JP7589015B2 - Architectural panel and assembly method for architectural panel - Google Patents

Description

The present invention relates to architectural panels used to form a specified space within a building and a method for assembling architectural panels.

Conventionally, for example, a partition wall between adjacent rooms in an apartment building is formed on a base of multiple wooden studs (hereinafter also referred to as "wooden shafts") installed at a specified interval and gypsum boards arranged on each room side and fixed to the studs. Although the wooden shafts are generally made of laminated veneer lumber (LVL) made from imported poplar, there is a risk that the Clean Wood Act, which came into effect in 2017, will make it difficult to adopt LVL in the future due to a reduction in supply and a rise in prices.

In addition to wood, studs are also made of steel. For example, so-called light steel studs are generally cylindrical square timber, but the light steel stud disclosed in Patent Document 1 (called stud 1 in the document) has a surface that faces the structural wall with a gap running longitudinally, while the surface opposite the above surface that is attached to the plasterboard is flat and has no gap (see Figure 3). The light steel stud is roll-formed by folding both sides of a long plate material with a roll forming machine to form a surface that is attached to the plasterboard, and folding the tip sides of the folded pieces corresponding to the above two sides in directions approaching each other and parallel to the surface that is attached to the plasterboard to form the surface that faces the structural wall.

JP 2002-285693 A

However, general light steel studs are not suitable for fine adjustments such as partial cutting, and wooden shafts are sometimes used in conjunction with them as a base, making them difficult to adopt as a substitute for wooden shafts in the Clean Wood Method. Furthermore, although the light steel studs in Patent Document 1 have gaps on the surface facing the structural wall due to roll forming, the action and effect of said surface is not disclosed, and the configuration is merely a change in the orientation of a conventional light steel stud (partition stud 11 in the document) based on the problem that the invention is trying to solve (see paragraph "0003" and Figure 24).

Depending on the structure, location, and construction procedure of a given space within a building based on recent building technology and trends, the studs used as the base are not limited in material or shape, as long as they ultimately fulfill the same role as wooden shafts or light steel studs, and they do not necessarily have to be placed at the construction site before the installation of the gypsum board. In other words, after much ingenuity, the inventors have discovered that depending on the material and shape of the studs, they can be expected to improve construction efficiency compared to wooden shafts or light steel studs.

The object of the present invention is to provide an architectural panel and an assembly method for the architectural panel that employs an axis material that can replace the conventional wooden axis or light steel studs as partitions, and that is expected to improve the construction efficiency in a given space.

In other words, the architectural panel of the present invention is an architectural panel that includes a plate material that is placed on the side of a specified space within a building, and a hollow shaft material that is placed outside the specified space from the plate material, and the shaft material has a pair of first surfaces that are arranged in parallel with a gap between them, and is placed in a state where the first surfaces are adhered to the plate material.

The shaft material is preferably made of foam resin.

It is desirable for the width of the first surface portion to be 1 to 5 times the thickness of the shaft material.

The shaft further has a pair of second surfaces that are continuous with the first surfaces in a direction away from the specified space, and a third surface that is parallel to the first surfaces and continuous with the second surfaces, and it is desirable that the third surfaces have a rougher surface than the first surfaces.

The shaft material is a first shaft material, and further includes a second shaft material different from the first shaft material, the second shaft material having a first surface portion, a second surface portion, and a third surface portion arranged in the same manner as the first surface portion, the second surface portion, and the third surface portion of the first shaft material, the width of the second shaft material is wider than the width of the first shaft material, and it is desirable that the third surface portion of the second shaft material does not have a rough surface.

The method of assembling a building panel in the present invention is characterized in that a hollow shaft member having a pair of first surfaces arranged parallel to each other with a gap therebetween is attached to a plate material that is to be placed on the side of a specified space in a building, from the first surfaces to the plate material.

The method of using the architectural panel in the present invention is characterized in that a specified space within a building is formed outside the building using the architectural panel or an architectural panel assembled by the architectural panel assembly method.

The architectural panel of the present invention allows the use of a shaft material that can replace the conventional wooden shafts and light steel studs as partition walls, and is expected to improve construction efficiency within a given space.

