Ground decoration one-time forming integral bathroom waterproof base plate and preparation method thereof

Abstract

The invention discloses a waterproof base plate for a ground decoration one-time formed integral bathroom and a preparation method thereof, and belongs to the technical field of indoor building construction.The waterproof base plate comprises a ground decoration material layer located on the uppermost layer, a secondary drainage groove is formed in the bottom of the outer side of the ground decoration material layer, the secondary drainage groove is a slope groove, and the lowest position of the secondary drainage groove is connected with a floor drain; an interface transition bonding material layer, a waterproof structure layer, a rigid strength layer and a chassis structure layer are sequentially arranged at the bottom of the ground decoration material layer and the bottom of the secondary drainage groove. A secondary drainage groove is reserved in the manufacturing process of the waterproof base plate, and water permeating into gaps can be emptied for the second time.

Description

Technical Field

[0001] The present invention belongs to the technical field of indoor building construction, and particularly relates to a one-piece formed integral bathroom waterproof floor pan for ground decoration and a preparation method thereof. Background Art

[0002] Generally, an integral bathroom waterproof floor pan is first made into a whole from multiple layers of materials in a factory and then transported to a bathroom for installation. During the manufacturing process, the vacuum infusion unsaturated resin method is usually used to bond the multiple layers of materials.

[0003] Chinese Patent CN 109130241 A discloses a floor pan for a prefabricated integral bathroom and a preparation method thereof, which specifically discloses that the floor pan for a prefabricated integral bathroom is sequentially provided with a first fiberglass layer, a sandwich layer, a second fiberglass layer, and a ceramic tile surface layer from bottom to top. The first fiberglass layer and / or the second fiberglass layer are both fiber reinforced plastics composed of glass fibers and / or carbon fibers bonded with unsaturated polyester resin. The sandwich layer is a light material with strong bonding force with unsaturated polyester resin, and the vacuum infusion unsaturated polyester resin method is also disclosed.

[0004] [[ID=~14]]However, during the use of the existing waterproof floor pan, when the sealant at the joint between the floor pan and the wall ages or the sealing is not tight, water will seep into the floor pan and the wall through the gap, resulting in mildew and damage to the floor pan and the wall. Summary of the Invention

[0005] The purpose of the present invention is to provide a new type of one-piece formed integral bathroom waterproof floor pan, which has a secondary drainage groove reserved during the manufacturing process to drain the water seeping into the gap for the second time.

[0006] The present invention achieves the above technical purpose through the following technical means.

[0007] A one-piece formed integral bathroom waterproof floor pan for ground decoration includes a ground decoration material layer at the uppermost layer. A secondary drainage groove is provided at the bottom outside the ground decoration material layer. The secondary drainage groove is a slope groove and its lowest point is connected to a floor drain. The ground decoration material layer and the bottom of the secondary drainage groove are sequentially provided with an interface transition bonding material layer, a waterproof structure layer, a rigid strength layer, and a floor pan structure layer.

[0008] Further, one side of the secondary drainage groove away from the ground decoration material layer extends outward and a water retaining wall skirt higher than the ground decoration material layer is provided at the end. The water retaining wall skirt includes an interface transition bonding material layer and a waterproof structure layer.

[0009] Further, the interface transition bonding material layer is formed by impregnating a fiberglass mat with a mixture of epoxy resin or vinyl resin and a silane coupling agent.

[0010] Furthermore, the waterproof structure layer is composed of fiberglass mat, fiberglass cloth, and unsaturated resin. The fiberglass mat and fiberglass cloth are laid crosswise, and the unsaturated resin completely penetrates the fiberglass mat and fiberglass cloth.

[0011] Furthermore, the rigid strength layer includes a reinforced bottom plate, a first reinforcing keel at the bottom of the reinforced bottom plate, and a second reinforcing keel at the end of the reinforced bottom plate. The rigid strength layer is one of a PET foam board, a corrosion-resistant wooden board and wooden square, or a PVC foam board.

[0012] Furthermore, a number of through holes are provided on the reinforced bottom plate from top to bottom, and a plurality of through holes are provided on the first reinforcing keel and the second reinforcing keel from top to bottom and from left to right.

[0013] Furthermore, the chassis structure layer is composed of fiberglass mat, fiberglass cloth, and unsaturated resin. The fiberglass mat and fiberglass cloth are laid crosswise, and the outermost layer is fiberglass cloth. The unsaturated resin completely penetrates the fiberglass mat and fiberglass cloth.

[0014] Furthermore, a drainage transition mechanism is provided on the waterproof chassis. The drainage transition mechanism includes a floor drain drainage transition mechanism, a toilet drainage transition mechanism, and a washbasin drainage transition mechanism.

