JP2017106228A - Panel structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight panel structure having excellent performance such as strength, heat insulating properties and sound insulating properties, particularly, a panel structure capable of being used as a substitute for a conventional ECP or ALC panel.SOLUTION: A panel structure (10) includes: a core panel (1) that includes first ceramics and first fibers; two reinforcement panels (3 and 3') that are arranged on both the sides of the core panel (1), respectively; and an outer cover (2) that includes second ceramics and second fibers and in which the core panel (1) and the two reinforcement panels (3 and 3') are embedded.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a panel structure, particularly a panel structure that can be used as a building material.

  As a building material, for example, a precast concrete panel prepared by arranging reinforcing bars such as reinforcing bars and mesh bars in a formwork and placing concrete from the upper side is known (for example, Patent Document 1). ).

  Conventionally, ECP, ALC panels, and the like are well known as lightweight concrete building materials that do not use reinforcing bars such as reinforcing bars and mesh bars.

  An ECP (extruded cement panel) is a panel obtained by extrusion molding into a hollow plate using cement, a siliceous raw material and a fibrous raw material as main raw materials, and curing the autoclave. ECP is mainly used as an outer wall and a partition wall.

  An ALC panel (autoclaved lightweight aerated concrete panel) is a panel that has been autoclaved by foaming cement, silica, quicklime, and aluminum powder as the main raw materials. ALC panels are mainly used as the outer walls, partition walls, roofs, and floors of steel structures.

Japanese Patent Laid-Open No. 10-140697

  The precast concrete panel has a specific gravity of 2.4 and includes reinforcing bars such as reinforcing bars and mesh bars, so that an increase in the weight is inevitable.

  On the other hand, ECP and ALC panels are lightweight and have excellent strength, but they are manufactured by extrusion molding and thus have a low degree of freedom in designing the panel shape. These panels were developed more than 40 to 50 years ago, are lighter than these panels, and have the same or higher strength, thermal insulation and sound insulation performance. Development of alternatives that also have

  Therefore, the present invention provides a panel structure that is lightweight and has excellent strength, heat insulation, sound insulation, and the like, and in particular, a panel structure that can be used as an alternative to conventional ECP and ALC panels. Let it be an issue.

This invention is made | formed in view of said subject, The panel structure of the 1st aspect which concerns on this invention is
A core panel comprising a first ceramic and a first fiber;
Two reinforcing panels respectively disposed on both sides of the core panel;
It includes a second ceramic and a second fiber, and includes an outer skin formed by embedding the core panel and the two reinforcing panels.

The panel structure according to the second aspect of the present invention is
A core panel comprising a first ceramic and a first fiber;
It includes a second ceramic and a second fiber, and an outer skin formed by embedding the core panel.

  The outer skin is preferably porous.

  The core panel preferably further includes a resin foam.

  The core panel may be porous.

  The first fiber and the second fiber are preferably one or a plurality of fibers each independently selected from the group consisting of organic fibers and inorganic fibers.

  The reinforcing panel is preferably made of metal.

  The panel structure is preferably used as a wall material.

  According to the present invention, it is possible to provide a panel structure that is lightweight and has excellent performance such as strength, heat insulation, and sound insulation, and an excellent appearance as required. In addition, according to the present invention, it is possible to provide a panel structure that can be used as a substitute for a conventional ECP or ACL panel, in particular, a conventional ALC panel.

It is a schematic perspective view which shows the panel structure body of the 1st Embodiment of this invention. It is a schematic sectional drawing in A-A 'of the panel structure body of 1st Embodiment shown in FIG. It is the schematic which shows the manufacturing method of the panel structure body of the 1st Embodiment of this invention in a cross section. It is a schematic sectional drawing of the panel structure body of the 2nd Embodiment of this invention. It is the schematic perspective view (a) and the schematic sectional drawing in B-B 'of the panel structure body of the 3rd Embodiment of this invention (b). It is a schematic sectional drawing of the decoration panel structure body of the 4th Embodiment of this invention.

<First Embodiment>
A panel structure 10 according to a first embodiment of the present invention is shown in FIGS. Here, the present invention is not limited to the illustrated embodiment.

