Floor pan

Abstract

The present invention provides a floor tray that allows for easy diversification of surface designs while suppressing a decrease in cushioning function. [Solution] The floor pan 1 comprises a base material 2, an intermediate layer 10 laminated on the upper side of the base material, and a film 7 attached to cover the intermediate layer, the intermediate layer comprising a foamed layer 11 having a large number of elongated cells 13 in the vertical direction.

Description

Technical Field

[0005] , , , , , , , , ,

[0004] , , ,

[0006] ,

[0001] The present disclosure relates to a floor pan.

Background Art

[0002] Conventionally, floor pans constituting bathroom units have been known. In order to impart patterns and color patterns such as various concavo-convex patterns to the surface of such a floor pan, a variety of molds and material changes are required. However, since it is relatively large-sized, an improvement in productivity has been desired. For example, Patent Document 1 below discloses a floor pan in which an intermediate member made of a resin foam is stacked on a base material and a film is attached to the surface thereof.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the floor pan described in Patent Document 1 above, when the film is adhered to the intermediate member in close contact, the intermediate member is likely to be deformed so as to be crushed, and there is a concern that its buffering function may be reduced.

[0005] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a floor pan that can easily diversify the surface design while suppressing a decrease in the buffering function.

Means for Solving the Problems

[0006] In order to achieve the above object, the floor pan according to the present disclosure includes a base material, an intermediate layer laminated on the upper side of the base material, and a film adhered so as to cover the intermediate layer, and the intermediate layer is characterized by including a foamed layer having a large number of cells that are long in the vertical direction. [Effects of the Invention]

[0007] The floor pan relating to this disclosure, with the configuration described above, makes it possible to easily diversify the surface design while suppressing a decrease in cushioning function. [Brief explanation of the drawing]

[0008] [Figure 1] (a) and (b) schematically show an example of a floor pan according to one embodiment of the present disclosure, where (a) is a partially broken schematic longitudinal section view, and (b) is a partially broken schematic enlarged longitudinal section view of the foamed layer of the floor pan. [Figure 2] This is a schematic disassembled perspective view of a bed pan. [Figure 3] (a) and (b) are schematic partially broken longitudinal cross-sectional views illustrating an example of a floor pan according to another embodiment of the present disclosure. [Modes for carrying out the invention]

[0009] Embodiments of this disclosure will be described below with reference to the drawings. In some of the figures, some of the detailed symbols have been omitted. Figures 1 and 2 schematically show an example of a floor pan according to the first embodiment.

[0010] As shown in Figures 1(a) and 2, the floor pan 1 according to this embodiment comprises a base material 2, an intermediate layer 10 laminated on the upper side of the base material 2, and a film 7 attached to cover the intermediate layer 10. With this configuration, by applying various decorations to the film 7, a common base material 2 can be used, and the surface design can be easily diversified. As shown in Figure 1(b), the intermediate layer 10 comprises a foamed layer 11 having a large number of elongated cells 13 in the vertical direction. With this configuration, the large number of elongated cells 13 in the vertical direction can resist loads in the thickness direction, making it less likely to collapse when the film 7 is attached, and suppressing a decrease in cushioning function. This can improve the feel underfoot and shock absorption when kneeling.

[0011] The floor pan 1 is roughly rectangular in shape when viewed from above (see Figure 2). This floor pan 1 constitutes the bathroom floor and, together with a bathtub (not shown), wall panels and fixtures that partition the four sides of the bathroom, and ceiling panels that make up the bathroom ceiling, constitutes a bathroom unit such as a unit bath (system bath). In the illustrated example, floor pan 1 consists only of the washing area floor pan that makes up the floor of the washing area, with the bathtub installed to the side of one of its edges. In other words, the illustrated example illustrates a floor pan that does not have a bathtub floor pan on which the bathtub is installed, but a configuration with a bathtub floor pan is also possible. In this case, the washing area floor pan (floor pan 1) and the bathtub floor pan may be integrally molded, separate, or further subdivided. This floor pan 1 may be installed on a foundation floor such as a slab via appropriate support legs or the like.

