JP3546353B2

JP3546353B2 - Maintenance method for resin sash

Info

Publication number: JP3546353B2
Application number: JP2000114593A
Authority: JP
Inventors: 文昭秋生; 益男山路; 邦夫内海
Original assignee: ＹｋｋＡｐ株式会社
Priority date: 2000-04-17
Filing date: 2000-04-17
Publication date: 2004-07-28
Anticipated expiration: 2020-04-17
Also published as: JP2001295551A

Description

【０００１】
【発明の属する技術分野】
本発明は、樹脂サッシに発生したヒビ割れ、亀裂、完全な割れなどの損傷部分を補修する保守方法に関する。
【０００２】
【従来の技術】
樹脂サッシは、例えば樹脂押出形材を用いてサッシ窓、障子を組み立てしたものが知られている。
このような樹脂サッシは地震等によって部分的な損傷が発生することがある。
例えば、図８（ａ）に示すように縦横の樹脂押出形材の形材１，２のコーナー部分にヒビ割れ３、図８（ｂ）に示すように亀裂４、図８（ｃ）に示すように完全な割れ５等が発生する。
【０００３】
前述の損傷が発生した場合には、その損傷部分を補修している。
例えば、熱風ドライヤーや半田小手等で溶接棒を溶かして損傷部分を溶接することで補修している。
また、接着剤で損傷部分を接着して補修している。
また、損傷部分にパテをつめて補修している。
【０００４】
前述のいずれかの方法で補修した後に、樹脂押出形材の中空部にウレタンを注入充填して補強することも行われている。
【０００５】
【発明が解決しようとする課題】
前述の溶接による補修方法では、形材表面に変形（歪み）が生じたり、形材や溶接棒の劣化、更には溶接部分の剥離が生じる等の不具合が発生する。
すなわち、前述の溶接による補修方法は、図９に示すように、エアードライヤー６で形材１，２と同一樹脂の溶接棒７を溶かし、形材１，２の損傷部分８に流し込んで溶接するので、形材１，２の表面９にエアードライヤー６の熱風が当り、その熱風によって形材１，２の表面９に変形（歪み）１０が生じる。
形材１，２や溶接棒７が熱によって劣化するので、溶接強度が弱い。
【０００６】
溶けた溶接棒は形材１，２の表面９寄り部分に流れ込み、裏面１１寄り部分にまで流れ込まないので、形材１，２の表裏方向中間（厚さ方向の中間）に溶接面１２があると共に、溶接されていない部分１３が存在し、溶接部分が剥離することがある。このことはヒビ割れ補修の際に顕著である。
【０００７】
接着剤、パテによる補修方法では十分な補修強度が得られない。
【０００８】
そこで、本発明は前述の課題を解決できるようにした樹脂サッシの保守方法を提供することを目的とする。
【０００９】
【課題を解決するための手段】
第１の発明は、樹脂サッシを形成する形材の損傷部分に樹脂の溶接棒を置き、鋭利形状の刃具を溶接棒、形材を溶かしながら形材の裏面まで押し込み形材の表面から裏面まで連続して溶接することで損傷部分を補修することを特徴とする樹脂サッシの保守方法である。
【００１０】
第２の発明は、第１の発明において前記刃具を超音波で振動させることで摩擦熱によって溶接棒、形材を溶かすようにした樹脂サッシの保守方法である。
【００１１】
【作用】
第１の発明によれば、刃具によって溶接棒、形材を局部的に溶かすので、形材表面に熱による変形（歪み）が発生しない。
溶接棒、形材の熱による劣化が僅かであるから溶接強度が強い。
形材の表面から裏面まで連続して溶接されるので、溶接部分が剥離することがない。
【００１２】
第２の発明によれば、刃具の振動による摩擦熱で溶接棒、形材を溶かすので、その溶接棒、形材の熱による劣化が著しく低減し、溶接強度がより強くなる。
【００１３】
【発明の実施の形態】
損傷部分を補修する方法の実施の形態を図１に基づいて説明する。従来と同一部材は符号を同一とする。
