JP2024158161A - Structural walls, houses and sauna rooms - Google Patents

Abstract

To provide a structural wall that can be easily installed.SOLUTION: A structural wall 1 has a body of a plurality of lightweight panels 10 arranged as partitions separating the inside of a house from the outside. The lightweight panel 10 is joined to another lightweight panel 10 arranged adjacently on the partition. The lightweight panels 10 are provided with fitting parts 12 along butt surfaces 11 at each of the butt surfaces 11 to be joined. A joining material 20 for joining the two lightweight panels 10 is filled into a joint 16 where the fitting parts 12 are fitted. An inner coating layer 21 is formed on an inner side of the lightweight panel, and durability is imparted to the lightweight panel 10 as the structural wall 1. The joining material 20 is filled into the joint 16 where the lightweight panels 10 are in contact, and the inner coating layer 21 is provided on the inner side of the lightweight panel 10, thereby forming the structural wall 1. For this reason, the structural wall 1 according to the embodiment can be easily installed.SELECTED DRAWING: Figure 3

Description

Application for application of Article 30, Paragraph 2 of the Patent Act has been filed. List of construction results Construction date: March 1, 2023 to March 8, 2023 Property name: Lake Kawaguchi Exhibition Center 1911 Nagahama, Fujikawaguchiko-cho, Minamitsuru-gun, Yamanashi Prefecture, and two other locations As per Appendix 1

The technical field of this specification relates to structural walls that can be easily installed, houses formed from these structural walls, and sauna rooms as houses.

As an example of a house that has traditionally used structural walls, Patent Document 1 describes a house formed by connecting multiple foam panels via fastening parts. Patent Document 2 describes a sauna room formed by connecting side panels made up of an interior panel, a side panel, and a foamed resin layer between them.

JP 2018-123493 A Utility Model Registration No. 3233199

Conventional structural walls use metal components and wood for fastening parts, interior panels, and side panels, and are constructed of heavy materials overall, which means they cannot be easily installed.

The problem that the technology in this specification aims to solve was made in consideration of the above points, and aims to provide a structural wall that can be easily installed.

The structural wall according to the embodiment of the present specification is a structural wall arranged as a partition separating the inside of a house from the outside,
The structure is made up of multiple lightweight panels.
The lightweight panel is joined to an adjacent lightweight panel in the partition of the house;
Each of the butt surfaces of the two lightweight panels is provided with a fitting portion along the butt surface,
A joint portion where the butt surfaces of the two lightweight panels are butted together and the fitting portions are fitted together is joined by a joining material that joins the two lightweight panels,
The method is characterized in that an inner coating layer is formed on the side of the lightweight panel that faces the interior of the house.

According to the structural wall according to the embodiment of the present specification, a structural body is made up of a plurality of lightweight panels arranged as partitions separating the inside of a house from the outside, and a joint formed by butting the abutting surfaces of a lightweight panel and an adjacent lightweight panel and fitting the fitting parts is joined with a joining material to form a structural wall of the house. In addition, an inner coating layer is formed on the side of the lightweight panel that faces the inside of the house, and durability is imparted to the lightweight panel as a structural wall. In the structural wall, the joints where the lightweight panels come into contact are joined with a joining material, and an inner coating layer is formed on the inside side of the lightweight panel. For this reason, the structural wall according to the embodiment can be easily installed.

Here, the structural wall can be configured so that an outer coating layer is formed on the side of the lightweight panel that faces the exterior of the house.

With this, an outer coating layer is formed on the side of the lightweight panel that faces the exterior of the house, giving durability to the lightweight panel as a structural wall from the outside.

In addition, in the structural wall, the elongation percentage (ASTM D-412) of the inner coating layer and the outer coating layer can each be 100% or more.

This allows the inner and outer coating layers to adapt to deformations caused by thermal expansion of the lightweight panel as a structural wall and vibrations caused by external factors, thereby further increasing the durability of the structural wall.

Here, in the house according to the embodiment, the partition can be the structural wall described above.

This allows the house of the embodiment to have increased durability.

In addition, the sauna room according to the embodiment is a sauna room in the above-mentioned house,
The interior may be provided with a heater for heating the interior, and an interior protection layer may be provided on the surface of the inner coating layer.

As a result, the sauna room of this embodiment can improve the heat resistance of the inner coating layer by using the interior protective layer.

The sauna room can also be configured so that an exterior protective layer is provided on the surface of the outer coating layer.

This allows the exterior protective layer to improve the heat retention of the sauna room.

The structural walls described in this specification can be easily installed.

A side view of a sauna room as a house equipped with the structural wall of the first embodiment. This is a front view of the sauna room. FIG. 2 is a cross-sectional view taken along line III-III in FIG. 1A is an enlarged view of the joint between the floor panel and the side panel, and FIG. 1B is an enlarged view of the joint between the upper side panel and the top panel. 13A is a front view and FIG. 13B is a side view of a box-type store as a house equipped with a structural wall of the second embodiment.