[0012] The base material 2 constitutes the main body of the floor pan 1 and has a roughly rectangular shape when viewed from above. This base material 2 may be a resin molded product formed from, for example, fiber-reinforced plastic (FRP). This base material 2 may also be formed from a sheet molding compound (SMC) containing reinforcing fibers such as glass fibers, or it may be made of artificial marble mainly composed of acrylic or polyester. The base material 2 has rising sections 3 that rise upward at its four perimeter ends. Wall panels are installed on three of these rising sections 3, and a bathtub is installed on the remaining side. An intermediate layer 10, described later, is placed on the bottom of the base material 2, surrounded by the rising sections 3. A drain recess 4 for receiving a drain cover (not shown) is provided on the bathtub side of the bottom of the base material 2. A drain outlet 5 that communicates with the drain pipe under the floor is provided on the bottom side of the drain recess 4. The bottom of the base material 2 may have an appropriate slope toward the drain recess 4. In addition, appropriate reinforcing ribs and receiving parts for the upper ends of support legs may be provided on the back side of the base material 2.

[0013] The intermediate layer 10 is in the shape of a rectangular plate. This intermediate layer 10 is placed on the bottom of the base material 2 such that its four circumferential end surfaces abut the inner circumferential surfaces of the four circumferential rising portions 3 of the base material 2. The intermediate layer 10 has notches formed in it corresponding to the drain recesses 4 described above. The thickness of this intermediate layer 10 may be, for example, about 3 mm to 10 mm. In this embodiment, the intermediate layer 10 is provided between the foam layer 11 and the film 7 and comprises a resin layer 15 that is harder than the foam layer 11. With this configuration, since the hard resin layer 15 is provided on the surface side of the relatively soft foam layer 11, the surface hardness of the floor pan 1 can be increased, and its durability against friction and the like can be improved.

[0014] The thicknesses of the foam layer 11 and the resin layer 15 may be set to appropriate dimensions from the viewpoint of ensuring the cushioning function of the foam layer 11 and the surface hardness of the resin layer 15, and the thickness of the foam layer 11 may be greater than the thickness of the resin layer 15. For example, the thickness of the resin layer 15 may be 0.2 mm to 1 mm and the thickness of the foam layer 11 may be 4 mm to 7 mm. If the thickness of the resin layer 15 is made too small, the surface hardness tends to decrease, and if the thickness of the resin layer 15 is made too large, it becomes difficult to follow the deformation of the foam layer 11, which tends to reduce the feel underfoot. Also, if the thickness of the foam layer 11 is made too small, the flexibility tends to decrease, and if the thickness of the foam layer 11 is made too large, the moldability and walking stability tend to decrease. With the above configuration, it is possible to improve the feel underfoot while ensuring an appropriate surface hardness.

[0015] As shown in the partially enlarged cross-sectional view in Figure 1(b), the foamed layer 11 is made of closed-cell foamed plastic with a large number of cells (bubbles) 13 dispersed within it. In other words, the numerous hollow cells 13 of the foamed layer 11 are separated by resin parts 12 that form walls. The foam layer 11 may be made of a material with excellent shape retention properties that compresses moderately when a load is applied and returns to its original shape when the load is removed. For example, the foam layer 11 may be PVC (polyvinyl chloride) foam, PUR (polyurethane) foam, PE (polyethylene) foam, EVA (ethylene vinyl acetate) foam, etc. The cells 13 of this foam layer 11 are arranged such that many cells 13 are elongated vertically, that is, the vertical dimension (vertical diameter) of the cell 13 is larger than the dimension in the direction perpendicular to the vertical direction (horizontal diameter). Not all cells 13 in the foam layer 11 need to be elongated vertically; some cells 13 may be roughly spherical, horizontally elongated, or horizontally flattened. For example, the majority (50% or more) of the cells 13 in the foam layer 11 may be elongated vertically.

