JPH10331320A - Wall panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a warp by providing a frame material on the peripheral edge of the back face of a face bar, and filling a fiber-reinforced reinforcing foam layer formed by the mechanical foaming method in a recess formed with the face bar and the frame material to mold a wall panel. SOLUTION: A face bar 2 made of a calcium silicate plate applied with a decorative pattern on the surface and an aluminum square material having a square cross section as a frame material 3 bonded to the peripheral edge of the back face of the face bar 2 are formed. An unsaturated polyester resin foam layer 4 mixed with glass short fibers and formed by the mechanical foaming method is uniformly filled in the recess formed with the face bar 2 and frame material 3. The expansion ratio of the foam layer 4 is changed when the introduction quantity of nitrogen gas is adjusted by the local switch of a compressed gas mixing device, and the quantity of the sprayed resin and the quantity of the glass fibers can be adjusted by the local switch of a spray gun. A lightweight panel excellent in a heat insulating property can be molded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a wall panel reinforced by a foam layer formed by a mechanical foaming method.

[0002]

2. Description of the Related Art A wall panel using a calcium silicate plate, an asbestos slate plate or the like as a face material and a frame material such as a metal such as wood, aluminum, or iron provided on a peripheral edge thereof is usually used to improve its rigidity. Placing gypsum board on the back of the face material,
The wooden crosses are assembled in a grid pattern and stuck together.

[0003]

However, in a wall panel manufactured by attaching a gypsum board to the back surface of a face material or assembling a wooden cross in a lattice shape, the water absorption of the gypsum board or the wooden cross is required. This may cause a decrease in strength at the time of high humidity and a warp at the time of drying.In addition, in the production of the above wall panels, cutting work of gypsum boards and wooden bars according to the size of the wall panels and bonding are performed. And the steps of applying and drying the adhesive are required, and the steps are complicated.

The present invention has been made in view of the above-mentioned circumstances, and its object is to eliminate the work of cutting a gypsum board or a wooden bar in a manufacturing process, and applying and drying an adhesive for bonding. It is an object of the present invention to provide a wall panel which is necessary and does not cause a decrease in strength at the time of high humidity or a warp at the time of drying.

[0005]

The inventor of the present invention has conducted various studies to improve the above-mentioned problems of the wall panel. As a result, the present inventors have used a reinforcing fiber reinforced unsaturated polyester resin foam layer formed by a mechanical foaming method. As a result, the inventors have found that the above problem can be improved and completed the present invention.

That is, in the wall panel of the present invention, a frame material is provided on a peripheral edge of a back surface of the face material, and a reinforcing fiber reinforced foam formed by a mechanical foaming method in a concave portion formed by the face material and the frame material. It is characterized in that the layer is filled.

As the face material and frame material used in the present invention, materials conventionally used for wall panels for building materials can be used, and are not particularly limited. , Calcium silicate plate, asbestos cement plate, etc., as the frame material, for example, steel, aluminum,
Wood etc. are mentioned. The method of attaching the frame material to the periphery of the face material may be the same as the conventional method, and examples include nails, screws, and adhesives.

In the present invention, the resin used for the reinforcing fiber reinforced foam layer is a resin generally used in the field of FRP molded articles, and examples thereof include unsaturated polyester resin, vinyl ester resin, diallyl phthalate resin and the like. No.

Examples of the reinforcing fibers used in the reinforcing fiber reinforced foam layer include inorganic fibers such as glass fibers and carbon fibers, and organic fibers such as aramid fibers and polyester fibers. And glass fibers are preferred.

As a method for forming a foamed layer formed by the mechanical foaming method, first, a stock solution obtained by adding a curing agent, a curing accelerator, a foam stabilizer and the like to the above resin, and a mixture of nitrogen gas and carbon dioxide gas are used. The compressed inert gas is guided to a compressed gas mixing device, mixed well, and the gas is finely dispersed to be contained in the stock solution to form a creamy foam.
Next, the compressed gas mixing device is connected to a conventionally known spray gun with a chopper, and the foamed stock solution and the cut reinforcing fibers are sprayed on the back side of the face material to form a layer, and the layer is cured. Let it form. In this case, the cutting length of the reinforcing fiber is suitably 6 to 12 mm, and the content of the reinforcing fiber with respect to the resin is suitably 10 to 15% by weight, and preferably 12 to 15% by weight.

