JPH11159056A - Panel for housing, house and manufacture of these - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate assembling work by constituting a panel for housing of an FRP panel member, constituting FRP veneer by constituting at least one surface of a house, and forming a sandwich structure by arranging FRP plates on both surfaces of a core material. SOLUTION: A reinforced fiber base material 12 is arranged along an inside surface of a cross-sectional U-shaped mold 11, and is covered with a bag film 14 by arranging a medium 13 to diffuse resin in the surface direction of the base material 12 on this reinforced fiber base material 12. Next, a liquid resin 18 is injected by suction by opening a valve 17 by reducing pressure of the inside covered with the bag film 14 in a vacuum state by a vacuum pump 16 through a suction port 15. An FRP housing panel is molded by impregnating/ hardening it in the thickness direction of the reinforced fiber base material 12 by diffusing the injected resin 18 over the whole surface of the reinforced fiber base material 12 through the medium 13. Therefore, a lightweight, highly strong and durable house can be easily manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a housing panel, a house, and a method of manufacturing the same, and more particularly to a housing panel applicable to a small to large house having high strength, light weight and excellent durability. , And houses using the same, and methods for producing them.

[0002]

2. Description of the Related Art Conventionally, various types of houses assembled using building materials such as boards and panels have been known, but usually a large number of building materials must be used to construct one side of the house.

[0003] Further, since the strength of conventional boards and panels themselves is not so high, aggregates or reinforcing materials constituting the skeleton of the house are required for these building materials or at the joints between the building materials. A house is not constructed unless boards or panels are supported by aggregates or reinforcements.

On the other hand, as a lightweight and high-strength material, FRP
(Fiber reinforced plastic) has been attracting attention in various industrial fields, among which CFRP (carbon fiber reinforced plastic)
However, attention has been paid to its excellent mechanical properties and the like.

[0005] However, such FRP has not received much attention as a building material so far, and even if it is used, it has been applied to only a small number of small members. This is probably because the technology for manufacturing large-scale FRP building materials has not been completed.

[0006]

In contrast to the prior art described above, the present inventors have now developed a technique for manufacturing a large-sized FRP panel as a building material for a house, and using the technique to manufacture a lightweight, high-strength, high-strength panel. Now that we have established a technology for making a house that is durable and easy to assemble, we provide it here.

[0007]

In order to solve the above-mentioned problems, a housing panel according to the present invention comprises an FRP housing panel constituting at least one surface of a house.

[0008] Here, the "one surface of the house" refers to any one of the four side walls, the roof, the ceiling wall, and the floor wall of the house, and preferably substantially the entire surface. "Substantially the entire surface" means the entire surface excluding the openings for windows and doors, if any, and a coupling member or the like is provided at a connection portion with another surface. In this case, it means the entire surface excluding the connecting member.

In the method for manufacturing a housing panel according to the present invention, the above-described relatively large panel constituting at least one surface of the house is manufactured by one-shot molding of FRP.

[0010] Here, the term "one-shot molding" means that the reinforcing fibers arranged at each site are impregnated with the resin substantially at the same time and are hardened substantially at the same time, whereby the integrated FRP member is simultaneously formed at each portion. Say that.

As the FRP housing panel, in addition to the one constituting the one surface of the house, one surface of the house and at least a part of at least one other surface connected to the one surface are integrally formed in one shot. Can be configured.

One-shot molding of such a housing panel is performed, for example, by arranging a reinforcing fiber base material in a mold, arranging a medium for diffusing the resin in a plane direction on or above and below the reinforced fiber base material. Covering with a bag film, evacuating the interior covered with the bag film, injecting resin to diffuse on the surface of the reinforcing fiber base, and impregnating the resin with the resin to form a single shot. Can be implemented.

The house according to the present invention is assembled using the FRP housing panel constructed as described above. In assembling, the housing panels may be connected to each other by a connecting member, or may be simply connected by bonding.

By using the FRP housing panel as described above, it is possible to assemble a house in which each surface or at least one surface is substantially composed of an FRP panel. It is possible to realize a small-sized to large-sized FRP house that was not performed.

FRP members, especially CFRP members, are lightweight and have excellent mechanical properties, and also exhibit excellent durability such as weather resistance, so that they are unprecedented in weight, high strength and high durability. House becomes possible. Further, since the housing panel is lightweight, transportation and house assembling work are also facilitated. Furthermore, if the FRP housing panel is configured as a one-shot molded body having a plurality of integrated surfaces,
The assembly work is further facilitated, and the number of members is reduced.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. The housing panel of the present invention is made of a panel member made of FRP and constitutes at least one surface of the house. The housing panel may have a single FRP configuration or a sandwich configuration in which FRP plates are arranged on both sides of a core material.

