Flooring for wet areas, its manufacturing method and bathroom

Abstract

To provide a floor member for a water area, a method for manufacturing the same, and a bathroom that can easily improve the degree of freedom in the arrangement of door.SOLUTION: The floor member 1 for a water area has a plurality of floor pans 2 including a first floor pan 21 and a second floor pan 22, which are connected to each other to form one floor structure 10. The floor structure 10 has a pan body 31 and an outer peripheral portion 32 surrounding the pan body 31. A door mounting surface 321 for mounting the door is formed on the outer peripheral portion 32 so as to straddle at least the first floor pan 21 and the second floor pan 22.SELECTED DRAWING: Figure 1

Description

Field of the Technology

[0007]

[0001] The present disclosure generally relates to a floor member for a plumbing area, a method for manufacturing the same, and a bathroom, and more particularly to a floor member for a plumbing area including a plurality of floor pans connected to each other to form a single floor structure, a method for manufacturing the same, and a bathroom.

Background Art

[0002] Patent Document 1 discloses a waterproof pan provided with split pieces split into two. In this waterproof pan, recesses are formed at the butting ends of each of the two split pieces. The two split pieces are connected by connecting members arranged across the two recesses being screwed to each split piece. Further, a plurality of tiles covering the connecting portion of the two split pieces are adhered to the upper surface of each split piece.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the configuration as described above, when installing a door, the installation position of the door is restricted by the shape of each split piece, and there are cases where the degree of freedom in arranging the door is reduced.

[0005] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a floor member for a plumbing area, a method for manufacturing the same, and a bathroom that are easy to improve the degree of freedom in arranging a door.

Means for Solving the Problems

[0006] A floor member for a plumbing area according to one aspect of the present disclosure includes a first floor pan and a second floor pan, and includes a plurality of floor pans connected to each other to form a single floor structure. The floor structure has a pan body and an outer peripheral portion surrounding the pan body. On the outer peripheral portion, a door mounting surface for mounting a door is formed so as to straddle at least the first floor pan and the second floor pan.

[0007] A method for manufacturing a floor member for a wet area according to one aspect of the present disclosure is a method for manufacturing a floor member for a wet area, comprising: a first molding step of forming the first floor pan; and a second molding step of forming the second floor pan.

[0008] A bathroom according to one aspect of the present disclosure comprises the floor member for water-related areas and a door disposed on the door mounting surface. [Effects of the Invention]

[0009] According to this disclosure, there is an advantage in that it is easier to improve the degree of freedom in the placement of doors. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1A is a schematic perspective view showing the floor pan of a bathroom floor member according to Embodiment 1. Figure 1B is a schematic perspective view showing the floor structure of the same bathroom floor member. [Figure 2] Figure 2 is a schematic perspective view of a bathroom using the same flooring material for wet areas. [Figure 3] Figure 3A is a schematic plan view of the same bathroom. Figure 3B is a schematic perspective view of the same bathroom. [Figure 4] Figure 4A is a schematic plan view of region Z1 in Figure 1A. Figure 4B is a schematic explanatory diagram showing the section along line A1-A1 in Figure 4A. Figure 4C is a schematic explanatory diagram showing the section along line A2-A2 in Figure 4A. [Figure 5] Figure 5A is a schematic perspective view showing the first and second floor pans of the same floor member for a wet area. Figure 5B is a schematic cross-sectional view corresponding to the section along line A1-A1 in Figure 5A, showing the first and second floor pans connected together. [Figure 6] Figure 6 is a schematic perspective view of the mold used to manufacture the floor components for wet areas mentioned above. [Figure 7] Figure 7 is a schematic perspective view of another mold used in the manufacture of the same floor material for bathrooms and kitchens. [Figure 8] Figures 8A and 8B are schematic perspective views showing an example of installing doors of different sizes on the same floor material for wet areas. [Figure 9] Figure 9A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 9B is a schematic perspective view of the same bathroom. [Figure 10] Figure 10A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 10B is a schematic perspective view of the same bathroom. [Figure 11] Figure 11A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 11B is a schematic perspective view of the same bathroom. [Figure 12] Figure 12A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 12B is a schematic perspective view of the same bathroom. [Figure 13] Figure 13A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 13B is a schematic perspective view of the same bathroom. [Figure 14] Figure 14A is a schematic plan view showing a specific example of a door layout in a bathroom using the floor material for wet areas according to Embodiment 2. Figure 14B is a schematic perspective view of the same bathroom. [Figure 15] Figure 15A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 15B is a schematic perspective view of the same bathroom. [Figure 16] Figure 16A is a schematic plan view showing a specific example of door layout in a bathroom using the same floor material for wet areas. Figure 16B is a schematic perspective view of the same bathroom. [Figure 17] FIG. 17A is a schematic plan view showing a specific example of the door layout in a bathroom using the floor member for a water area as described above. FIG. 17B is a schematic perspective view of the bathroom as described above. [Figure 18] FIG. 18A is a schematic plan view showing a specific example of the door layout in a bathroom using the floor member for a water area as described above. FIG. 18B is a schematic perspective view of the bathroom as described above. [Figure 19] FIG. 19 is a schematic perspective view of the floor member for a water area according to Embodiment 3.

MODE FOR CARRYING OUT THE INVENTION

[0011] (Embodiment 1) (1) Overview As shown in FIGS. 1A and 1B, the floor member 1 for a water area according to the present embodiment includes a plurality of floor pans 2 that are connected to each other to form one floor structure 10. That is, the floor member 1 for a water area includes a floor structure 10 composed of a system floor formed by combining a plurality of floor pans 2. The floor structure 10 realized by the plurality of floor pans 2 is used, for example, in a water area such as a bathroom B1 (see FIG. 2), a toilet, a dressing room, or a washroom. As shown in FIG. 1B, the floor structure 10 has a pan body 31 and an outer peripheral portion 32 that surrounds the pan body 31. That is, the floor structure 10 formed by combining a plurality of floor pans 2 has an outer peripheral portion 32 and a pan body 31 surrounded by the outer peripheral portion 32.

[0012] In a room (for example, the bathroom B1) using such a floor member 1 for a water area, as shown in FIG. 2, a door 4 is provided in at least one opening. The "door" referred to in the present disclosure is an opening / closing member arranged at the opening of a room using the floor member 1 for a water area, and includes doors (doors) in various forms such as swing doors, sliding doors, and folding doors. When the door 4 is closed, the opening is blocked, restricting the entry and exit of people into the room. When the door 4 is open, the opening is opened, allowing people to enter and exit the room.

[0013] Such a door 4 is placed on the outer perimeter 32 of the floor structure 10. However, the door 4 cannot be placed anywhere on the outer perimeter 32, but only on the door mounting surface 321 of the outer perimeter 32 that is designed to accommodate the door 4. Therefore, for example, if a door mounting surface 321 is formed on the outer perimeter 32 of one of the multiple floor pans 2 that make up the floor structure 10, the door 4 can only be placed on the outer perimeter 32 of this one floor pan 2, which reduces the degree of freedom in the placement of the door 4.

[0014] In the floor member 1 for wet areas according to this embodiment, the following configuration is adopted to facilitate the improvement of the degree of freedom in the placement of the door 4. Specifically, the floor member 1 for wet areas according to this embodiment includes a first floor pan 21 and a second floor pan 22, and comprises a plurality of floor pans 2 that are connected to each other to constitute a single floor structure 10. The floor structure 10 has a pan body 31 and an outer peripheral portion 32 that surrounds the pan body 31. The outer peripheral portion 32 is formed to have a door mounting surface 321 for placing the door 4 on, which spans at least the first floor pan 21 and the second floor pan 22.

[0015] In short, in this embodiment, the door mounting surface 321 formed on the outer periphery 32 of the floor structure 10, which consists of multiple floor pans 2, is formed not on just one of the floor pans 2, but spans at least two of the floor pans 2, the first floor pan 21 and the second floor pan 22. Therefore, according to the floor member 1 for wet areas of this embodiment, the door 4 can be positioned across the first floor pan 21 and the second floor pan 22, providing a floor member 1 for wet areas of a wet area with a high degree of freedom in the positioning of the door 4.

[0016] As illustrated in Figure 2, the bathroom B1 according to this embodiment comprises a floor member 1 for wet areas and a door 4 positioned on a door mounting surface 321. In other words, in bathroom B1, the door 4 is installed on the door mounting surface 321 of the floor member 1 for wet areas, which is a system floor made up of multiple floor pans 2 (here, as an example, a first floor pan 21, a second floor pan 22, a third floor pan 23, and a fourth floor pan 24). Walls 5 are installed in the outer perimeter 32 of the floor structure 10 where the door 4 is not installed. As a result, the space on the floor structure 10 is surrounded on all four sides by the door 4 and the walls 5, forming the bathroom B1 as a wet area space. Therefore, in bathroom B1 according to this embodiment, there is a high degree of freedom in the placement of the door 4.

[0017] (2) Details (2.1) Premise In this disclosure, "water-related areas" refers to places (rooms) within a building where water is used, including, for example, bathroom B1, toilet, dressing room, or washroom. Furthermore, "water" in this disclosure includes not only cold water but also heated water (hot water), and may also include all liquids having physical properties equivalent to water. In other words, the water-related floor member 1 is a floor member used in these water-related rooms. In this embodiment, as an example, the case in which the water-related floor member 1 is used in bathroom B1, which is a water-related area, will be explained.

