Manufacturing method for wall panel of building

Abstract

To provide a method for manufacturing a wall panel of a building capable of improving workability of a sash frame.SOLUTION: A wall panel of a building has: longitudinal and transverse members 6, 6, 7, 8 forming an outer frame 5; longitudinal and transverse members 9, 9, 10, 10 forming an opening 3; and an opening jig 4. The method for manufacturing the wall panel of the building includes the steps of: forming the opening 3 by arranging the longitudinal and transverse members 9, 9, 10, 10 around the opening jig 4; framing the longitudinal and transverse members 6, 6, 7, 8 to form the outer frame 5; and fixing the longitudinal and transverse members 9, 9 forming the opening 3 to the outer frame 5.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a wall panel of a building.

Background Art

[0002] As a building construction method, a method is known in which wall panels prefabricated in a factory are transported to a construction site and assembled. FIG. 10 shows a building construction method using a conventional wall panel. A horizontal member (base) 16 is placed on a foundation concrete (not shown), columns 17 are erected at the corner portions thereof, and a horizontal member (beam) (not shown) is placed between the upper ends of the columns 17 to form a building framework. A wall panel 90 prefabricated in a factory and transported to the construction site is lifted by a crane 14 and sequentially installed in an opening 18 between the base 16, the beam, and the columns 17 to construct a building. Openings 93 for attaching sash frames and openings 94 for attaching door frames are formed in the wall panel 90. In the construction method using such a conventional wall panel 90, improvement in workability of sash frames (including entrance and exit frames such as door frames and sliding door frames) has been demanded.

Summary of the Invention

Problems to be Solved by the Invention

[0003] In view of the above-described circumstances, an object of the present invention is to provide a method for manufacturing a wall panel of a building capable of improving workability of a sash frame.

Means for Solving the Problems

[0004] A method for manufacturing a wall panel of a building according to the invention described in claim 1 for achieving the above object includes a step of forming a vertical and horizontal member forming an outer frame, a vertical and horizontal member forming an opening, and an opening jig, arranging the vertical and horizontal members around the opening jig to form an opening, a step of framing the vertical and horizontal members to form an outer frame, and a step of fixing the vertical and horizontal members forming the opening to the outer frame.

[0005] The method for manufacturing a wall panel of a building according to the invention described in claim 2 is characterized in that a wall panel assembled at a factory with an opening jig fitted into an opening is transported to a construction site, the wall panel is installed in the building, and after a sash frame is attached to the opening with the opening jig attached to the opening, the opening jig is removed.

[0006] The method for manufacturing a wall panel of a building according to the invention described in claim 3 is characterized in that a wall panel with an opening jig fitted into an opening and a sash frame attached to the opening is assembled at a factory, the wall panel is transported to a construction site, the wall panel is installed in the building, and the opening jig is removed.

[0007] The method for manufacturing a wall panel of a building according to the invention described in claim 4 is characterized in that a wall panel assembled at a factory with an opening jig fitted into an opening is transported to a construction site, the wall panel is installed in the building, then a portion facing the lower surface of the opening jig of the lower frame of the wall panel is cut off, and after a sash frame is attached to the opening, the opening jig is removed.

Advantages of the Invention

[0008] The method for manufacturing a wall panel of a building according to the invention described in claim 1 has a step of forming an opening by arranging vertical and horizontal members forming an outer frame, vertical and horizontal members forming an opening, and an opening jig, and arranging the vertical and horizontal members surrounding the opening jig; a step of framing the vertical and horizontal members to form an outer frame; and a step of fixing the vertical and horizontal members forming the opening to the outer frame. Therefore, the accuracy of the opening can be improved, and the torsion and distortion of the wall panel can be suppressed to maintain the accuracy of the opening. Thus, the workability of installing the sash frame can be improved, and the mounting accuracy of the sash frame can be enhanced.

