JP2010106554A - Construction panel, manufacturing method of construction panel, and construction method of construction panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a construction panel which makes possible significant weight reduction compared to a traditional construction panel, makes possible an increase in the thickness of the panel as a result, can make the handling and workability of the panel at a site of construction significantly favorable, can reduce manufacturing cost, and is excellent in heat insulation. <P>SOLUTION: The construction panel is composed of a substrate, a base layer, and a finishing layer formed on the surface of the base layer. The substrate is formed of an expandable synthetic resin, and the base layer is formed on the surface of the substrate. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a building panel, a method for manufacturing the building panel, and a construction method for the building panel. More specifically, the building panel is affixed to a wall of a building or a structure, and the building. The present invention relates to a panel manufacturing method and a construction method for constructing the building panel.

  Conventionally, various panels have been used as affixed to the walls of buildings and structures. For example, natural stone panels have been used in order to beautify the appearance and bring out a sense of quality. As natural stone, for example, marble or granite is used. However, as the thickness of the panel increases, the weight increases, it is difficult to handle, the workability is poor, and the cost is increased.

  Therefore, in order to solve such problems, various panels have been developed in which the surface of the panel is actually made of natural stone without actually using natural stone. Such patent applications have been filed.

  As described in claim 1 of Patent Document 1, the invention according to Patent Document 1 “a building panel provided with a natural stone surface material on one or both sides of a lightweight inorganic incombustible material core” It is. However, as described in paragraph [0008] of the specification of the patent document, the invention according to Patent Document 1 includes a volcanic gravel plate mixed with, for example, glass fiber as a core material of a lightweight inorganic incombustible material. Since the surface material is made of natural stone itself, it is lighter than the case where the whole panel is made of natural stone, but it reduces the weight or improves handling and workability. Has its limits. Moreover, since natural stone is stuck to the surface of the core material through an adhesive, the manufacture of the panel itself before construction at the construction site is complicated.

  Furthermore, as described in claim 1 of Patent Document 2, the invention according to Patent Document 2 “mixes an aggregate of 0.1 to 5.0 mm with a thermosetting resin and performs heat compression molding. It is related to a civil engineering and building panel manufactured by mixing aggregate with a thermosetting resin at a predetermined ratio. However, as described in paragraph [0010] of the specification of Patent Document 2, inorganic particles such as stone, ceramic, and glass are used as the aggregate, and also described in claim 1 and the like. As shown, the mixing ratio of the aggregate and the resin is 2 to 15 parts by weight of the resin with respect to 100 parts by weight of the aggregate. There is still a limit to improving the performance or improving the handling and workability.

  On the other hand, since it is lighter than natural stone, an architectural panel using artificial stone such as artificial marble has been developed. As an invention relating to such an artificial stone architectural panel, for example, Patent Document 3 below Patent applications have been filed. However, since the invention according to Patent Document 3 is a panel made of artificial marble with a metal edge frame attached, it is not possible to reduce the weight essentially and to improve handling and workability. There are still limits.

  Furthermore, since natural heat and artificial stones as described above do not have sufficient heat insulation properties, panels made of these natural stones and artificial stones cannot be provided with good heat insulation properties. Therefore, such a panel cannot be applied alone to, for example, an outer heat insulating method for a wall surface.

JP-A-5-72111 JP 2003-160367 A JP 2001-234680 A

  The present invention has been made to solve such problems, and can be significantly reduced in weight as compared with the conventional building panel as described above, and as a result, the thickness of the panel is increased. It is also possible to provide a building panel that can significantly improve the handling and workability of the panel at the construction site, reduce the manufacturing cost, and improve the heat insulation. Let it be an issue.

  In order to solve such problems, the present invention comprises a base material made of a foamable synthetic resin, a base layer provided on the surface of the base material, and a finish layer provided on the surface of the base layer. It is intended to provide an architectural panel characterized by being configured.

