JP2000084762A - Panel for building and its manufacture and instrument used for the manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a panel for building with high efficiency without using an instrument, by arranging a rigid frame body for sealing the peripheral face of the panel between an external wall member composing both sides of the panel and face material, and by filling foaming material in the panel, and by arranging a soft foaming body layer on the connection part between the rigid frame body and the external wall member. SOLUTION: In this panel for a building 1, an external wall member, composing one side of the panel 1, is formed by, for example, plural stone tiles 2, and face material 5, composing the other face of the panel 1, is formed by, for example, a sheet of calcium silicate board. And a rigid frame body 4 formed by H sections for sealing the peripheral face of the panel 1 is arranged, and a soft foaming body layer 3 having continuous air bubbles closely on the whole peripheral face of the panel 1 is arranged on the connection part between the stone tiles 2 and the rigid frame body 4. And a foaming body 6 comprising a polyurethane type resin is filled inside the panel 1. The panel 1 of this type can be manufactured easily without requiring a lifting instrument or the like.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building panel used as an outer wall material of various buildings, a method of manufacturing the same, and a jig used for manufacturing the same.

[0002]

2. Description of the Related Art A stone tile is provided on one side of a structural material constituted by a rigid frame, and a face material is provided on the other side, and an interior formed by the rigid frame, the stone tile and the face material is provided. Architectural panels in which a space is filled with a foam material and foamed are known. As shown in FIG.
Stone tile 1 via the tile set jig 101
02 are arranged in a grid pattern, and the stone tiles 10
The structural material 103 is placed along the periphery of the two groups, and the face material 104 is further placed on the structural material 103. Thereafter, the upper plate 105 is pressed against the upper surface of the face material 104, and the upper plate 105 and the table 100 are connected to each other. By sandwiching the stone tile 102, the structural material 103, and the face material 104, a foam material is injected and filled from an injection hole 106 formed in an appropriate part of the structural material 103 in this state, and further left still for a predetermined time. It has been manufactured by a method of foaming the foamed material.

[0003] However, according to this manufacturing method, the unevenness of the thickness of the stone tiles 102 and the structural material 10
3 has a bend, and the holding force (pressing force) between the upper plate 105 and the table 100 is uneven, and so on.
2 was locally cracked or broken due to stress, and the yield of the resulting building panel was poor, and the manufacturing cost was high.

For this reason, a floating jig 107 having a special shape as shown in FIG. 8 is used to secure a small gap between the stone tile and a table on which the stone tile is mounted. After supporting the structural material and further mounting the face material on the upper surface of the structural material, press the upper plate against the upper surface of the face material and press the stone tile, rigid frame, face material between the upper plate and the table. In this state, the internal space formed by the rigid frame, the stone tile, and the face material is filled with a foam material and foamed, and the rigid frame, the stone tile, and the face material are integrally joined by the joining force of the foam material. It has been proposed to manufacture architectural panels in a modified manner. (Japanese Patent No. 2594413)

However, in this method, in order to secure a narrow gap between the stone tile and the rigid frame, it is necessary to directly fix the floating jig having a special shape to the rigid frame detachably by bolting. . If the floating jig is not fixed, the jig will not stand on its own and will fall down. For this reason, a hole for bolt insertion is usually drilled in a rigid frame made of H-shaped steel,
On the back side of the hole, a back nut for bolt fixing is fixed by welding, and the floating jig is fixed by bolting, but it takes time and effort to drill the rigid frame body and weld the back nut. Aligning the back nut is extremely difficult and requires a larger hole. Therefore,
Due to the looseness of the holes, the precision of the floating jig set deteriorates, and the rigid frame itself often twists, bends, and has dimensional differences.Therefore, there is an appropriate narrow gap between the stone tile and the rigid frame. It is difficult to secure the stone tile, and the rigid frame body comes into contact with the stone tile, and the stone tile may be cracked or broken. Furthermore, filling the foamed material into the internal space formed by the rigid frame, stone tile and face material,
When foaming, it is necessary to provide an exhaust hole for discharging generated gas in the rigid frame, but the foam leaks from this exhaust hole and a narrow gap between the stone tile and the rigid frame. There were drawbacks.