In this forming method, the expansion ratio is adjusted depending on the type of compressed gas used and the gas pressure. Depending on the type and amount of the reinforcing fibers used, the desired heat insulating properties, the desired reinforcing properties, etc., the specific gravity of the foam layer is usually
0.14 to 1.2. The thickness of the foam layer is usually the same as the thickness of the frame material used.

[0012]

According to the wall panel of the present invention, a frame material is provided on the periphery of the back surface of the face material, and a reinforcing fiber reinforced foam layer formed by a mechanical foaming method is formed in a recess formed by the face material and the frame material. Since it is filled, in the manufacturing process of this wall panel, it is not necessary to cut the conventional plasterboard or wooden bar for reinforcement, or to apply and dry the adhesive for bonding, etc. The wall panel does not cause a decrease in strength of the panel or warpage during drying.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION

FIG. 1 is a schematic sectional view showing an embodiment of the wall panel of the present invention. As shown in FIG. 1, a wall panel 1 has a face material 2, a calcium silicate plate having a decorative pattern on the surface having a thickness of 8 mm, and a square cross section as a frame material 3 adhered to the periphery of the back surface of the face material 2. And a 10 mm long glass short fiber uniformly filled in a recess formed by the face material 2 and the frame material 3 with an aluminum square material having a side length of 20 mm.
It is composed of an orthophthalic acid-based unsaturated polyester resin foam layer 4 (specific gravity 0.7) formed by a mechanical foaming method in which 2% by weight is mixed.

The foamed layer 4 is made of an orthophthalic acid unsaturated polyester resin (Rigolac FM-08B, manufactured by Showa Polymer Co., Ltd.) as the unsaturated polyester resin, and contains a curing agent, a curing accelerator and a foam stabilizer. In addition, a stock solution is prepared, and this stock solution and compressed nitrogen gas (gas pressure of 3500 kPa) are
The mixture is introduced into a compressed gas mixing device and mixed well, and the stock solution is turned into a creamy foam containing finely dispersed nitrogen gas. The foamed stock solution is supplied from a spray gun equipped with a chopper connected to the compressed gas mixing device. And the cut short fibers were sprayed on the back side of the face material 3 to form the short fibers.

The foaming layer 4 can change the foaming ratio by adjusting the amount of nitrogen gas introduced by the hand switch of the compressed gas mixing device, and can control the resin to be blown by the hand switch of the spray gun. Since the amount and the length and amount of glass fiber are also formed by an adjustable forming method,
It is easy to change the thickness of the foam layer 4 and the expansion ratio according to the dimensions of the frame material and the desired reinforcing strength.

Since the wall panel 1 is a foam layer 4 in which the reinforcing material is fiber reinforced, the weight is reduced as compared with a conventional wall panel in which a gypsum board is adhered to the back surface of the face material 2 and reinforced.
The insulation was improved.

[0018]

The construction of the wall panel according to the present invention is as described above. In the manufacturing process of this wall panel, a conventional work for cutting a plaster board or a wooden bar for reinforcement or applying an adhesive for bonding is performed. In addition, a wall panel that does not require operations such as drying and the like, does not cause a decrease in strength at the time of high humidity, and does not cause warpage at the time of drying, and is lightweight and has excellent heat insulating properties.

[0019]

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing one example of a wall panel of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wall panel 2 Face material 3 Frame material 4 Foam layer

Claims (1)

[Claims] 1. A frame material is provided on a peripheral edge of a back surface of a face material, and a concave portion formed by the face material and the frame material is filled with a reinforcing fiber reinforced foam layer formed by a mechanical foaming method. Characterized by wall panels.