As a cross-sectional structure in the FRP single plate structure, for example, a structure shown in FIG. The housing panel 1 is made of an FRP veneer 2, and the veneer 2 is formed into various panel shapes as shown in various examples of assembling a house to be described later. On the surface (one or both sides) of the FRP veneer 2, a surface layer 3 composed of a decorative layer, a layer of a flame retardant, a fire-resistant layer, or the like may be provided. Or a refractory or the like may be blended.

Further, as the sandwich structure, for example, a structure as shown in FIG. 2 can be employed. FRP boards 5a, 5b (FRP skin boards) on both sides of lightweight core material 4
Are arranged, and a reinforcing rib 6 extending between the FRP plates 5a and 5b is provided as necessary. Although the material of the rib 6 is not particularly limited, the rib 6 is also made of FRP, and can have a structure integrated with both the FRP plates 5a and 5b by one-shot molding as described later. The surface layer 3 as described above may be provided on the surface of the housing panel 7 having the sandwich structure.

In the housing panels 1 and 7 according to the present invention as described above, the FRP plates 2, 5a and 5b are plate-like bodies made of fiber reinforced resin (FRP). As the reinforcing fiber of the FRP, it is preferable to use a woven fabric, mat, and strand of carbon fiber, a woven fabric, mat, and roving of glass fiber alone or in combination. Particularly, in order to maximize the effect of weight reduction, it is preferable to use carbon fiber. And the number of filaments of one carbon fiber yarn is not less than the usual 10,000 filaments,
The use of tow-like carbon fiber filament yarns in the range of 10,000 to 300,000, and more preferably in the range of 50,000 to 150,000, is more suitable for resin impregnation and as a reinforcing fiber base. It is preferable because it is more excellent in handleability and economical efficiency of the reinforcing fiber base material. It is more preferable to arrange a carbon fiber woven fabric on the surface because the design of the surface is enhanced. In addition, a reinforcing fiber base is formed by laminating a plurality of layers of reinforcing fibers as necessary or in accordance with required mechanical properties or the like, and the reinforcing fiber base is impregnated with a resin. On the reinforcing fiber layer to be laminated, a fiber layer or a fabric layer aligned in one direction can be appropriately laminated, and the fiber orientation direction can be appropriately selected according to the direction of required strength.

As the FRP resin, a thermosetting resin such as epoxy, unsaturated polyester, phenol, and vinyl ester is preferable in terms of moldability and cost. However,
A thermoplastic resin such as nylon or ABS resin, or a mixed resin of a thermosetting resin and a thermoplastic resin can also be used.

As the core material for the sandwich-structured housing panel, a foam, wood, or the like can be used, and a foam is preferable in terms of weight reduction. As the material of the foam,
Polyurethane, polystyrene, polyethylene, polypropylene, PVC, silicon, etc. are used, and the specific gravity is 0.1.
It is preferred to choose between 02 and 0.2. If the specific gravity is less than 0.02, sufficient strength may not be obtained. When the specific gravity exceeds 0.2,
Although the strength is increased, the weight is increased, which is contrary to the purpose of reducing the weight. Also, a honeycomb material can be used as the core material. Examples of the material of the honeycomb material include an aluminum honeycomb and an aramid honeycomb, and the material and dimensions thereof can be selected according to the required strength and the like.

The FRP housing panel as described above can be formed by using a molding method such as a hand lay-up method, a sheet winding method, a vacuum bag method, a pressing method, and an RTM method alone or in combination. Although it can be made, it is particularly preferable to produce it by one-shot molding by a vacuum bag method.

