JP2010013851A - Tile unit and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a tile unit which firmly connects a tile even by using a small amount of resin of a connecting material, and also to provide a manufacturing method for the tile unit. <P>SOLUTION: The connecting material 12 is placed on a ruler table 20; the slender rod-like tiles 11 (11a-11f) are disposed in parallel on the connecting material 12; and the backsides of the tiles 11a-11f are integrated together by being bonded and connected to the connecting material 12 by heat treatment. The tile unit 10 is manufactured through the above steps. The connecting material 12 is formed in such a cord shape that a fiber 12b is coated with a coating material 12a. A thermoplastic resin or a reactive hotmelt is used as the coating material 12a. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a tile unit in which a plurality of tiles are arranged and adjacent tiles are connected by a connecting material, and a manufacturing method thereof.

  In recent years, a tile unit in which a plurality of tiles are integrated has been used in order to efficiently apply tiles to a wall surface of a building or a fence. As this tile unit, a tile unit in which a plurality of tiles are arranged in parallel and the back edges of adjacent tiles are connected by a connecting resin is used.

  In order to manufacture such a tile unit, as shown in FIG. 9, a connecting resin 32 is placed at a predetermined position on the surface plate 30, and the group of tiles 31 chucked by a vacuum chuck or the like is directed toward the surface plate 30. The tiles 31 are connected by the connecting resin 32 (for example, JP-A-2002-106148). As the connecting resin, a thermoplastic resin, a thermosetting resin, or the like is used.

  FIG. 10 is a cross-sectional view showing an example of a tile unit packing method. Each tile unit 40, 40A is formed by connecting six tiles 41 having different heights (thicknesses) with a connecting resin 42.

  In FIG. 10 (b), the tile unit 40A is directly stacked on the tile unit 40. For this reason, the connecting material 42 of the upper tile unit 40 </ b> A bends along the shape of the upper surface of the lower tile unit 40.

  According to the packing method of FIG. 10 (b), when the tile units 40, 40A immediately after manufacture are packed, the connecting material 42 is not sufficiently cured, so that the connecting material 42 of the upper tile unit 40A is It sticks to the upper surface of the tile 11 of the tile unit 40. Further, since the connecting member 42 is cured in the bent state of the upper tile unit 40A, the cured tile unit 40A has a bent shape. Further, since the connecting material 42 has a large thickness in order to ensure strength, the connecting material 42 is easily broken when the connecting material 42 is deformed. In order to avoid these problems, when the packaging material is cured until it is completely cured and then packed, it takes a long time to pack and a large curing space is required.

Therefore, as shown in FIG. 10 (a), the cushioning material 50 made of cardboard or the like is interposed between the tile units 40 and 40A. However, when the cushioning material 50 is used in this way, there are problems that the packaging cost is high and the amount of waste material generated on site is increased.
JP 2002-106148 A

  Since the conventional tile unit uses a connecting resin as a connecting material for tiles, it is necessary to use a large amount of the connecting resin and increase the thickness of the connecting material in order to ensure the strength of the connecting material. . For this reason, it takes a long time to cure the connecting resin. Further, when the tile unit is attached to the wall surface using the construction adhesive, it is necessary to increase the layer thickness of the construction adhesive.

  An object of this invention is to provide the tile unit which can connect a tile firmly even if the resin amount of a connection material is small, and the manufacturing method of this tile unit.

  The tile unit manufacturing method of the present invention (Claim 1) is a tile unit manufacturing method in which a plurality of tiles are arranged and the back surfaces of the tiles are connected to each other by a connecting material. The cord is coated with a covering material made of thermoplastic resin or reactive hot melt, and a plurality of tiles are mounted on the connecting material so that the covering material and the back surface of the tile are in contact with each other. And then the tile is bonded to the connecting material by heat treatment.

  The tile unit manufacturing method of the present invention (Claim 2) is a tile unit manufacturing method in which a plurality of tiles are arranged and the back surfaces of the tiles are connected to each other with a connecting material. It is of cord shape coated with a coating material made of thermoplastic resin or reactive hot melt, and a plurality of tiles are arranged so that the back surface is the top surface and straddles the back surfaces of the plurality of tiles The connecting material is placed on the tile, and then the tile is bonded to the connecting material by heat treatment.

