JP2862499B2 - Method for manufacturing two-by-four residential wall panels - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a two-by-four residential wall panel.

[0002]

2. Description of the Related Art The construction of a wall material in a conventional two-by-four construction method is performed as follows. First, wall structural members (upper and lower frames and vertical frames) with an outdoor structural plywood stretched thereon are raised one by one on a platform constituting a floor, and adjacent wall frame structural members and a lower frame and a platform are connected to each other. And the whole wall is integrated. Then, at the time of interior decoration work, after attaching insulation material such as glass wool from the inside, the gypsum boards constituting the indoor side are attached to the upper and lower frames and vertical frames, and furthermore, wallpaper application, cloth application, tile application, etc. And finish.

[0003]

As described above, in the construction of a wall material in the conventional two-by-four construction method, a work step of raising the structural plywood, a work step of attaching a heat insulating material, and a gypsum board Since it is necessary to carry out the work process of attaching the material on site, there are many problems in heat insulation and airtightness, and the construction of the wall material requires a great deal of time and labor.

[0004] Therefore, in advance, the formwork material, structural plywood,
By manufacturing a wall panel in which a gypsum board and a heat insulating material are integrated at a factory, it is conceivable to reduce the number of work steps on site. For example, it is conceivable that a heat insulating material is formed by injecting and foaming a foaming agent into a closed space formed by assembling the formwork material, the structural plywood, and the gypsum board. However, the use of such an integrated wall panel has the disadvantage that the electrical wiring cannot be performed or becomes difficult after the wall panel is raised on the platform.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to provide a two-by-four residential wall panel in which the number of work steps on site can be significantly reduced and electric wiring can be easily performed. Aim.

[0006]

The present invention has the following configuration to achieve the above object. That is, the invention of claim 1 is a method for manufacturing a two-by-four residential wall panel that is erected on a platform and forms a self-supporting wall, and a structural plywood is attached to a wall frame assembly in which upper and lower frames and a vertical frame are assembled. And arranging a mold having a convex portion along the longitudinal direction of the vertical frame on a surface of the wall frame assembly opposite to the structural plywood; and a structural plywood, a wall frame assembly, and a mold. A step of injecting and foaming a foaming agent into the closed space formed by the step, a step of removing the mold material from the wall frame assembly, and a gypsum board on the indoor side on the surface of the wall frame assembly opposite to the structural plywood. Adhering to a wall panel for a two-by-four residential wall panel.

According to a second aspect of the present invention, in the step of injecting and foaming a foaming agent into a closed space formed by the structural plywood, the wall frame assembly and the mold, a paper material is interposed between the inner surface of the mold and the foaming agent. The method for producing a two-by-four residential wall panel according to claim 1, wherein

According to the first aspect of the present invention, the structure is provided in a state in which a mold having a convex portion along the longitudinal direction of the vertical frame is arranged on the surface of the wall frame assembly opposite to the structural plywood. Plywood,
By injecting and foaming a foaming agent into a closed space formed by the wall frame assembly and the mold, a concave groove corresponding to the convex portion is formed in the foam. Then, after the foaming step, the mold material is removed from the wall frame assembly, and the indoor gypsum board is attached to the surface of the wall frame assembly opposite to the structural plywood, thereby forming a concave groove on the gypsum board side. An integrated wall panel with a foam as a heat insulator is obtained.

Therefore, if the integrated wall panel is manufactured in advance in a factory or the like and is constructed on site, the work steps such as the pasting work of the heat insulating material can be greatly reduced, and at the same time, the wall panel can be reduced. Since there is a concave groove of the foam inside, electric wiring can be provided in the groove by providing an insertion hole at an appropriate position of the wall panel.

According to the second aspect of the present invention, in the step of removing the mold from the wall frame assembly, the paper material is interposed between the inner surface of the mold and the foaming agent. Good releasability.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. 1A to 1E are cross-sectional views illustrating a method for manufacturing a two-by-four residential wall panel according to the present embodiment. FIG. 2 is a perspective view of the wall panel.
FIG. 3 is a horizontal sectional view of the wall panel. 4A to 4C are cross-sectional views illustrating a manufacturing method according to another embodiment.

The present embodiment is a method for manufacturing a two-by-four residential wall panel that is erected on a platform and forms a self-supporting wall. The manufacturing method will be described step by step with reference to FIG. (First Step) First, as shown in FIG. 1A, a structural plywood 8 is attached to a wall frame assembly 6 (see FIG. 2) in which the upper and lower frames 2 and the vertical frame 4 are assembled. The upper and lower frames 2 are composed of two sheets on the upper side and one sheet on the lower side. (Second Step) Next, as shown in FIG. 1B, the surface (the upper surface in the figure) of the wall frame assembly 6 opposite to the structural plywood 8 is
Mold member 10 having convex portion 10a along the longitudinal direction of vertical frame 4
Are arranged with the convex portions 10a facing inward. This molding 10
Is made of a plastic in which irregularities are continuously formed. After placing the mold member 10 on the upper surface of the wall frame assembly 6, the mold member 10 is pressed down using a predetermined jig. (Third Step) As a result, a space closed by the structural plywood 8, the wall frame assembly 6 and the mold 10 is formed, and FIG.
As shown in (c), a foaming agent is injected and foamed into the closed space. Specifically, after injecting the injection hole 12 from the side in the vertical frame 4 and attaching the injection hose 14 to the injection hole 12,
For example, a hose for injection of a foaming agent such as rigid urethane foam.
4 and injected with an injection gun, and kept as it is until curing of the injected foaming agent is completed. (Fourth Step) As shown in FIG. 1 (d), when the foaming agent is sufficiently cured, the mold 10 is removed from the wall frame assembly 6. (Fifth Step) Then, as shown in FIG. 1E, the gypsum board 16 on the indoor side is attached to the surface of the wall frame assembly 6 opposite to the structural plywood 8 to complete the process.

