JP2004011097A

JP2004011097A - Heat-insulating composite panel with earthquake resistance and fire resistance

Info

Publication number: JP2004011097A
Application number: JP2002161355A
Authority: JP
Inventors: Takamitsu Sakuraba; 櫻庭　高光
Original assignee: Tokai Information System Consultation; Matsumoto Kenko Co Ltd
Current assignee: Tokai Information System Consultation; Matsumoto Kenko Co Ltd
Priority date: 2002-06-03
Filing date: 2002-06-03
Publication date: 2004-01-15
Anticipated expiration: 2022-06-03
Also published as: JP3577061B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat-insulating composite panel with excellent earthquake resistance and fire resistance which never causes a deformation when building a panel and enables the beautiful laying of an interior surface plate. <P>SOLUTION: A frame body 4 is formed of an upper frame 4a and a lower frame 4b which are made of steel products, and a reinforcing steel product 4c for connecting the upper and lower frames in a rigid structure. A cement board layer 2 as an outer surface material is engagingly locked with the upper frame 4a and the lower frame 4b through a Z-clip 7, the inner faces of the upper frame 4a and the lower frame 4b and the Z-lip are covered with a fire resisting coating material 9 having water resistance, and a heat insulating layer 4 is filled, foamed and integrated thereto. Accordingly, this panel can counter a fire from the outside of a building with the cement board layer 2, a fire from the heat insulating layer on the inside of the building with the fire resisting coating material 9, and an earthquake or the like with the interlayer displacement absorbing function of the Z-clip 7 covered with the fire resisting coating material. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、鉄骨造建築物や、鉄筋コンクリート造建築物に好適に使用出来る外壁用の断熱複合パネルに関するものであり、建築技術分野に属するものである。
【０００２】
【従来の技術】
鉄筋コンクリート造建築物にあっては、外断熱工法として、断熱複合パネルをコンクリート壁などの躯体に型枠併用として配置し、コンクリート壁などと一体化して外壁を形成しており、断熱複合パネルを帳壁として単体で採用することはなかった。
また、鉄骨造建築物にあっては、従来よりパネルを鉄骨造躯体に帳壁として取付ける工法が採用されており、本出願人等が特願平９−１５２６２８号として提案し、特許第２９９９９８０号として特許登録されている断熱複合パネルである。
【０００３】
図９は、特許第２９９９９８０号のパネルであって、該パネルは、上枠、下枠及び両側枠から成る枠体の外面に、貫通孔を有する成形セメント板の３枚を並列接続した形態でＺクリップを介して止着し、枠体の内面には内装板（石膏ボード）を配置し、硬質ウレタンフォームの枠体内への注入充填発泡によって、セメント板、枠体、及び内装板を、硬質ウレタンフォーム断熱層によって一体化したものであり、鉄骨造建築物の帳壁パネルとして採用すれば、セメント板に対する断熱層の現場での吹付け作業も、内装面材の取付け作業も不要となり、建築工期の大幅な短縮化を可能とする、極めて有用な複合パネルである。
【０００４】
【発明が解決しようとする課題】
しかし、従来の断熱複合パネル（図９）にあっては、鉄骨造躯体へ帳壁として取付ける際に、クレーン等で吊上げて配置するが、吊上げ時のパネル変形防止のため、また、製作時の硬質ウレタンフォームの注入発泡時の堰止めのために側枠は必要不可欠であるが、側枠部が熱橋となって断熱機能を低下するため、側枠に対する煩雑な熱橋阻止手段（図９の緩衝体付設）を施す必要があった。
また、一体化された内装面材（石膏ボード）は、施工取扱中に欠損や汚染の損傷を受ける危険があり、特に、吸水によってカビを発生させることが多く、内装面材上に新規面材を貼着仕上げしても、カビの内部からの繁殖伝播によって後日に汚れの発現、及びアトピー等の健康問題があった。
【０００５】
また、本出願人が、先に開発に成功し、特願２００１−０２５１４２号として提案した、断熱複合パネルを単体で帳壁とする鉄筋コンクリート造建築物に、該断熱パネル（図９）を適用すれば、石膏ボード（内装面材）が床スラブに当接するため、コンクリートの配合水を吸水してカビを発生させる問題がある。
更に、断熱層の発泡凝固時の自己接着力によって、セメント板の枠体への係止部のＺクリップが固定され、枠体、セメント板、及び内装面材相互も固定されて複合パネル内での層間変位の吸収作用が生じないため、石膏ボード（内装面材）、特に石膏ボードの連結部に亀裂の発生する問題がある。
【０００６】
本発明は、特許第２９９９９８０号の断熱複合パネル（図９）の、上述の如き、鉄骨造建築物の帳壁として適用する際の種々の問題点を解決、又は改善すると共に、鉄筋コンクリート造建築物の帳壁外壁パネルとしても有効に採用出来る、新規、且つ実用性の極めて高い断熱複合パネルの提供を可能とするものである。
【０００７】
【課題を解決するための手段、及び作用】
本発明断熱複合パネルは、例えば図１に示す如く、鋼材から成る上枠４ａと下枠４ｂとを補強鋼材４ｃで連結した枠体４と、外面材としてのセメント板層２と、内面材としての断熱層３とを含み、セメント板層２は、上下端部を上枠４ａ及び下枠４ｂにＺクリップ７を介して取付け、断熱層３は、上枠４ａ及び下枠４ｂの内面をＺクリップ７を含めて耐水性を有する耐火被覆材９で被覆して枠体４内面に断熱層３を充填発泡一体化したものである（請求項１）。
尚、枠体４は、断熱層の充填発泡時の発泡圧に耐え、且つ充填剤の堰止め作用をすると共に、セメント板をも強固に保持する必要があるため、上下枠は、図２の如く、Ｚクリップ係止辺（水平辺）と堰止め立上り辺とを備えたアングル鋼材が好ましく、補強鋼材４ｃは上下枠と共に剛体枠を形成するため、上下枠間に複数本、平行に配置するのが好ましい。
【０００８】
この場合、耐火被覆材は、耐火性、耐水性、断熱性、吸音性、遮音性に富み、且つ、鋏（ハサミ）やナイフで簡単に切断出来る材料、例えば、カオウール（イソライト工業（株）商品名）等の採用が好適である。
この場合、断熱層３は吸水性が小さく、コンクリート付着性の高い慣用のプラスチック系材であれば良く、特許第２９９９９８０号パネル（図９）に採用した硬質ウレタンフォームが採用出来、セメント板層２としても公知パネル（図９）のセメント板の採用が可能である。
【０００９】
従って、断熱層３の充填発泡固化によって耐火被覆材９は、Ｚクリップや上下枠を被覆して寸法安定化し、本発明の断熱複合パネルは、外面のセメント板層２による外側からの耐火機能と、断熱材層３からの内側からの耐火機能を具備したため、断熱性、耐火性に優れた耐火建築物の帳壁としての採用が可能である。
しかも、Ｚクリップ係止部は、耐火被覆材９によって断熱層３による固定を免れ、Ｚクリップの変位吸収機能（地震等の大応力を受けた際の層間変位許容機能）の発揮が可能であるため、本発明の断熱複合パネルは、地震時のセメント板層の亀裂、落下の抑制出来る耐震性の帳壁としての採用が可能である。
【００１０】
そして、補強鋼材４ｃは、強度面では従来の側枠の機能を奏して側枠を不要としたため、本発明断熱複合パネルは、パネルの建付け施工時にもパネル変形を生じない剛構造体でありながら従来パネル（図９）の如き鋼材側枠が存在せず、側枠からの熱橋作用は発生しない。
しかも、パネル１の内面は、従来のパネルの如き内装面板（石膏ボード）が存在せず、耐水性を有する耐火被覆材と吸水性のない断熱層３が表出しているため、例えば、図７に示す如く、本発明パネルを鉄筋コンクリート建築に於ける帳壁パネルに採用しても、床スラブコンクリートからの吸水による断熱複合パネルの内表面でのカビ発生は抑制出来る。
【００１１】
また、断熱複合パネルの枠４は、上枠４ａ及び下枠４ｂが等辺山形鋼であり、補強鋼材４ｃが上枠４ａ及び下枠４ｂの立上り辺４Ｆの幅４Ｔ（図２）中央部を上下に連結固定するのが好ましい。
この場合、補強鋼材４ｃは、上枠４ａと下枠４ｂとを剛構造一体化出来、且つ、充填発泡断熱層３のパネル面からの浮上りが阻止出来れば良く、表面形状は、断熱層３を付着保持する平板形態、異形断面鋼材等、断熱層３と強固に一体化出来る形態が好ましい。
等辺山形鋼は、曲げ剛性に優れている上、入手も容易であり、且つアングルの一辺をセメント板止着当接面とし、他辺を断熱層３の堰止め型枠及びパネル取付端面と出来るので有利である。
しかも、補強鋼材４ｃが、図２（Ａ）の如く、断熱層３及び被覆材９の層の中央部に位置するため、断熱層３及び耐火被覆材９の浮上りを好適に阻止出来る。
【００１２】
また、セメント板層２の内面と断熱層３との界面には、シート材８を介在し、断熱層３のセメント板層２との凝固接着を防止するのが好ましい。
この場合、シート材８は断熱層３のセメント板面に対する接着一体化を阻止出来れば良く、通常のクラフト紙の採用が可能である。
従って、断熱層３とセメント板層２との層間変位が可能となり、Ｚクリップの層間変位吸収機能が支障なく発揮出来るため、セメント板層が躯体の地震、強風等の動きに追従して変位を吸収し、セメント板層の亀裂、脱落が抑制出来る。
【００１３】
また、本発明断熱複合パネル１にあっては、セメント板層２が外気導通用の通気層２ｈを備え、一側端には突起２２を、他側端には凹部２１を備えているのが好ましい。
尚、通気層としては、従来の慣用の外壁コンクリート型枠兼用のセメント板（図示せず）の如くセメント面内面に多数の条溝を並設したものでも良い。
従って、本発明複合パネルは、結露防止の通気層を備え、且つ、断熱性、耐震性、及び耐火性を備えたものとなり、パネル端縁での突起２２と凹部２１との存在によってパネル間接続も、目地への耐火性充填材（シーリング）付与もきれいに仕上がる、汎用性ある有用な断熱複合パネルとなる。
【００１４】
また、外面材としてのセメント板層２が複数枚の成形セメント板２Ｐの並列接続であるのが好ましい。
外壁材としてのセメント板は、押出成形体をローラー上を移動させてオートクレーブ室で養生させるが、衝撃によるひび割れや、養生の際の反りの発生等、製造面からは幅は狭いほうが有利であり、従って、コスト面、品質面で有利な幅狭のセメント板を入手して複数枚を必要パネル幅に接続するのが有利であり、本発明の耐震性、耐火性、及び断熱性を備えた高性能パネルの所望のパネル幅での提供が可能となる。
【００１５】
また、セメント板層２として複数枚のセメント板２Ｐを並列接続する場合には、各成形セメント板２Ｐ相互の並列接続を、図３（Ｂ）の如く、一側端の突起２２と他側端の凹部２１との不燃パッキング２３を介在した当接接続とするのが好ましい。
尚、不燃パッキング２３は両面接着タイプが好ましく、例えば、ＳＣブランケット（新日鉄化学（株）商品名）の採用が可能である。
この場合、耐火性のセメント板２Ｐ相互の接続部にも耐火性が付与出来るため、建物外側からの火災に対応出来、耐火性外壁の形成に有効である。
【００１６】
また、本発明パネル１で、複数枚の成形セメント板２Ｐを並列配置する場合には、補強鋼材４ｃを、各セメント板２Ｐの幅２Ｗの中央部で上下枠４ａ，４ｂ間に配置するのが好ましい。
この場合、補強鋼材４ｃが重量物としての各セメント板２Ｐを中央部で支承保持するため、上下枠での各セメント板２Ｐの機械的（力学的）保持がスムーズとなり、上下枠４ａ，４ｂ及び補強鋼材４ｃの過大重量化、即ち枠体４の重量化が抑制出来る。
【００１７】
また、補強鋼材４ｃとしては、平鋼板４ｃを用い、複数の平鋼板４ｃが断熱層３の厚み３Ｔ中間部で上下枠４ａ，４ｂ間を連結し、且つ断熱層３と一体化しているのが好ましい。
補強鋼材４ｃは、上下枠間の堅結補強と共に、断熱層３の浮上り阻止機能の期待されるものであるので、平鋼板４ｃは、入手容易、且つ連結容易であると共に、表裏の広い平面で充填発泡断熱層３と一体化して断熱層３の保持力も十分発揮する。しかも、断熱層３の厚さ中間部に埋設形態であるため、断熱層３と強固に一体化すると共に、熱橋作用も生じない。
【００１８】
また、平鋼板４ｃは、必要に応じて、断熱層３保持用の平板や丸棒鋼片を表面に差し渡し状に溶接する場合にも、付設取付作業が容易である。
勿論、平鋼板４ｃは、補強機能の力学的観点からは上下枠４ａ，４ｂに対して左右対称に，且つ上下枠とで方形枠を形成するように配置するのが好ましく、例えばセメント板層２が１枚のセメント板２Ｐの場合でも、少なくとも、上下枠の中央部、及び両側近傍に対称配置するのが好ましい。
【００１９】
また、本発明パネル１にあっては、上枠４ａ及び下枠４ｂの各立上り辺４Ｆが取付孔Ｈ１，Ｈ２，Ｈ３，Ｈ４を備えているのが好ましい。
図４の如く、上枠４ａには連結ピンＭＰ（図７）締着用の孔Ｈ２を、下枠４ｂには上枠４ａの孔Ｈ２に対応する孔Ｈ１を予め配置しておくことにより、断熱複合パネル１相互の上下連結が容易となる。
勿論、施工現場での取付孔穿孔も可能であるが、例えば、鉄骨造建築物の外壁パネルに採用する際にも、梁等の被固定材と対応した取付孔Ｈ１〜Ｈ４を配設しておけば、現場でのパネル取付作業が合理化出来る。
そして、枠体の取付孔は、パネル吊下げアイボルトの取付けや、断熱層３充填用の型枠（仕切板）締着孔、及び充填注入孔としての利用も可能である。
【００２０】
また、本発明断熱複合パネルにあっては、断熱層３が表面に条片下地材５を平行に埋設露出しているのが好ましい。
この場合、「埋設露出」は、埋設されてはいるが、表面が断熱層表面３ｆから露見出来る形態も、表面が断熱層表面３ｆから突出している形態も含む意味である。
そして、条片下地材５は、断熱層３への埋設によって断熱機能を低下させないことと、下地材に釘打ち等で止着した面板を保持することが必要機能であるため、なるべく細幅で、断熱層中の占有体積が少ないものが良く、図６の如く、アンカー部５０を備えた溝型材や、断面台形のプラスチック条片（図示せず）等が採用可能である。
【００２１】
従って該パネルは、必要な時、場所で、断熱層３に内装面板（図示せず）の下地材５を介した張設が可能であるため、例えば、鉄骨造建築への適用等、パネル内面の汚れの心配のない場合には、パネル下地材に所定の内装面板を予め止着して壁パネルとして施工することも、或いは、鉄筋コンクリート造建物の帳壁に採用する場合等、パネル内面に汚れやカビの発生する場合には、外壁として複合パネル１を張設後、下地材上へ必要内装面板を止着することも可能となり、断熱複合パネルとしての汎用性が高まる。
【００２２】
また、条片下地材５の表面５ｆが，断熱層表面３ｆから突出しているのが特に好ましい。
この場合、内装面板（図示せず）を条片下地材に取付ければ、内装面板と断熱層表面３ｆとの間には下地材５の突出による空隙空気層が存在し、内装面板と断熱層３との音の共振現象が阻止出来、遮音性が高まる。
【００２３】
また、条片下地材５は、上下方向配置であって、上端がパネル上端面Ｆｔと間隔Ｄ１を、下端がパネル下端面Ｆｂと間隔Ｄ２を有しているのが好ましい。
この場合の間隔Ｄ１，Ｄ２は、それぞれ対象建物への施工性を勘案して設定すれば良く、例えば、パネルを図７に示す如く、鉄筋コンクリート造建物の帳壁パネルとして採用する場合は、Ｄ１は、下地材上端が上階床スラブＳの型枠下端より下方で、型枠組付け作業に干渉しない位置とし、Ｄ２は、下地材下端が下方床スラブ上面Ｓｆより若干上方で、床スラブ表面Ｓｆの不陸に対処出来る位置とするものである。
勿論、鉄骨造建物の帳壁パネルとして採用する場合は、梁等の躯体取付部を外して内装面板の張設に必要な位置にのみ下地材５が存在するように間隔Ｄ１，Ｄ２を設定すれば良い。
【００２４】
従って、鉄筋コンクリート造建築に本発明パネルを採用すれば、図７に示す如く、パネル下端面Ｆｂは、雨水の床スラブ上面Ｓｆへの侵入を阻止するため、床スラブ上面Ｓｆより若干（標準１０ｍｍ）下方位置としても、突出下地材５の下端と床スラブ上面Ｓｆとは間隙ｄｂが存在することとなり、床スラブ上面Ｓｆの不陸面への対処取付が可能となる。
