JP2019038236A - Concrete panel laminated body, method for producing the same, and flask - Google Patents

Abstract

To provide a concrete laminated body usable as a building member having lightness and fire resistance and capable of being easily assembled, a method for easily producing the concrete laminated body, and a flask used for the production method.SOLUTION: Provided is a concrete panel laminated body whose circumference is surrounded by a frame body, made of a resin foam and having multiple reinforcement holes passing through a reinforcement and holding the same in the vicinity of the central part in a thickness direction, and, on either side of the edge at which the reinforcement holes are formed, comprising a frame body in which slits pressing the steel bar into the reinforcement holes are formed, and further, a cut face is provided at a part, and an upper concrete panel inserted from the upper part and a lower concrete panel inserted from the lower part at the hollow part of the flask, and in which the upper concrete panel and the lower concrete panel are integrated, and further, an intermediate layer made of adhesive mortar for burying the reinforcement is provided. Also provided are a method for producing the concrete panel laminated body, and a flask used for the production method.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a concrete panel laminate, a method for producing the concrete panel, and a formwork used in the method.

  In recent years, as a wall panel constituting a wall of a building, for example, ALC made of silica powder, cement, quicklime and foaming aluminum powder as described in Patent Document 1 (Japanese Patent Laid-Open No. 7-238614) as a raw material (autoclaved Lightweight aerate Concrete) panels are known. For the production of this ALC panel, as described in Patent Document 1, the inorganic material is cured in an autoclave (high heat and high pressure steam kettle) for about 10 hours under a high temperature of 180 ° C. or higher and a steam of 10 atmospheres or higher. There is a problem in terms of cost. In addition, since this ALC panel is essentially an inorganic porous plate, there are certain restrictions on the weight control. Furthermore, since it is an inorganic porous material, it has water absorption and cannot be used as it is as an outer wall of a building.

  In order to solve such problems of the ALC panel, the present inventor put two kinds of lath bodies on the surface of a core material made of a resin foam as shown in Patent Document 2 (Japanese Patent Laid-Open No. 2016-148148). Place the core material around the lath body to fix the lath body to the core material surface, apply mortar from above the fixed lath body, and accompanied the lath body all around the resin foam A concrete panel composite with thermal insulation with a mortar surface layer is proposed.

  And as shown in patent document 3 [Unexamined-Japanese-Patent No. 2016-148149], the laminated body which bonded together the concrete panel composite which has the heat insulation which has the above structures through the intermediate | middle layer which has arrange | positioned the reinforcing bar. By manufacturing, the reinforcing bar acts as a support member for supporting the laminate, and a wall surface made of the laminate can be formed.

  However, in the laminated body shown in Patent Document 3 described above, in order to use the reinforcing bars as support members, the reinforcing bars must be mutually engaged with the reinforcing bars of the adjacent laminated bodies. The structure which protruded from was forced to take.

  For this reason, when forming the intermediate layer, it is necessary to apply the intermediate layer with a flaw etc., and this step must be performed manually, and this step is used when the laminate of the present invention is manufactured. There was a problem that mass production was not possible due to the rate limiting process.

JP-A-7-238614 JP 2006-148148 A JP 2006-148149 A

  The present invention relates to a concrete laminate that can be used as a building member that is lightweight and has fire resistance and can be easily assembled, a method for easily producing the concrete laminate, and a frame used in the production method. It is intended to provide.

The present invention is made of foamed resin and has a number of reinforcing bar holes that penetrate and hold the reinforcing bar in the vicinity of the center in the thickness direction, and the reinforcing bar is formed on one side of the edge where the reinforcing bar hole is formed. A slit having a slit to be pushed in, and a frame having a cut surface at a part of the edge,
In the hollow part of the formwork, it has an upper concrete panel inserted from the upper part and a lower concrete panel inserted from the lower part,
The upper concrete panel and the lower concrete panel are integrated, and an intermediate layer made of an adhesive mortar for embedding a reinforcing bar is provided. The concrete panel laminate is surrounded by a formwork.
Here, the resin foam is preferably a polystyrene resin foam having an expansion ratio of 20 to 50 times.

  The upper concrete panel and the lower concrete panel are preferably composites in which a polystyrene foam core material is surrounded by a lath body and a concrete layer is disposed on the surface of the lath body.

The concrete panel laminate of the present invention is a slit formed in the upper part of the reinforcing bar hole in the reinforcing bar hole formed in the vicinity of the center part in the thickness direction of the opposite edge of the frame made of resin foam. Spreading the reinforcing bars between them and inserting the reinforcing bars between the opposing edges,
Placing the lower concrete panel by placing it on the lower push-up plate in the hollow part of the frame body from below in the frame body over which the reinforcing bars are stretched;
Filling the adhesive mortar so that the reinforcing bar is buried in the space where the reinforcing bar is stretched,
Inserting an upper concrete panel into a formwork above the filled adhesive mortar;
Adhesive mortar and lower part filled with lower concrete panel pushed up from upper part while lower concrete board is pushed up from lower part by pushing down lower plate from upper part of upper concrete panel to upper concrete panel The concrete panel and the upper concrete panel can be integrated, and the concrete panel laminate can be manufactured by the manufacturing method.
Here, the resin foam is preferably a polystyrene resin foam having an expansion ratio of 20 to 50 times.

  The upper concrete panel and the lower concrete panel are preferably composites in which a polystyrene foam core material is surrounded by a lath body and a concrete layer is disposed on the surface of the lath body.

  Furthermore, it is preferable to integrate the filled adhesive mortar with the lower concrete panel and the upper concrete panel with the upper push-down plate and the lower push-up plate while applying vibration to the upper push-down plate and the lower push-up plate.

Moreover, it is preferable that the said frame has a cut surface in a part of edge which forms this frame, and peels off and removes a frame from this cut surface.
The frame of the present invention is a mold made of a resin foam having a hollow portion for inserting an upper concrete panel and a lower concrete panel, and in the vicinity of the central part in the thickness direction of the facing edge of the mold In addition, a plurality of reinforcing bar holes are formed so as to pass through the reinforcing bar, and a slit is formed on the upper part of the reinforcing bar hole so that the reinforcing bar is expanded when the reinforcing bar is inserted to insert the reinforcing bar into the reinforcing bar hole. And having a cut surface in a part of the frame.
The resin foam forming the frame of the present invention is preferably a polystyrene resin foam having an expansion ratio of 20 to 50 times.