[0015] A preparation method for a one-piece formed integral bathroom waterproof chassis for floor decoration includes the following steps: Step S1: Clean the mold, wax the mold from the secondary drainage groove to the water retaining wall skirt, and do not wax the other molds; Step S2: Place the back of the floor decoration material layer upward on the mold, and seal the gap between the floor decoration material layer and the secondary drainage groove mold with sealant, masking paper, or putty ash. Seal the gap between the floor decoration materials with sealant, masking paper, or putty ash as well; Step S3: Cut the floor decoration material layer according to the shape of each drainage transition mechanism, and install each drainage transition mechanism; Step S4: Apply a mixed interface agent of epoxy resin or vinyl resin and silane coupling agent on the back of the ground decoration material layer and the drainage transition mechanism, then lay a fiberglass mat, and then use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the mixed interface agent, thus completing one layer of the waterproof chassis interface transition bonding material layer. If a second layer is needed, apply the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent again on the first layer of the waterproof chassis interface transition bonding material layer, then lay a fiberglass mat, and then use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the mixed interface agent, thus completing the second layer of the waterproof chassis interface transition bonding material layer, and so on. After completion, the standing time is 20 - 50 minutes at normal temperature or 10 - 20 minutes with heating assistance. Wait until the chemical reaction surface of the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent is not sticky, and then the next process can be carried out; Step S5: Apply unsaturated resin on the interface transition bonding material layer, then lay a fiberglass mat, and then use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the unsaturated resin. Then apply unsaturated resin again, then lay a fiberglass cloth, and then use a roller to roll the fiberglass cloth to completely immerse the fiberglass cloth in the unsaturated resin, and so on, to construct the chassis waterproof structure layer; Step S6: Place a reinforcing bottom plate on the multi - layer chassis waterproof structure layer above the ground decoration material layer. A plurality of first reinforcing keels are provided at the bottom of the reinforcing bottom plate, and a second reinforcing keel is provided at each of the four ends of the reinforcing bottom plate. A number of through - holes are provided on the reinforcing bottom plate from top to bottom. A number of through - holes are provided on the first reinforcing keels and the second reinforcing keels from top to bottom and from left to right. Place heavy objects above the reinforcing bottom plate, the first reinforcing keels, and the second reinforcing keels so that the unsaturated resin in the chassis waterproof structure layer penetrates through the reinforcing bottom plate, the first reinforcing keels, and the second reinforcing keels, and make the chassis waterproof structure layer bond with the reinforcing bottom plate, the first reinforcing keels, and the second reinforcing keels. Wait until the surface of the overflowing unsaturated resin on the reinforcing bottom plate, the first reinforcing keels, and the second reinforcing keels is dry and not sticky after the chemical reaction, and then the next process operation can be carried out; Step S7: Apply unsaturated resin on the reinforcing bottom plate, the first reinforcing keels, and the second reinforcing keels, then lay a fiberglass mat, and then use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the unsaturated resin. Apply unsaturated resin again on the soaked fiberglass mat, then lay a fiberglass cloth, and then use a roller to roll the fiberglass cloth to completely immerse the fiberglass cloth in the unsaturated resin, thus completing one layer of the chassis structure layer. If another layer needs to be operated, and so on; Step S8: After standing at normal temperature for 1 - 4 hours or with heating assistance for 30 - 40 minutes, take the product out of the mold, and correct and cut the process edges to complete the integral bathroom waterproof chassis product with a self - contained secondary drainage groove and a ground decoration formed in one step.