形材１，２の損傷部分（補修部分）８に溶接棒７を押しつけ、その溶接棒７に超音波カッター２０の刃具２１を当て、振動による摩擦熱で溶接棒７を溶かすと共に、その刃具２１を損傷部分（補修部分）８に図２に示すように押し込み、形材１，２を刃具２１の振動による摩擦熱で溶かしながら溶けた溶接棒７を裏面１１まで流し込み、形材１，２の表面９から裏面１１まで連続して溶接する。肉盛１４は形材１，２の裏面１１まで出来る。
前述した損傷部分８が形材１，２の中空部分に発生した場合には形材１，２の裏面１１が中空部内面である。
【００１４】
前記超音波カッター２０は、電圧を加えることで振動子が振動し、超音波が発生する。この超音波を振幅拡大器でさらに増幅し、刃具２１を超音波で振動、例えば１秒間に４万回振動させるものである。
前記刃具２１は形材１，２の損傷部分８に食い込み易いように鋭利な形状である。
【００１５】
前述のように、刃具２１の振動による摩擦熱で溶接棒７、形材１，２を溶かすので、形材１，２の表面に変形（歪み）が生じない。また形材１，２と溶接棒７の熱による劣化が僅かで溶接強度が大である。
形材１，２の表面９から裏面１１まで連続して溶接されるので、形材１，２の厚さ方向中間に溶接面がないし、溶接されない部分が無いので、溶接部分が剥離することがない。
【００１６】
前述の鋭利な形状の刃具２１に通電して発熱させ、その熱によって溶接棒７、形材１，２を溶かしながら表面９から裏面１１まで押し込んで溶接するようにしても良い。
このようにしても、刃具２１の発熱による溶接棒７、形材１，２の劣化が僅かであるから溶接強度が大となる。
すなわち、本発明の補修方法は形材１，２の損傷部分８に溶接棒７を置き、鋭利な形状の刃具２１を溶接棒７、形材１，２を溶かしながら形材１，２の表面９から裏面１１まで押し込むことで形材１，２の表面９から裏面まで連続して溶接することで補修する方法である。中空部分の損傷部分を補修する場合には形材１，２の表面９から中空部内面まで連続して溶接する。
【００１７】
次に充填物の注入充填による補強について説明する。
図３に示すように、縦の形材１と横の形材２は中空部３０を有する同一断面形状の樹脂押出形材で、縦の形材１の端部と横の形材２の端部を４５度に切断して突き合わせて溶着等で連結され、各中空部３０は連続する。
縦・横の形材１，２の表面９における補強（補修）部分の長手方向両端寄りに詰物用穴３１をそれぞれ形成すると共に、この２つの詰物用穴３１間の部分に固定用穴３２を長手方向に間隔を置いて複数形成する。
この各穴３１，３２は中空部３０に開口する。
【００１８】
前記各詰物用穴３１から詰物、例えばガラスウール３３を中空部３０にそれぞれ入れ、そのガラスウール３３を中空部内面３０ａに隙間なく接して充填物の流れを止める堰止め３４とする。
前記各固定用穴３２から充填物、例えばウレタン３５を中空部３０内に注入充填し、図４に示すようにウレタン３５を各固定用穴３２から表面９に出してウレタン３５を固定用穴３２に充填し、形材１，２とウレタン３５を固定する。
【００１９】
例えば、下の固定用穴３２からウレタン３５を中空部３０内に注入充填し、上の固定用穴３２からウレタン３０が漏れ出たら注入充填をやめる。
【００２０】
固定用穴３２から表面９まで漏れ出たウレタン３５は硬化後に削り取って形材１，２の表面９と略面一とし、塗装して形材１，２の表面と同一外観とする。
【００２１】
このようにすれば、形材１，２の樹脂とウレタン３５（充填物）の接着性が悪くても固定用穴３２に充填されたウレタン３５のために形材１，２とウレタン３５が強固に連結され、そのウレタン３５を注入充填した部分（補強部分）の強度が強いものとなる。なお、前記各詰物用穴３１は、詰物を入れた後は固定用穴３２と同等の穴としても良い。つまり、ウレタン３５を充填する。
【００２２】
また、中空部３０に注入充填したウレタン３５は充填物の流れを止める堰止め３４で補修（補強）部分以外に流れることがない。
【００２３】
前述の詰物は、圧縮変形することで小さな穴から入れ易く、中空部３０内でふっくらと元の状態に復元する素材を用いることが好ましい。
