Building panels, and methods for manufacturing building panels

Abstract

The objective is to provide building panels that can simplify on-site work at construction sites. [Solution] The building panel 1 in this embodiment comprises a gypsum board 20 cut to a size and shape according to the design information of the house, and an insulating board 10 which is cut to a size and shape according to the design information of the house, adhered to the surface of the gypsum board 20, and formed from foamed synthetic resin into a board shape. The insulating board 10 is pre-cut to have a surface area smaller than the surface area of ​​the gypsum board 20, and is adhered to the inside of the outer edge of the gypsum board 20.

Description

Technical Field

[0003] , , , , ,

[0001] The present invention relates to a building panel and a method for manufacturing the building panel.

Background Art

[0002] For example, Patent Document 1 discloses a pair of wall panels formed by attaching members corresponding to a divided wall structure between two panels constituting a wall and in the plane direction of the panels, wherein the divided wall structure includes at least studs. Further, Patent Document 2 discloses a wall panel stretched on a structural shaft member composed of vertical shaft members such as columns and studs and horizontal members such as a base, a body skirt, a beam, and a girder. The wall panel comprises a panel main body made of a plate-like body, a heat insulating material integrally laminated on the back surface of the panel main body leaving the four peripheral edges of the panel main body, and body edge members having a constant width and a constant thickness fixed in the longitudinal direction of the panel main body at a certain interval from both side edges of the panel main body on both sides of the surface of the panel main body, and nailable portions are formed on both side end portions of the surface of the panel main body exposed in the interval portions between the outer end surfaces of these body edge members and both side edges of the panel main body.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a building panel capable of simplifying on-site work at a construction site.

Means for Solving the Problems

[0005] The building panel according to the present invention comprises a gypsum board cut to a size and shape according to the design information of the house, and an insulating board formed from foamed synthetic resin, which is cut to a size and shape according to the design information of the house and bonded to the surface of the gypsum board. The insulating board is cut to a size and shape according to the design information of the house, pre-cut so that the surface area of ​​the insulating board is smaller than the surface area of ​​the gypsum board, and bonded to the inside of the outer edge of the gypsum board.

[0006] Preferably, the insulation board, which is cut to the size and shape according to the house design information, is bonded to the gypsum board, which is cut to the size and shape according to the house design information, at bonding positions corresponding to the house design information.

[0007] Preferably, the tape material is adhesive and elastic, and further comprises a viscoelastic member installed on the surface of the gypsum board to which the insulation board is not adhered, wherein the viscoelastic member is located between the gypsum board and the building structure when the gypsum board is installed on the building structure of the house.

[0008] Furthermore, the manufacturing method of building panels according to the present invention comprises the steps of: pre-cutting gypsum board based on the design information of a house; pre-cutting insulation board based on the design information of a house; and bonding the insulation board, which has been pre-cut based on the design information of a house, to the gypsum board, which has been pre-cut based on the design information of a house, at a position based on the design information of a house, wherein in the step of pre-cutting the insulation board, the surface area of ​​the insulation board is made smaller than the surface area of ​​the gypsum board, and in the bonding step, the insulation board is bonded to the inside of the outer edge of the gypsum board. [Effects of the Invention]

[0009] According to the present invention, on-site work at construction sites can be simplified. [Brief explanation of the drawing]

[0010] [Figure 1] This figure illustrates the configuration of the building panel 1 in the embodiment. [Figure 2] This diagram illustrates a surface structure with building panel 1 attached. [Figure 3] This is a flowchart illustrating the installation method (S10) for building panel 1. [Modes for carrying out the invention]

[0011] Embodiments of the present invention will be described below with reference to the drawings. However, the scope of the present invention is not limited to the illustrated examples. Figure 1 is a diagram illustrating the configuration of the building panel 1 in an embodiment. Figure 1(A) is a diagram illustrating the building panel, and Figure 1(B) is a cross-sectional view illustrating the building panel. As illustrated in Figures 1(A) and 1(B), the building panel 1 comprises an insulating material 10, a gypsum board 20, a viscoelastic member 30, and an adhesive 50. The building panel 1 is formed by bonding gypsum board 20, which has been pre-cut in advance at a factory or other location other than the construction site based on the design information of the house, to insulation material 10, which has also been pre-cut in a factory or other location other than the construction site based on the design information of the house, at bonding positions based on the design information of the house. Here, the design information of the house refers to drawing data of structural drawings that show the structural members of the building, such as columns, girders, beams, rafters, roof trusses, and ridge beams, and includes, for example, information on the distance between two structural members (span length), or dimensional information of the space enclosed by the structural members.

