JP2006097411A - Building panel unit and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a building panel unit for use in constructing a building structure such as a dome-like roof or other large-span roofs, and to provide its manufacturing method. <P>SOLUTION: The inside of a sealed space filled with foam resin at high pressure is divided by partition members arranged within a frame face of a peripheral side frame, to form a plurality of cells. Each cell has a filling port and an air vent hole. The volume of the cell before filling the foam resin is set to a size to spread the filled foam resin to every corner. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention belongs to the technical field of a building panel unit and a method for manufacturing the same, for example, when constructing a building structure such as a dome-shaped roof or other large span and large span roofs. The present invention relates to a large-sized building panel unit and a method of manufacturing the same.

  Conventionally, various building panel units have been developed in order to construct a building structure simply and lightly. In general, the metal thin plates forming the upper and lower surfaces are filled with foamed resin at a high pressure to form a peeled shape, which is lightweight and has high strength (Patent Documents 1 to 3).

  By the way, as a means to ensure the strength of the flat panel unit, the panel unit of Patent Document 4 has a crosspiece disposed in the frame surface of the peripheral frame frame, and an opening is provided in the crosspiece frame so that foam resin is used. It is devised not to disturb the distribution when filling.

JP 58-163635 A JP 60-101038 A JP 2003-206593 A Japanese Patent Laid-Open No. 10-252214

  When a typical two-component hard foamed urethane resin is considered as the foamed resin, the chemical reaction process from mixing the two stock solutions to curing is as shown in FIG. That is, if the filling operation is not completed within 20 seconds to 30 seconds, the foamed resin rapidly expands and cures, and the foamed resin may not reach all the corners of the metal sheet.

  On the other hand, the discharge capacity of a machine filled with foamed resin is about 100 N / min with a general low-pressure machine.

Therefore, even if the filling time of the foamed resin is set to the longest 30 seconds, only a foamed resin of about 50 N (the volume is about 0.15 m ^{3 in} the foamed state) can be filled. As an example, the length of one side (L ) And the thickness (d) ratio is set to (d / L) = 0.021, the square panel unit has a side of about 2.0 m as is apparent from FIG. It is a limit.

  However, the panel units of Patent Documents 1 to 4 are not configured to be filled with foamed resin a plurality of times, but are configured to complete filling of the foamed resin at a single time. I can't. Therefore, it is impossible to construct a large span building structure with the panel units of Patent Documents 1 to 4.

  An object of the present invention is to divide a sealed space formed by upper and lower metal thin plates and a peripheral frame frame with a partition material, and to set a cell with a preset volume so that foamed resin to be filled later reaches every corner. A large-sized building panel unit and a method of manufacturing the same can be provided by forming a plurality of the above and filling the cells with the foamed resin at a high pressure so that the foamed resin can be reliably distributed to every corner.

As means for solving the problems of the prior art, the building panel unit according to the invention described in claim 1 is:
An architectural panel in which a metal thin plate forming the upper and lower surfaces of the panel unit is attached to a peripheral frame frame to form a sealed space, and a foamed resin is filled in the sealed space with high pressure to give a certain film tension to the metal thin plate. A unit,
A plurality of cells are formed by dividing the inside of the sealed space filled with the foamed resin with high pressure by a partition material arranged in the frame surface of the peripheral frame, and each cell has a filling port, an air vent port, Having
The volume of the cell before filling with the foamed resin is set to a size that allows the filled foamed resin to reach every corner.

The manufacturing method of the building panel unit according to the invention described in claim 2
A panel unit for building is formed by attaching a metal thin plate that forms the upper and lower surfaces of the panel unit to the peripheral frame frame to form a sealed space, and filling the metal thin plate with a certain film tension by high-pressure filling with foamed resin in the sealed space. A method of manufacturing
The partition material is arranged in the frame surface of the peripheral frame frame to divide the sealed space formed by the upper and lower metal thin plates and the peripheral frame frame, so that the foam resin filled later spreads to every corner. Forming a plurality of pre-set cells,
Each of the cells is provided with a filling port and an air vent port, and air is removed from the air vent port while filling the foamed resin with a high pressure from each fill port.