The following describes a structural wall 1 and a house equipped with the structural wall 1 according to an embodiment of the present specification. The structural wall 1 of the embodiment is used as a wall as a structure arranged as a partition that separates the inside of the house from the outside. The house of the embodiment is installed outdoors, indoors, on the loading platform of a vehicle, on the deck of a ship, etc., and can be used as a sauna room 100 for steam and hot air bathing, a box-type store 100A selling food, beverages, and goods, a shelter for evacuation during an earthquake or the like, a temporary residence after an earthquake or the like, and the like. Note that the house in the embodiment refers to a room, shed, or house consisting of one room. In the embodiment, the sauna room 100 for steam and hot air bathing will be described as an example of the first embodiment, and the box-type store 100A selling food, beverages, and goods will be described as an example of the second embodiment.

First Embodiment
As shown in Figures 1 to 3, the sauna room 100 as a house equipped with the structural wall 1 of the first embodiment has a cylindrical body, the axial direction of the cylindrical shape is arranged horizontally, and the side surface is formed of a peripheral wall 110 consisting of a continuous structural wall 1 that goes around the circumference of the cylindrical shape, and the front and rear surfaces are closed by a front wall 120 and a rear wall 130 consisting of the structural wall 1. The front wall 120 is provided with a hinged door 101 that serves as an entrance and exit for people, and the peripheral wall 110 is provided with a light window 102 that lets in sunlight. Here, as shown in Figures 1 and 2, when the sauna room 100 is installed, the axial direction of the cylindrical shape is the front-to-rear direction, the surface (front wall 120) on which the hinged door 101 is provided is the front, and up, down, left, and right are the up, down, left, and right when the sauna room 100 is viewed from the front, and as used in the drawings, F indicates the front, B indicates the back, U indicates the top, D indicates the bottom, L indicates the left, and R indicates the right. In addition, the sauna room 100 may be referred to as the inside (side) or outside (side) based on the structural wall 1, and the circumferential direction (such as a clockwise direction) of the cylindrical sauna room 100 is the direction when the sauna room 100 is viewed from the front.

As shown in FIG. 1, the structural wall 1, which is arranged as a partition separating the inside of the sauna room 100 from the outside, is composed of a cylindrical peripheral wall 110 with the axial direction being the front-to-rear direction, and a front wall 120 and a rear wall 130 which respectively cover the front and rear surfaces surrounded by the peripheral wall 110.

As shown in Figures 2 and 3, the peripheral wall 110 is cylindrically shaped, with approximately rectangular lightweight panels 10 with an arc-shaped cross section arranged along the outer periphery in the up-down, left-right directions, with their long sides aligned in the front-to-back direction and their short sides aligned in the circumferential direction, forming a structural wall 1 that serves as a partition separating the inside of the sauna room 100 from the outside.

The lightweight panels 10 that make up the peripheral wall 110 as the structural wall 1 use a floor panel 111 that is placed below the peripheral wall 110, a side panel 112 that is placed on the side, a top panel 113 that is placed above, and upper side panels 114 that are placed on the left and right of the top panel 113, due to differences in the placement positions and the shapes of the fitting portions 12 provided at the butt surfaces 11.

The floor panel 111 is disposed below the peripheral wall 110, and the mating surfaces 11 at both left and right ends are each provided with a cutout recess 13 cut out in a rectangular cross section along the front-to-rear direction as a fitting portion 12.

The side panels 112 are arranged on the left and right side sides of the peripheral wall 110, and a protruding convex portion 14 with a protruding center in cross section is formed as a fitting portion 12 on the butt surface 11 of the lower end, and the protruding convex portion 14 fits into a notched recess 13 of the panel (floor panel 111 or side panel 112) arranged below. A notched recess 13 cut out in a rectangular cross section is formed as a fitting portion 12 on the butt surface 11 of the upper end.

The top panel 113 is disposed above the peripheral wall 110, and the mating surfaces 11 at both left and right ends are formed with a fitting portion 12 along the front-to-rear direction, with a notch 15 cut out on the inside of the peripheral wall 110.

The upper side panels 114 are disposed on the left and right sides of the top panel 113, and a protruding convex portion 14 is formed as a fitting portion 12 on the abutting surface 11 of the lower end, and the protruding convex portion 14 fits into the notched recess 13 of the side panel 112. A fitting portion 12 is formed on the abutting surface 11 of the upper end, with a notched portion 15 formed by cutting out the outer side of the peripheral wall 110, and the fitting portion 15 fits into the fitting portion 15 of the top panel 113.

As shown in Figures 2 and 3, the floor panel 111 is disposed at the bottom of the cylindrical peripheral wall 110, and side panels 112 are disposed on the circumference of the cylinder on both the left and right sides of the floor panel 111, and the protruding convex portions 14 of the side panels 112 fit into the notched recesses 13 at both the left and right ends of the floor panel 111.

