JP2019112909A - Floor structure and method of producing the same - Google Patents

Abstract

A floor structure capable of improving the degree of freedom in product design, and a method of manufacturing the same.
A floor structure according to the present invention includes a surface material 10, a heat insulating layer 20, a frame member 30, and a bottom plate member 40. The surface material 10 is flat. The heat insulating layer 20 is disposed below the surface material 10. The frame-like member 30 is disposed to extend along the outer peripheral portion 20 a of the heat insulating layer 20, and is engaged with the outer peripheral portion 20 a of the heat insulating layer 20. The bottom plate member 40 is disposed below the heat insulating layer 20.
[Selected figure] Figure 2

Description

  The present invention relates to a floor structure and a method of manufacturing the same.

  As a floor structure used for a bathroom floor etc., Patent Document 1 describes a floor structure provided with a deep dish-like main body, a surface material, and a high density foamed urethane layer. In the floor structure described in Patent Document 1, the main body is formed of FRP (Fiber-Reinforced Plastics), and the surface material is disposed to close an upper opening of the main body. In addition, the high density foamed urethane layer is disposed in the space surrounded by the main body and the surface material. The floor structure described in Patent Document 1 is excellent in strength and excellent in heat insulation because the high density foamed urethane layer is disposed in the lower layer of the surface material.

Unexamined-Japanese-Patent No. 10-219776

  However, in the floor structure described in Patent Document 1, it is necessary to produce a mold in order to produce an FRP body. Mold preparation requires a lot of cost and time. Therefore, the initial cost for producing the floor structure and the time required for the production become long. Furthermore, when the floor structure is redesigned, such as changing the size of the floor structure, it is necessary to remake the mold, and the design change of the floor structure requires much cost and time. Therefore, design changes can not be easily made, and the degree of freedom in product design is reduced. In order to address the above problems, it is also conceivable to make the body of the floor structure by hand lay-up molding. However, hand layup molding is not suitable for mass production. Therefore, if the main body of the floor structure is manufactured by hand lay-up molding, mass production of the floor structure becomes difficult.

  This invention is made in view of the said subject, The objective is firstly to provide the floor structure which can improve the freedom degree of product design, and its manufacturing method. Second, a floor structure capable of reducing the initial cost for producing the floor structure, shortening the time required for the floor structure production, and facilitating mass production of the floor structure, and its manufacture To provide a way.

  The floor structure disclosed in the present application includes a surface material, a heat insulating layer, a frame-like member, and a bottom plate member. The surface material is flat. The heat insulation layer is disposed below the surface material. The frame-like member is disposed to extend along the outer periphery of the heat insulating layer, and is engaged with the outer periphery of the heat insulating layer. The bottom plate member is disposed below the heat insulating layer.

  Moreover, in the floor structure disclosed in the present application, the frame-like member has a hollow portion and a peripheral wall surrounding the hollow portion. The peripheral wall has an opening. The opening opens toward the center of the heat insulating layer. The outer peripheral portion of the heat insulating layer is disposed inside the hollow portion via the opening.

  In the floor structure disclosed in the present application, the opening is formed in the peripheral wall so as to extend along the longitudinal direction of the frame-like member with a width dimension smaller than the dimension in the vertical direction of the peripheral wall of the frame-like member. ing. The width dimension of the opening is smaller than the dimension in the vertical direction of the outer peripheral portion of the heat insulating layer.

  Further, a method of manufacturing a floor structure disclosed in the present application is a method of manufacturing a floor structure including a heat insulating layer formed of a foamed resin, which includes a first step, a second step, a third step, and a third step. The fourth process, the fifth process, and the sixth process are provided. The first step is a step of placing a flat surface material on the lower mold. The second step is a step of placing a frame-like member engaged with the outer peripheral portion of the heat insulating layer on the lower mold along the outer peripheral edge of the surface material. The third step is a step of arranging a bottom plate member having a through hole above the surface material. The fourth step is a step of placing an upper mold on the bottom plate member. The fifth step is a step of injecting the foamed resin raw material into the space surrounded by the surface material, the frame-like member, and the bottom plate member through the through holes. The sixth step is a step of forming the heat insulation layer by foaming the foamed resin raw material.

  In the method for manufacturing a floor structure disclosed in the present application, the frame-like member has a hollow portion and a peripheral wall surrounding the hollow portion. The peripheral wall has an opening that opens toward the center side of the heat insulating layer. The fifth step includes introducing the foamed resin material into the hollow portion from the space through the opening.

