JP2003326324A - Method and device for manufacturing building panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a building panel manufacturing method and device that dispenses with drilling a hole for inserting a tool into a panel member and that thereby facilitate charging of a liquid filler. <P>SOLUTION: The device is composed of a box like fixing block 15 which stores/arranges a pair of panels 2, 3 formed in a flat square tubular frame, with the connecting fitting parts 2a, 3a projecting inwardly to each other; a device body 16 which, travelling inside both panels 2, 3 stored in the fixing block 15, caulks the inwardly projecting connecting fitting parts 2a, 3a of both panels 2, 3 by pressing the fitting parts against the inner face of the panel 2 or 3; and a caulking unit K2 which fixedly caulks both ends of the panels 2, 3 and the partially engaged part of a metallic end-blocking member 4 partially engaged at both ends. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a building panel used as a floor material, a roof material, a wall material, etc. of a building and an apparatus for the same.

[0002]

2. Description of the Related Art Conventionally, as this type of building panel, there is one disclosed in Japanese Patent Application Laid-Open No. 5-237962. In this panel, a pair of panel members formed by bending a metal plate around the U-shape are joined by rivets in a state where the bent portions are in contact with each other to form a panel body. It is a structure that is filled.

[0003]

In the above-mentioned conventional construction panel, a pair of panel members whose peripheral portions are bent and formed in a U-shape are joined by rivets in a state in which mutually bent inward protruding portions are in contact with each other. In order to rivet-connect the inwardly projecting bent parts in contact with each other, it is necessary to make many holes for inserting rivet tools in the required parts of one panel member. Therefore, when the liquid filling material is filled in the panel body, the filling work is difficult because the holes easily leak from the rivet tool holes. Further, since many holes are exposed on the surface of the panel, the appearance of the panel is not good and it may not be used depending on the installation location of the panel.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for manufacturing a building panel and an apparatus therefor which do not need to make a hole for inserting a tool in a panel member and can easily fill a liquid filler. To do.

[0005]

The invention according to claim 1 is
A pair of panel members 2 and 3 each having a metal plate formed in a substantially U-shaped cross section and having engagement fitting portions 2a and 2b projecting inward at both side edges in the longitudinal direction are joined together. The panel body is hermetically sealed by being joined by caulking with the fitting portions engaged, and the open end portions of the joined panel members 2 and 3 are each closed by the metal end closing member 4. A method of manufacturing a building panel, wherein the following steps are performed. Step of forming a pair of panel members 2 and 3 by forming a metal plate in a substantially U-shaped cross section and projecting inwardly the joining engaging portions 2a and 2b at both ends in the longitudinal direction The pair of panel members 2, 2 and 3 are overlapped with each other so that the joint engaging portion 2a of one panel member 2 and the joint engaging portion 3a of the other panel member 3 project inward from each other. Step of forming 3 into a flat box-cylinder frame shape A pair of panel members 2 and 3 formed into a flat box-cylinder frame shape as described above are housed and arranged in the box-shaped fixed block 15, and thus the fixed block 15 is formed. While the apparatus main body 16 is running inside the panel members 2 and 3 housed inside, the fitting engaging portions 2 for joining the panel members 2 and 3 that protrude inward from each other.
Step of forming a caulked portion K1 by press-contacting a and 3a to the inner surface of the panel member 2 or 3 Both panel members 2, 3 in which the joining engaging portions 2a, 3a are caulked and joined by the above steps A part of the metal end closing member 4 is fitted on both ends of the both panel members 2,
3 is a step of caulking and fixing both end portions of 3 and the part of the end closing member 4 which are fitted, and forming the caulking portion K2 so that the caulking portion is depressed inward from the surfaces of the panel members 2 and 3.