The side panels 112 are arranged on the circumference of the cylinder, and their lower ends are joined to the floor panel 111 or to a side panel 112 joined to the floor panel 111. The side panels 112 are stacked according to the size of the peripheral wall 110, and the protruding convex portion 14 of the side panel 112 fits into the cutout recess 13 of the floor panel 111 or the side panel 112.

The upper side panels 114 are arranged on the upper left and right sides of the circumference of the cylinder, with their lower ends joined to the side panels 112, and the protruding convex portions 14 on the lower sides of the upper side panels 114 fitting into the notched recesses 13 of the side panels 112. The upper sides of the upper side panels 114 arranged on the left and right sides each have a joint portion 15 with the outer side cut out.

The top panel 113 has notches 15 cut out on the inside of both left and right ends that fit into notches 15 cut out on the outside of the upper side panels 114 arranged on the left and right. This closes the circumference and forms a cylindrical peripheral wall 110.

As shown in FIG. 1, the front and back of the cylindrical peripheral wall 110 are closed by fitting a front wall 120 and a rear wall 130 made of lightweight panels 10 formed to the shape of the inner circumference of the peripheral wall 110, forming a structural wall 1 that acts as a partition separating the inside of the sauna room 100 from the outside. As shown in FIGS. 1 to 3, the cylindrical sauna room 100 is placed on a pedestal 106 that fits the shape of the peripheral wall 110 so that it can be installed stably, and is installed outdoors, etc.

The lightweight panel 10 can be made of polystyrene foam (EPS (expandable polystyrene beads)), which is easy to mold by bead foaming, and can have a thickness of 150 to 500 mm, a bulk density of 17 to 33 kg/ ^m3 , and an expansion ratio of 30 to 60. The lightweight panel 10 can be easily cut with a cutter knife or the like, so that the fitting portions 12 (notched recesses 13, protruding convex portions 14, and joint portions 15) can be easily formed on the butting surfaces 11, and the size of the lightweight panel 10 can be easily adjusted. Therefore, the size of the sauna room 100 as a house can be freely set.

When EPS as a lightweight panel 10 is used in the structural wall 1 arranged as a partition separating the inside of the sauna room 100 from the outside, it allows the structural wall 1 (sauna room 100) to stand on its own without the need for reinforcing materials such as metal members. As a result, the sauna room 100 formed from EPS is lightweight, easy to install, and easy to move. In addition, since EPS as a lightweight panel 10 has plasticity, when a user in the sauna room 100 hits their head or other parts of their body against the structural wall 1, the plasticity reduces the impact on the head or other parts of their body, protecting the head or other parts of their body.

The joint 16 between the protruding convex portion 14 and the notched recess 13 of the fitting portion 12 of the lightweight panel 10, the joint 16 between the notched joint portion 15 with the inner side cut out and the notched joint portion 15 with the outer side cut out, and the fitting portion 17 where the front wall 120 or the rear wall 130 is fitted into the peripheral wall 110 are each bonded with a caulking material as a bonding material 20.

The caulking material as the joining material 20 is a material that bonds the joints 16 between the lightweight panels 10 that form the peripheral wall 110 and the fitting parts 17 between the peripheral wall 110 and the front wall 120 or rear wall 130. The caulking material may be made of a moisture-curing silicone caulking material, a urethane caulking material, a dry-curing acrylic caulking material, a butyl rubber caulking material, or the like. In another embodiment, a moisture-curing caulking material that shrinks less when cured may be used, and in yet another embodiment, a silicone caulking material may be used.

The caulking material as the joining material 20 can be replenished by pressing the material into the joints 16 where the lightweight panels 10 come into contact with each other, and into the fitting parts 17 between the peripheral wall 110 and the front wall 120 or rear wall 130 from both the inside and outside of the sauna room 100 as a house. This allows the joints 16 and fitting parts 17 of the lightweight panels 10 to be filled with the caulking material as the joining material 20 without any gaps, improving the adhesion of the joints 16 and the fitting parts 17. Note that pressing is a method of applying the caulking material as the joining material 20 thinly and smoothly into the joints 16 by rubbing it with a plastering trowel.

The inner surface of the lightweight panel 10, which is the interior side of the sauna room 100 as a house, is coated with resin to form an inner coating layer 21 that provides durability, and an interior topcoat material that forms an interior protective layer 22 is applied to the surface of the inner coating layer 21 made of resin. In addition, the outer surface of the lightweight panel 10, which is the exterior of the sauna room 100, is coated with resin to form an outer coating layer 26 that provides durability, and an exterior topcoat material that forms an exterior protective layer 27 is applied to the surface of the outer coating layer 26 made of resin.