[0016] A preparation method for a one-piece bathroom waterproof floor tray with ground decoration, comprising the following steps: Step 1: Clean the mold, wax the mold from the secondary drainage groove to the water retaining wall skirt, and do not wax other molds; Step 2: Place the back of the ground decoration material layer upward on the mold, seal the gap between the ground decoration material layer and the secondary drainage groove mold with sealant or masking paper or putty ash, and also seal the gap between the ground decoration materials with sealant or masking paper or putty ash; Step 3: Cut the ground decoration material layer according to the shape of each drainage transition mechanism, and install each drainage transition mechanism; Step 4: Apply a mixed interfacial agent of epoxy resin or vinyl resin and silane coupling agent on the back of the ground decoration material layer and the drainage transition mechanism, then lay the fiberglass mat, and then roll the fiberglass mat with a roller to completely immerse the fiberglass mat in the mixed interfacial agent, thus completing a layer of waterproof floor tray interfacial transition bonding material layer. If a second layer is needed, apply the mixed interfacial agent of epoxy resin or vinyl resin and silane coupling agent again on the first layer of waterproof floor tray interfacial transition bonding material layer, then lay the fiberglass mat, and then roll the fiberglass mat with a roller to completely immerse the fiberglass mat in the mixed interfacial agent, thus completing the second layer of waterproof floor tray interfacial transition bonding material layer, and so on. After completion, the standing time is 20 - 50 minutes at normal temperature or 10 - 20 minutes with heating assistance. Wait until the chemical reaction of the mixed interfacial agent of epoxy resin or vinyl resin and silane coupling agent makes the surface non-sticky, and then the next process can be carried out; Step 5: Prepare putty ash by mixing an interfacial agent and putty with epoxy resin or vinyl resin and silane coupling agent, and manually apply it to the internal and external corners of the waterproof floor tray interfacial transition bonding material layer to form an arc transition; Step 6: Lay the fiberglass mat on the waterproof floor tray interfacial transition bonding material layer, and then lay the fiberglass cloth on the fiberglass mat, thus completing the operation of one layer of floor tray waterproof structure layer, and so on to complete multiple layers of floor tray waterproof structure layer; Step 7: Place a reinforcing bottom plate on the multiple layers of floor tray waterproof structure layer above the ground decoration material layer. A plurality of first reinforcing keels are arranged at the bottom of the reinforcing bottom plate, and one second reinforcing keel is arranged at each of the four ends of the reinforcing bottom plate. A plurality of through holes are arranged on the reinforcing bottom plate from top to bottom, and a plurality of through holes are arranged on the first reinforcing keels and the second reinforcing keels from top to bottom and from left to right. The first reinforcing keels and the reinforcing bottom plate, and the second reinforcing keels and the waterproof structure layer are respectively fixed by hand spraying adhesive; Step 8: Lay the fiberglass mat on the reinforcing bottom plate, the first reinforcing keels and the second reinforcing keels, and then lay the fiberglass cloth on the fiberglass mat, thus completing one layer of floor tray structure layer. If more than 2 layers are needed, and so on to complete the floor tray structure layer; Step 9: Lay a release cloth on the floor tray structure layer; Step 10: Lay the flow guide net on the demoulding cloth; Step 11: Arrange the flow guide pipes and rubber hoses on the flow guide net and on the mold product platform; Step 12: Seal the periphery of the production mold with self-adhesive rubber strips on the mold production platform, with the length × width range being 100 - 200 mm larger than the length × width of the production mold on each side; Step 13: Install a vacuum infusion mold on the flow guide pipe. The mold can be a transparent silicone mold or a transparent vacuum bag mold; the length × width size of the mold is 100 - 200 mm larger than the length × width size of the production mold on each side, and it is bonded to the self-adhesive rubber strips to ensure airtightness; Step 14: Connect the rubber hose to equipment such as an air compressor, start pumping out the air in the product, and at the same time manually expel the air at all internal corners to ensure that the vacuum infusion mold fits the product and there is no air, saving unsaturated resin; Step 15: Install the inlet injection port component and connect it to the flow guide pipe. Inject the unsaturated resin into the product through the injection port and the flow guide pipe. The unsaturated resin completely penetrates the product. Seal the injection port and the flow guide pipe orifice. The air compressor equipment still needs to pump out air and maintain pressure to ensure that no air enters the product during the chemical reaction process; Step 16: At normal temperature for 1 - 2 hours or with heating assistance for 20 - 30 minutes. When the heat generated by the chemical reaction of the product by hand feeling starts to drop slightly, start disassembling the vacuum mold, flow guide pipe, flow guide net, rubber hose, demoulding cloth, and self-adhesive sealing tape, and clean the production platform; Step 17: After the product continues the chemical reaction at normal temperature for 0.5 - 1 hour or with heating assistance for 10 - 15 minutes, take out the product from the mold, and trim and cut the process edges to complete the integral bathroom waterproof floor tray product with a self - contained secondary drainage groove and one - time formed floor decoration.

[0017] Compared with the prior art, the beneficial effects of the present invention are: (1) In this application, a secondary drainage groove is provided on one side of the integral bathroom waterproof floor tray, and the slope of the secondary drainage groove is set and the lowest point communicates with the floor drain. After installation, if the water on the floor of the integral bathroom waterproof floor tray enters the installation groove between the integral bathroom wall panel and the waterproof floor tray, it can flow into the floor drain through the self - contained secondary drainage groove, thereby preventing problems such as wall mildew and damage caused by the retention of waste water.

[0018] (2) During the production process of the integral bathroom waterproof floor tray in this application, putty ash is manually applied to the internal and external corners of the interface transition bonding material layer of the waterproof floor tray to form an arc transition, solving the problem that when vacuum - infusing unsaturated resin later, the unsaturated resin flows slowly and there are dead corners at the internal and external corners.

[0019] (3) During the production of the integral bathroom waterproof chassis of the present application, through holes are drilled on the strengthening bottom plate and the strengthening keel respectively, and installation grooves are arranged between the holes, which facilitates the flow of unsaturated resin. Description of the Drawings

[0020] Figure 1 It is a cross-sectional view of the waterproof chassis described in the present invention.

[0021] Figure 2 It is a schematic structural diagram of the drainage transition mechanism described in the present invention.

[0022] The description of the reference numerals is as follows: 1 - secondary drainage trough, 2 - floor decoration material layer, 3 - transition bonding material layer, 4 - waterproof structure layer, 5 - rigid strength layer, 6 - chassis structure layer, 7 - water retaining wall skirt, 8 - drainage transition mechanism. Detailed Embodiments

[0023] For the convenience of understanding the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Preferred embodiments of the present invention are shown in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the disclosure of the present invention more thorough and comprehensive. The present invention will be further described below with reference to the drawings and specific embodiments. Embodiment 1

[0024] An integrally formed integral bathroom waterproof chassis for floor decoration includes a floor decoration material layer 2 at the topmost layer. The floor decoration material here can be selected from common materials on the market such as natural stone, artificial stone, ceramic tiles, rock slabs, SPC floors, and PVC floors.

