JP2001293710A - Method for manufacturing wall panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a wall panel capable of forming a heat insulation reinforcing layer by using a gypsum material even when a decorative panel has a complicated shape without increasing expenses to treat an industrial waste even by using the gypsum material as the reinforcing layer on a rear surface of the panel. SOLUTION: The method for manufacturing the wall panel comprises the steps of forming the decorative panel by standing a frame edge on a peripheral edge of a rear surface of a decorative board, casting a liquid-like foamable gypsum material in a part surrounded by the frame edge from above the rear surface of the decorative panel, and forming a foaming layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a wall panel used for a bathroom unit or the like.

[0002]

2. Description of the Related Art Conventionally, bathroom units and toilet units have been installed in houses and the like. The bathroom unit is integrated with or separate from the waterproof pan forming the washing area, and a bathtub, and a wall panel that stands on the periphery of the waterproof pan and surrounds the periphery of the waterproof pan and the bathtub of the bathroom. And a ceiling panel that covers an upper opening formed by the wall panel.

[0003] Wall panels used in such bathroom units and toilet units include, for example, a decorative vinyl chloride steel plate obtained by laminating a vinyl chloride film on a steel plate, and a decorative layer on the surface of an inorganic base material such as a cement plate or a calcium silicate plate. Is widely used as a decorative panel for a wall panel. Wall panels have been manufactured by attaching a gypsum board to the back surface of these decorative PVC steel sheets or inorganic laminate decorative boards for the purpose of reinforcement or heat insulation.

[0004]

However, in recent years, there has been a problem that it is enormous and expensive to remove the gypsum board made of paper and gypsum material and to dispose of the paper. Further, since the shape of the decorative panel has become complicated due to the diversification of products of the bathroom unit, there is a problem that it is difficult to attach a plate-shaped gypsum board.

In view of such circumstances, the present invention does not increase the cost of treating industrial waste even if gypsum material is used as a heat insulating and reinforcing layer on the back surface of a wall panel.
It is another object of the present invention to provide a method of manufacturing a wall panel capable of forming a heat insulating and reinforcing layer using a gypsum material even if the decorative panel has a complicated shape.

[0006]

In order to achieve the above object, a method of manufacturing a wall panel according to the first aspect of the present invention (hereinafter referred to as a "method of manufacturing a wall panel of the first aspect"). Forms a decorative panel by erected a frame edge at the periphery of the rear surface of the decorative panel, and pours a liquid foamable gypsum material from above the rear surface of the decorative panel into a portion surrounded by the frame edge to form a foam layer. It is characterized by doing.

[0007] The decorative plate used in the present invention includes a PVC decorative steel plate obtained by laminating a vinyl chloride film on a steel plate, and an inorganic laminate plate provided with a decorative layer on the surface of an inorganic base material such as a cement plate or a calcium silicate plate. It is preferably used. In the case of a decorative panel made of PVC, a decorative panel made of a decorative sheet made of PVC is used in which a peripheral edge is bent to the back side to form a frame edge, and in the case of an inorganic laminate, it is cut. A frame having a frame edge formed by attaching a reinforcing frame to the peripheral edge of the back surface of the inorganic laminated plate is used.

As the expandable gypsum material used in the present invention, a powder mainly composed of calcined gypsum is preferably used. When this calcined gypsum and water are mixed, a foaming gas is generated by the reaction, and a liquid foaming gypsum material is obtained.

In the present invention, the foaming ratio of the foamed layer is not particularly limited, but is suitably 1.1 to 7.0 times. In particular, when used as a reinforcing material:
The ratio is preferably from 1 to 3.0 times, and when used as a heat insulating layer, the ratio is preferably from 2.0 to 7.0 times.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a wall panel manufactured by a method of manufacturing a wall panel according to a first embodiment of the present invention.

In the drawing, reference numeral 1 denotes a decorative board, and this decorative board 1
The decorative panel 3 is configured by the frame edge 2 standing upright on the back peripheral edge 11. A foam layer 4 made of a gypsum material is formed in a portion surrounded by the frame edge 2 of the decorative panel 3.

The decorative plate 1 is made of a calcium silicate plate and a thermosetting resin-impregnated paper such as diallyl phthalate (DAP) resin is heat-pressed on the surface of the plate and has a thickness of 5.0 mm.
It is cut into a flat plate having a width of 900 mm and a length of 1800 mm.

The frame edge 2 is formed by cutting a steel reinforcing frame having a height of 10 mm and a width of 10 mm so as to match the width and length of the decorative board 1.