Invention of Claim 3 in the manufacturing method of the building panel unit described in Claim 1 or the building panel unit described in Claim 2,
The volume V of the cell before filling with the foamed resin is obtained by the following [Equation 1],
[Formula 1] V ≦ (0.5 · Q) / (α · ρ)
However, Q (N / min): the foaming resin discharge capacity of the filling machine, α: the size and thickness of the cell, the rigidity of the metal sheet, the physical properties of the foam resin, the discharge pressure of the filling machine, etc. Filling magnification, ρ (N / m ³ ): Characterized by standard density of foamed resin.

Invention of Claim 4 is the manufacturing method of the building panel unit described in Claim 1 or the building panel unit described in Claim 2,
The thin metal plate is characterized in that a large plate is formed by seam welding a plurality of strips such as stainless steel plates so that the weld lines are substantially parallel.

Invention of Claim 5 in the manufacturing method of the panel unit for building or the panel unit for building described in any one of Claims 1-4,
The partition material is set up substantially vertically on the metal thin plate, the metal thin plate is attached to each of the peripheral frame frames so that the surfaces having the partition material face each other, and the upper and lower partition materials are wrapped by a predetermined length, thereby providing a sealed space. A plurality of cells having a preset volume are formed therein.

Invention of Claim 6 in the manufacturing method of the building panel unit or building panel unit as described in any one of Claims 1-5,
A partition material is set up substantially vertically on the metal thin plate, and the metal thin plates are attached to the peripheral frame frame so that the surfaces having the partition material face each other, and the upper and lower partition materials are arranged as a partition material in the diagonal direction of the peripheral frame frame. A plurality of cells having a predetermined volume are formed in the sealed space by wrapping the plate-like brace material and a predetermined length.

Invention of Claim 7 is the manufacturing method of the panel unit for building or the panel unit for building described in Claim 5 or 6,
The length in which the upper and lower partition members are wrapped with each other or with the brace member is set to a length that can maintain the wrap state even when the foamed resin is filled.

Invention of Claim 8 is the manufacturing method of the building panel unit or building panel unit as described in any one of Claims 1-7,
The partition material is arranged along the weld line of the thin metal plate.

The invention according to claim 9 is the method for manufacturing the building panel unit according to claim 1 or the building panel unit according to claim 2,
The filling port is arranged at a substantially central portion of each cell in the peripheral frame of the panel unit, and the air vent is arranged in the vicinity of the cell inner corners on both sides of the filling port.

Invention of Claim 10 in the manufacturing method of the panel unit for building or the panel unit for building described in Claim 1, 2 or 9,
The air vent is arranged in the vicinity of the corner in the cell on the side opposite to the side on which the filling port is arranged.

  In the method for manufacturing a building panel unit according to the present invention, the enclosed space formed by the upper and lower metal thin plates and the peripheral frame is divided by a partition material so that the foamed resin to be filled later reaches every corner. A plurality of cells with a preset volume (that is, a volume that can be filled with foamed resin at one time) are formed, and each cell is filled with foamed resin at a high pressure, so that the foamed resin can be spread to every corner of the cell. The panel unit can be formed into a large plate as the aggregate. In addition, since the foamed resin can be spread to every corner of the cell, the upper and lower metal thin plates are firmly inflated outwards to generate a convex lens-like peeling on the metal thin plate, and a predetermined size is set. The film tension can be reliably applied as prestress.

  Since the building panel unit according to the present invention is formed into a large plate as an aggregate of cells in which foamed resin spreads to every corner, for example, it is used as a roof member or a wall member to construct a large span building structure. be able to.

  A plurality of cells are formed by dividing the inside of the sealed space filled with the foamed resin with high pressure by a partition material arranged in the frame surface of the peripheral frame. Each cell has a filling port and an air vent. The volume of the cell before filling with the foamed resin is set to a size that allows the filled foamed resin to reach every corner.

  Embodiments of the building panel unit and the manufacturing method thereof according to the inventions described in claims 1 to 5 and claims 7 to 10 will be described with reference to FIGS.

  First, the manufacturing method of the building panel unit (hereinafter sometimes simply referred to as a panel unit) 1 according to the present invention will be described, and then the panel unit 1 according to the present invention manufactured by the manufacturing method will be described. The configuration will be described.

  In this manufacturing method, substantially the same as the manufacturing method of a conventional panel unit, the metal thin plates 2 and 2 forming the upper and lower surfaces of the panel unit 1 are attached to the peripheral frame frame 3 to form the sealed space 4. The foamed resin 5 is filled with a high pressure to give a certain film tension to the thin metal plates 2 and 2, but the sealed space 4 is divided to form a plurality of cells 6 as shown in FIGS. Later, each cell 6 is filled with foamed resin 5.