  By using the formwork of this invention, the concrete laminated body which has arrange | positioned the reinforcing bar for connection in the center part of thickness direction, and has arrange | positioned the concrete panel on both surfaces can be mass-produced easily.

  Here, as a concrete panel arranged on both sides, a composite body in which a foamed resin panel is used as a core material, a periphery of the foamed resin panel is surrounded by a lath body, and a concrete layer is formed on the surface with the lath body. By using, it is possible to obtain a heat-insulated lightweight concrete panel laminate that is lightweight, highly heat-insulating, and fire-resistant.

  In such a heat-insulated lightweight concrete panel laminate, the reinforcing bars for connecting the laminates must be placed in the center of the thickness direction, but the reinforcing bars protrude from the panel, and the reinforcing bars protrude. Therefore, automatic manufacturing equipment cannot be used, and this process becomes manual work, so mass production is difficult, but by using the formwork of the present invention, mass production is possible using machines. Become.

  In the present invention, by using a mold made of resin foam, it becomes possible to insert the reinforcing bar through the reinforcing bar while deforming the slit formed in the foamed resin mold, and the reinforcing bar penetrates the reinforcing bar. A rectangular shaped body can be used as a mold.

As described above, by using a rectangular molded body made of foamed resin as a mold, it has become possible to continuously manufacture a laminated body that has been a manual operation so far by using an automatic manufacturing apparatus.
The formwork arranged around the heat insulating lightweight concrete panel laminate in this way is a packaging material that protects the outer periphery of the heat insulating lightweight concrete panel laminate by placing it as it is without demolding after manufacturing the laminate. Also works.

FIG. 1 is an exploded perspective view showing an exploded apparatus for manufacturing a heat insulating lightweight concrete panel laminate of the present invention. 2 is a cross-sectional view taken along line XX in FIG. FIG. 3 is a view showing an example of an apparatus for producing an upper concrete panel and a lower concrete panel used in the present invention. FIG. 4 is a perspective view showing an example of a metal mold used when the upper concrete panel and the lower concrete panel are manufactured by the apparatus shown in FIG. FIG. 5 is a plan view showing an example of a metal mold plate. FIG. 6 is a cross-sectional view showing a cross section of an example of a corner auxiliary bar. FIG. 7 is a cross-sectional view showing a cross section of an example of the central auxiliary rod. 8 is a cross-sectional view taken along the line aa in FIG. 9 is a cross-sectional view taken along the line BB in FIG. FIG. 10 is a perspective view showing a specific example of a building structure of the present invention. FIG. 11: is a perspective view which shows the example of joining of the structure of the building of this invention which used the heat insulation panel. FIG. 12A is a perspective view showing an example of a rectangular columnar body used in the present invention. FIG. 12B is a cross-sectional view showing an example of a rectangular columnar body used in the present invention. FIG. 13 is a perspective view showing an example of a hook used in the present invention. FIG. 14 is a perspective view showing an example of a spacer used in the present invention.

Next, the heat insulation lightweight concrete panel laminated body of this invention is demonstrated concretely along the manufacturing process.
As shown in FIG. 2, the heat insulation lightweight concrete panel laminated body of this invention has the concrete panels 12a and 13a arrange | positioned at the front and back, and it is comprised so that an intermediate | middle layer may join this concrete panels 12a and 13a. .

  In the present invention, the upper concrete panel 12 and the lower concrete panel 13 are heat insulating concrete panels having the same configuration, and the upper concrete panel 12 can be formed of a resin foam. And a core material 12a. Here, the resin foam is not particularly limited. For example, a polystyrene foam, a polyolefin foam, a urethane resin foam, or the like can be used. It is preferable to use the body. When a polystyrene resin foam is used, the expansion ratio of the polystyrene resin foam is preferably in the range of 20 to 50 times. By setting it as such a foaming ratio, while having a suitable intensity | strength as a core material, weight reduction can be achieved.

  Although there is no restriction | limiting in particular in the thickness of this core material 12a, By setting it as 20 mm-50 mm, the thickness of the upper concrete panel 12 can be made into the appropriate thickness of 40-80 mm as a building material.

In addition, well-known flame retardants, such as aromatic phosphate ester, such as a triphenyl phosphate, an antimony compound, can also be mix | blended with the said resin foam.
The foaming method of the resin foam as described above is already known, and in the present invention, a resin foam produced according to a known method can be used.

  The core material 12a is surrounded by a lath body 12b. The lath body 12b used here includes a lath body made of synthetic resin, a metal lath body, etc. In the present invention, after surrounding the core 12a with a metal lath body, the outer periphery is synthesized. It is preferable to surround with a resin lath body. The lath body 12b is fixed to the surface of the core material with a stapler or the like with respect to the core material 12a.

A mortar surface layer 12c is formed on the surface of the lath body 12b to cover the entire circumference of the core material 12a with the lath body. Although there is no restriction | limiting in particular in the thickness of this mortar surface layer 12c, Usually, they are 5 mm-50 mm. By forming a mortar surface layer having such a thickness and curing the mortar surface layer, the upper concrete panel 12 becomes a hard plate state.
Similarly, the lower concrete panel 13 is formed of a core material 13a, a lath body 13b, and a mortar surface layer 13c.

  The upper concrete panel 13 and the lower concrete panel 12 can be manufactured by various methods. For example, the metal mold is placed on a conveying means that continuously pushes the metal mold forward. While advancing the metal mold, a cement material is placed on the metal mold from a cement extruder, and a core made of foamed resin is placed on the cement material cast in the metal mold. The core material placed and the placed cement material are pressed and integrated, and the integrated cement material and core material are transferred into the discharge pipe together with the metal mold, and the inside of the discharge pipe The cement material is filled in the metal mold by the extrusion machine provided in the pipe, and the metal mold filled with the cement material is inserted into the base provided at the tip of the discharge pipe, and the excess cement material Remove and place The molded into shape, after the metal form with insulation panels extruded from the mouthpiece and a period of time curing, it can be produced by removing the metal form.

Specifically, the upper concrete panel 13 and the lower concrete panel 12 are manufactured as follows.
In the concrete panel manufacturing apparatus suitably used in the present invention, the concrete panel is preferably manufactured using a metal mold 150 as shown in FIG.

