JP2023065576A - Face material for fabricating internal corner - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a face material capable of easily fabricating a wall structure with good finish.

SOLUTION: In a face material for fabricating internal corners, a first face material 4 has a first core material part 41, and a second core material part 42. The first core material part 41 is formed as a flat plate, has first and second main faces 41a and 41b facing each other in the thickness direction, and has a side face 41c located between the first and second main faces 41a and 41b, and includes a straight face 41cS where the side face 41c extends straight when viewed in the thickness direction. When viewed in the direction in which the straight face part 41cS extends straight, the straight face 41cS is inclined with respect to the thickness direction so as to form an acute angle with the first main face 41a and an obtuse angle with the second main face 41b. The second core material part 42 has a bonding face 42c that is bonded to the straight face part 41cS via an adhesive layer 46, and a first main adjacent face 42a that is positioned to form a convex corner part 48 in cooperation with the first main face 41a of the first core material part 41, with a bevel or notch 49 in the corner part 48.

SELECTED DRAWING: Figure 2

COPYRIGHT: (C)2023,JPO&INPIT

Description

The present invention relates to a face material for making an internal corner.

In the construction industry, corners that are concave to the observer are generally called internal corners, and convex corners are generally called external corners. An inside corner and an outside corner are formed between two walls, for example in a house. Inner corners and outer corners formed between such two walls are generally produced by butting two face members in an orthogonal state and fixing each face member to a pillar or the like.

FIG. 15A schematically shows a cross-sectional view of a typical internal corner structure using two wall facings to form an internal corner. In this internal corner structure, a column portion 10 extending in the vertical direction and having a rectangular cross section has adjacent first side surfaces 11 and second side surfaces 12, and the first side surface 11 and the second side surface 12 are adjacent to each other. The corner 10A of the portion 10 is formed. A rectangular parallelepiped first receiving portion 13 is attached to the first side surface 11 , and a rectangular parallelepiped second receiving portion 14 is attached to the second side surface 12 .

The first receiving portion 13 is fixed to the first side surface 11 so that one flat portion is in surface contact with the first side surface 11 and the other flat portion is flush with the second side surface 12 . The second receiving portion 14 is fixed to the second side surface 12 so that one flat portion is in surface contact with the second side surface 12 and the other flat portion is flush with the first side surface 11 . The first receiving portion 13 is fixed to the first side surface 11 by a nail 15 driven across the first receiving portion 13 and the column portion 10 , and the second receiving portion 14 is fixed to the second receiving portion 14 and the column portion 10 . It is fixed to the second side surface 12 by a nail 15 that is driven across.

On the other hand, a face member 101 is fixed to the first receiving portion 13 and a face member 102 is fixed to the second receiving portion 14 . The face material 101 and the face material 102 are each formed in a flat plate shape, and the front surface and the back surface facing each other in the thickness direction are formed in a rectangular shape. The face materials 101 and 102 are gypsum boards, but other plate materials may be used.

The back surface 101b of the face member 101 is in surface contact with the first receiving portion 13, and one of its four sides is in surface contact with the second receiving portion 14. As shown in FIG. In this state, the face member 101 is fixed to the first receiving portion 13 by screwing the screw 16 so as to straddle the face member 101 and the first receiving portion 13 . The back surface 102b of the face material 102 is in surface contact with the second receiving portion 14, and one side of the four sides thereof is in surface contact with the surface 101a of the face material 101. As shown in FIG. In this state, the face member 102 is fixed to the second receiving portion 14 by screwing the screw 16 so as to straddle the face member 102 and the second receiving portion 14 .

By fixing the face material 101 and the face material 102 as described above, the surface 101a of the face material 101 and the surface 102a of the face material 102 intersect each other at right angles. Here, in the internal corner structure of FIG. 15A , the wallpaper 18 is attached to the surface 101 a of the face material 101 and the surface 102 a of the face material 102 in a state of straddling the corners formed on the wallpaper 18 . It forms an internal corner RE.

At the internal corner RE formed as described above, the wall paper 18 is likely to tear starting from the boundary between the face members 101 and 102 due to shaking of the building, and the appearance may be impaired. In consideration of such problems, various techniques have conventionally been proposed for maintaining a good appearance of internal corners (see, for example, Patent Document 1).

JP 2017-14870 A

By the way, in a general internal corner structure as shown in FIG. The first receiving portion 13 is fixed to the first side surface 11 of the column portion 10 so as to be flush with each other. Further, the second receiving portion 14 is attached to the column portion 10 so that the flat portion of the second receiving portion 14 that contacts the back surface 102b of the face member 102 and the first side surface 11 of the column portion 10 are flush with each other. It is fixed to the second side surface 12 .

However, as shown in FIG. 15B, the corner 10A of the column portion 10 may be moved between the first receiving portion 13 and the second receiving portion 14 due to the skill of the pillar structure fabrication worker, deformation of members over time, and the like. may protrude from the In this case, contact between the corner 10A and the face material 101 may impair the finish of the inside corner.

The present invention has been made in consideration of the above-mentioned circumstances, and provides a face material that can easily produce a wall structure with a good finish, an inside corner structure using the same, a method for making an inside corner, and a method for forming a chamfer. intended to provide

The face material for forming an internal corner according to the present invention is formed in a flat plate shape, and has a first main surface and a second main surface facing each other in the thickness direction, and a surface material between the first main surface and the second main surface. a first core member including a rectilinear surface portion in which the side surface extends linearly when viewed along the thickness direction; and a second core member coupled to the rectilinear surface portion. , and when viewed along the direction in which the straight surface portion extends linearly, the straight surface portion forms an acute angle with the first main surface and an obtuse angle with the second main surface in the thickness direction. The second core portion has a convex shape in cooperation with a bonding surface that bonds to the rectilinear surface portion via an adhesive layer and the first principal surface of the first core portion. and a first major surface adjacent surface positioned to form a corner portion, wherein the corner portion formed by the first major surface and the first major surface adjacent surface is chamfered or notched. It is a surface material for forming an internal corner between two walls, between a wall and a ceiling, or between a wall and a floor.