[0025] A secondary drainage trough 1 is arranged at the outer bottom of the floor decoration material layer 2. The secondary drainage trough 1 is a slope trough and its lowest point is connected to the floor drain. The secondary drainage trough 1 is designed around the floor decoration material layer 2. Wall panels are installed above the secondary drainage trough, and the wall panels and the floor decoration material layer 2 are sealed with waterproof materials. When the waterproof material ages or is applied improperly, causing water on the bathroom floor to flow between the wall panel and the floor decoration material layer, the water will be collected by the secondary drainage trough and flow out from the floor drain, thus preventing the retention of sewage at the bottom of the waterproof tray and avoiding the growth of bacteria and odors.

[0026] One side of the secondary drainage trough 1 away from the floor decoration material layer 2 extends outward and a water retaining wall skirt 7 higher than the floor decoration material layer 2 is arranged at the end. The water retaining wall skirt 7 includes an interface transition bonding material layer 3 and a waterproof structure layer 4. The length of the outward extension should be determined by comprehensively considering the thickness of the wall panel plus the waterproof material layer and the width of the secondary drainage trough.

[0027] An interface transition bonding material layer 3, a waterproof structure layer 4, a rigid strength layer 5, and a chassis structure layer 6 are sequentially arranged at the bottom of the ground decoration material layer 2 and the secondary drainage trough 1.

[0028] The interface transition bonding material layer 3 is formed by soaking one or two layers of fiberglass mats with a mixture of epoxy resin or vinyl resin and a silane coupling agent mixed in a ratio of 1:2 to 8%. Its function is to increase the bonding force between the ground decoration material layer 2 and the waterproof structure layer 4.

[0029] The waterproof structure layer 4 is composed of fiberglass mats, fiberglass cloth, and unsaturated resin. The fiberglass mats and fiberglass cloth are cross-laid, and the unsaturated resin completely penetrates the fiberglass mats and fiberglass cloth. The number of layers of both the fiberglass mats and fiberglass cloth is more than two layers.

[0030] The rigid strength layer 5 includes a reinforcing bottom plate 51, a first reinforcing keel 52 located at the bottom of the reinforcing bottom plate 51, and a second reinforcing keel 53 located at the end of the reinforcing bottom plate 51. The second reinforcing keel 53 is located at the lower part from the secondary drainage trough 1 to the water retaining wall skirt 7. The material of the rigid strength layer 5 is one of PET foam board, corrosion-resistant wood board and wooden square, or PVC foam board.

[0031] When the rigid strength layer 5 uses PET or PVC foam board, the bulk density of the reinforcing bottom plate 51 is 100 - 200 kg / cm 3 , the thickness is 10 - 17 mm, the bulk density of the first reinforcing keel 52 is 80 - 120 kg / cm 3 , the minimum size of the height × width is 40 × 40 mm, and the bulk density of the second reinforcing keel 53 is 100 - 200 kg / cm 3 , the minimum height × width size is 40 × 40 mm. When the rigid strength layer 5 uses corrosion-resistant wood board and wooden square, the thickness of the reinforcing bottom plate 51 is 10 - 22 mm, and the minimum height × width size of the first reinforcing keel 52 and the second reinforcing keel 53 is 40 × 40 mm.

[0032] When the rigid strength layer 5 uses PET or PVC foam board, several through holes from top to bottom should be left during the production of the PET or PVC foam reinforcing bottom plate, and several through holes from top to bottom and from left to right should be left in the reinforcing keel. The function is to facilitate the flow of the unsaturated resin, and the function is to connect the waterproof structure layer 4, the rigid strength layer 5 and the chassis structure layer 6 into one body.

[0033] When the rigid strength layer 5 uses corrosion-resistant wooden boards and wooden squares, through holes with a diameter of ∅6 - ∅12 mm need to be manually processed on the reinforcement bottom plate 51 every 100 - 200 mm. Holes with a diameter of ∅6 - ∅12 are processed at intervals of 100 - 200 mm above, below, left, and right of the reinforcement keel. The holes above and below, as well as those on the left and right, are processed staggeredly. Processing grooves should be set between the holes, which is convenient for the unsaturated resin to flow. Its function is to connect the waterproof structure layer 4, the rigid strength layer 5, and the chassis structure layer 6 into one body.

[0034] The chassis structure layer 6 is composed of fiberglass felt, fiberglass cloth, and unsaturated resin. Among them, the fiberglass felt and fiberglass cloth are cross-laid, and one or more layers can be laid for each, but the outermost layer must be fiberglass cloth, and the unsaturated resin completely penetrates the fiberglass felt and fiberglass cloth.

