JP2003096969A - Bathroom wall material and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem that a bathroom wall material having high functionality cannot be manufactured at a low cost. SOLUTION: A heat-insulating material 213 is pressed in between steel plates 211 and 212 and the heat-insulating material 213 in the proximate portion to the steel plate 211 and the steel plate 212 is softened by hotpressing the material 213 in the thickness direction. Consequently, bubbles are compressed and the heat-insulating material 213 is stuck fast to the steel materials 211 and 213. Accordingly, rigidity at the proximate portion of the steel plates 211 and 213 is increased at a time when the material 213 is cooled and solidified, and a screw can be screwed firmly. Since the surface of the material 213 is welded to the steel plates 211 and 213, a working process for bonding with each steel plate is not required.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a bathroom wall material and a method for manufacturing a bathroom wall material.

[0002]

2. Description of the Related Art As a conventional bathroom wall material, there is known a material in which a plaster board or a heat insulating material is adhered to the back surface of a metal plate, or a material in which a urethane layer is wet-formed on the back surface of the metal plate.

[0003]

The above-mentioned conventional bathroom wall material has the following problems. In the case of a bathroom wall material equipped with a gypsum board, the rigidity of the wall surface can be secured, but the water resistance is low and the cost at the time of disposal is high. Further, in the case of a bathroom wall material provided with a heat insulating material, it is possible to secure heat insulating property, but it is not possible to secure the rigidity of the wall surface.

[0006] In addition, in the case of a bathroom wall material having a gypsum board and a bathroom wall material having a heat insulating material, a bonding step to the surface material is required, so that the manufacturing cost is increased. There was also a problem that Furthermore, in the case of a bathroom wall material provided with a urethane layer, warping may occur due to resin contraction, or the urethane layer may become non-uniform. Further, if foaming control is performed to ensure rigidity on the wall surface, there is also a problem that the manufacturing cost increases. The present invention has been made in view of the above problems, and an object of the present invention is to provide a bathroom wall material with low cost and high functionality, and a method for manufacturing the bathroom wall material.

[0005]

In order to achieve the above-mentioned object, the invention according to claim 1 is a bathroom wall material forming a wall surface of a bathroom, and is a heat insulating material composed of a thermoplastic resin between a pair of metal plates. The material is sandwiched and heat-pressed in the thickness direction. That is, the bathroom wall material is formed by sandwiching a heat insulating material made of a thermoplastic resin between a pair of metal plates and hot pressing in the thickness direction.
At this time, the heat applied to each metal plate is transferred to the heat insulating material, so that the heat insulating material is pressed in the thickness direction while being softened at a portion close to the metal plate. Then, when the heat insulating material is cooled, it solidifies in a state of being pressed in the thickness direction, so that the rigidity of the pressed portion increases while softening.

Therefore, when the wall surface is formed by the bathroom wall material, even if the metal plate is screwed or the like, the screw is firmly screwed to the portion where the rigidity is increased. In addition,
When performing the hot pressing, temperature and pressure control are effective in order to increase the rigidity of the bathroom wall material while ensuring the heat insulating property of the heat insulating material as much as possible.
That is, when temperature control is performed during hot pressing, the softening range of the heat insulating material can be adjusted to set the region where the resin density is increased to a desired range. Further, if the pressure is controlled during the hot pressing, the resin density after pressing can be set in a desired range. Therefore, a bathroom wall material having desired heat insulation performance and rigidity can be easily obtained.

As an example of the heat insulating material mentioned here, claim 2
The invention according to claim 1 is the bathroom wall material according to claim 1,
The heat insulating material is foam-molded. That is, the heat insulating material, when hot pressed, by pressing while softening the vicinity of the metal plate,
The bubbles are compressed in the thickness direction. Therefore, the area close to the metal plate has a high density, and the rigidity can be enhanced more effectively. Further, in claim 1 or claim 2, when the heat insulating material is pressed while being softened, a surface of the heat insulating material adheres to the metal plate. Therefore, when cooled, the surface of the heat insulating material solidifies in a state of being in close contact with the metal plate. Therefore, even if the heat insulating material is not separately bonded to the metal plate, the heat insulating material can be easily welded to the metal plate only by performing hot pressing.

It is also possible to provide an additional structure in order to strengthen the welding of the heat insulating material to the metal plate. As an example thereof, the invention according to claim 3 is the bathroom wall material according to claim 1 or claim 2, wherein the metal plate is provided with a protrusion projecting toward the facing metal plate. There is. That is, when hot pressing is performed, the protrusions protruding from the surface of the metal plate bite into the softened heat insulating material, and thus when cooled, the heat insulating material solidifies while holding the projections inside. Therefore, the welding of the heat insulating material to the metal plate becomes stronger.

