CN115427646B - Method for manufacturing wall plate - Google Patents

Method for manufacturing wall plate Download PDF

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Publication number
CN115427646B
CN115427646B CN202180029476.6A CN202180029476A CN115427646B CN 115427646 B CN115427646 B CN 115427646B CN 202180029476 A CN202180029476 A CN 202180029476A CN 115427646 B CN115427646 B CN 115427646B
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China
Prior art keywords
bending
reference line
plate material
line
parallel
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Application number
CN202180029476.6A
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Chinese (zh)
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CN115427646A (en
Inventor
宫岛胜二
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Qinping Industry Co ltd
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Qinping Industry Co ltd
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Publication of CN115427646A publication Critical patent/CN115427646A/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D19/00—Flanging or other edge treatment, e.g. of tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D19/00—Flanging or other edge treatment, e.g. of tubes
    • B21D19/08—Flanging or other edge treatment, e.g. of tubes by single or successive action of pressing tools, e.g. vice jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D51/00—Making hollow objects
    • B21D51/16—Making hollow objects characterised by the use of the objects
    • B21D51/52—Making hollow objects characterised by the use of the objects boxes, cigarette cases, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/72—Non-load-bearing walls of elements of relatively thin form with respect to the thickness of the wall
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/12—Small buildings or other erections for limited occupation, erected in the open air or arranged in buildings, e.g. kiosks, waiting shelters for bus stops or for filling stations, roofs for railway platforms, watchmen's huts or dressing cubicles

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Residential Or Office Buildings (AREA)
  • Panels For Use In Building Construction (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Finishing Walls (AREA)

Abstract

A method for manufacturing a wall panel capable of making the accuracy of the external dimensions extremely high. The manufacturing method comprises the following steps: b1, preparing a plate (10) attached with a sheet (39), and forming a notch part containing a 1 st datum line (21) at a 1 st corner (11); b2, forming a notch part containing a 2 nd datum line (22) at the 1 st corner part (11); b3, forming a notch part containing a 3 rd datum line (23) at the 2 nd corner part (12); a step C1 of bending the base material at a predetermined position against the 2 nd reference line (22) to form a 1 st bending surface (31 b); a step C2 of forming a 2 nd bending surface (32 b) by bending at a predetermined position against the 1 st bending surface (31 b); e1, abutting against the 1 st datum line (21) and the 3 rd datum line (23), and bending at a specified position to form a 3 rd bending surface (34 c); and E2, abutting against the 3 rd bending surface (34 c), and bending at a prescribed position to form a 4 th bending surface (33 c).

Description

Method for manufacturing wall plate
Technical Field
The present invention relates to a method for manufacturing a wall panel, and more particularly, to a method for manufacturing a wall panel constituting a wall portion of an integral bathroom.
Background
Regarding the wall plate constituting the wall part of the integral bathroom, techniques related to the structure and manufacturing method thereof are disclosed in patent document 1 (japanese patent laid-open publication No. 2003-033837), patent document 2 (japanese patent laid-open publication No. 2004-150253), and the like.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2003-033837
Patent document 2: japanese patent application laid-open No. 2004-150253
Disclosure of Invention
Problems to be solved by the invention
The above-described exemplary wall plate is placed in parallel with a gap of a predetermined size in a wall portion of the entire bathroom, and is used in a state where a water stopping effect is generated by embedding a joint material in the gap. If a curable liquid resin material is used as the joint material, even if the outer dimensions of the wall plate have low accuracy and the shape and dimensions of the gap vary, the gap can be filled to prevent water from entering the wall (the back side opposite to the indoor side). However, the joint material made of the liquid resin material takes time and effort in construction, and causes problems such as an increase in construction period and cost.
Accordingly, the wall panels described in patent documents 1 and 2 are configured to use a solid dry joint material formed of a resin material, and thus it is desired to facilitate the construction work, shorten the construction period, and reduce the cost. On the other hand, since the dry joint material is used, when the accuracy of forming the outer dimensions of the wall plate is slightly low, the gap in which the joint material is embedded cannot be completely sealed, and there is a problem in that water is immersed into the wall.
Here, the wall plate is manufactured by forming a rectangular metal plate material into a predetermined shape by press working. Therefore, even when a rectangular plate material whose error (angular tolerance) is set to be extremely small at the time of forming (cutting) the perpendicularity of the four corners is used as a raw material, the accuracy of forming the outer dimension of the wall plate formed by the press working can be improved. However, in order to prepare such a material, a device having high processing accuracy and high cost is required, and an operation of measuring a processed material to investigate an error is also required, and as a result, there is a problem that the cost of a plate material as a material increases.
Solution for solving the problem
The present invention has been made in view of the above-described circumstances, and an object thereof is to provide a manufacturing method capable of using, as a raw material, a rectangular plate material whose angular tolerance is set relatively large at the time of formation (at the time of cutting) in the perpendicularity of four corners, and capable of making the accuracy of forming the external dimension extremely high at the time of forming by press working, and capable of remarkably improving the water-stopping performance of the gap in which the dry-type joint material is fitted, and realizing shortening of the construction period and reduction of the cost by facilitating the construction work, in which the wall plate is used in a state where the wall plate material is placed in parallel with the wall portion of the entire bathroom with a gap of a predetermined dimension interposed therebetween and a water-stopping effect is generated.
As an embodiment, the problem is solved by the solution disclosed below.