[0009] The method for manufacturing a wall panel of a building according to the invention described in claim 2 is to transport the wall panel assembled at the factory with an opening jig fitted into the opening to the construction site, install the wall panel on the building, attach a sash frame to the opening with the opening jig attached to the opening, and then remove the opening jig. Therefore, the accuracy of the opening is improved, and the twisting and distortion of the wall panel are suppressed to maintain the accuracy of the opening. As a result, the workability of the sash frame can be improved, and the attachment accuracy of the sash frame can be improved. Since the opening jig can be repeatedly used, it is economical.

[0010] The method for manufacturing a wall panel of a building according to the invention described in claim 3 is to assemble at the factory a wall panel in which an opening jig is fitted into the opening and a sash frame is attached to the opening, transport the wall panel to the construction site, install the wall panel on the building, and remove the opening jig. Therefore, the accuracy of the opening is improved, and the twisting and distortion of the wall panel are suppressed to maintain the accuracy of the opening. As a result, the workability of the sash frame can be improved, and the attachment accuracy of the sash frame can be improved. Since the opening jig can be repeatedly used, it is economical. Since the labor for attaching the sash frame on-site can be saved, the workability is improved.

[0011] The method for manufacturing a wall panel of a building according to the invention described in claim 4 is to transport the wall panel assembled at the factory with an opening jig fitted into the opening to the construction site, install the wall panel on the building, then cut the portion facing the lower surface of the opening jig of the lower frame of the wall panel, attach a sash frame to the opening, and then remove the opening jig. Therefore, the accuracy of the opening is improved, and the twisting and distortion of the wall panel are suppressed to maintain the accuracy of the opening. As a result, the workability of the sash frame can be improved, and the attachment accuracy of the sash frame can be improved. Since the opening jig can be repeatedly used, it is economical.

Brief Description of the Drawings

[0012]

Figure 1

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Figure 10

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 7 shows a building construction method (panel method) of a building using the wall panel of the present invention. As described above, in the building construction method using the conventional wall panel 90 shown in FIG. 10, the accuracy of the openings 93 and 94 is poor, and due to the presence of the openings 93 and 94, the wall panel 90 is twisted and distorted (see the upper right figure in FIG. 10(b)). As a result, there are problems that the workability of the sash frame and the door frame is poor, and the mounting accuracy of the sash frame and the door frame is deteriorated. As shown in FIG. 7, the present invention is characterized in that by fitting an opening jig 4 into each opening 3 of a window wall panel 1 having an opening 3 to which a sash frame 11 (see FIG. 4) is attached and an entrance / exit window panel 2 having an opening 3 to which a door frame 12 (see FIG. 6) is attached, the accuracy of the opening 3 is improved, the rigidity of the wall panels 1 and 2 is increased, and the wall panels 1 and 2 are prevented from being twisted or distorted.

[0014] FIG. 1 shows an example of a manufacturing method of the window wall panel 1. First, as shown in FIG. 1(a), an opening jig 4 is prepared according to the shape and dimensions of the opening to be formed in the wall panel. The opening jig 4 only needs to have a strength capable of maintaining a predetermined shape and dimensions, and the material and structure are not particularly limited. For example, a metal frame can be used as the opening jig 4, or a material obtained by attaching a facing material to a metal frame can be used as the opening jig 4. Next, as shown in FIG. 1(b), vertical members 9, 9 and horizontal members 10, 10 made of wood are attached so as to surround the periphery of the opening jig 4. Next, as shown in FIG. 1(c), left and right vertical frames 6, 6, an upper frame 7, and a lower frame 8 made of wood are framed to form an outer frame 5, and the longitudinal end portions of the vertical members 9, 9 forming the opening 3 are fixed to the upper frame 7 and the lower frame 8.

