JP6918621B2 - How to manufacture bathroom floor members - Google Patents

Description

The present invention relates to a method for manufacturing a bathroom floor member that constitutes a floor portion of a system bath or the like.

When providing a bathroom in a house or the like, a system bath in which each part is manufactured in accordance with a predetermined standard and these are assembled and installed in the house or the like is widely used.
A general system bath is composed of each member such as a bathtub, a floor portion (floor pan portion) serving as a washing place, and a side panel serving as a side wall of a bathroom (see, for example, Patent Document 1). The joint between the bathtub and the floor pan, and the joint between the side panel and the floor have a waterproof structure to prevent hot water from leaking to the outside, and are exposed to the bathroom if necessary. Some are waterproofed.

FIG. 5 is a perspective view of a floor member manufactured by using a conventional method for manufacturing a floor member. The illustrated floor member 100 is composed of, for example, a stainless steel floor bottom member 110 formed of a stainless steel plate and a tile member 111 installed side by side on the upper surface (floor surface) of the stainless steel floor bottom member 110. , A drainage port 113 is installed at a predetermined side end portion.
FIG. 6 is an explanatory view showing a method of manufacturing the stainless steel floor bottom member 110 constituting the floor member 100 of FIG. When manufacturing the stainless steel floor bottom member 110, for example, a stainless steel plate is first pressed to form a substantially pan shape shown in FIG. 6 (a). The metal plate to be pressed is the above-mentioned stainless steel plate, for example, a composite plate material in which a heat insulating material and a steel steel plate are laminated on the upper side of the steel steel plate.

By the above press working, for example, in a floor shape having four sides, a drain port 113 is provided on one short side side, and the drain port 113 is at the lowest position so that hot water or the like flows into the drain port 113. The floor bottom 114 is formed so as to be inclined.
Around the floor bottom 114, there is a portion left substantially flat without being deformed by press working, and this portion is provided as the stainless steel floor surface 115 having the above four sides.

The stainless steel floor bottom member 110 formed into a predetermined shape by press working as described above is laser-cut at the portion shown in FIG. 6 (b). The laser cut is performed to remove the excess portion of the stainless steel floor surface portion 115, and the cut line L11 shown by the broken line in the drawing is irradiated with a laser to cut the cut piece 115a. Further, the cut line L12 is irradiated with a laser to excise the excision piece 115b, similarly, the excision piece 115c is excised from the position of the cut line L13, and the excision piece 115d is excised from the position of the cut line L14.

The stainless steel floor bottom member 110 that has been laser-cut as described above is bent at the edge portion of the stainless steel floor surface portion 115 as shown in FIG. 6 (c). Specifically, the cut piece 115a is cut to form a bent stainless steel floor surface portion 121a, and the cut piece 115b is cut to form a bent stainless steel floor surface portion 121b. Further, the cut piece 115c is cut to form a bent stainless steel floor surface portion 121c, and the cut piece 115d is cut to form a bent stainless steel floor surface portion 121d.

The stainless steel floor surface portions 121a to 121d formed as described above surround the plurality of tile members 111 arranged on the upper surface side of the stainless steel floor bottom member 110, and position the arranged tile members 111. Further, the bent portion is formed so as to be waterproofly joined to a bathtub, a side wall panel, or the like (not shown).
The flat portions of the stainless steel floor surface portions 121a to 121d are substantially flush with the tile members 111 arranged as described above and are exposed on the surface as a part of the bathroom floor surface to form an edge portion of the floor member 100. .. The tile member 111 has a pattern or the like formed on the surface thereof to prevent slipping, and various tile members 111 are used according to the tastes of the purchaser or user of the system bus.

Japanese Unexamined Patent Publication No. 2000-120283

However, when installing a system bath in a bathroom of a house or the like, it is necessary to cope with various floor surface shapes and floor surface sizes. Further, as for the tile member for decorating the floor surface, for example, the surface pattern and the color tone are selected according to the preference of the purchaser or the user as described above, and various sizes are used per sheet.
Therefore, it is necessary to mold the floor bottom member obtained by processing a metal plate such as a stainless steel plate into various sizes, which complicates design and production control, and increases the cost of installing production equipment. .. Further, when the size and the shape are diversified, there is a problem that the cost for inventory storage of the floor bottom member increases and the product price is pushed up.