[0012] The insulation material 10 is an insulation material formed from foamed synthetic resin into a plate shape. The insulation material 10 is a foamed plastic insulation material, such as polystyrene foam, phenolic foam, or rigid polyurethane foam. In this example, the insulation material 10 is phenolic foam from the viewpoint of thermal insulation and flame resistance. The insulation material 10 is pre-cut in advance at a factory or other location outside the construction site, and is cut to the size (dimensions) and shape according to the design information of the house. The insulation material 10 is pre-cut to a size smaller than the gypsum board 20, specifically, the surface area of ​​the insulation material 10 is pre-cut to be smaller than the surface area of ​​the gypsum board 20. Furthermore, the insulation material 10 is bonded to the bonding position corresponding to the design information of the house, and is bonded to the inside of the outer edge of the gypsum board 20. Note that the insulation material 10 is an example of an insulation board according to the present invention.

[0013] Gypsum board 20, also known as plasterboard, is a board-shaped building material primarily composed of gypsum. Specifically, gypsum board 20 is a building material for interior or exterior use, consisting of a board-shaped core material primarily composed of gypsum covered with gypsum board paper. Gypsum board 20 is a base gypsum board used for walls and ceilings of buildings, and is, for example, a structural gypsum board (Type A, Type B), gypsum board, or reinforced gypsum board as specified in JIS A 6901 (Gypsum Board Products). Gypsum board 20 is an inorganic load-bearing surface material and is installed as a surface material for load-bearing walls. In addition, gypsum board 20 has functions such as fire resistance, earthquake resistance, high water resistance, and high mold resistance. Furthermore, the gypsum board 20 is pre-cut in advance at a factory or other location other than the construction site, and is cut (processed) to the size (dimensions) and shape according to the design information of the house. The gypsum board 20 is pre-cut to a size larger than the insulation material 10, specifically, the surface area of ​​the gypsum board 20 is pre-cut to be larger than the surface area of ​​the insulation material 10. The gypsum board 20 is an example of the gypsum board according to the present invention.

[0014] The viscoelastic member 30 is an example of a viscoelastic member according to the present invention, and is a tape material that is adhesive and elastic, and is installed on the surface of a gypsum board 20 to which the insulation material 10 is not adhered. The viscoelastic member 30 is, for example, made of a butyl rubber-based material in the shape of a tape, and has adhesive layers on both sides thereof. The viscoelastic member 30 is located between the gypsum board 20 and the building frame when the gypsum board 20 is installed on the building frame of the house. Furthermore, the width of the viscoelastic member 30 is, for example, 30 mm or more and 100 mm or less. Also, the thickness of the viscoelastic member 30 is, for example, 5 mm or less and 1 mm or more and 3 mm or less.

[0015] The adhesive 50 is used to bond pre-cut insulation material 10, which is also pre-cut based on the house design information, to pre-cut gypsum board 20, which is also pre-cut based on the house design information. The adhesive 50 is, for example, a hot-melt adhesive. For example, if the adhesive 50 is a non-reactive hot-melt adhesive, it is an EVA resin-based, synthetic rubber-based, polyamide-based, or polyester-based adhesive, and if it is a reactive hot-melt adhesive, it is a PUR (urethane resin reaction)-based or POR (olefin resin reaction)-based adhesive. The adhesive 50 can be appropriately selected as either non-reactive or reactive.

[0016] Figure 2 illustrates a wall structure with building panel 1 attached. Figure 2(A) is an example of the internal structure of a load-bearing wall, and Figure 2(B) is an enlarged view illustrating the internal structure. As illustrated in Figures 2(A) and 2(B), the building panel 1 is installed, for example, as a shearing material for a load-bearing wall in a large-wall construction method. The building panel 1 may be installed as a shearing material for a large-wall construction method or as a shearing material for a traditional Japanese wall construction method. In this example, the building panel 1 is a shearing material for a large-wall construction method. The building panel 1 is installed on the structure of the house from the exterior side to the interior side. Specifically, the building panel 1 is installed so that the gypsum board 20 is located on the exterior side and the insulation material 10 is located on the interior side. The building panel 1 is installed so that the insulation material 10 fits into the space formed by the columns (including studs), beams, or girders that constitute the structure of the house, and the gypsum board 20 covers the framework of the columns, beams, or girders. The viscoelastic member 30 is located between the gypsum board 20 and the column or stud when the gypsum board 20 is installed on the structure of the house, and is bonded to the gypsum board 20 and the column or stud. For example, when a house shakes due to an earthquake or the like, columns and beams deform while maintaining a predetermined angle, whereas the gypsum board 20 does not deform, so a relative displacement occurs. However, since the viscoelastic member 30 can reduce this displacement, it is possible to prevent bending and pulling out of nails and screws that fix the gypsum board 20.