A notch may be formed in the corner portion, and the face member according to the present invention may further include a third core portion arranged inside the notch. The third core member has an inner surface aligned with the concave surface forming the cutout, an end point of the first main surface and an end point of the first main surface adjacent surface that are adjacent to each other with the cutout therebetween. and an outer surface extending along a straight line connecting the

The face material according to the present invention further includes a first covering sheet material that covers the first main surface, the chamfer or the notch, and the surface adjacent to the first main surface, and the first covering sheet material covers the first main surface. The first main surface and the first main surface adjacent surface may be combined by being attached to one main surface and the first main surface adjacent surface.

The second core member may further have a second main surface adjacent surface extending parallel to the first main surface adjacent surface from an end point of the coupling surface on the second main surface side.

A thickness of the second core portion determined by a distance from an end point of the bonding surface on the second surface side to the surface adjacent to the first main surface may be the same as a thickness of the first core portion. .

In addition, the face material according to the present invention further includes a second covering sheet material covering the second main surface and the surface adjacent to the second main surface, and the second covering sheet material includes the second main surface and the second main surface. The second main surface and the second main surface adjacent surface may be combined by being attached to the second main surface and the second main surface adjacent surface in a state of being bent over the two main surface adjacent surfaces.

The second covering sheet material includes a first sheet portion located on the second main surface side across the boundary between the second main surface and the second main surface adjacent surface, and the second main surface across the boundary. and a second sheet portion located on the side adjacent to the surface, and the first sheet portion and the second sheet portion may be joined via a sheet adhesion portion on the boundary.

The first sheet portion and the second sheet portion may be made of paper, and the sheet bonding portion may be made of a vinyl acetate resin-based adhesive.

The first core part and the second core part contain gypsum as a main component, and an adhesive layer that bonds the rectilinear surface part of the first core part and the bonding surface of the second core part, A silicone-modified polymer-based elastic adhesive may also be used.

The side surface includes an adjacent rectilinear surface portion adjacent to the rectilinear surface portion and linearly extending in a direction different from the rectilinear surface portion. , the first core portion is solid and has a notch on the same side in the thickness direction as the corner portion formed by the first main surface and the surface adjacent to the first main surface. may have.

Further, the internal corner structure according to the present invention includes a pillar portion forming a corner by adjacent first and second side surfaces, a first receiving portion provided on the first side surface, and a second side surface provided on the second side surface. and the face member, wherein the corner portion formed by the first main surface and the adjacent surface of the first main surface of the face member is provided at the corner portion of the face member. When the chamfer or the notch and the corner of the column portion face each other, the first receiving portion is in surface contact with the first main surface of the first core portion, and the second receiving portion is in surface contact with the surface adjacent to the first main surface of the second core portion, the first core portion is in surface contact with the first receiving portion, and the second core portion is in surface contact with the By providing a fastening member that straddles the first core portion and the first receiving portion in a state of surface contact with the second receiving portion, the face member is supported by the column structure, and the face member is an internal corner structure in which a part of the internal corner is formed by the second main surface of the.

In addition, a method for manufacturing an internal corner according to the present invention includes: a column portion forming a corner by adjacent first and second side surfaces; a first receiving portion provided on the first side surface; a step of providing a columnar structure having a second receiving portion, a step of preparing the face material, and the corner portion formed by the first main surface and the first main surface adjacent surface of the face material When the chamfer or the notch provided in and the corner of the column face each other, the first receiving portion is in surface contact with the first main surface of the first core portion, The second receiving portion is in surface contact with a surface adjacent to the first main surface of the second core portion, and the first core portion is in surface contact with the first receiving portion and the second By providing a fastening member that straddles the first core part and the first receiving part in a state where the core part is in surface contact with the second receiving part, the face material is supported by the column structure. and forming a part of the inside corner by the second main surface of the face material.

Further, the method for forming a notch according to the present invention includes the steps of preparing a planar face material intermediate body having a support layer and a core material layer provided on the support layer; A trapezoidal portion extending from the surface of the material layer opposite to the support layer toward the middle of the core material layer toward the support layer side, and is located between an upper base and a lower base and opposed to each other. A first portion whose width between a pair of first side portions gradually decreases toward the support layer side, and a first portion that changes direction with respect to the pair of first side portions so as to reach the support layer. A portion defined between a pair of second side portions connected to each of the pair of first side portions, wherein the width between the pair of second side portions extends toward the support layer side. a step of forming a groove in the core material layer, the groove having a second portion that gradually increases, gradually decreases, or becomes constant; are bent in the direction of closing the groove to couple the pair of first side portions in the first portion of the groove and to continuously connect the pair of second side portions in the second portion of the groove. In this state, when the pair of first side portions are joined together, a portion on one side and a portion on the other side are formed across the groove in the surface of the core material layer on the support layer side. forming a chamfer or notch formed of the pair of second side portions in the convex corner portion.

Here, when forming the groove, a projecting piece located on the support layer and projecting toward the first portion may be left within the range of the second portion. When the pair of first side portions are joined to each other, a notch is formed by the pair of second side portions, and the projecting piece is arranged inside the notch. The protruding piece arranged inside has an inner surface matching the concave surface forming the notch, and the one side portion and the other side of the support layer side surface of the core material layer forming the corner portion. and an outer surface extending along a straight line connecting end points adjacent to each other across the notch of the side portion.

Further, the support layer may cover the chamfer or the notch when the pair of first side portions are joined together.

According to the present invention, a well-finished wall structure can be easily manufactured.