[0018] In this embodiment, we assume that bathroom B1 is a relatively large bathroom, such as one located in a non-residential facility like a nursing home or hospital, large enough for multiple people to enter simultaneously. Furthermore, it is not necessary for bathroom B1 to have a bathtub; it may be a bathroom without a bathtub, such as a shower room. In this embodiment, we assume that bathroom B1 consists only of a washing area. In other words, all of the multiple floor pans 2 that make up the floor structure 10 are washing area floor pans that serve as the floor of the washing area.

[0019] In this disclosure, "washing area" refers to the space within bathroom B1 used by users of bathroom B1 to wash their bodies. In other words, there is no bathtub in the washing area, and users can wash their bodies while sitting on a chair on the floor or standing on the floor.

[0020] In this disclosure, "door" refers to an openable and closable member placed in an opening of a room (bathroom B1 in this embodiment) using a floor member 1 for wet areas, and includes various types of doors such as sliding doors, hinged doors, and folding doors. Sliding doors include both double sliding doors and single sliding doors. In this embodiment, the case in which door 4 is a three-panel sliding door is given as an example.

[0021] In this disclosure, when no particular distinction is made between the multiple floor pans 2 constituting the floor structure 10, each of these multiple floor pans 2 is simply referred to as "floor pan 2". That is, for example, when no particular distinction is made between the first floor pan 21 and the second floor pan 22, each of the first floor pan 21 and the second floor pan 22 may simply be referred to as "floor pan 2".

[0022] Furthermore, in this disclosure, the direction perpendicular (orthogonal) to the horizontal plane when the floor member 1 for the wet area is installed will be described as the "up and down direction." In other words, the surface 311 of the pan body 31 faces upward, becoming the "upper surface" of the pan body 31.

[0023] (2.2) Bathroom configuration As shown in Figure 2, the bathroom B1 according to this embodiment includes a floor member 1 for wet areas and a door 4. Figure 2 is a schematic exploded perspective view of the main components of bathroom B1.

[0024] In this embodiment, bathroom B1 further includes walls 5 in addition to the floor member 1 for wet areas and the door 4. In Figure 2, only the floor member 1 for wet areas, the door 4, and a portion of the walls 5 are shown among the components that make up bathroom B1, and the remaining walls 5 and the ceiling are not shown. Furthermore, bathroom B1 is equipped with various facilities such as water supply facilities (including faucets) such as showers, drainage facilities, ventilation facilities, lighting facilities, and heating facilities, but these facilities are also not shown in Figure 2. In other words, bathroom B1 according to this embodiment includes a ceiling and various facilities as components in addition to the floor member 1 for wet areas, the door 4, and the walls 5.

[0025] As described above, the floor member 1 for wet areas according to this embodiment includes a plurality of floor pans 2 that are connected to each other to form a single floor structure 10. In this embodiment, as an example, the floor member 1 for wet areas includes a total of four floor pans 2: a first floor pan 21, a second floor pan 22, a third floor pan 23, and a fourth floor pan 24. In other words, the plurality of floor pans 2 that make up the floor structure 10 include the first floor pan 21 and the second floor pan 22, as well as the third floor pan 23 and the fourth floor pan 24. The floor structure 10 formed by combining these four floor pans 2 is formed in a rectangular shape in plan view and constitutes the entire floor of the bathroom B1.

[0026] In other words, the floor of the bathroom B1 according to this embodiment is realized by a floor structure 10 composed of these multiple floor pans 2. The floor structure 10 has, as described above, a pan body 31 and an outer peripheral portion 32 that surrounds the pan body 31. In other words, the floor structure 10 has an outer peripheral portion 32 and a pan body 31 surrounded by the outer peripheral portion 32. In this embodiment, since the floor structure 10 as a whole is formed in a rectangular shape in plan view, the pan body 31 is also formed in a rectangular shape in plan view, and the outer peripheral portion 32 is also formed in a rectangular frame shape in plan view.

[0027] Furthermore, a door mounting surface 321 for placing a door 4 is formed on the outer perimeter 32 of the floor structure 10. In addition, wall mounting surfaces 322 for placing walls 5 are formed on the parts of the outer perimeter 32 other than the door mounting surface 321. In other words, the outer perimeter 32 of the floor structure 10 includes the door mounting surface 321 and the wall mounting surfaces 322, and a door 4 and a wall 5 can be placed on the outer perimeter 32. In this embodiment, as an example, the door mounting surface 321 is formed in only one place on the outer perimeter 32, and all parts of the outer perimeter 32 other than the door mounting surface 321 are wall mounting surfaces 322. Therefore, one door 4 and multiple walls 5 can be placed on the outer perimeter 32. The configuration of the floor member 1 for wet areas will be explained in detail in the section "(2.3) Configuration of floor member for wet areas".

[0028] In this embodiment, as an example, as shown in Figures 3A and 3B, the bathroom B1 comprises a floor structure 10, one door 4, and twelve walls 5. The one door 4 is positioned on the door mounting surface 321 of the outer perimeter 32, and the twelve walls 5 are positioned on the wall mounting surface 322 of the outer perimeter 32. Figure 3A shows a schematic plan view of the bathroom B1, and Figure 3B shows a schematic perspective view of the bathroom B1. In Figures 3A and 3B, as in Figure 2, only the water-resistant floor member 1, the door 4, and the walls 5 among the components constituting the bathroom B1 are shown, and the ceiling and various equipment are omitted from the illustration. Also, in Figure 2, for explanatory purposes, only the one door 4 and six walls 5 corresponding to the far half of the outer perimeter 32 are shown, and the illustration of the six walls 5 corresponding to the near half of the outer perimeter 32 is omitted. In Figure 3B, for illustrative purposes, door 4 and wall 5 are all shown with dashed lines, and the floor components for the wet areas 1 located behind door 4 or wall 5 are also shown with solid lines.

[0029] Therefore, as shown in Figures 3A and 3B, when the door 4 and multiple (12 in this case) walls 5 are arranged on the outer perimeter 32 of the floor structure 10, the pan body 31 of the floor structure 10 is surrounded by the door 4 and the multiple walls 5. In other words, the space (room) enclosed by the pan body 31, the door 4, and the multiple walls 5 becomes the bathroom B1. In reality, since there is also a ceiling opposite the pan body 31, the space (room) enclosed by the pan body 31, the ceiling, the door 4, and the multiple walls 5 becomes the bathroom B1. In a bathroom B1 with this configuration, the door 4 is placed at the opening. Therefore, when the door 4 is closed, the opening is blocked, restricting people from entering and exiting the bathroom B1, and when the door 4 is open, the opening is opened, allowing people to enter and exit the bathroom B1.

[0030] In this embodiment, as an example, the door 4 and the multiple walls 5 surrounding the pan body 31 have a uniform height from the surface 311 of the pan body 31 to their upper edges. Furthermore, the height of the door 4 and the multiple walls 5 from the surface 311 of the pan body 31 is smaller than the dimension in the shorter direction (short side length) of the rectangular pan body 31 in plan view. Therefore, the bathroom B1 enclosed by the pan body 31, the door 4 and the multiple walls 5 is rectangular in plan view and consists of a space on a rectangular parallelepiped that is flattened in the height direction (vertical direction).

[0031] Furthermore, the door 4 has a door frame 41 and a door body 42 that fits into the door frame 41 (see Figure 2). Therefore, the door body 42 does not rest directly on the door mounting surface 321 formed on the outer periphery 32 of the floor structure 10, but rather the lower frame portion of the door frame 41 rests on it. In this embodiment, as an example, the door mounting surface 321 is formed at a lower position than the surface 311 of the pan body 31 (see Figure 4B) so that when the lower frame portion is installed on the door mounting surface 321, a large step difference does not occur between the upper surface of the lower frame portion and the surface 311 of the pan body 31 (see Figure 4B).

[0032] By the way, in this embodiment, as described above, the door mounting surface 321 formed on the outer periphery 32 is formed to span at least the first floor pan 21 and the second floor pan 22. In other words, the door mounting surface 321 for mounting the door 4 is not contained within one of the multiple (four in this embodiment) floor pans 2 that make up the floor structure 10, but is formed to span at least two floor pans 2 (the first floor pan 21 and the second floor pan 22). Therefore, as shown in Figures 2, 3A, and 3B, the door 4 is positioned to span at least the first floor pan 21 and the second floor pan 22 among the multiple floor pans 2 that make up the floor structure 10.

[0033] More specifically, the outer perimeter 32, which is rectangular in shape when viewed from above, has a door mounting surface 321 formed on one side (one of the longer sides) along its longitudinal direction. In particular, the door mounting surface 321 is formed in the center of the longer side of the outer perimeter 32. That is, the first floor pan 21 and the second floor pan 22 are arranged side by side so as to be adjacent to each other along the longitudinal direction of the bathroom B1, and the door mounting surface 321 is formed so as to straddle these first floor pan 21 and second floor pan 22. Therefore, the door 4 is positioned along the longitudinal direction of the bathroom B1. Consequently, in this bathroom B1, it is possible for people to enter and exit through the door 4 from one of the longer sides.

