JPH08300546A - Wall panel and forming method therefor - Google Patents

Abstract

PURPOSE: To increase the sticking strength of a thin and light-weight structural member by employing a punching metal plate as a wall panel and to further simplify the connection of the panels or the assembling work of it and a metal frame. CONSTITUTION: The surface of a punching metal plate 5 having a standing peripheral edge 5b at the rear surface side and a surface layer material 3 for a wall panel by tiles 3a or decorative cement plates arranged on the front surface side are pressure stuck by a resin material, and a release inhibiting head 6a in which the resin material overflows from the through holes 5a of the plate 5 to the rear surface side and is solidified is fallen down.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wall panel suitable for use in a bathroom unit and the like, and a molding method for the wall panel.

[0002]

2. Description of the Related Art Conventionally, as a wall panel for a bathroom unit or the like, there are known various types such as a tile panel in which a tile is attached to a cement board, an FRP (reinforced plastic) panel, a panel in which a decorative cement board is lined with a plywood, and others. Has been.

[0003]

However, the above-mentioned tile panel has a thickness of 3 m in order to meet the market demand for non-asbestos cement boards and to maintain the strength of the cement boards.
/ M or more, the total thickness increases to 25 m / m,
As a result, not only the cost is increased, but also the tile, the cement plate, and the frame are bonded with an adhesive, so that the bonding strength is inevitable.

Further, since the FRP panel is press-molded using a mold and the mold cost is large, the cost must be maintained by mass production of a small variety of products, and it is inevitable that the FRP panel is produced in a small amount of a large variety of products. If you try to satisfy your requirements,
Product unit price becomes very high.

In view of the above-mentioned problems of the prior art, the present invention can reduce the thickness and the weight of the wall panel by appropriately using the punching metal plate in the first aspect. At the same time, it is an object of the invention to make it possible to maintain a large adhesive strength by means of a resin binder which is appropriately arranged, and to easily perform an assembling work with a metal frame or the like.

Further, according to a second aspect of the present invention, with respect to the method for forming the wall panel, it is possible to form the wall panel at a low cost even when the wall panel is produced in a small quantity and in a large variety. The purpose is to make it possible to easily and quickly form a wall panel made of tiles at low cost.

[0007]

In order to achieve the above-mentioned object, the present invention provides a surface of a punching metal plate having a rising peripheral edge on the back surface side and a surface provided on the front surface side. The wall panel surface layer material is pressure-bonded with a resin material, and the resin material is protruded from a large number of through-holes formed in the punching metal plate to the back side, and the solidified retaining head is raised. Is about to provide a wall panel that is characterized by

Further, according to a second aspect of the present invention, a wall panel surface layer material such as a tile, a decorative cement plate, an FRP flat plate or the like is disposed on the bottom surface of the female mold cavity, and the wall panel surface layer material is applied to the upper layer. On the resin material, the front surface side of the punching metal plate having the standing peripheral edge on the back surface side is placed,
By pressing this with a pressing die, the wall panel surface layer material and the surface of the punching metal plate are adhered by the resin material, and the resin material is passed through a large number of through holes formed in the punching metal plate. An object of the present invention is to provide a wall panel and a molding method thereof, which are characterized in that they are made to overflow and solidify to the back surface side so that the retaining head is raised.

In the third aspect of the present invention, a plurality of ridges are formed on the bottom surface of the female mold cavity so as to intersect each other in the biaxial direction, whereby a space defined by the ridges is formed. A tile having a size corresponding to this is arranged to form a surface layer material for a wall panel, and the joints formed by the above-mentioned projections are formed between the tiles so as to be provided from above the tiles. The resin material was flowed into the joints and laminated on the tile, and on the resin layer thus formed, the front surface side of the punching metal plate having an upright peripheral edge on the back surface side was loosely mounted. Then, by pressing this with a pressing die, the wall panel surface layer material made of the above tile and the surface of the punching metal plate are bonded by the above resin material, and a large number of the resin material is punched in the punching metal plate. From the formed through-hole, it overflows and solidifies to the back surface side to raise the retaining head, and the same as above, the resin material is also attached to the outer peripheral side surface of the punching metal plate at the rising peripheral edge thereof. It seeks to provide a method of forming wall panels.