1 is a cross-sectional view of an internal corner structure according to one embodiment of the present invention; FIG. 2 is an enlarged view of the periphery of an internal corner of the internal corner structure shown in FIG. 1; FIG. FIG. 2 is an enlarged view of the face material shown in FIG. 1; It is a figure for demonstrating the structure of the face material shown in FIG. It is a figure which shows an example of the manufacturing method of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. It is a figure which shows the example of a changed completely type of the face material shown in FIG. FIG. 14B is a cross-sectional view of the face member taken along line BB of FIG. 14A; FIG. 14B is a cross-sectional view of the face member taken along line CC of FIG. 14A; 14B is a diagram showing an example of use of the face material shown in FIG. 14A. FIG. 1 is a cross-sectional view of a general internal corner structure in which two face members are used to form an internal corner; FIG. FIG. 15B is an enlarged view of FIG. 15A;

An embodiment of the present invention will be described below with reference to the drawings. 15A and 15B of the general internal corner structure shown in FIGS. 15A and 15B are denoted by the same reference numerals, and description thereof may be omitted.

FIG. 1 is a cross-sectional view of an internal corner structure 1 manufactured using a face member (first face member 4 described later) according to an embodiment of the present invention. The internal corner structure 1 forms an internal corner RE between two walls oriented in opposite directions, and FIG. 1 shows a cross-sectional view of the internal corner structure 1 cut along the horizontal direction. In addition, the internal corner structure according to the present invention and the surface material used therein are not limited to those that form an internal corner between two walls. It can also be applied when forming an internal corner. Also, the face material may be used when forming the external corners.

The internal corner structure 1 shown in FIG. 1 includes a column structure 2 arranged to extend along the vertical direction, and a stud 3 arranged to extend along the vertical direction at a position separated from the column structure 2. , a first panel 4, a second panel 5, and wallpaper 18.

The columnar structure 2 has a columnar portion 10 that extends in the vertical direction and has a rectangular cross section. Of the first side surface 11 and the second side surface 12 , a rectangular parallelepiped first receiving portion 13 is attached to the first side surface 11 , and a rectangular parallelepiped second receiving portion 14 is attached to the second side surface 12 .

The first receiving portion 13 is fixed to the first side surface 11 so that one flat portion is in surface contact with the first side surface 11 and the other flat portion is flush with the second side surface 12 . The second receiving portion 14 is fixed to the second side surface 12 so that one flat portion is in surface contact with the second side surface 12 and the other flat portion is flush with the first side surface 11 . The first receiving portion 13 is fixed to the first side surface 11 by a nail 15 driven across the first receiving portion 13 and the column portion 10, and the second receiving portion 14 is connected to the second receiving portion 14 and the column portion. It is fixed to the second side surface 12 by a nail 15 driven across the portion 10 .

The first receiving portion 13 is provided to support the first face member 4 , and the second receiving portion 14 is provided to support the second face member 5 . The column portion 10, the first receiving portion 13, and the second receiving portion 14 are made of wood, but the material thereof is not particularly limited, and may be made of iron or resin.

Although the first receiving portion 13 and the second receiving portion 14 are rectangular parallelepipeds, the shape is not particularly limited. may be a three-dimensional shape in which the shape of is triangular. Moreover, the cross-sectional shape of the column part 10 is not specifically limited, either. In addition, in the column structure 2 of the present embodiment, the column portion 10, the first receiving portion 13, and the second receiving portion 14 are formed from different members and attached to each other to be integrated. may integrally have portions corresponding to the column portion 10, the first receiving portion 13 and the second receiving portion 14 on a single member.

2 is an enlarged view of the periphery of the internal corner RE in FIG. 1, and FIG. 3 is an enlarged view of the first face member 4. As shown in FIG. The first face member 4 in the present embodiment includes a first core member 41, a second core member 42, a third core member 43, a first covering sheet member 44, and a second covering sheet member 45. and have.

The first core member 41 is formed in a flat plate shape, and has a first main surface 41a and a second main surface 41b facing each other in the thickness direction, and a side surface located between the first main surface 41a and the second main surface 41b. 41c and. In the present embodiment, when viewed along the thickness direction, the first main surface 41a and the second main surface 41b are rectangular, and the side surface 41c includes four rectilinear surface portions 41cS forming four sides of the rectangular shape. , and the rectilinear surface portions 41cS extend linearly. 1 to 3 show one rectilinear surface portion 41cS out of the four rectilinear surface portions 41cS.

The rectilinear surface portion 41cS shown in FIGS. 1 to 3 forms an acute angle with the first main surface 41a when viewed along the direction in which the rectilinear surface portion 41cS extends linearly, that is, in the state shown in FIGS. Moreover, it is inclined with respect to the thickness direction so as to form an obtuse angle with the second main surface 41b. Here, the second core member 42 has a connecting surface 42c that connects to the rectilinear surface portion 41cS. The second core member 42 coupled to the first core member 41 extends linearly along the rectilinear surface portion 41cS of the first core member 41 when viewed in the thickness direction of the first core member 41. there is

The second core portion 42 has a first main surface located so as to cooperate with the first main surface a of the first core portion 41 in addition to the above-described coupling surface 42c to form a convex corner portion 48. The adjacent surface 42a, the second main surface adjacent surface 42b extending parallel to the first main surface adjacent surface 42a from the end point of the connecting surface 42c on the second main surface 41b side, the first main surface adjacent surface 42a and the second main surface and an end surface 42d located between the adjacent surface 42b and facing the coupling surface 42c.

A notch 49 is provided at a corner portion 48 formed by the first main surface 41 a of the first core member 41 and the first main surface adjacent surface 42 a of the second core member 42 . The notch 49 is formed in a convex shape toward the connecting surface 42c and the rectilinear surface portion 41cS to which the connecting surface 42c is connected. In the present embodiment, the notch 49 has a right-angled tip, but the shape of the notch 49 is not particularly limited, and may be curved or the like.

In the present embodiment, the first core member 41 and the second core member 42 are joined so as to form an L shape. may be combined in any way. In addition, the first main surface adjacent surface 42a and the second main surface adjacent surface 42b of the second core member 42 are formed in a rectangular shape, and the second core member 42 is formed in a substantially hexahedral shape. The overall shape of the two core members 42 is not particularly limited.