1 is a perspective view of the exterior of a predetermined space formed by a building panel according to one embodiment of the present invention; FIG. 2A is a plan view of the shaft material provided in the above-mentioned building panel, and FIG. 2B is a size explanatory diagram. FIG. 4 is a plan view of another shaft member provided on the above-mentioned building panel. 4 is an explanatory diagram of a method for assembling the architectural panel used to form the specified space. FIG.

Below, with reference to Figures 1 to 4, an architectural panel (hereinafter also referred to as "this architectural panel") in one embodiment of the present invention and an assembly method for this architectural panel will be described. In these figures, where there are multiple identical parts, only one part is numbered. For ease of explanation, certain parts and lines leading to these parts are shown with hidden lines (dashed lines) or imaginary lines (two-dot chain lines). In the explanation, terms indicating directions such as up, down, side, vertical, horizontal, etc. are basically based on a specific space within a normal building, and if other references are used, they will be explained appropriately.

<Overview of architectural panels>
As shown in Fig. 1, the architectural panel P is for forming a predetermined space R within a building. The "building" is, for example, an apartment building, a detached house, a temporary house, or a commercial facility, and is not limited to a structure or size such as reinforced concrete, steel frame, or wood. The "predetermined space" is, for example, a room, toilet, bathroom, or washroom in an apartment building, and it is sufficient that at least one surface of the side wall or ceiling is made of the architectural panel. It is preferable that the structure is movable after being formed outside the building and can be installed at a predetermined location within the building or the predetermined space, without limiting the use or size.

This building panel P is equipped with a plate material 1 arranged on the side of a specified space R in a building, and a hollow shaft material 2 arranged outside the specified space from the plate material 1. The "side of the specified space in a building" may be a position directly facing the specified space, or a position indirectly facing the specified space via another member. The "plate material" is, for example, gypsum board, but any plate-shaped wall material may be used. The "outside of the specified space from the plate material" may be, in other words, the back side of the plate material based on the specified space, and may or may not be visible from the specified space. The "hollow shaft material" is, in other words, a cylindrical rod material with a specified thickness, which may have a longitudinal length and a transverse width similar to those of a conventional partition wall, and may have a horizontal cross section in the transverse direction that is approximately triangular, rectangular, circular, or elliptical, and may have a linear slit or notch of a specified width in all or part of the longitudinal direction.

<Basic structure of shaft material>
As shown in Fig. 2(a), the shaft material 2 has a pair of first surfaces 21, 21 arranged in parallel with a gap S therebetween. In other words, the shaft material 2 has a horizontal cross section in a short direction that is generally U-shaped, includes a predetermined gap S in the entire longitudinal direction like the above-mentioned slit or notch, and has the first surfaces 21, 21 on both sides of the gap S and on the same plane. The shaft material 2 is arranged with the first surfaces 21, 21 bonded to the plate material 1, in other words, bonded to the plate material 1 so as to close the gap S. The first surfaces 21, 21 and the plate material 1 are bonded with a known adhesive such as an adhesive for wood or metal.

According to this configuration, for example, in a predetermined space such as a toilet that can be moved and installed after being formed at a location other than the construction site, the shaft material 2 can be used as an alternative to conventional wooden shafts and light steel studs, and by adopting this architectural panel P in which the plate material 1 and the shaft material 2 are pre-bonded, it is expected that the construction efficiency of the predetermined space will be improved. In other words, since the shaft material 2 is pre-bonded to the plate material 1 with an adhesive or the like, it is possible to expect the effect of expressing the structure of the desired predetermined space without any problems even if the area of the first surface portion 21, 21, which is the contact surface with the plate material 1, is relatively small compared to a wooden shaft or light steel stud fixed to the plate material 1 with nails or screws at the construction site. The adhesive strength of the shaft material 2 with the adhesive is not only comparable to the fixing strength of a wooden shaft or light steel stud fixed with nails or screws, but also comparable to the effect of fixing to the plate material 1 with double-sided tape.

<Axis material>
The shaft material 2 is made of a foamable resin, and may have as its main component a synthetic resin such as polyurethane, polystyrene, polyolefin including polyethylene or polypropylene, phenolic resin, polyvinyl chloride, urea resin, silicone, polyimide, melamine resin, or a mixture of two or more of these.The shaft material 2 may be foamed by chemically reacting a specified foaming agent further mixed into the resin or by vaporizing other solvents.The shaft material 2 is manufactured by extrusion molding in a specified device, but may also be manufactured by injection molding as long as it can be molded into the desired shape.