In order to manufacture a wall panel using the decorative panel 3, first, the decorative panel 1 is made of a powder of calcined gypsum from above the back surface of the decorative panel 3 with the decorative surface front side down. A liquid foaming gypsum material obtained by continuously mixing the body and water is poured. At this time, the calcined gypsum and the water react during the mixing to form a 3.0-fold foamed liquid gypsum material. The foamed liquid gypsum material is poured from above the back surface of the decorative panel 3 into the central portion surrounded by the frame edge 2, and is evenly adjusted to a uniform thickness until the level of the frame edge 2 made of a steel reinforcing frame is reached. And cure and harden.

[0015] The wall panel manufactured by the above method does not use paper unlike the gypsum board in the reinforcing and heat insulating layer, so that it can be easily treated as industrial waste.

FIG. 2 shows a wall panel manufactured by a method for manufacturing a wall panel according to a second embodiment of the present invention.

As shown in FIG. 2, reference numeral 1a denotes a decorative plate made of a PVC decorative steel plate. The decorative panel 3a is formed by bending the short side end and the long side end of the decorative plate 1a toward the back surface to erect the frame edge 2a. A foam layer 4a made of a gypsum material is formed in a portion surrounded by the frame edge 2a of the decorative panel 3a.

As the decorative plate 1a, a decorative vinyl chloride steel plate obtained by laminating a 200 μm-thick vinyl chloride film on a 450 μm-thick hot-dip galvanized steel plate and cutting it into a predetermined size and shape is used. And this decorative board 1a
On the vinyl chloride film side, which is the surface of the vinyl chloride decorative steel sheet, three elongated joint-shaped concave portions 12a are formed in the longitudinal direction by pressing into vertical stripe joints.

Decorative plate 1a made of the steel plate with the joint pattern
2 has a width W, for example, as shown in FIG.
Is 3 mm, the depth H is formed to be 3 mm, and the long side end 11a and the short side end (not shown) of the decorative board 1a formed from the jointed steel sheet are bent at a right angle. The frame edge 2a stands upright, and the joint-shaped concave portion 1 of the decorative board 1a is provided.
The joint-like convex portion 12b is formed so as to protrude on the back surface side corresponding to 2a.

In order to manufacture a wall panel using the decorative panel 3a, first, the decorative panel 1a is placed on the back side of the decorative panel 3a with the front side of the decorative surface facing downward, and the frame edge 2a is set from above.
A foamable gypsum material, which has been foamed 3.0 times as in the first embodiment, is poured into the central portion surrounded by. The cast gypsum foam material is leveled to the level of the frame edge 2a of the decorative panel 3a, a polypropylene film 5a having a thickness of 25 μm is laminated thereon, and then cured and cured.

The wall panel manufactured by the method of the second embodiment differs from the plaster board in that the reinforcing and heat insulating layers are different from the gypsum board even if the joint-like convex portion 12b is formed to project from the back side of the decorative panel. Since the layers are laminated in close contact with the back surface of the panel, they do not peel off.

The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific embodiment is not limited to this embodiment, and a design change or the like may be made without departing from the gist of the present invention. Even if present, it is included in the present invention. For example, as shown in FIG. 3, a paper honeycomb 6 is spread on a portion surrounded by the frame edge 2 on the back surface of the decorative panel 3, and then a liquid foaming gypsum material is poured to form a foam layer. Is also good. In this case, since the paper honeycomb 3 can improve the bending strength as a reinforcing core material of the foamed layer, the foaming ratio of the foamed layer can be increased to reduce the weight.

[0023]

According to the method for manufacturing a wall panel of the present invention, a decorative panel is formed by erection of a frame edge on a peripheral edge of a rear surface of a decorative panel, and a liquid foaming gypsum material is formed from above the rear surface of the decorative panel. Since it is a structure in which a foam layer is formed by pouring into a portion surrounded by a frame edge, even if gypsum material is used as a heat insulating and reinforcing layer on the back surface of the wall panel, it is expensive to treat industrial waste. Moreover, it is possible to manufacture a wall panel capable of coping with a complicated shape of a decorative panel.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing a first embodiment of a wall panel manufactured by the method of the present invention.

FIG. 2 is a schematic sectional view showing a second embodiment of a wall panel manufactured by the method of the present invention.

FIG. 3 is a perspective view illustrating a modification of the embodiment.

[Explanation of symbols]

 1, 1a decorative board 2, 2a frame edge 3, 3a decorative panel 4, 4a foam layer

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2E001 DD01 DH39 FA06 FA07 FA42 GA07 GA08 GA12 GA13 GA17 GA42 GA44 GA52 GA82 HA01 HA03 HA21 HB02 KA03 LA05 LA10 4G052 AB03 AB05 AB42 DA01 DA08 DB12 DC06

Claims (1)

[Claims] A decorative panel is formed by erecting a frame edge around the back surface of the decorative panel, and a liquid foaming gypsum material is poured into a portion surrounded by the frame edge from above the rear surface of the decorative panel, and foaming is performed. A method for manufacturing a wall panel, comprising forming a layer.