[0010]

When the surface layer material for a wall panel according to claim 3 is a tile, the tile is arranged in the cavity of the female die of the die with the surface thereof facing downward. Next, mix the epoxy resin with filler (sand, calcium carbonate, aluminum hydroxide, etc.) on the joints and back of the tile,
A resin layer is formed by laminating the resin materials whose viscosity has been adjusted to an appropriate thickness.

Next, a punching metal plate having standing edges on all edges (four sides) is placed on the above-mentioned resin layer, a pressing die is placed on the punching metal plate, and a press is applied to this to cure the punch. As a result, the resin material of the resin layer is pressure-bonded to the back surface of the tile and each joint portion, and is pushed into the plurality of through holes formed in the punching metal plate, and the punching metal is further pushed through the through holes. By overflowing to the upper surface of the plate, it solidifies as a retaining head having a shape like a bolt head, and thus the adhesive strength between the tile, the resin layer and the punching metal plate increases.

If the outer dimension of the punching metal plate is set smaller than the inner dimension of the cavity of the female mold by a predetermined dimension, the resin material of the resin layer is removed by pressing the punching metal plate with a pressing die. By being press-fitted into the gap between the inner surface of the cavity and the rising peripheral edge of the punching metal plate, it is possible to form a wall panel having an upward flange along the outer peripheral surface of the rising peripheral edge of the punching metal plate.

When the surface layer material for the wall panel is a decorative cement plate or an FRP flat plate, these are placed in a female mold cavity and the above resin layer is laminated on the upper surface (back surface) thereof. Similarly, the punching metal plate may be pressed through a pressing die to solidify the resin material.

Further, when the wall panel surface material is a FRP flat plate, a gel coat is sprayed into the cavity of the female mold, and then the FRP flat plates are laminated by a hand up method or a spray up method to have a predetermined thickness. Is
In addition, similarly to the above, the punching metal plate is pressed through the pressing die. In any of the above-mentioned cases, pressing is performed while the through-holes of the punching metal plate are not blocked by the pressing die.

[0015]

EXAMPLE A wall panel and a method for forming the same according to the present invention will be described below. First, FIG. 1 which is a cross-sectional view showing an example of a wall panel using tiles, and a step of forming the wall panel are sequentially described. Detailed description will be made below with reference to the sectional views shown in FIGS. 2, 3 and 4.

The female mold 1 shown in FIGS. 2 to 3 is provided with a cavity 2 having a flat rectangular shape made of a material such as silicon, and a bottom surface 2a thereof has a plurality of tiles 3a. Plural ridges 2b are formed in the biaxial direction so that the joint portions 4 are formed so as to be spaced apart from each other if the joints 4 are juxtaposed in the biaxial direction at regular intervals. Has been done.

As is well known, the punching metal plate 5 used for pressurizing the resin layer 6, which will be described later in detail, has a plurality of through holes 5a ... The upright peripheral edge 5b having a predetermined rising width is bent orthogonally. The dimension a of the punching metal plate 5 in the biaxial direction is determined by the cavity 2 of the female die 1 described above.
However, the dimension b is set smaller than the dimension b in the biaxial direction by a predetermined dimension. As shown in FIG. A gap c approximately equal to the layer thickness of the resin layer 6 to be described later is formed between and the rising edge 5b.

In FIG. 4, reference numeral 7 denotes a pressing die used to press the punching metal plate 5 from above, in which each through hole 5a of the punching metal plate 5 is provided.
A plurality of pressure-applying protrusions 7a are arranged in the biaxial direction so that the back surface of the punching metal plate 5 can be pressed so as not to block the through holes 5a. It is projected at regular intervals.

Therefore, the female mold 1 and the tile 3 explained above are used.
The surface layer material 3 for wall panel explained as a ...
In order to form the tile wall panel A shown in FIG. 1 by using the punching metal plate 5 and the pressing die 7, first, the plurality of tiles 3a ... , The tiles are placed in the space defined by the ridges 2b so that they are juxtaposed on the bottom surface 2a of the cavity 2 at regular intervals in the biaxial direction. The joint portions 4 are formed without any effort between the portions 3a.