In the present embodiment, an extension line from the notch 49 of the first main surface 41a of the first core member 41 and an extension line from the notch 49 of the first main surface adjacent surface 42a of the second core member 42 are perpendicular to each other, and the second main surface 41b of the first core member 41 and the second main surface adjacent surface 42b of the second core member 42 are perpendicular to each other. Further, the rectilinear surface portion 41cS of the first core portion 41 forms an angle of 45 degrees with respect to the thickness direction of the first core portion 41, and the coupling surface 42c of the second core portion 42 It forms an angle of 45 degrees with respect to the thickness direction of 42 . Such a shape and angle are not particularly limited, either. may form an obtuse angle or an acute angle of less than 90 degrees.

The thickness T2 of the second core member 42 is determined by the distance between the first main surface adjacent surface 42a and the second main surface adjacent surface 42b. The second main surface adjacent surface 42b is parallel, and the thickness T2 of the second core member 42 is the same as the thickness T1 of the first core member. The thickness of the second core member 42 may be different from the thickness of the first core member.

The third core member 43 is arranged inside the above-described notch 49 formed across the first core member 41 and the second core member 42 . It has a matching inner surface 43a and an outer surface 43b extending along a straight line connecting the end points of the first principal surface 41a and the end points of the first principal surface adjacent surface 42a that are adjacent to each other across the notch 49. ing. In the present embodiment, the tip of the notch 49 is right-angled, so that the third core portion 43 is in the shape of a right-angled isosceles triangle, and the inner surface 43a has a right-angled bent shape.

In the present embodiment, as is clear from FIGS. 2 and 3, the outer surface 43b of the third core member 43 is the first major surface a of the first core member 41 and the second major surface a of the second core member 42. It forms a chamfered portion with respect to a corner portion 48 formed by the first main surface adjacent surface 42a. Further, the third core member 43 is connected to the notch 49 via an adhesive layer, whereby the first core member 41, the second core member 42 and the third core member 43 are integrated. there is

The first core portion 41, the second core portion 42, and the third core portion 43 are plates or blocks made mainly of gypsum, and the linear surface portion 41cS of the first core portion 41 and the second core The adhesive layer 46 that adheres to the bonding surface 42c of the material portion 42 and the adhesive layer (not shown) between the third core portion 43 and the notch 49 are made of a silicone-modified polymer-based elastic adhesive. . More specifically, these adhesive layers 46 and the like are formed by drying and solidifying a silicone-modified polymer-based elastic adhesive, and contain a silicone-modified polymer. In this way, the adhesive layer 46 and the like are made of a silicone-modified polymer-based elastic adhesive that is compatible with gypsum from the viewpoint of bonding strength, so that the first core member 41, the second core member 42, and the third core member 43 bond strength is improved.

FIG. 4 is a diagram for explaining the structure of the first face member 4 in detail. , the state in which the first face member 4 is unfolded is shown. As shown in FIG. 4, in the first face member 4, the first core member 41 and the second core member 42 can be expanded into a flat plate shape. A groove 6 is formed between it and the core member 42 . That is, the first surface member 4 is chamfered or cut by forming a groove 6 in a flat member and connecting the first core member 41 and the second core member 42 so as to fill the groove 6 . It can be formed as a facing with notches. The details of the method for producing such a first face member 4 will be described later.

On the other hand, the first covering sheet material 44 includes the first main surface 41 a of the first core member 41 , the notch 49 , the outer surface 43 b of the third core member 43 inside thereof, and the second core member 42 . It covers the first main surface adjacent surface 42a. The first covering sheet material 44 is attached to the first main surface 41a of the first core member 41, the outer surface 43b of the third core member 43, and the first main surface adjacent surface 42a of the second core member 42. Thus, the first main surface 41a of the first core member 41, the outer surface 43b of the third core member 43, and the first main surface adjacent surface 42a of the second core member 42 are joined. The first covering sheet material 44 is paper, more specifically, gypsum board base paper.

Further, the second covering sheet material 45 covers the second main surface 41 b of the first core member 41 and the second main surface adjacent surface 42 b of the second core member 42 . The second covering sheet material 45 is attached to the second main surface 41b and the second main surface adjacent surface 42b in a state of being bent over the second main surface 41b and the second main surface adjacent surface 42b, so that the second main surface 41b and the second main surface adjacent surface 42b. The second covering sheet material 45 forms a base of the inside corner RE by a corner portion formed on a concave corner portion formed by the second main surface 41b and the second main surface adjacent surface 42b, and the second covering sheet material 45 forms a base of the inside corner RE in this embodiment. In , the wallpaper 18 is attached to the second covering sheet material 45 so that the wallpaper 18 forms the inside corner RE.

The inner corner RE formed by the wallpaper 18 forms an angle of 90 degrees, and the first surface material 4 is arranged such that the inner corner RE formed by the wallpaper 18 forms an angle of 90 degrees with the second main surface 41b and the second main surface 41b. The angle of the concave corner portion formed by the surface adjacent surface 42b is set to 90 degrees. However, if the angle of the concave corner portion is in the range of 88 degrees to 92 degrees, the first surface member 4 is slightly deformed, thereby forming a foundation that can properly form the internal corner RE of approximately 90 degrees. can be formed.

Further, the second covering sheet material 45 in the present embodiment includes a first sheet portion 45A located on the second main surface 41b side across the boundary between the second main surface 41b and the second main surface adjacent surface 42b, It has a second seat portion 45B located on the second main surface adjacent surface 42b side across the boundary between the second main surface 41b and the second main surface adjacent surface 42b, and the first seat portion 45A and the second seat portion 45B , are coupled via the sheet bonding portion 45C on the boundary.