  According to a third aspect of the present invention, there is provided a tile unit manufacturing method according to the first or second aspect, wherein after the tiles for a plurality of units are bonded to the connecting material by the heat treatment, the connecting material is cut for each unit.

  According to a fourth aspect of the present invention, there is provided the tile unit manufacturing method according to any one of the first to third aspects, wherein the connecting material is coated with the covering material over the entire length.

  According to a fifth aspect of the present invention, there is provided the tile unit manufacturing method according to any one of the first to fourth aspects, wherein the connecting member has a flat tape shape.

  The tile unit of the present invention (Claim 6) is manufactured by the method of any one of Claims 1 to 5.

  In the tile unit manufacturing method and the tile unit of the present invention, a fiber coated with a coating material made of thermoplastic resin or reactive hot melt is used as the connecting material. Thus, since the connecting material is reinforced with fibers, sufficient strength can be ensured even with a small amount of the covering material.

  In the method for manufacturing a tile unit according to claim 1, a plurality of tiles are placed on the connecting material so that the covering material and the back surface of the tile are in contact with each other, and then the tile is applied to the connecting material by heat treatment. Glue. At this time, since the tile is pressed against the connecting material by its own weight, the tile is firmly bonded to the connecting material.

  In the method of manufacturing a tile unit according to claim 2, a plurality of tiles are arranged so that the back surface thereof is an upper surface, and a connecting material is placed so as to straddle the back surfaces of the plurality of tiles, The tile is bonded to the connecting material by heat treatment. In this case, the tile is firmly bonded to the connecting material by pressing the connecting material from above with a weight or the like.

  In the tile unit manufacturing method according to the third aspect, after the tiles for a plurality of units are bonded to the connecting material by heat treatment, the connecting material is cut for each unit. Thereby, the improvement of the manufacturing efficiency of a tile unit can be aimed at.

  In the tile unit manufacturing method according to the fourth aspect of the present invention, a connecting material that is coated with a covering material over its entire length is used. Thereby, since the fibers are not exposed, dirt such as dust, dust, and organic matter can be adhered between the fibers, and fraying of the fibers can be prevented.

  In the tile unit manufacturing method according to claim 5, a flat tape-shaped one is used as the connecting material. Thereby, the contact area of a coating | covering material and a tile becomes large, and a tile adhere | attaches firmly on a connection material.

  Hereinafter, embodiments will be described with reference to the drawings. 1 is a front view of a tile unit according to an embodiment, FIG. 2 is a perspective view thereof, FIG. 3 is a perspective view of the back side thereof, FIG. 4 is a sectional view taken along line IV-IV in FIG. FIG. 5 is an explanatory diagram of a method for manufacturing a tile unit, and FIG. 6 is a cross-sectional view of a connecting material.

  In the present embodiment, as shown in FIG. 5, a connecting member 12 is placed on a surface plate 20, and a plurality of elongated rod-like tiles 11 (11a to 11f) are formed on the connecting member 12 (in this embodiment). 6) The tile unit 10 is manufactured by arranging in parallel and bonding and connecting the back surfaces of the tiles 11a to 11f to the connecting member 12 by heat treatment.

  As shown in FIGS. 5 and 6, the connecting member 12 has a flat cord shape (tape shape) in which fibers 12b are coated with a covering material 12a. Thus, since the connection material 12 is reinforced with the fibers 12b, the strength of the connection material 12 is high. For this reason, the connection material 12 is reliably prevented from being cut by the weight of the tile 11 or an external force. Moreover, since it is not necessary to ensure the strength of the connecting material 12 with the covering material 12a, the amount of the covering material 12a can be reduced. Thereby, the time required for hardening of the covering material 12a can be shortened.

  As this fiber 12b, glass fiber, synthetic fiber, carbon fiber or the like is preferably used. Examples of the synthetic fiber material include polyethylene, polypropylene, polyvinyl chloride, acrylic, vinylon, polyester, and nylon.

  As this covering material 12a, a thermoplastic resin or a reactive hot melt is used.