Next, as shown in FIG. 2, the tile 3a
From the back side of each of the joints 4 to each of the joints 4, the modified epoxy resin is mixed with sand, calcium carbonate, aluminum hydroxide, etc. as a filler, and the viscosity is adjusted to 200 to 300 PS. To form the resin layer 6, and then the punching metal plate 5 described above is applied to the above resin layer 6 as shown in FIG.
The pressing process is carried out as shown in FIG. 4 by the pressing die 7 placed on the punching metal plate 5.

After the above-mentioned pressing is performed under a pressure condition of about 0.5 to 1 kg / cm ² , the resin layer 6 is hardened. By such a treatment, the resin layer 6 passes through the punching metal plate 5. The pressure is applied to the back surface of each tile 3a ..., and the joints 4 ...
Not only inside but also through holes 5a of punching metal plate 5
Further, it is also pressed into the clearance c between the rising peripheral edge 5b of the punching metal plate 5 and the inner side surface 2c of the cavity 2.

As described above, not only the resin layer 6 in a compacted state is molded in the joint portions 4 between the tiles 3a, 3a, but also the through holes 5a of the punching metal plate 5 are formed.
As shown in FIG. 4, the resin pushed in from the upper end overflows from the upper opening edge to the upper surface of the punching metal plate 5, and this is a retaining head 6a such as a bolt or screw head. By solidifying as ..., it functions as a strong resin binder, and therefore the adhesive strength between the punching metal plate 5 and each tile 3a ... becomes large.

After molding as described above, by removing from the female mold 1, the flange 8 is formed on the entire peripheral edge on the back surface side as shown in FIG.
Thus, the tile wall panel A having the above is integrally formed.

Further, on the back surface of each of the above-mentioned tiles 3a, ..., As shown in the sectional view partially enlarged in FIG. 5, a desired number of recesses 3b ... And projections 3c. By providing .., the adhesion area with the resin layer 6 can be increased, and thus the adhesion strength between the two can be further increased.

As the surface layer material 3 for wall panel, of course,
The tile is not limited to the tile, and a decorative cement plate or an FRP flat plate (not shown) may be used. In such a case, in the female mold 1 described above, the bottom surface 2a of the cavity 2 may be used.
Need only be formed on a flat surface, the ridge 2b is not required, and in other points, it is the same as the case of the tile wall panel A.

Here, the surface layer material 3 for wall panel described above is FR
The forming method in the case of forming a P flat plate will be described in detail with reference to FIGS. 7 and 8. A female die 1 having a bottom surface 2a of the cavity 2 formed into a flat surface is used. As the pressing die 7, the same one as that used when the tile wall panel A is molded is used. Then, in order to mold an FRP wall panel using the above-mentioned female die 1, punching metal plate 5, and pressing die 7, as shown in FIG. To spray.

Next, if the FRP layer 3d is laminated in the cavity 2 by a hand up method or a spray up method so as to have a predetermined thickness,
As shown by FIG. 8, punching metal plate 5
Is placed on the FRP layer 3d, and the punching metal plate 5 is pressed by the pressing die 7 under the same pressurizing conditions as before, the FRP layer 3d is pressed, and the through holes 5a ... It is hardened after being pushed into the inside and the above-mentioned gap c, respectively. By this, FRP
Is spilled from each of the through holes 5a to the back surface of the punching metal plate 5 as described above, and the retaining head 3e such as a bolt or a screw head solidifies to function as a resin binder. This increases the adhesive strength between the FRP layer 3d and the punching metal plate 5.

Next, the FRP layer 3d and the punching metal plate 5 which are integral with each other are released from the female die 1, so that the FRP wall panel having the flanges 8 on the entire periphery (four sides) as shown in FIG. A'is to be molded.

In each of the wall panels A and A'shown above, the flange 8 thereof is connected to the joiner 1 as shown in FIGS. 9 and 10.
By using 0 and 11, they can be bonded to each other for practical use. Further, as shown in FIG. 11, the flanges 8 of the respective wall panels A and A ′ are cut off, and the rising edges 5b and 5b formed by the punching metal plates 5 and 5 are stopped by screws 12 ... It is also possible to join each other. Incidentally, in FIGS. 9 to 11, 13 is between the flanges 8 and 8 and the upstanding peripheral edges 5b and 5b.
The resin-based joint material sandwiched between the two is shown in FIG.
This is a screw in which the joiner 11 of is fixed to the flange 8.