The present invention has been proposed in view of the above circumstances. That is, it is an object of the present invention to provide a method for manufacturing a bathroom floor member that can correspond to various bathroom floors while suppressing the number of variations such as the shape and size of the floor bottom member processed from a metal plate.

In order to achieve the above object, the method for manufacturing a bathroom member according to the present invention includes a first step of pressing a metal plate to form a first floor bottom portion having a predetermined size, and an edge of the first floor bottom portion. The second step of forming a second floor bottom having a size corresponding to an arbitrary bathroom floor portion by cutting along the periphery, and bending the cut edge portion of the second floor bottom are performed. A third step of forming the shape into a predetermined shape, and a fourth step of fixing a side member formed so as to correspond to the floor decoration material installed on the arbitrary bathroom floor portion to the bent edge portion. It is characterized by having.

In the method for manufacturing a bathroom floor member according to the present invention, in the first step, a drain port is formed at a predetermined side end of the first floor bottom portion by the press processing, and hot water flows toward the drain port. As described above, the floor bottom surface of the first floor bottom portion is provided with an inclination, and in the second step, the first floor bottom portion is left with the drainage port and the inclined portion of the floor bottom surface of the first floor bottom portion. It is characterized in that it is cut.

The method for manufacturing a bathroom floor member according to the present invention is characterized in that the first floor bottom is cut so that the floor decorative material can cover substantially the entire upper surface of the second floor bottom. And.

In the method for manufacturing a bathroom floor member according to the present invention, in the fourth step, a gap is formed between the second floor bottom portion that has been bent in the third step and the edge of the arbitrary bathroom floor portion. The side member having a shape having no size is fixed so as to have waterproofness.

In the method for manufacturing a bathroom member according to the present invention, a first floor bottom formed by press working is cut to form a second floor bottom having a predetermined size, and a side member corresponding to the floor decoration material is attached to the second floor bottom. I made it. By this method, the number of variations of the first floor bottom portion manufactured by press working can be suppressed.

In the method for manufacturing a bathroom member according to the present invention, when cutting is performed, a drainage port provided by press working and a floor bottom surface inclined toward the drainage port are left. This method makes it possible to manufacture second floor bottoms of various sizes from the same first floor bottom.

In the method for manufacturing a bathroom member according to the present invention, the first floor bottom is cut so that the upper surface of the second floor bottom can be substantially covered when the floor decoration material is installed. By this method, almost the entire bathroom floor surface can be composed of the floor decorative material, and the design in the bathroom can be enhanced.

In the method for manufacturing a bathroom member according to the present invention, a side member having a size such that no gap is formed between the second floor bottom portion and the bathroom floor portion is used. By this method, it is possible to secure the waterproofness of the bathroom floor surface and install various floor decoration materials, and by increasing the choice of floor decoration materials, it is possible to meet the tastes of the purchaser or the user. Become.

It is a perspective view of the floor member manufactured by the manufacturing method of the bathroom floor member which concerns on embodiment of this invention. It is explanatory drawing which shows the manufacturing method which manufactures the floor bottom waterproof member of FIG. It is explanatory drawing which shows the manufacturing method of manufacturing the floor bottom waterproof member of FIG. It is explanatory drawing which shows the manufacturing method of manufacturing the floor bottom waterproof member of FIG. It is a perspective view of the floor member manufactured by using the conventional method of manufacturing a floor member. It is explanatory drawing which shows the manufacturing method of the floor pan part which comprises the floor member of FIG.