[0035] A drainage transition mechanism 8 is provided on the waterproof chassis. The drainage transition mechanism 8 includes a floor drain drainage transition mechanism, a toilet drainage transition mechanism, and a washbasin drainage transition mechanism. Taking the floor drain drainage transition mechanism as an example, the specific structure is as Figure 2 shown. Other drainage transition mechanisms are similar to it. Embodiment 2

[0036] This embodiment provides a preparation method for the above-mentioned integrally formed one-piece bathroom waterproof chassis for floor decoration, including the following steps: Step S1: Clean the mold, wax the mold from the secondary drainage groove to the water retaining wall skirt, and do not wax other molds; Step S2: Place the back of the floor decoration material layer upward on the mold. The gap between the floor decoration material layer and the secondary drainage groove mold is sealed with sealant, masking paper, or putty ash. The gap between the floor decoration materials is also sealed with sealant, masking paper, or putty ash; Step S3: Cut the floor decoration material layer 2 according to the shape of each drainage transition mechanism 8, and install each drainage transition mechanism 8; Step S4: Apply a mixed interface agent of epoxy resin or vinyl resin and silane coupling agent on the back of the floor decoration material layer 2 and the drainage transition mechanism 8, then lay the fiberglass felt, and then use a roller to roll the fiberglass felt to completely immerse the fiberglass felt in the mixed interface agent, thus completing a layer of waterproof chassis interface transition bonding material layer. If two layers are needed, apply the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent again on the first layer of waterproof chassis interface transition bonding material layer, then lay the fiberglass felt, and then use a roller to roll the fiberglass felt to completely immerse the fiberglass felt in the mixed interface agent, thus completing the second layer of waterproof chassis interface transition bonding material layer 3, and so on. After completion, the standing time is 20 - 50 minutes at normal temperature or 10 - 20 minutes with heating assistance. Wait until the chemical reaction of the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent makes the surface non-sticky, and then the next process can be carried out; Step S5: Apply unsaturated resin on the interfacial transition bonding material layer, then lay the fiberglass mat, and then roll the fiberglass mat with a roller to completely immerse the fiberglass mat in the unsaturated resin. Then apply unsaturated resin again, then lay the fiberglass cloth, and then roll the fiberglass cloth with a roller to completely immerse the fiberglass cloth in the unsaturated resin, and so on, to construct the chassis waterproof structure layer 4; Step S6: Place the reinforcing bottom plate 51 on the multiple layers of chassis waterproof structure layer 4 above the floor decoration material layer 2. A plurality of first reinforcing keels 52 are arranged at the bottom of the reinforcing bottom plate 51, and a second reinforcing keel 53 is arranged at each of the four ends of the reinforcing bottom plate 51. A number of through holes are arranged on the reinforcing bottom plate 51 from top to bottom, and a number of through holes are arranged on the first reinforcing keel 52 and the second reinforcing keel 53 from top to bottom and from left to right. Place heavy objects above the reinforcing bottom plate 51, the first reinforcing keel 52, and the second reinforcing keel 53 so that the unsaturated resin in the chassis waterproof structure layer 4 penetrates through the reinforcing bottom plate 51, the first reinforcing keel 52, and the second reinforcing keel 53, and bond the chassis waterproof structure layer 4 with the reinforcing bottom plate 51, the first reinforcing keel 52, and the second reinforcing keel 53. After the unsaturated resin overflowing on the reinforcing bottom plate 51, the first reinforcing keel 52, and the second reinforcing keel 53 undergoes a chemical reaction and the surface is dry and non-sticky, the next process can be carried out; Step S7: Apply unsaturated resin on the reinforcing bottom plate 51, the first reinforcing keel 52, and the second reinforcing keel 53, then lay the fiberglass mat, and then roll the fiberglass mat with a roller to completely immerse the fiberglass mat in the unsaturated resin. Apply unsaturated resin again on the soaked fiberglass mat, then lay the fiberglass cloth, and then roll the fiberglass cloth with a roller to completely immerse the fiberglass cloth in the unsaturated resin, thus completing one layer of the chassis structure layer 6. If another layer needs to be operated, and so on; Step S8: After standing at room temperature for ..... Example 3