The disclosed method for manufacturing a wall panel, which is formed by a processing step of processing a sheet made of a metal material into a predetermined shape while conveying the sheet on a production line, wherein the sheet is attached to one side surface with a sheet made of a resin material, the wall panel is placed in parallel with a wall portion of an entire bathroom with a predetermined size gap therebetween, and is used in a state in which a water-stopping effect is produced by embedding a solid dry joint material in the gap, the method is characterized in that the processing step comprises an A1 step, and in the A1 step, the sheet having a rectangular shape including an angular tolerance of 0.5 DEG or less produced during cutting in the perpendicularity of four corners is prepared, and the processing step comprises, after the A1 step: b1, forming a notch part comprising a1 st datum line at a1 st corner part where a1 st short side and a1 st long side of the plate material intersect, wherein the 1 st datum line is a datum position when the plate material is bent at a bending line parallel to the 1 st long side; b2, forming a notch part including a 2 nd reference line at the 1 st corner part, wherein the 2 nd reference line is a reference position when the plate material is bent at a bending line parallel to the 1 st short side; and a step B3 of forming a notch portion including a 3 rd reference line at a 2 nd corner portion where a 2 nd short side and the 1 st long side of the plate material intersect, the 3 rd reference line being a reference position when the plate material is bent at a bending line parallel to the 1 st long side, the processing step including, after the step B1, the step B2, and the step B3: a step C1 of pressing the plate material by pressing the plate material at a position parallel to the 2 nd reference line and apart from the 2 nd reference line by a predetermined dimension so as to form a1 st bending surface by abutting the 2 nd reference line against an abutting portion; and a C2 step of forming a 2 nd bending surface by bending the plate material by press working at a position parallel to the 1 st bending surface and apart from the predetermined dimension by abutting the 1 st bending surface against an abutting portion, wherein the working step includes a D1 step after the C1 step and the C2 step, and wherein the plate material is rotated by 90 DEG in an in-plane direction in the D1 step, and wherein the working step includes, after the D1 step: step E1 of pressing the 1 st reference line and the 3 rd reference line against the corresponding abutting portions, respectively, and bending the plate material by press working at a position parallel to the 1 st reference line and the 3 rd reference line and apart from the 1 st reference line by a predetermined dimension to form a 3 rd bending surface; and E2, abutting the 3 rd bending surface against an abutting portion, bending the plate material by press working at a position parallel to the 3 rd bending surface and apart from the plate material by a predetermined dimension to form a 4 th bending surface, wherein the D1 comprises the following steps: the sheet material is rotated by 90 DEG with the 1 st corner portion facing the start point side of the conveying direction of the production line and the error is within 1 DEG, and the step E1 comprises the following steps: when the 1 st reference line and the 3 rd reference line are abutted against the corresponding abutting portions, the sheet material is retracted toward the start point side in the line conveying direction, and is abutted against the sheet material, and is bent at a bending line parallel to the 1 st long side and the 2 nd long side at a position closer to the 2 nd long side than the 1 st long side.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, a method for manufacturing a wall panel which is provided in parallel to a wall portion of an entire bathroom with a gap of a predetermined size interposed therebetween and is used in a state where a water stop effect is generated by embedding a joint material in the gap, can use a rectangular plate material having a relatively large angular tolerance in the perpendicularity of four corners, which is inexpensive, as a raw material, and can manufacture a wall panel having extremely high accuracy in forming the outer dimensions. In this way, in a structure in which a solid dry joint material is used as a joint material without using a liquid resin, the water-stopping performance of a gap in which the joint material is fitted can be dramatically improved. Thus, the construction work can be simplified, the construction period can be shortened, and the cost can be reduced when the wall portion is constructed.
Drawings
Fig. 1 is a schematic view (front side perspective view) showing an example of a wall plate according to an embodiment of the present invention.
Fig. 2 is a schematic diagram (rear perspective view) showing an example of a wall plate according to an embodiment of the present invention.
Fig. 3 is a sectional view taken along line III-III in fig. 1.
Fig. 4 is a cross-sectional view taken along line IV-IV in fig. 1.
Fig. 5 is a schematic view (plan view) of a corner joint strip for connecting wall panels according to the present embodiment.
Fig. 6 is a schematic view (plan view) of a flat joint strip connecting wall panels of the present embodiment.
Fig. 7 is a schematic view (perspective view) of a dry joint material fitted into a gap formed by juxtaposing wall panels according to the present embodiment.
Fig. 8 is an explanatory view for explaining a method of forming a wall portion of an entire bathroom using the wall plate of the present embodiment.
Fig. 9 is an explanatory view for explaining a method of forming a wall portion of an entire bathroom using the wall plate of the present embodiment.
Fig. 10 is an explanatory view for explaining a method of forming a wall portion of an entire bathroom using the wall plate of the present embodiment.
Fig. 11 is a schematic diagram (schematic configuration diagram in plan view) showing an example of a manufacturing apparatus for manufacturing a wall plate according to the present embodiment.
Fig. 12A to 12C are schematic diagrams (top view of emphasized shape) of raw materials used in the production of the wall plate of the present embodiment.
Fig. 13 is a schematic diagram (plan view) showing a processing example (shape example) of a raw material in a step in the manufacturing method of the wall plate of the present embodiment.
Fig. 14 is an enlarged view of a portion a in fig. 13.
Fig. 15 is an enlarged view of a portion B in fig. 13.
Fig. 16 is a schematic view (plan view) of a 1 st press die provided in the manufacturing apparatus for manufacturing the wall plate according to the present embodiment.
Fig. 17 is a schematic view (plan view) of a 2 nd press die provided in the manufacturing apparatus for manufacturing the wall plate according to the present embodiment.
Detailed Description
The wall panel manufactured by the manufacturing method of the present embodiment is formed by a processing step of processing a metal plate material into a predetermined shape while conveying the plate material on a production line, wherein a sheet made of a resin material is attached to one surface of the plate material, and the wall panel is placed in parallel with a wall portion of an entire bathroom with a predetermined size gap therebetween, and is used in a state in which a water-stopping effect is generated by embedding a solid dry joint material into the gap. Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In all the drawings for explaining the embodiments, members having the same functions are denoted by the same reference numerals, and repeated descriptions thereof may be omitted.
(wall plate)
First, a structural example of the wall plate 30 of the present embodiment will be described. Fig. 1 is a perspective view of the front side (the indoor side of the entire bathroom) of the wall plate 30, and fig. 2 is a perspective view of the back side (the outdoor side of the entire bathroom) of the wall plate 30. Fig. 3 is a sectional view taken along line III-III in fig. 1, and fig. 4 is a sectional view taken along line IV-IV in fig. 1. For example, the wall plate 30 is formed to have a long side of about 1000mm to 2300mm and a short side of about 300mm to 1200mm, but is not limited thereto. The drawings such as fig. 1 are not shown to be strictly proportional to the actual dimensions.
As an example of a material for producing the wall plate 30, a rectangular (substantially rectangular) plate material (described in detail below) made of a metal material (for example, galvanized steel having a thickness of about 0.5mm or the like) is used, and a steel plate (hereinafter, sometimes simply referred to as "raw material") 10 (hereinafter) having a sheet (so-called "decorative sheet") 39 made of a resin material (for example, polyester resin having a thickness of about 0.1mm or the like) attached to one surface thereof is used. By changing the design of the tab 39, the wall design of the overall bathroom can be changed, and a wide variety of changes can be provided (i.e., the surface to which the tab 39 is attached becomes the surface of the wall panel 30). Using this material 10, a wall plate 30 having a rectangular wall surface structure in a plan view is manufactured by forming four corners into a predetermined shape by press working (cutting working) and then forming the four corners into a predetermined shape by press working (bending working), as will be described in detail later. The structure of the raw material 10 is not limited to the above example.
As an example of the structure of the wall plate 30, a bent portion 31 having a U-shaped cross section (more precisely, コ -shaped japanese katakana) is formed by bending the material 10 at a position closer to the 1 st short side 15 by 90 ° to the back surface side and then bending the material to the back surface side by 90 ° as shown in fig. 3. Further, the material 10 is bent at a position closer to the 2 nd short side 16 by 90 ° to the front surface side and then bent at 90 ° to the back surface side, whereby a bent portion 32 having an L-shaped cross section is formed as shown in fig. 3. On the other hand, the material 10 is bent at 90 ° to the back surface side, then bent at 120 ° to the back surface side, and then bent at 90 ° to the back surface side at both the position closer to the 1 st long side 17 and the position closer to the 2 nd long side 18, whereby the bent portions 33 and 34 having triangular cross sections are formed as shown in fig. 4. However, the structure is not limited thereto.