[0016] Preferably, the average of the aspect ratio ("vertical dimension (vertical diameter)" / "dimensional dimension in the direction perpendicular to the vertical direction (horizontal diameter)") of the cells 13 contained in the foam layer 11 may be 1.2 times or more. More preferably, 68% or more of the cells 13 contained in the foam layer 11 may have a vertical dimension that is 1.7 to 2.8 times the dimension in the direction perpendicular to the vertical direction. If the majority of the cells 13 contained in the foam layer 11 have a vertical dimension that is too small compared to the dimension perpendicular to the vertical direction, they tend to be easily crushed when the film 7 is attached. If the cells 13 are too large (too elongated vertically), the amount of deformation of the cells 13 themselves during compression will be large, causing the foam layer 11 to become hard. With the above configuration, the majority of the cells 13 contained in the foam layer 11 will be appropriately elongated vertically, and the deterioration of the cushioning function can be effectively suppressed. In other words, the foam layer 11 may contain 68% or more cells 13 whose vertical diameter is 1.7 to 2.8 times their horizontal diameter.

[0017] The content ratio of the cells 13 in the foam layer 11 as described above may be, for example, a value obtained by measuring the vertical and horizontal diameters of all or a predetermined number of cells 13 included in a predetermined range (for example, a range of several mm (about 1 mm to 5 mm) × several mm (about 1 mm to 5 mm)) at a plurality of locations (for example, about 4 to 10 locations) of the foam layer 11 using an electron microscope or the like, or by performing image analysis from imaging data. Also, the foam layer 11 may be such that the standard deviation (1σ) obtained by statistically processing such measurement data is 1.7 times to 2.8 times. The vertical diameter of the cell 13 included in the foam layer 11 may be about 100 μm to 800 μm, or may be about 150 μm to 500 μm. The porosity of this foam layer 11 may be about 20% to 40%, or may be about 30% to 35%. Such a foam layer 11 may have a configuration including a large number of vertically long cells 13 as described above, for example, by appropriately adjusting a foaming agent or the like contained during foam molding, or by moving the mold in the thickness direction during foam molding.

[0018] On the back surface of this foam layer 11, a large number of grooves 14 for receiving an adhesive that adheres the foam layer 11 to the base material 2 are formed. With such a configuration, the adhesive layer 6 formed by curing the adhesive enters the grooves 14 to obtain an anchor effect, and the adhesive strength between the intermediate layer 10 and the base material 2 can be improved. These grooves 14 may be formed at a plurality of locations at a predetermined pitch so as to extend in a first direction (for example, the floor pan width direction or the longitudinal direction) on the back surface of the foam layer 11 and at intervals in a second direction orthogonal to the first direction, or may be formed in a lattice pattern so as to extend in each of the first direction and the second direction. The groove width and groove depth of the grooves 14 may be appropriate dimensions from the viewpoint of improving the adhesive strength, etc., for example, about several mm, or may be about 1 mm to 3 mm. Similarly, the pitch for providing these grooves 14 may be about several mm, or may be about 2 mm to 5 mm. As the adhesive constituting the adhesive layer 6, an aqueous adhesive may be used, for example, an acrylic adhesive may be used.

[0019] The resin layer 15 may have a scratch hardness of H or higher. With this configuration, the durability of the floor pan 1 surface against friction and other factors can be further improved. The scratch hardness of this resin layer 15 may also be measured as pencil hardness according to the provisions of JIS K5600-5-4 (Scratch hardness of paints (pencil method)). On the surface side of the resin layer 15, irregularities (recesses 17 and protrusions 16) are formed, which correspond to the uneven pattern on the surface side of the film 7. With this configuration, by forming recesses 17 and protrusions 16 in the resin layer 15 that constitutes the intermediate layer 10, it is possible to more easily diversify the surface design of the floor pan 1 using a common base material 2. Furthermore, since the resin layer 15 is hard, the disappearance of irregularities due to wear and tear can be suppressed. In the illustrated example, protrusions 16 are provided at equal intervals on the surface of the resin layer 15, and recesses 17 are formed between adjacent protrusions 16. However, the uneven shape is not limited to this, and any uneven shape is acceptable, such as a textured surface, a matte finish, or a fine uneven pattern. The uneven shape of the resin layer 15 may be set to an appropriate shape from the viewpoint of tactile feel, slip resistance, water drainage, etc.