また、突出下地材５の上端も、上階床スラブ型枠組みでの型枠との干渉を避けることが可能であり、断熱複合パネル１の上端部の型枠組み作業が容易となる。
【００２５】
また、内装工事に於ける電気配線は、床から取出して上下方向に配向するため、条片下地材５が上下方向配置であれば、下地材５に対する電気配線のための切欠きが不要となり、電気配線工が容易となる。
しかも、下地材５を断熱層表面３ｆから突出させておくことにより、断熱層３と下地材に張設した内装面板とのスペースが電気配線スペースとなり、断熱層３に対する電気配線施工での切欠が最小限に抑制出来る。
【００２６】
また、条片下地材５は、断面台形のプラスチック材、木材等の非金属材であって、パネル上端面Ｆｔから間隔Ｄ１を、パネル下端面Ｆｂから間隔Ｄ２を保って横方向に、且つ、台形の上辺面を突出させて平行配置するのが好ましい。
この場合、埋設下地材５の断面台形の傾斜面が断熱層３に対するアンカー部として機能し、下地材５の断熱層３に対する強固な一体化保持が達成出来る。
また、プラスチック又は木材等の非金属材は、鋸で容易に切断出来、且つ熱不良導体を意味するものである。
【００２７】
従って、下地材５は、入手容易でコスト面で有利であると共に、熱橋作用を生ずる恐れもない。
そして、上枠４ａとは間隔Ｄ１を、下枠４ｂとは間隔Ｄ２を保った配置であるため、図７の如く、パネル１の上端の床スラブ型枠への組付け時、及びパネル１下端の床スラブＳ上への取付け時に、下地材５の干渉が避けられ、パネル取付作業が容易となる。
しかも、内装面板の張設も、下地材５が横方向配置であるため、慣用の長い短形の石膏ボード（内装面板）を縦方向にして並列配置する、作業性の良い縦貼り作業で遂行出来、作業性が良い。
そして、下地材５が横方向配置であれば、内装配線工事で下地材５の一部切欠の必要が生じても、非金属材であるため鋸等による切欠処理が容易である。
【００２８】
【発明の実施の形態】
〔セメント板層（図３）〕
図３（Ａ）に示す如く、セメント板層２は、３枚の成形セメント板２Ｐの並列接続で構成する。
各成形セメント板２Ｐは、幅２Ｗが５９０ｍｍで長さＬ１が２８８０ｍｍ、厚さ２Ｔが６０ｍｍであり、１側端には突起２２を、他側端には凹部２１を備え、長さ方向の貫通孔２ｈを備えている。
これら成形セメント板２Ｐの並列接続は、各凹部２１の底に、図３（Ｂ）の如く、両面接着性不燃パッキング２３として厚さ１２．５ｍｍのＳＣブランケット（新日鉄化学（株）商品名）を充填して各突起２２を不燃パッキング２３に当接すると共に、セメント板２Ｐの内側の板厚部Ｐｔ端縁間にも両面接着性を有する断熱材２５を充填して接続する。
尚、各成形セメント板２Ｐの接続部表面は、パネル張設後の目地仕上げ時に、図３（Ｂ）の如く、バッカ−２４´を介してシーリング２４を施す。
【００２９】
〔枠体４（図１、図４）〕
辺幅４Ｔが７５ｍｍで厚さ６ｍｍの等辺山形鋼（アングル鋼）から成る長さ１７７０ｍｍの上枠４ａ及び下枠４ｂ間に、幅５０ｍｍで厚さ６ｍｍの平鋼板４ｃを、３枚の各成形セメント板２Ｐの幅２Ｗの中央部に位置するように、且つ、上面が上下枠の立上り辺４Ｆの上端より３０ｍｍ下方となるように溶接固定する。
また、上枠４ａには、各平鋼板４ｃの両側に１対の取付孔Ｈ２（ネジ孔）と、両端部の吊上げ時のアイボルト（図示せず）締着用孔Ｈ３とを設け、下枠４ｂには、上枠４ａの取付孔Ｈ２の対応位置に取付孔Ｈ１（ピン孔）を、両端部にはボルト締着孔Ｈ４を設ける。
【００３０】
〔仕切板６（図５、図６）〕
仕切板６は、断熱複合パネル１を同時に複数枚製作する際に、下地材５を保持して枠体４に取付け、断熱層３を充填発泡するための型枠である。
即ち、仕切板６は、厚さ２４ｍｍの構造用材６ａの上面に離型用のポリエチレン板６ｂを貼ったものであり、両側には、該仕切板６を切断した型枠機能を奏するための立上り辺（側板）６Ｓを固定したものである。
また、仕切板６の上面には、幅Ｗ５の条片下地材５用の溝６Ｇを配設し、図６（Ｂ）の如く、先端にアンカー部５０を有する断面コ字状鋼板の下地材５を、表面５ｆを溝６Ｇの底面に当接し、下地材５が仕切板６から落下しない程度に両面接着テープ細片等で仮保持する。
【００３１】
〔断熱複合パネルの製作〕
成形用プレス台ＢＰ上に成形セメント板２Ｐを３枚並列接続してセメント板層２として載置し、図２の如く、セメント板２Ｐの上部及び下部には、内側の板厚部Ｐｔにボルト挿入孔ＨＰを穿孔して貫通孔２ｈの内側に平ナット７ａを当接し、Ｚクリップ７のボルト挿入用長孔（幅１２ｍｍ、長さ３０ｍｍ）にボルト７ｃを挿入して図４（Ｂ）の矢印Ｒの如く、Ｚクリップを回動可能に仮固定する。
次いで、セメント板層２上に載置した枠体４の上枠４ａ及び下枠４ｂの水平辺４ＨにＺクリップを回動係止してボルト７ｃを締着し、Ｚクリップ７は大応力を受ければ長孔によって変位可能に固定する。
【００３２】
また、セメント板層２上にはクラフト紙８を布設し、図１、図２に示す如く、上枠４ａ及び下枠４ｂの断熱層側、及びＺクリップ部に柔軟性のある繊維系の耐火被覆材９、即ち、耐火、耐水、断熱、吸音、遮音機能に優れ、ハサミやナイフで簡単に切断出来るブランケット状の繊維系不燃材（商品名、カオウール、イソライト工業（株）製）を被覆する。
この場合、平鋼板４ｃの基部の包み込みは、耐火被覆材に切れ目を入れると容易であり、上下枠から延出したＺクリップ７は、耐火被覆材９に図１の如く、突出部９´を付設すればよい。
【００３３】
また、枠体４上には、下地材５を仮保持した仕切板６を、図６（Ａ）の如く、下地材５が枠体４内に突出する形態に、且つ、仕切板側板（立上り辺）６Ｓが枠体４の側枠形態となるように載置し、上枠４ａ及び下枠４ｂ端でコーナー金具１２の、１片１２Ｓを仕切板側板（立上り辺）６Ｓに、他片１２Ｌを上枠４ａ、下枠４ｂに当接して、各コーナー金具１２の長孔Ｈ５を介して仕切板６と上下枠４ａ，４ｂとを固定する。
【００３４】
尚、仕切板側板６Ｓと金具１２との固定は、側枠６Ｓの外面に座金を配置して慣用のボルト締着し、上下枠４ａ，４ｂと金具１２との固定は、上枠のアイボルト用のネジ孔Ｈ３及び下枠４ｂのボルト取付孔（ネジ孔）Ｈ４を介してボルト締着し、第１段目の複合断熱パネル成形型Ｄｐとする。
次いで、同様の成形型Ｄｐを図６（Ｃ）の如く、順次複数段プレス台Ｂｐ上に重ねてプレス体Ｔｐで型締めし、各成形型中の上枠４ａ（下枠４ｂ）の取付孔Ｈ２（Ｈ１）から発泡ウレタン樹脂を注入充填し、発泡硬化する。
【００３５】
断熱層３としての硬質ウレタンフォームが硬化冷却した後、プレス体Ｔｐを開放して各成形型Ｄｐのコーナー金具１２を取外して仕切板６を取外せば、硬質ウレタンフォーム（断熱層）３が平鋼板４ｃ、クラフト紙８及び耐火被覆材９と一体化固着した本発明の断熱複合パネル１が得られる。
尚、仕切板６の取外しに際しては、側板６Ｓの内面及び仕切板内面が離型板としてのポリエチレン板６ｂを備えているため容易に離型する。
また、条片下地材５も、仕切板の溝６Ｇの深さｔ１で突出し、深さｔ２で断熱層３中に埋設し、アンカー部５０で強固に保持される。
【００３６】
〔断熱複合パネル１の使用（図７、図８）〕
上述の実施形態で得られる断熱複合パネル１は、本発明者が特願２００１−０２５１４２号として先に提案した新規な鉄筋コンクリート造外断熱建築物に適用すれば、極めて有効なものである。
即ち、図７に示す如く、断熱複合パネル１の下端を、コンクリート床スラブＳ前端に固定した取付金物Ｍから突出した連結ピン（取付ピン）ＭＰにパネル下枠４ｂの取付孔Ｈ１を挿通して、パネル下端面Ｆｂが床スラブ表面Ｓｆより下方で、雨水のパネル下端から床スラブ表面Ｓｆへの侵入を阻止するように取付け、パネル１の上端を、図７（Ｂ）に示すごとく、上階の床スラブ型枠内に組付けた取付金物Ｍと連結ピンＭＰによって係止する。
【００３７】
この場合、条片下地材５は、下端では、パネル下端Ｆｂと間隔Ｄ２を、上端では、パネル上端と間隔Ｄ１を有するため、下地材５は、下方床スラブＳの表面Ｓｆに不陸があっても間隙ｄｂの存在によって対処出来、上階床スラブ型枠の組立て時にも間隔Ｄ１の存在により下地材５の干渉なしに型枠組み作業が容易に実施出来る。
そして、上階床スラブ型枠内へのコンクリート打設に際しても、耐火被覆材９及び断熱層３がコンクリート付着性大で吸水性小であるため、パネル１が床スラブＳと隙間なく一体化し、コンクリート打設によって断熱層表面３ｆにコンクリート配合水が流出付着しても、床スラブ型枠解体後の断熱層表面３ｆでのカビの発生はない。
【００３８】
そして、内装工事に際しては、断熱層表面３ｆからｔ１（図６）突出した下地材表面５ｆに石膏ボード（内装面板）を張設しても、石膏ボードに対する複合パネル１側からのカビの伝播による汚染は生じない。
また、下地材５の突出によって形成される断熱層表面３ｆと石膏ボード間の空隙層は電気配線スペースとして利用出来、配線工事に伴う断熱層の欠損は最小限に抑制出来る。
しかも、石膏ボードと断熱層表面３ｆとの空隙層は、石膏ボードと断熱層３との音の共振現象を抑制するため、共振現象による遮音性低下は阻止出来る。
尚、セメント板層２相互の継目、及びセメント板２Ｐ相互の継目は、パネル張設後の外装仕上げで、図３（Ｂ）の如く、バッカ−２４´を介した耐火シーリング２４による目地仕上げする。
【００３９】
従って、本発明パネルで形成した帳壁は、クラフト紙８によってセメント板層２と断熱層３との一体化固着が阻止してあるため、地震、強風等の作用を受けても、断熱層３はセメント板層２と層間変位が可能となり、断熱層内面に張設した内装面板の衝接端縁での亀裂や欠損が最小限に抑制出来る。
しかも、上枠、下枠及びＺクリップ部等が耐火被覆材９で保護されてＺクリップも断熱層３による一体化固定を免れているため、Ｚクリップによるセメント板層２と枠体４との層間変位吸収も可能であって、地震時のセメント板層２の変位を吸収することにより、セメント板層２の亀裂の発生や欠損も防止出来て好適な耐震外壁となる。
その上、セメント板２Ｐの継目も不燃パッキング２３を備えているため、該パネルで構築した外壁は、目地部の不燃パッキング２３による外側からの火災にも、耐火被覆材９による内側からの火災にも対処した防火外壁とも成る。
【００４０】
また、該断熱複合パネル１は、従来の鉄骨造建築物の帳壁として採用しても、下地材５がパネル上端部及び下端部で間隔Ｄ１，Ｄ２を有するため、パネルの鉄骨造躯体への取付けは、下地材５の干渉なく実施出来ると共に、所望時点でのきれいな内装面板の張設となり、しかも、内装面板と断熱層３との下地材５を介した空隙層の存在によって遮音性の低下が抑制出来る。
勿論、鉄骨造建物の帳壁に採用しても、好適な耐震性、及び耐火性を備えた外壁となる。
従って、該断熱複合パネル１は、鉄筋コンクリート造建築物の帳壁パネルとしても、鉄骨造建築物の帳壁パネルとしても耐震性及び耐火性外壁が得られ、極めて優れた断熱複合パネルとなる。
【００４１】
〔その他〕
枠体構成材としての複数の縦設平鋼板４ｃ相互を横方向に鋼板又は鋼棒等で連結固定すれば断熱層３の浮上り阻止が確実となる。
また、仕切板６として、表面平滑なステンレス鋼を採用すれば、枠体４への取付け及び成形型の組付けが容易となると共に、条片下地材５の仮保持もネジ手段により容易となる。
また、必要に応じて、下枠４ｂ適所に立上り辺４Ｆの反対方向に支承鉄板を延出固定し、支承鉄板でセメント板層２を受けるようにすれば、セメント板層２の重力はＺクリップと支承鉄板とで支持されるようになり、セメント板層２の枠体４からの脱落が完全に阻止出来る。
また、非金属材の条片下地材５は、上下方向配置としても下地材としての所期の目的は達成出来る。
【００４２】
【発明の効果】
鋼材から成る枠体４が上枠４ａ、下枠４ｂ及び断熱層３中に埋設する補強鋼材４ｃのみであるため、熱橋防止は処理の容易な上枠及び下枠のみとなり、断熱機能低下の少ない断熱パネルとなる。
また、上枠４ａ、下枠４ｂの内面及びＺクリップが耐火被覆材で保護されているため、Ｚクリップは断熱層３による一体化固定を免れ、セメント板層２と枠体４との層間変位がＺクリップで吸収可能であって、耐震性及び耐火性を有する断熱複合パネルとなる。
【００４３】
また、セメント板層２と断熱層３との界面にはシート材８が存在してセメント板層２と断熱層３との一体化固定が阻止されているため、セメント板層２と断熱層３との層間変位が可能であり、地震や強風による枠体変位に伴うセメント板層２や断熱層３に固定した内装面板の亀裂発生が抑制出来る。
また、セメント板層２が複数のセメント板２Ｐを不燃パッキング２３を介して連接しているため、パネル外方からの火災に対しても耐火性を発揮する。
【００４４】
また、断熱層３が表面に条片下地材５を埋設露出しているため、パネル１の建付け後に内装面板を下地材５に張着することとなり、パネルの建付け施工時はパネル内面の汚染に配慮する必要がなく、施工が容易となる。
しかも、下地材５を断熱層表面３ｆより突出させたため、張設内装面板と断熱層表面３ｆとの間に空隙層が存在し、該空隙層は電気配線スペースとして利用出来ると共に、内装面板と断熱層３との音の共振現象を遮断して遮音機能が向上する。
【図面の簡単な説明】
【図１】本発明断熱複合パネルの一部切欠斜視図である。
【図２】本発明パネルの部分拡大図であって、（Ａ）は図１のＡ−Ａ線断面、（Ｂ）は図１のＢ−Ｂ線断面、（Ｃ）はＺクリップ取付部の斜視図である。
【図３】本発明パネルのセメント板層２の説明図であって、（Ａ）はセメント板２Ｐの並列接続状態図、（Ｂ）は（Ａ）のＢ部拡大図である。
【図４】本発明説明図であって、（Ａ）は断熱層を除いた斜視図、（Ｂ）及び（Ｃ）は、それぞれＺクリップ取付状態説明図である。
【図５】仕切板の説明図であって、（Ａ）は全体斜視図、（Ｂ）はコーナー金具斜視図、（Ｃ）はコーナー金具使用状態説明図である。
【図６】成形型の説明図であって、（Ａ）は１枚のパネル型のセット状態説明図、（Ｂ）は（Ａ）のＢ部拡大図、（Ｃ）は成形型の積層状態斜視図である。
【図７】本発明パネルの鉄筋コンクリート造建物の帳壁パネルへの使用状態説明図であって、（Ａ）はパネル上下端の固定状態を、（Ｂ）はパネル上端の床スラブ型枠への組付状態を示す図である。
【図８】本発明パネルを鉄筋コンクリート造建物に適用した状態の概略斜視図である。
【図９】従来例であって、（Ａ）はパネル全体斜視図、（Ｂ）は（Ａ）のＢ−Ｂ線断面図、（Ｃ）は（Ａ）のＣ−Ｃ線断面図である。
【符号の説明】
１：断熱複合パネル、　　　　　　　　　　　　２：セメント板層、
２Ｐ：セメント板（成形セメント板）、　　　　２ｈ：貫通孔（通気層）、
３：断熱層、　　　　　３ｆ：断熱層表面、　　４：枠体（枠）、
４ａ：上枠、　　　　　４ｂ：下枠、　　　　　４ｃ：補強鋼材（平鋼板）、
４Ｆ：立上り辺、　　　４Ｈ：水平辺、
５：条片下地材（下地材）、　　　　　　　　　５ｆ：下地材表面、
６：仕切板、　　　　　　　　　　　　　　　　６ａ：構造用合板、
６ｂ：ポリエチレン板（離型板）、　　　　　　６Ｇ：溝、
６Ｓ：仕切板側板（立上り辺）、
７：Ｚクリップ、　　　　　　　　　　　　　　８：シート材（クラフト紙）、
９：耐火被覆材、　　　　２１：凹部、　　　　２２：突起、
Ｄ１，Ｄ２：間隔[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a heat insulating composite panel for an outer wall that can be suitably used for a steel frame building or a reinforced concrete building, and belongs to the field of building technology.
[0002]
[Prior art]
In the case of reinforced concrete buildings, as an external heat insulation method, a heat insulation composite panel is placed together with a formwork on a concrete wall or other skeleton, and integrated with the concrete wall to form an external wall. It was never used alone as a wall.
Also, in the case of steel-framed buildings, a method of attaching panels to a steel-framed skeleton as a book wall has been conventionally employed. The applicant of the present invention has proposed this as Japanese Patent Application No. 9-152628, and Japanese Patent No. 29999980. It is a heat insulating composite panel registered as a patent.
[0003]