[0006]

Therefore, the present invention solves these problems of the prior art, does not require special jigs and complicated steps, is very efficient with simple steps, and has excellent performance. It is an object of the present invention to provide a building panel, a method of manufacturing the same, and a jig used for the manufacturing thereof.

[0007]

According to the present invention, the following structure is adopted to solve the above-mentioned problems. 1. From an outer wall member constituting one side of the panel, a face material constituting the other side of the panel, a rigid frame disposed between the outer wall member and the face material to seal the outer peripheral surface of the panel, and a foam material filled inside the panel An architectural panel, wherein a flexible foam layer having open cells is arranged at a connection portion between a rigid frame and an outer wall member. 2. 2. The building panel according to 1, wherein the outer wall member is constituted by a plurality of stone tiles. 3. A mounting jig having a projection on a table of a press device, the projection being in contact with a plurality of plate-like members serving as outer wall members constituting one side surface of the panel and being inserted between the plate-like members with a thickness greater than the plate-like members. A permeable soft foam layer having continuous cells without gaps is provided on the protruding portion of the mounting jig and the outer peripheral portion of the plate-like body, and on the mounting jig and the soft foam layer, After placing the rigid frame that seals the outer peripheral surface of the panel, a surface material constituting the other side surface of the panel is disposed on the rigid frame, and the outer wall member, the rigid frame, and the surface material are sandwiched by a press device. In the state in which the outer wall member, the rigid frame and the inner space formed by the face material are filled with a foam material,
A method for manufacturing an architectural panel, comprising foaming and joining and integrating an outer wall member, a rigid frame and a face material by a joining force of a foam material. 4. 4. The method for manufacturing a building panel according to 3, wherein the outer wall member is constituted by a plurality of stone tiles. 5. 3. A release treatment is performed on the surface of the mounting jig.
Or the manufacturing method of the building panel as described in 4. 6. A jig used for manufacturing an architectural panel thicker than a plate having a support piece for supporting an outer end surface of the plate as an outer wall member and a protrusion projecting from the support piece and inserted between the plate bodies. Utensils. 7. 7. The jig according to 6, wherein the thickness of the support piece is larger than the thickness of the protruding portion.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS There is no particular limitation on the outer wall member constituting one side of the architectural panel of the present invention, and the outer wall member of a normal architectural panel such as a stone tile, an artificial stone, a tile, a metal plate, and various decorative boards. Any of those used as can be used. Preferable examples of the outer wall member include stone tiles which usually have a high-grade appearance but are irregular in thickness and have warpage, so that they are usually difficult to use for building panels. The stone tile may be made of any material of natural stone and artificial stone, and its size is not particularly limited, but it is usually preferable to use a tile of about 600 mm square. Although the outer wall member of the building panel can be constituted by one stone tile, the outer wall member is usually constituted by using a plurality of stone tiles.

The face material constituting the other side of the building panel of the present invention is not particularly limited, and various materials made of inorganic materials such as metal materials, wood materials, gypsum boards, asbestos cement boards, plastic composite materials, and the like. Can be used. Further, the face material may be composed of one plate-like body, or may be composed of a plurality of plate-like bodies. Further, if desired, the face material can be made of the same material as the outer wall member such as a stone tile. These face materials can be fixed to the rigid frame body by means of welding, bolting, bonding with an adhesive or the like before filling and foaming the interior of the building panel with a foaming material as necessary.