The one-shot molding by the vacuum bag method is performed, for example, as shown in FIG. In FIG. 3, reference numeral 11 denotes a mold having a U-shaped vertical cross section, and a reinforcing fiber base 12 is arranged along the inner surface of the mold 11. Reinforced fiber substrate 1
As for 2, it is preferable that a plurality of layers of a reinforcing fiber layer or a woven fabric layer are laminated as described above. This reinforcing fiber substrate 1
A medium 13 for dispersing the resin in the surface direction of the substrate 12 is disposed on the substrate 2, and the medium 13 is entirely covered with a bag film 14. The medium 13 has a shape such that the flow resistance when flowing in the surface direction of the medium 13 is lower than that when the liquid resin flows into the reinforcing fiber base material 12 (in the thickness direction), and the liquid resin easily flows in the direction. For example, a mesh sheet of 50 mesh or less is used. The medium 13 is
If necessary, the reinforcing fiber base 12 can be arranged on the upper and lower surfaces (both surfaces). Next, the interior covered with the bag film 14 is depressurized to a so-called vacuum state by a vacuum pump 16 through a suction port 15, and a valve 17 is opened to inject a liquid resin 18 by suction. The injected resin is quickly diffused over the entire surface of the reinforcing fiber base 12 via the medium 13 and subsequently impregnated in the thickness direction of the reinforcing fiber base 12. Since the distance in the thickness direction is short, impregnation is completed in a short time, and after impregnation, it is cured and FRP
Is completed. As the resin to be injected, a room temperature-curable resin is preferable. Note that a rigid plate such as an iron plate having a smoother surface may be provided between the bag film 14 and the medium 13 in order to ensure the smoothness of the surface of the FRP to be formed. If the medium 13 is not desired to be left on the FRP panel, the resin is allowed to pass between the reinforcing fiber base 12 and the medium 13 but is peeled off after being cured and can be removed from the FRP panel. Materials (for example, a nylon taffeta woven sheet) may be provided.

FIG. 3 mainly shows a method of forming a housing panel having an FRP single-plate construction, but a housing panel having a sandwich structure can be formed in a single shot in the same manner. For example, as shown in FIG. 4, as shown in a method of forming a housing panel forming one side of a house, a core material 22 made of a foam or the like is disposed in a mold 21 and a reinforcing fiber base material 23 is provided on at least both sides thereof. Is arranged. The core member 22 has a plurality of divided structures in the present embodiment, and the plurality of core members 22 are arranged vertically and horizontally as viewed in plan. The end of the row of the arranged core materials 22 is
3 may be arranged so as to surround the core material 22,
As shown in FIG. 4, the U-shaped cap-shaped reinforcing fiber base material 2
8 may be arranged.

In this embodiment, each core member 22 is configured as shown in FIG.
And a large number of small grooves 25 branched from the large groove 24. The resin is diffused through the large grooves 24 and the small grooves 25 in the surface direction of the reinforcing fiber base 23, and the diffused resin is impregnated into the base 23 in the thickness direction of the reinforcing fiber base 23. Of course, the diffusion of the resin in the plane direction of the reinforcing fiber base 23 and the impregnation in the thickness direction of the reinforcing fiber base 23 may be performed substantially simultaneously. As described above, in the present embodiment, the groove portions of the core member 22 constitute a medium for diffusing the resin vertically and horizontally in the substrate surface direction.

In this embodiment, stepped portions 26 are formed on both sides (or four sides) of the core member 22, and ribs having a U-shaped cross section are formed on the stepped portions 26 as shown in FIG. The reinforcing fiber base 27 to be formed is arranged. At the center of the panel, the U-shaped reinforcing fiber bases 27 forming the ribs abut against each other, and at the end of the arranged core material 22, a U-shaped cap-shaped reinforcing fiber base 28 is disposed. These are covered with a reinforcing fiber base material 23 disposed on both sides together with the core material 22. However, when the end portions of the arranged core members 22 are covered with the reinforcing fiber base material 23, the U-shaped cap-shaped reinforcing fiber base material 28 at the end portions is not necessarily provided. .

The upper surface of the mold of the reinforcing fiber base 23 is covered with a bag film 29, and the inside is evacuated by suction by a vacuum pump 30. Next, the valve 31
Is opened, and the liquid resin 32 is injected into the mold 21 maintained in the vacuum state. The injection is performed through an edge breather 33 made of a porous material or the like, and the suction to the pump 30 is also performed through a similar edge breather 34. The resin injection position, the vacuum suction position, and the installation positions of the edge breathers 33 and 34 can be appropriately changed. For example, resin can be injected from the center of the panel. Also,
In the present embodiment, the upper surface of the reinforcing fiber base 23 is directly covered with the bag film 29. However, if necessary, the above-described release material which is peeled off after molding may be interposed.
In the above embodiment, the bag film 29 itself has a function of a peel ply (release material). Furthermore, a rigid plate such as an iron plate may be disposed between the bag film 29 and the upper surface of the mold of the reinforcing fiber base 23.