According to a second aspect of the present invention, there is provided a pair of panel members, each of which is formed by forming a metal plate in a substantially U-shaped cross section and at both side edge portions in a longitudinal direction of the engaging engaging portions protruding inward. , The panels are joined together by caulking with the joining engaging portions engaged with each other, and the open ends of the joined panel members are closed by metal end closing members, respectively, to form a hermetically sealed panel. An apparatus for manufacturing a building panel, in which a main body is formed, wherein a pair of panel members (2, 3) are overlapped with each other and a joint engagement portion (2a) of one panel member (2) and a joint member of another panel member (3) are joined. A box-shaped fixing block 15 for accommodating and arranging a pair of panel parts 2 and 3 formed in a flat box-cylinder frame shape so that the fitting part 3a protrudes inward from each other,
Both panel members 2 and 3 housed in the fixed block 15.
An apparatus main body 16 that crimps the inner engagement surfaces 2a and 3a of the panel members 2 and 3 protruding inwardly against each other while pressing the inner surface of the panel member 2 or 3 while traveling inside
Both ends of both panel members 2 and 3 in which the engaging fitting portions 2a and 3a for joining are crimped and joined to each other, and a partially fitted portion of the metal end closing member 4 partially fitted to both ends. And a caulking device K2 formed by caulking and fixing the caulking part K2 so that the caulking part K2 is recessed inward from the surfaces of the panel members 2 and 3.

[0007]

1 is a perspective view showing a building panel 1 according to the present invention, FIG. 2 is a cross-sectional view of the panel 1, and FIG. 3 is a building panel viewed from the direction of arrow X in FIG. 1 is a partially sectional enlarged side view of FIG. 1, FIG. 4A is an enlarged detailed sectional view of a portion surrounded by a circle shown by an arrow Y in FIG. 3, and FIG. 4B is an enlarged detailed plan view thereof. Further, FIGS. 5A to 5C and FIG.
FIG. 4A is a cross-sectional view showing a manufacturing process of panel 1. As can be seen by referring to these drawings, this building panel 1
A pair of upper and lower panel members 2 and 3 formed by bending a metal plate into a substantially U-shaped cross section and forming engaging engaging portions 2a and 3a on both side edges in the longitudinal direction thereof so as to project inwardly.
Are joined by crimping the joining engaging portions 2a and 3a to each other, and a pair of end closing members 4 and 4 are respectively provided at both ends of the panel members 2 and 3 thus joined. A hermetically-sealed panel body 5 is formed by joining, and a required filler 6 is filled in the hermetically-sealed panel body 5.

As shown in FIG. 5 (A), the upper panel member 2 of the pair of upper and lower panel members 2 and 3 is formed in a generally downwardly U-shaped cross section, and is formed on both side edges in the longitudinal direction thereof. The engaging engagement portions 2a, 2a each having an I-shaped cross section are formed so as to project inward in a mutually opposing direction, and the lower side panel member 3 is formed in a generally U-shaped cross section.
On both side edges of the longitudinal direction, joining engaging portions 3a, 3a having a substantially U-shaped cross section which can be engaged with the engaging engaging portions 2a, 2a of the upper side panel member 2, respectively, face inward and face each other. Is formed so as to protrude.

Therefore, the engaging engaging portion 2a of the upper side panel member 2 and the engaging engaging portion 3a of the lower side panel member 3 are crimped in a mutually engaged state, whereby both the upper and lower panel members 2, 2. 3 are integrally joined. In FIG. 1, FIG. 2 and FIG. 5 (C), the caulking joint portion in which the joint engaging fitting portions 2a, 3a of both panel members 2, 3 are caulked with each other is indicated by K
It shows with 1. In this case, by interposing a heat insulating sheet material between the joining engaging portion 2a of the upper side panel member 2 and the joining engaging portion 3a of the lower side panel member 3, both the upper and lower parts are interposed via this heat insulating sheet material. The heat bridge between the panel members 2 and 3 can be blocked. Each panel member 2, 3
The width is 500 to 1500 depending on a thin metal plate (black skin, plated steel plate, various steel plates such as color coated steel plate, or stainless steel plate or aluminum plate) of about 0.5 to 2.3 mm.
The length is about 1000 mm and the length is about 1000 to 3000 mm.