  According to the floor structure of the present invention, in the lower layer structure of the floor structure, the bottom plate member defining the horizontal size (horizontal length, width) of the floor structure and the thickness of the floor structure are defined. Since the frame-like member is a separate member, various design changes are easy, and the degree of freedom in product design can be improved. For example, when changing the size of the floor structure in the horizontal direction, it is only necessary to change mainly the length of the frame-like member, and design change is easy. In addition, it is not necessary to produce a mold having a shape corresponding to the shape of the lower layer structure in the floor structure, which can reduce the initial cost when producing the floor structure and reduce the time required for the floor structure to be manufactured. And the mass production of the floor structure can be facilitated.

It is a top view showing a floor structure concerning an embodiment. It is a sectional view showing a floor structure concerning an embodiment. (A) is a perspective view which shows the frame-shaped member which concerns on embodiment. (B) is a sectional view showing a frame-like member concerning an embodiment. (A) is an explanatory view showing the 1st process in the manufacturing method of the floor structure concerning an embodiment. (B) is explanatory drawing which shows the 2nd process in the manufacturing method of the floor structure which concerns on embodiment. (C) is explanatory drawing which shows the 3rd process-5th process in the manufacturing method of the floor structure which concerns on embodiment.

  Hereinafter, a floor structure according to an embodiment of the present invention will be described in detail based on the drawings. The embodiment described below is a preferred example for carrying out the present invention, so various limitations are technically made, but the present invention is intended to particularly limit the invention in the following description. Is not limited to this embodiment unless it is specified. Further, “upper”, “lower”, “right” and “left” in the description correspond to “upper”, “lower”, “right” and “left” in FIG.

Embodiment
[Basic principle]
The basic principle of the floor structure according to the embodiment of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a plan view showing a floor structure according to an embodiment. FIG. 2 is a cross-sectional view showing a floor structure according to the embodiment.

  As shown in FIG. 1 and FIG. 2, the floor structure according to the embodiment includes a surface material 10, a heat insulating layer 20, a frame-like member 30, and a bottom plate member 40. The surface material 10 is flat. The heat insulating layer 20 is disposed below the surface material 10. The heat insulating layer 20 has an outer peripheral portion 20 a. The frame-shaped member 30 is disposed to extend along the outer peripheral portion 20 a of the heat insulating layer 20 and is engaged with the outer peripheral portion 20 a. The bottom plate member 40 is disposed below the heat insulating layer 20.

  Moreover, the floor structure which concerns on embodiment has the drainage part 50 and the drainage hole 51, as shown in FIG. The drainage portion 50 includes a space formed to penetrate the surface material 10 and the heat insulating layer 20 in the thickness direction. The drainage portion 50 is covered by the cover member 52 with a space in which water flows. The drainage hole 51 is formed to penetrate the bottom plate member 40 in the thickness direction, and is communicated with a drainage trap (not shown). Moreover, the water conveyance part 53 is formed in the surface material 10. The water conveyance unit 53 is adjacent to the drainage unit 50 and guides water to the drainage unit 50.

[Surface material 10, thermal insulation layer 20]
Next, the surface material 10 and the heat insulating layer 20 will be described in detail with reference to FIGS. 1 and 2. The facing 10 is formed of tiles or natural stone. The surface material 10 has a substantially rectangular shape, and has a linearly extending outer peripheral edge 10a. The heat insulating layer 20 is formed of a foamed resin, for example, foamed urethane. In addition, the outer peripheral portion 20 a of the heat insulating layer 20 protrudes to the outer peripheral side than the outer peripheral edge 10 a of the surface material 10.

[Frame-shaped member 30]
Next, the frame-shaped member 30 will be described in detail with reference to FIGS. 2 and 3. FIG. 3A is a perspective view showing the frame-like member 30. FIG. FIG. 3 (b) is a cross-sectional view showing the frame-shaped member 30. In addition, in FIG.3 (b), the cross section of the edge part vicinity in the longitudinal direction X1 of the frame-shaped member 30 is shown.

  The frame-like member 30 has a hollow portion 31 and a peripheral wall 32 surrounding the hollow portion 31, as shown in FIG. The peripheral wall 32 has an opening 33. The opening 33 is open toward the center of the heat insulating layer 20, as shown in FIG. The outer peripheral portion 20 a of the heat insulating layer 20 is disposed inside the hollow portion 31 via the opening 33.