  The metal mold 150 includes a front metal frame 152 and a rear metal frame 154. The front metal mold plate 152 and the rear metal mold plate 154 are provided with auxiliary rod insertion holes on the facing surfaces. That is, as shown in FIG. 5, the front metal mold plate 152 and the rear metal mold plate 154 are provided with insertion holes 156 for the corner auxiliary rods 160 at the respective corners. An insertion hole 158 for the center auxiliary bar 162 is preferably provided in the center bottom.

  The front metal mold plate 152 and the rear metal mold plate 154 are connected by a corner auxiliary bar 160 and preferably a central auxiliary bar 162. That is, the corner auxiliary rod 160 has, for example, a substantially triangular cross section as shown in FIG. 6 and is formed at the corners of the front metal mold plate 152 and the rear metal mold plate 154. It has a shape that fits into the insertion hole 156 of the corner auxiliary rod 160 that has been made. Similarly, the insertion hole 158 of the central auxiliary rod 162 provided at the bottom of the front metal mold plate 152 and the rear metal mold plate 154 is, for example, a cross section of the central auxiliary rod 162 as shown in FIG. It has a trapezoidal shape corresponding to the shape, and the tip of the central auxiliary rod 162 is formed to be insertable into the insertion hole 158 of the central auxiliary rod 162.

  In this way, the front metal mold plate 152 and the rear metal mold plate 154 are connected to each other by the corner auxiliary rod 160 and preferably the central auxiliary rod 162, so that the rectangle is preferably used in the present invention. The metal mold 150 is formed. In addition, although the insertion hole 158 of the center part auxiliary | assistant stick | rod 162 can be formed in the bottom part of the front metal mold plate 152 and the rear metal mold plate 154, the front metal mold plate 152 and the rear metal An insertion hole for inserting the center auxiliary rod 162 is not formed in the upper part of the mold making frame plate 154 but is opened.

  The thickness (length in the vertical direction in FIG. 2) of the metal mold 150 is normally 20 mm to 50 mm in the core material, and the thickness of the cement material to be cast is adjusted to match the front and back surfaces. Since it is 30 mm-150 mm, it is 50 mm-200 mm.

  In addition, the width of the metal mold 50 (the length in the longitudinal direction of the mold plate) can be arbitrarily set according to the desired size of the heat insulating panel, and is usually within a range of 30 to 180 cm, preferably Is set to an arbitrary width within the range of 60 to 90 cm.

  Furthermore, the distance between the front metal mold plate 152 and the rear metal mold plate 154, that is, the length of the concrete panel can be appropriately set according to the use, but is usually 40 to 220 cm, preferably Is 60-180 cm.

The front metal mold plate 152, the rear metal mold plate 154, the corner auxiliary bar 160, and the central auxiliary bar 162 that form the metal mold 150 are usually formed of metal, but are synthesized. It may be formed of a resin or the like.
In addition, a packing member (not shown) may be disposed at the edge of the front metal mold plate 152 and the rear metal mold plate 154 in order to prevent leakage of the cement material from the cap portion.

Moreover, if the corner | angular part auxiliary | assistant stick | rod 160 has sufficient intensity | strength to the metal mold 150, the center part auxiliary | assistant stick | rod 162 does not need to arrange | position.
In order to stabilize the form of the metal mold 150, the front metal mold plate 152 and the rear metal mold plate 154, the corner auxiliary rod 160 and / or the central auxiliary rod 162 are preferably provided. You may screw together with a spiral.

The metal mold 150 as described above is placed on the conveying means of the concrete panel manufacturing apparatus 110 used in the present invention.
In the present invention, the conveying means is preferably a belt conveyor. In FIG. 3, a metal mold 150 is placed on the conveyor belt of the belt conveyor-1.

  In the present invention, the discharge force of the cement material 143 by the screw 142 of the extrusion machine 141 provided in the discharge pipe 140 becomes a propulsive force, but when the resistance in the base portion 144 is strong, the discharge force is placed on the belt conveyor-1. Extruding means 111 for extruding the formed metal mold 150 intermittently from the rear to the front may be provided.

  The metal mold 150 placed on the conveyor belt-1 is sent to the front conveyor belt-2 by rotation of the conveyor belt of the belt conveyor-1 and / or the pushing means 111.

  A cement extruder 112 is disposed above the conveyor belt-2, and a cement material 143 is driven to the bottom of the metal mold 150 by an internal screw 114. The width of the extrusion port for extruding cementite material of the cement extruder 112 is substantially the same as the width of the concrete panel to be manufactured.

  That is, the cement material is placed on the surface of the conveyor belt of the belt conveyor-2 between the front metal mold plate 152 and the rear metal mold plate 154, and the cast cement material is used in the subsequent steps. Then, the bottom surface of the heat insulation panel is formed.

  In addition, since the lateral direction of the metal mold 150 is open and the cast cement material 143 may spread in the lateral direction (longitudinal direction of the mold plate), as shown in FIG. Longitudinal guides 124 are preferably arranged on both sides in the lateral direction of the mold making frame 150 along the moving direction of the metal mold form 150.

  The core materials 12a and 13a are placed on the surface of the cement material 143 placed as described above, but the surface of the cement material 143 placed before the placement of the core materials 12a and 13a is smoothed. It is preferable to have a step of providing a smoothing means for flattening the surface of the placed cement material 143. As this process, for example, a plate material is arranged on the surface of the placed cement material 143 and the metal mold 150 filled with the cement material is advanced to smooth the surface of the placed cement material with the plate material. The process of making is mentioned.

  The core materials 12a and 13a are placed on the surface of the cement material 143 placed as described above. The core materials 12a and 13a used here are preferably those in which the entire surface of the plate material made of foamed resin is surrounded by a lath, preferably a metal lath. The metal lath is preferably fixed to the plate-like foamed resin with staples. Thus, by surrounding with metal lath, the core materials 12a and 13a and the cement material 143 can be firmly joined. Further, by fixing the metal lath to the surface of the foamed resin with staples or the like, it is possible to obtain a panel in which the core materials 12a and 13a and the cement material 143 are firmly bonded without forming a hole penetrating the foamed resin. Therefore, the formation of a cold bridge can be prevented.

Further, the core members 12a and 13a may be formed by arranging a metal lath on the entire circumference as described above and further surrounding the surface of the metal lath with a resin net.
After placing the core materials 12a and 13a on the cement material 143 as described above, the core materials 12a and 13a are usually buried in the cement material 143 on the belt conveyor-3. The core members 12a and 13a are pressed downward by pressing means such as the pressing roller 116. Accordingly, as shown in FIG. 8, the core materials 12a and 13a are embedded in the cement material 143, and preferably the cement material 143 enters the lath disposed in the core materials 12a and 13a. The cement material 143 reaches the surface, and a panel in which the core materials 12a and 13a and the cement material 143 are firmly bonded can be obtained.