例えば、前述のガラスウールや、風船、綿、スポンジなどが好ましい。
充填物としてはウレタンに限らずエポキシ系樹脂などを用いても良い。
【００２４】
次に充填物の充填による補強の他のやり方を説明する。
図５に示すように、形材１，２の表面９における補強（補修）する部分の長手方向両端寄りに詰物用穴３１をそれぞれ形成し、この詰物用穴３１から詰物、例えばガラスウール３３を前述と同様に中空部３０内に入れて充填物の流れ止め用の堰止め３４をそれぞれ形成する。
この詰物用穴３１を利用して中空部３０内に充填物、例えばウレタン３５を注入充填する。なお、注入充填用の穴を別にあけても良い。
【００２５】
中空部３０に注入充填したウレタン３５が硬化した後に、図６に示すように形材１，２の表面９から固定用穴３２をウレタン３５まで連続して形成し、ウレタン３５に固定用凹部３６を形成する。
形材１，２と同一の樹脂を溶かして固定用穴３２から固定用凹部３６まで流し込んで図７に示すように詰め、その詰めた樹脂３７で形材１，２とウレタン３５を連結する。
前記詰めた樹脂３７の表面を削り取って形材１，２の表面と略面一にして外観を良くする。なお、ウレタン３５が硬化した後にウレタン３５が充填した前記各詰物用穴３１に固定用穴３２を形成してウレタン３５に固定用凹部３６を形成しても良い。
【００２６】
前述の充填物の注入充填は損傷部分を補修した箇所に行って補修部分が地震等で再度損傷しないようにしても良いし、損傷部分が狭く奥行の深い場所で前述のように補修できない場合には損傷部分に注入充填して補修と補強を兼用させても良い。
また、損傷しない場合でも過去の経験によって地震等で損傷が発生する恐れがあると予想される箇所に注入して補強することで、地震等で損傷することを未然に防止しても良い。
【００２７】
【発明の効果】
請求項１に係る発明によれば、刃具によって溶接棒、形材を局部的に溶かすので、形材表面に熱による変形（歪み）が発生しない。
溶接棒、形材の熱による劣化が僅かであるから溶接強度が強い。
形材の表面から裏面まで連続して溶接されるので、溶接部分が剥離することがない。
【００２８】
請求項２に係る発明によれば、刃具の振動による摩擦熱で溶接棒、形材を溶かすので、その溶接棒、形材の熱による劣化が著しく低減し、溶接強度がより強くなる。
【図面の簡単な説明】
【図１】形材の損傷部分を補修する方法の実施の形態を示す斜視図である。
【図２】溶接部分の説明図である。
【図３】形材の補強について示す斜視図である。
【図４】補強部分の断面図である。
【図５】形材を補強する他のやり方を示す斜視図である。
【図６】固定用穴と固定用凹部を形成した補強部分の断面図である。
【図７】補強終了した状態の補強部分の断面図である。
【図８】形材の損傷状態の説明図である。
【図９】従来の形材の損傷部分の補修方法の斜視図である。
【符号の説明】
１…縦の形材、２…横の形材、３…ヒビ割れ、４…亀裂、５…完全な割れ、７…溶接棒、８…損傷部分、９…表面、１１…裏面、２０…超音波カッター、２１…刃具、３０…中空部、３０ａ…中空部内面、３１…詰物用穴、３２…固定用穴、３３…ガラスウール（詰物）、３４…充填物の流れ止め用の関止め、３５…ウレタン（充填物）、３６…固定用凹部。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a maintenance method for repairing a damaged portion such as a crack, a crack or a complete crack generated in a resin sash.
[0002]
[Prior art]
As a resin sash, a sash window and a shoji are assembled using, for example, an extruded resin material.
Such a resin sash may be partially damaged by an earthquake or the like.
