Building panel, building panel joint structure, method for manufacturing building panel, and method for constructing building panel joint structure

Abstract

To provide a building panel having high workability and productivity and capable of preventing water leakage from a connection part when a plurality of building panels are connected and laid, a building panel joint structure, a manufacturing method of the building panel, and a construction method of the building panel joint structure.SOLUTION: A building panel constituting a building comprises a face material 10 and a coated layer 20 provided over the entire length of an end part 10A of the face material 10 and formed of an adhesive.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an architectural panel that constitutes a building, an architectural panel joint structure using this architectural panel, a manufacturing method for this architectural panel, and a construction method for the architectural panel joint structure. [Background technology]

[0002] Plate-shaped architectural panels are widely used as building materials such as wall and roof materials for buildings. There has been a demand for large architectural panels to be used as building materials for large buildings, but the size of architectural panels is limited by production lines, and conventional architectural panels have been insufficient in size (width and length) to be used as building materials for large buildings. In addition, if architectural panels are made too large, there are problems such as difficulty in transporting them by truck, etc., and deterioration of workability during construction.

[0003] Therefore, a number of architectural panels are laid adjacent to each other to construct wall materials and roof materials for large buildings. In this case, it is known that adjacent architectural panels are partially overlapped with each other via a waterproof band (see, for example, Patent Document 1). However, when a number of architectural panels are overlapped and connected via a waterproof band and laid as a roof material, there is a risk of water leakage from the connection part of the architectural panels, causing a problem. Furthermore, in the structure described in Patent Document 1, it is difficult to sufficiently improve the workability and productivity of the architectural panel because a waterproof band must be provided. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Special Publication No. 61-12061 Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, the present invention aims to provide an architectural panel, an architectural panel joint structure, a manufacturing method for an architectural panel, and a construction method for an architectural panel joint structure that are easy to install and highly productive, and that can prevent water leakage from the connection parts when multiple architectural panels are connected and laid. [Means for solving the problem]

[0006] The present invention has been made to solve the above problems, and the gist of the present invention is as follows. [1] A construction panel constituting a building, comprising a face material and a coating layer formed of an adhesive and extending over the entire length of an end of the face material. [2] The architectural panel described in [1], which is placed adjacent to another architectural panel so that a portion of the face material overlaps with the other architectural panel via the coating layer. [3] The architectural panel according to [1] or [2], wherein the coating layer is formed from a hot melt adhesive. [4] The architectural panel according to any one of [1] to [3], wherein the coating layer has a thickness of 0.5 mm or more and 3.0 mm or less. [5] The architectural panel according to any one of [1] to [4], wherein the coating layer has a width of 5 mm or more and 30 mm or less. [6] The architectural panel according to any one of [1] to [5], wherein the face material has a corrugated cross-sectional shape in which valleys and peaks are repeated. [7] The architectural panel described in [6], wherein the coating layer is positioned inside the valley portion provided at the outermost end of the facing material. [8] The architectural panel according to any one of [1] to [7], further comprising a heat insulating material in an area other than the ends of the face material. [9] An architectural panel joint structure comprising a first architectural panel which is the architectural panel described in any one of [1] to [8] and a second architectural panel, wherein a face material of the first architectural panel is arranged so as to overlap a portion of a face material of the second architectural panel, and the face material of the first architectural panel and the face material of the second architectural panel are joined by the coating layer.

[10] The architectural panel joint structure described in [9], in which a fixing member penetrating the face material of the first architectural panel and the face material of the second architectural panel is provided at the point joined by the coating layer.

[11] A method for manufacturing an architectural panel that constitutes a building, comprising the steps of: preparing a surface material; and applying an adhesive to an end of the surface material over the entire length to form a coating layer.