Hereinafter, a method for manufacturing a bathroom floor member according to an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view of a floor member manufactured by the method for manufacturing a bathroom floor member according to an embodiment of the present invention. The illustrated floor member 1 is a floor bottom waterproof member 10 formed into a predetermined shape using a metal plate such as a stainless steel plate, a floor decorative material such as a tile member 11 installed and fixed on the surface of the floor bottom waterproof member 10. It is composed of side members 12a and 12b fixed to the side of the floor bottom waterproof member 10.
A drain port 13 is provided at a predetermined position of the floor bottom waterproof member 10, for example, at the right end of the floor bottom waterproof member 10 in the drawing. The tile member 11 has a quadrilateral shape whose surface is surrounded by four sides having a predetermined length, and is formed in a square shape, for example. A predetermined number of tile members 11 are arranged on the upper surface of the floor bottom waterproof member 10 to form a bathroom washroom floor surface. Here, the tile member 11 will be illustrated as an example, and the following description will be given. As the floor decorative material to be installed on the surface of the floor bottom waterproof member 10, vinyl chloride sheet, FRP (fiberglass decorative member), artificial marble, etc. It is also possible to use.

2 to 4 are explanatory views showing a manufacturing method for manufacturing the floor bottom waterproof member 10 of FIG. 1. FIG. 2 shows a process of pressing and laser cutting. Further, FIG. 3 shows a step of performing the bending process, and FIG. 4 shows a step of attaching and fixing the side members 12a and 12b.
As described above, the floor bottom waterproof member 10 uses a stainless steel plate, and may be press-processed, laser-cut, or the like. For example, a stainless steel plate having water resistance and corrosion resistance may be used. It may be a plywood which is arranged on the upper surface and a steel steel plate or the like is laminated on the lower layer so as not to come into contact with hot water.

When manufacturing the floor bottom waterproof member 10, first, the metal plate as described above is press-processed into a predetermined shape as shown in FIG. 2 (a). In this press working, for example, the drainage port 13 is provided at a predetermined position and formed into a substantially pan shape of an arbitrary size.
This substantially pan-shaped floor bottom member of arbitrary size is configured to have a shape and size suitable for, for example, the floor surface of any system bath, and the floor bottom surface 14 so that hot water flows into the drain port 13. Is tilted. This inclination is formed so as to descend from the portion to be the excision piece 1d, which will be described later, toward the portion to be the excision piece 1c.

Next, the floor bottom waterproof member 10 (substantially pan-shaped floor member) press-processed to a predetermined shape and size as described above is laser-cut as shown in FIG. 2 (b) to obtain a desired shape. A portion that becomes a surplus when the floor member 1 having a shape and size is manufactured is cut.
The laser cut is performed along the cut lines L1 to L2 shown by the broken lines in the figure so as to leave at least the drainage port 13 and the floor bottom surface 14 inclined toward the drainage port 13 (for example, partially). Perform cutting process.

Specifically, laser cutting is performed along the cut line L1, and for example, a cut piece 1a that is a side wall portion of a substantially pan shape is cut out. Further, laser cutting is performed along the cut line L2 to cut out the cut piece 1b which is the other side wall portion having a substantially pan shape.
By cutting out the cut pieces 1a and 1b in this way, for example, the floor bottom waterproof member 10 formed in a substantially rectangular shape is processed into a approximate size in the lateral direction.

Further, laser cutting is performed along the cut line L3 to cut out the cut piece 1c, and the portion on the side where the drain port 13 is installed is adjusted to an appropriate size (dimension).
Further, laser cutting is performed along the cut line L4 to cut out the cut piece 1d, which is processed to a approximate size in the longitudinal direction of the floor bottom member 10, and an inclined surface (floor bottom surface) in which hot water flows toward the drain port 13. The length of 14) is adjusted according to the size of the tile members 11 (or the size of the floor surface composed of the plurality of tile members 11) to be arranged on the inclined surface later.
The laser cut applied to each of the cut lines L1 to L4 is performed as long as it is possible to prevent the cut portion of the floor bottom waterproof member 10 from being distorted or deformed as an obstacle to the bending process described later. It is not limited to the cutting process by the above, and the cutting process using another cutting means may be used.