For example, as shown in FIG. 8A, cracks 3 are formed at corners of the extruded profiles 1 and 2 in the vertical and horizontal directions, a crack 4 is formed as shown in FIG. 8B, and FIG. As shown in FIG.
[0003]
When the above-mentioned damage occurs, the damaged part is repaired.
For example, the repair is performed by melting the welding rod with a hot-air drier or a soldering gage and welding the damaged portion.
In addition, the damaged portion is repaired by bonding the damaged portion with an adhesive.
In addition, putty is put on the damaged part to repair it.
[0004]
After repairing by any of the above-mentioned methods, urethane is injected into the hollow portion of the extruded resin material to reinforce it.
[0005]
[Problems to be solved by the invention]
The above-described repair method by welding causes problems such as deformation (strain) of the profile material, deterioration of the profile and the welding rod, and peeling of the welded portion.
That is, in the repairing method by welding described above, as shown in FIG. 9, the welding rod 7 of the same resin as the profiles 1 and 2 is melted by the air dryer 6 and poured into the damaged portion 8 of the profiles 1 and 2 for welding. Therefore, the hot air of the air dryer 6 hits the surface 9 of the shapes 1 and 2, and the hot air causes deformation (distortion) 10 on the surface 9 of the shapes 1 and 2.
Since the shape members 1 and 2 and the welding rod 7 are deteriorated by heat, the welding strength is low.
[0006]
The melted welding rod flows into the portion near the front surface 9 of the shaped members 1 and 2 and does not flow into the portion near the back surface 11. At the same time, there is an unwelded portion 13, and the welded portion may peel off. This is remarkable when cracks are repaired.
[0007]
Sufficient repair strength cannot be obtained with a repair method using an adhesive or putty.
[0008]
Therefore, an object of the present invention is to provide a method for maintaining a resin sash which can solve the above-mentioned problem.
[0009]
[Means for Solving the Problems]
According to a first aspect of the present invention, a resin welding rod is placed on a damaged portion of a profile that forms a resin sash, and a sharp-shaped cutting tool is pushed into the back surface of the profile while dissolving the welding rod and the profile, from the front to the back of the profile. A method for maintaining a resin sash, comprising repairing a damaged portion by continuous welding.
[0010]
A second invention is a method for maintaining a resin sash according to the first invention, wherein the welding tool and the profile are melted by frictional heat by vibrating the cutting tool with ultrasonic waves.
[0011]
[Operation]
According to the first aspect, since the welding rod and the profile are locally melted by the cutting tool, deformation (distortion) due to heat does not occur on the profile surface.
High welding strength due to slight deterioration of welding rods and profiles due to heat.
Since the profile is continuously welded from the front surface to the back surface, the welded portion does not peel off.
[0012]
According to the second aspect of the present invention, the welding rod and the profile are melted by frictional heat generated by the vibration of the cutting tool, so that the deterioration of the welding rod and the profile due to heat is significantly reduced, and the welding strength is further increased.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of a method for repairing a damaged portion will be described with reference to FIG. The same members as those in the related art have the same reference numerals.
The welding rod 7 is pressed against the damaged portion (repaired portion) 8 of each of the shaped members 1 and 2, the cutting tool 21 of the ultrasonic cutter 20 is applied to the welding rod 7, and the welding rod 7 is melted by frictional heat due to vibration. 2 into the damaged portion (repair portion) 8 as shown in FIG. 2, and the molten welding rod 7 is poured into the back surface 11 while melting the profiles 1 and 2 by frictional heat generated by the vibration of the cutting tool 21. The welding is continuously performed from the front surface 9 to the back surface 11. The overlay 14 can be formed up to the back surface 11 of the profiles 1 and 2.
When the damaged portion 8 described above occurs in the hollow portions of the profiles 1 and 2, the back surface 11 of the profiles 1 and 2 is the inner surface of the hollow portion.
[0014]
In the ultrasonic cutter 20, when a voltage is applied, the vibrator vibrates, and an ultrasonic wave is generated. This ultrasonic wave is further amplified by an amplitude expander, and the blade 21 is vibrated by ultrasonic waves, for example, 40,000 times per second.