  Examples of the thermoplastic resin include polyethylene, polypropylene, polyamide, polyester, polyvinyl chloride, polycarbonate, polystyrene, polyurethane, polyvinyl alcohol, acrylic resin, urea resin, epoxy resin, and ethylene vinyl acetate copolymer. When the thermoplastic resin is used, when the tile of the tile unit is reused, the tile can be easily peeled off from the connecting material and recovered by applying heat to the tile unit.

  Examples of the reactive hot melt include polyurethane-based, silicone-based, polyolefin-based, acrylic-based, and epoxy-based resins or polymer alloy resins.

  As shown in FIG. 5, the connecting member 12 preferably has a flat tape shape. In this case, the contact area between the connecting material 12 and the tile 11 increases, and the connection strength increases. Moreover, since the thickness of the connection material 12 is small, when the tile unit 10 is stuck to a wall surface using a construction adhesive, the layer thickness of the construction adhesive can be reduced.

  Even when manufacturing tile units having different product numbers, it is preferable to use a connecting member 12 having a constant thickness. In this case, when tile units having different product numbers are attached to the wall surface, it is not necessary to change the layer thickness of the construction adhesive for each product number of the tile unit. In addition, the connection strength between the connecting material 12 and the tile should be appropriately designed by increasing / decreasing the number of the connecting materials 12 to be used or increasing / decreasing the width of the connecting materials 12 to be used for each tile unit having a different product number. Can do.

  It is preferable that the connecting material 12 is obtained by coating a plurality of fibers 12b aligned in parallel without twisting with a covering material 12a. Thereby, the thickness of the connection material 12 can be made small. Further, when the connecting material 12 and the tile 11 are brought into contact with each other and heat-treated, the covering material 12a spreads in the width direction of the connecting material 12, and the fibers 12b also spread in the width direction, and the covering material 12a The contact area with the tile 11 becomes sufficiently large. However, a twisted fiber 12b may be used.

  The width of the connecting member 12 is preferably 1 to 5 mm, particularly preferably 2 to 3 mm. The thickness of the connecting material 12 is preferably 0.2 to 4.0 mm, particularly 0.5 to 1.5 mm.

The ratio (d ₂ / d ₁ ) between the thickness d ₁ before heat treatment and the thickness d ₂ after heat treatment of the portion of the connecting material 12 in contact with the tile 11 is 0.05 to 0.80, particularly 0. The ratio (w ₂ / w ₁ ) between the width w ₁ before the heat treatment and the width w ₂ after the heat treatment is preferably 1.5 to 16.0, particularly 2.0 to 12.2. 0 is preferred.

  The covering material 12 a only needs to be coated on at least a portion of the connecting material 12 that contacts the tile 11. However, since the fiber 12b is not exposed when it is coated over the entire length of the connecting material 12, it is possible to prevent dirt, dust, organic matter, and the like from adhering between the fibers.

  The coating amount of the covering material 12a per unit length of the connecting material 12 is preferably 1.0 to 3.5 g / m, particularly 1.5 to 2.5 g / m.

  The diameter of the fiber 12b is preferably 8 to 20 μm, particularly preferably 10 to 18 μm, and the number of the fibers 12b in the connecting material 12 is preferably 500 to 2500, particularly preferably 1000 to 1800.

  The heat treatment conditions for adhering the tile 11 to the connecting material 12 by heat treatment are appropriately determined depending on the materials and dimensions of the connecting material 12 and the tile 11. About seconds. For example, with respect to a connecting material (width 3 mm, thickness 1.5 mm) formed by coating glass fibers (diameter 14 μm, 1400) with an ethylene vinyl acetate copolymer resin-based thermoplastic resin covering material over the entire length, ceramics When the tiles 11 (length 235 mm × width 13 mm × height 13 mm) are bonded, the heat treatment temperature is 65 to 180 ° C., and the heat treatment time is about 3 to 60 seconds.

  The tiles 11a to 11f of the present embodiment have the same length in the longitudinal direction and the short width (the width in the left-right direction in FIG. 4) and the height (the length in the vertical direction in FIG. 4) is different. is there. These tiles 11a to 11f are long and slender, whose length in the longitudinal direction is about 11 times the short width.

