記加飾フィルムは、熱可塑性を有するフィルム本体を有し、
    　前記粒材は、前記フィルム本体に混合し、前記フィルム本体よりも軟化温度が高い、
    　請求項８に記載の水廻り部材の製造方法。     The decorative film has a film body having thermoplasticity, and has a film body.
    The granules are mixed with the film body and have a higher softening temperature than the film body.
    The method for manufacturing a water-related member according to claim 8.
  10. 　前記加飾フィルムは、熱可塑性を有するフィルム本体と、
    　前記フィルム本体の表面に設けられた塗膜と、を有し、
    　前記粒材は、前記塗膜に含まれている、
    　請求項８に記載の水廻り部材の製造方法。     The decorative film includes a film body having thermoplasticity and
    It has a coating film provided on the surface of the film body, and has
    The granules are contained in the coating film.
    The method for manufacturing a water-related member according to claim 8.
  11. 　複数の凸部を表面に有する水廻り基材の前記表面に、加熱により軟化させたフィルム本体を押し当てる押圧工程と、
    　真空圧空成形又は真空成形により前記フィルム本体を前記水廻り基材の前記表面に密着させる密着工程と、
    　前記水廻り基材に密着した前記フィルム本体の表面に、直径が１μｍ以上３０μｍ以下の粒材を含む塗料を塗布する塗布工程と、を備える、
    　水廻り部材の製造方法。     A pressing step of pressing the film body softened by heating against the surface of the water-related base material having a plurality of convex portions on the surface, and
    A close contact step in which the film body is brought into close contact with the surface of the water-related base material by vacuum pressure air forming or vacuum forming.
    A coating step of applying a paint containing a granular material having a diameter of 1 μm or more and 30 μm or less is provided on the surface of the film body in close contact with the water-related base material.
    Manufacturing method of water-related members.
PCT/JP2020/039189 2019-10-31 2020-10-16 Wet-area member and method for manufacturing wet-area member WO2021085195A1 (en)

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JP2021553408A JP7253726B2 (en) 2019-10-31 2020-10-16 Plumbing-related member and manufacturing method of the plumbing-related member
JP2023040492A JP2023082019A (en) 2019-10-31 2023-03-15 Sink member and manufacturing method of sink member
JP2023040493A JP2023082020A (en) 2019-10-31 2023-03-15 Sink member and manufacturing method of sink member

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH081894A (en) * 1994-06-20 1996-01-09 Dainippon Printing Co Ltd Molding having suede like surface and production thereof
JP2017141665A (en) * 2017-03-09 2017-08-17 大日本印刷株式会社 Floor decoration sheet and its manufacturing method
JP2017149154A (en) * 2012-05-16 2017-08-31 スリーエム イノベイティブ プロパティズ カンパニー Decorative sheet for road surface or floor
JP2019111810A (en) * 2017-12-25 2019-07-11 日本ポリプロ株式会社 Decorative film and method for manufacturing decorative molding using the same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH081894A (en) * 1994-06-20 1996-01-09 Dainippon Printing Co Ltd Molding having suede like surface and production thereof
JP2017149154A (en) * 2012-05-16 2017-08-31 スリーエム イノベイティブ プロパティズ カンパニー Decorative sheet for road surface or floor
JP2017141665A (en) * 2017-03-09 2017-08-17 大日本印刷株式会社 Floor decoration sheet and its manufacturing method
JP2019111810A (en) * 2017-12-25 2019-07-11 日本ポリプロ株式会社 Decorative film and method for manufacturing decorative molding using the same

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