[0037] This example provides another preparation method for the floor decoration one-piece integral bathroom waterproof chassis, including the following steps: Step 1: Clean the mold, wax the mold from the secondary drainage groove to the water retaining wall skirt, and do not wax the other molds; Step 2: Place the back of the floor decoration material layer 2 upward on the mold, and seal the gap between the floor decoration material layer and the secondary drainage groove mold with sealant or masking paper or putty ash. The gap between the floor decoration materials is also sealed with sealant or masking paper or putty ash; Step 3: Cut the floor decoration material layer 2 according to the shape of each drainage transition mechanism 8, and install each drainage transition mechanism 8; Step 4: Apply a mixed interface agent of epoxy resin or vinyl resin and silane coupling agent on the back of the floor decoration material layer 2 and the drainage transition mechanism 8, then lay a fiberglass mat, and then roll the fiberglass mat with a roller to completely immerse the fiberglass mat in the mixed interface agent, thus completing a waterproof chassis interface transition bonding material layer. If a second layer is needed, apply the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent again on the first waterproof chassis interface transition bonding material layer, then lay a fiberglass mat, and then roll the fiberglass mat with a roller to completely immerse the fiberglass mat in the mixed interface agent, thus completing the second waterproof chassis interface transition bonding material layer 3, and so on. After completion, the standing time is 20 - 50 minutes at normal temperature or 10 - 20 minutes with heating assistance. Wait until the chemical reaction of the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent makes the surface non-sticky, and then the next process can be carried out; Step 5: Prepare putty ash by mixing an interface agent and putty with epoxy resin or vinyl resin and silane coupling agent, and manually apply it to the internal and external corners of the waterproof chassis interface transition bonding material layer 3 to form an arc transition; Step 6: Lay a fiberglass mat on the waterproof chassis interface transition bonding material layer 3, and then lay a fiberglass cloth on the fiberglass mat, thus completing the operation of one layer of the chassis waterproof structure layer 4, and so on to complete multiple layers of the chassis waterproof structure layer 4; Step 7: Place a strengthening base plate 51 on the multiple layers of the chassis waterproof structure layer 4 above the floor decoration material layer 2. A plurality of first strengthening keels 52 are provided at the bottom of the strengthening base plate 51, and a second strengthening keel 53 is provided at each of the four ends of the strengthening base plate 51. A plurality of through holes are provided on the strengthening base plate 51 from top to bottom, and a plurality of through holes are provided on the first strengthening keel 52 and the second strengthening keel 53 from top to bottom and from left to right. The first strengthening keel 52 and the strengthening base plate 51, and the second strengthening keel 53 and the waterproof structure layer 4 are fixed by hand spraying adhesive respectively; Step 8: Lay a fiberglass mat on the strengthening base plate 51, the first strengthening keel 52 and the second strengthening keel 53, and then lay a fiberglass cloth on the fiberglass mat, thus completing one layer of the chassis structure layer 6. If more than 2 layers are needed, and so on to complete the chassis structure layer 6; Step 9: Lay a release cloth on the chassis structure layer 6; Step 10: Lay a flow guide net on the release cloth; Step 11: Arrange flow guide pipes and rubber hoses on the flow guide net and the mold product platform; Step 12: Seal the periphery of the production mold with self-adhesive rubber strips on the mold production platform, and the sealing range is 100 - 200 mm longer and wider than the length and width of the production mold on each side; Step 13: Install a vacuum infusion mold on the diversion tube. The mold can be a transparent silicone mold or a transparent vacuum bag mold. The length×width dimension of the mold is 100 - 200 mm larger than the length×width dimension of the production mold on each side. Bond it with the self-adhesive rubber strip to ensure airtightness. Step 14: Connect the rubber tube to equipment such as an air compressor, and start pumping out the air in the product. At the same time, manually expel the air at all internal corners to ensure that the vacuum infusion mold fits the product tightly and there is no air, saving unsaturated resin. Step 15: Install the inlet injection component and connect it to the diversion tube. Inject unsaturated resin into the product through the injection port and the diversion tube. Ensure that the unsaturated resin completely penetrates the product. Seal the injection port and the diversion tube orifice. The air compressor equipment still needs to pump out air and maintain pressure to ensure that no air enters the product during the chemical reaction process. Step 16: Keep it at room temperature for 1 - 2 hours or use heating assistance for 20 - 30 minutes. When the heat generated by the chemical reaction of the product by hand feeling starts to drop slightly, start disassembling the vacuum mold, diversion tube, diversion net, rubber tube, release cloth, and self-adhesive sealing tape, and clean the production platform. Step 17: After the product continues the chemical reaction at room temperature for 0.5 - 1 hour or with heating assistance for 10 - 15 minutes, take the product out of the mold, and trim the process edges to complete the one-piece bathroom waterproof floor tray product with a built-in secondary drainage groove and floor decoration.

[0038] The internal and external corners in the above preparation method refer to the 90° right angles located inside the product as shown in Figure 1 such as the four right angles at the position of the secondary drainage groove.

[0039] The series of detailed descriptions listed above are only specific descriptions of the feasible implementation modes of the present invention. However, the present invention is not limited to the above embodiments. Without departing from the essence of the present invention, any obvious improvements, substitutions, or modifications that those skilled in the art can make all fall within the protection scope of the present invention.

Claims

1. An integrally formed one-piece bathroom waterproof floor tray for ground decoration, characterized in that, It includes a floor decoration material layer (2) located at the topmost layer. A secondary drainage trough (1) is provided at the bottom outside the floor decoration material layer (2). The secondary drainage trough (1) is a sloped trough and its lowest point is connected to a floor drain. An interface transition bonding material layer (3), a waterproof structure layer (4), a rigid strength layer (5), and a chassis structure layer (6) are sequentially provided between the floor decoration material layer (2) and the bottom of the secondary drainage trough (1).

2. The integral bathroom waterproof floor tray for one - time forming of floor decoration according to claim 1, wherein, One side of the secondary drainage trough (1) away from the floor decoration material layer (2) extends outward and a water retaining wall skirt (7) higher than the floor decoration material layer (2) is provided at the end. The water retaining wall skirt (7) includes an interface transition bonding material layer (3) and a waterproof structure layer (4).

3. The one-piece integral bathroom waterproof floor tray according to claim 1, characterized in that, The interface transition bonding material layer (3) is formed by impregnating a fiberglass mat with epoxy resin or a mixture of vinyl resin and silane coupling agent.

4. The integral bathroom waterproof chassis for floor decoration formed in one step according to claim 1, characterized in that, The waterproof structure layer (4) is composed of a fiberglass mat, a fiberglass cloth, and an unsaturated resin. The fiberglass mat and the fiberglass cloth are cross-laid, and the unsaturated resin completely impregnates the fiberglass mat and the fiberglass cloth.