Next, the laser-cut floor bottom waterproof member 10 is bent as shown in FIG. This bending process is performed on each of the four side portions of the floor bottom waterproof member 10, and as shown in FIG. 3A, the bent end portions 21a and 21b on the side of the inclined surface (floor bottom surface 14) are described later. The edges are bent downward so as to be a portion for attaching and fixing the side members 12a and 12b.
Further, the bent end portion 21d arranged on the higher side of the inclined surface is bent upward so as to position and fix the ends of the plurality of tile members 11 arranged on the upper surface of the floor bottom waterproof member 10 as described later. ing.

As shown in FIG. 3B, the bent end portion 21c arranged on the lower side of the inclined surface on which the drainage port 13 is installed has a drainage groove for guiding hot water or the like to the drainage port 13 at one end of the floor member 1. It is formed along the sides, and when the system bath is assembled, it is bent into a shape that is waterproof and can be joined to the side wall of the bathroom or the like.
The floor bottom surface 14 of the floor bottom waterproof member 10 that has been bent in this way has a tile floor surface having a size (area, surface shape) formed when a predetermined number of tile members 11 are arranged on the floor bottom surface 14. (Area of the entire floor decorative material installed on the floor bottom surface 14, surface shape) is substantially the same as the size of the above.

Next, the side members 12a and 12b are attached and fixed to the side of the bent floor bottom waterproof member 10 as shown in FIG.
The side members 12a and 12b are formed by using a material having water resistance and corrosion resistance, for example, a stainless steel material or a hard resin.
As shown in FIG. 4A, the side members 12a and 12b have, for example, a substantially U-shaped cross section, and the substantially U-shaped opening portion is formed on the floor of the floor bottom waterproof member 10. It is attached and fixed to the side of the floor bottom waterproof member 10 so as to face in one direction.

Specifically, a substantially U-shaped opening back surface portion of the side member 12a is joined to the bent edge portion 21a formed on the side of the floor bottom surface 14, and the opening back surface portion of the side member 12b is joined to the bent edge portion 21b. Are joined together, and these jointed portions are fixed using a waterproof fixing means.
Further, when the upper end portions of the side members 12a and 12b are fixed to the bent edge portions 21a and 21b as described above, they come into contact with the edge portions of the tile members 11 arranged on the upper surface of the floor bottom waterproof member 10. It stands upward so as to be positioned and fixed, and is formed so as to have the same height as the upper end portion of the bent edge portion 21d.

That is, when the side members 12a and 12b are attached and fixed to both sides of the floor bottom waterproof member 10, they are in contact with both longitudinal sides of the floor surface formed by the plurality of tile members 11 arranged on the upper surface of the floor bottom waterproof member 10. It is configured to touch.
In other words, the side members 12a and 12b have a length in the lateral direction of the floor surface formed by the plurality of tile members 11 between the side members 12a attached and fixed to the floor bottom waterproof member 10 and the side members 12b. It is configured to have a size protruding from the side of the floor bottom waterproof member 10 so as to be equivalent to (dimensions).

Further, in a state where the side members 12a and 12b are fixed to the bent edge portions 21a and 21b, respectively, the outer end portions of the side members 12a and 12b form a system bath, such as a bathtub, a side wall portion, or a house. It is abutted and fixed to the frame material that constitutes the bathroom part. That is, the side members 12a and 12b are in contact with the end of the floor surface made of the plurality of tile members 11 as described above, and the floor member 1 or the floor bottom waterproof member 10 and the bathtub, the side wall portion, and the frame material are described above. It has a size and shape that does not create a gap between the member and the like that are the edge portion of the bathroom floor.

The floor bottom waterproof member 10 and the side members 12a and 12b are, for example, one end of a drainage groove formed in the bent edge portion 21c when the bent edge portion 21b and the side member 12b shown in FIG. 4B are joined. The side member 12b closes the joint portion between the bent end portion 21a and the side member 12a (not shown), but the side member 12a closes the other end of the drainage groove of the bent end portion 21c to form a drainage groove. It is formed so that hot water does not leak to the outside of the floor bottom waterproof member 10 from each end of the floor.
The joint (fixed) portions of the bent edge portions 21a and 21b and the side members 12a and 12b are configured to be in close contact with each other to provide waterproofness. At the time of installation, for example, a seal member or a sealer (sealing agent) (not shown) may be attached for assembly.