The rigid frame constituting the outer peripheral surface of the architectural panel of the present invention may be a metal frame such as iron, aluminum, stainless steel or the like, wood, concrete, or other rigid rigid material. Can be used. The cross-sectional shape of the rigid frame can be any shape such as H-type, L-type, and C-type, and these are appropriately combined to form a generally rectangular frame. The joining means of the members constituting the frame body is determined by their materials. For example, welding or bolting using appropriately reinforcing metal is used for joining metal materials, and appropriately reinforcing is used for joining wood. Bolting, nailing, and the like using hardware are employed. When the rigid frame is made of concrete or the like, the frame may be formed into a seamless integral structure. As a preferable rigid frame body, a member formed by appropriately combining metal materials such as an H-shaped steel, an L-shaped steel, and a C-shaped steel and joining them is exemplified. In the present invention, unlike the prior art, it is not necessary to provide a bolt insertion hole for fixing the floating jig to the rigid frame, a gas discharge hole for filling and foaming the foam material, and the like. Can be omitted. In particular, the present invention is suitable for manufacturing a panel using a rigid frame which does not have a fixing portion of a jig such as a C-shaped steel or an L-shaped steel as a rigid frame and requires a jig to be fixed without fail. In the rigid frame, if necessary, vertically, horizontally, diagonally,
A reinforcing member may be provided.

As the foaming material to be filled in the interior of the building panel, foamable synthetic resins such as polyurethane and phenolic resin, foamable concrete, and other injectable foamable materials can be used. These foamable materials are used to set the members constituting the building panel of the present invention, fill the inside of the building panel with each member sandwiched by a press device, foam the panel, and form the panel by the bonding force of the foam. Are joined and integrated.

In manufacturing the building panel of the present invention, a mounting jig as shown in FIG. 2 is used. This mounting jig
A support piece that is made of a material thicker than the plate-like body constituting the outer wall member of the building panel and supports the outer end surface of the plate-like body, and a protruding portion that projects from the support piece and is inserted between the plate-like bodies Having. The shape of the mounting jig viewed from above is usually a T-shape in the middle of the building panel, which is inserted between the plate-like bodies.
What is arranged at the end of the building panel is L-shaped, but it goes without saying that other shapes may be used. Filling the inside of the panel with foam material
There is no particular limitation as long as the material can withstand the heat generated during foaming and the load applied by the pressing device. Metal materials such as iron, aluminum, and stainless steel, wood materials, and plastic materials can be used. Particularly preferred materials include metal materials such as steel and stainless steel, which are excellent in heat resistance, rigidity and releasability. As shown in FIG. 2, the mounting jig can be joined to a support piece for supporting the outer end surface of the plate-like body after forming a protrusion inserted between the plate-like bodies as a separate body. The piece and the protrusion may be formed integrally. In addition, after the foaming material is filled into the building panel and foamed, the members constituting the panel are joined and integrated, and then the surface of the mounting jig is easily removed from the building panel. It is preferable to apply a release treatment such as coating a release tape made of a silicone-based resin or a fluorine-based resin, or applying various release agents.

The building panel of the present invention is characterized in that a breathable soft foam layer having open cells is arranged at a connection portion between a rigid frame and an outer wall member such as a stone tile. As this soft foam layer, a soft synthetic resin foam such as polyurethane or polyvinyl chloride is used, but it is necessary to use a foam having open cells with air permeability. This flexible foam layer is provided without gaps on the projecting portion of the mounting jig arranged between the outer peripheral portions of the plurality of plate-like members constituting the outer wall member and the plate-like members when manufacturing the building panel. The rigid frame is disposed on the soft foam layer. On the rigid frame, a surface material constituting the other side of the building panel is further arranged, and a foaming material is filled inside the panel with the pressing device sandwiching each member constituting the panel, and the panel is foamed to form the panel. Although it is manufactured, the soft foam layer acts as a cushioning material by interposing the soft foam layer at the connecting portion between the outer wall member and the rigid frame, so that the plate-like body constituting the outer wall member is not warped or has a reduced thickness. The uniformity and the local stress resulting from the torsion, bending, and dimensional difference of the rigid frame body are absorbed, thereby making it possible to prevent the plate-like body constituting the outer wall member from being cracked or cracked.