[0034] Furthermore, as described above, in this embodiment, we assume that bathroom B1 consists only of a washing area, so there is no bathtub in bathroom B1. In other words, the multiple floor pans 2 that constitute the floor structure 10 are all washing area floor pans used on the floor of the washing area in bathroom B1. To put it another way, the first floor pan 21, the second floor pan 22, the third floor pan 23, and the fourth floor pan 24 are all washing area floor pans. The multiple floor pans 2 that serve as washing area floor pans are connected so as to be almost flush with each other, so that no large steps are created at their respective boundaries. Therefore, the pan body 31 has a surface 311 that is close to flat and has no large steps.

[0035] (2.3) Configuration of floor components for wet areas Next, the configuration of the floor member 1 for wet areas according to this embodiment will be described in more detail with reference to Figures 1A, 1B, 4A, and 4B.

[0036] As described above, the floor member 1 for wet areas according to this embodiment includes four floor pans 2 (first floor pan 21, second floor pan 22, third floor pan 23, and fourth floor pan 24) that are connected to each other to form a single floor structure 10. That is, the multiple floor pans 2 that make up the floor structure 10 include not only the first floor pan 21 and the second floor pan 22, but also the third floor pan 23 and the fourth floor pan 24. These four floor pans 2 are combined to form a rectangular floor structure 10 in plan view, as shown in Figure 1B. This makes it possible to construct a system floor with a larger area compared to the case where the floor structure 10 is made up of only the first floor pan 21 and the second floor pan 22.

[0037] Since the floor member 1 for wet areas is used in a wet area (bathroom B1 in this embodiment), all of the multiple floor pans 2 that make up the floor structure 10 are waterproof. Furthermore, the floor pans 2 are made of molded resin. In this embodiment, as an example, the floor pans 2 are made of FRP (Fiber Reinforced Plastics).

[0038] These four floor pans 2 are installed on a rectangular subfloor to form a rectangular floor structure 10. Each floor pan 2 is installed indirectly to the subfloor via legs. The four floor pans 2 are arranged in pairs along both the longitudinal and transverse directions of the subfloor. In other words, the four floor pans 2 are arranged in pairs along both the longitudinal (longitudinal) and transverse (transverse) directions of the subfloor. Each floor pan 2 is positioned so that there are no gaps between adjacent floor pans 2.

[0039] In this embodiment, the first floor pan 21, the second floor pan 22, the third floor pan 23, and the fourth floor pan 24 have different shapes from each other. This makes it possible to construct floor structures 10 of a wider variety of shapes. Here, the first floor pan 21, the second floor pan 22, the third floor pan 23, and the fourth floor pan 24 are all rectangular in plan view, but they differ in shape (including size). The first floor pan 21 and the second floor pan 22 are arranged side by side in the longitudinal direction of the floor structure 10 so that they are adjacent to each other in the longitudinal direction of the floor structure 10. The first floor pan 21 and the third floor pan 23 are arranged side by side in the short direction of the floor structure 10 so that they are adjacent to each other in the short direction of the floor structure 10. In addition, the first floor pan 21 and the fourth floor pan 24 are arranged side by side in the diagonal direction of the floor structure 10 so that they are adjacent to each other in the diagonal direction of the floor structure 10. As a result, the second floor pan 22 and the fourth floor pan 24 are adjacent to each other in the short direction of the floor structure 10, and the third floor pan 23 and the fourth floor pan 24 are adjacent to each other in the long direction of the floor structure 10.

[0040] More specifically, the first floor pan 21, the second floor pan 22, and the third floor pan 23 are all rectangular in plan view and are arranged so that their longitudinal directions coincide with the longitudinal direction of the floor structure 10. The fourth floor pan 24 is square in plan view. Therefore, the sum of the lengths of the long side of the first floor pan 21 and the long side of the second floor pan 22 coincides with the longitudinal dimension of the floor structure 10. Similarly, the sum of the length of the long side of the third floor pan 23 and the length of one side of the fourth floor pan 24 coincides with the longitudinal dimension of the floor structure 10. Also, the sum of the lengths of the short side of the first floor pan 21 and the short side of the third floor pan 23 coincides with the short side dimension of the floor structure 10. Similarly, the sum of the length of the short side of the second floor pan 22 and the length of one side of the fourth floor pan 24 coincides with the short side dimension of the floor structure 10.

[0041] As described above, the floor structure 10, which is formed by combining these multiple floor pans 2, has a pan body 31 and an outer peripheral portion 32 that surrounds the pan body 31. In this embodiment, as described above, the floor structure 10 is formed by arranging two floor pans 2 side by side in the vertical and horizontal directions, so the pan body 31 and the outer peripheral portion 32 are distributed among the four floor pans 2. That is, the first floor pan 21, the second floor pan 22, the third floor pan 23, and the fourth floor pan 24 each have a part of the pan body 31 and a part of the outer peripheral portion 32.

[0042] In the following, unless otherwise specified, the structure of the floor pan 2 will be explained using the first floor pan 21 as an example, among the first floor pan 21, second floor pan 22, third floor pan 23, and fourth floor pan 24. Furthermore, as described above, the pan body 31 and the outer periphery 32 are distributed among the four floor pans 2, and only when the four floor pans 2 are combined does one pan body 31 and one outer periphery 32 form. In other words, each floor pan 2 only has a part of the pan body 31 and a part of the outer periphery 32, and multiple floor pans 2 do not each have a pan body 31 and an outer periphery 32. However, in this disclosure, the part of each floor pan 2 that functions as the pan body 31 is simply referred to as the "pan body 31," and the part of each floor pan 2 that functions as the outer periphery 32 is simply referred to as the "outer periphery 32."

[0043] In other words, as shown in Figure 1A, the floor pan 2 has a pan body 31 and an outer perimeter 32. That is, in the case of a rectangular floor pan 2 in plan view, an L-shaped outer perimeter 32 is provided along two sides (long side and short side) that form the outer perimeter when four floor pans 2 are combined. The pan body 31 constitutes the surface layer of the bathroom B1 floor. Therefore, the pan body 31 of the floor pan 2 has not only waterproofing properties, but also sufficient strength to support the weight of the user, a water slope, and irregularities to ensure good drainage.

[0044] Furthermore, the floor pan 2 has an edge piece 33. The edge piece 33 protrudes downward from the edges of the pan body 31 and outer periphery 32 of the floor pan 2 that abut against other adjacent floor pans 2. In other words, in the rectangular floor pan 2 in plan view, the L-shaped edge piece 33 is provided across the two sides (long side and short side) where the outer periphery 32 is not provided. The edge piece 33 is provided continuously from the pan body 31 to the outer periphery 32.

[0045] Furthermore, a recess 34 is formed at the end of the pan body 31 that connects to the edge piece 33. The recess 34 is provided along the outer edge of the pan body 31 in the floor pan 2. In other words, in the floor pan 2, which is rectangular in plan view, an L-shaped recess 34 is provided across the two sides (long side and short side) where the outer perimeter 32 is not provided.

[0046] Furthermore, in this embodiment, recesses 34 are formed not only on the pan body 31 but also on the ends of the outer periphery 32 that connect to the edge pieces 33. Since the outer periphery 32 includes the door mounting surface 321 and the wall mounting surface 322, the recesses 34 are formed on either the door mounting surface 321 or the wall mounting surface 322.

[0047] The recess 34 is a portion that is recessed one step from the surface 311 of the pan body 31, or the door mounting surface 321 or wall mounting surface 322 of the outer periphery 32. Here, the recess 34 is open upward and outward (towards the adjacent floor pan 2). The side wall 341 of the recess 34 (see Figure 5B) protrudes downward from the surface 311 of the pan body 31, or the door mounting surface 321 or wall mounting surface 322 of the outer periphery 32. The bottom 342 of the recess 34 (see Figure 5B) protrudes from the lower end of the side wall 341 toward the adjacent floor pan 2. The edge piece 33 protrudes downward from the edge of the bottom 342 toward the adjacent floor pan 2.

[0048] The edge piece 33 and recess 34 are used to connect two adjacent floor pans 2. At the connection point between the two adjacent floor pans 2, a watertight structure 6 (see Figure 5B) is employed to prevent water leakage from the gap between the two floor pans 2. The watertight structure 6 will be explained in detail in section (2.4) "Watertight Structure".

[0049] As shown in Figure 1B, two adjacent floor pans 2 are installed with their edge pieces 33 facing each other. In this installation state, the surface 311 of the pan body 31 is positioned at the same height on the two adjacent floor pans 2. Therefore, in a floor structure 10 in which multiple (four in this case) floor pans 2 are combined, the surface 311 of the pan body 31 is positioned at the same height across all of the floor pans 2. Furthermore, in this installation state, the upper surface of the bottom 342 of the recess 34 (the bottom surface of the recess 34) is also positioned at the same height on the two adjacent floor pans 2. Therefore, in a floor structure 10 in which multiple (four in this case) floor pans 2 are combined, a groove consisting of two recesses 34 is formed between the two adjacent floor pans 2. Since this groove (two recesses 34) is filled with a floor connecting cover (see Figure 5B), the pan body 31 achieves a surface 311 that is nearly flat with no large steps.