FIG. 9 shows a panel of Japanese Patent No. 29999980 in which three molded cement plates having through holes are connected in parallel to the outer surface of a frame composed of an upper frame, a lower frame, and both side frames. Fastened via Z-clip, an interior plate (plaster board) is placed on the inner surface of the frame, and the cement plate, the frame, and the interior plate are hardened by injecting and foaming the rigid urethane foam into the frame. It is integrated with a urethane foam heat insulation layer, and if it is adopted as a book wall panel of a steel-framed building, the work of spraying the heat insulation layer on the cement board at the site and the work of attaching the interior surface materials are unnecessary, and the construction This is an extremely useful composite panel that can significantly shorten the construction period.
[0004]
[Problems to be solved by the invention]
However, in the case of the conventional heat insulating composite panel (FIG. 9), when it is mounted on a steel frame as a book wall, it is suspended by a crane or the like. The side frame is indispensable for damping during injection and foaming of the rigid urethane foam. However, since the side frame portion serves as a heat bridge to reduce the heat insulating function, a complicated heat bridge preventing means for the side frame (FIG. 9) (With a shock absorber).
In addition, the integrated interior facing material (gypsum board) is liable to be damaged by damage or contamination during construction and handling. In particular, mold is often generated by water absorption, and a new facing material is applied on the interior facing material. However, even if the sticky finish was applied, there were health problems such as the appearance of dirt and atopy at a later date due to propagation and propagation from inside the mold.
[0005]
In addition, the present applicant can apply the heat insulating panel (FIG. 9) to a reinforced concrete building that has been successfully developed earlier and proposed as Japanese Patent Application No. 2001-025142 and uses a heat insulating composite panel as a book wall alone. For example, since the gypsum board (interior surface material) comes into contact with the floor slab, there is a problem that mold mixing is caused by absorbing the mixed water of the concrete.
Furthermore, the self-adhesive force of the heat insulating layer during foam solidification fixes the Z-clip of the engaging portion to the frame of the cement plate, and also fixes the frame, the cement plate, and the interior facing material to each other in the composite panel. Since the effect of absorbing the interlayer displacement is not generated, there is a problem that cracks are generated in the gypsum board (interior surface material), particularly in the connecting portion of the gypsum board.
[0006]
The present invention solves or ameliorates various problems of applying the heat insulating composite panel (FIG. 9) of Japanese Patent No. 29999980 (FIG. 9) as described above to a book wall of a steel-framed building, and also improves a reinforced concrete building. It is possible to provide a novel and highly practical heat-insulating composite panel that can be effectively used as a book wall outer wall panel.
[0007]
Means and Action for Solving the Problems
As shown in FIG. 1, for example, the heat insulating composite panel of the present invention includes a frame 4 in which an upper frame 4a and a lower frame 4b made of a steel material are connected by a reinforcing steel material 4c, a cement plate layer 2 as an outer surface material, and an inner surface material. The cement board layer 2 has upper and lower ends attached to the upper frame 4a and the lower frame 4b via the Z-clip 7, and the heat insulating layer 3 has inner surfaces of the upper frame 4a and the lower frame 4b. The frame 7 is covered with a water-resistant refractory covering material 9 including the clip 7 and the inner surface of the frame 4 is filled with the heat insulating layer 3 and foamed and integrated (claim 1).
In addition, since the frame body 4 needs to withstand the foaming pressure at the time of filling and foaming of the heat insulating layer, and also acts to block the filler, and also needs to firmly hold the cement plate, the upper and lower frames are formed as shown in FIG. As described above, an angle steel material having a Z-clip locking side (horizontal side) and a damming rising side is preferable, and a plurality of reinforcing steel materials 4c are arranged in parallel between the upper and lower frames to form a rigid frame together with the upper and lower frames. Is preferred.
[0008]
In this case, the fire-resistant coating material is a material that is excellent in fire resistance, water resistance, heat insulation, sound absorption, sound insulation, and can be easily cut with scissors or a knife, for example, kao wool (a product of Isolite Industry Co., Ltd.). Is preferred.
In this case, the heat-insulating layer 3 may be a conventional plastic material having low water absorption and high adhesiveness to concrete, and the hard urethane foam used for the Patent No. 2999980 panel (FIG. 9) can be used. It is also possible to adopt a cement panel of a known panel (FIG. 9).
[0009]
Accordingly, the refractory coating material 9 covers the Z-clip and the upper and lower frames and is dimensionally stabilized by the filling, foaming and solidification of the heat-insulating layer 3, and the heat-insulating composite panel of the present invention has the function of preventing fire from the outside by the cement plate layer 2 on the outer surface. Since it has a fireproof function from the inside from the heat insulating material layer 3, it can be adopted as a book wall of a fireproof building having excellent heat insulation and fire resistance.
Moreover, the Z-clip locking portion is prevented from being fixed by the heat-insulating layer 3 by the fire-resistant coating material 9 and can exhibit the Z-clip displacement absorbing function (interlayer displacement permitting function when subjected to a large stress such as an earthquake). Therefore, the heat-insulating composite panel of the present invention can be adopted as an earthquake-resistant book wall capable of suppressing cracking and falling of the cement plate layer during an earthquake.
[0010]
The reinforcing steel material 4c has the function of a conventional side frame in terms of strength and does not require a side frame. Therefore, the heat-insulating composite panel of the present invention is a rigid structure that does not deform the panel even when the panel is constructed. However, there is no steel side frame as in the conventional panel (FIG. 9), and no thermal bridging action from the side frame occurs.
Moreover, since the interior surface of the panel 1 does not have an interior face plate (plaster board) as in the conventional panel, the water-resistant fire-resistant covering material and the heat-absorbing heat-insulating layer 3 are exposed. As shown in the above, even if the panel of the present invention is used for a book wall panel in a reinforced concrete building, the generation of mold on the inner surface of the heat insulating composite panel due to the absorption of water from the floor slab concrete can be suppressed.
[0011]
In the frame 4 of the heat insulating composite panel, the upper frame 4a and the lower frame 4b are equilateral angle irons, and the reinforcing steel material 4c moves up and down the center of the width 4T (FIG. 2) of the rising side 4F of the upper frame 4a and the lower frame 4b. It is preferable to connect and fix to
In this case, the reinforcing steel material 4c only needs to be able to integrate the upper frame 4a and the lower frame 4b with a rigid structure and to prevent the filled foam insulation layer 3 from rising from the panel surface. It is preferable to adopt a form that can be firmly integrated with the heat insulating layer 3, such as a flat plate form that adheres and retains, a deformed section steel material, and the like.
