Panel for structure and structure using the same

Abstract

To provide a panel constituting an outer surface side of a structure that is lightweight but strong while ensuring waterproof performance of the structure without the need for excessive effort and cost.SOLUTION: In a panel 10 for a structure, connection grooves 10a, 10b, 10c, 10d are formed in an intermediate position in a thickness direction on vertical / horizontal end faces as being attached to a frame of the structure and forming its outer peripheral surface or / and roof surface, and connection projections 40, 41 or connection members 42 are fitted into so that the connection between the panel and the frame or / and panels is reinforced. An inner plate 12 and an outer plate 13 are made of rectangular plastic corrugated board, and onto both front and rear surfaces of a frame body 11 made of square timbers assembled into a rectangular profile, the inner plate 12 and the outer plate 13 which are larger in length and width, are attached and fixed so that their vertical / horizontal end edges project from vertical / horizontal end edges of the frame body 11 with a predetermined width so that the connection grooves 10a, 10b, 10c, 10d are formed with a groove width matching a thickness of the frame body 11.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a panel for a structure and a structure using the same, and more particularly to a panel attached to a frame forming a skeleton of a structure for partitioning the inside and outside of the structure, and a structure formed by assembling them to form a space inside.

Background Art

[0002] As prefabricated structures constructed by assembling a plurality of panels, as described in JP-A-11-30050 and JP-A-2016-37816, there is a method in which frame members forming the skeleton of a building and component members with unified standards such as floor panels, wall panels, and roof panels are transported to the site and assembled. Since a set of members can be transported by a truck or the like and assembled and disassembled in a relatively short time, it is used for emergency evacuation during disasters, villas, detached buildings, or temporary wards and outpatient departments during the spread of infectious diseases.

[0003] By adopting such a method of constructing a building by simply combining a frame and panels with unified standards, it has become possible to assemble and disassemble relatively easily on the foundation, and it is possible to respond in a relatively short time in various situations. However, attaching the panel to the frame requires the labor of fixing the upper, lower, left, and right end sides of the panel to the frame with bolts. Also, although the work of assembling the building on the foundation itself is not difficult, in order to newly provide a foundation on site, specialized techniques and dedicated equipment for forming a solid foundation structure capable of stably supporting the total weight of the building and an accurate horizontal plane are required, and it takes a certain amount of labor and time until the completion of the entire building and the removal.

[0004] To solve this problem, the inventors and applicants of the present application proposed in Japanese Patent Application Laid-Open No. 2018-127891 a prefabricated simple house in which a panel is detachably attached to a frame structure. As shown in Fig. 11(B), the panel 10C has connecting grooves 10f formed longitudinally on the upper, lower, left, and right end faces, and the side faces of the frame where the panel end faces contact are fitted and connected to those provided with connecting ridges made of an elastic body that fit into the connecting grooves 10f longitudinally. At least the four corners of the base frame are supported by support legs with a jack function so that they can move up and down.

[0005] By adopting the method of connecting the panels while fitting the connecting ridges into the connecting grooves formed longitudinally on the upper, lower, left, and right end faces of the panels in this way, it is possible to relatively easily connect the panel end face sides while ensuring the airtightness and liquid tightness of the connecting parts. By providing a jack function for the support legs that support the base frame, the foundation of the house can be horizontally adjusted in a short time even on sloping ground.

[0006] However, the panel 10C in the above-described technology is formed by attaching an inner panel 17 and an outer panel 18 made of veneer or the like to both the front and rear sides of a wooden frame 16 from the viewpoints of manufacturing cost and weight reduction of the building. However, it is likely to be a problem that it is difficult to ensure the waterproofness and weather resistance on the outer surface side. Also, even when waterproof coating is applied to the outer surface and the upper, lower, left, and right end faces of the panel 10C, there is a drawback that the waterproof function deteriorates over time and the outer panel 18 and the frame 16 as the framework are likely to corrode and deteriorate.