  The pushing roller 116 is urged downward and is arranged so as to be movable up and down. Accordingly, when the cores 12a and 13a pass below the roller 116, the cores 12a and 13a are pressed downward, but the front metal mold plate 152 and the rear metal mold plate 154 When passing, it is arranged so as not to hinder the passage of the front metal mold plate 152 and the rear metal mold plate 154 ascending upward.

Further, the pressing roller 116 may be a single roller or may be a divided roller.
In addition, instead of the pressing roller 116 or together with the pressing roller 116, a pressing plate (not shown) movable up and down may be arranged.

  After the cement material 143 at the bottom and the core materials 12a and 13a are integrated in the metal mold 150, the metal mold 50 thus obtained is inserted into the discharge pipe 140 along the upper and lower guides 118.

  In the discharge pipe 140, the metal mold 150 is pushed in the direction of the cap part 144 by the cement material 143 pushed out by the screw 142 in the extrusion pipe 120 having the screw 142 inside. An extrusion molding machine 141 is provided obliquely at the rear of the discharge pipe 140, and the cement material 143 is supplied into the discharge pipe 140 under pressure by the extrusion molding machine 141. The discharge pipe 140 is provided with a cap part 144. A perforated guide plate 122 is provided from the guide 118 to the base part 144 so that the cement material 143 can be filled into the mold form from below even when the metal mold form 150 passes through the discharge pipe 140. Is formed.

The extruder 141 also supplies a propulsive force for propelling the metal mold 150 into the base part 144 by supplying the cement material 143 into the discharge pipe 40 under pressure.
As described above, the metal mold 150 introduced into the discharge pipe 140 from the belt conveyor-3 via the guide 118 has the cement material 143 placed in the lower part of the cores 12a and 13a. Sufficient cement material is not supplied to the upper, front and rear, and side portions of the materials 12a and 13a. In the discharge pipe 140, the cement material pressurized by the extrusion molding machine 141 is supplied into the discharge pipe 140, so that the cement material 143 is filled not only in the upper part of the core materials 12a and 13a but also in the front and rear parts and the side parts. Is done. The cement material 143 is supplied not only from above but also from below by arranging the perforated guide plate 122.

  Further, since the cement material is under pressure in the discharge pipe 140, when the core materials 12a and 13a surrounded by the lath body are used, the inside of the lath body arranged on the surfaces of the core materials 12a and 13a is used. Further, the cement material 143 penetrates to the surface of the resin foam, and a strong bonding force is developed between the core materials 12a, 13a and the cement material 143, so that the core materials 12a, 13a and the cement material 143 are integrated. Turn into.

  In this way, the metal mold 150 filled with the cement material 143 moves to the base part 144. The cross section of the cap part 144 has the same shape as the metal mold 150, and is a shape through which the metal mold 150 can pass. Accordingly, when the metal mold 50 passes through the base portion 144, excess cement material 143 on the upper, lower and both sides of the metal mold 150 is scraped off (removed), and the metal mold is removed. The cement material 143 is pressed so as to have the shape of the frame 150, and a plate-like cement extruded body 145 having the same cross-sectional shape as the metal mold frame 150 is formed.

  FIG. 9 is a cross-sectional view taken along the line BB in the base part 144. As shown in FIG. 9, the cement extruded body 145 is extruded into the same cross-sectional shape as the metal mold 150 by passing through the cap portion 144.

The cement extrusion molded body 145 formed in the base part 144 as described above is sent out by the feed roller 146 provided at the outlet of the base part 144 and sent to the belt conveyor-4.
The cement extruded body (concrete panel with formwork) 145 sent out in this way is cured without removing the formwork until the shape is stabilized. This curing may be performed at normal temperature and normal pressure, and may be performed by heating and pressurizing by heating to a temperature at which the core material does not change under pressure, or by steam curing.

  When the shape is stabilized after curing in this manner, the concrete panels 12 and 13 are obtained by removing the metal mold 150 from the cement extruded body (concrete panel with mold) 145.

  In the concrete panel thus obtained, the core material and the cement material are integrated and a strong bonding force is expressed between the two. Preferably, the entire circumference of the resin foam as the core material is a metal lath body. More preferably, a resin lath body surrounds the outer periphery of the metal lath body, and the cement material reaches the surface of the resin foam as the core material from the gap between these laths. As a result, the core material made of the foamed resin and the cement material are integrated, and a strong bonding force is expressed between them.

  Then, the core material made of the foamed resin and the cement material are integrated to become a structural material having a very high strength, and the structural material thus obtained becomes a concrete panel having a very high heat insulating property.

Moreover, the specific gravity of the concrete panel thus obtained is usually less than 1, which is very lightweight and also has a characteristic of floating in water.
In the present invention, for example, the upper concrete panel 12 and the lower concrete panel 13 manufactured as described above are bonded and integrated by an intermediate layer 15 made of an adhesive mortar 21.

  As shown in FIG. 1, the mold 30 used in the present invention is formed from a resin foam. By this formwork 30, the lower concrete panel 13, the intermediate layer 15, and the upper concrete panel 12 are united to surround the concrete panel laminated body 10.

  The mold 30 is a rectangular frame made of a resin foam having a space for fitting a concrete panel. A plurality of reinforcing bar holes 34 extending through the vertical bars 24 and the horizontal bars 22 (reinforcing bars) are formed in the vicinity of the central portion in the thickness direction of the opposing edges of the rectangular frame. In addition, a slit 31 is formed in the upper part of the reinforcing bar hole 34 so that when the reinforcing bars 22 and 24 are inserted into the reinforcing bar hole 34, the reinforcing bars 22 and 24 are expanded and inserted into the reinforcing bar hole 34.

  Although there is no restriction | limiting in particular in the resin foam which forms this formwork 30, For example, although a polystyrene foam, a polyolefin foam, a urethane-type resin foam etc. can be used, a moldability, economical efficiency, flexibility From the viewpoint of strength, it is preferable to use a polystyrene resin foam. When a polystyrene resin foam is used, the expansion ratio of the polystyrene resin foam is preferably in the range of 20 to 50 times. By setting such an expansion ratio, a suitable strength can be given to the frame.