(Joint strip)
Next, a structural example of the joint strips 40, 50 connecting the wall plates 30 of the present embodiment will be described. Fig. 5 is a plan view of the corner joint strip 40 disposed at the corner (corner) of the entire bathroom, and fig. 6 is a plan view of the flat joint strip 50 disposed at the side (middle) of the entire bathroom.
The corner joint strip 40 is formed by bending a rectangular plate material made of a metal material (for example, galvanized steel) into a predetermined shape. As shown in fig. 5, the plate material has bent portions 41 and 42 formed to be bent at the ends (i.e., the long side portions) in the width direction, respectively, and having a triangular cross section. The bent portions 41 and 42 are formed as openings 44 therebetween, and the inside thereof is formed as a hollow portion 46.
The flat joint strip 50 is formed by bending a rectangular plate material made of a metal material (for example, galvanized steel) into a predetermined shape. As shown in fig. 6, the plate material has bent portions 51 and 52 formed to be bent at the ends (i.e., the long side portions) in the width direction, respectively, and having a triangular cross section. The bent portions 51 and 52 are formed as openings 54 therebetween, and as hollow portions 56 therein.
(method of use)
Next, a method of forming a wall portion of the entire bathroom using the wall plate 30 of the present embodiment will be described. In brief, the wall plate 30 is disposed along the outer peripheral edge of a floor portion (for example, a shallow box-shaped floor pan) 62 together with the corner joint strip 40 and the flat joint strip 50, which are connecting members, to constitute a wall portion of the entire bathroom. Further, block members 66 to 69 made of a resin material are fitted to the upper and lower ends of the corner joint strip 40 and the upper and lower ends of the flat joint strip 50. Hereinafter, the description will be made in detail.
First, as shown in fig. 8, one wall plate 30 (30A) is erected on the outer edge of the floor portion 62 at a position (adjacent position) near one corner of the floor portion 62 formed in a rectangular shape. At this time, the bent surface 31b (1 st bent surface) of the bent portion 31 of the wall plate 30 (30A) is configured to abut (closely contact) the under-wall seal 64 provided on the abutment surface 62a of the outer edge portion of the floor portion 62, thereby preventing water from entering. As an example of the under-wall seal 64, a known waterproof tape made of a resin material or the like is used.
Next, the corner joint strip 40 is erected at a predetermined position (a corner position adjacent to the wall plate 30 (30A)) of the floor portion 62. Specifically, after the corner joint strip 40 is attached to the wall plate 30 (30A), the lower end portion of the corner joint strip 40 is fitted into the block member 67 provided in the floor portion 62, whereby the corner joint strip 40 and the wall plate 30 are positioned at a predetermined position and erected.
When the corner joint strip 40 is attached to the wall plate 30 (30A), the bent portion 33 of the wall plate 30 (30A) is inserted into the hollow portion 46 from the opening 44 of the corner joint strip 40, and is locked to the bent portion 42. At this time, the bending surface 33a (the 2 nd locking surface) of the bending portion 33 is in contact with the bending surface 42a (the 2 nd supporting surface) of the bending portion 42.
Next, one wall plate 30 is erected on the outer edge of the floor portion 62 (30B). At this time, the bent portion 34 of the wall plate 30 (30B) is inserted into the hollow portion 46 from the opening 44 of the corner joint strip 40, and is locked to the bent portion 41. At this time, the bending surface 34a (the 1 st locking surface) of the bending portion 34 is in contact with the bending surface 41a (the 1 st supporting surface) of the bending portion 41. In addition, as in the case of the wall plate 30 (30A), the bent surface 31B (1 st bent surface) of the bent portion 31 of the wall plate 30 (30B) is configured to be in contact (in close contact) with the under-wall seal 64 provided on the contact surface 62a of the outer edge portion of the floor portion 62, thereby preventing water from entering.
Next, as shown in fig. 9, a block member 66 is attached to the upper end portion of the corner joint strip 40. The block member 66 is provided with a projection-like insertion portion (not shown) that is inserted into the bending portion 33 (specifically, the hollow portion 33 d) of the wall plate 30 (30A) and the bending portion 34 (specifically, the hollow portion 34 d) of the wall plate 30 (30B), respectively. By inserting the insertion portion into the bent portion 33 (hollow portion 33 d) and the bent portion 34 (hollow portion 34 d), the block member 66 can be prevented from falling off, and the insertion portion can be reliably fixed in a state where the bent surface 33a (2 nd engagement surface) of the wall plate 30 (30A) is in contact with the bent surface 42a (2 nd support surface) of the bent portion 42 of the corner joint strip 40 and in a state where the bent surface 34a (1 st engagement surface) of the wall plate 30 (30B) is in contact with the bent surface 41a (1 st support surface) of the bent portion 41 of the corner joint strip 40. However, the structure of the block member 66 is not limited to the above-described example.
Next, the flat joint strip 50 is erected at a predetermined position (intermediate position adjacent to the wall plate 30B) of the floor portion 62. Specifically, after the flat joint strip 50 is attached to the wall plate 30B, the lower end portion of the flat joint strip 50 is fitted into the block member 69 provided on the floor portion 62, whereby the flat joint strip 50 and the wall plate 30 are positioned at a predetermined position and erected.
When the flat joint strip 50 is attached to the wall plate 30 (30B), the bent portion 33 of the wall plate 30 (30B) is inserted into the hollow portion 56 from the opening 54 of the flat joint strip 50, and is locked to the bent portion 52. At this time, the bending surface 33a (the 2 nd locking surface) of the bending portion 33 is in contact with the bending surface 52a (the 4 th supporting surface) of the bending portion 52.
Next, as shown in fig. 10, a block member 68 (68A) is attached to the upper end portion of the flat joint strip 50. The block member 68 (68A) is provided with a projection-like insertion portion (not shown) that is inserted into the bent portion 33 (specifically, the hollow portion 33 d) of the wall plate 30 (30B). By inserting the insertion portion into the bent portion 33 (hollow portion 33 d), the block member 68 (68A) can be prevented from falling off, and the flat joint strip 50 can be reliably fixed in a state in which the bent surface 33a (2 nd locking surface) of the wall plate 30 (30B) is in contact with the bent surface 52a (4 th supporting surface) of the bent portion 52. However, the structure of the block member 68 (68A) is not limited to the above-described example.
Next, one wall plate 30 is erected on the outer edge of the floor portion 62 (30C). At this time, the bent portion 34 of the wall plate 30 (30C) is inserted into the hollow portion 56 from the opening 54 of the flat joint strip 50, and is locked to the bent portion 51. At this time, the bending surface 34a (the 1 st locking surface) of the bending portion 34 is in contact with the bending surface 51a (the 3 rd supporting surface) of the bending portion 51. In addition, as in the case of the wall panels 30A and 30B, the bent surface 31B (1 st bent surface) of the bent portion 31 of the wall panel 30C is configured to come into contact (close contact) with the under-wall seal 64 provided on the contact surface 62a of the outer edge portion of the floor portion 62, thereby preventing water from entering.