The equilateral angle iron is excellent in bending stiffness and easily available, and one side of the angle can be used as a cement plate fixing contact surface, and the other side can be used as a damping formwork and a panel mounting end surface of the heat insulating layer 3. This is advantageous.
Moreover, as shown in FIG. 2A, the reinforcing steel material 4c is located at the center of the layers of the heat insulating layer 3 and the coating material 9, so that the floating of the heat insulating layer 3 and the fire-resistant coating material 9 can be suitably prevented.
[0012]
In addition, it is preferable that a sheet material 8 is interposed at the interface between the inner surface of the cement plate layer 2 and the heat insulating layer 3 to prevent solidification adhesion of the heat insulating layer 3 to the cement plate layer 2.
In this case, the sheet material 8 only needs to prevent the heat insulating layer 3 from being bonded and integrated to the cement plate surface, and ordinary kraft paper can be used.
Therefore, interlayer displacement between the heat insulating layer 3 and the cement board layer 2 becomes possible, and the interlayer displacement absorbing function of the Z-clip can be exerted without hindrance. By absorbing, cracks and falling off of the cement board layer can be suppressed.
[0013]
Further, in the heat insulating composite panel 1 of the present invention, the cement plate layer 2 is provided with a ventilation layer 2h for conducting outside air, a projection 22 is provided at one end, and a recess 21 is provided at the other end. preferable.
The ventilation layer may be one in which a large number of grooves are juxtaposed on the inner surface of the cement surface, such as a conventional cement plate (not shown) also used as a concrete frame for the outer wall.
Therefore, the composite panel of the present invention is provided with a ventilation layer for preventing dew condensation, and also has thermal insulation, earthquake resistance, and fire resistance, and the connection between panels due to the presence of the projections 22 and the recesses 21 at the panel edges. In addition, the application of the refractory filler (sealing) to the joints can be finished neatly, resulting in a versatile and useful heat insulating composite panel.
[0014]
Moreover, it is preferable that the cement board layer 2 as an outer surface material is a parallel connection of a plurality of molded cement boards 2P.
The cement board as the outer wall material is cured in an autoclave chamber by moving the extruded body on a roller.However, it is advantageous that the width is narrower from the manufacturing point of view, such as cracks due to impact and warpage during curing. Therefore, it is advantageous to obtain a narrow cement board, which is advantageous in terms of cost and quality, and connect a plurality of the cement boards to the required panel width, and have the earthquake resistance, fire resistance, and heat insulation of the present invention. It is possible to provide a high-performance panel with a desired panel width.
[0015]
When a plurality of cement boards 2P are connected in parallel as the cement board layer 2, the parallel connection of the molded cement boards 2P is made by connecting the protrusion 22 at one end and the other end as shown in FIG. It is preferable to make a contact connection with the concave portion 21 through the non-combustible packing 23.
The non-combustible packing 23 is preferably a double-sided adhesive type. For example, an SC blanket (trade name of Nippon Steel Chemical Co., Ltd.) can be used.
In this case, since fire resistance can be imparted to the connection portion between the fire-resistant cement boards 2P, it is possible to cope with a fire from the outside of the building, which is effective for forming a fire-resistant outer wall.
[0016]
In the panel 1 of the present invention, when a plurality of molded cement boards 2P are arranged in parallel, the reinforcing steel material 4c is arranged between the upper and lower frames 4a and 4b at the center of the width 2W of each cement board 2P. preferable.
In this case, since the reinforcing steel material 4c supports and holds each cement plate 2P as a heavy object at the center, mechanical (mechanical) holding of each cement plate 2P in the upper and lower frames becomes smooth, and the upper and lower frames 4a, 4b and Excess weight of the reinforcing steel material 4c, that is, weight of the frame 4 can be suppressed.
[0017]
Further, as the reinforcing steel material 4c, a flat steel plate 4c is used, and a plurality of flat steel plates 4c connect the upper and lower frames 4a, 4b at an intermediate portion of the heat insulating layer 3 with a thickness of 3T, and are integrated with the heat insulating layer 3. preferable.
Since the reinforcing steel material 4c is expected to have a function of preventing the heat insulating layer 3 from rising together with the reinforcement between the upper and lower frames, the flat steel plate 4c is easily available and easily connected, and has a wide flat surface. Thus, the heat insulating layer 3 is sufficiently integrated with the filled foamed heat insulating layer 3. In addition, since it is embedded in the middle part of the thickness of the heat insulating layer 3, the heat insulating layer 3 is firmly integrated with the heat insulating layer 3 and no thermal bridge action occurs.
[0018]
Further, the flat steel plate 4c can be easily attached and attached even when a flat plate or a round bar piece for holding the heat insulating layer 3 is welded across the surface as required.
Of course, the flat steel plate 4c is preferably disposed symmetrically with respect to the upper and lower frames 4a and 4b and so as to form a rectangular frame with the upper and lower frames from the viewpoint of the mechanical strength of the reinforcing function. Is a single cement board 2P, it is preferable to arrange it symmetrically at least in the center of the upper and lower frames and in the vicinity of both sides.
[0019]
Further, in the panel 1 of the present invention, it is preferable that each rising side 4F of the upper frame 4a and the lower frame 4b is provided with mounting holes H1, H2, H3, H4.
As shown in FIG. 4, a hole H2 for fastening the connecting pin MP (FIG. 7) is provided in the upper frame 4a, and a hole H1 corresponding to the hole H2 of the upper frame 4a is provided in the lower frame 4b in advance, so that heat insulation is achieved. Up and down connection of the composite panels 1 is facilitated.
Of course, it is also possible to drill mounting holes at the construction site. For example, even when employed in an outer wall panel of a steel-framed building, mounting holes H1 to H4 corresponding to a fixed material such as a beam are provided. If done, panel installation work on site can be streamlined.
The mounting hole of the frame can be used as a mounting hole for a panel hanging eyebolt, as a fastening hole for a mold (partition plate) for filling the heat insulating layer 3, and as a filling injection hole.
[0020]
Moreover, in the heat insulation composite panel of the present invention, it is preferable that the heat insulation layer 3 bury and expose the strip base material 5 in parallel on the surface.
In this case, “buried exposure” means a form in which the surface is exposed from the heat insulating layer surface 3f and a form in which the surface protrudes from the heat insulating layer surface 3f, although the surface is buried.
The strip base material 5 has a function of not lowering the heat insulating function by being buried in the heat insulating layer 3 and holding the face plate fixed to the base material by nailing or the like. It is preferable that the volume occupied by the heat insulating layer is small. For example, as shown in FIG. 6, a channel member having an anchor portion 50 or a plastic strip (not shown) having a trapezoidal cross section can be employed.