This structure is lighter than conventional wooden shafts and light steel studs, so it is expected to improve workability, and it can be easily molded into the desired shape without the complex roll molding required for light steel studs. In addition, the foamed resin foams to a specified thickness, and strength and rigidity can be designed by the type and amount of synthetic resin used, so you can expect the desired bending strength and nail/screw fastening effect.

<Detailed structure of shaft material>
As shown in Figure 2 (a), the shaft material 2 has a first portion 2a, 2a including first surface portions 21, 21, a second portion 2b, 2b including a pair of second surface portions 22, 22 molded integrally with the first portion 2a, 2a and continuing from and approximately perpendicular to the first surface portions 21, 21 in a direction away from the specified space R, and a third portion 2c including a third surface portion 23 molded integrally with the second portion 2b, 2b and including a third surface portion 23 that is parallel to the first surface portions 21, 21 and continuing from and approximately perpendicular to the second surface portions 22, 22.

The shaft material 2 is formed with a first portion 2a, 2a, a second portion 2b, 2b, and a third portion 2c, so that the horizontal cross section is generally U-shaped. The shaft material 2 may be formed so that the first portions 2a, 2a are continuously and integrally connected to form a generally concave horizontal cross section, or the concave portion may be a gap S. The boundaries between the first surface portions 21, 21 and the second surface portions 22, 22, and the boundaries between the second surface portions 22, 22 and the third surface portion 23 may be chamfered.

The shaft material 2 only needs to have at least the first portions 2a, 2a, and there are no limitations on the shape or dimensions of the other portions molded integrally with the first portions 2a, 2a. The first portions 2a, 2a have a triangular tapered shape toward the gap S, but may also have a curved or rectangular bulging shape. The second portions 2b, 2b and the third portion 2c have the same thickness, which corresponds to the thickness of the shaft material 2, but may be different from each other. The first surface portions 21, 21, the second surface portions 22, 22, and the third surface portion 23 correspond to the surface of the shaft material 2. The third surface portion 23 is also parallel to the plate material of another specified space (not shown) adjacent to the specified space R or the exterior wall of the building.

The width W1 of the first surface portion 21 may be wider or narrower than the thickness W2 of the shaft material 2 depending on the shape of the first portion 2a, but is preferably 1 to 5 times the thickness W2 of the shaft material 2, and more preferably 1.5 to 3 times. If it is narrower than 1 time, the adhesive strength with the plate material 1 will be too weak, and if it is wider than 5 times, the gap S will be narrow and the overall weight will be heavy, or conversely, the thickness W2 of the shaft material 2 will be too thin, reducing the bending strength. Therefore, by keeping the width W1 in the above range, it is expected that the desired strength and rigidity design can be achieved, and the adhesive work to the plate material 1 will also be easier.

The third surface 23 is a relatively rough surface compared to the first surfaces 21, 21; in other words, it does not have to be a smooth surface suitable for bonding with an adhesive like the first surfaces 21, 21; it may be roughened during extrusion molding, or roughened by blasting or sandpaper after extrusion molding. In other words, the third surface 23 corresponds to the back side of the architectural panel P, and is unlikely to affect the structure of the architectural panel P and the formation of the specified space R, but after the specified space formed by the architectural panel P is installed, the board material 10 on the other specified space side may be fixed to the third surface 23 with double-sided tape, so the rough surface is expected to have the effect of obtaining the desired adhesive strength.

As shown in FIG. 2(b), an example of the size of the shaft material 2 is that the width W1 of the first surface portion 21 is 10 mm, the thickness W2 of the shaft material 2 is 5 mm, the width W3 and depth W4 of the shaft material 2 are 40 mm, the angle of the inclined surface of the first portion 2a is 45° with respect to the first surface portion 21, and the chamfers of each corner are R1 to R3.

<Other shaft materials>
The shaft material of the architectural panel P may include shaft material 200 as a second shaft material shown in Fig. 3 in addition to shaft material 2 as a first shaft material shown in Fig. 2. Note that for shaft material 200, only the parts that are different from shaft material 2 will be described, and a description of the equivalent parts will be omitted. For ease of reference, the parts equivalent to those shown in Fig. 3 are numbered by adding 100 to the numbers in Fig. 2.