  Specifically, the partition material 7 is arranged in the frame surface of the peripheral frame 3 to divide the sealed space 4, and a predetermined volume (that is, a foamed resin 5 to be filled later) is spread to every corner (that is, A plurality of cells 6 having a volume capable of being filled with the foamed resin 5 at one time are formed.

As the means, first, the volume V of the cell 6 is obtained by the following [Equation 1] (the invention according to claim 3).
[Formula 1] V ≦ (0.5 · Q) / (α · ρ)
However, Q (N / min): the foaming resin discharge capacity of the filling machine, α: the size and thickness of the cell, the rigidity of the metal sheet, the physical properties of the foam resin, the discharge pressure of the filling machine, etc. Filling magnification, ρ (N / m ³ ): Standard density of foamed resin

  Next, four stainless steel strips 2a cut out from a standard roll material having a width dimension of about 1.2 m (however, the number of sheets is not particularly limited) so that the welding line A is substantially parallel. The large metal sheet 2 is formed by seam welding (see FIGS. 3 and 4, the invention according to claim 4). Since the weld lines A do not intersect, the welding operation is easy and the rain finish is good.

  In this embodiment, one surface of the thin metal plate 2 (the surface having the bent welding allowance 8 in FIG. 4) is formed so that the inside of the sealed space 4 can be divided to form the cell 6 having the volume set as described above. 3), the three partition members 7 are erected substantially vertically in an arrangement along the weld line A. Since the welding allowance 8 exhibits a role as a reinforcing rib, a rigidity effect can be expected and the partition material 7 can be easily joined. Then, the two thin metal plates 2 and 2 are attached to the peripheral frame frame 3 so that the surfaces having the partition material 7 face each other, and the upper and lower partition materials 7 and 7 are wrapped by a predetermined length. As a result, the partition member 7 is disposed in the frame surface of the peripheral frame 3 and four cells 6 having a rectangular shape in plan view are formed in the sealed space 4 with a preset volume. (Invention of Claim 8)

Incidentally, the length for wrapping the upper and lower partition members 7, 7 is set to a length H ₁ that can maintain the wrap state even when the foamed resin 5 is filled later (see FIG. 4, claim 7). invention). Therefore, the filled foamed resin 5 does not leak into the adjacent cells 6, and the foamed resin 5 can be reliably filled into the cells 6.

  Although not specifically shown, the peripheral frame 3 is provided with the filling port 9 and the air vent port 10 in advance in order to arrange the filling port 9 and the air vent port 10 in each cell 6. Then, air is removed from the air vent 10 while filling the foamed resin 5 with a high pressure from the filling port 9 of each cell 6 (see FIG. 2). Since each cell 6 has a volume that can be filled with the foamed resin 5 at a time, the foamed resin 5 can be spread to every corner of the cell 6, and the panel unit 1 can be made into a large plate as an aggregate. Can be formed. In addition, since the foamed resin 5 can be spread to every corner of the cell 6, the upper and lower metal thin plates 2, 2 are firmly inflated outwardly to generate a convex lens-like peeling on the metal thin plates 2, 2. Thus, a predetermined film tension can be reliably applied as prestress.

  The filling port 9 is arranged at a substantially central portion of each cell 6 in the peripheral frame 3 of the panel unit 1 (in this embodiment, a substantially central portion of one short side 6a of the cell 6 having a rectangular shape in plan view). The air vent 10 is arranged in the vicinity of the cell inner corners on both sides of the filling port 9 (the invention according to claim 9). And since the cell 6 of a present Example is long in depth, the air vent 10 is arrange | positioned also in the cell inner corner vicinity of the short side 6b which opposes the short side 6a in which the said filling port 9 is arrange | positioned ( (Invention of Claim 10) The filled foamed resin 5 spreads to the inner corner on the depth side of the cell 6 so as to be guided to the air excluded from the air vents 10 and 10 disposed on the short side 6 b of the cell 6. Then, it is pushed back to the cured foamed resin 5 and now reaches the inner corner on the front side of the cell 6 so as to be guided to the air removed from the air vents 10 and 10 disposed on the short side 6a of the cell 6. Reasonably, the foamed resin 5 can be filled to every corner of the cell 6.