[0050] By the way, in the floor member 1 for wet areas according to this embodiment, as described above, the outer periphery 32 of the floor structure 10 includes a door mounting surface 321 for mounting a door 4 and a wall mounting surface 322 for mounting a wall 5. In this embodiment, the door mounting surface 321 is formed in only one location, spanning the first floor pan 21 and the second floor pan 22, and all parts of the outer periphery 32 other than the door mounting surface 321 are wall mounting surfaces 322. Therefore, of the first floor pan 21, second floor pan 22, third floor pan 23 and fourth floor pan 24, the door mounting surface 321 is formed only on the first floor pan 21 and the second floor pan 22. The wall mounting surface 322 is formed on any of the first floor pan 21, second floor pan 22, third floor pan 23 and fourth floor pan 24.

[0051] In other words, in the first floor pan 21 of the multiple floor pans 2, both a door mounting surface 321 and a wall mounting surface 322 are formed as the outer periphery 32, as shown in Figures 4A to 4C. Figure 4A is a schematic plan view of region Z1 in Figure 1A showing the first floor pan 21. Figure 4B is an explanatory diagram schematically showing the cross section along line A1-A1 in Figure 4A, and Figure 4C is an explanatory diagram schematically showing the cross section along line A2-A2 in Figure 4A.

[0052] The door mounting surface 321 is a portion (surface) of the outer periphery 32 on which the door 4 is directly or indirectly mounted. Therefore, the door mounting surface 321 of the outer periphery 32 has sufficient strength to support the door 4. As shown in Figure 1B, such a door mounting surface 321 is formed spanning the first floor pan 21 and the second floor pan 22. The door 4 is fixed to the floor structure 10 and the wall 5 while resting on the door mounting surface 321. A watertight structure is applied between the door mounting surface 321 and the door 4 to prevent water leakage from the gap between the door 4 and the floor structure 10. In this embodiment, since walls 5 are arranged on both sides of the door 4 in the circumferential direction of the outer periphery 32, a watertight structure is also applied between these two walls 5 and the door 4 to prevent water leakage from the gap between the walls 5 and the door 4.

[0053] In this embodiment, the door mounting surface 321 is located lower than the surface 311 of the pan body 31, as shown in Figure 4B. Here, the door mounting surface 321 is located even lower than the upper surface of the bottom 342 of the recess 34 formed in the surface 311 of the pan body 31 (the bottom surface of the recess 34). In other words, the door mounting surface 321 of the outer periphery 32 is a relatively large recessed portion relative to the surface 311 of the pan body 31. Therefore, when the lower frame of the door 4 is installed on the door mounting surface 321, no large step difference is created between the upper surface of the lower frame and the surface 311 of the pan body 31. Furthermore, when multiple (in this case, four) floor pans 2 are combined, the door mounting surface 321 is positioned at the same height for the first floor pan 21 and the second floor pan 22.

[0054] The wall mounting surface 322 is a portion (surface) of the outer periphery 32 on which the wall 5 is directly or indirectly supported. Therefore, the wall mounting surface 322 of the outer periphery 32 has sufficient strength to support the wall 5. As shown in Figure 1B, such a wall mounting surface 322 is formed spanning from the second floor pan 22 to the first floor pan 21 in a clockwise direction in a plan view. The wall 5 is fixed to the floor structure 10 while resting on the wall mounting surface 322. A watertight structure is applied between the wall mounting surface 322 and the wall 5 to prevent water leakage from the gap between the wall 5 and the floor structure 10. In this embodiment, since 12 walls 5 are arranged in a line in the circumferential direction of the outer periphery 32, a watertight structure is also applied between these 12 walls 5 to prevent water leakage from the gap between two adjacent walls 5.

[0055] In this embodiment, the wall mounting surface 322 is located higher than the surface 311 of the pan body 31, as shown in Figure 4C. In other words, the wall mounting surface 322 of the outer periphery 32 is a portion that protrudes upward relative to the surface 311 of the pan body 31. Therefore, when the wall 5 is installed on the wall mounting surface 322, the lower edge of the wall 5 is located above the surface 311 of the pan body 31. Furthermore, when multiple (in this case, four) floor pans 2 are combined, the wall mounting surface 322 is positioned at the same height for all of the floor pans 2.

[0056] In this configuration, the door mounting surface 321 is integrally molded with the pan body 31. In other words, in this embodiment, the pan body 31, the outer periphery 32, and the edge piece 33 of the floor pan 2 are integrated as a single molded product. Therefore, not only the door mounting surface 321 but also the wall mounting surface 322 is integrally molded with the pan body 31. In short, in this embodiment, the pan body 31, the outer periphery 32, and the edge piece 33 of the floor pan 2 are integrally molded products and are inseparable. Therefore, in each floor pan 2, the pan body 31 and the outer periphery 32 are continuous without seams, and the pan body 31 and the outer periphery 32 are seamlessly integrated. This makes it difficult for water to leak from between the pan body 31 and the door mounting surface 321.

[0057] In this embodiment, of the first floor pan 21, second floor pan 22, third floor pan 23, and fourth floor pan 24, drainage holes 35 are formed in the first floor pan 21 and the third floor pan 23. In this embodiment, as an example, a pair of circularly opening drainage holes 35 are formed in a part of the pan body 31. On the lower surface of the pan body 31, drainage equipment such as drainage pipes are connected to the drainage holes 35, allowing drainage from the surface 311 side of the pan body 31 to the drainage equipment through the drainage holes 35. When the floor structure 10 is actually used, the drainage holes 35 are covered with drainage covers.

[0058] (2.4) Water-stopping structure Next, the watertight structure 6 at the connection point between two adjacent floor pans 2 will be explained with reference to Figures 5A and 5B. Figure 5B is a schematic cross-sectional view corresponding to the A1-A1 section in Figure 5A, showing the first floor pan 21 and the second floor pan 22 connected (combined). Figures 5A and 5B illustrate the watertight structure 6 at the connection point between the first floor pan 21 and the second floor pan 22, but basically the same watertight structure 6 can be applied to the connection points between other floor pans 2, such as the first floor pan 21 and the third floor pan 23.

[0059] As shown in Figures 5A and 5B, the water-stopping structure 6 includes a packing 61, a first sealing material 62, a connecting plate 63, a waterproof packing 64, a cover material 65, a waterproof tape 66, and a second sealing material 67.

[0060] The packing 61 is positioned between the edge piece 33 of the first floor pan 21 and the edge piece 33 of the second floor pan 22 when the first floor pan 21 and the second floor pan 22 are assembled. That is, the edge pieces 33 of two adjacent floor pans 2 abut against each other via the packing 61. The packing 61 is sandwiched between the edge pieces 33 of the two adjacent floor pans 2, sealing the space between the two edge pieces 33. The packing 61 is provided between the two adjacent floor pans 2, extending along the entire length of the edge pieces 33. In this embodiment, as an example, the packing 61 is a round packing formed with a circular cross-section, making it easy to push from above between the edge pieces 33 of the two adjacent floor pans 2.

[0061] The first sealant 62 is positioned between the edge pieces 33 of two adjacent floor pans 2, above the packing 61. For example, the first sealant 62 consists of a silicone-based caulking material filled between the edge pieces 33 of two adjacent floor pans 2. The first sealant 62 seals the space between the edge pieces 33 of the two adjacent floor pans 2 at a position above the packing 61. Here, the upper surface of the first sealant 62 is flush with the upper surface of the bottom 342 of the recess 34 of the two adjacent floor pans 2 (the bottom surface of the recess 34).

[0062] The connecting plate 63 is positioned on the bottom portion 342, spanning the recesses 34 of two adjacent floor pans 2. The connecting plate 63 is made of, for example, a metal plate. In this embodiment, as an example, the connecting plate 63 is made of a hot-dip galvanized steel plate. The connecting plate 63 is provided along the entire length of the recesses 34 of two adjacent floor pans 2. The connecting plate 63 has holes formed in pairs, where the edge pieces 33 of the two adjacent floor pans 2 are aligned in opposing directions.

[0063] The waterproof packing 64 is plate-shaped and is placed between the connecting plate 63 and the bottom 342 of the recess 34. In other words, the connecting plate 63 is placed on the bottom 342 of the recesses 34 of the two adjacent floor pans 2 via the plate-shaped waterproof packing 64.

[0064] Screws 71 are inserted into each hole of the connecting plate 63 from above. One example of a screw 71 is a countersunk tapping screw. Each hole in the connecting plate 63 is tapered, with the diameter increasing towards the top, and the countersunk (conical) head of the screw 71 fits into each hole. As a result, the upper surface of the head of each screw 71 is flush with the upper surface of the connecting plate 63.

[0065] Each screw 71 that passes through the connecting plate 63 passes through the waterproof packing 64, the bottom 342, and the fixing bracket 72 in that order from above, and its tip is screwed into the frame 73. In this embodiment, the frame 73 is made of composite wood formed by compounding wood powder and resin. The fixing bracket 72 is formed in an L-shape in cross-section and is positioned along the bottom 342 and edge piece 33 of the recess 34. In other words, the fixing bracket 72 reinforces the bottom 342 and edge piece 33 from the inside (bottom side). In this way, two adjacent floor pans 2 are connected by fixing the connecting plate 63 to the ends of each floor pan 2 with screws 71. The waterproof packing 64 is sandwiched between the bottom 342 of the two adjacent floor pans 2 and the connecting plate 63, sealing the space between the bottom 342 of the two adjacent floor pans 2 and the connecting plate 63.