  The mold 30 has a cut surface 33 at a part of an edge forming the mold. By forming the cut surface 33 in this way, the mold frame 30 can be peeled off from the cut surface 33 when the mold frame 30 is removed. That is, for example, when the mold 30 is removed from the cut surface 33 by removing the mold 30, the mold 30 is usually peeled to the next slit 31 and the reinforcing bar hole 34, and is broken and removed at this portion. Then, when the mold 30 is peeled off from the slit 31 and the reinforcing bar hole 34 and then peeled off to the next slit 31 and the reinforcing bar hole 34, the mold 30 is usually peeled up to the next slit 31 and the reinforcing bar hole 34. It is broken and removed. By repeating this, the formwork 30 surrounding the concrete panel laminate 10 can be removed.

  The thickness of the frame 30 is slightly thinner than the length of the reinforcing bars 22 and 24 protruding from the intermediate layer 15 as shown in FIG. By setting the thickness of the frame 30 in this way, the reinforcing bars 22 and 24 can be stably fixed.

Moreover, it is preferable that the diameter of the reinforcing bar hole 34 substantially matches the diameter of the reinforcing bars 22 and 24. By providing the reinforcing bar hole 34 having such a diameter, leakage of the adhesive mortar 21 from the intermediate layer 15 can be effectively prevented.
The size of the frame 30 can be appropriately set according to the upper concrete panel 12 and the lower concrete panel 13.

  Reinforcing bar holes 34 are formed in a frame 30 made of a resin foam used in the manufacture of the concrete panel laminate 10 of the present invention in a pair in the vicinity of the center of the opposing edge in the thickness direction. The slit 31 formed in the upper part of the reinforcing bar hole is pushed and expanded into the reinforcing bar hole 34, and the reinforcing bars 22 and 24 are inserted so that the vertical bars 24 and the horizontal bars 22 are stretched between the opposing edges.

At this time, it is preferable to join each other by spot welding or the like at the intersection of the horizontal bars 22 and the vertical bars 24. Thus, by joining the horizontal stripes 22 and the vertical stripes 24 to each other, the hooks 26 formed at the tips of the horizontal stripes 22 and the vertical stripes 24 can be fixed in a fixed direction.
The slit 31 that has been spread out is closed when the horizontal bars 22 and the vertical bars 24 are placed in the reinforcing bar holes due to the flexibility of the resin foam.

  The intermediate layer 15 composed of the adhesive mortar 21 formed in the present invention is not particularly limited as long as the mortar has fluidity and has adhesiveness to the surfaces of the upper and lower concrete panels. For example, the water cement ratio is usually adjusted within the range of 20 to 40%, the fine aggregate is usually 4 to 6 times the weight of the cement, and the polymer type admixture is usually 0 to the cement. It can be formed using a mortar kneaded by adding 0.01 to 0.1 times by weight. As the polymer-type admixture used here, for example, one containing a water-soluble adhesive polymer and a surfactant can be used.

In this intermediate layer, a plurality of vertical bars 24 and horizontal bars 22 are arranged, embedded in the adhesive mortar 21, and integrated with the cured body of the adhesive mortar 21.
The laminate as described above pushes up the lower concrete panel 13 placed on the push-up plate 41 in contact with the lower lot 45 from the lower side of the mold 30 in which the vertical bars 24 and the horizontal bars 22 are arranged in the reinforcing bar holes 34, After the lower concrete panel 13 is pushed into the space formed inside the formwork 30, an adhesive mortar 21 is placed on the surface of the lower concrete panel 13, and the stretched vertical and horizontal bars 24 and 22 are embedded. Let

The push-up plate 41 pushes up the lower concrete panel 13 so that the lower end surface of the lower concrete panel 13 is flush with the lower end portion of the mold 30.
It is preferable that the amount of the adhesive mortar 21 to be cast is such that the casting depth of the adhesive mortar is 2 to 4 times the total of the diameter of the vertical bars 24 and the diameter of the horizontal bars 22. By placing the adhesive mortar in such an amount, the vertical and horizontal stripes can be completely embedded in the adhesive mortar.

Next, the upper concrete panel 12 is placed on the adhesive mortar 21 that has been placed, and the upper concrete panel 12 is pushed in contact with the push-down plate 42 from above the upper concrete panel 12, and the lower concrete panel 13 and the intermediate layer are pressed. 15 and the upper concrete panel 12 are integrated. At this time, vibration is applied from the upper lot 44 that pushes down the push-down plate 42 and the lower lot 45 that pushes up the push-up plate 41 to vibrate the interface between the lower concrete panel 13 and the intermediate layer 15 and the upper concrete panel 12 and the intermediate layer 15. The adhesive mortar 21 of the intermediate layer 15 is preferably fluidized. By vibrating in this way, the adhesive mortar 21 spreads over the surface of the concrete panel, and it becomes difficult to form a gap at the interface. Moreover, generation | occurrence | production of the void in the adhesive mortar 21 can also be prevented.
In addition, in FIG. 1, notation is abbreviate | omitted about the adhesive mortar cast.

  The push-down plate 42 is pushed down until the upper surface of the upper concrete panel 12 is flush with the upper edge of the mold 30, and the lower plate of the lower concrete panel 13 is preferably placed on the lower surface of the mold 30 while giving vibration. The concrete panel laminate of the present invention is formed by being pushed up so as to be flush with the lower edge.

The pressurization by the push-up plate 41 and the push-down plate 42 as described above is performed until an adhesive force is developed between the adhesive mortar 21 and the concrete panel.
After pressurizing until the adhesive force is developed between the adhesive mortar 21 and the upper concrete panel 12 and the lower concrete panel 13, the push-down plate 42 and the push-up plate 41 are removed, and the laminate is left with the formwork 30. Take care.

  Thus, the formwork 30 surrounding the concrete panel laminate 10 can be used as a packaging body for the concrete panel laminate 10 by maintaining the enclosed state as it is even after the adhesive mortar is cured. That is, the corners of the concrete panel laminate 10 may be lost during transportation, but by surrounding the periphery with the frame 30, the frame 30 becomes a cushioning material and the corners are lost. Can be prevented.