[0007] Therefore, the inventors and applicants of the present application proposed in Japanese Patent Application Laid-Open No. 2022-65312 that, as shown in Fig. 11(A), an outer skin body 100 made of a sheet-like or plate-like waterproof material is provided so as to cover the entire surface of the wooden outer panel 15 in the panel 10B having the connecting groove 10e. The edge side of the outer skin body 100 is bent at a right angle at least at the positions of the left and right edge lines of the outer panel 15 and is in close contact with the end face of the panel body, and then further bent inward to be provided along the inner surface of the connecting groove 10e, so as to exhibit a waterproof function.

[0008] However, even if the waterproof outer body 100 is provided in this way, it is difficult to completely prevent water from entering the inside of the panel 10B main body including the wooden outer panel 15. In addition, providing the outer body 100 so as to cover the entire surface of the outer panel 15 tends to result in excessive manufacturing labor and costs. Also, providing connecting grooves on both the left and right end faces and both the upper and lower end faces while manufacturing the entire structure of the panel 10B from wood also tends to be a factor in increasing labor and costs. Furthermore, when manufacturing a panel from wood, considering portability, large-area outer panels and inner panels have to be made of thin plate materials such as veneer to reduce weight, but it has been difficult to achieve both strength and lightness as a member constituting the outer wall of a structure such as a building.

Prior Art Documents

Patent Documents

[0009]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0010] The present invention aims to solve the above problems, and for a panel constituting the outer surface of a structure, it is an object to provide a panel that is lightweight and has excellent strength while ensuring the waterproof performance of the structure without requiring excessive labor and costs.

Means for Solving the Problems

[0011] Therefore, the present invention is attached to a frame forming the skeleton of a structure and partitions the inner and outer spaces while forming the outer peripheral surface and / or the upper surface of the structure. A connecting groove is formed in the middle position in the thickness direction of the upper, lower, left, and right end surfaces over the longitudinal direction, and by inserting and fitting a connecting ridge or a connecting member having a shape that fits into this groove, in a panel for a structure in which the connection between the panel and the frame and / or between the panels is reinforced, the inner panel constituting the inner surface and the outer panel constituting the outer surface are made of rectangular plastic corrugated cardboard, and on both the front and back surfaces of a frame body formed by assembling square timbers into a rectangular contour, an outer panel and an inner panel having longitudinal and transverse sizes larger than those of the frame body are attached and fixed such that their upper, lower, left, and right edges protrude from the upper, lower, left, and right edges of the frame body by a predetermined width, whereby a connecting groove having a groove width corresponding to the thickness of the frame body is formed.

[0012] In this way, by simply attaching an inner panel and an outer panel made of plastic corrugated cardboard, which are larger in longitudinal and transverse sizes than a frame body formed by assembling square timbers such as wood into a rectangle, not only can a connecting groove with a depth due to the size difference be formed, but also it has waterproof properties due to the plastic material, and by adopting a sandwich structure using plastic corrugated cardboard that is lightweight yet has high strength, a panel for a structure such as a prefabricated house that is lightweight and has excellent strength can be manufactured without excessive labor and cost.

[0013] Also, in this case, screw insertion holes for screw fixation by arranging nut members are opened in at least one of the upper, lower, left, and right end surfaces of the frame body, and are used for screw fixation to reinforce and fix the connection by the connecting ridge or the connecting member. If this is made a feature, a structure with even better strength can be constructed with minimal effort.

[0014] Furthermore, if the above-described panel for a structure is characterized by constituting the outer wall and / or roof of a prefabricated house, by using plastic corrugated board for the panel, in addition to being lightweight, having high strength and water resistance, and excellent portability, its high heat insulation property makes it easy to maintain a good indoor living environment. By attaching and assembling this panel for a structure for a prefabricated house to a frame to form a space inside, a prefabricated house can be provided that can meet various needs and can be set up and removed in a short time.