  The panel structure 10 embeds the core panel 1, the two reinforcing panels 3 and 3 ′ disposed on both surfaces of the core panel 1, and the core panel 1 and the two reinforcing panels 3 and 3 ′ together (or And outer skin 2 formed by covering or embedding.

[Core panel]
The core panel 1 includes at least a first ceramic and a first fiber. Although the shape of the core panel 1 will not be specifically limited if it is plate shape, From a geometrical and dynamic viewpoint, it is preferable that it is a rectangular parallelepiped.

  There is no restriction | limiting in particular in the length of the longitudinal direction of the core panel 1, For example, they are 1000 mm-5000 mm, Preferably they are 1800 mm-2800 mm.

  There is no restriction | limiting in particular in the length of the width direction (perpendicular | vertical direction with respect to a longitudinal direction) of the core panel 1, For example, it is 600 mm-2400 mm, Preferably it is 900 mm-1200 mm.

  There is no restriction | limiting in particular in the thickness of the core panel 1, For example, they are 75 mm-150 mm, Preferably they are 100 mm-125 mm.

  As the first ceramic, a solid material that can be composed of an inorganic non-metallic substance can be arbitrarily selected and contained, and examples thereof include inorganic compounds such as carbide, nitride, boride, cement (hardened body), and the like. It is done.

  Examples of the first fibers include organic fibers (for example, polyvinyl alcohol fibers (vinylon fibers), polyolefin fibers such as polypropylene fibers and polyethylene fibers, aramid fibers, etc.) and inorganic fibers (for example, steel fibers, stainless fibers, carbon fibers, One or more fibers selected from the group consisting of glass fibers and the like.

  There is no restriction | limiting in particular in the length of a 1st fiber, For example, it is 1-150 mm, Preferably it is 1-120 mm, More preferably, it exists in the range of 6 mm-40 mm. Moreover, there is no limitation in particular also in the thickness, Usually, they are 1 micrometer-2000 micrometers, Preferably they are 10 micrometers-1000 micrometers.

  Content of the 1st fiber in the core panel 1 is 0.1 weight%-5 weight% with respect to the total weight of the core panel 1, for example, Preferably it is 0.1 weight%-1 weight%.

  In the present embodiment, at least the first ceramic and the first fiber are mixed and formed based on a method known in the art according to the type of the ceramic and the fiber, and thereafter, for example, fired or heated. The core panel 1 can be produced by curing, curing, drying, and the like.

  The core panel 1 may be porous for the purpose of reducing its weight. In this specification, the core panel being “porous” means that, for example, a foaming agent, a foaming agent, or the like is used to include bubbles such as closed cells and / or open cells in the core panel. When the core panel 1 is porous, the specific gravity (specific gravity with respect to water) is preferably 0.5 to 2.0, and more preferably 0.8 to 1.2, for example.

  The core panel 1 may further include a resin foam for the purpose of reducing its weight. When the core panel 1 includes a resin foam, the core panel 1 may be porous as described above, or may not be porous.

  As the resin foam, a foam of a natural or synthetic thermoplastic resin can be used without particular limitation. For example, styrene resins such as polystyrene, olefin resins such as polypropylene and polyethylene, copolymers such as acrylonitrile-styrene copolymers and styrene-ethylene copolymers, and polyvinyl chloride such as polyvinyl chloride and polyvinylidene chloride. Examples include resin foams.

  There is no restriction | limiting in particular in the foaming ratio of resin foam itself, For example, they are 3 to 200 times, Preferably they are 30 to 150 times, More preferably, they are 50 to 150 times.

  There is no restriction | limiting in particular in the spherical diameter of a resin foam, For example, they are 1 mm-10 mm, Preferably they are 2 mm-6 mm, More preferably, they are 3 mm-5 mm.

  The content of the resin foam is, for example, 0.1 wt% to 10 wt%, preferably 2 wt% to 8 wt%, with respect to the total weight of the core panel 1.

  When the core panel 1 contains a resin foam, the specific gravity (specific gravity with respect to water) of the core panel 1 is, for example, 0.1 to 0.8, preferably 0.1 to 0.6, and more preferably 0.1 to 0.00. 4.