  The concrete panel laminate 10 manufactured in this manner is used to remove the surrounding formwork 30 from the cut surface 33 and weld the reinforcing bars 22 and 24 protruding from the ends of the adjacent concrete panel laminate 10, By joining, and then filling the joint part with a sealing material, a continuous wall body can be manufactured. However, the wall body has not only a linear structure but also an L-shaped end or T-shape. Such an L-shaped structure, a T-shaped structure, or the like is difficult to form with only the concrete panel laminate 10 described above.

  Therefore, when the corner is formed by joining the concrete panel laminate 230 in an L shape as shown in FIG. 10, a corner columnar body 210 as shown in FIGS. 12A and 12B is used. In the corner columnar body 210, the corner columnar body 220 or 231 shown by the cross section a-1 or a-2 used when the concrete panel laminate 230 is joined to the L shape, and the laminated heat insulation panel are formed in a T shape. Corner columnar body 240 or 250 shown in section B-1 or B-2 used for joining, and corner columnar form shown in section C-1 or C-2 used for joining a concrete panel laminate to a cross. There is a body 260 or 270.

Each of the corner columnar bodies 120 has a single vertical stripe 212 near the center of the YY cross section.
In the square columnar body 220 shown by the cross section (a-1), an L-shaped core material-1 (221) whose outer periphery is surrounded by a cement hardened body 225 is disposed. The horizontal streak-1 (241) and the horizontal streak-2 (242) integrated in an L-shape along the inner edge of the core material-1 (221) are arranged at predetermined intervals in the vertical direction. The vertical width of the horizontal bars can be set as appropriate according to the width of the vertical bars and horizontal bars formed in the concrete panel laminate, but is usually within a range of 10 to 60 cm, preferably 15 to 50 cm. It is in the range. In the cross section (a-1), a core material-2 (222) is usually arranged at a portion sandwiched between the horizontal muscle-1 (241) and the horizontal muscle-2 (242), and an L-shaped core material- 1 (221), the transverse muscle-1 (241), the transverse muscle-2 (242), and the core material-2 (222) are joined together with a cement material 228, so that the sectional shape is represented by the number 220. The square columnar body 210 can be formed by forming a quadrangular shape. In addition, since the core material-2 (222) is located on the inner side when forming an L-shaped building structure, the core material-2 (222) does not significantly affect the heat insulation performance. (222) may be replaced by cement material 224. See section (a-2) corner columnar body 231.

  The vertical bars 212 of the corner columnar body 210 formed as described above are extended from the corner columnar body 210, and the distal ends thereof are bent into an L-shape to engage the vertical bars (bar arrangement connector). 214 is formed. The same applies hereinafter.

Further, the horizontal bar 216 extending from the side edge of the corner columnar body 210 has its distal end bent into an L shape to form a horizontal bar engaging tool 217. The same applies hereinafter.
A corner columnar body 210 represented by (B-1) in FIG. 12 has a cross section 240 of the corner columnar body used when the laminated heat insulation panel 230 is joined to a T-shape.

In the corner columnar body 210 having a cross section indicated by (B-1), the core material-1 (221) surrounded by a hardened cement body made of a resin foam having an I-shaped cross section is arranged on the side facing the outside. The lateral streak-1 (245) is arranged along the core material-1 (221). A horizontal bar-2 (246) is extended perpendicularly from the vicinity of the center of the horizontal bar-1 (245), and a corner columnar body near the intersection of the horizontal bar-1 (245) and the horizontal bar-2 (246). One vertical streak (212) is arranged in the vicinity of the central portion of 240. A core material-2 (222) surrounded by a hardened cement body and a core material-3 (223) surrounded by a hardened cement body can also be arranged on the indoor side of the horizontal streak-1 (245). As shown in B-2), the core material-2 (222) and the core material-3 (223) do not significantly affect the heat insulation property because the core material-1 (221) is on the outdoor side. Therefore, the core material-2 (222) and the core material-3 (223) may be replaced with the cement material 224. See section (B-2) corner columnar body 250.
Each member as described above is integrated with a cement material 228.

  The corner columnar body 210 having a cross section indicated by (C-1) is a section of the corner columnar body 260 used when the concrete panel laminated body 230 is joined in a cross shape. As shown in (C-1), it has two horizontal stripes-1 (251) and horizontal stripes-2 (252) arranged in a cross, and a vertical stripe 212 penetrating vertically in the vicinity of the intersection of these horizontal stripes. , The core material 1 (221) surrounded by the hardened cement body, the core material 2 (222) surrounded by the hardened cement body, and the core material surrounded by the hardened cement body- 3 (223) and the core material-4 (224) surrounded by the cement hardened body are arranged.

When four concrete panel laminates 230 are joined together to form a frame, the connecting portion is indoors. In this case, the heat insulation of the building can be achieved without arranging a core made of resin foam. There is no particular effect, and in the cross section (C-1), the core material-1 (221), the core material-2 (222), the core material-3 (223), and the core material-4 (224) are replaced with cement materials. (Refer to section (C-2) corner columnar body 270).
Each of these members is integrated with a cement material 228.

  In the case of connecting the concrete panel laminates 230a and 230b shown in FIG. 10 in series, the building structure of the present invention first has a transverse bar engaging tool 217 extending from the horizontal bar of the concrete panel laminate 230a. Then, the horizontal bar engaging tool 217 extending from the horizontal bar of the adjacent concrete panel laminate 230b is joined. For joining these horizontal bars, the joints may be bundled or welded. When the horizontal bars are joined in this way, a gap is formed between the laminated heat insulation panels 230a and 230b, and sealing is performed with a sealing material 229 so as to fill the gap.

  That is, in order to join the adjacent concrete panel laminates 230 to each other, the engaging portions of the horizontal bars formed at the front ends of the horizontal bars extending from the side edges of the adjacent concrete panel laminates are bound or welded. Then, they are integrated, and then this engaging portion is sealed with the joint sealant 229, so that it can be completely joined.

  As the sealant 229 for the joint used for this seal, a resin sealant such as a silicone sealant, a modified silicone sealant, a urethane sealant, and an acrylic sealant can be used. Can be used. In particular, in the present invention, after sealing using cement mortar, it is preferable to seal with a resin sealant such as a modified silicone sealant. By using cement mortar as a joint sealant and further sealing with a resin sealant such as a modified silicone sealant, the cement mortar is cured and integrated with the concrete panel laminate 230 to provide high strength. In addition to being expressed, excellent heat insulation is also exhibited by a resin-based sealing material such as a modified silicone-based sealing material.