Next, the block member 68 (68B) is attached to the upper end portion of the flat joint strip 50. The block member 68 (68B) is provided with a projection-like insertion portion (not shown) that is inserted into the bent portion 34 (specifically, the hollow portion 34 d) of the wall plate 30 (30C). By inserting the insertion portion into the bent portion 34 (hollow portion 34 d), the block member 68 (68B) can be prevented from falling off, and the flat joint strip 50 can be reliably fixed in a state in which the bent surface 34a (1 st locking surface) of the wall plate 30 (30C) is in contact with the bent surface 51a (3 rd supporting surface) of the bent portion 51. However, the structure of the block member 68 (68B) is not limited to the above-described example.
Then, according to the design specification of the entire bathroom (here, the horizontal dimension of the wall portion), either one of the two steps of attaching the corner joint strip 40 to the wall plate 30C to terminate the wall surface and attaching the flat joint strip 50 to the wall plate 30C to extend the wall surface is performed. In addition, in both the case of mounting the corner joint strip 40 and the case of mounting the flat joint strip 50, the mounting method is the same as in the above-described respective cases, and therefore, a repetitive description is omitted.
By assembling the wall plate 30, the corner joint strip 40, and the flat joint strip 50 in this order, the wall portion can be formed so as to surround one round along the outer peripheral edge of the floor portion 62. At this time, the wall plate 30, the corner joint strip 40 and the flat joint strip 50 are integrally drawn together, and the wall surface of the entire bathroom can be easily formed without providing any special members. At this time, the bending surfaces 34a (1 st locking surface), 33a (2 nd locking surface) of the wall plate 30, the bending surfaces 41a (1 st supporting surface), 42a (2 nd supporting surface) of the corresponding corner joint strip 40, and the bending surfaces 51a (3 rd supporting surface), 52a (4 th supporting surface) of the flat joint strip 50 are elastically locked.
In addition, the following state is established: more specifically, a gap is formed between the wall plates 30 arranged in parallel, which are locked to the corner joint strip 40, and more specifically, between the bent portion 33 of one wall plate 30 (30A) inserted into the hollow portion 46 from the opening portion 44 and the bent portion 34 of the other wall plate 30 (30B) inserted into the hollow portion 46 from the opening portion 44. Thus, the step of embedding the dry joint material 60 shown in fig. 7 in the gap to block the gap is performed to prevent water from entering. As an example, the dry joint material 60 is formed into a solid shape capable of elastic deformation using a resin material. That is, the dry joint material 60 has the following structure: the back surface (outdoor side surface) of the base 60a is elastically brought into contact with the surface of the wall plate 30, and the protruding portion 60b is elastically brought into contact with the bent portion 33 (here, the 4 th bent surface 33 c) and the bent portion 34 (here, the 3 rd bent surface 34 c) of the wall plate 30, whereby a gap water blocking function (a function of preventing water from entering the wall) is generated. However, the structure of the dry-seam material 60 is not limited to the above examples.
Similarly, the following state is established: more specifically, a gap is formed between the wall plates 30 arranged in parallel and locked to the flat joint strip 50, and more specifically, between the bent portion 33 of one wall plate 30 (30B) inserted into the hollow portion 56 from the opening portion 54 and the bent portion 34 of the other wall plate 30 (30C) inserted into the hollow portion 56 from the opening portion 54. Thus, the step of embedding the dry joint material 60 shown in fig. 7 in the gap to block the gap is performed to prevent water from entering. As described above, the dry joint material 60 is formed into a solid shape capable of elastic deformation using a resin material. That is, the dry joint material 60 has the following structure: the back surface (outdoor side surface) of the base 60a is elastically brought into contact with the surface of the wall plate 30, and the protruding portion 60b is elastically brought into contact with the bent portion 33 (here, the 4 th bent surface 33 c) and the bent portion 34 (here, the 3 rd bent surface 34 c) of the wall plate 30, whereby a gap water blocking function (a function of preventing water from entering the wall) is generated. However, the structure of the dry-seam material 60 is not limited to the above examples. The dry joint material may be configured differently for the corner portion and the side portion (intermediate portion) (not shown).
Through the above steps, the wall of the whole bathroom is formed.
As described above, if a curable liquid resin material is used as the joint material, even if the outer dimensions of the wall plate 30 are formed with low accuracy and the gaps are formed with a different shape or size, the gaps can be filled to prevent water from entering the wall (the back side opposite to the indoor side). However, the joint material made of the liquid resin material takes time and effort in construction, and causes problems such as an increase in construction period and cost. Therefore, in the present embodiment, the use of the solid dry joint material 60 made of a resin material as shown in fig. 7 can simplify the construction work (see fig. 8 to 10), and can reduce the construction period and the cost.
However, since a solid dry joint material is used, the lower the accuracy of forming the outer dimensions of the wall plate 30, the less the water-stopping effect of the gap in which the joint material is fitted is obtained, and the problem of water penetration into the wall arises. Specifically, in the wall plate 30, when the perpendicularity of the bending surface 33c (4 th bending surface) of the bending portion 33 with respect to the bending surface 31b (1 st bending surface) of the bending portion 31 and the perpendicularity of the bending surface 34c (3 rd bending surface) of the bending portion 34 with respect to the bending surface 31b (1 st bending surface) of the bending portion 31 are inaccurate, water may be impregnated into the wall (back side opposite to the indoor side). That is, when the wall plate 30 is erected by bringing the bending surface 31b (the 1 st bending surface) into close contact (close contact) with the floor portion 62 (here, the under-wall seal 64 provided on the contact surface 62 a), if the perpendicularity is inaccurate, the bending surface 33c (the 4 th bending surface) and the bending surface 34c (the 3 rd bending surface) of the wall plate 30 are placed in a state shifted (inclined) from the vertical direction. Therefore, the gap between the bending surface (here, the 4 th bending surface 33 c) of one wall plate 30 and the bending surface (here, the 3 rd bending surface 34 c) of the other wall plate 30 is deformed into a trapezoid or the like, and a gap is formed between the solid dry joint material 60 and the bending surfaces (the 4 th bending surface 33c and the 3 rd bending surface 34 c) at the time of insertion, resulting in the penetration of water. Conversely, if the bending surface of one wall plate 30 (here, the 4 th bending surface 33 c) and the bending surface of the other wall plate 30 (here, the 3 rd bending surface 34 c) are kept parallel in the vertical direction, a gap is formed between the bending surface 31b (the 1 st bending surface) of the wall plate 30 and the floor portion 62 (here, the under-wall seal 64 provided on the contact surface 62 a), and water is caused to enter.
Here, the wall plate 30 is manufactured by forming a rectangular raw material 10 (the decorative steel plate) into a predetermined shape by press working. Therefore, if the press working based on the outline standard is performed using a rectangular plate material in which the error (angular tolerance) at the time of forming (cutting) the perpendicularity of the four corners is set to be extremely small as the raw material 10, the accuracy of forming the outline dimension of the formed wall plate 30 can be improved. However, in order to prepare such a raw material 10, a device having high processing accuracy and high cost is required, and an operation of measuring a processed material to investigate an error is also required, and as a result, there is a problem that the cost of a plate material as the raw material 10 increases.