[12] A construction method for an architectural panel joint structure, comprising: preparing a first architectural panel which is an architectural panel as described in any one of [1] to [8]; and a second architectural panel; arranging the face material of the first architectural panel and the face material of the second architectural panel so that a portion of the face material of the first architectural panel and the face material of the second architectural panel overlap with each other via the coating layer; and joining the face material of the first architectural panel and the face material of the second architectural panel with the coating layer. Effect of the Invention

[0007] According to the present invention, it is possible to provide an architectural panel, an architectural panel joint structure, a manufacturing method for an architectural panel, and a construction method for an architectural panel joint structure, which are easy to install and highly productive and capable of preventing water leakage from the connection parts when multiple architectural panels are connected and laid. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1(a) is a cross-sectional view of a building panel according to one embodiment of the present invention, and FIG. 1(b) is a plan view of the building panel according to one embodiment of the present invention. [Diagram 2] 1 is a cross-sectional view (part 1) of a construction panel according to one embodiment of the present invention. [Diagram 3] FIG. 2 is a cross-sectional view (part 2) of a construction panel according to one embodiment of the present invention. [Figure 4] FIG. 4(a) is a cross-sectional view showing a preliminary stage for constructing an architectural panel joint structure according to one embodiment of the present invention, and FIG. 4(b) is a cross-sectional view of the architectural panel joint structure according to one embodiment of the present invention. [Diagram 5]FIG. 5(a) is a cross-sectional view of a building panel according to one embodiment of the present invention, and FIG. 5(b) is a plan view of the building panel according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, the drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, and the like differ from the actual ones. Therefore, the specific thickness and dimensions should be determined in light of the following description. In addition, it goes without saying that the drawings include parts with different dimensional relationships and ratios.

[0010] [Architectural panels] The building panel of the present invention is disposed adjacent to other building panels so as to overlap partially therewith, and functions as a building material for constructing a building. Hereinafter, the architectural panel of the present invention will be described in detail as an embodiment.

[0011] 1, a building panel 1a according to an embodiment of the present invention comprises a facing material 10 and a coating layer 20 formed of an adhesive and provided over the entire length of an end portion 10A of the facing material 10. The building panel 1a having the above configuration has high workability and productivity, and can prevent water leakage from the connection portions when multiple building panels are connected and laid. In this specification, the direction along one of the surface directions of the building panel 1a is defined as the X direction, the direction along the surface direction and perpendicular to the X direction is defined as the Y direction, and the thickness direction of the building panel 1a perpendicular to the X direction and the Y direction is defined as the Z direction. The coating layer 20 is preferably provided along the Y direction.

[0012] An architectural panel (hereinafter sometimes referred to as the first architectural panel) 1a overlaps with a part of an adjacent architectural panel 1b (hereinafter sometimes referred to as the second architectural panel) at an end 10A, which is a part of the surface material 10, and a part of the surface material 10 of the architectural panel 1b (the end of the surface material 10) is overlapped on one surface 10C of the end 10A. That is, the end 10A is an overlapping portion that overlaps a part of the building panel 1b that is disposed adjacent to the building panel 1a. The end 10a may be disposed in a region of the building panel 1a that is closer to the outer edge than the center in the X direction, and the coating layer 20 may be disposed in a region that is closest to the outer edge when the building panel 1a is divided into eight equal parts in the X direction.

[0013] The coating layer 20 is formed of an adhesive, preferably a hot melt adhesive. The architectural panel 1a is bonded to the architectural panel 1b via the coating layer 20. The coating layer 20 formed of an adhesive may have adhesiveness, but preferably has weak adhesiveness so that the bonded architectural panel 1b can be rebonded. The coating layer 20 having weak adhesiveness allows the architectural panel 1b to be rebonded for alignment with the adjacent architectural panel 1b, and the position adjustment of each panel can be easily performed. In addition, the coating layer 20 may have elasticity, and by having elasticity, when the architectural panel 1a is bonded to the adjacent architectural panel 1b, it is possible to compress the architectural panel 1b and fill the gap while bonding, thereby enhancing the water-stopping property after bonding.