[0021]
Therefore, the panel can be installed on the heat insulating layer 3 via the base material 5 of the interior face plate (not shown) at the place when necessary, and therefore, for example, the panel inner surface such as an application to a steel frame building. If there is no concern about stains on the inside of the panel, it is also possible to attach the specified interior face plate to the panel base material in advance and install it as a wall panel, or to apply it to the book wall of a reinforced concrete building, etc. In the case where mold or mold is generated, it is also possible to fix the necessary interior face plate on the base material after stretching the composite panel 1 as an outer wall, and the versatility as a heat insulating composite panel is enhanced.
[0022]
It is particularly preferable that the surface 5f of the strip base material 5 protrudes from the heat insulating layer surface 3f.
In this case, if the interior face plate (not shown) is attached to the strip base material, a void air layer exists between the interior face plate and the heat insulating layer surface 3f due to the protrusion of the base material 5, and the interior face plate and the heat insulating layer 3 can be prevented, and the sound insulation can be improved.
[0023]
Moreover, it is preferable that the strip | seat base material 5 is arrange | positioned in the up-down direction, and the upper end has the space | interval D1 with the panel upper end surface Ft, and the lower end has the space | interval D2 with the panel lower end surface Fb.
The intervals D1 and D2 in this case may be set in consideration of the workability for the target building. For example, as shown in FIG. 7, when the panel is adopted as a book wall panel of a reinforced concrete building, D1 is The upper end of the base material is positioned below the lower end of the formwork of the upper floor slab S so as not to interfere with the assembling work of the upper floor slab S, and the lower end of the base material is slightly higher than the upper surface Sf of the lower floor slab, and It is a position that can cope with uneven land.
Of course, in the case of adopting as a book wall panel of a steel frame building, the intervals D1 and D2 are set so that the frame mounting portion such as a beam is removed and the base material 5 is present only at a position necessary for stretching the interior face plate. Good.
[0024]
Therefore, if the panel of the present invention is adopted in a reinforced concrete building, as shown in FIG. 7, the panel lower end surface Fb is slightly (standard 10 mm) smaller than the floor slab upper surface Sf in order to prevent rainwater from entering the floor slab upper surface Sf. Even at the lower position, a gap db exists between the lower end of the protruding base material 5 and the upper surface Sf of the floor slab, so that the floor slab upper surface Sf can be attached to the uneven surface.
In addition, the upper end of the protruding base material 5 can also avoid interference with the formwork of the upper floor slab formwork, thereby facilitating the formwork operation of the upper end of the heat insulating composite panel 1.
[0025]
Moreover, since the electric wiring in the interior work is taken out from the floor and oriented vertically, if the strip base material 5 is arranged in the vertical direction, the notch for the electric wiring to the base material 5 becomes unnecessary, Electrical wiring work becomes easier.
Moreover, since the base material 5 is projected from the surface 3f of the heat insulating layer, the space between the heat insulating layer 3 and the interior face plate stretched on the base material becomes an electric wiring space, and the notch in the electric wiring work for the heat insulating layer 3 is reduced. Can be minimized.
[0026]
The strip base material 5 is a non-metallic material such as a plastic material or wood having a trapezoidal cross section, and keeps an interval D1 from the upper end face Ft of the panel and a distance D2 from the lower end face Fb of the panel in the lateral direction, and It is preferable that the trapezoid is arranged in parallel with the upper side surface protruding.
In this case, the inclined surface of the trapezoidal cross section of the buried base material 5 functions as an anchor portion for the heat insulating layer 3, and strong integration and holding of the base material 5 with respect to the heat insulating layer 3 can be achieved.
A non-metallic material such as plastic or wood means a conductor that can be easily cut with a saw and has poor heat.
[0027]
Accordingly, the base material 5 is easily available and advantageous in terms of cost, and there is no possibility of causing a thermal bridge effect.
Since the distance D1 is maintained with the upper frame 4a and the distance D2 is maintained with the lower frame 4b, the upper end of the panel 1 is attached to the floor slab form as shown in FIG. At the time of installation on the floor slab S, the interference of the base material 5 can be avoided, and the panel installation work becomes easy.
Moreover, since the base material 5 is arranged in the horizontal direction, the interior face plate is also stretched by a vertical sticking work with good workability in which conventional long and short gypsum boards (interior face plates) are vertically arranged in parallel. Workability is good.
If the base material 5 is arranged in the horizontal direction, even if it is necessary to partially cut the base material 5 in the interior wiring work, the base material 5 is a nonmetallic material, so that the notch processing with a saw or the like is easy.
[0028]
BEST MODE FOR CARRYING OUT THE INVENTION
[Cement board layer (Fig. 3)]
As shown in FIG. 3A, the cement plate layer 2 is configured by connecting three molded cement plates 2P in parallel.
Each molded cement board 2P has a width 2W of 590 mm, a length L1 of 2880 mm, a thickness 2T of 60 mm, a projection 22 on one side end and a recess 21 on the other side end, and a penetration in the length direction. A hole 2h is provided.
As shown in FIG. 3 (B), a 12.5 mm-thick SC blanket (trade name of Nippon Steel Chemical Co., Ltd.) is used as a double-sided adhesive noncombustible packing 23 at the bottom of each recess 21 as a parallel connection of these molded cement plates 2P. The protrusions 22 are filled so as to abut against the non-combustible packing 23, and a heat insulating material 25 having double-sided adhesive is also filled and connected between the edges of the thick portion Pt inside the cement plate 2P.
In addition, the surface of the connection portion of each molded cement board 2P is subjected to sealing 24 via a backer 24 'as shown in FIG.
[0029]
[Frame 4 (FIGS. 1 and 4)]
Three flat steel plates 4c each having a width of 50 mm and a thickness of 6 mm are formed between an upper frame 4a and a lower frame 4b each made of an equilateral angle steel (angle steel) having a side width 4T of 75 mm and a thickness of 6 mm. The cement plate 2P is fixed by welding so that it is located at the center of the width 2W of the cement board 2P and the upper surface is 30 mm below the upper end of the rising edge 4F of the upper and lower frames.
The upper frame 4a is provided with a pair of mounting holes H2 (screw holes) on both sides of each flat steel plate 4c and an eye bolt (not shown) fastening hole H3 for lifting both ends. , A mounting hole H1 (pin hole) is provided at a position corresponding to the mounting hole H2 of the upper frame 4a, and bolt fastening holes H4 are provided at both ends.
[0030]
[Partition plate 6 (FIGS. 5 and 6)]
The partition plate 6 is a mold for holding and attaching the base material 5 to the frame 4 and filling and foaming the heat insulating layer 3 when a plurality of heat insulating composite panels 1 are manufactured at the same time.