[0015] The window wall panel 1 may be composed only of the framework 6, 7, 8, 9, 10 made of wood and the opening jig 4 as described above. However, a heat insulating material (not shown) is placed in the space between the vertical and horizontal members 9, 9, 10, 10 forming the opening 3 and the vertical and horizontal members 6, 6, 7, 8 forming the outer frame 5, and a facing material (not shown) made of plywood or the like having holes formed according to the position and size of the opening 3 is attached to both sides or one side of the outdoor side surface and the indoor side surface. Further, an outer wall may be attached to the outdoor side surface, and an inner wall may be attached to the indoor side surface (the same applies to the entrance / exit wall panel described later). The steps up to this point are carried out at a factory.

[0016] FIG. 2 shows another example of the manufacturing method 1 of the window wall panel. The steps up to FIG. 2(a) to (c) are the same as those in FIG. 1(a) to (c). The wall panel 1 for window is different in that the sash frame 11 is pre - attached to the opening 3 at the factory as shown in Fig. 2(d).

[0017] In this way, since the wall panel 1 for window is assembled with the opening jig 4 as a reference, the accuracy of the vertical and horizontal dimensions of the opening 3 can be improved. Also, because the opening jig 4 is fitted into the opening 3, the rigidity of the wall panel 1 is increased, and the twisting and distortion of the wall panel 1 can be suppressed.

[0018] Fig. 8 shows an example of the variation of the wall panel 1 for window. Fig. 8(a) has the same shape as Figs. 1 and 2 described above. In Fig. 8(b), the lower horizontal member 10 forming the opening 3 is also used as the lower frame 8 of the outer frame 5. In Fig. 8(c), the upper and lower horizontal members 10, 10 forming the opening 3 are also used as the upper frame 7 and the lower frame 8 of the outer frame 5. In Fig. 8(d), one of the vertical members 9 forming the opening 3 is also used as the vertical frame 6 of the outer frame 5.

[0019] Fig. 9 shows an example of the wall panel 2 for entrance / exit. As shown in Fig. 9(a), the vertical members 9, 9, the horizontal member 10, and the lower frame 8 are attached so as to surround the opening jig 4 according to the shape and dimensions of the opening formed in the wall panel, and further, the left and right vertical frames 6, 6 and the upper frame 7 are attached to form the outer frame 5, and the upper ends of the vertical members 9, 9 are fixed to the upper frame 7. Also, similar to the wall panel 1 for window described above, a heat insulating material (not shown) is placed in the space between the vertical members 9, 9 and the horizontal member 10 forming the opening 3 and the vertical frames 6, 6 and the upper frame 7 forming the outer frame 5, and a facing material (not shown) is attached to both sides or one side of the outdoor - side surface and the indoor - side surface. As shown in Fig. 9(b), after the wall panel 2 for entrance / exit is installed on the foundation 13, the portion facing the lower surface of the opening jig 4 of the lower frame 8 is cut off.

[0020] The wall panels 1 and 2 manufactured in the factory in this way are lifted by a crane 14 as shown in Fig. 3(a), stacked flat or vertically on the loading platform of a truck 15 as shown in Fig. 3(b), and transported to the construction site. At the construction site, as shown in Fig. 3(c), the wall panels 1 and 2 are lifted one by one by the crane 14 and installed in the opening 18 between the foundation 16 of the building, the beam (not shown), and the column 17. Since the opening jig 4 is fitted into the opening 3 of the wall panels 1 and 2, it is possible to prevent the wall panels 1 and 2 from being twisted or deformed during lifting by the crane 14 or transportation by the truck 15, etc., and maintain the accuracy of the opening 3.