[0015] In this case, if the connecting ridge or / and connecting member is characterized by being made of unpainted wood, not only is it easy to ensure the strength of the connecting part, but also the moisture absorption from the surface of the unpainted wood causes it to expand while enhancing the adhesion between the members, resulting in a prefabricated house with excellent waterproof performance.

[0016] And if it is provided as a structure formed by attaching and assembling the above-described panel for a structure to a frame to form a space inside, it can be set up and removed in a short time while meeting various needs.

[0017] In this case, if the connecting ridge or / and connecting member is characterized by being made of unpainted wood, not only is it easy to ensure the strength of the connecting part, but also the moisture absorption from the surface of the unpainted wood causes it to expand while enhancing the adhesion between the members, resulting in a structure with excellent waterproof performance.

Effect of the Invention

[0018] According to the present invention, in which inner and outer panels made of plastic corrugated board having a size larger than that of a frame formed by assembling square timbers into a rectangle are attached to form a connecting groove, without requiring excessive labor and cost, it is lightweight and has excellent strength while ensuring the waterproof performance of the structure.

Brief Description of the Drawings

[0019]

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Embodiments for Carrying Out the Invention

[0020] Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

[0021] FIG. 1 shows a state in which a part of the panel 10 for the structure of the present invention is cut away so that the inside can be seen. This panel 10 is suitable as a member constituting the outer wall and roof of a structure such as the prefabricated house 1 shown in FIG. 10, and is attached to the metal frame 2 forming the skeleton of the structure to form the outer peripheral surface and / or the roof surface while partitioning the inner and outer spaces. It is assumed that the size of the panel for the structure, which is a plate-like member having a predetermined thickness, is standardized and used as a common part.

[0022] As shown in the cross-sectional partial views of FIGS. 3 and 4 cut along the lines A-A and B-B in FIG. 1, connecting grooves 10a, 10b, 10c, 10d having the same groove width and depth extending in the longitudinal direction are formed at intermediate positions in the thickness direction of the upper, lower, left, and right end faces. By inserting and fitting a connecting ridge or a connecting member having a shape that fits into this, the panel 10 and the frame 2 or the panels 10, 10 are connected to each other.

[0023] And, as shown in the exploded view of FIG. 2, the inner panel 12 that constitutes the inner surface and the outer panel 13 that constitutes the outer surface are made of rectangular plastic corrugated board having a predetermined thickness, and the inner panel 12 and the outer panel 13, which are larger in vertical and horizontal sizes than the frame body 11 formed by assembling square timbers having a common thickness into a rectangular contour, are attached and fixed to both the front and back surfaces of the frame body 11 such that their upper, lower, left, and right edges protrude from the upper, lower, left, and right edges of the frame body 11 by the depth of the connecting grooves. Thus, the connecting grooves 10a, 10b, 10c, 10d are formed with a groove width equal to the thickness of the frame body 11, and this is the most characteristic part of the present invention.

[0024] That is, unlike the conventional example where a waterproof outer body is provided on the veneer outer panel and the edge side is provided into the connecting groove while being bent by the end face of the panel body to ensure waterproofness, by simply attaching the inner panel 12 and the outer panel 13 made of plastic corrugated board, which are larger in vertical and horizontal sizes than the frame body 11 formed by assembling square timbers made of wood or the like with a rectangular cross-section, to the frame body 11, the connecting grooves 10a, 10b, 10c, 10d with the same groove width are formed on the upper, lower, left, and right end faces without requiring labor, and since the portion exposed on the outer surface side is made of a resin material, it has extremely strong waterproof performance against rainwater and the like.

[0025] Also, by adopting a sandwich structure in which the frame body 11 made of wood or the like is sandwiched between the inner panel 12 and the outer panel 13 made of plastic corrugated board, which has a predetermined thickness and is lightweight and high-strength, the panel, which is a member constituting a structure such as a prefabricated house, can be manufactured without excessive labor and cost.