  A plurality of grooves are preferably formed on the surface of the substrate, and the groove is filled with a base layer to form ribs of the base layer. Preferably, a mesh is provided in the underlayer. The finishing layer is made of, for example, crushed stone, cement, and synthetic resin.

  Further, in the present invention, a base material is applied to the surface of a base material made of a foamable synthetic resin, dried and cured to form a base layer, a finishing material is poured into a mold, and the base layer is formed on the surface. After the base material is pressed against the finishing material and the finishing material is dried, the finishing material, the base layer, and the base material are removed from the mold, and the base material made of the foamable synthetic resin is removed. The present invention provides a method for manufacturing a building panel, characterized by manufacturing a building panel having a finish layer provided on the surface with a base layer interposed therebetween.

  By forming a plurality of grooves on the surface of the base material, in the step of applying the base material to the base material, the base material is filled in the groove portion of the base material, thereby, as described above, The rib of the foundation layer constituted by the foundation material is formed.

  Further, the present invention provides a building panel comprising a base material made of a foamable synthetic resin, a base layer provided on the surface of the base material, and a finishing layer provided on the surface of the base layer. The construction method of the panel for construction characterized by sticking and constructing to the construction places, such as, is provided.

  As described above, the building panel of the present invention is composed of a base material made of a foamable synthetic resin, a base layer provided on the surface of the base material, and a finishing layer provided on the surface of the base layer. Since the base material is made of a foamable synthetic resin, it is significantly lighter than a conventional building panel. As a result, the thickness of the panel can be increased, thereby providing a profound feeling, and, for example, by creating a natural stone tone or the like for the finishing layer, a high-class feeling can be exhibited along with the profound feeling. There is an effect that can be done.

  In addition, as described above, the substrate can be made of a foamable synthetic resin to significantly reduce the weight of the panel, so that the handling and workability of the panel at the construction site can be made significantly better than before. it can.

  Furthermore, since the base material is made of a foamable synthetic resin, the heat insulation of the panel is improved, and there is an advantage that it can be applied to, for example, an outer heat insulation method for a wall surface.

  Further, when a plurality of groove portions are formed on the surface of the base material and the base material is filled in the groove portions to form the ribs of the base layer, According to the fitting structure with the groove portion of the base material, both the base material and the base layer are reinforced, and not only the strength of the panel is improved, but also the base layer from peeling off from the base material is suitably prevented. effective.

  Furthermore, when the mesh is provided in the underlayer, the strength of the underlayer is further improved, and the peeling of the underlayer from the base material is more preferably prevented.

  Furthermore, in the method for manufacturing a building panel of the present invention, a base material is applied to the surface of a base material made of a foamable synthetic resin, dried and cured to form a base layer, and a finishing material is poured into the mold, After the base material having the base layer formed on the surface is pressed against the finishing material and the finishing material is dried, the finishing material, the base layer, and the base material are removed from the mold and foamed. This is a method for manufacturing a building panel in which a finishing layer is provided on the surface of a base material made of a synthetic resin via a base layer, so that the entire manufacturing process is simple and the manufacturing cost of the panel is reduced. There is an effect that can be.

  Furthermore, the construction method of the building panel of the present invention comprises a base material made of a foamable synthetic resin, a base layer provided on the surface of the base material, and a finishing layer provided on the surface of the base layer. Since the construction panel is attached to a construction site such as a wall surface, the base material is made of a foamable synthetic resin, the base layer provided on the surface of the base material, By preparing an easy-to-handle building panel composed of a finishing layer provided on the surface of the geological layer, it is easy to simply attach such a building panel to a construction site such as a wall surface. It is possible to carry out construction with a simple work, and the construction work is remarkably facilitated.

  Hereinafter, embodiments of the present invention will be described. As described above, the building panel of the present invention is composed of a base material made of a foamable synthetic resin, a base layer provided on the surface of the base material, and a finishing layer provided on the surface of the base layer. It has been made.