  The cross-sectional shape of the peripheral wall 32 is generally rectangular as shown in FIG. 3, and the peripheral wall 32 has a vertical surface portion 32a, an upper surface portion 32b, a lower surface portion 32c, an upper opening peripheral portion 32d, and a lower opening peripheral portion 32e. Have. The vertical surface portion 32 a is disposed substantially perpendicularly to the horizontal direction so as to face the opening 33. The upper surface portion 32 b is substantially horizontal and is provided continuously with the upper end portion of the vertical surface portion 32 a. The lower surface portion 32c is substantially horizontal, and is continuously provided to the lower end portion of the vertical surface portion 32a. The upper opening circumferential portion 32d and the lower opening circumferential portion 32e are continuously provided to the upper surface portion 32b or the lower surface portion 32c, and are disposed substantially perpendicularly to the horizontal direction so as to face the vertical surface portion 32a.

  As shown in FIG. 2, the vertical surface portion 32 a is disposed on the outer peripheral side of the heat insulating layer 20 than the upper opening circumferential portion 32 d and the lower opening circumferential portion 32 e. The upper surface portion 32 b is exposed on the outer peripheral side of the outer peripheral edge 10 a of the surface material 10 as shown in FIGS. 1 and 2.

  The opening 33 of the frame member 30 is formed in the peripheral wall 32 so as to extend along the longitudinal direction X1 of the frame member 30 with a width L1 smaller than the height L0 in the vertical direction of the peripheral wall 32. Further, as shown in FIG. 2, the width dimension L1 of the opening 33 is smaller than the thickness dimension L2 in the vertical direction of the outer peripheral portion 20 a of the heat insulating layer 20.

  Further, as shown in FIG. 3, the frame-shaped member 30 has a first extending portion 32 f. The first extending portions 32f are continuously provided so as to extend upward from the upper end portion of the vertical surface portion 32a. The first extending portion 32f has a hook-like engaging portion 32g at the upper end. The engaging portion 32g engages with a structural member of the bathroom (not shown).

  Specifically, the frame-like member 30 is a section made of an aluminum alloy extending in a straight line. And the floor structure which concerns on embodiment has four frame-shaped members 30 as shown in FIG. The four frame members 30 are connected to each other by a connecting fitting 11 having an L-shaped cross section. More specifically, as shown in FIG. 3, the frame-shaped member 30 has a plurality of female screw portions 34 extending in the longitudinal direction X1. The frame-shaped members 30 are connected to each other at each end in the longitudinal direction X1 by screwing the connection fitting 11 to the plurality of female screw portions 34.

[Bottom plate member 40]
Next, the bottom plate member 40 will be described in detail with reference to FIG. Specifically, the bottom plate member 40 is a steel material formed in a tray shape, and includes a main body portion 41, a second extending portion 42, and a rising portion 43. The main body portion 41 has a rectangular shape corresponding to the surface material 10, and a through hole 44 is formed in the central portion. The through hole 44 is a hole for passing the foamed resin raw material which is a raw material of the heat insulating layer 20, and is formed to penetrate the main body portion 41 in the thickness direction. The foamed resin raw material is, for example, a two-component urethane foamed raw material containing a polyol and an isocyanate. The second extending portions 42 are continuously provided so as to extend from the outer peripheral edge of the main body portion 41 to the outer peripheral side, and are in contact with the lower surface portion 32 c of the frame shaped member 30. The rising portion 43 is continuous with the outer peripheral edge of the second extending portion 42 substantially perpendicularly, and is in contact with the vertical surface portion 32 a of the frame-shaped member 30.

[Method of manufacturing floor structure]
Next, with reference to FIG. 4, the manufacturing method of the floor structure which concerns on embodiment is demonstrated. The floor structure manufacturing method according to the embodiment includes the first to sixth steps. Fig.4 (a) is explanatory drawing which shows the 1st process in the manufacturing method of the floor structure which concerns on embodiment. FIG.4 (b) is explanatory drawing which shows the 2nd process in the manufacturing method of the floor structure which concerns on embodiment. FIG.4 (c) is explanatory drawing which shows the 3rd process-5th process in the manufacturing method of the floor structure which concerns on embodiment. Hereinafter, a manufacturing method of manufacturing a floor structure as a bathroom floor including the heat insulating layer 20 will be described.

  As shown in FIG. 4A, in the first step, a flat surface material 10 is placed on the lower mold 2. A slope 2 a is formed at a position near the center of the upper surface of the lower die 2. The facing 10 is placed on the slope 2a. The shape of the slope 2 a corresponds to the shape of the surface material 10. The slope 2a is inclined with respect to the horizontal plane. Placing the facing 10 on the slope 2 a gives the facing 10 an inclination for water drainage.