The first sheet portion 45A and the second sheet portion 45B are paper, more specifically, base paper for gypsum board. On the other hand, the sheet bonding portion 45C is made of a vinyl acetate resin-based adhesive, more specifically, a vinyl acetate resin-based solvent-based adhesive. The sheet bonding portion 45C is formed by drying and solidifying a vinyl acetate resin-based adhesive, and contains vinyl acetate resin. Since the sheet bonding portion 45C is made of vinyl acetate resin, which is compatible with the gypsum board base paper in terms of bonding strength, the bonding strength of the sheet portions 45A and 45B can be improved.

Regarding the dimensional relationship between the first core member 41 and the second core member 42, as shown in FIG. ), the length L1 from the boundary between the second main surface 41b and the second main surface adjacent surface 42b to the end surface of the first core member 41 facing the rectilinear surface portion 41cS is the second It is longer than the length L2 to the end surface 42d of the core portion 42. As shown in FIG.

Although the values of the length L1 and the length L2 are not particularly limited, the length L1 is 390 mm in this embodiment. If the length L1 is 385 mm or more, for example, it is possible to construct the first core member 41 between the studs and the pillars separated by a predetermined distance according to the specifications of a general framing construction method. The versatility of the material 4 can be improved.

Also, the length L2 is 23 mm in this embodiment. It is desirable that the length L2 be in the range of 20 mm or more and 30 mm or less. As a result, bulkiness of the first surface member 4 during transportation and storage can be effectively suppressed.

On the other hand, the second surface member 5 is formed in a flat plate shape, and a pair of main surfaces opposed to each other in the thickness direction are formed in a rectangular shape. In this embodiment, the second face material 5 is a gypsum board.

In this embodiment, the first face member 4 and the second face member 5 are made of gypsum board. Specifically, the first face member 4 is a flat plate-like gypsum board that sandwiches a gypsum board core material composed mainly of gypsum between two sheets of base paper for gypsum board. Then, the gypsum boat is bent so as to fill the groove 6. On the other hand, the second face member 5 is formed without processing a flat gypsum board. However, the materials and the like of the first face member 4 and the second face member 5 are not particularly limited, and the face members 4 and 5 do not have to be made of gypsum board. The face materials 4 and 5 may be made of, for example, a calcium silicate plate or a magnesium carbonate plate.

When the first face member 4 configured as described above is attached to the column structure 2, the first core member 41 first comes into surface contact with the first receiving member 13 and the second core member 42 are placed in surface contact with the second receiving portion 14 . Next, the first face member 4 is in a state of being supported by the first receiving portion 13 only by the screw 16 which is a fastening member straddling the first core portion 41 and the first receiving portion 13 . In the present embodiment, when supporting the first face member 4 on the first receiving portion 13, only the screws 16 straddling the first core member portion 41 and the first receiving portion 13 are used. The first face member 4 may be further fixed to the second receiving portion 14 by a screw extending between the material portion 42 and the second receiving portion 14 .

As described above, the first receiving portion 13 is mounted on the column portion 10 so that one flat portion is in surface contact with the first side surface 11 of the column portion 10 and the other flat portion is flush with the second side surface 12 . is fixed to the first side surface 11 of the The second receiving portion 14 is fixed to the second side surface 12 so that one flat portion is in surface contact with the second side surface 12 of the column portion 10 and the other flat portion is flush with the first side surface 11. ing. Here, the above-described other plane portion of the first receiving portion 13 and the other plane portion of the second receiving portion 14 form a right angle. 4 faces the corner 10A of the column portion 10, the first receiving portion 13 comes into surface contact with the first main surface 41a of the first core portion 41, and the second receiving portion 14 is in surface contact with the first main surface adjacent surface 42 a of the second core member 42 .

Here, in the first face member 4 according to the present embodiment, a notch 49 is formed in the convex corner portion 48 , and the third core member portion 43 is arranged inside the notch 49 . The third core member 43 has an inner surface 43a matching the concave surface forming the cutout 49, and an end point of the first main surface 41a and the first main surface adjacent surface 42a adjacent to each other with the cutout 49 interposed therebetween. and an outer surface 43 b extending along a straight line connecting the end points, the outer surface 43 b forming a chamfered portion with respect to the corner portion 48 . This avoids interference between the convex corner portion 48 of the first face member 4 and the corner 10A of the column portion 10 .

After that, in a state in which the second surface member 5 is arranged so as to be in surface contact with the second receiving portion 14 , a screw 16 is provided so as to straddle the second surface member 5 and the second receiving portion 14 . It is supported by the receiving portion 14 . In the present embodiment, after that, wallpaper 18 is affixed so as to straddle the first face member 4 and the second face member 5, thereby forming the internal corner RE.

An example of a method for manufacturing the above-described first surface material 4 having a bent shape will be described below with reference to FIG. 5 .

In this example, as shown in FIG. 5A, gypsum 200 is first poured between a first covering sheet material 44 and a second covering sheet material 45, which are base papers for gypsum board. Here, the first covering sheet material 44 is supplied from a first base paper supply section 71 that sequentially feeds out the sheet materials, and the second covering sheet material 45 is supplied from a second base paper supply section 72 that sequentially feeds out the sheet materials. Also, the gypsum 200 is supplied from the gypsum supply section 75 .

The gypsum 200 poured in this manner dries and hardens over time. When the gypsum 200 is dried and hardened in this manner, needle-like crystals are generated on the outer surface of the gypsum board core portion 201 formed by hardening the gypsum 200, and these needle-like crystals form the first covering sheet material 44 and the The second covering sheet material 45 is pierced. As a result, the first covering sheet material 44 and the second covering sheet material 45 are fixed to the gypsum board core portion.

Next, as shown in FIG. 5B, a face material intermediate body having a predetermined size is formed from a plate formed by fixing the first covering sheet material 44 and the second covering sheet material 45 to the gypsum board core part 201. Next, as shown in FIG. 300 are cut out. The face material intermediate 300 is a flat plate-shaped gypsum board including a gypsum board core portion 201, a first covering sheet member 44, and a second covering sheet member 45 cut out to a predetermined size.