5. The integral bathroom waterproof floor pan formed in one piece for floor decoration according to claim 1, wherein, The rigid strength layer (5) includes a reinforcement bottom plate (51), a first reinforcement keel (52) located at the bottom of the reinforcement bottom plate (51), and a second reinforcement keel (53) located at the end of the reinforcement bottom plate (51). The rigid strength layer (5) is one of a PET foam board, a corrosion-resistant wooden board and wooden square, or a PVC foam board.

6. The integral bathroom waterproof chassis for ground decoration formed in one step according to claim 5, characterized in that, A number of through holes are provided on the reinforcement bottom plate (51) from top to bottom. A number of through holes are provided on the first reinforcement keel (52) and the second reinforcement keel (53) from top to bottom and from left to right.

7. The integral bathroom waterproof floor tray for ground decoration formed in one step according to claim 1, characterized in that, The chassis structure layer (6) is composed of a fiberglass mat, a fiberglass cloth, and an unsaturated resin. The fiberglass mat and the fiberglass cloth are cross-laid, and the outermost layer is a fiberglass cloth. The unsaturated resin completely impregnates the fiberglass mat and the fiberglass cloth.

8. The integral bathroom waterproof floor tray for ground decoration formed in one step according to claim 1, wherein, A drainage transition mechanism (8) is provided on the waterproof chassis. The drainage transition mechanism (8) includes a floor drain drainage transition mechanism, a toilet drainage transition mechanism, and a washbasin drainage transition mechanism.

9. The preparation method of the integrally formed one-piece bathroom waterproof floor for ground decoration according to any one of claims 1-8, characterized in that, It includes the following steps: Step S1: Clean the mold, wax the mold from the secondary drainage trough to the water retaining wall skirt (7), and do not wax other molds. Step S2: Place the back of the floor decoration material layer upward on the mold. Seal the gap between the floor decoration material layer and the secondary drainage trough mold with sealant, masking tape, or putty ash. Seal the gap between the floor decoration materials with sealant, masking tape, or putty ash as well. Step S3: Cut the floor decoration material layer (2) according to the shape of each drainage transition mechanism (8), and install each drainage transition mechanism (8). Step S4: Apply a mixed interface agent of epoxy resin or vinyl resin and silane coupling agent on the back of the floor decoration material layer (2) and the drainage transition mechanism (8). Then lay the fiberglass mat, and use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the mixed interface agent, thus completing one layer of the waterproof chassis interface transition bonding material layer. If a second layer is needed, apply the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent again on the first layer of the waterproof chassis interface transition bonding material layer. Then lay the fiberglass mat, and use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the mixed interface agent, thus completing the second layer of the waterproof chassis interface transition bonding material layer (3), and so on. After completion, the standing time is 20 - 50 minutes at normal temperature or 10 - 20 minutes with heating assistance. Wait until the chemical reaction surface of the mixed interface agent of epoxy resin or vinyl resin and silane coupling agent is not sticky, then the next process can be carried out; Step S5: Apply unsaturated resin on the interface transition bonding material layer, then lay the fiberglass mat, and use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the unsaturated resin. Then apply unsaturated resin again, then lay the fiberglass cloth, and use a roller to roll the fiberglass cloth to completely immerse the fiberglass cloth in the unsaturated resin, and so on, to construct the chassis waterproof structure layer (4); Step S6: Place the reinforcement bottom plate (51) on the multiple layers of the chassis waterproof structure layer (4) above the floor decoration material layer (2). A plurality of first reinforcement keels (52) are provided at the bottom of the reinforcement bottom plate (51), and a second reinforcement keel (53) is provided at each of the four ends of the reinforcement bottom plate (51). A number of through holes are provided on the reinforcement bottom plate (51) from top to bottom. A number of through holes are provided on the first reinforcement keel (52) and the second reinforcement keel (53) from top to bottom and from left to right. Place heavy objects above the reinforcement bottom plate (51), the first reinforcement keel (52), and the second reinforcement keel (53) so that the unsaturated resin in the chassis waterproof structure layer (4) penetrates through the reinforcement bottom plate (51), the first reinforcement keel (52), and the second reinforcement keel (53), and bond the chassis waterproof structure layer (4) with the reinforcement bottom plate (51), the first reinforcement keel (52), and the second reinforcement keel (53). Wait until the surface of the overflowing unsaturated resin on the reinforcement bottom plate (51), the first reinforcement keel (52), and the second reinforcement keel (53) is dry and not sticky after the chemical reaction, then the next process operation can be carried out; Step S7: Apply unsaturated resin on the reinforcement bottom plate (51), the first reinforcement keel (52), and the second reinforcement keel (53), then lay the fiberglass mat, and use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the unsaturated resin. Apply unsaturated resin again on the soaked fiberglass mat, then lay the fiberglass cloth, and use a roller to roll the fiberglass cloth to completely immerse the fiberglass cloth in the unsaturated resin, thus completing one layer of the chassis structure layer (6). If another layer needs to be operated, and so on; Step S8: After standing at room temperature for 1 - 4 hours or with heating assistance for 30 - 40 minutes, take the product out of the mold, and correct and cut the process edge to complete the integral bathroom waterproof chassis product with a built-in secondary drainage groove and ground decoration formed in one piece.