The injected resin is, as described above, the core material 2
The resin is diffused in the surface direction of the reinforcing fiber base 23 along the second large groove 24 and the small groove 25, and the diffused resin is impregnated in the thickness direction of the reinforcing fiber base 23. At this time, simultaneously, the resin is also impregnated into the U-shaped reinforcing fiber base materials 27 and 28 forming the ribs and the cap. The impregnated resin is hardened at room temperature or, in some cases, by heating to complete an FRP housing panel. After curing, the bag film 29 is removed, and the cured FRP housing panel is removed from the mold 21. In this way, the FRP housing panel is formed in one shot.

The housing panel formed in one shot as described above is formed, for example, as shown in FIGS. 6 to 8 show a type of house in which one of the housing panels integrally forms one surface of the house and at least a part of at least one other surface connected to the one surface. FIG. A unit-assembled house in which a housing panel constituting the house is divided into six parts is shown. Each of the housing panels shown in these examples is formed into a single-shot FRP housing panel as described above.

In the embodiment shown in FIG. 6, the housing panel constituting the house 41 is a housing panel 4 constituting one side wall of the house, half of the roof and half of the floor wall.
2, 43 and a housing panel 4 constituting a door-side wall
4 and a housing panel 45 constituting a window-side wall. The housing panels 42 to 45 are connected to each other in the arrangement shown in FIG.

In the embodiment shown in FIG. 7, the housing panel forming the house 51 includes a housing panel 52 forming three surfaces of both side walls and a floor wall, a housing panel 53 forming a roof, and a door side. And a housing panel 55 forming a window-side wall. These housing panels 52-
55 are connected to each other in the arrangement shown in FIG.

In the embodiment shown in FIG. 8, the housing panel forming the house 61 includes a housing panel 62 forming one side wall and a floor wall of the house, and a housing side panel and a roof (or ceiling) forming the other side wall of the house. Panel 63 for housing and housing panel 64 for forming a door-side wall
And a housing panel 65 forming a window-side wall. The housing panels 62 to 65 are connected to each other in the arrangement shown in FIG.

In the embodiment shown in FIG. 9, the housing panel constituting the house 71 is composed of six housing panels constituting each surface. That is, a housing panel 72 constituting each side wall of the house 71,
73, a housing panel 74 forming a roof, a housing panel 75 forming a floor wall, a housing panel 76 forming a door side wall, and a housing panel 77 forming a window side wall. . The housing panels 72 to 77 are connected to each other in the arrangement shown in FIG.

When assembling the house, the adjacent housing panels may be directly bonded to each other by direct bonding, but it is preferable to connect the housing panels to each other by a dedicated connecting member. As the connecting member, FIG.
Although a member as shown in FIG. 11 can be used, it is not limited to these.

FIGS. 10 (a) to 10 (d) show examples of the fitting type fitting member. In the example shown in FIG.
1 are formed with grooves 82a and 82b on both sides.
The housing panels 83a and 83b are fitted into the housings 2a and 82b, respectively, and fixed with, for example, an adhesive.
In the example shown in (b), each housing panel 84a, 8
The end of 4b is formed in a stepped shape, and each stepped portion is fitted and fixed in the grooves 86a, 86b of the coupling member 85.
With this configuration, a flush structure between the coupling member 85 and the housing panels 83a and 83b can be achieved. (C)
Shows a connecting member 88 when the housing panels 87a and 87b are connected at an inclined angle,
(D) shows the connecting member 90 when the housing panels 89a and 89b are connected at right angles.

FIGS. 11 (a) to 11 (d) show examples of fixing and joining using fastening members such as screws or rivets. In the example shown in (a), the housing panels 93a and 93b are attached to stepped portions 92a and 92b formed on both sides of the coupling member 91, and the coupling member 9 is fixed by screws 94.
1 and the respective housing panels 93a and 93b are connected. In the example shown in FIG.
a, 96b are formed, and stepped portions 98a, 98b are also formed in the respective housing panels 97a, 97b, and the corresponding stepped portions are fixed with screws 99. With this configuration, it is possible to make the connecting member 95 and the housing panels 97a and 97b flush. (C) is a panel 100a for each housing,
100b shows a connecting member 102 when the screws 100b are connected with screws 101 at an inclined angle, and (d) shows that each housing panel 103a, 103b is
4 shows the connecting member 105 when the connecting member 105 is used for connection.

As described above, the housing panels can be connected to each other in various modes, and an optimum connecting member can be selected in accordance with the part of the house to be assembled.