  In FIG. 1, the left end of the uppermost (first) tile 11a is positioned at the leftmost portion of the tile unit 10, and the right end of the second tile 11b is positioned at the rightmost end of the tile unit. The right ends of the third and fifth stage tiles 11c and 11e slightly recede to the left side of the right end of the second stage tile 11b, and the right ends of the fourth and sixth stage tiles 11d and 11f further Retreats to the left.

  Since the tiles 11a to 11f have the same length, when the tile units 10 are arranged side by side, the right end portion of the left tile unit 10 and the left end portion of the right tile unit 10 are completely united. The tile ends of the other tile unit enter between the tile ends of one tile unit.

  Therefore, a tile wall excellent in design property that does not allow vertical joints can be constructed by arranging and attaching the tile units to both flat portions of the wall surface in the vertical and horizontal directions.

  In the present embodiment, as shown in FIG. 3, two connecting members 12 are used for one tile unit 10, but the present invention is not limited to this, and three or more connecting members 12 may be used. Good.

  In the present embodiment, the tile unit 10 is manufactured by connecting one unit (six) of tiles 11 to the connecting material 12 having a length of one unit. However, the present invention is not limited to this. Absent. For example, the back surface of a tile for a plurality of units is brought into contact with a connecting material having a length for a plurality of units, and after the tile is bonded to the connecting material by heat treatment, the connecting material is cut into units to obtain a tile unit. Also good.

  In the tile unit 10 of the present embodiment, only one tile 11 is arranged in the longitudinal direction of the tile 11 (left and right direction in FIG. 1), but a plurality of tiles 11 may be arranged. For example, two tile units 10 are arranged to face each other in the longitudinal direction of the tile 11 (left and right direction in FIG. 1), and the left side of the tiles 11a, 11d, and 11f in the right tile unit 10 and the left tile unit 10 By connecting and bonding the connecting material 12 in the lateral direction of the tile 11 (vertical direction in FIG. 1) so as to straddle the right side of the back surface of the tiles 11b, 11c, and 11e, two pieces in the longitudinal direction of the tile 11 The tile unit may be twice as large as the tiles 11 arranged. The same applies when three or more tiles 11 are arranged in the longitudinal direction of the tiles 11.

  When arranging a plurality of tiles 11 in the longitudinal direction of the tiles 11, the connecting material 12 is arranged in the longitudinal direction of the tiles 11 (left and right direction in FIG. 1) so as to straddle the plurality of tiles 11 in the longitudinal direction. You may arrange and adhere. However, in this case, the connecting material 12 extending in the longitudinal direction (left and right direction in FIG. 1) of the tile 11 and the connecting material 12 extending in the short direction (up and down direction in FIG. 1) intersect. Therefore, it is preferable that the connecting member 12 extends in the short direction of the tile 11 as described above, since the crossing portion may become thick.

  1 to 6, the tiles 11 are placed on the connecting material 12 and heat-treated to manufacture the tile unit. However, as shown in FIG. A tile unit may be manufactured by placing the connecting member 12 on the back surface of the substrate and heat-treating it.

  As shown in FIG. 7, a plurality of (six in the present embodiment) recesses 21a to 21f having different depths are provided on the upper surface of the surface plate 21. In these recesses 21a to 21f, a plurality of (six in this embodiment) tiles 11a to 11f having different heights are arranged with the back surface facing up. At this time, the back surfaces of these tiles 11a to 11f have the same height.

  Next, the connecting material 12 is disposed so as to straddle the back surfaces of the tiles 11a to 11f. And the tile unit 10 is obtained by pressing the connecting material 12 from the upper side against the back surfaces of the tiles 11a to 11f and performing heat treatment using the presser plate 22.

  Note that the tile unit 10 may be manufactured without using the presser plate 22. In this case, in FIG. 7, the length of the connecting member 12 is made larger than the length of the tile unit 10 in the tile short direction (the length from the left end of the tile 11a to the right end of the tile 11f in FIG. 7). The left end and the right end of the connecting member 12 are extended from the left end of the tile 11a and the right end of the tile 11f. Then, the connecting material 12 is pressed against the back surface of the tile 11 by pulling both ends of the connecting material 12 downward in FIG. By performing heat treatment in this state, the tile unit 10 is obtained.