[0021] The window wall panel 1 (without the sash frame 11 attached) transported to the construction site is lifted by the crane 14 as shown in Fig. 4(a) and installed in the opening 18 between the foundation 16 of the building, the beam (not shown), and the column 17 as shown in Fig. 4(b). The window wall panel 1 is fixed to the beam at the upper part and the foundation 16 at the lower part respectively. Next, as shown in Fig. 4(c), the sash frame 11 is attached to the opening 3 of the wall panel 1. Since the opening jig 4 is attached to the opening 3 and the accuracy of the opening 3 is maintained, the sash frame 11 can be easily attached, and the attachment accuracy of the sash frame 11 is improved. After that, as shown in Fig. 4(d), the opening jig 4 is removed from the opening 3 of the wall panel 1. The removed opening jig 4 can be reused. Note that the figures described within the dotted lines in Fig. 4 are schematic longitudinal sectional views of the window wall panel 1 at each stage (the same applies to Figs. 5 and 6).

[0022] The window wall panel 1 (with the sash frame 11 attached) transported to the construction site is lifted by the crane 14 as shown in Fig. 5(a) and installed in the opening 18 between the foundation 16 of the building, the beam (not shown), and the column 17 as shown in Fig. 5(b). The window wall panel 1 is fixed to the beam at the upper part and the foundation 16 at the lower part respectively. Since the sash frame 11 is already attached to the opening 3 of the wall panel 1, the labor of attaching the sash frame 11 on site can be saved. Thereafter, as shown in FIG. 5(c), the opening jig 4 is removed from the opening 3 of the wall panel 1. The removed opening jig 4 can be reused.

[0023] The wall panel 2 for the entrance / exit transported to the construction site is lifted by a crane 14 as shown in FIG. 6(a), and after being installed at a predetermined position of the opening 18 between the building foundation 16, a beam (not shown), and the column 17 as shown in FIG. 6(b), the portion facing the lower surface of the opening jig 4 of the lower frame 8 is cut off. Next, as shown in FIG. 6(c), the door frame 12 is attached across the opening 3 of the wall panel 2 and the notch 19 formed in the foundation 13. Since the accuracy of the opening 3 is maintained because the opening jig 4 is attached to the opening 3, the door frame 12 can be easily attached and the attachment accuracy of the door frame 12 is improved. Thereafter, as shown in FIG. 6(d), the opening jig 4 is removed from the opening 3 of the wall panel 2. The removed opening jig 4 can be reused.

[0024] The wall panels 1 and 2 (see FIG. 7(c)) installed at positions adjacent to the column 17 are caulked between them and the column 17. Also, the adjacent wall panels 1 and 2 are caulked between them. The vertical frames 6 of the wall panels 1 and 2 installed at positions adjacent to the column 17 can also be fixed to the column 17 with nails or bolts, or the vertical frames 6 of the adjacent wall panels 1 and 2 can be fixed to each other with nails or bolts. In that case, the facing material is not pasted on the indoor side surface of the wall panels 1 and 2.

[0025] As described above, the method for manufacturing a wall panel of a building according to the present invention includes vertical and horizontal members (vertical frames 6, 6, upper frame 7, lower frame 8) forming the outer frame 5, vertical and horizontal members (vertical members 9, 9, horizontal members 10, 10) forming the opening 3, and an opening jig 4. A step of forming the opening 3 by arranging the vertical and horizontal members 9, 9, 10, 10 surrounding the opening jig 4, a step of forming the outer frame 5 by framing the vertical and horizontal members 6, 6, 7, 8, and a step of fixing the vertical and horizontal members 9, 9 forming the opening 3 to the outer frame 5 (see FIG. 1). Therefore, the accuracy of the opening 3 can be improved, and the twist and distortion of the wall panels 1, 2 can be suppressed to maintain the accuracy of the opening 3. Thus, the workability of the sash frames 11, 12 can be improved, and the mounting accuracy of the sash frames 11, 12 can be enhanced.

[0026] Further, in the method for manufacturing a wall panel of a building according to the present invention, the wall panel 1 assembled at the factory with the opening jig 4 fitted into the opening 3 is transported to the construction site, the wall panel 1 is installed in the building, and after the sash frame 11 is attached to the opening 3 with the opening jig 4 attached to the opening 3, the opening jig 4 is removed (see FIG. 4). Therefore, the accuracy of the opening 3 is improved, and the twist and distortion of the wall panel 1 can be suppressed to maintain the accuracy of the opening 3. Thus, the workability of the sash frame 11 can be improved, and the mounting accuracy of the sash frame 11 can be enhanced. Since the opening jig 4 can be repeatedly used, it is economical.