[0014] Further, by using the foam layer having air-permeable open cells, even when the foam material to be filled in the interior of the building panel is foamed, generated gas passes through the open cells of the foam layer. Since the gas is discharged outside the panel, there is no need to provide a gas discharge hole in the rigid frame as in the prior art, so that the process can be simplified and the foam enters the open cells of the soft foam layer. Since the density of the foam is about 5 to 10 times that of a general part, the strength of the obtained building panel is greatly improved. Furthermore, according to the prior art, there is a drawback that the foam material to be filled into the interior of the building panel leaks out from the gas discharge holes provided in the rigid frame and the narrow gap between the stone tile and the rigid frame. In the present invention, the foam filled in the panel is retained in the open cells of the soft foam layer and does not leak to the outside.

Next, the architectural panel and the method of manufacturing the same according to the present invention will be described in more detail with reference to the drawings. However, the following specific examples do not limit the present invention. FIG. 1 is a partially enlarged schematic view showing a sectional structure of a building panel of the present invention. In this building panel 1, an outer wall member serving as one side of the panel is constituted by a plurality of stone tiles 2, and a face member 5 serving as the other side of the panel is constituted by one calcium silicate plate.
The rigid frame 4 that seals the outer peripheral surface of the panel 1 is formed by welding an H-shaped steel, and the connecting portion between the stone tile 2 and the rigid frame 4 is filled with open cells without gaps over the entire outer peripheral surface of the panel 1. The flexible foam layer 3 is disposed.
The inside of the panel is filled with a foam 6 made of polyurethane resin.

Next, a method for manufacturing a building panel according to the present invention will be described. 2 to 4 are views showing an example of a mounting jig used for manufacturing the building panel of the present invention. FIG. 2 is a perspective view of the mounting jig, and FIG. FIG. 4 is a plan view showing a state of being arranged between stone tiles, and FIG. 4 is a partially enlarged side view of FIG. FIG. 5 is a diagram showing a state immediately before filling the foam material with each member constituting the building panel of the present invention being sandwiched by a press device. This mounting jig 10
Is a stone tile made of stainless steel and used as an outer wall member 2
A support piece 11 for supporting the outer end face of the stone tile 2 and a protruding portion 12 protruding from the support piece 11 and inserted between the stone tiles 2. As shown in FIG. 4, the thickness of the mounting jig 10 is about 2 to 10 mm, preferably 3 to 5 mm, compared to the stone tile 2.
It is configured to have a certain thickness so that the load by the rigid frame 4 and the pressing devices 21 and 22 is not directly applied to the stone tile 2.

The mounting jig 10 is preferably inserted between a plurality of stone tiles 2 arranged on a table 21 of a press device, after the surface of the mounting jig 10 is preferably covered with a release tape made of fluororesin or the like. Next, a permeable soft foam layer 3 having open cells made of urethane-based resin or the like is provided on a portion of the mounting jig 10 where the rigid frame 4 is mounted on the projecting portion 12 and the outer peripheral portion of the stone tile 2. Is provided without any gap using an adhesive or the like as appropriate. The thickness of the soft foam layer 3 is set to be about 1 to 15 mm, preferably about 3 to 10 mm thicker than the thickness difference between the stone tile 2 and the mounting jig 10, so that the rigid foam layer 3 has a rigidity. It is necessary to prevent a gap from occurring when the frame 4 is placed (see FIG. 5). By adjusting the thickness of the soft foam layer 3 in this manner, the soft foam layer 3 is compressed to such an extent that it does not lose air permeability when the rigid frame 4 is placed, and warpage of the stone tile 2 and The unevenness of thickness and the local stress caused by twisting, bending, dimensional difference, etc. of the rigid frame 4 can be absorbed to prevent the stone tile 2 from cracking or cracking.

