JPH09201811A - Manufacture of decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative panel free from the deterioration of an outer presentable appearance by preventing an efflorescence or duct from adversely affecting the appearance. SOLUTION: A decorative board 2 is laid over another board 2 with a backup material sandwiched there between, in a molding frame, and a water impermeable coating material 6 is applied to the rear face of the decorative board 2. In addition, a reinforcing iron bar 9 is arranged and a concrete 10 is tempted. Thus, the decorative board 2 with a lining reinforcing concrete is prepared. When molding this liming reinforced concrete by the above method, a gasket 7 is inserted into a gap formed by holding the backup material between the decorative boards 2 laid in the molding frame 1. The gasket 7 is equipped with a first plate-like part inserted into the gap, a second flange-like part formed on the end, corresponding to the rear face side of the decorative board, of the first part and a sealing member for the gap formed on the first part. The second part is wider than the width of the gap.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative panel as an interior / exterior panel system for a building, and for example, constitutes a frame portion of a steel structure such as a high-rise building, a large span building, or a steel frame house. TECHNICAL FIELD The present invention relates to a decorative panel applied to a steel material, which is a decorative panel and a method of manufacturing a decorative panel having a concrete backing. More specifically, in the formwork, laying decorative sheets and arranging a backup material between them, and applying a water-impermeable coating material to the back surface of these decorative sheets,
The present invention relates to a method for manufacturing a so-called prefabricated type decorative panel in which reinforcing bars are arranged and concrete is driven from thereover to form a decorative board with reinforced concrete containing reinforcing bars.

[0002]

2. Description of the Related Art A method for manufacturing a decorative panel of this type is known, and in the conventional method, as shown in FIGS. 9 to 12, first, a decorative plate 52 is laid in a fixed position in a form 51. At that time, a member 53 (see FIG. 12; hereinafter, referred to as “backup material”) for forming a gap, that is, a joint between the decorative plates 52 is arranged between the decorative plates 52 arranged in parallel. It is sandwiched between them (Fig. 9). The backup material also defines the joint depth. Furthermore, the paste-like waterproof material 54 is filled into the joints from the back surface side of the decorative plate 52 (FIG. 10), and then the reinforced concrete 55 with reinforcing bars is molded by the mold 51. The uncured decorative panel 50 with reinforced concrete (FIG. 11) thus obtained is used as a backup material 53.
It is normal to leave concrete on for several days outdoors and then cure the concrete.

In FIGS. 10 and 11, reference numeral 56 is an anchor for strengthening the engagement of the lining concrete 55 with the decorative plate 52. The hook 56a of the anchor 56 is locked in the locking groove 52a formed on the back surface of the decorative plate 52,
The adhesive 57 fixes the decorative plate 52. FIG.
Reference numeral 58 denotes a joint material that is jointed for sealing after the makeup panel 50 is applied to a makeup target object (not shown).

In the above-mentioned leaving step, a gap is often generated between the waterproof material 54 and the backup material 53 in the uncured decorative panel with concrete. It is known to those skilled in the art that when voids are formed, water is accumulated in the voids, and as a result, the curing time of concrete is prolonged.

Further, after the manufactured decorative panel is applied to the makeup object, moisture such as rainwater infiltrates into the void portion between the joint material 58 and the waterproof material 54, and as a result, the peripheral portion of the joint is caused. It causes efflorescence (white flower phenomenon) and significantly impairs the appearance of the decorative panel.

[0006] As means for eliminating such a defect,
There is a method disclosed in Japanese Patent Application Laid-Open No. 1-148507, which discloses a method for manufacturing a decorative panel in which a paste-like injection material as a joint material and a waterproof material is filled up to near the surface of a decorative plate.

[0007]

However, according to the method disclosed in the above publication (hereinafter referred to as the "latter"), dark stains are produced around the joints of the decorative panel depending on the type of the waterproofing material, which may cause a dark stain on the building. The problem of spoiling the appearance still remains.

In the latter case, among the waterproof materials, the silicone-based or modified silicone-based resin contains free silicone molecules, and when the free silicone molecules come into contact with rainwater, the peripheral portion of the joint of the decorative sheet in the decorative panel is affected. It seems that the cause is that it diffuses into the air, and the floating dust in the atmosphere adheres to it to generate dirt.

[0009] Further, these silicone-based and modified silicone-based resins must be cleaned after the joint is put in, for example, to remove the joint feces and to repair irregularities, and these work related to the appearance is performed. Requires a high level of technology, and the number of steps is large and the efficiency is low, which is not preferable. Construction of joint material requires a finish without small irregularities or protrusions, and it is not easy to achieve this. The same applies to other paste-like joint materials such as two-component polysulfide resin, elastic epoxy resin, urethane resin, butyl rubber, and polysulfide rubber.

SUMMARY OF THE INVENTION The main object of the present invention is to eliminate the above problems and to provide a method of manufacturing a decorative panel which prevents efflorescence and dust from adhering to the aesthetic panel.

Further, the present invention intends to simplify the construction of the decorative panel if necessary and improve the work efficiency.