[0014] In addition, the hot melt adhesive used in the coating layer 20 exhibits fluidity when heated, and can be applied by melting it, and after application, it solidifies and exhibits the adhesive properties, preferably weak adhesive properties, as described above. The hot melt adhesive is not particularly limited, but may contain, for example, a thermoplastic polymer such as an ethylene-vinyl acetate copolymer, an ethylene-acrylic acid copolymer, a styrene-based polymer, or an acrylic-based polymer, and a tackifier. Examples of the tackifier include rosin, ester gum, polyterpene resin, C5-based petroleum resin, C9-based petroleum resin, DCPD-based petroleum resin, a styrene-based resin, an alkylphenol resin, a terpene phenol resin, and hydrogenated versions thereof. The hot melt adhesive may further contain a softener such as a plasticizer, polybutene, polyisobutylene low polymer, polyvinyl isobutyl ether low polymer, lanolin, depolymerized rubber, process oil, naphthene-based oil, paraffin-based oil, or vulcanized oil.

[0015] The thickness T (see FIG. 2) of the coating layer 20 provided on the architectural panel 1a is preferably 0.5 mm to 3.0 mm, more preferably 0.75 mm to 2.75 mm, even more preferably 1.0 mm to 2.5 mm, and most preferably 1.3 mm to 2.2 mm. When the thickness T of the coating layer 20 is within the above range, the water-stopping property can be improved after bonding with the adjacent architectural panel 1b.

[0016] The width W (see FIG. 2) of the coating layer 20 provided on the architectural panel 1a is preferably 5 mm to 30 mm, more preferably 7.5 mm to 27.5 mm, even more preferably 10 mm to 20 mm, and most preferably 13 mm to 18 mm. By having the width W of the coating layer 20 within the above range, the water-stopping property can be improved after bonding with the adjacent architectural panel 1b.

[0017] The surface material 10 is not particularly limited, and may be formed of a metal material such as a steel plate, or a resin material such as fiber-reinforced plastic (FRP) or polycarbonate, and a metal material such as a steel plate is preferable. As shown in FIG. 3, the surface material 10 is preferably corrugated in cross section with repeated valleys 12 and peaks 13. The corrugated surface material 10 can be suitably used when the architectural panel 1a constitutes a roofing material. The valleys 12 are recesses when viewed from one surface 10C. The peaks 13 are protrusions when viewed from one surface 10C. The corrugation as the cross section of the surface material 10 may be a round wave type (small wave type, large wave type) in which the valleys 12 and peaks 13 are formed by curved surfaces, as shown in FIG. 3, or may be an angular wave type (not shown) in which the valleys 12 and peaks 13 are formed by flat surfaces. The valleys 12 and peaks 13 are preferably repeated along the X direction. The longitudinal directions of the recesses of the valleys 12 and the protrusions of the peaks 13 are preferably arranged along the Y direction.

[0018] When the cross-sectional shape of the facing material 10 is a wave shape in which valleys 12 and peaks 13 are repeated, the coating layer 20 may be provided on either the valleys 12 or the peaks 13. When multiple coating layers 20 are provided on either the valleys 12 or the peaks 13, the multiple coating layers 20 are provided in parallel over the entire length of the end portion 10A of the facing material 10. In addition, the coating layer 20 has a valley portion 12 at the outermost end. 1 The coating layer 20 is preferably disposed inside the valley portion 12 at the outermost end. 1 By disposing the coating layer 20 at the valley portion 12 at the outermost end, the workability is improved when bonding the adjacent architectural panel 1b. 1 By arranging the panel 1b in this manner, it is possible to enhance the waterproofing effect after the panel 1b is attached to the adjacent architectural panel 1b. The cross-sectional shape of the face material 10 is not limited to a corrugated shape in which the valleys 12 and peaks 13 are repeated, but may be a flat plate shape without the valleys 12 and peaks 13 .