The inner coating layer 21 and the outer coating layer 26 are made of the same type of resin and are formed on the inside and outside of the sauna room 100 to give the sauna room 100 durability. A resin with an elongation rate (ASTM D-412) of 100 to 1000% can be used. With an elongation rate of 100 to 1000%, the inner coating layer 21 and the outer coating layer 26 can follow deformations caused by thermal expansion of the sauna room 100 and vibrations caused by external factors, ensuring the durability of the house. If the elongation rate of the inner coating layer 21 and the outer coating layer 26 is less than 100%, they will not be able to follow deformations of the sauna room 100, and cracks may occur in the inner coating layer 21 and the outer coating layer 26, making it difficult to ensure durability. On the other hand, if the elongation rate of the inner coating layer 21 and the outer coating layer 26 exceeds 1000%, durability can be ensured, but the inner coating layer 21 and the outer coating layer 26 become flexible and soft, causing a sticky feeling and making them more susceptible to dirt adhesion, and there is a risk of causing discomfort to users of the sauna room 100. In another embodiment, the elongation rate of the inner coating layer 21 and the outer coating layer 26 is 150 to 800%, and in yet another embodiment, the elongation rate is 200 to 600%.

As the resin forming the inner coating layer 21 and the outer coating layer 26, general-purpose resins such as urea resin, urethane resin, silicone resin, and acrylic resin can be used. As another embodiment, urea resin or urethane resin that can be instantly cured can be used, and as a further embodiment, urea resin that is difficult to hydrolyze can be used. Urea resin (polyurea) is a resin that is generated by mixing an isocyanate component and an amine component at the tip of a spray gun. Urethane resin (polyurethane) is a resin that is generated by mixing an isocyanate component and a polyol component at the tip of a spray gun. In addition, a mixture of urea resin and urethane resin can also be used as the resin forming the inner coating layer 21 and the outer coating layer 26. In addition, the resin forming the inner coating layer 21 and the outer coating layer 26 can also be colored with a pigment or colored aggregate.

The coating amount of the inner coating layer 21 and the outer coating layer 26 can be 0.5 to 5 kg/m ² (film thickness: about 0.5 to 5 mm), respectively. This is because sufficient durability can be exhibited. If the coating amount of the inner coating layer 21 and the outer coating layer 26 is less than 0.5 kg/m ² , the film thickness is thin, and when an impact is received from an external factor, the inner coating layer 21 and the outer coating layer 26 may crack or peel off, and durability may not be maintained. On the other hand, if the coating amount of the inner coating layer 21 and the outer coating layer 26 exceeds 5 kg/m ² , durability is ensured, but the film thickness is excessive, and it may be uneconomical. In another embodiment, the coating amount of the inner coating layer 21 and the outer coating layer 26 can be 1 to 4 kg/m ² (film thickness: about 1 to 4 mm), respectively, and in yet another embodiment, it can be 2 to 3 kg/m ² (film thickness: about 2 to 3 mm).

In the embodiments, the "amount applied" and the "parts by mass (%)" used to express the blending amount and blending ratio of resin and topcoat material refer to the "amount applied of the non-volatile content" excluding the volatile content, and "parts by mass (%) of the non-volatile content," unless otherwise specified.

The interior protective layer 22 is applied to improve the heat resistance of the inner coating layer 21. The interior topcoat material forming the interior protective layer 22 is applied to the inside of the sauna room 100 as a house, so a general-purpose emulsion paint with excellent heat resistance can be used. The resin emulsion of the interior topcoat material forming the interior protective layer 22 can be a vinyl acetate emulsion, an ethylene vinyl acetate emulsion, an acrylic emulsion, an acrylic styrene emulsion, an acrylic silicone emulsion, an acrylic urethane emulsion, etc., depending on the resin composition. In another embodiment, an acrylic emulsion, an acrylic styrene emulsion, an acrylic silicone emulsion, or an acrylic urethane emulsion, which are excellent in heat resistance, can be used. In yet another embodiment, an acrylic emulsion, an acrylic silicone emulsion, or an acrylic urethane emulsion, which are excellent in heat resistance and water resistance, can be used.

The interior topcoat material that forms the interior protective layer 22 can contain metallic pigments. Metallic pigments have excellent heat-shielding properties and reflect the heat of the sauna room 100, further improving the heat resistance of the inner coating layer 21. Examples of metallic pigments that can be used include titanium oxynitride powder, titanium-manganese composite oxide powder, titanium dioxide powder, and aluminum powder.

Metallic pigments can be contained in the interior topcoat material forming the interior protective layer 22 at 1 to 50% by mass. This is because the interior protective layer 22 can retain heat-shielding properties and improve the heat resistance of the inner coating layer 21. If the content of metallic pigments is less than 1% by mass, the interior protective layer 22 may not retain sufficient heat-shielding properties. On the other hand, if the content of metallic pigments is more than 50% by mass, the resin component becomes relatively small and may not be able to follow the movement of the inner coating layer 21, resulting in cracking and peeling. In another embodiment, the metallic pigments can be contained in the interior topcoat material forming the interior protective layer 22 at 3 to 25% by mass, and in yet another embodiment, at 5 to 15% by mass.