As shown in FIGS. 1 and 3, each end closing member 4 is formed in a U-shaped cross section consisting of upper and lower plate portions 7 and 8 and a horizontal plate portion 9 connecting both plate portions 7 and 8. With the lateral plate portion 9 facing inward, the panel members 2 and 3 and the upper and lower plate portions 7 are partially fitted into the ends of the upper and lower panel members 2 and 3 joined to each other. , 8 are joined to the end portions of both panel members 2, 3 by caulking. Figure 1
Also, FIG. 4 shows the upper plate portion 7 of the panel member 2 and the end closing member 4.
The swaged portion of the is indicated by K2. 4A is an enlarged vertical sectional view of the caulking portion K2, and FIG. 4B is a plan view of the caulking portion K2. As can be seen from these drawings,
The caulking portion K2 is formed so as to protrude inward of the panel member 2 and the surface of the panel member 2 is depressed. Although not shown, the caulking portion between the panel member 3 and the lower plate portion 8 of the end closing member 4 is the same as the caulking portion K2.

Each of the end block members 4 is usually formed of a steel plate thicker than the panel members 2 and 3, but may have any plate thickness depending on the size of the panel 1 and the like.
Further, as shown in FIG. 1, for example, two panel mounting bolt holes 10 are provided in the lower plate portion 8 of each end closing member 4, and the upper plate portion 7 is used for mounting each panel of the lower plate portion 8. Bolt hole 1
A bolt tightening work hole 11 is cut out at a position directly above 0. Further, as shown by the dotted line in FIG. 1, one of the both end portion closing members 4 and 4 has a filling hole 12 for filling the filling material 6 into the panel main body 5, and an air hole. A hole 13 is provided.

As shown in FIG. 2, a metal frame member 14 made of a steel plate having a substantially Z-shaped cross section is interposed between the panel members 2 and 3 to be joined to each other and extends in the longitudinal direction of the panel. The frame member 14 having a substantially Z-shaped cross section has an upper support piece 14a.
Is in contact with the lower surface of the panel member 2, and the lower support piece 14
b is brought into contact with the upper surface of the panel member 3, and is caulked to the panel members 2 and 3 in the same manner as in the case where the end closing member 4 and the panel members 2 and 3 are caulked. Although not shown, the frame body 14 is provided with communication openings at required intervals so that the left and right space portions that separate the frame body 14 communicate with each other. When the liquid filling material 6 is filled inside, the liquid filling material 6 is spread over the entire inside of the panel body 5.

The filler 6 to be filled in the panel body 5 is preferably an inorganic filler such as cement-based aerated milk, concrete or gypsum, but may be other than these.
However, the above-mentioned inorganic filler has sufficient compressive strength, heat insulation, fire resistance, vibration damping, and the like, and further has excellent sound insulation against heavy impact noise. Further, such an inorganic filler is excellent in fire resistance and functions as a noncombustible material for the panel 1.

Next, a method of manufacturing a building panel 1 and an apparatus therefor according to an embodiment of the present invention will be specifically described. First, as shown in FIG. 5A, a pair of panel members 2, From the state where 3 is opposed, both panel members 2, 3
For arranging one of the panel members 2 while arranging the joint engaging portion 2a of the one panel member 2 and the joint engaging portion 3a of the other panel member 3 to be positioned in the front-back direction of the panel longitudinal direction. The engagement fitting portion 2a is engaged with the joining engagement portion 3a of the other panel member 3 to be in a state as shown in FIG.

As shown in FIG. 7, the panel members 2 and 3 in which the joining engaging portions 2a and 3a are engaged with each other as described above are housed in the box-shaped fixing block 15 of the caulking device T1. Deploy. In this way, while the device body 16 is running inside the panel members 2 and 3 housed in the fixed block 15, the joining engaging portions 2a and 3a of the panel members 2 and 3 which are engaged with each other are caulked to the device body 16. Seal ring 17
By caulking with the guide roller 18, the engaging fitting portions 2a for joining the two panel members 2, 3 to each other,
3a is one panel member 2 as shown in FIG. 5 (C).
The caulked joint portion K1 is pressed against the inner surface of the.