  In the panel unit 1 manufactured by the above manufacturing method, the inside of the sealed space 4 in which the foamed resin 5 is filled with high pressure is divided by the partition material 7 disposed in the frame surface of the peripheral frame frame 3, so that a plurality of cells 6 are obtained. Are formed, and each cell 6 has a filling port 9 and an air vent 10. The volume of the cell 6 before filling with the foamed resin 5 is set to a size that allows the foamed resin 5 to be filled to reach every corner (the invention according to claim 1). Since the panel unit 1 is formed into a large plate (4 m to 8 m) as an assembly of cells 6 in which the foamed resin 5 has spread to every corner, the panel unit 1 is used as a roof member or a wall member, for example. Building structures can be built.

  In this embodiment, the partition member 7 is joined to the surface having the welding allowance 8 of the thin metal plate 2 as shown in FIG. 4, but the partition member 7 is joined to the opposite surface as shown in FIG. Can be similarly implemented.

  In this embodiment, the partition member 7 is disposed along the weld line A of the thin metal plate 2. However, the partition member 7 may be disposed so that a cell 6 having a preset volume can be formed in the sealed space 4. .

  As shown in FIGS. 6 and 7, the panel unit 11 of this embodiment forms a cell 6 by arranging a plate-like brace material 12 as a partition material in the sealed space 4.

  Specifically, two plate-like brace members 12, 12 are crossed and integrated, a rectangular peripheral frame frame 3 having the brace members 12, 12 as diagonal lines is assembled, and the frame of the peripheral frame frame 3 is assembled. The brace materials 12 and 12 are arranged in the plane. The outer peripheral length, height, and the like of the peripheral frame 3 are adjusted so that a cell 6 having a preset volume can be formed in the sealed space 4 later by the brace materials 12 and 12.

  In addition, as shown in FIG. 6, when the both ends of the brace material 12 protrude from the peripheral frame frame 3, the said protrusion part can be used as a blade | wing material.

  A partition material 13 arranged along the brace material 12 is erected substantially vertically on the metal thin plate 2 when the metal thin plate 2 is attached to the peripheral frame 3. The two thin metal plates 2 and 2 are attached to the peripheral frame frame 3 so that the surfaces having the partition material 13 face each other, and the upper and lower partition materials 13 and 13 are connected to the plate-like brace material 12 and a predetermined length. Wrap it. As a result, four cells 6 having a triangular shape in plan view are formed in the sealed space 4 (the invention according to claim 6).

  Thereafter, the foamed resin 5 is filled with high pressure from the filling port (not shown) of each cell 6 as in the first embodiment. Since the brace material 12 is disposed in the frame surface of the peripheral frame 3, the rigidity of the panel unit 11 can be increased.

Incidentally, when the length of the upper and lower partition members 13 and 13 to be wrapped with the brace material 12 is set to a length H ₂ that can maintain the wrapped state even when the foamed resin 5 is filled, it is convenient as in the first embodiment. (Invention of claim 7)

  In the second embodiment, the brace material 12, 12 arranged in the diagonal direction of the peripheral frame 3 is used as a main member to divide the inside of the sealed space 4 to form four cells 6. Although not shown in the figure, partition members 14 and 14 wrapped up and down in the same manner as in the first embodiment are used together as a main member, and the sealed space 4 is divided into a plurality (12 pieces in FIG. 8). Cells 6 may be formed (see FIG. 8).

  The panel units 1 (11) of the first to third embodiments wrap the partition material 7 (13, 14) for a predetermined length. If the gap generated when the foamed resin 5 is filled is slight, There is no need to wrap. In short, since the foamed resin 5 rapidly expands and hardens, the sealing property of the cell 6 may not be perfect, and the material of the partition material and the joining method are not particularly limited.

  Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments and can be implemented in various forms without departing from the gist of the present invention.