Accordingly, the inventors of the present application have studied a manufacturing method capable of using, as a raw material 10, a rectangular plate material having a relatively large angular tolerance in forming (in cutting) the four corners, and capable of making the accuracy of forming the outer dimensions in press working extremely high.
(manufacturing method)
Next, a method for manufacturing the wall plate 30 according to the present embodiment will be described. The manufacturing method includes a main step of manufacturing the wall plate 30 having a predetermined shape by performing cutting/bending processing while conveying the raw material 10 on a production line. In addition, the manufacturing apparatus 100 that performs processing by one production line is used in manufacturing. Fig. 11 is an explanatory view (schematic structural view in plan view) of the manufacturing apparatus 100. In the figure, arrow X indicates the line conveyance direction.
For the raw material 10, a rectangular plate (the above-described decorative steel plate) is used. Here, regarding the shape of the "rectangle", it is desirable that the angles of the four corners are all 90 ° (±0°), but in practice, the angles of the four corners include errors (referred to as "angle tolerance" in the present application) at the time of forming (at the time of cutting processing) (that is, include not only a geometrically defined rectangle but also a substantially rectangle). In general, the smaller the angular tolerance, the more expensive the material, and the greater the angular tolerance, the cheaper the material.
According to the manufacturing method of the present embodiment, by including the following characteristic structure (step), an inexpensive rectangular plate material having a relatively large angular tolerance at the time of formation (at the time of cutting) in the perpendicularity of four corners can be used as the raw material 10. When the example of the material 10 is emphasized and illustrated in an easy-to-understand manner, even a material having a shape such as the diamond-shaped material 10 (10A) shown in fig. 12A, the trapezoid-shaped material 10 (10B) shown in fig. 12B, or the material 10 (10C) having a curvature shown in fig. 12C can be used (the shape is emphasized for the sake of illustration, and not a reduced view of the actual shape). As in the above example, as the raw material 10, a rectangular plate material having a relatively large angular tolerance with respect to the perpendicularity of four corners can be used, and specifically, rectangular plate materials having angles of four corners (angle θ1 of the 1 st corner 11, angle θ2 of the 2 nd corner 12, angle θ3 of the 3 rd corner 13, angle θ4 of the 4 th corner 14) within ±0.5° with respect to the perpendicularity (90 °) can be used, and the wall plate 30 having high external shape accuracy can be manufactured. Hereinafter, the description will be made in detail.
First, a step (A1) of preparing a rectangular plate material (plate material that allows the above-described angular tolerance) as the raw material 10 and feeding the plate material into the production line is performed. As an example, a method of placing a plurality of such plates one by one on a production line (here, on the start end 104) at a predetermined timing from the inside of the storage cabinet 102 in which the plates are stacked and stored using a conveyor (not shown) such as a feeder, or the like, may be employed. In addition, a conveyor (not shown) such as a belt conveyor is mainly used for the line conveyance of the raw material 10 thereafter. As an example, the 1 st short side 15 side is conveyed to the rotary movement unit 110 (described later) as the tip, and the 2 nd long side 18 side is conveyed from the rotary movement unit 110 as the tip, but the present invention is not limited to this configuration.
Next, after step A1, steps B1, B2, and B3 are performed in the chamfer processing section 106. As an example, the corner cutting portion 106 includes a1 st press die 160 and a 2 nd press die 170 for cutting (details will be described later). Fig. 13, 14 (a portion enlarged view) and 15 (B portion enlarged view) show examples of the shape of the raw material 10 formed by performing steps B1, B2 and B3 (plan view).
First, as a B1 step, the following steps are performed: a notch 24 including a 1 st reference line 21 is formed in a 1 st corner 11 where the 1 st short side 15 and the 1 st long side 17 intersect in the material 10 by press working (cutting working) using a 1 st press die 160, and the 1 st reference line 21 is a reference position when bending the material 10 at a bending line parallel to the 1 st long side 17. In the present application, "parallel" is not limited to "parallel" defined geometrically, but means along a predetermined direction with respect to the direction to be the object.
Further, as the B2 step, the following steps are carried out: a notch 25 including a 2 nd reference line 22 is formed in the 1 st corner 11 by press working (cutting working) using a 2 nd press die 170, and the 2 nd reference line 22 is a reference position when bending the material 10 at a bending line parallel to the 1 st short side 15.
Further, as the B3 step, the following steps are carried out: a notch 26 including a 3 rd reference line 23 is formed in the 2 nd corner 12 where the 2 nd short side 16 and the 1 st long side 17 intersect in the material 10 by press working (cutting working) using the 2 nd press die 170, and the 3 rd reference line 23 is a reference position when bending the material 10 at a bending line parallel to the 1 st long side 17.
In the present embodiment, steps B1, B2, and B3 are performed sequentially, but the present application is not limited thereto. For example, the steps B2, B1, and B3 may be performed in the order of steps. Alternatively, the 1 st press die and the 2 nd press die may be configured as a single die (not shown), and the steps B1 and B2 may be simultaneously performed as a single step.
Next, after steps B1, B2, and B3, steps C1 and C2 are performed in the short-side processing unit 108. As an example, the short-side processing unit 108 includes: a press die 130 for bending; abutment portions 132, 136 for setting reference positions at which the raw material 10 is positioned; and positioning devices 134, 138 for holding the raw material 10 from the reference position and precisely moving the same for positioning. The abutting portion 132 moves forward and backward in the left-right direction with respect to the line conveying direction, and has an abutting surface on the start end side in the line conveying direction. The abutting portion 136 moves forward and backward in the up-down direction with respect to the line conveying direction, and has an abutting surface on the start end side in the line conveying direction. However, the present application is not limited to this configuration.
First, as step C1, the 2 nd reference line 22 of the material 10 is brought into contact with the contact portion 132, and a reference position for positioning the press working position in the material 10 is set. Next, the following steps are performed: in the material 10, the 1 st bending surface 31b is formed by bending the material 10 by press working at a predetermined position (specifically, a position parallel to the 2 nd reference line 22 and apart from the predetermined position). In the present embodiment, since the end portion of the material 10 near the 1 st short side 15 is bent twice to form the bent portion 31 having the bent surface 31a and the bent surface 31b (1 st bent surface), two positions are set as the predetermined positions. Thus, the raw material 10 is moved in the same direction as the conveying direction of the production line by the positioning device 134, and the following operations are performed twice (i.e., two times): the press working (bending working) is performed while positioning the predetermined position so as to coincide with the press working position in the press die 130. In addition, "parallel" in the present application means "parallel" defined geometrically, but includes tolerance due to processing or the like.