As described above, the engaging fitting portions 2a, 3 for joining each other are provided.
As shown in solid lines and virtual illustrations in FIG. 6, the end closing member 4 is partially fitted from the lateral plate portion 9 side to both end portions of both panel members 2 and 3 which are crimped and joined by a. . In this way, the upper and lower plate portions 7 and 8 of each end closing member 4 and the panel member 2 are respectively fitted with the end closing members 4 partially fitted to both ends of both panel members 2 and 3, respectively. The caulking device T2 as shown in FIG. This caulking device T2 has an upper frame 19 and a lower frame 20, a pressure ram 22 having a caulking punch 21 attached to a lower end thereof is provided on the upper frame 19 so as to be movable up and down, and the lower frame 20 is provided with the caulking punch 21. A caulking die 23 is provided at a position opposed to the upper frame 7 and the lower frame 20 by inserting the upper plate portion 7 or the lower plate portion 8 of the end block member 4 between the upper frame 19 and the lower frame 20. 7, 8 and the panel member 2 are swaged by the swaging punch 21 at the lower end of the pressure ram 22,
A crimped portion K2 as shown in FIGS. 4A and 4B is formed. As a result, the sealed panel body 5 is formed.

A liquid filling material 6, for example, cement-based aerated milk is filled inside the sealed panel body 5 thus formed. The filling of the bubbled milk is performed through the filling hole 12 provided in one end closing member 4 as shown by the dotted line in FIG. The foamed milk filled in the panel body 5 is foamed and solidified over a certain period of time, and the floor panel 1 is completed.

The box-shaped fixed block 15 of the caulking device T1 shown in FIG. 7 includes an upper block plate 15a and a lower block plate 2.
5b and left and right lateral block plates 15c, 15c. These block plates 15a, 15b, 15c, 15c
Both panel members 2 and 3 in which the joining engaging portions 2a and 3a are engaged with each other are housed along the inner peripheral surface of the. In this case, the horizontal block plates 15c are the upper and lower block plates 15a, 1
Since the fitting grooves 24 and 25 are formed in the inner surface of 5b at a constant pitch in the width direction, respectively, the fitting grooves 24 and 25 to which the horizontal block plate 15c is fitted can be changed. The space (panel width) between the left and right horizontal block plates 15c, 15c can be changed by replacing the horizontal block plate 15c with a horizontal block plate 15c 'having a different height, so that the space (panel thickness) between the upper and lower blocks 15a, 15b can be changed. Can be changed.

Further, the device body 16 of the caulking device T1.
Are caulking seal ring 17 and guide roller 1 respectively.
8 is attached between the left and right brackets 26, 26 with a plurality of spacer blocks 27 interposed between them and the nut member 2
8 are integrally connected to each other, a ball screw 29 driven by a motor (not shown) is screwed into the nut member 28, and the rotation of the ball screw 29 causes the main body 16 of the apparatus to be fixed to the fixed block 15 It passes through the inside of both panel members 2 and 3 housed inside. Then, by appropriately replacing the spacer block 27, the lateral width of the apparatus body 16 can be changed. Reference numeral 30 is a block plate that changes the thickness of the apparatus body 16.

In FIG. 9, a pair of left and right panel members 2, 3 each having a joining engaging portion 2a, 3a formed on both side edges in the longitudinal direction so as to project inwardly are joined together.
a is engaged by being crimped in a fitted state to form caulking joints K1 and K1 and the construction panel 3
1 shows that the two panel members 2 and 3 are caulked and joined at the central portions of the upper and lower surfaces of the panel 31, respectively.
Different from the building panel 1 shown in FIG. In building panel 1,
The left and right ends of the panel 1 are caulked and joined at their central portions.