[0027] Moreover, in the method for manufacturing a wall panel of a building according to the present invention, the wall panel 1 with the opening jig 4 fitted into the opening 3 and the sash frame 11 attached to the opening 3 is assembled at the factory, the wall panel 1 is transported to the construction site, the wall panel 1 is installed in the building, and the opening jig 4 is removed (see FIG. 5). Therefore, the accuracy of the opening 3 is improved, and the twist and distortion of the wall panel 1 can be suppressed to maintain the accuracy of the opening 3. Thus, the workability of the sash frame 11 can be improved, and the mounting accuracy of the sash frame 11 can be enhanced. Since the opening jig 4 can be repeatedly used, it is economical. The labor for attaching the sash frame 11 on-site can be saved, so the workability is improved.

[0028] In addition, in the method for manufacturing the wall panel 2 of the building according to the present invention, the wall panel 2 assembled at the factory with the opening jig 4 fitted into the opening 3 is transported to the construction site. After the wall panel 2 is installed in the building, the portion of the lower frame 8 of the wall panel 2 facing the lower surface of the opening jig 4 is cut off. After attaching the sash frame (door frame) 12 to the opening 3, the opening jig 4 is removed (see FIG. 6). Therefore, the accuracy of the opening 3 is improved, and the twisting and distortion of the wall panel 2 are suppressed, and the accuracy of the opening 3 can be maintained. Thus, the workability of the sash frame 12 can be improved, and the attachment accuracy of the sash frame 12 can be improved. Since the opening jig 4 can be repeatedly used, it is economical.

[0029] The present invention is not limited to the embodiments described above. The structure, shape, and material of the wall panel can be appropriately changed. The vertical and horizontal members forming the opening only need to have the end portions extending to the outer frame fixed to the outer frame. The opening jig only needs to be able to maintain a certain shape and dimensions, and its specific structure and material are not limited. The opening jig can also be fitted into the opening of the wall panel later. The present invention can also be applied to buildings using the two-by-four construction method or the like.

Description of Reference Numerals

[0030] 1 Window wall panel (wall panel) 2 Entrance wall panel (wall panel) 3 Opening 4 Opening jig 5 Outer frame 6 Vertical frame (vertical and horizontal members forming the outer frame) 7 Upper frame (vertical and horizontal members forming the outer frame) 8 Lower frame (vertical and horizontal members forming the outer frame) 9 Vertical member (vertical and horizontal members forming the opening) 10 Horizontal member (vertical and horizontal members forming the opening) 11 Sash frame 12 Door frame (sash frame)

Claims

1. A method for manufacturing a wall panel of a building, comprising vertical and horizontal members forming an outer frame, vertical and horizontal members forming an opening, having an opening jig, arranging the vertical and horizontal members around the opening jig to form an opening, framing the vertical and horizontal members to form an outer frame, and fixing the vertical and horizontal members forming the opening to the outer frame.

2. Transporting a wall panel assembled in a factory with an opening jig fitted into the opening to a construction site, installing the wall panel in a building, attaching a sash frame to the opening with the opening jig attached to the opening, and then removing the opening jig.

3. Assembling a wall panel in a factory with an opening jig fitted into the opening and a sash frame attached to the opening, transporting the wall panel to a construction site, installing the wall panel in a building, and removing the opening jig.

4. Transporting a wall panel assembled in a factory with an opening jig fitted into the opening to a construction site, installing the wall panel in a building, cutting off a portion facing the lower surface of the opening jig of the lower frame of the wall panel, attaching a sash frame to the opening, and then removing the opening jig.

Images