[0066] The cover material 65 is positioned on the connecting plate 63, straddling the recesses 34 of the two adjacent floor pans 2. The cover material 65 is formed in a flat plate shape. Like the connecting plate 63, the cover material 65 is provided along the entire length of the recesses 34 of the two adjacent floor pans 2. The width dimension of the cover material 65 is greater than or equal to the width dimension of the connecting plate 63, and the cover material 65 covers the top of the connecting plate 63. The upper surface of the cover material 65 is flat and flush with the surface 311 of the pan body 31 in the two adjacent floor pans 2. The upper surface of the cover material 65 is the same color or a similar color as the surface 311 of the pan body 31 and has a design (such as an uneven shape) that mimics the surface 311 of the pan body 31.

[0067] The waterproof tape 66 has adhesive surfaces on both sides and is placed between the cover material 65 and the connecting plate 63. In other words, the cover material 65 is attached to the upper surface of the connecting plate 63 with the waterproof tape 66. The waterproof tape 66 is made of butyl rubber adhesive tape, for example. The waterproof tape 66 is provided over the entire upper surface of the connecting plate 63 and seals off water between the cover material 65 and the connecting plate 63. Furthermore, the waterproof tape 66 covers the upper surface of the head of each screw 71, preventing water that has seeped between the cover material 65 and the connecting plate 63 from reaching the holes in the connecting plate 63 into which the screws 71 are inserted.

[0068] The second sealing material 67 is placed between the laminate, which is made up of a waterproof packing 64, a connecting plate 63, a waterproof tape 66, and a cover material 65, and the side walls 341 of the recesses 34 of two adjacent floor pans 2. As an example, the second sealing material 67 consists of a silicone-based caulking material that is filled between the laminate and the side walls 341. In other words, when viewed from above, the gaps that occur on both sides in the width direction of the cover material 65 are sealed by the second sealing material 67. The second sealing material 67 prevents water from entering between the laminate and the side walls 341. Here, the upper surface of the second sealing material 67 is flush with the surface 311 of the pan body 31 of the two adjacent floor pans 2 and the upper surface of the cover material 65. In the example of Figure 5B, a recess is formed at the end on the side wall 341 side of the upper surface of the bottom 342, and a portion of the second sealing material 67 is filled into this recess. This ensures that the second sealing material 67 is reliably filled into the vicinity of the recess, thereby improving the watertightness provided by the second sealing material 67.

[0069] With the above configuration, the water-stopping structure 6 prevents water on the surface 311 of the pan body 31 from leaking out to the subfloor (below the floor pan 2) through the connecting portion of the two adjacent floor pans 2. In other words, the water-stopping structure 6 functions as a water-stopping material that prevents water from leaking out through gaps, and prevents water from leaking out through the gap between the two adjacent floor pans 2. In addition, water on the surface 311 of the pan body 31 may also leak out to the subfloor (below the floor pan 2) through the portion (bottom 342) through which the screw 71 penetrates in the floor pan 2. In this embodiment, however, since the water-stopping structure 6 seals all gaps from the surface 311 of the pan body 31 to the screw 71, it is also possible to prevent water on the surface 311 of the pan body 31 from leaking out to the subfloor (below the floor pan 2) through the portion through which the screw 71 penetrates in the floor pan 2.

[0070] In forming the floor structure 10, the waterproofing structure 6 is constructed, for example, in the following procedure. First, the worker places each floor pan 2 on the subfloor via the legs. Next, the worker presses a packing 61 into the gap formed between two adjacent floor pans 2 from above. Next, the worker forms a first sealing material 62 by pouring caulking material into the gap above the packing 61 from above. Next, the worker places a connecting plate 63 in the recess 34 of the two adjacent floor pans 2 via a waterproof packing 64.

[0071] Next, the worker fastens screws 71 through the connecting plate 63, waterproof packing 64, bottom 342, and fixing bracket 72 to the frame 73 in that order from above. This connects two adjacent floor pans 2. When screwing each screw 71 into the frame 73, it is preferable for the worker to apply sealant to the holes into which the screws 71 are inserted beforehand. For example, a silicone-based sealant can be used for this sealant treatment. By applying this sealant treatment, the space between the screw 71 and the inner surface of the holes in the connecting plate 63, waterproof packing 64, bottom 342, fixing bracket 72, and frame 73 into which the screw 71 is inserted is sealed by the sealant.

[0072] Next, the worker places the cover material 65 on the connecting plate 63 via the waterproof tape 66. Then, the worker forms the second sealing material 67 by pouring caulking material from above into the gap between the laminate, which is made up of the laminate of the waterproof packing 64, the connecting plate 63, the waterproof tape 66, and the cover material 65, and the side wall 341 of the recess 34.

[0073] According to the watertight structure 6 described above, the cover material 65 is housed in the recesses 34 formed at the abutting ends of two adjacent floor pans 2, straddling both recesses 34, and the upper surface of the cover material 65 is flush with the surface 311 of the pan body 31. Therefore, a nearly continuous, flush (flat) floor surface can be formed across the two adjacent floor pans by the surface 311 of the pan body 31 and the upper surface of the cover material 65. Consequently, there is no need to install a large number of tiles on the upper surface of the floor pans 2 to form a flush floor surface, making the construction of the floor structure 10 easier.

[0074] Furthermore, according to the watertight structure 6 described above, the bottom 342 of the recess 34 formed at the end of the pan body 31 is positioned on the frame 73. A connecting plate 63, which spans the recesses 34 of two adjacent floor pans 2, is fixed to the frame 73 by screws 71 that penetrate the bottom 342 of the recesses 34 of the two adjacent floor pans 2. Therefore, two adjacent floor pans 2 can be connected using the connecting plate 63 and screws 71. In particular, in this embodiment, the frame 73 is made of synthetic wood which has superior watertightness and water resistance compared to natural wood, so compared to when the screws 71 are screwed into natural wood, water leakage from the part of the floor pan 2 through which the screws 71 are passed can be suppressed.

[0075] Furthermore, in the aforementioned water-stopping structure 6, the cover material 65 is attached to the upper surface of the connecting plate 63 with waterproof tape 66. Therefore, water leakage between the connecting plate 63 and the cover material 65 can be made less likely by the waterproof tape 66. In addition, since the heads of each screw 71 are covered by the waterproof tape 66, water leakage from the parts of the floor pan 2 through which the screws 71 pass can be further suppressed.

[0076] Furthermore, according to the water-stopping structure 6 described above, the bottom 342 and edge piece 33 of the recess 34 are reinforced by fixing fittings 72 arranged along the bottom 342 and edge piece 33. Therefore, after the floor pan 2 is formed, it is possible to prevent the edge piece 33 from warping outwards (towards the adjacent floor pan 2).

[0077] By the way, in this embodiment, as shown in Figure 5A, the edge portion 33 and the recess 34 are formed not only on the pan body 31 but also on the outer peripheral portion 32. Therefore, the water-sealing structure 6 described above is applied not only to the pan body 31 but also to the outer peripheral portion 32. In particular, since the door mounting surface 321 of the outer peripheral portion 32 is formed to span at least the first floor pan 21 and the second floor pan 22, the water-sealing structure 6 is applied to the door mounting surface 321 at the connection point between the first floor pan 21 and the second floor pan 22.

[0078] In other words, the floor member 1 for wet areas according to this embodiment is equipped with a water-stopping structure 6. The water-stopping structure 6 is provided at the connection point between the first floor pan 21 and the second floor pan 22, and prevents water leakage from the gap between the first floor pan 21 and the second floor pan 22. The water-stopping structure 6 is provided from the pan body 31 of the floor structure 10 to the door mounting surface 321. That is, in this embodiment, since the door mounting surface 321 is formed to straddle the first floor pan 21 and the second floor pan 22, the water-stopping structure 6 is extended and provided up to the door mounting surface 321 at the connection point between the first floor pan 21 and the second floor pan 22. Therefore, the water-stopping structure 6 can also prevent water leakage from the gap between the two adjacent floor pans 2 below the door 4.

[0079] Furthermore, in this embodiment, the water-stopping structure 6 is provided not only on the door mounting surface 321 of the outer periphery 32, but also on the wall mounting surface 322. Therefore, the water-stopping structure 6 can prevent water leakage from the gap between the two adjacent floor pans 2 below the wall 5.

[0080] (3) Method for manufacturing floor components for wet areas Next, the manufacturing method of the floor member 1 for wet areas according to this embodiment will be described with reference to Figures 6 and 7.