The coating amount of the interior protective layer 22 can be 0.05 to 0.5 kg/m ² (film thickness: about 0.05 to 0.5 mm). This is because sufficient heat resistance can be exhibited. If the coating amount of the interior protective layer 22 is less than 0.05 kg/m ² , the thickness of the interior protective layer 22 is thin and it may not be able to follow the movement of the inner coating layer 21, which may cause cracking or peeling. On the other hand, if the coating amount of the interior protective layer 22 exceeds 0.5 kg/m ² , although heat resistance is ensured, the thickness becomes excessive, which may be uneconomical. In another embodiment, the coating amount of the interior protective layer 22 can be 0.06 to 0.2 kg/m ² (film thickness: about 0.06 to 0.2 mm), and in yet another embodiment, it can be 0.07 to 0.1 kg/m ² (film thickness: about 0.07 to 0.1 mm).

The inner coating layer 21 and the interior protection layer 22 formed on the inside surface of the lightweight panel 10 are flexible. Therefore, when a user of the sauna room 100, which uses the lightweight panel 10 as its main body, hits the lightweight panel 10 (structural wall 1) on which the inner coating layer 21 and the interior protection layer 22 are formed, the flexibility reduces the impact on the head and protects the head and other parts of the body.

The exterior protective layer 27 is applied to improve the weather resistance of the outer coating layer 26 and to improve the heat retention of the sauna room 100. The exterior protective layer 27 also adds design to the exterior of the sauna room 100. For this reason, the exterior protective layer 27 contains 30 to 50 mass% of filler (aggregate).

The exterior topcoat material forming the exterior protective layer 27 is applied to the outside of the sauna room 100 as a house, so a general-purpose emulsion paint with excellent weather resistance can be used. The resin emulsion of the topcoat material forming the exterior protective layer 27 can be a vinyl acetate emulsion, an ethylene vinyl acetate emulsion, an acrylic emulsion, an acrylic styrene emulsion, an acrylic silicone emulsion, an acrylic urethane emulsion, etc., depending on the resin composition. In another embodiment, an acrylic emulsion, an acrylic styrene emulsion, an acrylic silicone emulsion, or an acrylic urethane emulsion, which have excellent weather resistance, can be used. In yet another embodiment, an acrylic emulsion, an acrylic silicone emulsion, or an acrylic urethane emulsion, which have excellent weather resistance and water resistance, can be used.

The fillers (aggregates) contained in the exterior topcoat material that forms the exterior protective layer 27 include calcium carbonate, silica sand, glass beads, etc. These fillers (aggregates) have a particle diameter (d50 (cumulative 50 vol% diameter)) of 0.1 to 2.0 mm to impart design to the exterior protective layer 27.

The exterior topcoat material that forms the exterior protective layer 27 can contain inorganic pigments. This is because inorganic pigments have excellent heat absorption properties for sunlight and can improve the heat retention of the sauna room 100. Examples of inorganic pigments that can be used include carbon black, iron oxide, yellow iron oxide, and red ochre.

The coating amount of the exterior protective layer 27 can be 0.5 to 3.0 kg/m ² (film thickness: about 0.5 to 3.0 mm). This is because sufficient weather resistance and heat retention can be achieved. If the coating amount of the exterior protective layer 27 is less than 0.5 kg/m ² , the thickness of the exterior protective layer 27 is thin and it may not be able to follow the movement of the inner coating layer 21, which may cause cracking or peeling. On the other hand, if the coating amount of the exterior protective layer 27 exceeds 3.0 kg/m ² , although the weather resistance and heat retention are ensured, the thickness becomes excessive, which may be uneconomical. In another embodiment, the coating amount of the exterior protective layer 27 can be 0.8 to 2.0 kg/m ² (film thickness: about 0.8 to 2.0 mm), and in yet another embodiment, it can be 1.0 to 1.5 kg/m ² (film thickness: about 1.0 to 1.5 mm).

Next, a method for installing a sauna room 100 using the structural wall 1 of the first embodiment will be described. The method for installing the sauna room 100 of the embodiment includes an assembly process in which the lightweight panel 10 is joined and assembled to the cylindrical structural wall 1, an equipment installation process in which the front wall 120 and rear wall 130 are attached and equipment such as a hinged door 101 is installed in the sauna room 100, a coating layer formation process in which an inner coating layer 21 and an outer coating layer 26 are formed on the inner and outer surfaces of the sauna room 100, an interior protective layer formation process in which an interior protective layer 22 is formed on the surface of the inner coating layer 21, and an exterior protective layer formation process in which an exterior protective layer 27 is formed on the surface of the outer coating layer 26, in that order.

The lightweight panel 10 that forms the main body of the structural wall 1 of the sauna room 100 is made of polystyrene foam (EPS) with an expansion ratio of 50, a bulk density of 20 kg/ ^m3 , a thickness of 120 mm, a front-to-back length of 3,500 mm, and a circumferential length of 600 to 800 mm.