[0030]

As described above, the wall panel according to the first aspect of the present invention is constructed by using the punching metal plate as the base material, so that the thickness can be reduced and the weight can be reduced. Adhesive strength can be increased by the action as a resin binder, and the flange can be used for joining the panels to each other as it is, and the punching metal plate can be used for welding with the metal frame. Can be performed simply and quickly, and cost can be reduced.

Further, according to the wall panel molding method of the second aspect, it is possible to easily and inexpensively mold a wall panel which is thin, lightweight and has a high adhesive strength, and also to mold a large number of small quantities of wall panels. It can be provided at a relatively low cost, and when using the method for molding a wall panel with tiles according to the third aspect, it can be manufactured easily, quickly and inexpensively.

[Brief description of drawings]

FIG. 1 is a vertical sectional view showing an embodiment of a wall panel according to the present invention.

FIG. 2 is a vertical cross-sectional view showing a state in which tiles are juxtaposed in a female cavity and a resin layer is laminated on the back surface and joint portions in the molding process of the wall panel shown in FIG.

FIG. 3 is a vertical cross-sectional view showing a state in which a punching metal plate is placed on the resin layer in the cavity in the molding process of the upper wall panel.

FIG. 4 is a vertical cross-sectional view showing a pressed state of a punching metal plate and a resin layer by a pressing die in the molding process of the upper wall panel.

FIG. 5 is a partially enlarged vertical sectional view showing another embodiment of the wall panel according to the present invention.

FIG. 6 is a vertical sectional view showing a different embodiment of the wall panel according to the present invention.

7 is a vertical cross-sectional view showing a state in which a gel coat is sprayed into a female mold cavity and a resin layer is laminated in the molding process of the wall panel shown in FIG.

FIG. 8 is a vertical cross-sectional view showing a state in which a punching metal plate is placed on the resin layer and pressed by a pressing die in the same forming step.

FIG. 9 is a vertical cross-sectional view of a joining portion showing a state where the wall panels according to the present invention are joined on the same plane using a joiner.

FIG. 10 is a vertical cross-sectional view of a joining portion showing a state where the wall panels according to the present invention are joined to each other at right angles by using a joiner and a screw.

FIG. 11 is a vertical cross-sectional view of a joint portion showing a state in which the wall panels according to the present invention are joined to each other by cutting the flange.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Female mold 2 Cavity 2a Bottom surface 2b Ridge 3 Surface layer material for wall panel 3a Tile 3d FRP layer 3e Stopping head 4 Joint part 5 Punching metal plate 5a Through hole 5b Standing edge 6 Resin layer 6a Stopping head 7 Push type

Claims (3)

[Claims] 1. A surface of a punching metal plate having a raised peripheral edge on the back surface side and a surface material for a wall panel disposed on the surface side are pressure-bonded with a resin material, and the resin material is also attached. From a large number of through holes on the punching metal plate,
A wall panel, characterized in that a retaining head that is overflowing and solidified on the back side is raised. 2. A wall panel surface layer material such as a tile, a decorative cement plate, or an FRP flat plate is provided on the bottom surface in the female cavity, and the resin material is applied on the upper layer of the wall panel surface layer material. Then, by placing the front surface side of the punching metal plate having an upright peripheral edge on the back surface side and pressing it with a pressing die, the surface material for the wall panel and the surface of the punching metal plate are bonded to the resin material described above. Adhered by
A wall panel and a method for forming the wall panel, characterized in that a large number of the resin material is overflowed and solidified from a through hole formed in a punching metal plate to the back surface side so that a retaining head is raised. 3. A plurality of ridges are formed on the bottom surface of the female mold cavity so as to intersect with each other in the biaxial direction. And the surface layer material for wall panels is formed, and the joint portions formed by the above-mentioned ridges are formed separately between the tiles, and the resin material provided from above these tiles is The surface side of the punching metal plate having the rising peripheral edge on the back surface side is loosely fitted and placed on the resin layer thus formed by flowing into the joint portion and onto the tile, and this is pressed by the die. By applying pressure, the wall panel surface layer material by the tile and the surface of the punching metal plate are bonded by the resin material, and the resin material is passed through a plurality of through holes formed in the punching metal plate, Behind A molding method of a wall panel, which overflows and solidifies to a surface side and a retaining head is raised, and the same resin material as above is adhered to the standing peripheral edge of the punching metal plate and also to the outer peripheral side surface thereof.