[0081] The manufacturing method for the floor member 1 for wet areas according to this embodiment includes a first molding step for molding a first floor pan 21 and a second molding step for molding a second floor pan 22. In other words, in this embodiment, the floor structure 10 is composed of a plurality of floor pans 2, including the first floor pan 21 and the second floor pan 22, so the manufacturing method for the floor member 1 for wet areas includes a molding step for molding each of these plurality of floor pans 2. In this embodiment, as an example, the floor structure 10 is composed of four floor pans 2, including the first floor pan 21 and the second floor pan 22, as well as a third floor pan 23 and a fourth floor pan 24. Therefore, the manufacturing method for the floor member 1 for wet areas includes, in addition to the first and second molding steps, a third molding step for molding the third floor pan 23 and a fourth molding step for molding the fourth floor pan 24. These plurality of molding steps (first molding step to fourth molding step) may be performed sequentially or simultaneously.

[0082] In this embodiment, since each floor pan 2 is a resin molded product, in each of the multiple molding processes (first molding process to fourth molding process), the floor pan 2 is molded using the mold M1, as shown in Figure 6. In other words, the uneven surface shape of the mold M1 is transferred to the floor pan 2.

[0083] In particular, in this embodiment, each floor pan 2 is formed by hand lay-up molding using a mold M1. Here, "hand lay-up molding" refers to a method of forming a resin molded product by layering a base material such as a glass fiber mat impregnated with resin on a mold M1 until it reaches a predetermined thickness, and then demolding it after curing.

[0084] Here, the molding die M1 is not a single piece, but comprises a main body mold M11 and a freestanding mold M12, as shown in Figure 6. The main body mold M11 is used to mold parts of the floor pan 2 other than the door mounting surface 321. The freestanding mold M12 is used to mold the door mounting surface 321 of the floor pan 2. The freestanding mold M12 is assembled with the main body mold M11 by being placed on top of it. Specifically, the freestanding mold M12 is positioned on a part of the main body mold M11 that corresponds to the outer periphery 32. Then, the floor pan 2 is molded using the molding die M1 in this state, with the freestanding mold M12 assembled to the main body mold M11.

[0085] In short, in this embodiment, the door mounting surface 321 of the outer peripheral portion 32 is a relatively large recessed portion relative to the surface 311 of the pan body 31, so it is formed so that the stand mold M12 is transferred to a position corresponding to the stand mold M12 placed on the main body mold M11. In other words, by placing the stand mold M12 on the surface (top surface) of the main body mold M11, a bulge (convex portion) of the shape of the stand mold M12 is created from the surface of the main body mold M11. This bulge is transferred to the floor pan 2, thereby forming the recessed door mounting surface 321 relative to the surface 311 of the pan body 31. The door mounting surface 321 is formed only on the first floor pan 21 and the second floor pan 22 of the four floor pans 2 that constitute the floor structure 10, so the stand mold M12 is used only in the first and second molding processes out of the multiple molding processes (first molding process to fourth molding process).

[0086] Thus, in the first and second molding processes, a separate mold M12 is used, which is attached to the outer periphery 32 of the main mold M11. The door mounting surface 321 is formed at a position corresponding to the mold M12. Therefore, by changing the position (relative position) of the mold M12 with respect to the main mold M11, it is possible to change the position of the door mounting surface 321 on the floor pan 2. As a result, even while using the same molding die M1 (main mold M11 and mold M12), it becomes possible to freely change the position of the door mounting surface 321 on the floor pan 2, dramatically improving the freedom of placement of the door 4.

[0087] Furthermore, in this embodiment, as shown in Figure 7, the stand-up mold M12 is divided into multiple parts. That is, the stand-up mold M12 is constructed by combining multiple mold pieces M121. In the example in Figure 7, the stand-up mold M12 is constructed of four mold pieces M121 divided in the longitudinal direction (circumferential direction of the outer periphery 32). Therefore, the size (length) or shape of the stand-up mold M12 can be changed by changing the number of mold pieces M121 that make up the stand-up mold M12. In addition, the multiple mold pieces M121 may have different sizes (lengths) or shapes from each other. In this case, the size (length) or shape of the stand-up mold M12 can also be changed depending on which mold pieces M121 are combined.

[0088] If the size (length) or shape of the freestanding mold M12 changes, the size or shape of the door mounting surface 321 formed on the floor pan 2 changes, making it possible to change the size of the door 4 placed on the door mounting surface 321. For example, as shown in Figure 8A, when the first floor pan 21 and the second floor pan 22 are formed using a freestanding mold M12 made by combining four mold pieces M121, a door mounting surface 321 with a length D1 is formed on the outer periphery 32 from the first floor pan 21 to the second floor pan 22. In this case, a door 4 with a width dimension W1 can be installed on the door mounting surface 321. On the other hand, as shown in Figure 8B, when the first floor pan 21 and the second floor pan 22 are formed using a freestanding mold M12 made by combining two mold pieces M121, a door mounting surface 321 with a length D2 is formed on the outer periphery 32 from the first floor pan 21 to the second floor pan 22. Length D2 is shorter than length D1 (D1 > D2). In this case, a door 4 with a width dimension W2 shorter than the width dimension W1 can be installed on the door mounting surface 321 (W1 > W2).

[0089] In other words, as shown in Figures 8A and 8B, if the size (width dimension) of the door 4 is different, the size (length) of the door mounting surface 321 on which the door 4 is placed will also be different. Such door mounting surfaces 321 of different sizes can be realized, for example, by changing the number or combination of mold pieces M121 that make up the freestanding type M12. That is, if only one mold piece M121 is used, a door mounting surface 321 of the size corresponding to one mold piece M121 is formed, and if two mold pieces M121 are used, a door mounting surface 321 of the size corresponding to two mold pieces M121 is formed. In this way, by changing the number or combination of mold pieces M121, it is possible to form multiple types of door mounting surfaces 321 that correspond to doors 4 of different sizes.

[0090] Thus, the manufacturing method of the floor member 1 for wet areas according to this embodiment has the advantage of a high degree of freedom in the placement of the door 4.

[0091] (4) Layout example Next, a specific example of the layout of the door 4 in the bathroom B1 using the floor member 1 for wet areas according to this embodiment will be described with reference to Figures 9A to 13B.

[0092] Figures 9A, 10A, 11A, 12A, and 13A show schematic plan views of bathroom B1. Figures 9B, 10B, 11B, 12B, and 13B show schematic perspective views of bathroom B1. In Figures 9B, 10B, 11B, 12B, and 13B, for explanatory purposes, doors 4 and walls 5 are all shown with dashed lines, and floor members for wet areas 1, etc., located behind doors 4 or walls 5 are shown with solid lines. In Figures 9A to 13B, as with Figures 3A and 3B, only the floor members for wet areas 1, doors 4 and walls 5, which make up bathroom B1 are shown, and the ceiling and various equipment are omitted from the illustration.

[0093] Figures 9A and 9B show a bathroom B1 with a layout in which a single door 4 is positioned along one side of the floor structure 10 in the shorter direction. In this example, the two floor pans 2 that include the side in which the door 4 is positioned, i.e., the two floor pans 2 aligned in the shorter direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22.

[0094] Figures 10A and 10B show a bathroom B1 with a layout in which two doors 4 are arranged on two opposing sides (facing each other) in the short direction of the floor structure 10. In this example, the two floor pans 2 that include one of the sides in which each door 4 is placed, i.e., the two floor pans 2 aligned in the long direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. Furthermore, a door mounting surface 321 is also formed spanning the third floor pan 23 and the fourth floor pan 24.

[0095] Figures 11A and 11B show a bathroom B1 with a layout in which two doors 4 are placed on two adjacent sides (two sides forming an L-shape) of the floor structure 10. In this example, the two floor pans 2 that include one of the sides on which each door 4 is placed, i.e., the two floor pans 2 aligned in the longitudinal direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. Furthermore, a door mounting surface 321 is also formed spanning the second floor pan 22 and the fourth floor pan 24.

[0096] Figures 12A and 12B show a bathroom B1 with a layout in which three doors 4 are arranged on three sides of the floor structure 10. In this example, two floor pans 2 that include one side on which each door 4 is placed, i.e., two floor pans 2 aligned in the longitudinal direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. Furthermore, a door mounting surface 321 is also formed spanning the third floor pan 23 and the fourth floor pan 24. Furthermore, a door mounting surface 321 is also formed spanning the second floor pan 22 and the fourth floor pan 24.

[0097] Figures 13A and 13B show a bathroom B1 with a layout in which four doors 4 are arranged around all four sides (circumference) of the floor structure 10. In this example, two floor pans 2 that include one of the sides on which each door 4 is placed, i.e., two floor pans 2 aligned in the longitudinal direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. Furthermore, a door mounting surface 321 is also formed spanning the third floor pan 23 and the fourth floor pan 24. Furthermore, a door mounting surface 321 is also formed spanning the second floor pan 22 and the fourth floor pan 24. Furthermore, a door mounting surface 321 is also formed spanning the first floor pan 21 and the third floor pan 23.

[0098] In the examples shown in Figures 10A to 13B, the door mounting surfaces 321 are provided at multiple locations on the outer perimeter 32. In other words, in order to arrange multiple doors 4 at multiple locations in the bathroom B1, it is necessary to have door mounting surfaces 321 formed at multiple locations on the outer perimeter 32, rather than just one location. With this configuration, the doors 4 can be arranged at multiple locations on the floor structure 10. The door mounting surfaces 321 formed at multiple locations may be the same size (length) or may be different sizes (lengths).