Next, as shown in FIG. 5C, the second covering sheet material 45 and the gypsum board core portion 201 are cut while leaving the first covering sheet material 44, so that the grooves 6 are formed in the face material intermediate body 300. It is formed. The groove 6 is formed linearly from one end to the other end in one direction in the planar direction of the face material intermediate 300 . A cutting tool is used to form the grooves 6 . Here, in the face material intermediate 300, the first core member 41 is formed on one side of the groove 6, and the second core member 42 is formed on the other side. In this embodiment, the first covering sheet member 44 corresponds to the support layer of the present invention, and the gypsum board core portion 201 corresponds to the core layer of the present invention.

As shown in the enlarged view area of FIG. 5(C) , the groove 6 has a cross-sectional shape and extends from the surface of the gypsum board core portion 201 opposite to the first covering sheet material 44 side to the first covering sheet material 44 side. The width between a pair of first side portions 61A located between the upper base and the lower base and facing each other is the first A first portion 61 that gradually decreases toward the covering sheet material 44 side, and a pair of first side portions 61A that change direction with respect to the pair of first side portions 61A and reach the first covering sheet material 44. It is a portion defined between a pair of second side portions 62A connected to each other, and the width between the pair of second side portions 62A is constant toward the first covering sheet material 44 side. two parts 62;

One of the pair of first side portions 61A forms the rectilinear surface portion 41cS of the first core portion 41, and the other forms the coupling surface 42c of the second core portion . Also, the pair of second side portions 62</b>A form the concave surface of the notch 49 . Further, in this example, when the groove 6 is formed, the third core portion 43 is located on the first covering sheet material 44 and becomes convex toward the first portion 61 side within the range of the second portion 62 . are left.

Next, as shown in FIG. 5D, a silicone-modified polymer-based elastic adhesive B is applied to the first side portion 61A of the first portion 61 and the second side portion 62A of the second portion 62 of the groove 6. be done.

Next, as shown in FIG. 5E, the first core member 41 and the second core member 42 are bent in a direction to close the groove 6. Then, as shown in FIG. Here, by connecting the pair of first side portions 61A of the first portion 61 together and connecting the pair of second side portions 62A of the second portion 62, the first core portion A notch 49 consisting of a pair of second side portions 62A is formed in a convex corner portion 48 formed by the first main surface 41a of the second core member 41 and the first main surface adjacent surface 42a of the second core member 42. . The third core portion 43 is arranged inside the notch 49 , and the outer surface 43 b of the third core portion 43 forms a chamfered portion with respect to the corner portion 48 .

After the above-mentioned silicone-modified polymer-based elastic adhesive B applied to the first side portion 61A and the second side portion 62A is dried, the linear surface portion 41cS of the first core portion 41 and the second core portion 42 are bonded together. An adhesive layer 46 is formed between the surface 42c and an adhesive layer between the third core member 43 and the notch 49 is formed.

Further, when the first core part 41 and the second core part 42 are bent, the second covering sheet material 45 (the first sheet part 45A) on the side of the first core part 41 divided by the groove 6 is And the second covering sheet material 45 (second sheet portion 45B) on the side of the second core portion 42 approaches or contacts. Here, the first sheet portion 45A and the second sheet portion 45B are adhered by applying a vinyl acetate resin-based adhesive between the first sheet portion 45A and the second sheet portion 45B. After the vinyl acetate resin-based adhesive dries, the sheet bonding portion 45C is formed.

In the first surface member 4 described above, a notch 49 is formed in the corner portion 48 formed by the first main surface 41a and the first main surface adjacent surface 42a, and the third core material is formed inside the notch 49. A portion 43 is arranged. An outer surface 43 b of the third core member 43 forms a chamfered portion for the corner portion 48 . In this case, when the convex corner portion 48 of the first surface member 4 and the corner 10A of the column portion 10 face each other, interference between the corner portion 48 and the corner 10A is avoided. As a result, the internal corner structure 1, which is a well-finished wall structure, can be easily manufactured.

When the rectilinear surface portion 41cS of the first core portion 41 and the coupling surface 42c of the second core portion 42 are separated from each other to develop the first surface member 4 as described above, the first core portion 41 and the second core portion 41 are separated from each other. The core member 42 is developed in a flat plate shape, and the groove 6 is formed between the first core member 41 and the second core member 42 . That is, as shown in FIG. 5, the first face member 4 is formed by forming a groove 6 in a face member intermediate body 300 which is a plate-like member, and filling the groove 6 with the first core member 41 and the first core member 41 . By combining the two core members, a face member having a chamfer or a notch can be formed. The first face member 4 formed by such a procedure may be able to finish the wall structure better than the face member formed by simply shaving the corner portion to form a chamfer or notch. For example, when chamfering or notching the corners of a gypsum board, it is conceivable to remove the gypsum board base paper and then process the corners, but such processing may be very troublesome in some cases. It can be difficult to get a good finish on the chamfer or notch. In such cases, the first face member 4 according to the present invention can be effectively used. Note that the first face member 4 may be used when forming an external corner, and in this case, it is possible to easily produce a chamfered external corner with a good finish.

In addition, in the first surface member 4, the third core member 43 is arranged inside the notch 49, and the third core member 43 has an inner surface 43a aligned with the concave surface forming the notch 49, and a notch. It has an outer surface 43b extending along a straight line connecting the end points of the first main surface 41a and the end points of the first main surface adjacent surface 42a that are adjacent to each other with the 49 interposed therebetween. In this case, a large cross-sectional area can be secured for the first face member 4, so that the strength can be improved.

In addition, the first surface material 4 further includes a first covering sheet material 44 that covers the first main surface 41a, the notch 49, the outer surface 43b of the third core member 43 inside thereof, and the first main surface adjacent surface 42a. In addition, the first covering sheet material 44 is attached to the first main surface 41a, the outer surface 43b of the third core portion 43, and the first main surface adjacent surface 42a, thereby forming the first main surface 41a and the third core material. The outer surface 43b of the portion 43 and the first main surface adjacent surface 42a are joined together. As a result, the first core member 41, the second core member 42, and the third core member 43 are firmly connected.