  Hereinafter, although the case where the core panel 1 contains cement as a 1st ceramics is demonstrated in detail as an example, this invention should not be limited and limited to such an example.

  Examples of the cement include Portland cement (JIS R 5210) defined by Japanese Industrial Standards (hereinafter JIS) (for example, ordinary Portland cement, early-strength Portland cement, ultra-early strong Portland cement, moderately hot Portland cement, low heat Portland cement) , Sulfate resistant Portland cement, white Portland cement, etc.), mixed cement (for example, blast furnace cement (JIS R 5211), silica cement (JIS R 5212), fly ash cement (JIS R 5213), etc.), eco cement (JIS R) 5204), cements such as super-hard cement, grout cement, oil well cement, low heat cement, etc. can be used without particular limitation.

  When the core panel 1 uses cement as the first ceramic, the inside of the core panel 1 mainly includes a cement hardened body and a first fiber obtained by reacting the cement with an appropriate amount of water. Can be. As described above, the core panel 1 may be molded as a hardened cement body including at least the first fiber.

  When the core panel 1 is made porous, the above-mentioned cement is generally well-known as a foaming agent for cement, mortar, concrete, and more specifically, a protein-based foaming agent, Surfactant-based foaming agents such as polyethers, aromatic sulfonates (such as alkylbenzene sulfonates), sulfur-containing compounds (such as higher alkyl ether sulfates), and resin-based foaming agents What is necessary is just to make the core panel 1 porous by mix | blending. Thus, the core panel 1 may be molded as a foamed cement hardened body including at least the first fiber.

  Examples of the method for adding the foaming agent include pre-forming, mix forming, after-forming, and the like. Typically, pre-forming can be applied.

  Furthermore, you may use metal type foaming agents, such as aluminum powder, with a foaming agent as needed. In addition, in this embodiment, there is no restriction | limiting in particular in the quantity of the foaming agent and foaming agent to be used.

The cement further includes, for example, fine aggregates such as pearlite (for example, those containing components such as SiO ₂ , Al ₂ O ₃ , Fe ₂ O ₃ , CaO, Na ₂ O), admixtures, water reducing agents ( For example, an additive such as a naphthalene-based water reducing agent, a sulfonic acid-based water reducing agent, or a polycarboxylic acid-based water reducing agent) may be added as necessary. In this embodiment, there is no restriction | limiting in particular in the quantity of the additive to be used.

[Reinforcement panel]
The reinforcing panels 3 and 3 ′ may be the same or different, and can be arranged on at least both surfaces of the core panel 1. Thereby, the intensity | strength of the core panel 1 and by extension, the panel structure 10, for example, bending strength, etc. can be improved.

  The reinforcing panels 3 and 3 ′ are not particularly limited in size and shape as long as they can be arranged on both surfaces of the core panel 1, but preferably have a main surface having the same area as the main surface of the core panel 1.

  There is no restriction | limiting in particular in the thickness of the reinforcement panel 3, 3 ', For example, they are 50 micrometers-3000 micrometers, More preferably, they are 50 micrometers-300 micrometers.

  For example, a metal or non-metal panel can be used as the reinforcing panels 3 and 3 ′. Examples of the metal panel include a metal plate made of a metal such as iron, aluminum, copper, titanium, molybdenum, or chromium, or an alloy thereof (for example, steel or stainless steel). Non-metallic panels include, for example, carbon fiber reinforced plastic (CFRP), glass fiber reinforced plastic (GFRP), pultrusion fiber reinforced plastic (PFRP), kepla fiber reinforced plastic (KFRP), and aramid fiber reinforced plastic (AFRP). And panels made of fiber reinforced plastic (FRP). Especially, it is preferable to use metal panels, and it is especially preferable to use a steel plate.

  When the reinforcing panels 3 and 3 ′ are made of metal, the surface thereof may be subjected to plating treatment (for example, melting (or immersion) plating, electroplating, etc.) from the viewpoint of preventing corrosion. Galvanized steel sheets that have been hot-dip galvanized or electrogalvanized, and plated steel sheets such as galvalume steel sheets and ZAM steel sheets can be used.