[0019] The facing material 10 may be provided with a heat insulating material 30 in a portion 10B other than the end portion 10A on the surface 10C provided with the coating layer 20. The heat insulating material 30 may be provided so as to be laminated over the entire portion 10B. For example, a foam such as polyurethane foam may be used as the heat insulating material 30. The polyurethane foam as the heat insulating material 30 may be formed, for example, by mixing a polyol liquid agent containing a polyol and a polyisocyanate liquid agent containing a polyisocyanate to obtain a polyurethane composition, and reacting the obtained polyurethane composition on the surface 10C of the building panel 1a to foam and harden it. In this case, the polyol liquid agent may contain additives such as a catalyst and a flame retardant in addition to the polyol. The foaming agent may be blended with the polyol liquid agent, or may be mixed with the polyol liquid agent and the polyisocyanate liquid agent when they are mixed together.

[0020] As shown in FIG. 1, the architectural panel 1a includes a facing 10, a coating layer 20 formed of an adhesive over the entire length of the end 10A of the facing 10, and a heat insulating material 30 at a portion 10B other than the end 10A on the surface 10C having the coating layer 20, and no facing material is provided on the side of the heat insulating material 30 opposite to the surface on which the facing 10 is provided. The cross-sectional shape of the facing 10 of the architectural panel 1a is preferably corrugated, and the cross-sectional shape of the facing 10 is corrugated, so that the coating layer 20 can be easily provided in the valleys of the corrugation. When the cross-sectional shape of the facing 10 is corrugated, the peaks of the heat insulating material 30 enter the inside of the valleys of the facing 10, and the valleys of the heat insulating material 30 cover the outside of the peaks of the facing 10, resulting in a form in which the facing 10 and the heat insulating material 30 are in close contact with each other. 1 shows a form in which the coating layer 20 of the architectural panel 1a is provided on the side of the facing material 10 on which the insulating material 30 is provided, but it may be provided on the side of the insulating material 30 opposite to the side on which the facing material 10 is provided. In a form in which the coating layer 20 is provided on the side of the insulating material 30 opposite to the side on which the facing material 10 is provided, the insulating layer 30 is present on the side of the end portion 10A opposite to the side on which the coating layer 20 is provided, and no insulating layer is present on the end portion as an overlapping portion that overlaps with a part of the architectural panel 1b arranged adjacent to the architectural panel 1a. The architectural panel 1a may be configured such that another surface material (not shown) is provided on the side of the insulation material 30 opposite to the surface on which the surface material 10 is provided. The other surface material provided on the opposite side is present only on the insulation layer 30 and is not present on the end portion 10A of the surface material 10. The other surface material provided on the opposite side may be formed from a metal material such as a steel plate, a paper material such as kraft paper, or the like. The surface of the heat insulating material 30 opposite to the surface on which the facing material 10 is provided may be a flat surface or may have projections and recesses.

[0021] The architectural panel 1a may be used as a building material such as a wall material or a roof material, and is preferably used as a roof material. The architectural panel 1a can be suitably used as a roof material because the coating layer 20 enhances the waterproofing property of the architectural panel 1a.

[0022] [Manufacturing method of architectural panels] The method for producing the building panel 1a of the present invention includes the steps of preparing a face material 10 and applying an adhesive to an end portion 10A of the face material 10 over the entire length to form a coating layer 20. As an example of a method for manufacturing the architectural panel 1a, a method for manufacturing the architectural panel 1a shown in FIG. 1 will be described below.

[0023] First, a flat plate material such as a steel plate is prepared, and the flat plate material is bent into a corrugated shape using a bending machine to form the face material 10. The corrugation of the face material 10 can be formed into various shapes depending on the bending machine.

[0024] Next, a foamable composition is supplied to one surface of the corrugated facing material 10, and the foamable composition is reacted on the facing material 10 to foam and harden, thereby forming a foamed insulating material 30. At this time, another facing material may be further laminated on the surface of the foam (insulating material 30) opposite to the surface on which the facing material 10 is provided, in order to regulate the thickness and shape of the foam. The foamable composition is not placed on the portion corresponding to end 10A of facing material 10, and a foam (insulating material 30) does not have to be formed on the portion corresponding to end 10A of facing material 10. However, the foamable composition may be placed over the entire surface of one side of facing material 10, a foam may be formed, and then the foam from the portion corresponding to end 10A may be removed.