[0020] This resin layer 15 may be formed from a non-foaming resin composition, and may be harder than the foamed layer 11 and have a moderate elasticity that can follow the compressive deformation of the foamed layer 11 caused by stepping on it. This resin layer 15 may be, for example, a PVC (polyvinyl chloride) sheet, an ABS (acrylonitrile butadiene styrene) sheet, a PMMA (acrylic resin) sheet, etc. This resin layer 15 may be laminated and integrated onto the foam layer 11 via an appropriate adhesive, or it may be laminated and integrated by lamination (heat bonding) or the like.

[0021] The film 7 is provided so as to cover the entire surface (top surface) of the intermediate layer 10. The film 7 may be attached so as to span the intermediate layer 10 and the base material 2. For example, in addition to the surface of the intermediate layer 10, the film 7 may also be attached to the inner and upper surfaces of the rising portion 3 of the base material 2, or it may also be attached to the outer surface of the rising portion 3. The film 7 may be a decorative film with an appropriate pattern applied to it. For example, such a film 7 may comprise a surface layer which is the outermost layer of the film 7, and a printed layer located on the back side (substrate 2 side) of the surface layer. Alternatively, the film 7 may comprise a base layer located on the back side of the printed layer and an adhesive layer located on the back side of the base layer. The surface layer may be formed from, for example, transparent PMMA or PVC. Alternatively, granular material may be mixed into the surface layer.

[0022] The printed layer of film 7 is a layer that imparts color and patterns to the film 7, and various patterns may be formed by printing. For example, various patterns such as leather-like, wood-grain, metallic, and stone-like textures may be formed on the printed layer. The base layer of film 7 may be formed from, for example, rigid PVC or ABS. The adhesive layer of film 7 may be, for example, a PMMA-based adhesive that is resistant to hydrolysis, or it may be formed from various adhesives such as epoxy or urethane-based adhesives. The film 7 may have a thickness of approximately 0.1 mm to 0.3 mm. The layer structure of the film 7 is not limited to the configuration described above, and may have various other configurations. The film 7 may be attached to the surface of the intermediate layer 10 (and the substrate 2) via a primer layer. The primer layer may be formed by applying, for example, an isocyanate-based primer.

[0023] The film 7 may be adhered to the surface of the intermediate layer 10 (and the substrate 2) by TOM (Three-Dimensional Overlay Method) molding (vacuum / pressure molding). Furthermore, various molding methods such as vacuum molding, in-mold molding, and insert molding can be used to adhere the film 7 to the surface of the intermediate layer 10 (and the substrate 2). This film 7 adheres closely to the uneven surface of the intermediate layer 10 (resin layer 15), as well as to the irregularities of the base material 2, such as the raised portion 3 and the drain recess 4. Furthermore, after attaching the film 7, the excess portion corresponding to the drain port 5 and the surrounding area may be removed as appropriate by trimming or other means.

[0024] Next, other embodiments of the floor pan will be described with reference to Figure 3. In the following embodiments, the differences from the previously described example will be mainly explained. Similar components will be denoted by the same reference numerals, and their descriptions will be omitted or simplified. In the following embodiments, the same effects and other aspects as those described in the previously described example will also be omitted or simplified.

[0025] Figure 3(a) is a schematic diagram showing an example of a floor pan according to the second embodiment. The floor pan 1A according to this embodiment differs from the example described above in the configuration of the resin layer of the intermediate layer 10A. In this embodiment, the resin layer of the intermediate layer 10A is composed of multiple layers (two layers in the illustrated example), and the resin layer on the film 7 side (first resin layer 15A) is harder (higher hardness) than the resin layer on the foam layer 11 side (second resin layer 18). With this configuration, while ensuring surface hardness with the first resin layer 15A on the surface side, it is possible to reduce the crushing of the protrusions 16 and recesses 17 formed on the first resin layer 15A due to the adhesion of the film 7. In other words, if protrusions 16 and recesses 17 are formed on the hard and thin first resin layer 15A, it is easy to form an uneven shape on the back side as well, but the second resin layer 18 on the back side can fill the recesses on the back side of the first resin layer 15A, making the back side of the resin layer flat, and the protrusions 16 and recesses 17 on the surface side are less likely to be crushed. Furthermore, by interposing a second resin layer 18, which is softer than the first resin layer 15A, between the hard first resin layer 15A and the soft foam layer 11, delamination between the layers can be suppressed.