In the lightweight panel 10 that will become the floor panel 111, a rectangular cutout recess 13 is formed in the front-to-rear direction on the butt surfaces 11 of both left and right ends in the circumferential direction as a fitting portion 12. In the lightweight panel 10 that will become the side panel 112, a protruding convex portion 14 protruding from the center of the cross section is formed in the butt surface 11 of the lower end as a fitting portion 12, and a rectangular cutout recess 13 is formed in the butt surface 11 of the upper end as a fitting portion 12. In the lightweight panel 10 that will become the top panel 113, a mating portion 15 is formed in the front-to-rear direction on the butt surfaces 11 of both left and right ends in the circumferential direction as a fitting portion 12. The lightweight panel 10 that becomes the upper side panel 114 has a protruding convex portion 14 formed as a fitting portion 12 on the butt surface 11 of the lower end, and a notch portion 15 with the outside cut out formed as a fitting portion 12 on the butt surface 11 of the upper end.

In the assembly process, the lightweight panels 10 were placed along the outer periphery of the cylindrical sauna room 100, and the bonding material 20 was applied to each of the fitting portions 12 of the joints 16 of the butt surfaces 11 of the lightweight panels 10, and the butt surfaces 11 of the lightweight panels 10 were joined together while being assembled.

The procedure of the assembly process is as follows: the floor panel 111 is placed on the placement surface on which the sauna room 100 is placed, the protruding convex parts 14 of the side panel 112 are joined to the left and right notched recesses 13 of the floor panel 111 from the left and right, respectively, and the protruding convex parts 14 of the side panel 112 are joined to the left and right notched recesses 13 of the left and right side panels 112 from the left and right, respectively, to gradually form a cylindrical shape. Then, the protruding convex parts 14 of the upper side panel 114 are joined to the left and right notched recesses 13 of the left and right side panels 112 from the left and right, respectively, and the joint parts 15 with the outer side cut out as the fitting parts 12 appear at the opposing ends of the left and right upper side panels 114. The top panel 113 with the joint parts 15 with the inner side cut out on the left and right sides is fitted so as to connect the joint parts 15 with the outer side cut out on the left and right, and the peripheral wall 110 of the sauna room 100 is closed in the circumferential direction to form a cylindrical shape.

In the assembly process, a silicone-based caulking material 20 was applied to the fitting portion 12, which was the joint 16 of the butt surface 11 that formed the joint of the lightweight panels 10, to bond the lightweight panels 10 together. In addition, the joint surface 11 that formed the joint of the lightweight panels 10 was replenished with the joint material 20 from both the inside and outside of the sauna room 100 by pressing, thereby improving the adhesion of the joint 16.

The equipment installation process is a process of attaching the front wall 120 to the front side and the rear wall 130 to the rear side of the peripheral wall 110 of the sauna room 100, and attaching the hinged door 101 to the front wall 120 and the light window 102 to the peripheral wall 110. The front wall 120 and the rear wall 130 are attached to the peripheral wall 110 by bonding them with a bonding material 20 made of a silicone-based caulking material, and by driving fixing nails (not shown) into the front wall 120 and the rear wall 130 from the outside of the peripheral wall 110. The hinged door 101 is attached by fitting the outer frame (not shown) of the hinged door 101 into the front wall 120, and the light window 102 is attached by fitting the outer frame (not shown) of the light window 102 into the peripheral wall 110. The hinged door 101 and skylight window 102 are masked with masking tape on both the inside and outside to prevent resin and other substances from adhering to them and becoming dirty after the next coating layer formation process.

In the coating layer forming process, resin is applied to the inner and outer surfaces of the lightweight panel 10, which will be the inner and outer surfaces of the sauna room 100 as a house, to form the inner and outer coating layers 21 and 26. In this embodiment, a commercially available urea resin formed by mixing an isocyanate component and an amine component at the tip of a spray gun is used as the resin to form the inner coating layer 21 and the outer coating layer 26. The inner coating layer 21 and the outer coating layer 26 made of urea resin in this embodiment have an elongation rate (ASTM D-412) of 300%, and the coating amount was 2.0 kg/ ^m2 (film thickness: about 2.0 mm).

The interior protective layer forming process is a process of applying an interior topcoat material that forms the interior protective layer 22 to the surface of the inner coating layer 21 formed from resin. In the embodiment, a general-purpose acrylic emulsion paint (JIS K 5660 glossy synthetic resin emulsion paint) is used as the interior topcoat material, and the application amount is 0.08 kg/ ^m2 (film thickness: about 0.08 mm). The acrylic emulsion paint of the interior topcoat material contains about 10 mass% titanium dioxide powder to reflect the heat of the sauna room 100 by its heat insulating properties.

The exterior protective layer forming process is a process of applying a topcoat material that forms the exterior protective layer 27 to the surface of the outer coating layer 26 formed from resin. In the embodiment, the exterior topcoat material is a general-purpose acrylic emulsion paint (JIS A 6909 Exterior Thin Coating Material E), and the application amount is 1.2 kg/ ^m2 (film thickness: about 1.2 mm). The acrylic emulsion paint of the exterior topcoat material contains about 3% by mass of carbon black and is colored black in order to absorb heat from sunlight and improve the heat retention of the sauna room 100.