That is, the partition plate 6 is formed by attaching a polyethylene plate 6b for release to the upper surface of a structural material 6a having a thickness of 24 mm, and is provided on both sides with a rising edge for performing the form function of cutting the partition plate 6. The side (side plate) 6S is fixed.
On the upper surface of the partition plate 6, a groove 6G for the strip base material 5 having a width W5 is provided, and as shown in FIG. 5 is temporarily held by a double-sided adhesive tape strip or the like so that the front surface 5f abuts against the bottom surface of the groove 6G and the base material 5 does not drop from the partition plate 6.
[0031]
[Production of thermal insulation composite panel]
Three molded cement plates 2P are connected in parallel on the molding press table BP and placed as a cement plate layer 2. As shown in FIG. 2, bolts are attached to the upper and lower portions of the cement plate 2P at the inner plate thickness portion Pt. The insertion hole HP is pierced, the flat nut 7a is brought into contact with the inside of the through hole 2h, and the bolt 7c is inserted into the long bolt insertion hole (12 mm wide, 30 mm long) of the Z-clip 7 to insert the bolt 7c shown in FIG. As indicated by the arrow R, the Z clip is temporarily fixed so as to be rotatable.
Next, the Z-clip is rotatably locked to the horizontal side 4H of the upper frame 4a and the lower frame 4b placed on the cement plate layer 2 and the bolt 7c is fastened. If it is received, it is displaceably fixed by a long hole.
[0032]
Also, a kraft paper 8 is laid on the cement plate layer 2, and as shown in FIGS. 1 and 2, a flexible fiber-based fireproof material is provided on the heat insulating layer side of the upper frame 4a and the lower frame 4b and on the Z clip portion. Coating material 9, that is, a blanket-shaped fibrous incombustible material (trade name, Kao Wool, manufactured by Isolite Industry Co., Ltd.) that has excellent fire resistance, water resistance, heat insulation, sound absorption, and sound insulation functions and can be easily cut with scissors or a knife. .
In this case, it is easy to enclose the base of the flat steel plate 4c by making a cut in the refractory coating, and the Z-clip 7 extending from the upper and lower frames is provided with a projection 9 'on the refractory coating 9 as shown in FIG. It may be attached.
[0033]
Further, on the frame 4, a partition plate 6 temporarily holding the base material 5 is provided in such a manner that the base material 5 protrudes into the frame 4 as shown in FIG. 6S is placed in the form of a side frame of the frame body 4, and one end 12S of the corner fitting 12 at the ends of the upper frame 4a and the lower frame 4b is placed on the partition plate side plate (rising side) 6S and the other end 12L. Is in contact with the upper frame 4a and the lower frame 4b, and the partition plate 6 and the upper and lower frames 4a, 4b are fixed via the elongated holes H5 of the corner fittings 12.
[0034]
The partition plate side plate 6S and the metal fittings 12 are fixed to the outer surface of the side frame 6S with a washer and fastened with a conventional bolt, and the upper and lower frames 4a and 4b and the metal fitting 12 are fixed to the upper frame eye bolts. And a bolt mounting hole (screw hole) H4 of the lower frame 4b, thereby forming a first-stage composite heat insulating panel forming die Dp.
Next, as shown in FIG. 6 (C), similar forming dies Dp are successively overlapped on a multi-stage press table Bp and clamped by a press body Tp, and the mounting holes of the upper frame 4a (lower frame 4b) in each forming die. A foamed urethane resin is injected and filled from H2 (H1), and foamed and cured.
[0035]
After the hard urethane foam as the heat insulating layer 3 is hardened and cooled, the press body Tp is opened, the corner fitting 12 of each mold Dp is removed, and the partition plate 6 is removed, so that the rigid urethane foam (heat insulating layer) 3 is flat. The heat insulating composite panel 1 of the present invention, which is integrally fixed to the steel plate 4c, the kraft paper 8 and the fireproof covering material 9, is obtained.
When the partition plate 6 is detached, the inner surface of the side plate 6S and the inner surface of the partition plate are easily released since the polyethylene plate 6b is provided as a release plate.
The strip base material 5 also projects at the depth t1 of the groove 6G of the partition plate, is buried in the heat insulating layer 3 at the depth t2, and is firmly held by the anchor portion 50.
[0036]
[Use of thermal insulation composite panel 1 (FIGS. 7 and 8)]
The heat-insulating composite panel 1 obtained in the above embodiment is extremely effective if applied to a new reinforced concrete external heat-insulating building previously proposed by the present inventor as Japanese Patent Application No. 2001-025142.
That is, as shown in FIG. 7, the lower end of the heat insulating composite panel 1 is inserted through the mounting hole H1 of the panel lower frame 4b through a connecting pin (mounting pin) MP protruding from the mounting hardware M fixed to the front end of the concrete floor slab S. The panel lower end face Fb is located below the floor slab surface Sf so as to prevent rainwater from entering the floor slab surface Sf from the panel lower end, and the upper end of the panel 1 is placed on the upper floor as shown in FIG. Of the floor slab formwork and the connecting pin MP.
[0037]
In this case, since the strip base material 5 has a space D2 with the panel lower end Fb at the lower end and a space D1 with the panel upper end at the upper end, the base material 5 has unevenness on the surface Sf of the lower floor slab S. However, due to the existence of the gap db, the work of the formwork can be easily carried out without interference of the base material 5 due to the presence of the space D1 even when assembling the upper floor slab formwork.
When the concrete is poured into the upper floor slab formwork, the panel 1 is integrated with the floor slab S without gaps because the refractory coating material 9 and the heat insulating layer 3 have large concrete adhesion and small water absorption. Even if concrete mixed water flows out and adheres to the heat insulating layer surface 3f due to concrete casting, no mold is generated on the heat insulating layer surface 3f after dismantling the floor slab formwork.
[0038]
Then, at the time of interior construction, even if a gypsum board (interior face plate) is stretched on the base material surface 5f projecting from the heat insulating layer surface 3f by t1 (FIG. 6), the propagation of mold from the composite panel 1 side to the gypsum board. No pollution occurs.
In addition, the gap layer between the gypsum board and the heat insulating layer surface 3f formed by the protrusion of the base material 5 can be used as an electric wiring space, and loss of the heat insulating layer due to wiring work can be minimized.
In addition, since the gap layer between the gypsum board and the heat insulating layer surface 3f suppresses the resonance phenomenon of the sound between the gypsum board and the heat insulating layer 3, it is possible to prevent the sound insulation from being reduced due to the resonance phenomenon.
The joint between the cement plate layers 2 and the joint between the cement plates 2P are exterior finishes after the panel is stretched, and as shown in FIG. 3 (B), are joint-finished by the fireproof sealing 24 via the backer 24 '. .
[0039]