As described above, in the present invention, since the heat insulating material is welded to the metal plate by the hot press, the respective members constituting the bathroom wall material are integrated, but the assembled state of the respective members is changed. It is also possible to provide an additional configuration for a more reliable one. As an example thereof, the invention according to claim 4 is the bathroom wall material according to any one of claims 1 to 3, wherein the metal plate is provided with a side wall standing by bending a peripheral portion, The side wall of one metal plate is press-fitted into the inner side wall of the other metal plate by the heat pressing. That is, the side wall which is bent and erected is formed at the peripheral portion of each metal plate. Here, the outer surface dimension of the side wall of one of the metal plates is
Since it is almost equal to the inner surface dimension of the side wall of the other metal plate,
During the hot pressing, the side wall of one metal plate is press-fitted inside the side wall of the other metal plate. Therefore, the metal plates are firmly assembled to each other.

As a structural example for further strengthening the assembled state of the metal plates, the invention according to claim 5 is the bathroom wall material according to claim 4, wherein the side wall of one of the metal plates is the side wall. The side wall of the other metal plate and the side wall of the other metal plate are crimped to each other on the tip side. That is, when the side wall of the one metal plate is inserted inside the side wall of the other metal plate, the tip ends of the side walls are caulked and fixed to each other. Then, since the inserted side wall does not move in the thickness direction of the bathroom wall material,
Assembling of metal plates becomes stronger.

It is also possible to make the assembled state of the metal plates stronger by another method. As an example thereof, in the invention according to claim 6, in the bathroom wall material according to claim 4 or 5, an engaging hole is provided in a side wall of the one metal plate, and the other of the other metal plates is provided. The side wall of the metal plate is provided with a tongue piece that is formed by making a substantially U-shaped cut at a portion facing the engagement hole. That is, when the side wall of the one metal plate is inserted inside the side wall of the other metal plate, the tongue provided on the side wall of the other metal plate is provided on the side wall of the same metal plate. Since the tongue piece faces the engagement hole, the tongue piece is pushed from the outside toward the engagement hole. Then, since the tongue piece engages with the engagement hole, the same press-fitted side wall cannot move in the thickness direction of the bathroom wall material, and the metal plates are more firmly assembled.

Further, the method for manufacturing the bathroom wall material having the above-mentioned structure is also useful.
As an example thereof, the invention according to claim 7 sandwiches a heat insulating material composed of a thermoplastic resin between a pair of metal plates,
While heating the same metal plate so as to soften the vicinity of each metal plate in the heat insulating material, the metal plates are pressed in a direction in which they approach each other, after pressing until the heat insulating material has a predetermined thickness, The metal plate and the heat insulating material are cooled. That is, the bathroom wall material described in claims 1 to 6 can be easily manufactured by adopting the method of claim 7, which is useful for reducing the manufacturing cost. Becomes

[0013]

As described above, the present invention can provide a bathroom wall material having low cost and high functionality. According to the invention of claim 2, the rigidity of the heat insulating material can be effectively increased. Further, according to the invention of claim 3, the heat insulating material can be more firmly welded to the metal plate. Further, according to the inventions of claims 4 to 6, the assembled state of each member constituting the bathroom wall material can be made stronger. Further, according to the invention of claim 7, it is possible to provide a method for manufacturing a bathroom wall material having low cost and high functionality.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Here, embodiments of the present invention will be described in the following order. (1) Composition of bathroom: (2) Composition of wall material: (3) Manufacturing process of wall material: (4) Composition of wall material according to first modification: (5) Composition of wall material according to second modification Composition: (6) Summary:

(1) Structure of bathroom: FIG. 1 is a perspective view showing a schematic external view of a bathroom according to this embodiment, and FIG. 2 is an exploded perspective view showing components of the bathroom. The bathroom is
The floor material 100, a wall surface unit 200 standing upright so as to surround the floor material 100 from four sides, and a ceiling material 300 that seals an opening formed above the floor material 100 are formed in a rectangular housing shape. A bathtub 400 is housed inside. Here, the wall surface unit 200 includes a plurality of wall members 210.
Are installed side by side and assembled to form a wall surface on each side of the floor material 100.