  Although the kind of expandable synthetic resin which comprises a base material is not specifically limited, For example, a foamed polystyrene can be used conveniently. This is because it is lightweight, easy to handle, inexpensive, and highly versatile as a synthetic resin. However, it is also possible to use synthetic resins other than expanded polystyrene, such as expanded polyethylene.

  In addition, the shape of the base material is not questioned, and it can be formed in any shape according to the construction location, but for the convenience of the work of attaching multiple panels to the construction location such as the wall surface, Are formed in rectangles or squares.

  Further, a plurality of grooves are preferably formed on the surface of the substrate. By forming such a plurality of groove portions on the base material, when the base material is applied to the surface of the base material, the base material is filled into the groove portions of the base material, and the base material is cured. When the base layer is formed, the portion of the base layer filled in the groove portion of the base material becomes a rib shape, and the portion of the base layer that becomes the rib shape and the groove portion of the base material are in a fitted state with each other. . As a result, both the base material and the base layer are reinforced by the fitting structure of the base layer rib and the groove portion of the base material, and the strength of the panel is improved. Moreover, peeling of the base layer from the base material is suitably prevented.

  The plurality of groove portions can be formed in a lattice shape, for example, by intersecting the surface of the substrate in the vertical and horizontal directions. However, the shape of the groove appearing on the surface of the substrate is not limited to the lattice shape, and can be formed in an arbitrary shape. Moreover, you may form a groove part in both the front side and back side of a base material, and it is also possible to form only in any one of a front side and a back side.

  Furthermore, joints can be formed on the side surfaces of the substrate. By forming such joints, the base material made of the foamable synthetic resin can be provided with moisture permeability.

  The underlayer is made of, for example, a polymer cement mortar, and the underlayer can be made of a base material other than the polymer cement mortar. The underlayer can be provided with a mesh. As the mesh, for example, a net-like body made of glass fiber or synthetic resin can be used.

  A finishing layer can be comprised with finishing materials, such as crushed stone, cement, and a synthetic resin, for example, and can also be comprised with finishing materials other than this. Using such an arbitrary finishing material, it is possible to finish an arbitrary decorative layer such as a sandstone tone or a terrazzo tone.

  In addition, as described above, the method for manufacturing a building panel according to the present invention applies a base material to the surface of a base material made of a foamable synthetic resin, and dries and cures to form a base layer. Pour the material, press the base material having the base layer formed on the surface against the finishing material, and after the finishing material is dried, remove the finishing material, the base layer, and the base material from the mold And it is the method of manufacturing the panel for construction by which the finishing layer was provided in the surface of the base material which consists of a foamable synthetic resin through the base layer.

  When the base layer is provided with a mesh, first the base material is applied to the surface of the base material and primary coating is performed, then the mesh is placed on the base material and then the base material is applied. Perform the next painting. By doing in this way, a mesh will be loaded between the two layers of base materials applied by primary coating and secondary coating. However, since the secondary coating is performed before the primary-coated base material is completely cured, the primary coating and the secondary-coated base material do not cause a clear interlayer.

  For example, after applying the base material to one of the front and back surfaces of the base material, the base material is reversed and the base material is applied to the other surface side, and then applied to the side surface side of the base material. This is done by applying a base material.

  Pour the finishing material into the formwork, press the base material with the base layer on the surface, press the base material against the finishing material, and remove the mold after the finishing material is dried. A finishing layer is formed by applying a finishing material on the other surface side opposite to the one surface side of the substrate on which the finishing layer is formed, so that a base layer is formed on the front surface and the back surface of the substrate. It is also possible to form a finishing layer via the. The finishing layer can be provided with various design properties such as forming on a rough surface or a smooth surface by arbitrarily selecting the shape of the mold surface.

  Furthermore, the construction method of the building panel of the present invention comprises a base material made of a foamable synthetic resin, a base layer provided on the surface of the base material, and a finishing layer provided on the surface of the base layer. This is a method in which a building panel is attached to a construction site such as a wall surface.