After attaching and fixing the side members 12a and 12b to the floor bottom waterproof member 10 as described above, a predetermined number of tile members 11 are placed side by side on the upper surface of the floor bottom waterproof member 10, that is, the floor bottom 14, and adhered, for example. Fix it with an agent or the like to form a tile floor surface. As shown in FIG. 1, the tile member 11 is placed so as to cover substantially the entire floor bottom surface 14, so as not to block the drainage port 13 and its surroundings (such as the drainage groove described above). , The tile floor surface is installed and fixed so as to have an inclination (along the inclination) of the floor bottom surface 14.
The tile member 11 may be installed and fixed by fixing the side members 12a, 12b or the floor bottom waterproof member 10 to the bathtub, the side wall portion, the frame material of the bathroom, or the like, as described later.

As described above, when the side members 12a and 12b are fixed to the bent edge portions 21a and 21b, respectively, the outer end portions of the side members 12a and 12b are formed on a bathtub, a side wall portion, a house or the like constituting the system bath. It is abutted and fixed to the frame material that constitutes the bathroom part.
In the floor member 1 illustrated here, the side members 12a and 12b are attached along the inclination direction of the floor bottom surface 14.
When the outer end portions of the side members 12a and 12b are fixed to the bathtub, the side wall portion, or the frame material of a house or the like, the inclination of the floor bottom surface 14 does not disappear or inclines in other directions, that is, The outer end portions of the side members 12a and 12b are joined and fixed to the bathtub, the side wall portion, the frame material constituting the bathroom portion, and the like so as to maintain the inclination direction and the angle when formed in the pressing process. That is, the side members 12a and 12b are formed in a shape that can be joined to the bathtub, the side wall portion, the frame material constituting the bathroom portion, etc. while maintaining the inclination of the floor bottom surface 14.

When assembling and installing the system bath, for example, a seal member or a sealer (sealing agent) (not shown) is used to make these joints waterproof, and the bathroom or the joint portion is provided with waterproofness. Fix each joint so that water does not leak from each part of the system bus. Further, the joint portion between the bent end portions 21c and 21d and, for example, the side wall portion is also fixed with waterproofness as described above.

Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments. The present invention can make various design changes without departing from the matters described in the claims.

1 Floor member 1a to 1d Cut piece 10 Floor bottom waterproof member 11 Tile member 12a, 12b Side member 13 Drain port 14 Floor bottom surface 21a to 21d Bent end 100 Floor member 110 Stainless floor bottom member 111 Tile member 113 Drain port 114 Floor bottom 115 Stainless floor surface 115a to 115d Cut pieces 121a to 121d Stainless floor surface

Claims (4)

The first step of pressing a metal plate to form a first floor bottom of a predetermined size,
A second step of performing a cutting process along the periphery of the edge of the first floor bottom to form a second floor bottom having a size corresponding to an arbitrary bathroom floor portion.
The third step of bending the edge portion of the second floor bottom, which has been cut, to form a predetermined shape.
A fourth step of fixing a side member formed so as to correspond to a floor decorative material installed on the arbitrary bathroom floor portion to the bent edge portion.
A method for manufacturing a bathroom floor member. The first step is
By the press working, a drainage port is formed at a predetermined side end of the first floor bottom portion, and the floor bottom surface of the first floor bottom portion is inclined so that hot water flows toward the drainage port.
The second step is
The first floor bottom is cut, leaving the drainage port and the inclined portion of the floor bottom of the first floor.
The method for manufacturing a bathroom floor member according to claim 1. The second step is
The first floor bottom is cut so that the floor decorative material has a size that can cover substantially the entire upper surface of the second floor bottom.
The method for manufacturing a bathroom member according to claim 1 or 2, wherein the bathroom member is manufactured. The fourth step is
The side member having a size shape that does not create a gap between the second floor bottom portion that has been bent in the third step and the edge of the arbitrary bathroom floor portion is fixed so as to have waterproofness. do,
The method for manufacturing a bathroom member according to any one of claims 1 to 3, wherein the bathroom member is manufactured.

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