10. The preparation method of the integrally formed one-piece bathroom waterproof floor pan for ground decoration according to any one of claims 1-8, characterized in that, It includes the following steps: Step 1: Clean the mold, wax the mold from the secondary drainage groove to the water retaining wall skirt (7), and do not wax the other parts of the mold; Step 2: Place the back of the ground decoration material layer (2) upward on the mold, seal the gap between the ground decoration material layer and the secondary drainage groove mold with sealant or masking paper or putty ash, and also seal the gap between the ground decoration materials with sealant or masking paper or putty ash; Step 3: Cut the ground decoration material layer (2) according to the shape of each drainage transition mechanism (8), and install each drainage transition mechanism (8); Step 4: Brush the epoxy resin or vinyl resin and silane coupling agent mixed interface agent on the back of the ground decoration material layer (2) and the drainage transition mechanism (8), then lay the fiberglass mat, and then use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the mixed interface agent, thus completing the first layer of the waterproof chassis interface transition bonding material layer. If a second layer is needed, brush the epoxy resin or vinyl resin and silane coupling agent mixed interface agent again on the first layer of the waterproof chassis interface transition bonding material layer, then lay the fiberglass mat, and then use a roller to roll the fiberglass mat to completely immerse the fiberglass mat in the mixed interface agent, thus completing the second layer of the waterproof chassis interface transition bonding material layer (3), and so on. After completion, the standing time is 20 - 50 minutes at room temperature or 10 - 20 minutes with heating assistance. Wait until the epoxy resin or vinyl resin and silane coupling agent mixed interface agent does not stick to the hand due to chemical reaction, and then the next process can be carried out; Step 5: Prepare putty ash by mixing the interface agent and putty with epoxy resin or vinyl resin and silane coupling agent, and manually brush the inside and outside corners of the waterproof chassis interface transition bonding material layer (3) to form an arc transition; Step 6: Lay the fiberglass mat on the waterproof chassis interface transition bonding material layer (3), and then lay the fiberglass cloth on the fiberglass mat, thus completing the operation of the first layer of the chassis waterproof structure layer (4), and so on to complete multiple layers of the chassis waterproof structure layer (4); Step 7: Place the strengthening bottom plate (51) on the multiple layers of the chassis waterproof structure layer (4) above the ground decoration material layer (2). A plurality of first strengthening keels (52) are arranged at the bottom of the strengthening bottom plate (51), and one second strengthening keel (53) is arranged at each of the four ends of the strengthening bottom plate (51). A number of through holes are arranged on the strengthening bottom plate (51) from top to bottom, and a number of through holes are arranged on the first strengthening keel (52) and the second strengthening keel (53) from top to bottom and from left to right. The first strengthening keel (52) and the strengthening bottom plate (51), and the second strengthening keel (53) and the waterproof structure layer (4) are fixed respectively by hand spraying adhesive; Step 8: Lay a fiberglass mat on the reinforcement bottom plate (51), the first reinforcement keel (52) and the second reinforcement keel (53), and then lay a fiberglass cloth on the fiberglass mat, thus completing one layer of the chassis structure layer (6). If more than 2 layers are required, the chassis structure layer (6) can be completed in the same way; Step 9: Lay a release cloth on the chassis structure layer (6); Step 10: Lay a flow guide net on the release cloth; Step 11: Arrange flow guide pipes and rubber hoses on the flow guide net and the mold product platform; Step 12: Seal the periphery of the production mold with self-adhesive rubber strips on the mold production platform. The length × width range is 100 - 200 mm larger than the length × width of the production mold on each side; Step 13: Install a vacuum infusion mold on the flow guide pipe. The mold can be a transparent silicone mold or a transparent vacuum bag mold; the length × width size of the mold is 100 - 200 mm larger than the length × width size of the production mold on each side, and it is bonded to the self-adhesive rubber strip to ensure airtightness; Step 14: Connect the rubber hose to equipment such as an air compressor, start pumping out the air in the product, and at the same time manually drive out the air at all internal corners to ensure that the vacuum infusion mold fits the product and there is no air, saving unsaturated resin; Step 15: Install an inlet injection port component and connect it to the flow guide pipe. Inject unsaturated resin into the product through the injection port and the flow guide pipe. The unsaturated resin completely penetrates the product. Seal the injection port and the flow guide pipe orifice. The air compressor equipment still needs to pump out air and maintain pressure to ensure that no air enters the product during the chemical reaction process; Step 16: At normal temperature for 1 - 2 hours or with heating assistance for 20 - 30 minutes. When the heat generated by the chemical reaction of the product by hand feeling starts to drop initially, start disassembling the vacuum mold, the flow guide pipe, the flow guide net, the rubber hose, the release cloth, and the self-adhesive sealing tape, and clean the production platform; Step 17: After the product continues the chemical reaction at normal temperature for 0.5 - 1 hour or with heating assistance for 10 - 15 minutes, take the product out of the mold, and trim and cut the process edge to complete the integral bathroom waterproof chassis product with a self - contained secondary drainage groove and floor decoration formed in one step.

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