  Further, the reinforcing panels 3 and 3 ′ may be a punching metal obtained by punching the metal panel, or a lath metal processed into a mesh shape.

  In the present embodiment, it is preferable that the reinforcing panels 3 and 3 ′ are physically and / or chemically fixed to the surface of the core panel 1. For example, adhesives (for example, vinyl acetate-acrylic, styrene-acrylic, ethylene-vinyl acetate, styrene-butadiene, nitrile rubber, chloroprene rubber, modified silicone, cyanoacryl, urethane, epoxy The reinforcing panels 3 and 3 ′ can be fixed to the surface of the core panel 1 by phenol, melamine, urea, polyamide, nitrocellulose, polyvinyl alcohol, polyester, or the like.

[Hull]
The outer skin 2 includes at least the second ceramic and the second fiber. If the core panel 1 and the reinforcing panels 3 and 3 ′ can be embedded (or covered or embedded), the outer skin 2 can have the dimensions and There is no particular limitation on the shape. As shown in FIG. 1, it is preferable that the outer skin 2 embeds the outer surfaces of the core panel 1 and the reinforcing panels 3 and 3 ′ with substantially the same thickness. Moreover, it is preferable that it is a rectangular parallelepiped from a geometrical and dynamic viewpoint. When the outer skin 2 is a rectangular parallelepiped, the edge part, especially the edge part of a longitudinal direction may be chamfered as needed.

The outer skin 2 is particularly limited to the thicknesses L ₁ (upper surface side) and L ₂ (lower surface side) (see FIG. 2) for embedding the core panel 1 and the reinforcing panels 3 and 3 ′ provided on both sides thereof. However, they are each 10 mm to 50 mm, preferably 10 mm to 30 mm, and may be the same or different.

  The outer skin 2 may be porous or may not be porous. Whether or not the outer skin 2 is porous can be appropriately determined according to the application. For example, when the panel structure needs to be lightweight, it can be made porous.

  In order to make the outer skin 2 porous, bubbles such as closed cells and / or open cells may be formed inside the outer skin 2 using the above-mentioned foaming agent and foaming agent. When the outer skin 2 is porous, the specific gravity (specific gravity with respect to water) is, for example, 0.1 to 2.2, preferably 0.5 to 1.9, and more preferably 0.7 to 1.9. .

  As the second ceramic, the same material as the first ceramic can be used. In the present embodiment, the second ceramic may be the same as or different from the first ceramic.

  As a 2nd fiber, the 1 or several fiber selected from the group which consists of an organic fiber and an inorganic fiber similar to the above-mentioned 1st fiber can be included. In the present embodiment, the second fiber may be the same as or different from the first fiber.

  There is no restriction | limiting in particular in the length and thickness of a 2nd fiber, For example, it may exist in the same range as a 1st fiber.

  The content of the second fiber in the outer skin 2 is, for example, 0.1 wt% to 10 wt%, preferably 0.1 wt% to 5 wt%, with respect to the total weight of the outer skin 2.

  When the outer skin 2 is porous, in order to improve the strength of the panel structure, hard fibers such as steel fibers, carbon fibers, and glass fibers are used as the second fibers, or the amount of the second fibers Or increase it.

  In the present embodiment, for example, using a formwork or the like, a structure in which the reinforcing panels 3 and 3 ′ are arranged on both surfaces of the core panel 1 is appropriately positioned and disposed. Inject a mixture containing at least the second ceramic and the second fiber, and, for example, firing, heating, curing, and drying according to a method known in the art according to the type of the ceramic and the fiber. For example, the outer skin 2 can be formed by solidifying.

  When the outer skin 2 uses cement as the second ceramic, the same material as that of the core panel 1 can be used.

<Performance evaluation>
The performance of the panel structure of the present invention, particularly the specific gravity, strength, heat insulation, and sound insulation, will be described.

-About specific gravity The panel structure of this invention is 0.3-1.2, preferably 0.5-1.0, more preferably 0.6-0.8 by having said structure and structure. Specific gravity (specific gravity with respect to water) can be achieved. Here, the specific gravity (specific gravity with respect to water) of the core panel is 0.1 to 0.8, preferably 0.1 to 0.6, and more preferably 0.1 to 0.4. Specific gravity) is 0.1 to 2.2, preferably 0.5 to 1.9, more preferably 0.7 to 1.9.