[0026] The first resin layer 15A may be formed from a hard resin such as ABS. The second resin layer 18 may be made of a resin that is softer than the first resin layer 15A, for example, a PVC sheet. This second resin layer 18 may be a PVC sheet that is softer than the resin layer 15 described in the first embodiment above. The thicknesses of the first resin layer 15A and the second resin layer 18 may be such that the sum of their thicknesses is approximately the same as the thickness of the resin layer 15 in the first embodiment described above. For example, the thicknesses of the first resin layer 15A and the second resin layer 18 may be approximately 0.1 mm to 0.5 mm each.

[0027] Figure 3(b) is a schematic diagram showing an example of a floor pan according to the third embodiment. The floor pan 1B according to this embodiment differs from the examples described above in the configuration of the intermediate layer 10B. In this embodiment, a hard coat layer 19 is formed on the surface of the resin layer 15. With this configuration, the surface hardness can be further increased compared to a configuration in which the resin layer 15 is only a resin sheet, and the durability of the floor pan 1B against friction and the like can be further improved. In addition, by providing such a hard coat layer 19, the scratch hardness can be made higher than that of a resin sheet alone, for example, it is possible to make it about 3H to 6H. Furthermore, even if the resin layer 15 is provided with the same protrusions 16 and recesses 17 as described above, the hard coat layer 19 can be formed by coating, so the uneven shape will not disappear. The hard coat layer 19 may be, for example, an acrylic coat layer. In this case, the resin layer 15 may be the same as the resin layer 15 described in the first embodiment, or it may be a softer PVC sheet than described above.

[0028] The different configurations described in each of the above embodiments may be modified, rearranged, or combined as appropriate and as needed. For example, a configuration in which a hard coat layer 19 is further provided on the surface of the first resin layer 15A described in the second embodiment may be used. In the embodiments described above, examples are shown in which the surface of the resin layers 15 and 15A is provided with irregularities that form an uneven pattern on the surface side of the film 7. However, a configuration without such irregularities is also possible.

[0029] In the embodiments described above, examples are shown in which resin layers 15, 15A, and 18 are provided on the intermediate layers 10, 10A, and 10B, but configurations without such resin layers are also possible. In other words, the intermediate layers 10, 10A, and 10B may be composed solely of the foamed layer 11. In the embodiments described above, an example is shown in which grooves 14 are provided on the back side of the foam layer 11. However, instead of grooves 14, a configuration with numerous recesses (embossing) or the like may be provided, or furthermore, a configuration without grooves 14 or recesses may be provided. The specific configurations of the parts and members constituting the floor pans 1, 1A, and 1B according to the above embodiments are not limited to those described above, and various other modifications are possible.

[0030] Next, an example of an embodiment of the floor pan according to this disclosure will be described with reference to Table 1. In each of Examples 1 and 2 and the Comparative Example, the substrate, resin layer, and film had the same configuration, with only the foam layer having a different configuration. In Examples 1 and 2, the vertical and horizontal diameters of cells within a 2 mm x 2 mm area at four locations in the cross-section of the foam layer were measured using an electron microscope, and the standard deviation (1σ) obtained by statistically processing the measurement data was used. In Example 1, the foamed layer was made of PVC foam with a 32% void ratio. Of the cells contained in this foamed layer, 68% had a vertical dimension that was 1.7 to 2.8 times larger than the dimension in the direction perpendicular to the vertical direction. In Example 2, the foamed layer was made of PVC foam with a void ratio of 34%. Of the cells contained in this foamed layer, 68% had a vertical dimension that was 0.95 to 1.65 times the dimension in the direction perpendicular to the vertical direction. In the comparative example, the foamed layer was made of PE (polyethylene) foam with a 32% bubble content. Most of the cells in this foamed layer were elongated horizontally.

[0031] The floor pan test specimens of each of the above-described examples 1 and 2 and comparative examples were evaluated in the following two ways. <Percentage change in thickness> The thickness of the foamed layer in each of Examples 1 and 2 and the Comparative Example was measured before and after TOM molding, and the thickness change rate was calculated. In Example 1, the thickness after TOM molding was 4.8 mm compared to the thickness before TOM molding (5 mm), resulting in a thickness change rate of 5%, which is a good result. In Example 2, the thickness after TOM molding was 4.5 mm compared to 7 mm before TOM molding, resulting in a thickness change rate of 35.7%. In the comparative example, the thickness after TOM molding was 15 mm compared to 24 mm before TOM molding, resulting in a thickness change rate of 37.5%.