[0017] FIG. 3 is a flowchart for explaining a manufacturing method (S10) of the building panel 1. As illustrated in FIG. 3, in step 100 (S100), an operator, for example, at a processing factory, cuts (precuts) the gypsum board 20 into a size (dimension) and shape corresponding to the housing design information based on the housing design information. The operator precuts the gypsum board 20 to have a larger board surface area than the board surface area of the heat insulating material 10 described later.

[0018] In step 102 (S102), an operator, for example, at a processing factory, cuts (precuts) the heat insulating material 10 into a size (dimension) and shape corresponding to the housing design information based on the housing design information. The operator precuts the heat insulating material 10 to have a smaller board surface area than the board surface area of the gypsum board 20.

[0019] In step 104 (S104), an operator adheres the heat insulating material 10 precut based on the housing design information to a position based on the housing design information on the gypsum board 20 precut based on the housing design information. Specifically, the operator applies an adhesive 50 between the heat insulating material 10 and the gypsum board 20, and adheres the heat insulating material 10 and the gypsum board 20 (hot melt bonding) with the heat insulating material 10 positioned inside from the outer edge of the gypsum board 20.

[0020] In step 106 (S106), the worker adheres the viscoelastic member 30 to the surface of the gypsum board 20, to which the insulation material 10 has not yet been attached, at the processing plant, in a position based on the house design information. Specifically, the worker adheres the viscoelastic member 30 to the surface of the gypsum board 20 at the position where the gypsum board 20 will come into contact with the framework, such as columns or studs, while the gypsum board 20 is installed on the house frame. The worker adheres the viscoelastic member 30 so as to surround the insulation material 10. In this way, workers can reduce the amount of work at the construction site by manufacturing the building panels 1 at the processing plant. In this method, the case in which the gypsum board 20 is pre-cut before the insulation material 10 is pre-cut is described, but this is not the only way; the insulation material 10 may be pre-cut before the gypsum board 20, and the order of work can be changed.

[0021] As described above, the building panel 1 in this embodiment simplifies work at the construction site by manufacturing the building panel 1 at a processing plant. This reduces the workload on workers and shortens working time. Furthermore, it allows for consistent quality of the building panel 1. Furthermore, by using gypsum board as the facing material, the building panel 1 is less prone to cracking than volcanic glass composite boards and has higher fire resistance than wood-based structural MDF boards, thus improving these performance characteristics. Although embodiments of the present invention have been described above, the invention is not limited thereto, and various modifications and additions are possible without departing from the spirit of the invention. [Explanation of Symbols]

[0022] 1… Building panels 10…Insulation panels 20... Gypsum board 30… Viscoelastic material 50…Adhesive

Claims

1. Gypsum board cut to the size and shape according to the house design information, The insulation board is cut to the size and shape according to the design information of the house, and is bonded to the surface of the gypsum board, and is made of foamed synthetic resin formed into a board shape. It has, The insulation board is pre-cut to have a surface area smaller than that of the gypsum board, and is bonded to the inside of the outer edge of the gypsum board. Building panels.

2. The gypsum board, cut to the size and shape according to the house design information, is bonded to the insulation board, cut to the size and shape according to the house design information, at adhesive positions corresponding to the house design information. The building panel according to claim 1.

3. A viscoelastic member that is an adhesive and elastic tape material and is installed on the surface of the gypsum board to which the insulation board is not attached. It further possesses, The viscoelastic member is positioned between the gypsum board and the building frame when the gypsum board is installed on the building frame of the house. The building panel according to claim 2.

4. The process of pre-cutting gypsum boards based on the house design information, The process involves pre-cutting insulation boards based on the house design information, The process involves bonding the insulation board, which has been pre-cut based on the house design information, to the gypsum board, which has been pre-cut based on the house design information, in a position based on the house design information. It has, In the process of pre-cutting the insulation board, the surface area of ​​the insulation board is pre-cut to be smaller than the surface area of ​​the gypsum board. In the bonding process, the insulation board is bonded to the inside of the outer edge of the gypsum board. A method for manufacturing building panels.

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