[0026] Since the plastic corrugated cardboard has a corrugated rib structure inside, it generally has a direction with high strength and a direction with low strength in the direction of the applied force. However, it is recommended from the viewpoint of ensuring strength to use a product such as Proper (registered trademark, manufactured by Kawakami Sangyo Co., Ltd.) in which a plurality of circular convex portions are arranged inside to make it difficult for a direction with weak strength to occur. For example, when the thickness of the panel 10 is 30 mm, the thickness of the frame body 11 may be 12 mm, and the thickness of the plastic corrugated cardboard on the front and back may be 9 mm each. As a result, the structure will have a good balance between lightness and strength.

[0027] Also, from the viewpoint of ensuring ease of handling while realizing the lightness and low cost of the panel for the structure, the outer panel 13 that requires relatively high strength is set to a thickness of 9 mm, and the inner panel 12 that does not require high strength is set to a thickness of, for example, 5 mm. For the inner panel, a plastic corrugated cardboard thinner than the outer panel may be used.

[0028] Furthermore, in addition to being excellent in strength and water resistance, the plastic corrugated cardboard has a feature that it contains a large amount of air inside to form an air layer and is also excellent in heat insulation. Since an air layer is also formed in the space surrounded by the frame body 11 between the inner panel 12 and the outer panel 13 made of such plastic corrugated cardboard, the panel 10 of this embodiment has a triple heat insulation layer with a high air content rate, and thus can exhibit extremely excellent heat insulation even with a relatively thin member.

[0029] FIG. 5 shows the procedure of inserting and fixing the rubber connecting protrusion 40 provided on the side surface of the aluminum square column 20 constituting the frame 2 into the connecting groove 10b of the panel 10 shown in FIG. 3. FIG. (A) shows the state immediately before insertion, and FIG. (B) shows the state after insertion and connection. In this way, it is connected only by fitting the connecting protrusion 40 on the frame 2 side, and the rubber connecting protrusion 40 is elastically deformed by the fitting during connection and adheres to the inner surface of the connecting groove 10b, so the airtightness and liquid tightness of that part can be ensured.

[0030] Also, as shown in FIGS. 1, 2, and 4, screw insertion holes 35 are formed at the upper, lower, left, and right end faces of the frame body 11 for screw fixing by arranging nut members 30, 30, 30, 30 having screw holes, and these are used for screw fixing to reinforce the connection by connecting ridges or connecting members.

[0031] That is, as shown in FIG. 6, which is a view showing a cut at the position of the screw insertion hole 35 when connecting the aluminum square columns 20, while inserting screw insertion holes 25, 25, 45, 46 penetrating the aluminum square columns 20 and the connecting ridge 40 with a single screw 70, inserting it into the screw insertion hole 35 of the frame body 11, and screwing the tip side into the screw hole of the nut member 30, the screw fixing is completed in this way. As a result, a structure with excellent strength can be assembled with a minimum of effort.

[0032] In addition, plastic corrugated cardboard is likely to deteriorate due to ultraviolet rays depending on the resin material used, and many of them do not have very high weather resistance. Therefore, for the outer panel 13 directly exposed to sunlight, as shown in FIG. 9, it is recommended to attach a weather-resistant sheet 100 or use a plastic corrugated cardboard pre-coated with a weather-resistant material on its surface.

[0033] Also, as the material of the connecting ridge or connecting member, a material rich in elasticity and excellent in adhesion such as rubber is suitable. However, when using plastic corrugated cardboard having a certain degree of elasticity in the inner panel 12 and the outer panel 13 themselves, as shown in FIG. 7, the connecting ridge can be a connecting ridge 41 made of wood (square timber), or as shown in FIG. 8, the connecting member can be a connecting member 42 made of wood having a shape and size in which two connecting ridges 41 are combined. In this case, it is preferable that the surface of the wood is unpainted.

[0034] In this way, by using wood as the material of the connecting ridge and connecting member, in addition to making it easier to ensure the strength of the connecting part due to the strength of the material itself, when using unpainted wood, the wood swells while absorbing rain moisture on its surface, thereby enhancing the adhesion between members and making it even more excellent in waterproof performance, similar to the case of wooden shipbuilding.

