JPH0462258A - Production of wall panel - Google Patents

Abstract

PURPOSE:To easily form joints at jointing spots, by applying an adhesives on the surface of a base member and coating a jointing material with good leveling property and then sticking a resin molded plate on the base member to cure. CONSTITUTION:A base member 4 is placed on a trestle 10 and a bank 11 made of a resin band surrounding this base member 4 is arranged. And an epoxy adhesive, 3a mixed with glass bead having 0.5mm in diameter is applied on the whole surface of the base member 4. After that, the adhesive 3a is removed over the wider width than the joint in the place corresponding to the joint to the extent that the adhesive 3a remains as a thin water proof layer where a joint cement slurry 5a having a good leveling property is charged. Next, resin molded plates 2 are pressed on specified positions in order with a joint width. And the joint cement 5a is cured until the level becomes even to cure it.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing wall panels, particularly wall panels suitable for sanitary equipment rooms such as bathroom units.

(Prior Art) In general, a wall panel 1 constituting a sanitary equipment room, such as a bathroom unit or a shower room, is made of a resin molded plate 2 formed into a tile shape using an adhesive, as shown in FIGS. 12 and 13. 3 to the surface of the base material 4, and after curing of the adhesive 3,
The joint is formed by filling the joint with a joint material 5, such as joint cement or a sealant.

(Problems to be Solved by the Invention) However, in such wall panels, complicated work is required to form joints after the adhesive has hardened.

For example, for cement joints, use a trowel to fill the joint by rubbing it into the joint, then wipe off the joint cement adhering to the surface of the resin molded board with a damp sponge, and then let the joint cement harden. After that, it was necessary to wipe the resin molded plate with a cloth until the cracks appeared.

In addition, when forming joints with sealant, if the sealant adheres to the resin molded board, the gloss will change and the aesthetic appearance will be impaired, so after masking the resin molded board with Gio tape, etc., make sure that no air bubbles remain. Fill with sealant, then press the sealant into the surface with your fingertips until the surface is smooth, push out the excess sealant onto the masking tape, and make sure the sealant is on the surface of the resin molded plate before it hardens. The masking tape had to be carefully removed to prevent it from sticking.

As described above, the joint forming operation requires a very complicated work in order to fill the narrow joint portion with joint material.

The present invention has been made in view of these problems, and provides a method for manufacturing a wall panel in which joints can be easily formed at joint portions.

(Means for solving the problem) First invention (Well, a base material surrounded by an embankment is placed on a pedestal, and an adhesive is applied to the surface of this base material in an area smaller than the area of the resin molded plate. At the same time, apply a joint material with good leveling properties (wider than the width of the joint formed between adjacent resin molded plates), and with these adhesives and joint materials coexisting, apply a joint material with good leveling properties to the base material. It is characterized by being adhered to the surface and allowed to harden.

In addition, the second invention includes placing a base material surrounded by an embankment on a pedestal, applying an adhesive to the surface of this base material in an area smaller than the area of the resin molded plate, and improving leveling properties. Apply a good joint material wider than the width of the joint formed between adjacent resin molded plates, place the resin molded plates on the base material with these adhesives and joint materials coexisting, and then The method is characterized in that after a mounting plate is placed on the molded plate and the pressure is reduced, the periphery of the plate is covered with a membrane and exposed to atmospheric pressure in a sealed state to allow curing and hardening.

Here, ``Glut material with good leveling properties is defined by JIS
Refers to self-leveling type joint material specified by A3758.

(Function) A base material is placed on a pedestal, and an embankment is provided around the base material to prevent joint material with good leveling properties from flowing and spilling from the base material. Then, adhesive is applied to the surface portion of the base material to which the resin molded plate is to be adhered in an area smaller than the dimensions of the resin molded plate to ensure an area for applying the joint material. Next, after applying a joint material with good leveling properties in a width larger than the joint width formed between the resin molded plates, the adhesive and joint material are moved by pasting and curing the resin molded plates. to raise the joint material to the set height,
Form joints.

In this way, since the joints are formed at the same time as the resin molded plates are attached, the work can be done easily and at the same time, the work time can be shortened.

In addition, when depressurizing with a resin molded plate attached,
Air remaining on the back side of the resin molded plate is reliably sucked out,
It is possible to prevent air from entering the joint area. Then, when the pressure is returned to atmospheric pressure, the adhesive quickly moves to a uniform thickness, and in conjunction with the movement of the adhesive, the joint material also moves so that its height is uniform. , the formation of joints is forced and the wall panels can be manufactured continuously.

(Example) Hereinafter, an example of the method for manufacturing a wall panel according to the present invention will be described based on the drawings.

[First Example] A base material 4 is placed on a pedestal 10, and an embankment 11 made of a resin band is provided around the base material 4. Then, apply epoxy adhesive 3a mixed with glass beads with a diameter of 0.5 m to the entire surface of the base material 4 (Fig. 2), and then apply adhesive 3a to the part corresponding to the joint with a width larger than the joint width.
Remove a to the extent that it remains as a thin waterproof layer (Figure 3),
The area from which the adhesive 3a has been removed is filled with a joint cement slurry 5a having good leveling properties (FIG. 4).