  The construction location is not limited to a wall surface, and the construction panel of the present invention can be constructed on a floor surface, a roof, or the like, for example.

  Hereinafter, more specific embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
As shown in FIG. 1, the building panel 1 according to the present embodiment has a generally rectangular front shape, and has a predetermined thickness as shown in FIG. And this building panel 1 consists of the structure by which the base layer 3 was provided in the whole surface of the base material 2, as shown in FIG. As shown in the figure, a mesh 5 is provided in the underlayer 3. In the cross-sectional view of FIG. 3, for the sake of convenience, the mesh 5 is illustrated as being continuous in all directions. Since it is provided in the formation 3, the both ends of the folded mesh are in a slightly spaced state.

  The base material 2 is made of expanded polystyrene, the base layer 3 is made of polymer cement mortar, and the mesh 5 is made of a network made of glass fiber or synthetic resin.

  Furthermore, a finishing layer 4 is provided on the front side of the substrate 2 with the base layer 3 interposed therebetween. The finishing layer 4 is made of, for example, crushed stone, cement, and synthetic resin. By applying these crushed stone, cement, synthetic resin, and the like to the base layer 3, for example, sandstone-like, terrazzo-like, etc. It has been finished.

  And the manufacturing method which manufactures the panel 1 for construction which consists of such a structure is demonstrated. First, as shown in FIG. 4, the whole has a substantially rectangular front shape, and a base material 2 having a predetermined thickness as shown in FIG. 5 is prepared.

  Next, as shown in FIG. 6, a base material is applied to the surface of the substrate 2 to form the base layer 3. More specifically, first, the base material is applied and primary coating is performed, and then the mesh 5 is placed on the upper surface of the base material, and then the base material is applied before the primary coated base material is dried. Apply secondary coating to dry the base material.

  By drying the primary and secondary coated base materials in this manner, the mesh 5 is provided in a state of being interposed between both base materials. The formation of the base layer 3 including the mesh 5 is performed on the entire six surfaces of the substrate 2.

  Next, a mold 6 is prepared as shown in FIG. 7, and the finishing material 4a is poured into the mold 6 as shown in FIG. Then, after the base material 2 on which the base layer 3 is formed as described above is housed in the mold 6 into which the finishing material 4a is poured as shown in FIG. 9, as shown in FIG. The base material 2 accommodated inside is pressed against the finishing material 4a.

  After the finishing material 4a is dried, as shown in FIG. 11, the base material 2 provided with the finishing layer 4 is removed from the mold through the base layer 3. By such demolding, the manufacturing of the building panel 1 in which the base layer 3 is provided on the surface of the base material 2 and the finishing layer 4 is provided on the front side of the base material 2 is completed.

  A large number of building panels 1 manufactured in this way are prepared, transported to a construction site such as a wall surface, and the construction is performed by sticking a large number of building panels 1 to the wall surface or the like.

  In this case, since the base material 2 of the building panel 1 is composed of lightweight foamed polystyrene as described above, the building panel 1 is used when the building panel 1 is adhered to a wall surface or the like as described above. Is very easy to handle and the workability is very good. The building panel can be attached using a general mortar adhesive or resin adhesive.

(Embodiment 2)
FIG. 12 is a front view of a substrate according to another embodiment, and FIG. 13 is a cross-sectional view taken along the line CC of FIG. In the present embodiment, as shown in FIGS. 12 and 13, groove portions 8 are formed on the front side and the back side of the substrate 2. As shown in the figure, the grooves 8 are arranged in a plurality of vertical and horizontal directions, and are formed so as to intersect with each other to form a lattice shape as a whole.

  Also in the present embodiment, the base layer 3 is formed by applying a base material to the surface of the substrate 2 as in the first embodiment. In this case, the mesh 5 is provided in the underlayer 3 as in the first embodiment.