[0099] (5) Variant Embodiment 1 is just one of many embodiments of the present disclosure. Embodiment 1 can be modified in various ways depending on the design, etc., as long as it achieves the objectives of the present disclosure. The figures described in the present disclosure are schematic diagrams, and the ratios of the size and thickness of each component in each figure do not necessarily reflect the actual dimensional ratios.

[0100] The following lists modifications of Embodiment 1. The modifications described below can be applied in appropriate combination with Embodiment 1.

[0101] The multiple floor pans 2 constituting the floor structure 10 only need to include a first floor pan 21 and a second floor pan 22; including a third floor pan 23 and a fourth floor pan 24 is not a necessary configuration for the floor member 1 for wet areas. Alternatively, the floor structure 10 may consist of a total of three floor pans 2: a first floor pan 21, a second floor pan 22, and a third floor pan 23.

[0102] Furthermore, it is not necessary for the first floor pan 21, the second floor pan 22, the third floor pan 23, and the fourth floor pan 24 to have different shapes from each other; at least two of the floor pans 2 may have the same shape.

[0103] Furthermore, the floor structure 10, which is composed of multiple floor pans 2, is not limited to a rectangular shape in plan view, but may also have any suitable shape in plan view, such as a square, trapezoid, triangular, polygonal (pentagonal, etc.), circular, elliptical, L-shaped, or H-shaped.

[0104] Furthermore, the layout of door 4 in bathroom B1 described in Embodiment 1 is merely an example and can be changed as appropriate.

[0105] Furthermore, bathroom B1 only needs to be equipped with a floor component 1 for wet areas and a door 4; it is not essential for bathroom B1 to have walls 5, a ceiling and various fixtures as components.

[0106] Furthermore, each floor pan 2 is not limited to being made of FRP; it may also be made of a resin other than FRP, or a material other than resin.

[0107] Furthermore, the door mounting surface 321 of the outer periphery 32, on which the door 4 is placed, is not limited to being located at a lower position than the surface 311 of the pan body 31. That is, the door mounting surface 321 may be at the same height (flush) as the surface 311 of the pan body 31, or it may be located at a higher position than the surface 311 of the pan body 31.

[0108] Furthermore, the wall mounting surface 322 of the outer periphery 32, on which the wall 5 is placed, is not limited to being located at a higher position than the surface 311 of the bread body 31. That is, the wall mounting surface 322 may be at the same height (flush) as the surface 311 of the bread body 31, or it may be located at a lower position than the surface 311 of the bread body 31.

[0109] (Embodiment 2) The floor member 1 for wet areas according to this embodiment differs from the floor member 1 for wet areas according to Embodiment 1 in that the floor structure 10 is composed of six or more floor pans 2, as shown in Figures 14A to 18B. Hereinafter, components similar to those in Embodiment 1 will be denoted by common reference numerals and their descriptions will be omitted as appropriate.

[0110] In other words, in this embodiment, the multiple floor pans 2 constituting the floor structure 10 include, in addition to the first floor pan 21, second floor pan 22, third floor pan 23, and fourth floor pan 24, a fifth floor pan 25 and a sixth floor pan 26. In the example shown in Figures 16A to 18B, the multiple floor pans 2 constituting the floor structure 10 include, in addition to the first floor pans 21 to the sixth floor pans 26, a seventh floor pan 27 and an eighth floor pan 28.

[0111] Hereinafter, a specific example of the layout of the door 4 in bathroom B1 using the floor member 1 for wet areas according to this embodiment will be described with reference to Figures 14A to 18B.

[0112] Figures 14A, 15A, 16A, 17A, and 18A show schematic plan views of bathroom B1. Figures 14B, 15B, 16B, 17B, and 18B show schematic perspective views of bathroom B1. In Figures 14B, 15B, 16B, 17B, and 18B, for explanatory purposes, doors 4 and walls 5 are all shown with dashed lines, and floor members for wet areas 1, etc., located behind doors 4 or walls 5 are shown with solid lines. In Figures 14A to 18B, as with Figures 3A and 3B, only the floor members for wet areas 1, doors 4 and walls 5, which make up bathroom B1 are shown, and the ceiling and various equipment are omitted from the illustration.

[0113] Figures 14A and 14B show a bathroom B1 with a layout in which two doors 4 are arranged on two opposing sides (facing each other) in the short direction of the floor structure 10. In this example, the two floor pans 2 that include one of the sides on which each door 4 is placed, that is, the two floor pans 2 aligned in the longitudinal direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. The door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. In the example of Figures 14A and 14B, each door 4 is arranged spanning three floor pans 2 aligned in the longitudinal direction of the floor structure 10. That is, the door 4 is arranged spanning the first floor pan 21, the second floor pan 22 and the fifth floor pan 25, so the door mounting surface 321 is also formed spanning the first floor pan 21, the second floor pan 22 and the fifth floor pan 25. Similarly, a door mounting surface 321 is formed spanning the third floor pan 23, the fourth floor pan 24, and the sixth floor pan 26.

[0114] Figures 15A and 15B show a bathroom B1 with a layout in which four doors 4 are arranged around all four sides (circumference) of the floor structure 10. In this example, two floor pans 2 that include one of the sides on which each door 4 is placed, i.e., two floor pans 2 aligned in the longitudinal direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. The door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. In the example of Figures 15A and 15B, each door 4 is arranged spanning three floor pans 2 aligned in the longitudinal direction of the floor structure 10. That is, the doors 4 are arranged spanning the first floor pan 21, the second floor pan 22, and the fifth floor pan 25, so the door mounting surface 321 is also formed spanning the first floor pan 21, the second floor pan 22, and the fifth floor pan 25. Similarly, the door mounting surface 321 is formed spanning the third floor pan 23, the fourth floor pan 24, and the sixth floor pan 26. Furthermore, the door mounting surface 321 is formed even when spanning the first floor pan 21 and the third floor pan 23. Furthermore, the door mounting surface 321 is formed even when spanning the fifth floor pan 25 and the sixth floor pan 26.

[0115] Figures 16A and 16B show a bathroom B1 with a layout in which two doors 4 are arranged side by side along one side of the longitudinal direction of the floor structure 10. In this example, the two floor pans 2 that include the side in which the two doors 4 are placed, i.e., the two floor pans 2 aligned along the longitudinal direction of the floor structure 10, are the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. However, a fifth floor pan 25 and a sixth floor pan 26 are placed between the first floor pan 21 and the second floor pan 22, and no door mounting surface 321 is formed on these fifth floor pans 25 and the sixth floor pan 26.

[0116] Figures 17A and 17B show a bathroom B1 with a layout in which four doors 4 are arranged side by side, two on each of two opposing sides (facing each other) in the short direction of the floor structure 10. In this example, two floor pans 2 that include one of the sides in which each door 4 is placed, i.e., two floor pans 2 aligned in the long direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. However, a fifth floor pan 25 and a sixth floor pan 26 are positioned between the first floor pan 21 and the second floor pan 22, and no door mounting surface 321 is formed on these fifth floor pans 25 and the sixth floor pan 26. Furthermore, a door mounting surface 321 is also formed spanning the third floor pan 23 and the fourth floor pan 24.

[0117] Figures 18A and 18B show a bathroom B1 with a layout in which six doors 4 are arranged around all four sides (circumference) of the floor structure 10. Furthermore, in the example of Figures 18A and 18B, two doors 4 are arranged side by side along each longitudinal side. In this example, two floor pans 2 that include one of the sides in which each door 4 is arranged, i.e., two floor pans 2 aligned along the longitudinal direction of the floor structure 10, become the first floor pan 21 and the second floor pan 22. A door mounting surface 321 is formed spanning these first floor pans 21 and the second floor pan 22. However, a fifth floor pan 25 and a sixth floor pan 26 are arranged between the first floor pan 21 and the second floor pan 22, and no door mounting surface 321 is formed on these fifth floor pans 25 and the sixth floor pan 26. Furthermore, a door mounting surface 321 is also formed spanning the third floor pan 23 and the fourth floor pan 24. Furthermore, the door mounting surface 321 is formed even when spanning the second floor pan 22 and the fourth floor pan 24. Furthermore, the door mounting surface 321 is formed even when spanning the first floor pan 21 and the third floor pan 23.

[0118] Even if the floor structure 10 is composed of six or more floor pans 2, as in Embodiment 2, there may be only one door 4 installed in the bathroom B1.

[0119] Furthermore, while Embodiment 2 illustrates a case where the floor structure 10 is composed of six floor pans 2 or eight floor pans 2, the example is not limited to this, and the floor structure 10 may be composed of nine or more floor pans 2, for example.

[0120] The various configurations (including modified versions) described in Embodiment 2 can be appropriately combined with the various configurations (including modified versions) described in Embodiment 1.

[0121] (Embodiment 3) The floor member 1 for wet areas according to this embodiment differs from the floor member 1 for wet areas according to Embodiment 1 in that it is equipped with a drainage channel 7, as shown in Figure 19. Hereinafter, components similar to those in Embodiment 1 will be denoted by the same reference numerals and their descriptions will be omitted as appropriate.