-Strength The panel structure of the present invention can achieve excellent bending strength and the like by having the above-described configuration and structure. The flexural strength, for example, 1.0 N / mm ² or more, preferably 1.5 N / mm ² or more, more preferably 2N / mm ² or more. Such bending strength can be measured according to JIS A 1414-2.

-Thermal insulation The panel structure of the present invention has a thermal conductivity of, for example, 0.17 W / m · K or less, preferably 0.1 W / m · K or less, by having the above-described configuration and structure. be able to. Moreover, there is no restriction | limiting in particular in the minimum of heat conductivity, What is necessary is just to exceed 0 W / m * K. Such thermal conductivity can be measured according to JIS A 1412-2.

-About sound insulation The panel structure of this invention can have the outstanding sound insulation over the frequency of 100 Hz-8000 Hz, for example by having said structure and structure. In particular, the transmission loss at 1000 Hz is preferably 40 dB or more when the thickness of the panel structure is 100 mm, for example. Further, there is no limit on the upper limit of such transmission loss.

<Panel manufacturing method>
Hereinafter, as an example, a method of manufacturing the panel structure 10 according to the first embodiment of the present invention will be briefly described with reference to FIG. In addition, the manufacturing method of the panel structure of this invention is not limited to such a method.

(Process A)
A mixture containing at least the first ceramic (or its precursor) and the first fiber is formed into a desired shape in a mold, and is fired, heated, cured, and dried according to a conventionally known method. To form an ingot (lumb) 1 ′ of the core panel 1.

(Process B)
The core panel 1 is formed by slicing the ingot 1 'to a desired thickness. In the process A, when the ingot 1 ′ is formed with the dimensions of the core panel 1, the process B can be omitted.

(Process C)
Reinforcing panels 3, 3 ′ are arranged on both sides of the core panel 1, respectively. Preferably, it is physically and / or chemically fixed.

(Process D)
For example, the core panel 1 on which the reinforcing panels 3 and 3 ′ are arranged is arranged at an appropriate position in the mold, and a mixture containing at least the second ceramic (or its precursor) and the second fiber is placed in the mold. In accordance with a conventionally known method, for example, the panel structure 10 can be obtained by solidifying by baking, heating, curing, and drying to form the outer skin 2.

<Second Embodiment>
FIG. 4 is a schematic cross-sectional view of the panel structure 20 according to the second embodiment of the present invention. The panel structure 20 includes a core panel 21 and an outer skin 22 formed by embedding (or covering or embedding) the core panel 21. In the present embodiment, the last digit of the reference numeral having substantially the same components as those in the first embodiment is the same as that in the first embodiment. That is, the core panel 21 and the outer skin 22 can respectively correspond to the core panel 1 and the outer skin 2 in the first embodiment, and almost all of the above description applies. Therefore, a detailed description of the same contents is omitted, and only differences from the first embodiment are described below.

  The panel structure 20 does not include the reinforcing panel used in the first embodiment. Therefore, for the purpose of improving the strength of the panel structure 20, it is preferable that the first fiber included in the core panel 21 is a hard fiber such as a steel fiber, a carbon fiber, or a glass fiber.

<Third Embodiment>
FIG. 5 shows a perspective view (a) of a panel structure 30 according to a third embodiment of the present invention and a cross-sectional view (b) along BB ′. The panel structure 30 includes a core panel 31 and reinforcing panels 33 and 33 ′ disposed on both sides thereof (see FIG. 5B). In the present embodiment, the last digit of the reference numerals of the components that are substantially the same as those in the first embodiment is the same number as in the first embodiment. This point is the same as in the second embodiment. That is, the core panel 31 and the reinforcing panels 33 and 33 ′ can respectively correspond to the core panel 1 and the reinforcing panels 3 and 3 ′ in the first embodiment, and almost all of the above description applies. Therefore, a detailed description of the same contents is omitted, and only differences from the first embodiment are described below.