FIG. 10 shows a state in which the end portion of the building panel 1 is attached to the beam member 32 made of H-shaped steel.
An end portion of the panel 1 is placed on the beam member 32, and a panel mounting bolt hole 10 is provided in the lower plate portion 8 of the end portion closing member 4.
After aligning the bolt with the bolt insertion hole 33 of the beam 2, bolt 34
From the bolt hole 10 of the lower plate portion 8 to the bolt insertion hole 3 of the beam member 2.
It can be tightened with a nut (not shown) through the screw 3, and this tightening work can be performed using the bolt tightening work hole 11 of the upper plate portion 7.

The building panel 1 as described above has a pair of upper and lower panel members 2 and 3 in which joint engaging fittings 2a and 3a are formed so as to project inwardly on both side edges in the longitudinal direction.
Are joined to each other by caulking inside the panel members 2 and 3 with the joining engaging portions 2a and 3a engaged with each other, and the opening portions at both ends of the joined panel members 2 and 3 are The closed panel body 5 is formed by being closed by the end closing members 4 and 4, and it is not necessary to form a hole such as a rivet tool insertion hole in the panel members 2 and 3 unlike the related art. Therefore, it becomes possible to fill the liquid filling material 6 into the panel body 5. In addition, the engagement fitting portion 2 for joining
Since the caulking joint portion K1 of a and 3a fits inside both panel members 2 and 3 and does not project to the outside, the appearance is good and the surface of panel 1 can be used effectively, and the use of panel 1 is also possible. In doing so, the panels 1 can be arranged close to each other.

Further, each end closing member 4 is formed by a metal plate into upper and lower plate portions 7 and 8 and a horizontal plate portion 9 connecting both plate portions 7 and 8 in a U-shaped cross section. The horizontal plate portions 9 are respectively provided in the open ends of the joined panel members 2 and 3.
Since the panel members 2 and 3 and the upper and lower plate portions 7 and 8 are partly fitted to each other from both sides, both end portions of the panel members 2 and 3 are reinforced by the end closing member 4 to form a panel. The strength of the main body 5 increases. Also in this case, each panel member 2, 3
The caulking portion K2 between the upper and lower plate portions 7 and 8 is the panel member 2,
Since it does not project to the surface side of 3, the surfaces of the panel members 2 and 3 can be effectively used. Further, panel mounting bolt holes 10 are provided in the lower plate portion 8 of each end closing member 4, and the upper plate portion 7 is bolted to a position directly above each panel mounting bolt hole 10 of the lower plate portion 8. Since the working hole 11 is notched, as shown in FIG. 10, when the panel 1 is mounted on the beam member 2, the mounting work is simple and easy.

Further, in the building panel 1, the panel body 5 is formed by the pair of panel members 2 and 3 made of a metal plate and the metal end closing member 4 as described above. Since the inside of the panel body 5 forms a watertight closed space, the strength of the panel 1 can be borne by the panel body 5, and the panel body 5
The filling material 6 to be filled inside is self-adhesive, that is, it does not need to be adhered to the inner peripheral surface of the panel body 5, and thus the filling material 6 is not limited to a special one and may be any desired one. It is possible to use the filler 6.

[0025]

According to the method of manufacturing a building panel of the invention according to claim 1, a pair of panel members formed so as to project inwardly the joining engaging portions at both side edges in the longitudinal direction are joined to each other. Are joined together by crimping the fitting parts for engagement, and the open ends of the joined panel members are closed by metal end closing members to form a hermetically sealed panel body. Since it is possible to fill the filling material into the sealed panel body, it is not necessary to form holes such as rivet tool insertion holes in the panel member as in the conventional case. Therefore, the liquid filling material can be filled into the panel body.

According to the building panel manufacturing apparatus of the second aspect of the present invention, the pair of panel members, which are formed by projecting inwardly the engaging engaging portions on both side edges in the longitudinal direction, are connected to each other. They are joined by crimping with the fitting portions engaged, and the open end portions of the joined panel members are closed by metal end closing members to form a hermetically sealed panel body. Since this is a manufacturing apparatus capable of filling the inside of the hermetically sealed panel body with the filling material, it is not necessary to form a hole such as a rivet tool insertion hole in the panel member as in the conventional case. As a result, the liquid filling material can be filled into the panel body.