  As shown in FIG. 4 (b), in the second step, the frame-shaped member 30 is placed on the lower die 2 along the outer peripheral edge 10 a of the surface material 10. The frame-like member 30 has an engaged portion engaged with the outer peripheral portion 20 a of the heat insulating layer 20. The engaged portion is the peripheral wall 32 having the opening 33 in the embodiment. On the upper surface of the lower mold 2, the adjacent part 2 b is formed at a position adjacent to the slope 2 a. The shape of the adjacent portion 2 b corresponds to the shape of the upper surface portion 32 b of the frame-like member 30. The frame-like member 30 is placed on the adjacent portion 2 b such that the upper surface portion 32 b contacts the adjacent portion 2 b.

  Further, in the method of manufacturing the floor structure according to the embodiment, four adjacent portions 2 b are formed on the upper surface of the lower mold 2 corresponding to the four frame members 30. The four adjacent portions 2b have the same height in the vertical direction. Further, on the upper surface of the lower mold 2, the step portion 2 c is provided continuously to the outer peripheral edge of the adjacent portion 2 b. The dimension in the vertical direction of the stepped portion 2c is substantially equal to the dimension in the extending direction X2 (see FIG. 3A) in which the extending portion 32f extends.

  As shown in FIG. 4C, in the third step, the bottom plate member 40 is disposed above the facing material 10. Specifically, the bottom plate member 40 is placed on the frame-like member 30. The bottom plate member 40 has a through hole 44. In the fourth step, the upper die 3 is placed on the bottom plate member 40. In the fifth step, the foamed resin raw material M is injected into the space S1 surrounded by the surface material 10, the frame member 30, and the bottom plate member 40 through the through holes 44. The fifth step may include introducing the foamed resin raw material M into the hollow portion 31 from the space S1 through the opening 33. In the sixth step, the foamed resin raw material M is foamed to form the heat insulating layer 20. The heat insulating layer 20 is formed in the space S1 and the hollow portion 31. The expansion ratio of the heat insulating layer 20 is set to 7 times to 10 times.

  As described above with reference to FIGS. 1 to 4, according to the present embodiment, the frame-shaped member 30 is engaged with the outer peripheral portion 20 a of the heat insulating layer 20. Therefore, the bonding strength between the heat insulating layer 20 and the frame member 30 can be increased, and the robustness of the floor structure can be improved. That is, greater bonding strength can be obtained between the heat insulating layer 20 and the frame member 30 than in a structure in which the frame member 30 and the heat insulating layer 20 are in contact without engagement. Further, according to the present embodiment, in the lower layer structure of the floor structure, the bottom plate member 40 defining the horizontal size (horizontal length, width) of the floor structure and the thickness of the floor structure are defined. Since the frame-like member 30 is a separate member, various design changes are easy, and the degree of freedom in product design can be improved. For example, in the lower layer structure of the floor structure, when changing the size in the horizontal direction, it is only necessary to mainly change the length of the frame-like member 30, and a mold having a shape corresponding to the shape of the lower layer structure is produced. There is no need to rework, and design changes are easy.

  Further, as described with reference to FIG. 2, according to the present embodiment, the outer peripheral portion 20 a of the heat insulating layer 20 is disposed inside the hollow portion 31 via the opening 33 of the frame-like member 30. . Therefore, the bonding strength between the frame member 30 and the heat insulating layer 20 can be further increased, and the robustness of the floor structure can be further improved. In addition, the heat insulating properties of the floor structure can be improved by arranging the heat insulating layer 20 to the hollow portion 31 of the frame-like member 30.

  Further, as described with reference to FIG. 2, according to the present embodiment, the width dimension L1 of the opening 33 is smaller than the thickness dimension L2 of the outer peripheral portion 20 a of the heat insulating layer 20. Therefore, the outer peripheral portion 20 a of the heat insulating layer 20 is very hard to be removed from the hollow portion 31, and the bonding strength between the frame-like member 30 and the heat insulating layer 20 can be further increased. Can.

  The embodiments of the present invention have been described above with reference to the drawings (FIGS. 1 to 4). However, this invention is not limited to said embodiment, It is possible to implement in a various aspect in the range which does not deviate from the summary (for example, (1)-(3) shown below).

  (1) As described with reference to FIGS. 1 to 4, in the embodiment, the surface material 10 is formed of a tile or a natural stone, but not limited to this, the surface material 10 is made of a resin such as FRP. It may be formed. Alternatively, the facing 10 may be in the form of a sheet. Moreover, the frame-shaped member 30 may be formed not only from aluminum alloy but from resin, such as FRP. The bottom plate member 40 is not limited to steel but may be made of resin such as FRP.