  FIG. 8 is a cross-sectional view for explaining a method of packing the tile unit.

  The tile unit 10 </ b> A and the tile unit 10 </ b> B are formed by connecting six tiles 11 with a connecting material 12. These tile units 10A and 10B are manufactured by the method shown in FIG. 1 to FIG. 6 or FIG.

  As shown in FIG. 8, the lower tile unit 10A and the upper tile unit 10B are directly stacked and packed without the cushioning material 50 of FIG. 10 (a) interposed therebetween. The reason for this will be described below.

  As shown in FIG. 6, the connecting material 12 of these tile units 10A and 10B is obtained by coating fibers 12b with a covering material 12a. Thus, since the connecting material 12 is reinforced with the fibers 12b, it is not necessary to secure the strength of the connecting material 12 with the covering material 12a, and the amount of the covering material 12a can be reduced. As a result, the connecting material 12 is excellent in flexibility. Therefore, even if the tile unit 10B is directly stacked on the tile unit 10A, the tile unit 10B flexes flexibly in accordance with the shape of the upper surface of the lower tile unit 10A, so that the covering material 12a is damaged. Is prevented. Further, since the connecting material 12 has a small amount of the covering material 12a, the covering material 12a is cured in a short time during cooling after the heat treatment. For this reason, even if the tile unit 10B is directly stacked on the tile unit 10A, the connecting material 12 of the tile unit 10B is prevented from sticking to the upper surface of the tile 11 of the tile unit 10A. When the tile unit 10B is taken out and used at the site, this bending is restored. Further, when the tile unit 10B is attached to the wall surface, it is possible to make a delicate adjustment by bending the connecting member 12 present at the joint of the tile unit 10B. For these reasons, the tile units 10A and 10B can be directly stacked and packed.

It is a front view of the tile unit which concerns on embodiment. It is a perspective view of the tile unit 10 of FIG. It is a perspective view of the back side of the tile unit 10 of FIG. It is sectional drawing which follows the IV-IV line of the tile unit 10 of FIG. It is explanatory drawing of the construction method of the tile unit 10 of FIG. 3 is a schematic cross-sectional view of a connecting material 12. FIG. It is explanatory drawing of the different construction method of the tile unit 10 of FIG. It is sectional drawing explaining the packing method of tile unit 10A, 10B. It is sectional drawing which shows the construction method of the conventional tile unit. It is sectional drawing explaining the packing method of the conventional tile unit.

Explanation of symbols

10, 10A, 10B Tile unit 11, 11a to 11f Tile 12 Coupling body 12a Coating material 12b Fiber 13 Gap 20, 21 Surface plate 22 Presser plate

Claims (6)

In the method of manufacturing a tile unit in which a plurality of tiles are arranged and the back surfaces of the tiles are connected by a connecting material,
The connecting material is a cord having a fiber coated with a coating material made of a thermoplastic resin or a reactive hot melt,
A plurality of tiles are placed on the connecting material so that the covering material and the back surface of the tile are in contact with each other,
Next, the tile unit is bonded to the connecting material by a heat treatment, and the tile unit manufacturing method is characterized in that: In the method of manufacturing a tile unit in which a plurality of tiles are arranged and the back surfaces of the tiles are connected by a connecting material,
The connecting material is a cord having a fiber coated with a coating material made of a thermoplastic resin or a reactive hot melt,
A plurality of tiles are arranged so that the back surface is the top surface, and the connecting material is placed so as to straddle the back surfaces of the plurality of tiles,
Next, the tile unit is bonded to the connecting material by a heat treatment, and the tile unit manufacturing method is characterized in that:   3. The method for manufacturing a tile unit according to claim 1, wherein tiles for a plurality of units are bonded to the connecting material by the heat treatment, and then the connecting material is cut for each unit.   4. The method for manufacturing a tile unit according to claim 1, wherein the connecting material is coated with the covering material over the entire length. 5.   5. The method for manufacturing a tile unit according to claim 1, wherein the connecting member has a flat tape shape.   A tile unit manufactured by the method according to any one of claims 1 to 5.

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