1 is a structural diagram schematically showing a building panel unit of Example 1. FIG. It is the top view which showed roughly the cell formed in the sealed space of the panel unit for building, and the filling port and air vent which were arrange | positioned at the said cell. It is the perspective view which showed the metal thin plate. It is the expanded sectional view which showed the lapping state of the partition material. It is sectional drawing which showed notionally the metal thin plate which has arrange | positioned the welding allowance outside. It is the perspective view which showed schematically the panel unit for construction of Example 2. FIG. It is the figure which showed the lapping state of a partition material and a brace material. It is the top view which showed schematically the panel unit for construction of Example 3. FIG. It is the figure which showed the chemical reaction process of the foamed resin. It is the figure which showed the relationship between the size of a square-shaped panel unit, and the weight of the foaming resin required for filling.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Construction panel unit 2 Metal thin plate 3 Peripheral frame 4 Sealed space 5 Foamed resin 6 Cell 7 Partition material 9 Filling port 10 Air vent 11 Building panel unit 12 Brace material (partition material)
13 Partition material 14 Partition material A Welding line H ₁ , H ₂ Wrap length of partition material

Claims (10)

An architectural panel in which a metal thin plate forming the upper and lower surfaces of the panel unit is attached to a peripheral frame frame to form a sealed space, and a foamed resin is filled in the sealed space with a high pressure to give a certain film tension to the metal thin plate. A unit,
A plurality of cells are formed by dividing the inside of the sealed space filled with the foamed resin with high pressure by a partition material arranged in the frame surface of the peripheral frame, and each cell has a filling port, an air vent port, Having
The building panel unit is characterized in that the volume of the cell before filling with the foamed resin is set to a size that allows the filled foamed resin to reach every corner. A panel unit for building is formed by attaching a metal thin plate that forms the upper and lower surfaces of the panel unit to the peripheral frame frame to form a sealed space, and filling the metal thin plate with a certain film tension by high-pressure filling with foamed resin in the sealed space. A method of manufacturing
The partition material is arranged in the frame surface of the peripheral frame to divide the sealed space formed by the upper and lower metal thin plates and the peripheral frame, and the volume of the foam resin to be filled later is spread all over. Forming a plurality of pre-set cells,
A method for producing a building panel unit, wherein a filling port and an air vent port are provided in each of the cells, and air is excluded from the air vent port while being filled with foamed resin at a high pressure. The volume V of the cell before filling with the foam resin is obtained by the following [Equation 1]
[Formula 1] V ≦ (0.5 · Q) / (α · ρ)
However, Q (N / min): the foaming resin discharge capacity of the filling machine, α: the size and thickness of the cell, the rigidity of the metal sheet, the physical properties of the foam resin, the discharge pressure of the filling machine, etc. Filling magnification, ρ (N / m ³ ): The building panel unit according to claim 1 or the manufacturing method of the building panel unit according to claim 2, characterized by a standard density of foamed resin.   2. The building panel according to claim 1, wherein the metal thin plate is formed into a large plate by seam welding a plurality of strips such as stainless steel plates so that the welding lines are substantially parallel to each other. A method for manufacturing a unit or a building panel unit according to claim 2.   The partition material is set up substantially vertically on the metal thin plate, the metal thin plate is attached to each of the peripheral frame frames so that the surfaces having the partition material face each other, and the upper and lower partition materials are wrapped by a predetermined length, thereby providing a sealed space. A plurality of cells having a preset volume are formed in the building panel unit or the method for manufacturing a building panel unit according to any one of claims 1 to 4.   A partition material is set up substantially vertically on the metal thin plate, and the metal thin plates are attached to the peripheral frame frame so that the surfaces having the partition material face each other, and the upper and lower partition materials are arranged as a partition material in the diagonal direction of the peripheral frame frame. A plurality of cells having a predetermined volume are formed in the sealed space by wrapping with a plate-shaped brace material having a predetermined length, and the building according to any one of claims 1 to 5, Manufacturing method of panel unit or building panel unit.   The construction according to claim 5 or 6, wherein the length of the upper and lower partition members to be wrapped with each other or with the brace material is set to a length that can maintain the wrap state even when the foamed resin is filled. Of manufacturing panel unit for building or panel unit for building.   8. The manufacturing method of a building panel unit or a building panel unit according to any one of claims 1 to 7, wherein the partition material is disposed along the weld line of the metal thin plate.   The filling port is disposed at a substantially central portion of each cell in the peripheral frame of the panel unit, and the air vent is disposed in the vicinity of a cell inner corner on both sides of the filling port. The manufacturing method of the building panel unit described in Claim 1 or the building panel unit described in Claim 2.   10. The building panel unit or building panel according to claim 1, 2 or 9, wherein the air vent is arranged in the vicinity of a cell inner corner of a side facing the side where the filling port is arranged. Unit manufacturing method.

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