Next, the resin molded plate 2 is pressed and adhered to a predetermined position with the joint widths being the same (FIG. 5). Then, the joint cement 5a is cured and hardened until it reaches the same level.

As a result, it was possible to manufacture a wall panel 1 with uniform joint depth by omitting the complicated joint work and wiping work (FIG. 6).

[Second Example] Similarly to the first example, a base material 4 is installed on a pedestal 10, and a dike 11 formed of a resin band is provided around the base material 4. Then, the urethane adhesive 3b mixed with glass beads having a diameter of 0.3 mm is applied to the surface of the base material 4 in a stripe shape smaller than the area of the resin molded plate 2, and then the adhesive 3b is applied. A silicone sealing material 5b having a viscosity of 10,000 cP is filled into the joint area with a width wider than the joint width. Next, the resin molded plate 2 is placed on the base material 4 with the joint widths aligned.
A plywood board 1 is used as a mounting plate (Fig. 7), which allows the mounting plate to be placed without being pressed upward (Fig. 7), and has been subjected to mold release treatment to prevent joint displacement
Attach 2. After the sealing material 5b flows horizontally, they are stored in a vacuum container 20 and heated to 700 wH.
g (Fig. 8), then cover them with a film-like material 13 such as a sheet or film larger than the base material 4 and press the periphery to seal it (Fig. 9). Air is supplied to 20 to apply atmospheric pressure (Figure 10). As a result, a differential pressure acts between the inside and outside of the membrane-like body 13, which causes the plywood board 12 to press the resin molded board 2, and the adhesive 3b applied below it. It moves so that it has a uniform thickness commensurate with its volume. Next, after releasing the seal with the film-like body 13, the plywood board 12 is left to be left in a natural curing chamber to be cured. When the plywood board 12 was removed after 24 hours, the resin molded board 2 was adhered to its back surface without any air bubbles, and the joints formed by the silicone sealant 5b had a uniform thickness and no air bubbles were trapped (No. 11 Figure) 6 As a result, the complicated work of applying masking tape and wiping the joints can be omitted.

Further, by performing the work under reduced pressure, the air mixed between the adhesive 3 and the resin molded plate 2 is reliably exhausted, so that no air bubbles remain in the joint material 5. Therefore, there is an advantage that cracking or peeling of the joints due to vibration or bending during transportation or at a construction site, which would be caused by air bubbles remaining, can be prevented. Furthermore, since the joints are forcibly formed under reduced pressure, the wall panels can be manufactured rapidly and continuously.

Although the embankment 11 is formed of a resin band, it is only necessary to prevent the joint material 5 having good leveling properties from leaking out from around the base material 4, and a tape or the like may be used instead of the resin band. You can also do that.

(Effects of the Invention) As described above, according to the present invention, since the joint is formed using a joint material with good leveling properties at the same time as the resin molded plate is attached, the formation of complicated joints is avoided. It becomes possible to perform the work easily, and it is possible to easily manufacture wall panels with uniform joint thickness.

[Brief explanation of the drawing]

The drawings illustrate an embodiment of the method for manufacturing a wall panel of the present invention, and FIG. 1 is an overall perspective view without showing the outline, and FIGS. 2 to 6 are process diagrams illustrating the manufacturing process, and FIG. 7 to 11 are process diagrams illustrating manufacturing steps by other manufacturing methods, FIG. 12 is a perspective view showing a bathroom unit as a sanitary equipment room with a part omitted, and FIG. 13 is a configuration of the bathroom unit. FIG. 1... Wall panel 3... Adhesive 5... Joint material 11... Embankment 13... Membrane body 2... Resin molded plate 4... Base material 10... Frame 12 ...Place plate 3-shi Fig. 7 Fig. 11 Fig. 8''A] No. 9x Fig. 12 Fig. 13 '2

Claims (1)

[Claims] 1) A base material surrounded by an embankment is placed on a pedestal,
Adhesive is applied to the surface of this base material in an area smaller than the area of the resin molded plates, and a joint material with good leveling properties is applied wider than the joint width formed between adjacent resin molded plates. A method for manufacturing a wall panel, which comprises adhering a molded resin plate to a base material in the presence of an adhesive and a joint material, and curing and curing the plate. 2) Place the base material surrounded by an embankment on the pedestal,
Adhesive is applied to the surface of this base material in an area smaller than the area of the resin molded plates, and a joint material with good leveling properties is applied wider than the joint width formed between adjacent resin molded plates. Resin molded plates are placed on the base material with the adhesive and joint material coexisting, and then the mounting plate is placed on top of these resin molded plates to reduce the pressure, and then the surroundings are covered with a membrane-like material. A method for producing a wall panel, which is characterized by curing and curing the panel in a sealed state and exposing it to atmospheric pressure.