Accordingly, since the book wall formed by the panel of the present invention prevents the cement plate layer 2 and the heat insulating layer 3 from being integrally fixed by the kraft paper 8, the heat insulating layer 3 is not affected by an earthquake, a strong wind or the like. Can be displaced between the cement board layer 2 and the cement board layer 2, so that cracks and defects at the contact edge of the interior face board stretched on the inner surface of the heat insulating layer can be suppressed to a minimum.
In addition, since the upper frame, the lower frame, the Z clip portion and the like are protected by the refractory covering material 9 and the Z clip is also prevented from being integrally fixed by the heat insulating layer 3, the cement plate layer 2 and the frame body 4 formed by the Z clip are connected. It is also possible to absorb the interlayer displacement, and by absorbing the displacement of the cement plate layer 2 at the time of the earthquake, it is possible to prevent the occurrence and cracking of the cement plate layer 2 and to provide a suitable earthquake-resistant outer wall.
In addition, since the seam of the cement board 2P is also provided with the non-combustible packing 23, the outer wall constructed of the panel is protected from a fire from the outside by the non-combustible packing 23 at the joint portion and a fire from the inside by the refractory coating material 9. It also serves as a fire protection outer wall.
[0040]
Further, even if the heat-insulating composite panel 1 is adopted as a book wall of a conventional steel-framed building, since the base material 5 has the intervals D1 and D2 at the upper end and the lower end of the panel, the heat-insulating composite panel 1 can be applied to the steel frame of the panel. Attachment can be carried out without interference of the base material 5, and a clean interior face plate can be stretched at a desired time. In addition, the presence of a gap layer between the interior face plate and the heat insulating layer 3 through the base material 5 lowers sound insulation. Can be suppressed.
Of course, even if it is adopted as a book wall of a steel frame building, it becomes an outer wall having suitable earthquake resistance and fire resistance.
Therefore, the heat insulating composite panel 1 can provide an earthquake-resistant and fire-resistant outer wall both as a book wall panel of a reinforced concrete building and as a book wall panel of a steel frame building, and becomes an extremely excellent heat insulating composite panel.
[0041]
[Others]
If the plurality of vertical flat steel plates 4c as frame constituent members are connected and fixed to each other by a steel plate or a steel bar in the horizontal direction, it is possible to reliably prevent the heat insulating layer 3 from floating.
Further, if stainless steel having a smooth surface is adopted as the partition plate 6, it is easy to attach to the frame 4 and assemble the forming die, and also to temporarily hold the strip base material 5 by the screw means. .
If necessary, a supporting iron plate may be extended and fixed in the opposite direction of the rising side 4F in a proper position of the lower frame 4b, and the cement plate layer 2 may be received by the supporting iron plate. And the supporting iron plate, and the falling off of the cement plate layer 2 from the frame 4 can be completely prevented.
The intended purpose as a base material can be achieved even if the strip base material 5 made of a nonmetallic material is arranged vertically.
[0042]
【The invention's effect】
Since the steel frame 4 is only the reinforcing steel 4c embedded in the upper frame 4a, the lower frame 4b, and the heat insulating layer 3, thermal bridge prevention is limited to the upper frame and the lower frame which are easy to process, and the heat insulating function is reduced. Less insulation panels.
Further, since the inner surfaces of the upper frame 4a and the lower frame 4b and the Z clip are protected by the fire-resistant coating material, the Z clip is prevented from being integrally fixed by the heat insulating layer 3, and the interlayer displacement between the cement plate layer 2 and the frame 4 is prevented. Can be absorbed by the Z-clip, resulting in an insulating composite panel having earthquake resistance and fire resistance.
[0043]
In addition, since the sheet material 8 is present at the interface between the cement plate layer 2 and the heat insulating layer 3 to prevent the cement plate layer 2 and the heat insulating layer 3 from being integrally fixed, the cement plate layer 2 and the heat insulating layer 3 Can be suppressed, and the occurrence of cracks in the interior face plate fixed to the cement plate layer 2 or the heat insulating layer 3 due to the displacement of the frame due to an earthquake or strong wind can be suppressed.
Moreover, since the cement board layer 2 connects the plurality of cement boards 2P via the non-combustible packing 23, the cement board layer 2 exhibits fire resistance even from a fire from outside the panel.
[0044]
Further, since the heat insulating layer 3 has the strip base material 5 embedded and exposed on the surface, the interior face plate is stuck to the base material 5 after the panel 1 is assembled. There is no need to consider contamination, and construction is easy.
In addition, since the base material 5 protrudes from the heat insulating layer surface 3f, there is a gap layer between the stretched interior face plate and the heat insulating layer surface 3f. The sound resonance function is improved by blocking the resonance phenomenon of the sound with the layer 3.
[Brief description of the drawings]
FIG. 1 is a partially cutaway perspective view of a heat insulating composite panel of the present invention.
FIGS. 2A and 2B are partial enlarged views of the panel of the present invention, wherein FIG. 2A is a cross-sectional view taken along line AA of FIG. 1, FIG. 2B is a cross-sectional view taken along line BB of FIG. It is a perspective view.
3A and 3B are explanatory diagrams of a cement plate layer 2 of the panel of the present invention, wherein FIG. 3A is a view showing a parallel connection state of cement plates 2P, and FIG. 3B is an enlarged view of a portion B of FIG.
4A and 4B are explanatory views of the present invention, wherein FIG. 4A is a perspective view without a heat insulating layer, and FIGS.
5A and 5B are explanatory views of a partition plate, wherein FIG. 5A is an overall perspective view, FIG. 5B is a perspective view of a corner fitting, and FIG.
6A and 6B are explanatory diagrams of a molding die, wherein FIG. 6A is an explanatory diagram of a set state of one panel mold, FIG. 6B is an enlarged view of a B portion of FIG. 6A, and FIG. It is a perspective view.
FIGS. 7A and 7B are explanatory diagrams of a use state of the panel of the present invention to a book wall panel of a reinforced concrete building, wherein FIG. 7A shows a fixed state of the upper and lower ends of the panel, and FIG. It is a figure showing an assembly state.
FIG. 8 is a schematic perspective view of the panel of the present invention applied to a reinforced concrete building.
9 (A) is a perspective view of the entire panel, FIG. 9 (B) is a sectional view taken along line BB of FIG. 9 (A), and FIG. 9 (C) is a sectional view taken along line CC of FIG. 9 (A). .
[Explanation of symbols]
1: Heat insulation composite panel, 2: Cement board layer,
2P: cement board (molded cement board), 2h: through hole (vent layer),
3: heat insulation layer, 3f: heat insulation layer surface, 4: frame (frame),
4a: Upper frame, 4b: Lower frame, 4c: Reinforced steel (flat steel plate),
4F: rising edge, 4H: horizontal edge,
5: strip base material (base material), 5f: base material surface,
6: partition plate, 6a: structural plywood,
6b: polyethylene plate (release plate), 6G: groove,
6S: partition plate side plate (rising side),
7: Z clip, 8: Sheet material (kraft paper),
9: refractory coating material, 21: recess, 22: protrusion,
D1, D2: interval