Rigid frame 4 placed on flexible foam layer 3
A surface material 5 such as a calcium silicate plate is disposed on the upper surface of the device, and a stone tile 2, a mounting jig 10, a soft foam layer 3, and a rigid frame which constitute a building panel between the press devices 21 and 22. 4 and the face material 5 are sandwiched (see FIG. 5), a foam material such as a polyurethane-based resin is filled into the internal space from an injection hole (not shown) provided in the rigid frame 4 and foamed. The building panel is manufactured by joining and integrating the members by the joining force of the foam material. The gas generated when the foam material is foamed is discharged to the outside from the soft foam layer 3 having air permeability. Therefore, there is no need to provide a gas discharge hole in the rigid frame 4 unlike the related art.
Also, at the end of foaming, the foaming material partially enters the open cells of the soft foam layer 3, but is retained in the open cells,
The foam does not leak out of the building panel unlike the prior art in which a floating jig is used to secure a narrow gap.
After the foaming of the foam is completed, the press apparatus is fully cured with the mold clamped, the mold clamp is released, and the mounting jig 10 is removed, whereby the building panel 1 is completed.

In the above-described example, the supporting jig 10 supporting the outer end face of the stone tile 2 and the projecting portion 12 inserted between the stone tiles 2 having the same thickness are used as the mounting jig 10. As shown in FIG. 6, the thickness of the support piece 11 may be made larger than the thickness of the protruding portion 12 so that the support piece 11 holds the outer edge of the lower end of the rigid frame 4.
Further, instead of the H-shaped steel, a C-shaped steel or an L-shaped steel may be used as the rigid frame. Furthermore, stone tile 2, mounting jig 1
Needless to say, when arranging the flexible foam layer 3, the face material 5, and the like, temporary fixing may be performed using an adhesive, an adhesive tape, or the like in a conventional manner.

The dimensions, shape and the like of the building panel of the present invention can be appropriately selected. However, as an example of the dimensions of each component, the building panel 1 is used for the outer wall of the first floor of a house. 3m in length, 1.8m in width, used for 2nd floor, 8m in length, 1.8m in width, 12 in thickness
It is about 5 mm. The stone tile 2 is 15m thick
m, 600mm long, 600mm wide and weighs 15kg
The length of the supporting piece 11 of the mounting jig 10 of FIG. 2 used for the stone tile 2 is 250 mm, and the width is 50 m.
m, the length of the protrusion is 100 mm, the width is 8 mm, and the thickness is 20 mm. And the breathable soft foam layer 3
Used is a material having a thickness of about 10 mm and substantially the same width as the rigid frame 4.

[0021]

As described above, the present invention is inserted between a plurality of plate-like members which are outer wall members constituting one side surface of a building panel and is thicker than the plate-like members. By disposing a mounting jig having a protruding portion, and providing a breathable soft foam layer having open cells at a connection portion between the rigid frame and the outer wall member, the rigid frame and the outer wall are opposite to the prior art. The present invention is characterized in that a rigid frame body is placed without providing a narrow gap at a connection portion of members to manufacture a building panel, and the following remarkable effects are obtained. (1) Without the need for special jigs such as floating jigs,
Simply place a mounting jig with a simple shape between the plate-like bodies that will be the outer wall member, and float it on a rigid frame to weld the bolt insertion holes for fixing the jig and the back nut for fixing the bolt Steps such as formation of gas exhaust holes can be omitted. (2) Since the rigid frame has no gas exhaust holes and no narrow gap is provided between the rigid frame and the outer wall member, the foam does not leak to the outside when the foam is filled in the panel. (3) The soft foam layer absorbs local stress due to warpage and uneven thickness of the outer wall member and torsion, bending, and dimensional difference of the rigid frame member, and cracks and cracks of the outer wall member. Can be prevented. (4) The rigid frame has no bolt insertion holes or gas exhaust holes, and the foaming material filled in the panel enters into the open cells of the soft foam layer, and has a density close to almost no foaming. Therefore, the adhesive strength, the strength of the panel, and the like are improved, and a panel having excellent properties can be obtained. (5) The manufacturing process can be greatly reduced because the process of manufacturing the panel is simplified and the yield is improved.