The width W100 of the first surface portion 210 is approximately equal to the thickness W200 (7 mm) of the shaft material 200, but since the thickness W200 is thicker, the desired adhesive strength can be expected even if the width W100 is one time the thickness W200. Even if the first portion 200a has a shape that curves and bulges toward the gap S100, the effect of supplementing the strength of the shaft material 200 can be expected. Since the width W300 of the shaft material 200 is wider than the width W3 of the shaft material 2, it becomes easier to fix the plate materials 10a and 10b on the other specified space side to the third portion 200c with screws B, so the third surface portion 230 does not need to be rough, in other words, it may be a smooth surface similar to that of the first surface portion 210, and it is expected that the manufacturing burden of the roughening process will be reduced. Each corner portion does not need to be chamfered.

<Assembly method of this architectural panel>
As shown in Fig. 4, the architectural panels P are a wall panel P1 and a ceiling panel P2, each of which has common plate materials and shaft materials and is assembled in a common manner. Hereinafter, an example of an assembly method will be explained for the wall panel P1, and differences from the above example will be explained for the ceiling panel P2.

As shown in the wall panel P1 in FIG. 4, the first surface portions 21, 21 of the shaft 2 shown in FIG. 2 and the first surface portions 210, 210 of the shaft 200 shown in FIG. 3 are glued to the back surface of the plate material 1, which is placed on the side of the specified space R, from the outside of the specified space R of the plate material 1. Before gluing the shaft material 2 and the shaft material 200, a specified frame material F may be attached in advance to the top, bottom, left and right edges of the back surface of the plate material 1. In this case, the shaft material 2 and the shaft material 200 are glued to the back surface of the plate material 1 closer to the inside than the frame material F. By arranging the shaft material 200 at a specified pitch (for example, 90 cm) with respect to the width of the plate material 1, the plate materials 10a and 10b on the other specified space side as shown in FIG. 3 can be attached.

As shown in ceiling panel P2 in Figure 4, the panel may be assembled by gluing together shaft material 2a in the same direction as the longitudinal direction of the plate material and shaft material 2b in a direction perpendicular to shaft material 2a, and the number and arrangement of shaft material 2a and 2b are not limited. In this case, shaft material 2a or shaft material 2b may be fitted into a notch provided in the other.

The architectural panel shown in this embodiment is not limited to the above, and includes any shape, position, or size of any part, or any relationship between parts, as long as the same effect is obtained.

R: specified space P: architectural panel, P1: wall panel, P2: ceiling panel 1: plate material on specified space side 10, 10a, 10b: plate material on other specified space side 2,200: shaft material 21, 210: first surface portion, 22, 220: second surface portion, 23: third surface portion 2a, 200a: first portion, 2b: second portion, 2c, 200c: third portion S, S100: gap B: screw F: frame material

Claims (5)

A building panel comprising a plate material arranged on a predetermined space side in a building and a hollow shaft material arranged outside the predetermined space from the plate material,
The architectural panel is characterized in that the shaft material is made of a foamable resin, has a pair of first surface portions arranged in parallel with a gap therebetween, and is arranged in a state in which the first surface portions are adhered to the plate material. A building panel comprising a plate material arranged on a predetermined space side in a building and a hollow shaft material arranged outside the predetermined space from the plate material,
The shaft material is
A pair of first surfaces arranged in parallel with a gap therebetween;
A pair of second surfaces continuous with the first surface in a direction away from the predetermined space;
a third surface portion that is parallel to the first surface portion, continuous with the second surface portion, and has a rougher surface than the first surface portion;
A building panel, characterized in that the first surface portion is placed in a state where it is adhered to the board material . 3. The architectural panel according to claim 1, wherein the width of the first surface portion is 1 to 5 times the thickness of the shaft member. The shaft material is a first shaft material,
Further comprising a second shaft member different from the first shaft member;
The second shaft member has a first surface portion, a second surface portion, and a third surface portion arranged in the same manner as the first surface portion, the second surface portion, and the third surface portion of the first shaft member,
The width of the second shaft is wider than the width of the first shaft,
3. The building panel according to claim 2 , wherein the third surface of the second shaft is not rough. A method for assembling an architectural panel, characterized in that a hollow foamable resin shaft having a pair of first surfaces arranged parallel to each other with a gap therebetween, and positioned outside the specified space of a plate material to be placed on the side of a specified space within a building, is adhered to the plate material from the first surfaces.

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