According to the manufacturing method of the present embodiment as described above, the surface of the wall frame assembly 6 opposite to the structural plywood 8 is
When the foaming agent is injected and foamed into the closed space in the state where 0 is provided (the third step), a concave groove 18a corresponding to the convex portion 10a is formed in the foam 18. After the foaming step, the mold member 10 is removed from the wall frame assembly 6 (the fourth step), and a gypsum board 16 is attached to the surface of the wall frame assembly 6 opposite to the structural plywood 8 (the fifth step). Step), the wall panel 20 provided with the foam 18 as a heat insulating material having the concave groove 18a on the indoor side (FIG. 2)
And FIG. 3). In addition, what is shown by the code | symbol 22 in FIG. 2 is for nailing formed in the gypsum board 16 in order to join the member (left and right wall panels, a platform, etc.) adjacent to the wall panel 20 and the wall frame assembly 6. The hole.

Therefore, if the integrated wall panel 20 is manufactured in advance in a factory or the like and transported to the site for construction, it is possible to greatly reduce the number of work steps such as the conventional work of attaching heat insulating material. Since there is a concave groove 18a of the foam 18 in the wall panel 20, the groove 1 is formed by providing an insertion hole communicating with the groove 18a at an appropriate position of the wall panel 20.
8a can be provided with electrical wiring.

This embodiment is a preferred embodiment of the present invention, and the technical scope of the present invention is not limited to this embodiment. For example, in order to avoid that the foam 18 adheres to the inner surface of the mold 10 in the fourth step, in the third step, a paper surface material 24 is interposed between the inner surface of the mold 10 and the foaming agent. Is also good.

That is, before placing the template 10 on the wall frame assembly 6, a paper surface material 24 such as kraft paper or release paper is placed on the wall frame assembly 6 as shown in FIG. In this state, the mold member 10 is placed on the wall frame member 6 as shown in FIG. 4B, and as shown in FIG.
A foaming agent is injected between 4 and structural plywood 8. By doing so, the paper surface material 24 comes into close contact with the inner surface of the wall frame assembly 6 and the inner surface of the mold material 10 due to the foaming pressure of the foaming agent. Thereby, since the foam 18 does not directly contact the inner surface of the mold 10, the releasability when removing the mold 10 is improved, and at the same time, the foaming agent can be prevented from leaking to the outside by the paper surface 24. . In addition, you may make it attach the paper surface material 24 to the inner surface of the shape | mold material 10 according to the uneven shape. In this case, if the paper surface material 24 and the molding material 10 are bonded with an adhesive, the paper surface material 24 is
Can be left on the side.

Instead of using the paper surface material 24, a mold release agent or a release agent capable of improving the releasability at the time of release is used as the mold material 10.
May be applied to the inner surface.

[0018]

As described above, according to the present invention, in a two-by-four residential wall panel, the number of work steps on site can be significantly reduced, and electrical wiring can be easily performed.

[Brief description of the drawings]

1A and 1B are cross-sectional views illustrating a method for manufacturing a two-by-four residential wall panel according to an embodiment, wherein FIG. 1A is a diagram illustrating a first process, FIG. 1B is a diagram illustrating a second process, (c) is a view showing a third step, (d) is a view showing a fourth step,
(E) is a diagram showing a fifth step.

FIG. 2 is a perspective view of a two-by-four residential wall panel according to the embodiment.

FIG. 3 is a horizontal sectional view of a two-by-four residential wall panel according to the embodiment.

FIG. 4 is a view showing a method for manufacturing a two-by-four residential wall panel according to another embodiment, wherein (a) is a view showing a first step, (b) is a view showing a second step, c) is the third
FIG.

[Explanation of symbols]

 2 Upper and lower frame 4 Vertical frame 6 Wall frame assembly 8 Structural plywood 10 Mold 10a Convex portion 16 Gypsum board 18 Foam 18a Concave groove 20 Two-by-four wall panel for house 24 Paper surface material

Continuation of the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) E04C 2/52 B32B 5/20 E04B 1/80 E04B 2/00

Claims (2)

(57) [Claims] 1. A method for producing a two-by-four residential wall panel erected on a platform to form a self-supporting wall, comprising: attaching a structural plywood to a wall frame assembly in which upper and lower frames and a vertical frame are assembled; A step of arranging a mold having a convex portion along the longitudinal direction of the vertical frame on a surface of the wall frame assembly opposite to the structural plywood, and formed by the structural plywood, the wall frame assembly and the mold; A step of injecting and foaming a foaming agent into the closed space, a step of removing the mold material from the wall frame assembly, and a step of attaching an indoor gypsum board to a surface of the wall frame assembly opposite to the structural plywood A method for producing a two-by-four residential wall panel, comprising: 2. A step of injecting and foaming a foaming agent into a closed space formed by the structural plywood, the wall frame assembly, and the mold material, wherein a paper surface material is interposed between the inner surface of the mold material and the foaming agent. The method for producing a two-by-four residential wall panel according to claim 1.