Claims

A frame body (4) in which an upper frame (4a) and a lower frame (4b) made of a steel material are connected by a reinforcing steel material (4c), a cement plate layer (2) as an outer surface material, and a heat insulating layer ( 3), the cement board layer (2) has upper and lower ends attached to the upper frame (4a) and the lower frame (4b) via the Z-clip (7), and the heat insulating layer (3) has the upper frame ( 4a) and the inner surfaces of the lower frame (4b), including the Z-clip (7), are covered with a water-resistant refractory coating material (9), and the inner surface of the frame (4) is filled with a heat insulating layer (3) to form an integrated foam. Insulation composite panel.

The upper frame (4a) and the lower frame (4b) are equilateral angle irons, and the reinforcing steel material (4c) moves up and down the center of the width (4T) of the rising side (4F) of the upper frame (4a) and the lower frame (4b). 2. The heat insulating composite panel according to claim 1, wherein said panel is connected and fixed to said panel.

A sheet material (8) is interposed at the interface between the inner surface of the cement board layer (2) and the heat insulating layer (3) to prevent solidification adhesion of the heat insulating layer (3) to the cement board layer (2). 1 or 2 insulating composite panels.

4. A cement plate layer (2) comprising a ventilation layer (2h) for conducting outside air, a projection (22) at one end and a recess (21) at the other end. Or the heat insulating composite panel of item 1.

The heat insulating composite panel according to any one of claims 1 to 4, wherein the cement board layer (2) as the outer surface material is a parallel connection of a plurality of molded cement boards (2P).

6. The heat insulation according to claim 5, wherein the parallel connection of the molded cement plates (2P) is a contact connection between the projection (22) at one end and the recess (21) at the other end via a non-combustible packing (23). Composite panel.

The heat insulating composite panel according to claim 5 or 6, wherein the reinforcing steel material (4c) is disposed between the upper and lower frames (4a, 4b) at the center of the width (2W) of each cement board (2P).

The reinforcing steel material (4c) is a flat steel plate, and the plurality of flat steel plates (4c) connect the upper and lower frames (4a, 4b) at an intermediate portion of the thickness (3T) of the heat insulating layer (3), and The heat insulating composite panel according to any one of claims 1 to 7, which is integrated with (1).

The heat insulating composite panel according to any one of claims 1 to 8, wherein each of the rising edges (4F) of the upper frame (4a) and the lower frame (4b) has a mounting hole (H1, H2, H3, H4).

The heat insulating composite panel according to any one of claims 1 to 9, wherein the heat insulating layer (3) burying and exposing the strip base material (5) in parallel on the surface.

The heat insulating composite panel according to claim 10, wherein the surface (5f) of the strip base material (5) protrudes from the heat insulating layer surface (3f).

The strip base material (5) is vertically arranged, and has an upper end having an interval (D1) with the panel upper end surface (Ft), and a lower end having an interval (D2) with the panel lower end surface (Fb). 11 thermal insulation composite panels.

The strip base material (5) is a non-metallic material such as a plastic material or wood having a trapezoidal cross section, and has an interval (D1) from the panel upper end surface (Ft) and an interval (D2) from the panel lower end surface (Fb). The heat-insulating composite panel according to claim 10 or 11, wherein the heat-insulating composite panel is arranged in a horizontal direction while keeping the trapezoidal upper side surface protruding.