[0025] Next, an adhesive, preferably a hot melt adhesive, is applied over the entire length of the portion of the facing material 10 where the foam (thermal insulation material 30) is not provided, to form the coating layer 20. As a coating method for forming the coating layer 20, a known coating method such as applying heated and melted hot melt with a glue gun can be selected.

[0026] According to the above manufacturing method, the coating layer 20 is also formed on the upper surface of the facing material 10 on which the insulating material is formed, so that the coating layer 20 can be formed by applying an adhesive without turning over the facing material 10 after the insulating material is formed. Furthermore, each of the above steps can be performed while the long facing material is fed roll-to-roll. Therefore, this manufacturing method can simplify the steps and improve factory productivity. It should be noted that the long face material sent by roll-to-roll may be cut into individual face materials 10. In this case, the face material 10 may be cut before or after the adhesive is applied. In the above manufacturing method, the insulating material and the coating layer are formed in this order on one side of the facing material 10, but they do not have to be formed in this order, and the insulating material may be formed after the coating layer is formed. Also, the facing material does not have to be fed by roll-to-roll, and the insulating material and the coating layer may be formed on one side of the facing material without transporting the facing material.

[0027] [Architectural panel joint structure] The architectural panel joint structure 40 of the present invention includes a first architectural panel 1a and a second architectural panel 1b, as shown in Fig. 4(a). As shown in Fig. 4(a), in the architectural panel joint structure 40, the face material 10 of the first architectural panel 1a is arranged so as to overlap a part of the face material 10 of the second architectural panel 1b, and as shown in Fig. 4(b), the face material 10 of the first architectural panel 1a and the face material 10 of the second architectural panel 1b are joined by a coating layer 20.

[0028] The second building panel 1b may have the same material as the first building panel 1a, but as shown in FIG. 1, the coating layer may be omitted. In the building panel joint structure 40, the second building panel 1b may be overlapped on the first building panel 1a such that the valley of the second building panel 1b enters the valley of the first building panel 1a, and the peak of the first building panel 1a enters the peak of the second building panel 1b. In FIG. 4, the first and second building panels 1a and 1b are arranged so that two peaks and two valleys overlap, but it is sufficient that at least one valley overlaps. However, it is preferable that at least one valley and at least one peak overlap.

[0029] As shown in FIG. 4(b), the architectural panel joint structure 40 may be provided with a fixing member 50 penetrating the facing 10 of the first architectural panel 1a and the facing 10 and the heat insulating material 30 of the second architectural panel 1b at the portion joined by the coating layer 20. The fixing member 50 penetrates the first architectural panel 1a and the second architectural panel 1b and fixes them to a support material 51 constituting a wall material and a roof material, etc., thereby improving the joint strength between the first architectural panel 1a and the second architectural panel 1b, thereby improving the water-stopping property of the joint. In addition, the first and second architectural panels 1a and 1b can be attached to the support material 51 by the fixing member 50. Examples of the fixing member 50 include screws, screws, and tacks.

[0030] In Figure 4, the architectural panel joint structure 40 is shown in a form in which insulation material 30 is provided on each of the first architectural panel 1a and the second architectural panel 1b, but it may also be in a form in which insulation material 30 is provided on only one of the first architectural panel 1a and the second architectural panel 1b, or in which insulation material 30 is not provided on either of the first architectural panel 1a and the second architectural panel 1b. In addition, the architectural panel joint structure 40 may be configured such that the second architectural panel 1b is provided with a heat insulating material 30 in the portion overlapping with the facing material 10 of the first architectural panel 1a, as shown in Fig. 4. This allows the heat insulating material 30 to be provided without interruption even in the connection portion between the first architectural panel 1a and the second architectural panel 1a.

[0031] [Construction method for building panel joint structure] The construction method of the architectural panel joint structure 40 of the present invention includes the steps of preparing a first architectural panel 1a and a second architectural panel 1b, arranging the face material 10 of the first architectural panel 1a and the face material 10 of the second architectural panel 1b so that a portion of the face material 10 overlaps with a coating layer 20 interposed therebetween, and joining the face material 10 of the first architectural panel 1a and the face material 10 of the second architectural panel 1b with the coating layer.