As shown in FIG. 3, the sauna room 100 is equipped with a seat 103, a heater (not shown), and other components inside, allowing it to function as a sauna room 100 for steam and hot air bathing.

According to the structural wall 1 according to the embodiment of the present specification, the structural wall 1 of the house can be formed by filling the joint 16 formed by butting the butt surfaces 11 of the lightweight panels 10 and the fitting parts 12 of the adjacent lightweight panels 10 together with a bonding material 20. In addition, the structural wall 1 has an inner coating layer 21 formed on the side of the lightweight panels 10 that faces the interior of the house, which gives durability to the lightweight panels 10 as the structural wall 1. The structural wall 1 is formed by filling the joint 16 where the lightweight panels 10 are in contact with the bonding material 20 and providing the inner coating layer 21 on the interior side of the lightweight panels 10. Therefore, the structural wall 1 according to the embodiment can be easily installed.

Second Embodiment
Hereinafter, a box-type store 100A as a house equipped with a structural wall 1 according to a second embodiment of the present specification will be described with reference to Fig. 5. In the second embodiment, elements common to the first embodiment will be denoted by the same reference numerals and will not be described.

As shown in FIG. 5, the box-type store 100A of the second embodiment has a generally box-shaped shape, and a peripheral wall 110 is formed from a continuous structural wall 1 that goes around the circumference of a cylindrical side. The peripheral wall 110 is formed by filling a joint 16 where abutting surfaces 11 of a lightweight panel 10 and an adjacent lightweight panel 10 are butted together and a fitting portion 12 is fitted, with a joining material 20. The front and rear surfaces surrounded by the peripheral wall 110 of the box-type store 100A are closed by a front wall 120 and a rear wall 130 made of the structural wall 1. A sales window 107 for selling food, beverages, and goods to customers is provided in the front wall 120, and a hinged door 101 for employees to enter and exit is provided on the right side of the peripheral wall 110. Since employees will be working inside the box-type store 100A, it is required that the room temperature does not rise excessively, and when handling food and drink, the inside must be water-resistant.

The inner surface of the lightweight panel 10, which is the interior side of the box-type store 100A, is coated with resin to form an inner coating layer 21 that provides durability, and an interior topcoat material that forms an interior protective layer 22A is applied to the surface of the inner coating layer 21 made of resin. In addition, the outer surface of the lightweight panel 10, which is the exterior of the box-type store 100A, is coated with resin to form an outer coating layer 26 that provides durability, and an exterior topcoat material that forms an exterior protective layer 27A is applied to the surface of the outer coating layer 26 made of resin.

The interior protective layer 22A is applied to improve the water resistance of the inner coating layer 21. The interior topcoat material that forms the interior protective layer 22A can be a general-purpose emulsion paint that has excellent water resistance. In this embodiment, a glossy synthetic resin emulsion paint (JIS K 5660) is used as the interior topcoat material that forms the interior protective layer 22A.

The coating amount of the interior protective layer 22A can be 0.05 to 0.5 kg/m ² (film thickness: about 0.05 to 0.5 mm). This is because sufficient water resistance can be exhibited. If the coating amount of the interior protective layer 22A is less than 0.05 kg/m ² , the film thickness is thin and the layer cannot follow the movement of the inner coating layer 21, which may cause cracking or peeling, resulting in poor water resistance. On the other hand, if the coating amount of the interior protective layer 22A exceeds 0.5 kg/m ² , although water resistance is ensured, the film thickness becomes excessive, which may be uneconomical. In another embodiment, the coating amount of the interior protective layer 22 can be 0.06 to 0.2 kg/m ² (film thickness: about 0.06 to 0.2 mm), and in yet another embodiment, the coating amount can be 0.07 to 0.1 kg/m ² (film thickness: about 0.07 to 0.1 mm).

The exterior protective layer 27A is applied to improve the weather resistance of the outer coating layer 26. The exterior topcoat material forming the exterior protective layer 27A is applied to the outside of the box-type store 100A, so a general-purpose emulsion paint with excellent weather resistance can be used. In the embodiment, a high solar reflectance paint for roofs (JIS K5675) Class 1 LG grade was used for the exterior topcoat material forming the exterior protective layer 27A. The high solar reflectance paint for roofs contains titanium-manganese composite oxide powder as a metal pigment and effectively reflects the radiant heat of the sun, so it has excellent weather resistance and can suppress the rise in room temperature inside the box-type store 100A. In addition, the high solar reflectance paint for roofs as an exterior topcoat material can contain 10 to 30 mass% hollow filler, which can further suppress the rise in room temperature inside the box-type store 100A.