(2) Construction of wall material: The construction of the wall material 210 will be described below. As shown in FIG. 3, the wall material 210 includes a rectangular steel plate 211 forming an inner wall of the bathroom, a rectangular steel plate 212 forming an outer wall of the bathroom, and a steel plate 21.
Rectangular heat insulating material 213 sandwiched between 1 and 212
It has and. The heat insulating material 213 here is formed by foaming a thermoplastic resin such as polystyrene resin or PET resin. Near the center in the thickness direction,
While air bubbles are left as they were at the time of forming, each steel plate 2
On the side close to 11 and 212, air bubbles are compressed to increase rigidity, and the surface is welded to each steel plate 211 and 212.

(3) Manufacturing process of wall material: Next, a manufacturing process of the wall material having the above structure will be described. The heat insulating material 213 is sandwiched between the steel plates 211 and 212. Then, as shown in FIG. 4, the heating press device 500 in which the press parts 510 and 520 are heated is pressed in the thickness direction. Then, the steel plates 2 are pressed by the press parts 510 and 520.
11 and 212 are heated. Therefore, due to the heated steel plates 211 and 212, the heat insulating material 213 is softened at a portion close to the steel plates 211 and 212 as shown in FIG.

Therefore, the heat insulating material 213 is made of the steel plates 211 and 211.
Since the part close to 12 is pressed while being softened,
The bubbles are compressed. In addition, the softened surface portion is the steel plate 2
Steel plates 211, 21 due to being pressed against 11, 212
Stick to 2. Here, when the wall material 210 is pressed to a predetermined thickness, the press parts 510 and 520 are separated from the steel plates 211 and 212. Then, the steel plate 21
Along with the cooling of the sheets 1 and 212, the portions of the heat insulating material 213 that are close to the steel plates 211 and 212 are cooled and solidified while maintaining the shape at the time of pressing.

As described above, the heat insulating material 213 is the steel plate 21.
Since air bubbles are compressed in the vicinity of the steel plates 211 and 212 to increase the rigidity, when fixing screws from the steel plates 211 and 212 side,
It is possible to firmly screw the screw into the heat insulating material 213 having increased rigidity. Further, since the surface of the heat insulating material 213 is welded to the steel plates 211 and 212, each steel plate 21
It is also useful in that it is not necessary to provide a work process for bonding to 1 and 212. In the present embodiment, the steel plate 21
Although the heat insulating material 213 is sandwiched by 1 and 212, from the viewpoint that it can be heated and pressed, the rigidity is such that it can be sandwiched between the pressed portions 510 and 520, and it is provided from the pressed portions 510 and 520. Any plate material may be used as long as it has heat conductivity enough to transfer heat to the heat insulating material 213. For example, an aluminum plate or the like may be used instead.

(4) Structure of wall material according to first modification: As described above, the heat insulating material 213 is made of steel plates 211 and 212.
Are welded to the steel plates 211 and 212 by heating and pressing in opposite directions, it is possible to provide an additional structure so that the welding becomes stronger. That is, as shown in FIG. 6, a plurality of protrusions 211a and 212a are formed on the surfaces of the steel plates 211 and 212 in advance. Then, when being heated and pressed, the protrusions 211a and 212a bite into the softened heat insulating material 213, so that the heat insulating material 2
13 is in close contact with the steel plates 211 and 212 while holding the protrusions 211a and 212a inside. Therefore, the structure is useful in that stronger welding is possible.

(5) Structure of wall material according to second modification: It is also possible to provide an additional structure for more firmly assembling the steel plates 211 and 212. That is, as shown in FIG. 7, the side walls 211b and 212b are erected by bending the peripheral edge portions of the steel plates 211 and 212, respectively.
The 12 side walls 211b and 212b are heated and pressed until they overlap each other. Then, as shown in FIG. 8, since the side wall 212b of the steel plate 212 is press-fitted into the opening 211c of the steel plate 211, the steel plates 211 and 212 are firmly assembled. Of course, the side walls 211b, 2 of each steel plate 211, 212
It goes without saying that the side walls 212b of the steel plate 212 may be press-fitted into the openings 211c of the steel plate 211 from the tip side by hot pressing while facing the 12b.

Further, as shown in FIG. 8, when the side walls are press-fitted, the tip ends of the side walls are crushed together in the thickness direction,
The side walls 211b, 21 are rolled or bent.
It is also possible to crimp 2b together. Then, it becomes possible to carry out a stronger assembly. Furthermore, each steel plate 21
It is also possible to add a structure for engaging the 1 and 212 with each other. That is, as shown in FIG.
Engagement holes 212b1 are provided in the side walls 212b of the members 11, 212, and a tongue piece 211b1 is provided by making a U-shaped cut in the side wall 211b of the steel plate 211. With this configuration,
When heated and pressed, the tongue piece 211b1 is engaged with the engagement hole 212b.
As shown in FIG. 10, the tongue pieces 211b face each other.
1 is pressed from the outside and pushed into the engagement hole 212b1.
Then, the tongue piece 211b1 engages with the engagement hole 212b1, so that the steel plates 211 and 212 can be firmly assembled.