[0122] In this embodiment, the floor structure 10 is composed of two floor pans 2 (a first floor pan 21 and a second floor pan 22). The drainage channel 7 is provided at the connection point between the first floor pan 21 and the second floor pan 22. The drainage channel 7 drains water from the first floor pan 21 and the second floor pan 22. On the underside of the floor structure 10, drainage equipment such as a drain pipe is connected to the drainage channel 7, allowing drainage from the surface 311 side of the pan body 31 to the drainage equipment through the drainage channel 7. When the floor structure 10 is in use, the drainage channel 7 is covered by a drainage cover 71.

[0123] In other words, the floor member 1 for wet areas according to this embodiment is provided at the connection point between the first floor pan 21 and the second floor pan 22, and further includes a drainage channel 7 for draining water from the first floor pan 21 and the second floor pan 22. This makes it possible to efficiently drain water using the connection point between the first floor pan 21 and the second floor pan 22. In addition, since the door mounting surface 321 is formed spanning the first floor pan 21 and the second floor pan 22, the door 4 can also be placed on the extension of the drainage channel 7.

[0124] In Embodiment 3, the floor structure 10 is exemplified as being composed of two floor pans 2 (a first floor pan 21 and a second floor pan 22), but it is not limited to this example and may be composed of three or more floor pans 2.

[0125] The various configurations (including modified examples) described in Embodiment 3 can be appropriately combined with the various configurations (including modified examples) described in Embodiment 1 or 2.

[0126] (summary) The floor member (1) for a wet area according to the first embodiment includes a first floor pan (21) and a second floor pan (22), and comprises a plurality of floor pans (2) that are connected to each other to form a single floor structure (10). The floor structure (10) has a pan body (31) and an outer peripheral portion (32) that surrounds the pan body (31). The outer peripheral portion (32) is formed such that a door mounting surface (321) for placing a door (4) spans at least the first floor pan (21) and the second floor pan (22).

[0127] According to this embodiment, the door mounting surface (321) formed on the outer periphery (32) of the floor structure (10) is formed not on just one floor pan (2), but spanning at least two floor pans (2), namely the first floor pan (21) and the second floor pan (22). Therefore, the door (4) can be positioned across the first floor pan (21) and the second floor pan (22), which has the advantage of making it easier to improve the degree of freedom in the placement of the door (4).

[0128] The water-resistant floor member (1) according to the second embodiment further comprises a water-sealing structure (6) in the first embodiment. The water-sealing structure (6) is provided at the connection point between the first floor pan (21) and the second floor pan (22) and prevents water leakage from the gap between the first floor pan (21) and the second floor pan (22). The water-sealing structure (6) is provided from the pan body (31) of the floor structure (10) to the door mounting surface (321).

[0129] According to this embodiment, water leakage from the gap between the two adjacent floor pans (2) is also easily suppressed below the door (4).

[0130] In the third embodiment of the floor member for wet areas (1), in the first or second embodiment, a wall mounting surface (322) for mounting a wall (5) is formed in the outer periphery (32) other than the door mounting surface (321).

[0131] According to this embodiment, a wall (5) can be placed on the outer perimeter (32) alongside the door (4).

[0132] In the fourth embodiment of the floor member for wet areas (1), in any of the first to third embodiments, the door mounting surface (321) is provided at multiple locations on the outer periphery (32).

[0133] According to this embodiment, doors (4) can be placed at multiple locations on the floor structure (10).

[0134] In the fifth embodiment of the floor member for wet areas (1), in any of the first to fourth embodiments, the door mounting surface (321) is integrally molded with the pan body (31).

[0135] According to this embodiment, a gap is less likely to occur between the door mounting surface (321) and the pan body (31).

[0136] In the sixth embodiment of the floor member for a wet area (1), in any of the first to fifth embodiments, the plurality of floor pans (2) further include a third floor pan (23) and a fourth floor pan (24).

[0137] According to this embodiment, a wider floor structure (10) can be realized compared to the case where there are only a first floor pan (21) and a second floor pan (22).

[0138] In the seventh embodiment of the floor member for wet areas (1), in the sixth embodiment, the first floor pan (21), the second floor pan (22), the third floor pan (23), and the fourth floor pan (24) have different shapes from each other.

[0139] According to this embodiment, it is easy to realize floor structures (10) of various shapes.

[0140] The eighth embodiment of the floor member for wet areas (1) further comprises a drainage channel (7) in any of the first to seventh embodiments. The drainage channel (7) is provided at the connection point between the first floor pan (21) and the second floor pan (22) and is a part for draining water from the first floor pan (21) and the second floor pan (22).

[0141] According to this embodiment, the door (4) can also be placed on the extension of the drainage channel (7).

[0142] In the ninth embodiment of the water-related floor member (1), in any of the first to eight embodiments, the multiple floor pans (2) are all washing area floor pans used on the floor of the washing area of ​​the bathroom (B1).

[0143] According to this embodiment, the degree of freedom in arranging the doors (4) in the washing area can be improved.

[0144] A manufacturing method for a floor member for a wet area according to the tenth embodiment is a manufacturing method for a floor member for a wet area (1) according to any of the first to ninth embodiments, comprising a first molding step of molding a first floor pan (21) and a second molding step of molding a second floor pan (22).

[0145] This embodiment has the advantage of making it easier to improve the degree of freedom in the placement of the doors (4).

[0146] In the manufacturing method for a floor member for a wet area according to the 11th embodiment, in the 10th embodiment, in the first molding step and the second molding step, a door mounting surface (321) is formed at a position corresponding to the freestanding mold (M12) using a freestanding mold (M12). The freestanding mold (M12) is separate from the main body mold (M11) and is combined with the part of the main body mold (M11) corresponding to the outer periphery (32).

[0147] According to this embodiment, the position of the door mounting surface (321) can be adjusted by the position of the freestanding unit (M12).

[0148] In the manufacturing method for a floor member for a wet area according to the twelfth embodiment, in the eleventh embodiment, the freestanding mold (M12) is constructed by combining a plurality of mold pieces (M121).

[0149] According to this embodiment, the size or shape of the door mounting surface (321) can be changed by changing the number or combination of mold pieces (M121) used.

[0150] The bathroom (B1) according to the 13th embodiment comprises a floor member (1) for water-related areas according to any of the 1st to 9th embodiments, and a door (4) placed on a door mounting surface (321).

[0151] This embodiment has the advantage of making it easier to improve the degree of freedom in the placement of the doors (4).

[0152] The configurations relating to the second to ninth aspects are not essential to the floor member (1) for wet areas and can be omitted as appropriate. [Explanation of symbols]

[0153] 1. Flooring material for wet areas 2 floor pan 4-door 5 walls 6. Water-stopping structure 7 Drainage 10 Floor structure 21 First Floor Bread 22 Second Floor Bread 23 Third Floor Bread 24. 4th Floor Bread 31 Bread body 32 Outer periphery 321 Door mounting surface 322 Wall mounting surface B1 Bathroom M11 main body type M12 Tabletop M121 mold piece

Claims

1. A plurality of floor pans including a first floor pan and a second floor pan are connected to each other to form a single floor structure; The floor structure has a pan body and an outer periphery surrounding the pan body, A door resting surface for resting a door is formed on the outer periphery so as to span at least the first floor pan and the second floor pan. Flooring components for wet areas.

2. The vehicle further includes a water-stopping structure provided at a connecting portion between the first floor pan and the second floor pan to prevent water leakage from a gap between the first floor pan and the second floor pan, The water-stopping structure is provided from the pan body of the floor structure to the door support surface.

2. The wet area floor member according to claim 1.

3. A wall mounting surface for mounting a wall is formed in a portion of the outer periphery other than the door mounting surface.

3. A floor member for use in a wet area according to claim 1 or 2.

4. The door support surface is provided at a plurality of locations on the outer periphery.

4. A floor member for use in a wet area according to claim 1.

5. The door rest surface is integrally formed with the pan body.

5. A floor member for use in a wet area according to claim 1.

6. The plurality of floor pans further includes a third floor pan and a fourth floor pan.

6. A floor member for use in a wet area according to any one of claims 1 to 5.

7. The first floor pan, the second floor pan, the third floor pan, and the fourth floor pan have different shapes from one another.

7. The wet area floor member according to claim 6.

8. Further provided is a drain groove provided at a connection portion between the first floor pan and the second floor pan for draining water from the first floor pan and the second floor pan.

8. A floor member for use in a wet area according to claim 1.

9. The plurality of floor pans are all washing area floor pans used on the floor of a bathroom washing area.

9. A floor member for use in a wet area according to any one of claims 1 to 8.

10. A method for manufacturing a floor member for use in a wet area according to any one of claims 1 to 9, a first molding step of molding the first floor pan; and a second molding step of molding the second floor pan. A method for manufacturing floor components for wet areas.

11. In the first molding step and the second molding step, a stand-alone mold that is separate from the main body mold and is combined with a portion of the main body mold that corresponds to the outer periphery is used to form the door mounting surface at a position corresponding to the stand-alone mold. A method for manufacturing a floor member for use in a wet area according to claim 10.

12. The stand-alone mold is configured by combining a plurality of mold pieces separated from each other. A method for manufacturing a floor member for use in a wet area according to claim 11.

13. A floor member for use in a wet area according to any one of claims 1 to 9, a door to be placed on the door rest surface, bathroom.

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