[0032] <Rebound force> The surface of the floor pans in each of Examples 1 and 2 and the Comparative Example was pressed 0.4 mm with a rod-shaped object with a diameter of 20 mm, and the resulting load was measured using a load cell. In Example 1, the reading was 57 kPa; in Example 2, it was 42 kPa; and in the Comparative Example, measurement was not possible. [Table 1] From the above results, it was shown that the floor pans of Examples 1 and 2, which have a foamed layer with many elongated cells in the middle layer, have better rebound force compared to the comparative floor pan, meaning they return to their original shape more easily when stepped on, thus improving the feel underfoot. Furthermore, it was shown that the floor pan of Example 1 has an extremely small rate of change in thickness before and after molding compared to the floor pan of Example 2, thus maintaining its flexibility before molding, and further improvements in the feel underfoot can be expected.

[0033] <Note> The following technologies are disclosed based on the above description of embodiments. <Technology 1> A floor pan comprising a base material, an intermediate layer laminated on the upper side of the base material, and a film attached to cover the intermediate layer, wherein the intermediate layer is a foamed layer having a large number of elongated cells in the vertical direction. <Technology 2> The floor pan according to Technology 1, wherein 68% or more of the cells contained in the foam layer have a vertical dimension that is 1.7 to 2.8 times the dimension in the direction perpendicular to the vertical direction. <Technology 3> The floor pan according to Technology 1 or Technology 2, wherein the back surface of the foam layer has a number of grooves formed to receive an adhesive for bonding the foam layer to the substrate. <Technology 4> The floor pan according to any one of the three technologies, wherein the intermediate layer is provided between the foam layer and the film and comprises a resin layer that is harder than the foam layer. <Technology 5> The floor pan according to Technology 4, wherein the surface side of the resin layer has irregularities that form an uneven pattern on the surface side of the film. <Technology 6> The aforementioned resin layer is a floor pan according to Technology 4 or Technology 5, wherein the scratch hardness is H or higher. <Technology 7> A floor pan according to any one of the technologies 4 to 6, wherein a hard coat layer is formed on the surface of the resin layer. <Technology 8> A floor pan according to any one of the following technologies, wherein the thickness of the resin layer is 0.2 mm to 1 mm and the thickness of the foam layer is 4 mm to 7 mm. [Explanation of symbols]

[0034] 1,1A,1B Floor pan 2 Base material 7 Film 10,10A,10B middle layer 11 Foam layer 13 cells 14 groove 15 Resin layer 15A 1st resin layer (resin layer) 18 Second resin layer (resin layer) 19. Hard court layer

Claims

1. It comprises a base material, an intermediate layer laminated on the upper side of the base material, and a film attached to cover the intermediate layer. The floor pan is characterized in that the intermediate layer comprises a foamed layer having a large number of elongated cells in the upper and lower positions.

2. In claim 1, A floor pan characterized in that 68% or more of the cells contained in the foamed layer have a vertical dimension that is 1.7 to 2.8 times the dimension in the direction perpendicular to the vertical direction.

3. In claim 1, A floor pan characterized in that a number of grooves are formed on the back surface of the foamed layer to receive an adhesive for bonding the foamed layer to the substrate.

4. In any one of claims 1 to 3, The floor pan is characterized in that the intermediate layer is provided between the foam layer and the film and comprises a resin layer that is harder than the foam layer.

5. In claim 4, A floor pan characterized in that the surface side of the resin layer has irregularities that form an uneven pattern on the surface side of the film.

6. In claim 4, The aforementioned resin layer is characterized by having a scratch hardness of H or higher.

7. In claim 4, A floor pan characterized in that a hard coat layer is formed on the surface of the resin layer.

8. In claim 4, A floor pan characterized in that the thickness of the resin layer is 0.2 mm to 1 mm, and the thickness of the foam layer is 4 mm to 7 mm.

Images