The cutting tool 21 has a sharp shape so as to easily penetrate into the damaged portion 8 of the profiles 1 and 2.
[0015]
As described above, the welding rod 7 and the shaped members 1 and 2 are melted by frictional heat generated by the vibration of the cutting tool 21, so that the surfaces of the shaped members 1 and 2 are not deformed (distorted). In addition, the shape members 1 and 2 and the welding rod 7 are slightly deteriorated by heat and have high welding strength.
Since welding is continuously performed from the front surface 9 to the back surface 11 of the profiles 1 and 2, there is no welding surface in the middle of the profiles 1 and 2 in the thickness direction, and there is no portion that is not welded. Absent.
[0016]
The above-mentioned sharp-shaped cutting tool 21 may be energized to generate heat, and the heat may be used to melt the welding rod 7 and the shaped members 1 and 2 while pushing it from the front surface 9 to the rear surface 11 for welding.
Even in this case, the welding strength is increased because the welding rod 7 and the shaped members 1 and 2 are slightly deteriorated by the heat generated by the cutting tool 21.
That is, according to the repair method of the present invention, the welding rod 7 is placed on the damaged portion 8 of the profiles 1 and 2, and the sharp cutting tool 21 is melted on the welding rod 7 and the profiles 1 and 2 to melt the surfaces of the profiles 1 and 2. This is a method of repairing by continuously welding from the front surface 9 to the back surface of the profiles 1 and 2 by pressing from 9 to the back surface 11. When repairing the damaged portion of the hollow portion, welding is continuously performed from the surface 9 of the profiles 1 and 2 to the inner surface of the hollow portion.
[0017]
Next, the reinforcement by the filling and filling of the filler will be described .
As shown in FIG. 3, the vertical profile 1 and the horizontal profile 2 are resin extruded profiles of the same cross section having a hollow portion 30, and the end of the vertical profile 1 and the end of the horizontal profile 2 The portions are cut at 45 degrees, butted and connected by welding or the like, and each hollow portion 30 is continuous.
Filling holes 31 are respectively formed near both ends in the longitudinal direction of the reinforcing (repair) portion on the surface 9 of the vertical and horizontal profiles 1 and 2, and a fixing hole 32 is formed between the two filling holes 31. A plurality is formed at intervals in the longitudinal direction.
Each of the holes 31 and 32 opens into the hollow portion 30.
[0018]
Filling material, for example, glass wool 33 is put into the hollow portion 30 from each of the filling holes 31, and the glass wool 33 is brought into contact with the hollow portion inner surface 30a without any gap to form a dam 34 for stopping the flow of the filling material.
A filling material, for example, urethane 35 is injected and filled into the hollow portion 30 from each of the fixing holes 32, and the urethane 35 is discharged from each of the fixing holes 32 to the surface 9 as shown in FIG. And the shaped members 1 and 2 and the urethane 35 are fixed.
[0019]
For example, the urethane 35 is injected and filled into the hollow portion 30 through the lower fixing hole 32, and the injection and filling is stopped when the urethane 30 leaks from the upper fixing hole 32.
[0020]
The urethane 35 which has leaked from the fixing holes 32 to the surface 9 is hardened and scraped off to be substantially flush with the surfaces 9 of the profiles 1 and 2, and is painted to have the same appearance as the surfaces of the profiles 1 and 2.
[0021]
In this way, even if the adhesiveness between the resin of the profiles 1 and 2 and the urethane 35 (filling material) is poor, the profiles 1 and 2 and the urethane 35 are strong because of the urethane 35 filled in the fixing holes 32. And the portion (reinforcement portion) in which the urethane 35 is injected and filled has a high strength. The filling holes 31 may be the same as the fixing holes 32 after filling. That is, the urethane 35 is filled.
[0022]
Further, the urethane 35 injected and filled into the hollow portion 30 does not flow to a portion other than the repair (reinforcement) portion by the dam 34 for stopping the flow of the filler.
[0023]
It is preferable to use a material which can be easily inserted through a small hole by compressing and deforming, and which restores the original state in the hollow portion 30 plumply.
For example, the above-mentioned glass wool, balloons, cotton, sponge and the like are preferable.