[Brief description of the drawings]

FIG. 1 is a partially enlarged schematic cross-sectional view showing one example of a building panel of the present invention.

FIG. 2 is a perspective view showing an example of a mounting jig used for manufacturing a building panel according to the present invention.

FIG. 3 is a plan view showing a state where the mounting jig of FIG. 2 is arranged between stone tiles.

FIG. 4 is a partially enlarged side view of FIG. 3;

FIG. 5 is a partially enlarged cross-sectional schematic view showing a state in which each member constituting the building panel of the present invention is sandwiched by a press device.

FIG. 6 is a perspective view showing another example of the mounting jig used for manufacturing the building panel of the present invention.

FIG. 7 is a view showing a manufacturing process of a conventional building panel.

FIG. 8 is a view showing another example of a conventional process of manufacturing a building panel.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Building panel 2,102 Stone tile 3 Soft foam layer 4 Rigid frame 5,104 Face material 6 Foam 10 Mounting jig 11 Supporting piece 12 Projection 21,22 Press device 100 Table 101 Tile set jig 103 Structural material 105 Upper plate 106 Injection hole 107 Floating jig

 ──────────────────────────────────────────────────続 き Continued on the front page F-term (reference) 2E162 BA01 BA02 BA03 BA04 BA05 BB01 BB02 BB03 CA04 CA08 CA10 CA16 CB01 CC01 CD04 CE08 DA09 3C030 CB02 CB03 CB04 CB12 CB14 CB16 CB17 4F100 AA17 AA20 AC06A AC01 AT01BA01 AT01A00 BA10A BA10B DB06C DB17C DC23A DC28A DD27C EJ02C EJ022 EJ172 GB07 JK13C JK20 JL02

Claims (7)

[Claims] 1. An outer wall member forming one side surface of a panel, a face member forming another side surface of the panel, a rigid frame disposed between the outer wall member and the face member to seal an outer peripheral surface of the panel, and filling the inside of the panel. An architectural panel comprising a foamed material, and a flexible foam layer having open cells is disposed at a connection portion between a rigid frame and an outer wall member. 2. The building panel according to claim 1, wherein the outer wall member is constituted by a plurality of stone tiles. 3. A protruding portion which is in contact with a plurality of plate-like members serving as outer wall members constituting one side surface of a panel and which is thicker than the plate-like members and is inserted between the plate-like members on a table of a press device. A mounting jig having the same is provided, and a permeable flexible foam layer having open cells without gaps is provided on the protruding portion of the mounting jig and the outer peripheral portion of the plate-like body, and the mounting jig and the soft After placing a rigid frame for sealing the outer peripheral surface of the panel on the foam layer, disposing a surface material constituting the other side surface of the panel on the rigid frame, and using a press device to form an outer wall member and a rigid frame. An outer wall member, a foam material is filled and foamed in the internal space formed by the rigid frame and the surface material in a state where the face material is sandwiched, and the outer wall member is formed by a joining force of the foam material.
A method for manufacturing a building panel, comprising joining and integrating a rigid frame and a face material. 4. The method for manufacturing a building panel according to claim 3, wherein the outer wall member is constituted by a plurality of stone tiles. 5. The method for manufacturing a building panel according to claim 3, wherein a release treatment is performed on a surface of the mounting jig. 6. An architectural panel having a thickness greater than that of a plate-like body, comprising: a support piece for supporting an outer end surface of a plate-like body serving as an outer wall member; and a projecting portion projecting from the support piece and inserted between the plate-like bodies. Jig used for manufacturing 7. The jig according to claim 6, wherein the thickness of the support piece is greater than the thickness of the protruding portion.