  In the present embodiment, since the plurality of groove portions 8 are formed on the front side and the back side of the base material 2, the base material is applied to the surface of the base material 2, whereby the base material becomes the groove portions 8 of the base material 2. Filled in. Then, when the base layer 3 is formed by curing the base material, the portion of the base layer 3 filled in the groove 8 is formed as the rib 9, and the rib 9 of the base layer 3 and the base material 2 are formed. The groove portions 8 are in a fitted state with each other.

  Thus, the base material 2 and the base layer 3 are reinforced together by the rib 9 of the base layer 3 and the groove portion 8 of the base material 2 being fitted to each other, so that the strength of the building panel 1 is increased. Not only improves, but peeling of the base layer 3 from the base material 2 is suitably prevented.

  Further, in this manner, the base layer 3 provided on the surface of the base material 2 is accommodated in the mold 6 into which the finishing material is poured, and pressed against the finishing material, as in the first embodiment. Then, after the finishing material is dried, the base layer 3 is provided on the surface of the base material 2 as shown in FIG. Thus, the building panel 1 provided with the finishing layer 4 is manufactured.

  Also in this embodiment, since the base material 2 is made of expanded polystyrene, when the building panel 1 is adhered to a wall surface or the like as in the first embodiment, the handling of the building panel 1 is very easy. Yes, workability is very good.

  Furthermore, in this embodiment, since the rib 9 of the foundation layer 3 and the groove part 8 of the base material 2 are in a mutually fitted state as described above, the strength of the building panel 1 is maintained after construction. In addition, inadvertent peeling of the base layer 3 from the substrate 2 is suitably prevented.

(Embodiment 3)
FIG. 16 is a front view of a substrate according to another embodiment. Also in the present embodiment, a plurality of groove portions 8 are formed on the front side and the back side of the base material 2 as in the second embodiment. However, as shown in FIG. 16, the groove 8 is provided such that a plurality of other grooves 8 are radially arranged with respect to the central groove 8. In this respect, the arrangement mode of the groove portions 8 is different from the second embodiment in which the plurality of groove portions 8 are arranged in a lattice shape.

  Thus, although the arrangement mode of the groove 8 is different from that of the second embodiment, the groove 8 is filled with the base material, and the groove 8 of the substrate 2 and the foundation layer 3 filled in the groove 8 are formed. The point which the rib 9 will be in a mutual fitting state is the same as that of Embodiment 2.

  Therefore, also in this embodiment, both the base material 2 and the foundation layer 3 are reinforced, and not only the strength of the building panel 1 is improved, but also the peeling of the foundation layer 3 from the base material 2 is suitably performed. Will be prevented.

  The point that the mesh 5 is provided in the underlayer 3, the point that the finishing layer 4 is provided on the front side of the base material 2 through the underlayer 3, and the like are the same as those in the first and second embodiments, and therefore the details thereof Description is omitted.

  Also in this embodiment, since the base material 2 is made of expanded polystyrene, the building panel 1 is very handled when the building panel 1 is attached to a wall surface or the like as in the first and second embodiments. It is easy and the workability is very good.

(Other embodiments)
In the first to third embodiments, the base material 2 is formed in a substantially rectangular shape on the front surface. Therefore, the building panel 1 is also formed in a substantially rectangular shape on the front surface. The shape is not limited to the first to third embodiments, and can be formed in a substantially square shape, for example. It is also possible to form in other shapes.

  Moreover, in the said each embodiment, although the base material 2 was comprised with the expanded polystyrene, it is also possible to comprise with a raw material other than this. In short, it may be made of a foamable synthetic resin.

  Furthermore, in each said embodiment, although the finishing layer 4 was provided only in the front side of the building panel 1, the finishing layer 4 can also be provided in both the front side and the back side. In short, it is only necessary that the finishing layer 4 is provided on the surface of the building panel 1 via the base layer 3.