The filler is not limited to urethane, and an epoxy resin or the like may be used.
[0024]
Next , another method of reinforcement by filling with a filler will be described .
As shown in FIG. 5, filling holes 31 are respectively formed near both ends in the longitudinal direction of a portion to be reinforced (repaired) on the surface 9 of the profiles 1 and 2, and a filling material, for example, a glass wool 33 is formed from the filling holes 31. In the same manner as described above, dams 34 for stopping the flow of the filling material are formed in the hollow portions 30 respectively.
A filling material, for example, urethane 35 is injected and filled into the hollow portion 30 using the filling hole 31. In addition, a hole for injection filling may be separately provided.
[0025]
After the urethane 35 injected and filled in the hollow portion 30 is hardened, the fixing holes 32 are continuously formed from the surfaces 9 of the profiles 1 and 2 to the urethane 35 as shown in FIG. To form
The same resin as that of the shape members 1 and 2 is melted and poured from the fixing hole 32 to the fixing concave portion 36 and packed as shown in FIG. 7. The filled material 37 connects the shape material 1 and the urethane 35.
The surface of the packed resin 37 is scraped off to make it substantially flush with the surfaces of the profiles 1 and 2 to improve the appearance. After the urethane 35 is cured, the fixing holes 32 may be formed in the filling holes 31 filled with the urethane 35, and the fixing recesses 36 may be formed in the urethane 35.
[0026]
The above-mentioned filling and filling may be performed at the place where the damaged part is repaired so that the repaired part is not damaged again by an earthquake or the like, or when the damaged part cannot be repaired as described above in a narrow and deep place. May be used for both repair and reinforcement by injecting and filling the damaged part.
Further, even in the case where there is no damage, damage may be prevented from being caused by an earthquake or the like by injecting and reinforcing a place where it is expected that damage may occur due to an earthquake or the like based on past experience.
[0027]
【The invention's effect】
According to the first aspect of the present invention, since the welding rod and the profile are locally melted by the cutting tool, deformation (distortion) due to heat does not occur on the profile surface.
High welding strength due to slight deterioration of welding rods and profiles due to heat.
Since the profile is continuously welded from the front surface to the back surface, the welded portion does not peel off.
[0028]
According to the second aspect of the present invention, the welding rod and the profile are melted by frictional heat generated by the vibration of the cutting tool, so that the deterioration of the welding rod and the profile due to heat is significantly reduced, and the welding strength is further increased.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an embodiment of a method for repairing a damaged portion of a profile.
FIG. 2 is an explanatory diagram of a welding portion.
FIG. 3 is a perspective view showing reinforcement of a profile.
FIG. 4 is a sectional view of a reinforcing portion.
FIG. 5 is a perspective view showing another way of reinforcing a profile.
FIG. 6 is a cross-sectional view of a reinforcing portion in which a fixing hole and a fixing recess are formed.
FIG. 7 is a cross-sectional view of a reinforced portion in a state where reinforcement has been completed.
FIG. 8 is an explanatory diagram of a damaged state of a profile.
FIG. 9 is a perspective view of a conventional method for repairing a damaged portion of a profile.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Vertical shape material, 2 ... Horizontal shape material, 3 ... Cracking, 4 ... Cracking, 5 ... Complete cracking, 7 ... Welding rod, 8 ... Damaged part, 9 ... Front surface, 11 ... Back surface, 20 ... Super Sonic cutter, 21 ... cutting tool, 30 ... hollow part, 30a ... hollow part inner surface, 31 ... filling hole, 32 ... fixing hole, 33 ... glass wool (filling), 34 ... stop for filling flow prevention, 35: urethane (filled), 36: fixing recess.

Claims

Place a welding rod of resin on the damaged part of the profile that forms the resin sash, push the sharp-shaped cutting tool to the back of the profile while melting the welding rod and the profile, and weld continuously from the top to the back of the profile. A method for maintaining a resin sash, wherein the damaged portion is repaired by a method.

The method for maintaining a resin sash according to claim 1, wherein the welding rod and the profile are melted by frictional heat by vibrating the cutting tool with ultrasonic waves.