The second core member 42 further has a second main surface adjacent surface 42b extending parallel to the first main surface adjacent surface 42a from the end point of the connecting surface 42c on the second main surface 41b side. In this case, the first surface material 4 has a bent shape, and damage to the wallpaper 18 can be effectively suppressed when an internal corner is formed with the first surface material 4 . That is, the second main surface 41b and the second main surface adjacent surface 42b forming a concave corner portion serving as the base of the inside corner are formed by the first core material portion 41 and the second core material portion 42 being inclined rectilinear surfaces. 41cS and the bonding surface 42c are bonded through the adhesive layer 46, so that they are firmly bonded. Therefore, positional deviation between the second main surface 41b and the second main surface adjacent surface 42b is suppressed, and it is possible to effectively suppress the breakage of the wallpaper 18 starting from the bending point.

Moreover, the thickness of the second core member 42 is the same as the thickness of the first core member 41 . In this case, when the rectilinear surface portion 41cS of the first core portion 41 and the coupling surface 42c of the second core portion 42 are separated and developed, the first core portion 41 and the second core portion 42 are kept in a constant state. It becomes a thick flat plate. In this case, since the first face material 4 can be formed from a face material intermediate having a constant thickness, the productivity of the first face material 4 can be improved.

In addition, the first surface member 4 further includes a second covering sheet material 45 that covers the second main surface 41b and the second main surface adjacent surface 42b. The second main surface 41b and the second main surface adjacent surface 42b are joined by being attached to the second main surface 41b and the second main surface adjacent surface 42b in a state of bending over the main surface adjacent surface 42b. The state of bonding between the first core member 41, the second core member 42, and the third core member 43 is strengthened.

In particular, the second covering sheet material 45 includes a first sheet portion 45A located on the second main surface 41b side across the boundary between the second main surface 41b and the second main surface adjacent surface 42b, and a second sheet portion 45A across the boundary. The first sheet portion 45A and the second sheet portion 45B are joined on the boundary via the sheet bonding portion 45C. In this case, the sheet bonding portion 45C joins the first sheet portion 45A and the second sheet portion 45B, and between the rectilinear surface portion 41cS of the first core portion 41 and the joining surface 42c of the second core portion 42, Since it can permeate and bond them together, the bonding strength between the first core member 41 and the second core member 42 can be improved.

The first sheet portion 45A and the second sheet portion 45B are made of paper, and the sheet adhesive portion 45C is made of a vinyl acetate resin adhesive. In this case, since the sheet bonding portion 45C is made of a vinyl acetate resin-based adhesive that is compatible with paper from the viewpoint of bonding strength, the bonding strength between the first sheet portion 45A and the second sheet portion 45B can be improved. .

On the other hand, the first core portion 41 and the second core portion 42 contain gypsum as a main component, and the straight surface portion 41cS of the first core portion 41 and the bonding surface 42c of the second core portion 42 are bonded together. The layer consists of a silicone-modified polymer-based elastic adhesive. In this case, the adhesive layer 46 is made of a silicone-modified polymer-based elastic adhesive that is compatible with the gypsum board (gypsum board core portion) from the viewpoint of bonding strength, so that the first core portion 41 and the second core portion 42 bond strength can be improved. In addition, since the adhesive layer 46 can function as an elastic member, the first surface member 4 is imparted with appropriate flexibility. Thereby, the durability of the 1st surface material 4 can be improved.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications may be made to the above-described embodiments.

6 to 13 show modified examples of the first face member 4. FIG. 6 to 13, (A) shows a cross section of the first face member 4 according to the modification, and (B) shows the first core member of the first face member 4 shown in (A). The unfolded state before the portion 41 and the second core portion 42 are joined is shown.

In the modified example of FIG. 6, the third core member 43 is not arranged inside the notch 49 of the corner portion 48 of the first face member 4 . In this case, in the state before the first core part 41 and the second core part 42 are joined, the inner side of the groove 6 formed between the first core part 41 and the second core part 42 5(C) is not formed to form the third core member 43. As shown in FIG.

In the modified example of FIG. 7, the first core member 41 and the second core member 42 are not joined to form an L-shape, and the first surface member 4 has a flat plate shape.

In the modification shown in FIG. 8, the third core member 43 does not have the shape of an isosceles right triangle, but has the shape of a right scalene triangle.

In the modification of FIG. 9, the notch 49 of the corner portion 48 of the first face member 4 is not formed, and the pair of second side portions 62A of the second portion 62 of the groove 6 are linearly continuous with each other. , forming a chamfer for the corner portion 48 . In this example, the width between the pair of second side portions 62A in the second portion 62 of the groove 6 gradually increases toward the first covering sheet material 44 in the unfolded state shown in FIG. 9B. The width between the pair of second side portions 62</b>A may gradually decrease toward the first covering sheet material 44 depending on the shape of the first surface member 4 .

In the modified example of FIG. 10, the notch 49 of the corner portion 48 of the first face member 4 is arcuate. In the modified example of FIG. 11, the corner portions 48 of the first face member 4 are chamfered.

In the modified example of FIG. 12, the first core member 41 and the second core member 42 are joined so as to form an obtuse angle. In the modified example of FIG. 13, the first core member 41 and the second core member 42 are joined to form an acute angle.

As described above, the first surface member 4 can be formed in various forms. The first surface member 4 can be efficiently formed in various forms by variously changing the shape of the grooves 6 as shown in FIGS. 6(B) to 13(B). In addition, although not shown, the notch 49 of the corner portion 48 of the first face member 4 may be formed in a dome shape, a trapezoid shape, or the like.

Further, the face member 400 according to the modification shown in FIGS. 14A to 14D is formed in a rectangular flat plate shape. The four sides positioned between the front and back surfaces of the face material 400 are positioned facing each other in a direction that intersects the direction in which the pair of first side portions 401 face each other. and a pair of second side portions 402 that are aligned with each other. End portions located on the same side of the pair of first side portions 401 are connected by a second side portion 402 .