As described above, a house assembled using the FRP housing panel according to the present invention is lightweight, has high strength, and has high durability inherent to FRP. Further, since each housing panel before assembly is lightweight, it is extremely easy to carry and assemble. Further, by forming the housing panel on one or more surfaces, the number of molding steps is reduced, the number of parts of the house is also reduced, and the manufacturing cost, the number of assembly steps, and the cost are reduced.
In particular, a housing panel formed by one-shot molding is extremely effective in reducing the number of molded products and cost.

[0039]

As described above, according to the housing panel, the house and the method of manufacturing the same according to the present invention,
It is possible to easily and inexpensively manufacture a lightweight, high-strength house having excellent durability. Then, according to the manufacturing method by one-shot molding according to the present invention, houses of virtually any size and shape from small to large can be easily manufactured and assembled.

[Brief description of the drawings]

FIG. 1 is a partial sectional view of a housing panel according to an embodiment of the present invention.

FIG. 2 is a partial sectional view of a housing panel according to another embodiment of the present invention.

FIG. 3 is a schematic configuration diagram showing an example of a one-shot molding method according to the present invention.

FIG. 4 is a schematic configuration diagram showing another example of the one-shot molding method according to the present invention.

FIG. 5 is an enlarged perspective view of a core material used in the method of FIG.

FIG. 6 is an exploded perspective view of a house according to an embodiment of the present invention.

FIG. 7 is an exploded perspective view of a house according to another embodiment of the present invention.

FIG. 8 is an exploded perspective view of a house according to still another embodiment of the present invention.

FIG. 9 is an exploded perspective view of a house according to still another embodiment of the present invention.

FIG. 10 is a view showing each aspect of a connecting member of the housing panels according to the present invention.

FIG. 11 is a view showing another aspect of the connecting member of the housing panels according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Single-panel structure housing panel 2 FRP board 3 Surface material 4 Core material 5a, 5b FRP board 6 Rib 7 Sandwich-structure housing panel 11 Type 12 Reinforcement fiber base material 13 Medium 14 Bag film 15 Suction port 16 Vacuum pump 17 Valve 18 Resin 21 Mold 22 Core material 23 Reinforced fiber base material 24, 25 Groove 26 Step-down portion 27, 28 U-shaped reinforcing fiber base material 30 Vacuum pump 31 Valve 32 Resin 33, 34 Edge breather 41, 51, 61, 71 House 42, 43, 44, 45, 52, 53, 54, 55, 6
2, 63, 64, 65, 72, 73, 74, 75, 7
6, 77 Housing panel 81, 85, 88, 90, 91, 95, 102, 105
Coupling member

Claims (16)

[Claims] 1. An FR constituting at least one side of a house
Panel for housing made of P. 2. The housing panel according to claim 1, which is formed by one-shot molding. 3. The housing panel according to claim 1, wherein one surface of the house and at least a part of at least one other surface connected to the one surface are integrally formed. 4. The housing panel according to claim 1, which has a sandwich structure in which FRP plates are arranged on both surfaces of a core material. 5. The housing panel according to claim 1, further comprising CFRP. 6. The reinforcing fiber base material of the CFRP has a tow-like carbon fiber filament yarn having a filament number in a range of 10,000 to 300,000.
Panel for housing. 7. The housing panel according to claim 1, which has a surface layer. 8. A house assembled using the housing panel according to any one of claims 1 to 7. 9. The house of claim 8, wherein the housing panels are joined together by a joining member. 10. A method for manufacturing a panel for a housing, wherein a panel constituting at least one surface of a house is manufactured by one-shot molding of FRP. 11. The method of manufacturing a housing panel according to claim 10, wherein one surface of the house and at least a part of at least one other surface connected to the one surface are integrally formed by one shot. 12. A reinforcing fiber base material is arranged in a mold, and a medium for diffusing a resin in a surface direction is arranged above or below the mold. Then, the whole is covered with a bag film, and the inside covered with the bag film is formed. The method for producing a panel for a housing according to claim 10 or 11, wherein a vacuum is formed, a resin is injected to diffuse the resin into the surface of the reinforcing fiber base material, and the resin is impregnated into the reinforcing fiber base material to perform one-shot molding. 13. A method of manufacturing a house, comprising assembling a house using the housing panel manufactured by the method according to claim 10. 14. The method of manufacturing a house according to claim 13, wherein the housing panels are joined to each other by a joining member. 15. A housing panel manufactured by the method according to claim 12. 16. A house assembled using the housing panel according to claim 15.