In step C2, the 1 st bending surface 31b of the material 10 is brought into contact with the contact portion 136, and a reference position for positioning the press working position in the material 10 is set. Next, the following steps are performed: in the raw material 10, the 2 nd bending surface 32b is formed by bending the raw material 10 by press working at a predetermined position (specifically, a position parallel to the 1 st bending surface 31b and apart from the predetermined position). In the present embodiment, since the end portion of the material 10 near the 2 nd short side 16 is bent twice to form the bent portion 32 having the bent surface 32a and the bent surface 32b (2 nd bent surface), two positions are set as the predetermined positions. Thus, the raw material 10 is moved by the positioning device 138 in a direction opposite to the conveying direction of the production line, and the following operations are performed twice (i.e., two times): the press working (bending working) is performed while positioning the predetermined position so as to coincide with the press working position in the press die 130.
As a modification, a press die for performing the press working in the C1 step and a press die (not shown) for performing the press working in the C2 step may be constituted by two different dies.
Next, after steps C1 and C2, step D1 is performed in the rotary movement unit 110. As an example, the rotary movement unit 110 is configured to include a rotary movement device (not shown) that changes the conveyance direction of the production line by rotationally moving the raw material 10. As step D1, a step of rotating the raw material 10 by 90 ° in the in-plane direction is performed.
Next, after step D1, step E1 is performed in the long side processing unit 112 (112A). In addition, step E2 is performed in the long side processing unit 112 (112B). As an example, the long side processing unit 112 (112A) includes: a press die 140 for bending; an abutting portion 142 (142A, 142B) that sets a reference position at which the raw material 10 is positioned; and a positioning device 144 that pushes the raw material 10 from the reference position to move it precisely and perform positioning. In the present embodiment, the positioning device 144 has a mechanism for moving the abutting portion 142, and is configured to abut against the raw material 10 (i.e., to push the raw material 10 while being held in abutment). The abutting portion 142 moves forward and backward in the up-down direction with respect to the line conveying direction, and has an abutting surface on the terminal end side in the line conveying direction. However, the present invention is not limited to this configuration.
On the other hand, the long side processing portion 112 (112B) is configured to include: a press die 146 for bending; an abutting portion 148 (148A, 148B) for setting a reference position when positioning the raw material 10; and a positioning device 150 that pushes the raw material 10 from the reference position to precisely move and position it. In the present embodiment, the positioning device 150 has a mechanism for moving the abutting portion 148, and is configured to abut against the raw material 10 (that is, in a state of being held in abutment) by the abutting portion 148 and push the raw material 10. The abutting portion 148 moves forward and backward in the up-down direction with respect to the line conveying direction, and has an abutting surface on the start end side in the line conveying direction. However, the present invention is not limited to this configuration.
First, as step E1, the 1 st reference line 21 and the 3 rd reference line 23 of the raw material 10 are respectively abutted against the corresponding abutment portion 142 (specifically, the 1 st reference line 21 is abutted against the abutment portion 142A, and the 3 rd reference line 23 is abutted against the abutment portion 142B), and a reference position at the time of positioning the press working position in the raw material 10 is set. Next, the following steps are performed: in the raw material 10, the 3 rd bending surface 34c is formed by bending the raw material 10 by press working at a predetermined position (specifically, a position parallel to the 1 st reference line 21 and the 3 rd reference line 23 and apart from the predetermined dimension) where bending is performed. In the present embodiment, the end portion of the raw material 10 near the 2 nd long side 18 is bent three times to form the bent portion 34 having the bent surface 34a (1 st locking surface), the bent surface 34b, and the bent surface 34c (3 rd bent surface), and therefore, three positions are set as the above-described predetermined positions. Thus, the raw material 10 is moved in the same direction as the conveying direction of the production line by the positioning device 144, and the following operations are performed three times (i.e., three times): the press working (bending working) is performed while positioning the predetermined position so as to coincide with the press working position in the press die 140.
In addition, as step E2, the 3 rd bending surface 34c of the raw material 10 is abutted against the abutting portions 148 (148A, 148B), and a reference position at the time of positioning the press working position in the raw material 10 is set. Next, the following steps are performed: in the raw material 10, the 4 th bending surface 33c is formed by bending the raw material 10 by press working at a predetermined position (specifically, a position parallel to the 3 rd bending surface 34c and apart from the predetermined position). In the present embodiment, the end portion of the material 10 near the 1 st long side 17 is bent three times to form the bent portion 33 having the bent surface 33a (the 2 nd locking surface), the bent surface 33b, and the bent surface 33c (the 4 th bent surface), and therefore, three positions are set as the above-described predetermined positions. Thus, the raw material 10 is moved by the positioning device 150 in a direction opposite to the conveying direction of the production line, and the following operations are performed three times (i.e., three times): the press working (bending working) is performed while positioning the predetermined position so as to coincide with the press working position in the press die 146.
According to the method for manufacturing the wall plate 30 of the present embodiment, the following significant effects can be obtained by providing the above-described main steps in close cooperation. Specifically, since a plate material having low machining accuracy (that is, shape accuracy of the outer shape) is used as the raw material 10, for example, a rectangular plate material having an angle tolerance of 0.5 ° or less generated at the time of cutting is included in the perpendicularity of four corners, the cost of the material can be reduced. Even if such a plate material having low accuracy is used, a rectangular wall plate 30 having extremely small tolerances (machining errors) in the perpendicularity (i.e., perpendicularity of four corners) between the short side bending surface (here, the 1 st bending surface 31b and the 2 nd bending surface 32 b) and the long side bending surface (here, the 3 rd bending surface 34c and the 4 th bending surface 33 c) can be manufactured.
Therefore, a high water-stopping effect (water-penetration-preventing effect) can be obtained by simply disposing the solid dry joint material 60 in parallel with a predetermined gap in the wall portion of the entire bathroom and fitting the solid dry joint material 60 into the gap. That is, since it is not necessary to fill the gap with the liquid joint material to stop water, the wall portion can be simply installed in a short time, and the cost of site work can be reduced.
Next, the 1 st press die 160 and the 2 nd press die 170 used in carrying out the steps B1, B2, and B3 will be described in detail. Here, fig. 16 is a plan view (schematic view) of the 1 st press die 160, and fig. 17 is a plan view (schematic view) of the 2 nd press die 170.
The 1 st press die 160 of the present embodiment includes a 1 st cutting surface 162 as a cutting surface for forming the 1 st reference line 21. On the other hand, the 2 nd press die 170 of the present embodiment includes the 2 nd cutting surface 172 as the cutting surface for forming the 2 nd reference line 22, and includes the 3 rd cutting surface 174 as the cutting surface for forming the 3 rd reference line 23. Here, the 2 nd edge surface 172 of the 2 nd press die 170 is configured to be 90 ° with respect to the 1 st edge surface 162 of the 1 st press die 160, and the angular tolerance is within 0.05 °. In addition, the 3 rd edge face 174 of the 2 nd stamping die 170 is configured at 90 ° to the 2 nd edge face 172 and within an angular tolerance of 0.05 °.
Thus, the step B1 of the present embodiment includes a step of forming the 1 st cutting surface 162 into the 1 st reference line 21 by press working (cutting working) using the 1 st press die 160.