[0032] According to the facing material and architectural panel joint structure of the present invention, when multiple architectural panels are connected and laid, the coating layer disposed at the connection portion can prevent water leakage from the connection portion. In order to improve the water-stopping property of the connection portion of adjacent facing materials, it is preferable to adopt a coating layer formed of a hot melt type adhesive.

[0033] [Other embodiments] The present invention is not limited to the configurations of the above-described embodiments, and any improvements and modifications may be made without departing from the technical spirit of the present invention.

[0034] For example, in the above description, an example was given of a configuration in which a heat insulating material is provided on each building panel, but the heat insulating material may be omitted.

[0035] In the above description, the valleys 12 and peaks 13 of the facing material 10 are described as being repeated along the X direction, but as shown in FIG. 5, the valleys 12 and peaks 13 of the facing material 10 may be repeated along the Y direction. In this case, as shown in FIG. 5(b), the coating layer 20 is provided along the Y direction, following the undulations of the valleys 12 and peaks 13, over the entire length of the end 10A of the facing material 10. As shown in FIG. 5(a), the valleys 12 and peaks 13 of the facing material 10 are repeated along the Y direction. The first building panel 1a and the second building panel 1b are arranged in the X direction, and the valleys and peaks of the first building panel 1a and the second building panel 1b are arranged so that they overlap each other. In this way, a building panel joint structure can be formed by arranging and joining the first building panel 1a and the second building panel 1b. [Explanation of symbols]

[0036] 1a…Building panel (first building panel) 1b…Adjacent building panel (second building panel) 10…Surface material 10A...end 10B: Areas other than the ends 12. Valley 13…Yamabe 20…Coating layer 30…Insulation material 40…Architectural panel joint structure 50…Fixing member 51...Support material

Claims

1. A building panel constituting a building, An architectural panel comprising a face material and a coating layer formed from an adhesive and extending over the entire length of an end of the face material.

2. The building panel according to claim 1 , which is disposed adjacent to another building panel so that a portion of the facing material overlaps with the other building panel via the coating layer.

3. The building panel according to claim 1 , wherein the coating layer is formed from a hot melt pressure sensitive adhesive.

4. 2. The building panel according to claim 1, wherein the coating layer has a thickness of 0.5 mm or more and 3.0 mm or less.

5. 2. The building panel according to claim 1, wherein the coating layer has a width of 5 mm or more and 30 mm or less.

6. 2. The architectural panel according to claim 1, wherein the face material has a corrugated cross-sectional shape in which valleys and peaks are repeated.

7. The building panel according to claim 6 , wherein the coating layer is disposed inside the valley portion provided at the outermost end of the facing material.

8. The building panel according to claim 1 , further comprising a heat insulating material in a portion of the panel other than the ends.

9. A first building panel which is the building panel according to any one of claims 1 to 8, and a second building panel, The facing of the first building panel is disposed so as to overlap a portion of the facing of the second building panel; An architectural panel joint structure, in which the face material of the first architectural panel and the face material of the second architectural panel are joined by the coating layer.

10. The architectural panel joint structure according to claim 9, wherein a fixing member penetrating the face material of the first architectural panel and the face material of the second architectural panel is provided at the location joined by the coating layer.

11. A method for manufacturing an architectural panel that constitutes a building structure, comprising the steps of: preparing a surface material; and applying an adhesive to an end of the surface material over the entire length to form a coating layer.

12. A construction method for an architectural panel joint structure, comprising: preparing a first architectural panel which is the architectural panel according to any one of claims 1 to 8; and a second architectural panel; arranging the first architectural panel and the second architectural panel so that a portion of the surface material of the first architectural panel and the surface material of the second architectural panel overlap with each other via the coating layer; and joining the surface material of the first architectural panel and the surface material of the second architectural panel with the coating layer.

Images