When connecting the concrete panel laminated body 230 at a right angle, as shown in FIG. 10, the concrete panel laminated body 230 is joined via the corner columnar body 210.
For example, as shown in FIG. 10, when the concrete panel laminate 230b and the concrete panel laminate 230c are joined at a right angle, the corner having a cross-sectional structure as shown by a-1 or a-2 in FIG. The columnar body 210 is used.

  That is, the horizontal bar engagement tool 217 formed at the tip of the horizontal bar-1 (241) of the corner columnar body 10, and the horizontal bar engagement tool 217 formed on the side edge of the concrete panel laminate 230b. Are bound or welded. By joining the concrete panel laminated body 230b and the corner columnar body 210 in this way, the lateral stripes extending from the lateral stripes-2 (242) of the corner columnar body 210 to the indoor side at the tip of the concrete panel laminated body 230b. The engagement tool 217 can be formed.

  The horizontal bar engagement tool formed at the edge of the concrete panel laminate 230c is bound to the horizontal bar engagement tool extended from the horizontal bar-2 (242) of the corner columnar body 210 formed in this manner. Alternatively, by welding, the concrete panel laminate 230c can be formed perpendicular to the concrete panel laminate 230b.

  In addition, the gap between the concrete panel laminate 230b and the corner columnar body 210 and the corner columnar body 210 integrated as described above and the gap between the corner columnar body 210 are filled with the above-described sealing material and cured, Strength and heat insulation can be imparted. In particular, since a resin foam having an L-shaped cross section is disposed as a core material in the corner columnar body 210, the corner columnar body 210 also has sufficient heat insulation.

As described above, it is preferable to dispose a horizontal trunk edge 285 across the seal portion on the indoor side surface of the concrete panel laminated body 230 that has been joined in an L shape.
The horizontal trunk edge 285 can be installed so as to be sandwiched between hooks 271 installed on the surface of the concrete panel laminate 230. As shown in FIG. 13, the hook used here has a base plate portion 278 and an overhang portion 275, and sandwiches a horizontal trunk edge 285 between the base plate portion 278 and the overhang portion 275, thereby providing a concrete panel. It is comprised so that it can arrange | position to the laminated body 230 surface.

  An insertion portion (anchor) 277 is formed on the back surface of the substrate portion 278 of the hook 271. From the hardened cement body-1 (232), the core material-1 (234), and the hardened cement body-2 (236). Cement cured body-1 (232) of the first heat insulation panel to be formed is pierced from the surface of the heat insulation panel and fixed.

  When the hook 271 as described above is installed and the horizontal trunk edge 285 is disposed, a gap is formed between the horizontal trunk edge 285 and the concrete panel laminate 230 at a portion where the hook 271 is not formed, and the horizontal trunk edge is formed. Since 285 may become unstable, it is preferable to arrange a spacer 273 to prevent this. As with the hook 271, the spacer 273 has an insertion portion (anchor) 277 formed on the back surface of the substrate portion 278, and two screw holes 276.

  By disposing the spacer 273 as described above, the lateral trunk edge 285 can be stabilized. The spacer 273 is usually formed of a metal such as iron or aluminum.

  It is preferable that the horizontal trunk edges 285 arranged as described above are fixed to each other by using the L-shaped horizontal trunk edge fixing tool 280 at the corners. The L-shaped lateral trunk edge fixture 280 is usually formed of a metal such as iron or aluminum.

  By arranging the horizontal trunk edge 285 in this way and fixing them together using the L-shaped horizontal trunk edge fixture 280, the laminated heat insulation panel can be installed more stably, and this horizontal trunk edge 285 is also provided. On the other hand, an interior material (not shown) can be arranged, so that there is an advantage that the interior work becomes easy. Therefore, it is preferable that the lateral trunk edge 285 is made of wood that can be nailed.

  Furthermore, since this horizontal trunk edge 285 is disposed so as to straddle the sealing portion 229 of the concrete panel laminate 230, the strength of the portion that has joined the concrete panel laminate 230 can be compensated. Further, since the horizontal trunk edge 285 of the laminated heat insulation panel joined at a right angle is joined by the L-shaped horizontal trunk edge fixture 280, the strength in the vicinity of the arrangement position of the corner columnar body 210, which tends to be low in strength. It is also possible to compensate for stability.

  When the concrete panel laminate 230 is joined to the letter T in the building structure of the present invention, the cross section of the corner columnar body 240 or B-2 having the cross-sectional structure of B-1 in FIG. 12 as described above. A square columnar body 250 having a structure is used.

  By using the corner columnar body 210 having such T-shaped horizontal stripes, a T-shaped building structure can be formed by joining the laminated heat insulation panels in the same manner as described above. Moreover, it is preferable to arrange | position the horizontal trunk edge 285 similarly to the above in the T-shaped building structure formed in this way. In this case, it is preferable to provide the lateral trunk edges 285 on both sides of the T-shaped leg portion of the T-shaped building structure.

  In the building structure of the present invention, when the concrete panel laminated body 230 is crossed over, the cross-sectional structure of the corner columnar body 260 or C-2 having the cross-sectional structure of C-1 in FIG. The square columnar body 270 is used.

  By using such a square columnar body having cross-shaped horizontal stripes and connecting the concrete panel laminated body in the same manner as described above, a building structure continued to the cross-shaped can be formed. Moreover, it is preferable to arrange | position the horizontal trunk edge 285 similarly to the above in the building structure succeeded by the cross formed in this way. In this case, it is preferable to provide a horizontal trunk edge 285 on the entire surface facing the room of the building structure inherited by the cross.

Although the above description is an example of forming a wall body using the concrete panel laminate 230, a floor body, a ceiling body, or the like can be formed by placing the wall body sideways.
When the building structure of the present invention is used as, for example, a wall body, the surface wall material is disposed on the surface, and when used as a floor body, the floor material is disposed on the surface. However, when used as a ceiling body, a ceiling material is arranged and used.

  Further, in the present invention, by using the vertical bar engaging tool provided by extending the vertical bars of the concrete panel laminated body 230, the concrete panel laminated body is vertically connected, so that a multi-layer structure such as a two-story structure or a three-story structure is obtained. It is possible to form a floor building structure.

  Since the building structure formed in this way is lightweight, it can be constructed without using large-scale building equipment, and since the resin foam is used twice as a core material, it is insulated. Also excellent in properties. In addition, since the periphery of the resin foam used as the core material is surrounded by the hardened cement body and there is no portion where the resin foam is exposed, termites do not enter and can be stably maintained for a long time. Furthermore, since the resin foam which is a core material is not exposed and the entire periphery is covered with the cement cured body, the cured building body of the present invention is also excellent in fire resistance.