[0012]

In order to achieve the above-mentioned object, a method for manufacturing a decorative panel according to the present invention comprises:
Laminated decorative sheets and put a backup material between them, apply a water-impermeable coating material to the back surface of those decorative sheets, and then arrange reinforcing bars and concrete concrete from above.
In the method for manufacturing a decorative panel in the form of a decorative plate with reinforced concrete with reinforced concrete, when forming the reinforced concrete with reinforced concrete, by sandwiching the backup material between decorative plates laid in the formwork. A gasket is inserted into the created gap, and the gasket is formed at a plate-shaped first portion inserted into the gap and at an end of the first portion corresponding to the back surface side of the decorative plate. A flange-shaped second portion and a seal member for the gap formed in the first portion are provided, and the second portion is wider than the width of the gap. .

In the above method for manufacturing a decorative panel, a gasket having a flange-shaped third portion having substantially the same width as the gap of the decorative plate is formed at the end of the first portion opposite to the second portion. It is desirable to allocate

In order to sufficiently prevent the penetration of water from the backing concrete into the decorative plate in the second portion of the gasket, the surface of the second portion or the edge extending in the lengthwise direction of the second portion is formed. It is recommended to apply a waterproof material so as to cover it.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of a method for manufacturing a decorative panel according to the present invention will be described below with reference to the drawings.

The decorative plates 2 are laid out at predetermined positions in the formwork 1. At that time, the backup material 3 is sandwiched between the decorative plates 2. The purpose of using the backup material 3 is similar to that of the conventional one. The decorative plate 2 can be filled with a known material such as natural stone or porcelain plate. An anchor 4 similar to a conventional one is attached to the back surface of the laid decorative plates 2 and fixed with an adhesive 5.

A water-impermeable coating material 6 is applied to the back surface of the laminated decorative plates 2. The coating material 6 may be a known one such as a one-pack type modified silicone resin, a two-pack type elastic epoxy resin, and a modified epoxy resin.

The gasket 7 is inserted into the gap X between the parallel decorative plates 2 (FIG. 2). As shown in FIG. 3, the gasket 7 includes a plate-shaped first portion 7a, a flange-shaped second portion 7b formed at an end of the first portion 7a corresponding to the back surface of the decorative plate 2, and It has a tongue-shaped sealing member 7c for the gap X formed in the first part 7a. On the side opposite to the second portion of the first portion 7a, the width W
It is preferable that 2 forms a flange-shaped third portion 7d having a degree of joint width M (FIG. 2).

The first portion 7a is formed wider than the joint width M. The height H of the first portion 7a is equal to the decorative plate 2
To the extent that the thickness of the backup material 3 is subtracted from the thickness of, for example, when the thickness of the decorative plate 2 is 13 mm and the thickness of the backup material 3 is 5 mm, the height H
Is 8 mm.

In order to improve the sealing property with respect to the back surface of the decorative plate 2, it is desirable to form a convex portion 7a 'protruding downward on the edge portion extending in the lengthwise direction of the second portion 7b.

The seal member 7c extends obliquely from both side surfaces of the first portion 7a toward the second portion 7b, and its width W1 is slightly larger than the joint width M (for example, M is 8).
When W is 11 mm, W1 is 11 mm), and those shown in FIG. 3 can be mentioned as preferable examples. Seal member 7
c is not limited to one pair, but two pairs (FIG. 4) or more can be formed. A pair of sealing members 7c is suitable for a shallow joint or a thin decorative plate, and a plurality of pairs is suitable for a deep joint or a thick decorative plate.

Chloroprene rubber is the most preferable material for the gasket 7. The gasket 7 can be molded by extrusion molding, compression molding, or the like. When the gasket 7'by extrusion molding is used, a gasket 7 "having a cross shape in plan view as shown in FIG.
Each end face of the four arms of the gasket 7 ″ and the gasket 7 ′
The end face of the is fixed by heat welding or the like. Thus, the decorative plate 2
It is possible to obtain a lattice-shaped gasket 7 that fits the joints (gap X) of FIG.

The first portion 7a of the gasket 7 is press-fitted into the gap X until the base end surface (lower surface in FIG. 3) of the gasket 7 contacts the backup material 3 and the second portion 7b contacts the back surface of the decorative plate 2. It At this time, the seal member 7c formed on the first portion 7a is inserted so as to be pushed between the inner surfaces of the joint facing each other.

As described above, the insertion of the gasket 7 into the gap X is a simple operation in which the base end of the portion 7a abuts on the backup material 3 and / or the portion 7b presses on the decorative plate 2 as a guide. You can adjust the depth with.

Next to the above-described preliminary step for forming the backing concrete, the reinforcing bars 9 were laid out, the concrete 10 was driven in, and after leaving for several days, steam curing or autoclave curing was performed, and the reinforcing bar-reinforced concrete 1
Make a makeup panel with 1. The decorative panel with the reinforced concrete 11 containing reinforcing bars is taken out from the mold outside the drawing, and the decorative panel shown in FIG. 8 is obtained. It is desirable that the anchors 5 and the reinforcing bars 9 be attached or arranged in a suspended state using a jig or the like from a peripheral formwork (not shown) so that these loads are not applied to the decorative plate 2.