The step B2 of the present embodiment described above includes the steps of: after the raw material 10 is conveyed in the production line so as to be parallel to the 1 st reference line 21 formed in step B1 and have an error (herein, an error (offset) in the angular direction (rotational direction) in the in-plane direction in which the raw material 10 is conveyed) of 0.03 ° or less, the 2 nd edge surface 172 is formed into the 2 nd reference line 22 by press working (cutting working) using the 2 nd press die 170. That is, the 2 nd reference line 22 is processed to be 90 ° with respect to the 1 st reference line 21, and the angular tolerance is within 0.05 °.
By providing the above steps, the following significant effects can be obtained. Specifically, the bending width (here, the width dimension in the width direction of the 1 st bending surface 31 b) of the wall portion on the short side which becomes the floor side at the time of installation can be arbitrarily set. That is, a plurality of types of wall panels 30 having different external shapes (in this case, the width dimensions) can be manufactured by one manufacturing line. Further, since the raw material 10 can be cut into a shape in which the tolerance (processing error) of the perpendicularity of the 1 st reference line 21 and the 2 nd reference line 22 is extremely small, a rectangular wall plate 30 in which the tolerance (processing error) of the perpendicularity of the short side bending surface (here, the 1 st bending surface 31 b) and the long side bending surface (here, the 3 rd bending surface 34c and the 4 th bending surface 33 c) is extremely small can be manufactured. Therefore, when the wall portion is formed, a high water-stopping effect can be obtained by merely inserting the dry joint material 60 into the gap between the parallel wall panels 30.
The step B3 of the present embodiment described above includes the steps of: after the raw material 10 is conveyed in the production line so that the error (here, the error (offset) of the angular direction (rotational direction) in the in-plane direction in which the raw material 10 is conveyed) is within 0.03 ° with respect to the 1 st reference line 21 formed in the B1 step, the raw material 10 is moved so that the error (here, the error (offset) of the angular direction (rotational direction) in the in-plane direction in which the raw material 10 is conveyed) is within 0.03 ° with respect to the 2 nd reference line 22 formed in the B2 step, and the 3 rd edge surface 174 is formed into the 3 rd reference line 23 by press working (cutting working) using the 2 nd press die 170. At this time, the 3 rd reference line 23 is processed so as to be parallel to the 1 st reference line 21 and have a tolerance (herein, an error in the separation dimension) of 0.5mm or less (more preferably, 0.2mm or less).
By providing the above steps, the following significant effects can be obtained. Specifically, since the raw material 10 can be cut into a shape in which the tolerance (processing error) of the parallelism of the 1 st reference line 21 and the 3 rd reference line 23 is extremely small, a rectangular wall plate 30 in which the tolerance (processing error) of the perpendicularity of the short side bending surface (here, the 1 st bending surface 31 b) and the long side bending surface (here, the 3 rd bending surface 34c and the 4 th bending surface 33 c) is extremely small can be manufactured. Therefore, when the wall portion is formed, a high water-stopping effect can be obtained by merely inserting the dry joint material 60 into the gap between the parallel wall panels 30.
The step D1 of the present embodiment described above includes the steps of: the raw material 10 is rotated by 90 ° so that the 1 st corner 11 faces the start end side in the conveyance direction of the production line, and an error (herein, an error (offset amount) of an angular direction (rotational direction) in the in-plane direction in which the raw material 10 is generated during the rotational movement) is within 1 °.
The step E1 of the present embodiment described above includes the steps of: when the 1 st reference line 21 and the 3 rd reference line 23 are abutted against the corresponding abutting portions 142A and 142B, the raw material 10 is retracted toward the start end side in the line conveyance direction, and the raw material 10 is bent at a bending line parallel to the 1 st long side 17 and the 2 nd long side 18 at a position closer to the 2 nd long side 18 than the 1 st long side 17.
By providing the above steps, the following significant effects can be obtained. Specifically, the 1 st corner 11 used as a reference position having high accuracy (in particular, accuracy of the perpendicularity of the 1 st reference line 21 and the 2 nd reference line 22) can be positioned at any one of the left and right sides (in the present embodiment, the right side in the line conveying direction, but may be the left side) in the line conveying direction. That is, when the raw material 10 is processed, the abutting portion 132 abutting the 2 nd reference line 22 and the abutting portion 142 (142A) abutting the 1 st reference line 21 can be arranged so as to be aligned on either one of the left and right sides in the line conveying direction (in this case, the right side in the line conveying direction). Thus, the adjustment accuracy when the abutment surfaces of the two abutment portions 132, 142 (142A) are adjusted in parallel with each other can be improved.
In addition, in a state where the 1 st reference line 21 and the 3 rd reference line 23 provided on the 1 st long side 17 side are abutted against the abutting portions 142A, 142B, the 1 st reference line 21 and the 3 rd reference line 23 formed with high accuracy can be used as the reference for positioning by bending at a position closer to the 2 nd long side 18 than the 1 st long side 17, and the moving distance when the raw material 10 is moved to the press position can be made as small as possible, so that the outer dimension of the wall plate 30 can be formed with high accuracy.
As described above, the rectangular wall plate 30 having extremely small tolerances (machining errors) in the perpendicularity between the short side bending surface (here, the 1 st bending surface 31 b) and the long side bending surface (here, the 3 rd bending surface 34c and the 4 th bending surface 33 c) can be manufactured. Therefore, when the wall portion is formed, a high water-stopping effect can be obtained by merely inserting the dry joint material 60 into the gap between the parallel wall panels 30.
Further, in order to achieve the above-described operational effects, that is, in order to improve the machining accuracy (shape accuracy) of the wall plate 30, a rotary motion device having a large error (low accuracy) in the rotary motion can be used in the rotary motion portion 110, which has a great technical significance (specifically, simplification and cost reduction of the manufacturing apparatus 100).
In addition, after the E2 step, the required steps are appropriately performed. As an example, in the corner processing portions 114 (114A, 114B), steps F1, F2 are performed in which corner portions of the raw material 10 are formed into predetermined shapes by press processing. Next, step G1 is performed in which the wall plate 30 formed into a predetermined shape after the processing of the raw material 10 in the manufacturing apparatus 100 is completed is placed on the terminal 116. Next, a step H1 of conveying the wall plates 30 one by one from the production line (here, the terminal 116) into the storage cabinet 118 using a conveying device (not shown) such as a feeder, and stacking and storing the wall plates is performed. However, the process is not limited to the above-described step, and other additional processing may be performed after the F2 step. In this case, the additional processing of the wall plate 30 may be performed by providing the manufacturing apparatus 100 with a necessary mechanism, or the additional processing may be performed after the wall plate 30 is conveyed (transferred) to another manufacturing apparatus (not shown).
As described above, according to the method for manufacturing a wall plate of the present invention, a rectangular plate material having a relatively large angular tolerance in the perpendicularity of four corners and inexpensive can be used as a raw material, and a wall plate having extremely high accuracy in forming the outer dimensions can be manufactured. In this way, in a structure in which a solid dry joint material is used as a joint material without using a liquid resin, the water-stopping performance of a gap in which the joint material is fitted can be dramatically improved. Therefore, the construction work can be simplified, the construction period can be shortened, and the cost can be reduced when the wall of the whole bathroom is formed.