  (2) As described with reference to FIG. 4, in the embodiment, the bottom plate member 40 is placed on the frame-like member 30 in the third step. The invention is not limited to this, and the bottom plate member 40 may be disposed inside the area surrounded by the four frame members 20 by reducing the length and width in the horizontal direction. In the third step, when arranging the bottom plate member 40 inside the area surrounded by the four frame members 20, for example, a square rod-like spacer is placed on the surface material 10, and the bottom plate member 40 is placed on the spacer. You may put it.

  (3) As described with reference to FIG. 2, in the embodiment, the bottom plate member 40 includes the main body portion 41, the second extending portion 42, and the rising portion 43. However, the present invention is not limited thereto. The member 40 may include only the main body portion 41 and the rising portion 43, and may not include the second extending portion 42. This is because when the bottom plate member 40 is disposed inside the region surrounded by the four frame members 20 as described in (2), the second extending portion 42 is unnecessary. Further, when the bottom plate member 40 is disposed inside the area surrounded by the four frame members 20, the rising portion 43 contacts, for example, the lower opening circumferential portion 32e instead of the vertical surface 32a of the frame member 30.

  The present application further discloses the following supplementary notes. The following appendices do not limit the present invention.

  (Supplementary Note 1) In the floor structure disclosed in the present application, the surface material (10) has a rectangular shape, and the four frame-like members (30) are arranged along the four sides of the surface material (10). It will be set up.

  According to this configuration, by changing the lengths of the four frame members (30), the horizontal size of the floor structure can be variously changed, and the degree of freedom in product design can be further improved. it can.

  (Supplementary Note 2) In the floor structure disclosed in the present application, the upper surface portion (32b) is exposed at the outer peripheral side than the outer peripheral edge (10a) of the surface material (10).

  According to this configuration, as shown in FIG. 2, the surface material (10) can be freely inclined regardless of the constant height dimension (L0) of the peripheral wall (32) of the frame-like member (30). And the degree of freedom in product design can be further improved.

M: Foam resin raw material L 0 ... Height dimension (dimension in the vertical direction of the peripheral wall)
L1 ... Width dimension L2 ... Thickness dimension (dimension in the vertical direction at the outer peripheral portion)
S1: Space 2: Lower mold 3: Upper mold 10: surface material 10a: outer peripheral edge 20: heat insulation layer 20a: outer peripheral portion 30: frame-like member 31: hollow portion 32: peripheral wall 33: opening 40: bottom plate member 44: penetrating Hole

Claims (5)

Flat surface material,
A heat insulating layer disposed below the surface material;
A frame-shaped member disposed to extend along the outer peripheral portion of the heat insulating layer and engaged with the outer peripheral portion of the heat insulating layer;
And a bottom plate member disposed under the heat insulation layer. The frame-like member has a hollow portion and a peripheral wall surrounding the hollow portion,
The peripheral wall has an opening that opens toward the center side of the heat insulating layer,
The floor structure according to claim 1, wherein the outer peripheral portion of the heat insulating layer is disposed inside the hollow portion through the opening. The opening is formed in the peripheral wall so as to extend along the longitudinal direction of the frame-like member with a width dimension smaller than the dimension in the vertical direction of the peripheral wall of the frame-like member.
The floor structure according to claim 2, wherein the width dimension of the opening is smaller than the dimension in the vertical direction at the outer peripheral portion of the heat insulating layer. A method of manufacturing a floor structure including a heat insulating layer formed of a foamed resin, comprising:
A first step of placing a flat plate-like surface material on the lower mold,
Placing a frame-like member engaged with the outer peripheral portion of the heat insulating layer along the outer peripheral edge of the surface material on the lower mold;
A third step of disposing a bottom plate member having a through hole above the surface material;
A fourth step of placing an upper die on the bottom plate member;
A fifth step of injecting a foamed resin material into the space surrounded by the surface material, the frame-like member, and the bottom plate member through the through holes;
And 6. a sixth step of foaming the foamed resin raw material to form the heat insulating layer. The frame-like member has a hollow portion and a peripheral wall surrounding the hollow portion,
The peripheral wall has an opening that opens toward the center side of the heat insulating layer,
The method for manufacturing a floor structure according to claim 4, wherein the fifth step includes introducing the foamed resin raw material from the space into the hollow portion through the opening.

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