FIG. 14B is a cross-sectional view taken along line BB in FIG. 14A, and is a cross-sectional view when the face member 400 is cut in a direction perpendicular to the direction in which the first side portion 401 extends linearly. As shown in FIG. 14B, the corner portion formed at the connecting portion between the first side portion 401 and the surface of the face member 400 is formed by the first core portion 41 and the second core portion similar to those in the above-described embodiment. 42 is formed by a first covering sheet material 44 positioned over a corner portion 48 formed by . A notch 49 is formed in a corner portion 48 formed by the first core member 41 and the second core member 42 , and the third core member 43 is arranged in the notch 49 . Accordingly, the corner portion formed at the connection portion between the first side portion 401 and the surface of the face member 400 has a first chamfered portion 401C. Although only one side of the pair of first side portions 401 is shown in FIG. 14B, the first chamfered portion 401C is also formed on the other side.

On the other hand, FIG. 14C is a cross-sectional view taken along line CC in FIG. 14A, and is a cross-sectional view when the surface material 400 is cut in a direction perpendicular to the linearly extending direction of the second side portion 402 . As shown in FIG. 14C , a second chamfered portion 402C is formed at a corner portion formed at the connecting portion between the second side portion 402 and the surface of the face member 400 . Although only one side of the pair of second side portions 402 is shown in FIG. 14C, a second chamfered portion 402C is formed on the other side.

The second chamfered portion 402C includes an adjacent straight surface portion 402S adjacent to the straight surface portion 41cS on the side surface 41c of the first core portion 41 and forming a base of the second side portion 402, It is formed by the first covering sheet material 44 on the chamfer 402B formed by, for example, shaving the corner portion formed with the surface 41a. That is, in a cross-sectional view obtained by cutting the first core member 41 in a direction perpendicular to the linearly extending direction of the adjacent rectilinear surface portion 402S, the first core member 41 has a solid shape, and the adjacent rectilinear surface portion 402S and the first main portion 402S are solid. A corner portion formed with the surface 41a has a chamfer 402B. A solid state means a state in which the cross section is not divided or the like.

FIG. 14D shows an example of use of the facing 400 shown in FIG. 14A. In FIG. 14D, a plurality of facings 400 are tiled in a plane. The chamfered portions of adjacent face members 400 face each other. When facings 400 are used in this manner, concave grooves are formed between adjacent facings 400 by the opposed chamfers. Such concave grooves can be used for putty treatment. Therefore, according to the face material 400, it is possible to improve the work efficiency when constructing the wall structure. In addition, by forming the chamfer in an appropriate shape on the side of the face material manufacturer, the finish of the wall structure can be improved.

DESCRIPTION OF SYMBOLS 1... Inner corner structure, 2... Column structure, 3... Stud, 4... First surface material, 41... First core material part, 41a... First main surface, 41b... Second main surface, 41c... Side surface, 41cS Straight surface portion 42 Second core member 42a First main surface adjacent surface 42b Second main surface adjacent surface 42c Coupling surface 42d End surface 43 Third core member 43a Inside Surface 43b... Outer surface 44... First covering sheet material 45... Second covering sheet material 45A... First sheet part 45B... Second sheet part 45C... Sheet adhesion part 46... Adhesion layer 48... Corner part 49 Notch 5 Second face material 6 Groove 61 First part 61A First side part 62 Second part 62A Second side part 10 Column Part 10A... Corner 11... First side 12... Second side 13... First receiving part 14... Second receiving part 15... Nail 16... Screw 18... Wallpaper 71... First base paper supply part , 72... Second base paper supply unit 75... Gypsum supply unit 101... Face material 101a... Front side 101b... Back side 102... Face material 102a... Front side 102b... Back side 200... Gypsum 201... Gypsum board core Material part 300 Face material intermediate 400 Face material 401 First side 401C First chamfered portion 402 Second side 402B Chamfered 402C Second chamfered portion 402S …Adjacent straight surface

Claims (4)

It is formed in a flat plate shape and has a first main surface and a second main surface facing each other in the thickness direction, and a side surface located between the first main surface and the second main surface. a first core member including a rectilinear surface portion in which the side surface extends linearly when viewed along;
and a second core member coupled to the rectilinear surface,
When viewed along the linearly extending direction of the rectilinear surface portion, the rectilinear surface portion is inclined with respect to the thickness direction so as to form an acute angle with the first principal surface and an obtuse angle with the second principal surface. and
The second core member is configured to form a convex corner portion in cooperation with a bonding surface that is bonded to the rectilinear surface portion via an adhesive layer and the first main surface of the first core member. a first major surface adjacent surface located,
The corner portion formed by the first main surface and the first main surface adjacent surface is provided with a chamfer or a notch, and the corner portion is provided between two walls, between a wall and a ceiling, or between a wall and a floor. Face material for making an internal corner to form an internal corner between The first core part and the second core part are joined to form an L shape,
A length from a boundary between the second main surface of the first core member and the second core member to an end face of the first core member is 385 mm or more, and the boundary from the second core member is 385 mm or more. 2. The face material for forming an internal corner according to claim 1, wherein the length to the end face of the portion is 20 mm or more and 30 mm or less. The first core part and the second core part are joined to form an L shape,
a first covering sheet material that covers the first main surface, the chamfer or the notch, and the surface adjacent to the first main surface;
A second covering sheet material covering the second main surface and a second main surface adjacent surface located opposite to the first main surface adjacent surface of the second core member,
The first covering sheet material is attached to the first main surface and the first main surface adjacent surface to join the first main surface and the first main surface adjacent surface,
3. The second covering sheet material is attached to the second main surface and the surface adjacent to the second main surface to join the second main surface and the surface adjacent to the second main surface. The face material described in . 2. The surface according to claim 1, wherein said corner portion formed by said first main surface and said first main surface adjacent surface is provided with said notch, and no member is provided inside said notch. material.

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