(6) Summary: In the present embodiment, the steel plate 21
1 and the steel plate 212 while sandwiching the heat insulating material 213 between them and heat-pressing in the thickness direction.
The heat insulating material 213 in the vicinity of 12 is softened and pressed. Therefore, in the heat insulating material 213, air bubbles are compressed and adhere to the steel plates 211 and 212. Therefore, when cooled and solidified, the heat insulating material 213 has increased rigidity in a portion close to the steel plates 211 and 212, and the screws can be firmly screwed together. The surface of the heat insulating material 213 is the steel plate 21.
Since it is welded to the steel plates 1 and 212, it is not necessary to provide a work process for adhering to the steel plates 211 and 212.

[Brief description of drawings]

FIG. 1 is a perspective view showing a schematic appearance of a bathroom according to this embodiment.

FIG. 2 is an exploded perspective view showing components of a bathroom.

FIG. 3 is a perspective view showing an appearance of a wall material.

FIG. 4 is a side view showing a situation during hot pressing.

FIG. 5 is a side view showing a portion which is softened by heating the press portion.

FIG. 6 is a perspective view showing a situation in which a wall material is formed using a steel plate having projections on its surface.

FIG. 7 is a perspective view showing a situation in which a wall material is formed using a steel plate provided with side walls.

FIG. 8 is a cross-sectional view showing a configuration of a wall material formed by using a steel plate having a side wall.

FIG. 9 is a perspective view showing a situation in which an engagement structure is provided between steel plates to form a wall material.

FIG. 10 is a cross-sectional view showing a configuration of a wall material formed by using a steel plate having an engagement structure.

[Explanation of symbols]

100 ... Floor material 200 ... Wall unit 210 ... Wall material 211, 212 ... Steel plate 211a, 212a ... Protrusion 211b, 212b ... Side wall 211b1 ... tongue 211c ... Opening 212b1 ... Engagement hole 213 ... Insulation material 300 ... Ceiling material 400 ... Bathtub 500 ... Heating press device 510, 520 ... Press section

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) E04H 1/12 301 E04H 1/12 301 // B29L 7:00 B29L 7:00 9:00 9:00 9:00 F term (reference) 2E025 BA01 BB05 BC01 2E162 CB01 CD01 4F100 AB01A AB01C AB03 AB10 AK01B AK12 AK42 BA03 BA06 BA10A BA10C DB07A DC11C DD03A DD03C DJ01B EJ202 EJ422 EJ503 GB08 JB16B JJ03B 4F211 AD03 AD08 AD17 AD24 AE02 AG02 AG03 AH48 AH49 TA01 TC02 TD11 TH02 TH06 TH17 TQ01 TQ04

Claims (7)

[Claims] 1. A bathroom wall material for forming a wall surface of a bathroom, which is characterized in that a heat insulating material made of a thermoplastic resin is sandwiched between a pair of metal plates and heat-pressed in a thickness direction. Bathroom wall material. 2. The bathroom wall material according to claim 1, wherein the heat insulating material is foam-molded. 3. The bathroom wall material according to claim 1, wherein the metal plate is provided with a protrusion projecting to the side of the metal plate facing the metal plate. 4. A side wall of the metal plate is bent so that its peripheral portion is bent, and the side wall is erected. The side wall of one metal plate is press-fitted into the side wall of the other metal plate by the heat pressing. The bathroom wall material according to any one of claims 1 to 3. 5. The bathroom wall material according to claim 4, wherein the side wall of the one metal plate and the side wall of the other metal plate are caulked on the tip side of each other. 6. An engaging hole is provided in a side wall of the one metal plate, and a side wall of the other metal plate is provided.
The bathroom wall material according to claim 4 or 5, wherein a tongue piece formed by cutting a substantially U-shaped cut is provided at a portion facing the engagement hole. 7. A heat insulating material made of a thermoplastic resin is sandwiched between a pair of metal plates, and the metal plates are heated so as to soften a portion of the heat insulating material close to each metal plate,
A method for manufacturing a bathroom wall material, characterized in that the metal plates are pressed in a direction in which they are close to each other, the heat insulating material is pressed to a predetermined thickness, and then the metal plate and the heat insulating material are cooled.