[Brief description of drawings]

FIG. 1 is a perspective view showing a building panel manufactured according to the present invention.

FIG. 2 is a cross-sectional view of the panel.

3 is a partially cross-sectional enlarged side view of the building panel viewed from the direction of arrow X in FIG.

4A is an enlarged detailed sectional view of a portion surrounded by a circle shown by an arrow Y in FIG. 3, and FIG. 4B is an enlarged detailed plan view thereof.

FIG. 5 shows an embodiment of the present invention, in which (A)-
(C) is sectional drawing which shows the manufacturing process of a panel.

FIG. 6 is a cross-sectional view showing the manufacturing process of the panel.

FIG. 7 is a perspective view of a caulking device used for caulking a joint engagement portion of a panel member.

FIG. 8 is a perspective view of a caulking device used for caulking the upper and lower plate portions of the end closing member and the panel members.

FIG. 9 is a perspective view showing another example of a building panel manufactured according to the present invention.

FIG. 10 is a perspective view showing a state in which a building panel manufactured according to the present invention is attached to a beam member.

[Explanation of symbols]

1 building panel 2,3 panel members 2a, 3a Joint engagement part 4 Edge blocking member 5 panel body 6 Filling material 7 Upper plate 8 Lower plate 9 Horizontal plate part 10 Panel mounting bolt holes 11 Bolt tightening work hole K1 caulking joint K2 caulking section 14 Metal frame material 15 Box-shaped fixed block 16 Device body K1 caulking device K2 caulking device

Claims (2)

[Claims] 1. A pair of panel members, each of which is formed by forming a metal plate in a substantially U-shaped cross-section and projecting inwardly-engaging fitting fitting portions at both side edges in a longitudinal direction, are fitted together. The panels are joined together by crimping with the parts engaged, and the open end portions of the joined panel members are closed by metal end closing members to form a sealed panel body. A method for manufacturing a building panel, comprising the following steps. A step of forming a pair of panel members by forming a metal plate in a substantially U-shaped cross section and projecting inwardly the engaging engagement portions at both ends in the longitudinal direction. The step of forming a pair of panel members into a flat box-cylinder frame shape so that the joining engaging portion of the panel member and the joining engaging portion of the other panel member protrude inward from each other. A pair of panel members formed in a flat box-cylinder frame shape are housed and arranged in a box-shaped fixed block, and both panel members are made to travel inside the panel members housed in the fixed block in this manner. The step of forming the caulked portion by press-contacting the inwardly projecting joining engaging fitting portions with each other on the inner surface of the panel member of both panel members in which the joining engaging portions are caulked and joined. Metal ends on both ends A part of the closing member is fitted and both ends of both panel members and a part of the end closing member which are fitted together are caulked and fixed so that the caulking part is depressed inward from the surface of the panel member. Process of forming caulked part 2. A pair of panel members, which are formed by forming a metal plate in a substantially U-shaped cross section and projecting inwardly a joining engagement portion at both side edges in the longitudinal direction, are engaged together. The panels are joined together by crimping with the parts engaged, and the open end portions of the joined panel members are closed by metal end closing members to form a sealed panel body. A construction panel manufacturing apparatus, wherein a pair of panel members are overlapped with each other such that a joint engagement portion of one panel member and a joint engagement portion of the other panel member protrude inward from each other. And a box-shaped fixed block for accommodating and arranging a pair of panel members formed in the shape of a flat box cylinder, and running inside the both panel members housed in the fixed block, the two panel members are inwardly directed toward each other. Projected mating part for joining A device main body which is crimped to the inner surface of the panel member by crimping, both end portions of both panel members which are joined by crimping the respective joint engaging fitting portions, and a metal end portion partially fitted with the both end portions A caulking device for caulking a part of a closing member to be caulked and fixed so that the caulking portion is depressed inward from the surface of the panel member, and an apparatus for manufacturing a building panel.