  In addition, the building structure of this invention forms a housing, and can form an exterior material, an interior material, etc. according to a normal construction method. When arranging the exterior material, it is preferable to provide the exterior material by arranging the horizontal trunk edge or the vertical trunk edge (not shown) described above in detail on the outer peripheral surface of the building structure of the present invention. .

DESCRIPTION OF SYMBOLS 10 ... Concrete panel laminated body 12a ... Concrete panel 13a ... Concrete panel 12 ... Upper concrete panel 12a, 13a ... Core material 12b, 13b ... Lath body 12c, 13c ... Mortar Surface layer 13 ... lower concrete panel 15 ... intermediate layer 21 ... adhesive mortar 22 ... longitudinal bars (rebar)
24 ... Horizontal bars (rebars)
26 ... Hook 30 ... Formwork 31 ... Slit 33 ... Cut surface 34 ... Reinforcing bar hole 41 ... Push-up plate 42 ... Push-down plate 44 ... Upper lot 45 ... Lower lot 110 ... Concrete panel manufacturing apparatus 111 ... Extruding means 112 ... Cement extruder 114 ... Screw 116 ... Pushing roller 118 ... Guide 120 ... Extruding tube 122 ... Hole Empty guide plate 124 ... longitudinal direction guide 141 ... extrusion molding machine 143 ... cement material 140 ... discharge pipe 141 ... extrusion molding machine 142 ... screw 143 ... cement material 144 ... · Cap 146 ... Feed roller 150 ... Metal mold 152 ... All metal mold plate 154 ... Rear metal mold plate 156 ... Insertion hole 158・ ・ ・ Insertion hole 160 ・ ・ ・ Corner part auxiliary bar 162 ・ ・ ・ Center part auxiliary bar 210 ・ ・ ・ Corner columnar body 212 ・ ・ ・ Vertical line 214 ・ ・ ・ Vertical line engaging tool 216 ・ ・ ・ Horizontal line 217 ... Horizontal bar engagement tool 220 ... Corner columnar body 221 ... Core material-1
222 ・ ・ ・ Core-2
223 ... Core-3
224 ... Core-4
225: Hardened cement body 228: Cement material 229 ... Sealing material 230 ... Concrete panel laminate 230a ... Concrete panel laminate 230b ... Concrete panel laminate 230c ... Concrete panel laminate Body 231 ... Corner columnar body 232 ... Cement hardened body-1
234 ... Core material-1
236 ... hardened cement body-2
240 ... Square columnar body 241 ... Horizontal muscle-1
242 ... transverse muscle-2
245 ... Transverse muscle-1
246 ・ ・ ・ Horizontal muscle-2
250 ... corner columnar body 251 ... transverse muscle -1
252 ・ ・ ・ Horizontal muscle-2
260 ... corner columnar body 271 ... hook 273 ... spacer 275 ... overhang part 276 ... screw hole 277 ... insertion part (anchor)
278 ... Substrate part 280 ... L-shaped horizontal trunk edge fixture 285 ... Horizontal trunk edge

Claims (10)

Made of foamed resin, it has many rebar holes that pass through and hold the rebar in the vicinity of the center in the thickness direction, and a slit for pushing the rebar into the rebar hole is formed on one side of the edge where the rebar hole is formed And a frame having a cut surface at a part of the edge,
In the hollow part of the formwork, it has an upper concrete panel inserted from the upper part and a lower concrete panel inserted from the lower part,
A concrete panel laminate in which the upper concrete panel and the lower concrete panel are integrated and has an intermediate layer made of an adhesive mortar in which a reinforcing bar is embedded, surrounded by a frame.   The concrete panel laminate according to claim 1, wherein the resin foam is a polystyrene resin foam having an expansion ratio of 20 to 50 times.   The said upper concrete panel and the lower concrete panel are the composites which surrounded the circumference | surroundings of the polystyrene foam core material with the lath body, and has arrange | positioned the concrete layer on the surface of this lath body. Concrete panel laminate. Insert the rebar by expanding the slit formed in the upper part of the rebar hole into the rebar hole formed in the vicinity of the center part in the thickness direction of the opposite edge of the frame made of resin foam Extending the reinforcing bars between the opposing edges;
Placing the lower concrete panel by placing it on the lower push-up plate in the hollow part of the frame body from below in the frame body over which the reinforcing bars are stretched;
Filling the adhesive mortar so that the reinforcing bar is buried in the space where the reinforcing bar is stretched,
Inserting an upper concrete panel into a formwork above the filled adhesive mortar;
Adhesive mortar and lower part filled with lower concrete panel pushed up from upper part while lower concrete board is pushed up from lower part by pushing down lower plate from upper part of upper concrete panel to upper concrete panel A method for producing a concrete panel laminate, wherein the concrete panel and the upper concrete panel are integrated.   The method for producing a concrete panel laminate according to claim 4, wherein the resin foam is a polystyrene resin foam having an expansion ratio of 20 to 50 times.   The said upper concrete panel and a lower concrete panel are the composites which surrounded the circumference | surroundings of the polystyrene foam core material with the lath body, and has arrange | positioned the concrete layer on the surface of this lath body. A method for producing a concrete panel laminate.   5. The adhesive mortar filled with the lower concrete panel and the upper concrete panel is integrated by the upper push-down plate and the lower push-up plate while applying vibration to the upper push-down plate and the lower push-up plate. The manufacturing method of the concrete panel laminated body of description.   The said frame body has a cut surface in a part of edge which forms this frame body, and peels off and removes a frame body from this cut surface, The manufacture of the concrete panel laminated body of Claim 4 characterized by the above-mentioned. Method.   A mold made of a resin foam having a hollow portion for inserting an upper concrete panel and a lower concrete panel, and in the vicinity of the central part in the thickness direction of the opposite edge of the mold, A plurality of reinforcing bar holes are formed, and a slit is formed on the upper part of the reinforcing bar hole so that the reinforcing bar is expanded when the reinforcing bar is inserted to insert the reinforcing bar into the reinforcing bar hole. A mold having a cut surface in part.   The frame according to claim 9, wherein the resin foam is a polystyrene resin foam having an expansion ratio of 20 to 50 times.

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