The coating amount of the exterior protective layer 27A can be 0.1 to 1.0 kg/m ² (film thickness: about 0.1 to 1.0 mm). This is because sufficient weather resistance can be exhibited. If the coating amount of the exterior protective layer 27A is less than 0.1 kg/m ² , the film thickness is thin and cannot follow the movement of the inner coating layer 21, causing cracks and peeling, which may result in poor weather resistance. On the other hand, if the coating amount of the exterior protective layer 27A exceeds 1.0 kg/m ² , although weather resistance is ensured, the film thickness becomes excessive, which may be uneconomical. In another embodiment, the coating amount of the exterior protective layer 27A can be 0.2 to 0.8 kg/m ² (film thickness: about 0.2 to 0.8 mm), and in yet another embodiment, it can be 0.3 to 0.5 kg/m ² (film thickness: about 0.3 to 0.5 mm).

The structural wall 1 as a partition for a house in the embodiment can also be modified in its configuration as follows:

In the structural wall 1 of the embodiment, the lightweight panel 10 uses polystyrene foam (EPS), which is easy to mold by bead foaming, but the lightweight panel 10 can be any lightweight panel. Polymer foam and inorganic foam can be used as the material for the lightweight panel. As the polymer foam, polystyrene foam, polyurethane foam, polyphenol foam, polyolefin foam (polyethylene foam, polypropylene foam), etc. can be used. As the inorganic foam, aluminum hydroxide foam (Talbocel), cement-based foam (ALC (autoclaved lightweight aerated concrete)), etc. can also be used.

In the structural wall 1 of the embodiment, the lightweight panel 10 uses EPS with an expansion ratio of 50 times, but any expansion ratio between 30 and 60 times can be used as the EPS for the lightweight panel 10. If the expansion ratio of the EPS is less than 30 times, a large amount of resin (beads) is required, which may be uneconomical. On the other hand, if the expansion ratio of the EPS is more than 60 times, the strength is weak and there is a risk of plastic deformation when it receives an impact. In another embodiment, the expansion ratio of the EPS can be 40 to 55 times.

In the embodiment of the sauna room 100, the lightweight panels 10 of the structural wall 1 are joined together and the gaps between the lightweight panels 10 are sealed using caulking material as the joining material 20. However, if there are gaps between the lightweight panels 10 to be joined, a panel made of the same material as the lightweight panels 10 can be processed to a size that fills the gap, thereby sealing the gap between the lightweight panels 10.

Furthermore, other technical ideas that can be understood from the structural wall 1 of the embodiment are described below.

A sauna room characterized in that the interior protective layer is formed from a glossy synthetic resin emulsion paint (JIS K 5660) containing metallic pigments, and the exterior protective layer is formed from an acrylic emulsion paint (JIS A 6909 Exterior Thin Coating Material E) containing inorganic pigments. This can improve the heat retention of the sauna room.

A box-type store characterized by an interior protective layer formed from glossy synthetic resin emulsion paint (JIS K 5660) and an exterior protective layer formed from high solar reflectance paint for roofs (JIS K 5675). This makes it possible to increase the water resistance inside the store and suppress the rise in room temperature inside the store.

REFERENCE SIGNS LIST 1 Structural wall 10 Lightweight panel 11 Butt surface 12 Fitting portion 13 Notched recess 14 Protruding convex portion 15 Joint portion 16 Joint portion 17 Fitting portion 20 Joint material 21 Inner coating layer 22 Interior protection layer 22A Interior protection layer 26 Outer coating layer 27 Exterior protection layer 27A Exterior protection layer 100 Sauna room 100A Box-type store 101 Swing door 102 Light window 103 Seat 107 Sales window 106 Pedestal 110 Periphery wall 111 Floor panel 112 Side panel 113 Top panel 114 Upper side panel 120 Front wall 130 Rear wall

Claims (6)

A structural wall that is arranged as a partition separating the inside of a house from the outside,
The structure is made up of multiple lightweight panels.
The lightweight panel is joined to an adjacent lightweight panel in the partition of the house;
Each of the butt surfaces of the two lightweight panels is provided with a fitting portion along the butt surface,
A joint portion where the butt surfaces of the two lightweight panels are butted together and the fitting portions are fitted together is joined by a joining material that joins the two lightweight panels,
A structural wall, characterized in that an inner covering layer is formed on the side of the lightweight panel that faces the interior of the house. The structural wall according to claim 1, characterized in that an outer coating layer is formed on the side of the lightweight panel that faces the exterior of the house. The structural wall according to claim 2, characterized in that the elongation percentage (ASTM D-412) of the inner coating layer and the outer coating layer is 100% or more. A house characterized in that the partition is a structural wall according to claim 2 or 3. The house according to claim 4 is a sauna room,
A sauna room characterized in that a heater for heating the inside is provided inside the sauna room, and an interior protection layer is provided on the surface of the inner coating layer. The sauna room according to claim 5, characterized in that an exterior protective layer is provided on the surface of the outer coating layer.

Images