The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the present invention. The wall plate is preferably used when forming the wall of the integral bathroom, but needless to say, the wall plate can be used when forming a wall other than the integral bathroom.

Claims (3)

1. A method for manufacturing a wall panel, which is formed by a processing step of processing a metal plate material into a predetermined shape while conveying the plate material on a production line, wherein a sheet made of a resin material is attached to one side surface of the plate material, and the wall panel is placed in parallel with a predetermined size gap in a wall portion of an entire bathroom, and is used in a state where a water-stopping effect is generated by embedding a solid dry joint material in the gap,
the processing step includes a step A1, wherein in the step A1, rectangular plate materials with angle tolerance within 0.5 degrees generated during cutting processing are prepared in the perpendicularity of four corners,
the processing step includes, after the A1 step:
b1, forming a notch part comprising a1 st datum line at a1 st corner part where a1 st short side and a1 st long side of the plate material intersect, wherein the 1 st datum line is a datum position when the plate material is bent at a bending line parallel to the 1 st long side;
B2, forming a notch part including a 2 nd reference line at the 1 st corner part, wherein the 2 nd reference line is a reference position when the plate material is bent at a bending line parallel to the 1 st short side; and
b3 forming a notch portion including a 3 rd reference line at a 2 nd corner portion where a 2 nd short side and the 1 st long side of the plate material intersect, the 3 rd reference line being a reference position when bending the plate material at a bending line parallel to the 1 st long side,
the processing step includes, after the B1 step, the B2 step, and the B3 step:
a step C1 of pressing the plate material by pressing the plate material at a position parallel to the 2 nd reference line and apart from the 2 nd reference line by a predetermined dimension so as to form a 1 st bending surface by abutting the 2 nd reference line against an abutting portion; and
a step C2 of pressing the plate material to form a 2 nd bending surface by pressing the plate material at a position parallel to the 1 st bending surface and apart from the 1 st bending surface by a predetermined dimension,
the processing step includes a D1 step after the C1 step and the C2 step, and in the D1 step, the sheet material is rotated by 90 DEG in the in-plane direction,
the processing step includes, after the step D1:
Step E1 of pressing the 1 st reference line and the 3 rd reference line against the corresponding abutting portions, respectively, and bending the plate material by press working at a position parallel to the 1 st reference line and the 3 rd reference line and apart from the 1 st reference line by a predetermined dimension to form a 3 rd bending surface; and
e2, abutting the 3 rd bending surface against the abutting part, bending the plate material by press working at a position parallel to the 3 rd bending surface and separated from the plate material by a predetermined dimension to form a 4 th bending surface,
the step D1 comprises the following steps: the sheet is rotated by 90 DEG with an error of 1 DEG or less in such a manner that the 1 st corner is directed to the start point side of the conveying direction of the production line,
the step E1 comprises the following steps: when the 1 st reference line and the 3 rd reference line are abutted against the corresponding abutting portions, the sheet material is retracted toward the start point side in the line conveying direction, and is abutted against the sheet material, and is bent at a bending line parallel to the 1 st long side and the 2 nd long side at a position closer to the 2 nd long side than the 1 st long side.
2. A method for manufacturing a wall panel, which is formed by a processing step of processing a metal plate material into a predetermined shape while conveying the plate material on a production line, wherein a sheet made of a resin material is attached to one side surface of the plate material, and the wall panel is placed in parallel with a predetermined size gap in a wall portion of an entire bathroom, and is used in a state where a water-stopping effect is generated by embedding a solid dry joint material in the gap,
The processing step includes an A1 step, wherein in the A1 step, rectangular plate materials with angle tolerance within 0.5 degrees generated during cutting processing are prepared in the perpendicularity of four corners;
the processing step includes, after the A1 step:
b1, forming a notch part comprising a1 st datum line at a1 st corner part where a1 st short side and a1 st long side of the plate material intersect, wherein the 1 st datum line is a datum position when the plate material is bent at a bending line parallel to the 1 st long side;
b2, forming a notch part including a 2 nd reference line at the 1 st corner part, wherein the 2 nd reference line is a reference position when the plate material is bent at a bending line parallel to the 1 st short side; and
b3 forming a notch portion including a 3 rd reference line at a 2 nd corner portion where a 2 nd short side and the 1 st long side of the plate material intersect, the 3 rd reference line being a reference position when bending the plate material at a bending line parallel to the 1 st long side,
the processing step includes, after the B1 step, the B2 step, and the B3 step:
a step C1 of pressing the plate material by pressing the plate material at a position parallel to the 2 nd reference line and apart from the 2 nd reference line by a predetermined dimension so as to form a1 st bending surface by abutting the 2 nd reference line against an abutting portion; and
A step C2 of pressing the plate material to form a 2 nd bending surface by pressing the plate material at a position parallel to the 1 st bending surface and apart from the 1 st bending surface by a predetermined dimension,
the processing step includes a D1 step after the C1 step and the C2 step, and in the D1 step, the sheet material is rotated by 90 DEG in the in-plane direction,
the processing step includes, after the step D1:
step E1 of pressing the 1 st reference line and the 3 rd reference line against the corresponding abutting portions, respectively, and bending the plate material by press working at a position parallel to the 1 st reference line and the 3 rd reference line and apart from the 1 st reference line by a predetermined dimension to form a 3 rd bending surface; and
e2, abutting the 3 rd bending surface against the abutting part, bending the plate material by press working at a position parallel to the 3 rd bending surface and separated from the plate material by a predetermined dimension to form a 4 th bending surface,
the step B1 comprises the following steps: formed by press working using a 1 st press die having a 1 st edge face as an edge face for forming the 1 st reference line,
the step B2 comprises the following steps: after the sheet material is conveyed in a line so as to be parallel to the 1 st reference line formed in the step B1 and have an error of 0.03 ° or less, the sheet material is formed by press working using a 2 nd press die having a 2 nd edge surface having an angle tolerance of 0.05 ° or less with respect to the 1 st edge surface as an edge surface forming the 2 nd reference line.
3. The method of manufacturing a panel according to claim 2, wherein,
the step B3 comprises the following steps: after the sheet material is conveyed in a line so as to be parallel to the 1 st reference line and have an error of 0.03 ° or less formed in the B1 step, the sheet material is moved so as to be parallel to the 2 nd reference line and have an error of 0.03 ° or less formed in the B2 step, and is formed by press working using the 2 nd press die having a 3 rd edge surface having an angle tolerance of 0.05 ° or less with respect to the 2 nd edge surface as an edge surface for forming the 3 rd reference line.
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JP2020132966A JP6839467B1 (en) 2020-08-05 2020-08-05 How to manufacture wall panels
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JP2002294905A (en) * 2001-03-28 2002-10-09 Toto Ltd Connection structure of wall panel on internal corner part
JP2003033837A (en) * 2001-07-19 2003-02-04 Matsushita Electric Works Ltd Metal panel and method for manufacturing the same
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