  In the panel structure 30, the outer skin 32 can correspond to the outer skin 2 of the first embodiment described above, but as shown in FIGS. 5 (a) and 5 (b), at least two of the outer skin 32. Convex portions 34 and concave portions 35 are formed on the side surfaces (for example, two longitudinal side surfaces). In FIG. 5B, the convex portion 34 and the concave portion 35 are described as protrusions and corresponding grooves, but in the present embodiment, the convex portion 34 and the concave portion 35 are limited to such shapes. It is not necessary to have shapes that can be engaged with each other.

  The panel structure 30 having such convex portions 34 and concave portions 35 can be obtained by using two or more of them, and by simply engaging the side surfaces of the panel structure 30 with each other (for example, a surface having a larger area (for example, Wall surface, floor surface) can be formed.

  The convex portion 34 and the concave portion 35 can be formed, for example, by molding the outer skin 32 or by cutting the outer skin 32 after molding.

  In the panel structure 30, by making the size and shape of the outer skin 32 the same as, for example, a conventional ECP or ALC panel, it can be used as a substitute for the conventional ECP or ALC panel. In that case, it is desirable to have performance such as strength, heat insulation, sound insulation and the like equal to or higher than those of conventional ECP and ALC panels.

  In addition, since the panel structure 30 is manufactured by driving molding, it is possible to perform tile pasting or main stone pasting. In particular, in the conventional ECP and ALC panels manufactured by extrusion molding, the metal fittings cannot be integrally formed and it is impossible to paste the stone, so the panel of the present invention is superior to these panels. Have the advantages.

<Fourth Embodiment>
FIG. 6 shows a decorative panel structure 40 in which a decorative panel 46 is attached to one of the main surfaces of the outer skin 32 of the panel structure 30 described above. The decorative panel 46 can be a printed layer in which a tile, a main stone such as natural stone or artificial stone, a pattern imitating a pattern of natural stone material or a pattern of natural wood, or the like is printed on, for example, paper or a resin sheet. The decorative panel 46 can be attached to the panel structure 30 by using a conventional method, for example, an adhesive (tiling). In particular, when the decorative panel 46 is used as a printing layer, a beautiful design full of luxury such as natural stone or natural wood can be easily formed on the surface of the panel structure 30 at a low cost. Further, the upper surface of the printing layer may be coated with a paint containing an ultraviolet curable resin or the like, and a further improved appearance can be provided.

  As described above, the panel structure of the present invention has been described with reference to some embodiments, but the present invention is not limited to such embodiments.

  As described above, the panel structure of the present invention can provide performance such as light weight and excellent strength, heat insulation, sound insulation and the like, and an excellent design as necessary. It can be beneficially used as a building material such as flooring, especially as a wall material, especially as an outer wall material. It can also be used as an alternative to conventional ECP and ACL panels, especially ALC panels.

1, 21, 31 Core panel 2, 22, 32 Outer skin 3, 3 ′, 33, 33 ′ Reinforcing panel 10 Panel structure (first embodiment)
20 Panel structure (second embodiment)
30 Panel structure (third embodiment)
34 Convex part 35 Concave part 40 Decorative panel structure (fourth embodiment)
46 Decorative Panel

Claims (8)

A core panel comprising a first ceramic and a first fiber;
Two reinforcing panels respectively disposed on both sides of the core panel;
A panel structure including a second ceramic and a second fiber, and including an outer skin formed by embedding the core panel and the two reinforcing panels. A core panel comprising a first ceramic and a first fiber;
A panel structure including a second ceramic and a second fiber, and an outer skin formed by embedding the core panel.   The panel structure according to claim 1, wherein the outer skin is porous.   The panel structure according to claim 1, wherein the core panel further includes a resin foam.   The panel structure according to claim 1 or 2, wherein the core panel is porous.   The said 1st fiber and the said 2nd fiber are 1 or a plurality of fibers each independently selected from the group which consists of an organic fiber and an inorganic fiber, The any one of Claims 1-5. Panel structure.   The panel structure according to any one of claims 1 to 6, wherein the reinforcing panel is made of metal.   The panel structure according to any one of claims 1 to 7, which is used as a wall material.

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