The operation of the present invention will be described below.

In the above-mentioned production of the decorative panel with reinforced concrete containing reinforcing bars, the width of the gap formed at the end on the predetermined side of the first portion of the gasket inserted into the gap between the laminated decorative plates The wide flange-shaped second portion seals the lining concrete side of the gap by contacting the bottom surface with the back surface of the decorative plate. Therefore, the water-impermeable coating material is applied to the back surface of the decorative plate, and the boundary between the decorative plate and the backing concrete prevents the permeation of water from the backing concrete into the decorative plate and into the joints. Further, even when the water-impermeable coating film on the back surface of the decorative plate is a modified silicone resin, free components from the resin do not diffuse to the surface of the decorative plate. This is because the seal member of the gasket seals the joint. Since there is no diffusion of the free components on the surface of the decorative plate, there is no dust adhesion that has been conventionally seen.

On the other hand, the seal member formed on the first portion of the gasket seals the joint by the pushing intervening action between the inner surfaces of the joint which is the gap. For this reason, rainwater or the like does not enter from the outside through the joints and does not collect in the joints.

Further, the fact that the joint can be structurally sealed without filling the joint material, unlike the conventional case, solves the various problems described above due to the use of the joint material.

Thus, according to the present invention, the efflorescence around the joints of the decorative panel is eliminated, and the above-mentioned problem associated with the generation of voids which are water pools in the joints, which has been conventionally seen, is solved. It is possible to eliminate the generation of dark stains around the joints.

According to the present invention, when the waterproof material is applied to cover the entire back surface of the second portion of the gasket or the edge extending in the lengthwise direction, the sealing property of the joint is improved.

At the predetermined end of the first portion of the gasket,
When forming a flange-shaped third portion having substantially the same width as the joint width, the gasket is pushed into the joint until the third portion contacts the backup material in the joint, so that the lower surface of the portion is It plays a role as a good makeup joint without unevenness, and unlike the case of using a conventional joint material, it does not require the above-mentioned additional finishing and repair work, simplifies the makeup panel construction, and improves work efficiency. Can be achieved.

[0033]

As described above, according to the first aspect of the present invention.
According to the method for manufacturing a decorative panel according to (1), it is possible to manufacture a decorative panel that prevents efflorescence and dust adhesion and does not impair aesthetics.

According to the manufacturing method of the second aspect of the present invention, the construction of the decorative panel can be simplified and the work efficiency can be improved.

[Brief description of drawings]

FIG. 1 is an explanatory view of a method for manufacturing a decorative panel according to the present invention, which is a partial vertical sectional view showing a state of an intermediate step thereof.

2 is an explanatory view of a step following FIG. 1, and is a partial vertical cross-sectional view.

FIG. 3 is a cross-sectional perspective view of a gasket used in the method for manufacturing a decorative panel according to the present invention.

FIG. 4 is a partial cross-sectional perspective view corresponding to FIG. 3, showing another example of the gasket.

FIG. 5 is a plan view showing a connection mode of gaskets.

6 is a plan view showing a part of the gaskets connected by the connection mode of FIG. 4 in a different scale.

FIG. 7 is a longitudinal sectional view showing a part of a decorative panel manufactured by the method according to the present invention.

FIG. 8 is a perspective view showing an entire decorative panel manufactured by the method according to the present invention.

FIG. 9 is an explanatory view of a conventional method for manufacturing a decorative panel, which is a partial vertical cross-sectional view showing a state of an intermediate step thereof.

FIG. 10 is an explanatory diagram of a step following FIG. 7, and is a partial cross-sectional view.

FIG. 11 is a partial cross-sectional view showing a decorative panel manufactured by a conventional method for manufacturing a decorative panel.

FIG. 12 is a perspective view showing a part of a backup material.

[Explanation of symbols]

 1 Formwork 2 Decorative Panel 3 Backup Material 4 Anchor 5 Adhesive 6 Water-Impermeable Coating Material 7 Gasket 7a First Part 7b Second Part 7c Sealing Member 7d Third Part 8 Waterproof Material 9 Reinforcing Bar 10 Concrete 11 Reinforcing Bar Filled concrete molding

Claims (2)

[Claims] 1. A veneer is laid in a formwork, a backup material is sandwiched between them, and a water-impermeable coating material is applied to the back surface of the veneer. In a method of manufacturing a decorative panel in the form of making a decorative plate with reinforced concrete containing reinforcing bars, in the case of forming the reinforced concrete with reinforcing bars, the backup material is placed between the decorative plates laid in the formwork. A gasket is inserted into a gap formed by sandwiching the gasket, and the gasket is a plate-shaped first portion inserted into the gap, and an end of the first portion corresponding to the back surface side of the decorative plate. A flange-shaped second portion formed on the first portion, and a seal member for the gap formed on the first portion, wherein the second portion is wider than the width of the gap. Method for producing a decorative panel characterized by and. 2. The method for manufacturing a decorative panel according to claim 1, wherein the gasket is a third flange-shaped gasket having substantially the same width as the gap of the decorative plate at the end of the first portion opposite to the second portion. A method for manufacturing a decorative panel, characterized in that a part is formed.