  Furthermore, although each said embodiment demonstrated the case where the construction panel 1 was constructed on a wall surface, it is also possible to construct not only on a wall surface but on a floor surface, a roof, etc., for example. In particular, as in the second and third embodiments, the groove portion 8 is formed in the base material 2 and the groove portion 8 is filled with the base material so that the base layer 3 and the groove portion 8 are in a fitted state. In the case of the construction, there is an effect that the strength can be suitably exerted against the treading pressure not only when the construction is performed on the wall surface as described above but also when the construction is performed on the floor surface.

  Moreover, when constructing on the floor surface, since the base material 2 is made of a foamable synthetic resin, the cushioning property of the base material 2 also improves the impact resistance against the treading pressure. In the case of construction on the floor surface, tiles can be used as the finishing layer 4.

  Furthermore, instead of forming the groove portion 8 in the base material 2 as described above, it is possible to drive a pile into the base material 2 in order to improve the strength of the building panel 1. Moreover, although it is desirable to construct the construction panel 1 in the construction site by sticking, it is also possible to use a connecting jig for connecting the panels to each other instead of the adhesive or a fastener to the construction site. It is also possible to use these connecting jigs and fasteners together with an adhesive.

The front view of the building panel of one Embodiment. The same side view. AA sectional view taken on the line AA of FIG. The front view which shows the process of preparing a base material in the manufacturing method of the building panel of one Embodiment. BB sectional drawing of FIG. Sectional drawing which shows the process of forming a base layer. Sectional drawing which shows the process of preparing a formwork. Sectional drawing which shows the process of pouring finishing material in a formwork. Sectional drawing which shows the process of accommodating the base material which has a base layer in the formwork in which the finishing material was poured. Sectional drawing which shows the process of accommodating a base material in a formwork and pressing it against a finishing material. Sectional drawing which shows the process of demolding the base material in which the finishing layer was provided through the base layer from a formwork. The schematic front view of the base material of other embodiment. The CC sectional view taken on the line of FIG. Sectional drawing which shows the process of forming a base layer. Sectional drawing which shows the process of forming a finishing layer. The front view of the panel for construction of other embodiments.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Construction panel 2 Base material 3 Underlayer 4 Finishing layer 5 Mesh 8 Groove part 9 Rib

Claims (7)

  A base material (2) made of a foamable synthetic resin, a base layer (3) provided on the surface of the base material (2), and a finishing layer (4) provided on the surface of the base layer (3); An architectural panel characterized by comprising:   A plurality of grooves (8) are formed on the surface of the substrate (2), and the rib (9) of the foundation layer (3) constituted by the foundation material is filled in the grooves (8). The building panel of claim 1 configured to be formed.   The building panel according to claim 1 or 2, wherein a mesh (5) is provided in the ground layer (3).   The building panel according to any one of claims 1 to 3, wherein the finishing layer (4) is made of crushed stone, cement, and synthetic resin.   Applying a base material to the surface of the base material (2) made of foamable synthetic resin, drying and curing the base material to form a base layer (3), pouring a finishing material into the mold (6), The base material (2) on which the underlayer (3) is formed is pressed against the finishing material in the mold (6), and after the finishing material is dried, the finishing formed by the finishing material. The layer (4), the base layer (3), and the base material (2) are removed from the mold (6), and the base layer (3) is formed on the surface of the base material (2) made of a foamable synthetic resin. A method for producing a building panel comprising producing a building panel provided with a finishing layer (4).   By applying a base material to the base material (2) on which a plurality of groove portions (8) are formed, the base material is filled in the groove portions (8) of the base material (2), and the base material is configured. The manufacturing method of the building panel of Claim 5 which forms the rib (9) of a foundation layer (3) which is.   A base material (2) made of a foamable synthetic resin, a base layer (3) provided on the surface of the base material (2), and a finishing layer (4) provided on the surface of the base layer (3); A construction method for a building panel, characterized in that the construction panel constructed of is attached to a construction site such as a wall surface.

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