[0035] And, if the panel 10 for the prefabricated house described above is provided and assembled as an exterior wall material or / and a roof material to the frame 2 as shown in FIG. 10 to form a structure with a space inside, a kit for constructing the prefabricated house 1 can be provided, which can meet various needs and can be easily obtained and implemented even by a non-professional in construction, enabling the installation and removal of the prefabricated house in a short time.

[0036] In addition, such a simple prefabricated house 1 that can be easily assembled is expected to be used as a temporary housing for disasters, a temporary villa, etc. In such applications, there are few cases where it can be installed on a flat and leveled place. Therefore, as shown in FIG. 10, while using the steel beam bundle 90 having a jack function, the bottommost part of the frame 2 is adjusted horizontally, and the peg 80 is driven into the ground through the fixing holes opened in the foot plate that is the base part of the steel beam bundle 90, so that it is possible to prevent the displacement and floating of the foot plate.

[0037] However, simply driving the peg 80 downward into the fixing hole of the foot plate is insufficient as an anti-floating and anti-pulling-out effect during strong winds. In addition, even if the height difference between each steel beam bundle 90 can be eliminated by adjustment using the jack function, if the ground on which the foot plate is placed is inclined, it is difficult to stably install and fix with the steel beam bundle 90. In this case, there are also products that provide a slight rocking function at the connection part between the bolt-shaped main shaft and the foot plate and can cope with an inclination of up to about 10 degrees by the rocking, but they cannot cope with a greater inclination. Also, for a foot plate with a small bottom area, when placed on soft ground, there is a problem that it sinks into the ground and the support state becomes unstable.

[0038] Therefore, as shown in FIG. 12(A) and FIG. 12(B) which is a plan view of the lower part from the sole plate 92 thereof, as a member disposed between the sole plate 92 of the steel bundle 90 and the ground, while inserting pegs 80, 80, 80 at positions corresponding to the fixing holes 92a, 92b, 92c of the sole plate 92, a support plate 95 provided with peg holes 95a, 95b, 95c which are oriented to guide the tip ends to open away from each other is used to fix the sole plate 92 with the three pegs 90 in a conically opened state as shown in FIG. (A).

[0039] Thereby, even if the sole plate 92 of the steel bundle 90 has a small area, in addition to the steel bundle 90 being stably supported on the ground by the support plate 95 having a larger area than this, by driving the three pegs 90 into the ground in a conical shape at the peg holes 95a, 95b, 95c, a state where the steel bundle 90 is difficult to come out of the ground can be ensured.

[0040] In this case, if the bottom surface of the support plate 95 is inclined at a predetermined angle with respect to its upper surface as shown in the figure, it becomes easier to cope with the inclination of the ground. For example, if the sole plate 92 of the steel bundle 90 in FIG. 12 swings within a range of 10 degrees, by making the bottom surface of the support plate 95 also inclined by about 10 degrees, it becomes possible to cope with an inclination of up to 20 degrees from the horizontal by the combination thereof.

[0041] FIG. 13 shows a living room 1B for a camping car as another example of a structure using the panel for a structure of the present invention. This living room 1B can be used as a camping car as it is, for example, just by loading it as luggage on the loading platform of a light truck 200 as shown in the figure.

[0042] This living room 1B can be relatively easily assembled while attaching it to a frame made of aluminum corner posts 21, 22, etc., mainly using panels 10D shorter than the panel 10 used in the prefabricated house 1 described above as shown in FIG. 13(A). Just by assembling it and placing it on the loading platform of the light truck 200, the light truck 200 becomes a camping car.

[0043] In this case, it is also possible to partially use the panel 10E for the window using a transparent plastic corrugated board. Also, as shown in the figure, short panels 10D and 10E connected horizontally are configured to have two upper and lower levels, and while arranging the upper peripheral wall portion to cover the outer surface of the lower peripheral wall portion, the upper peripheral wall portion can be fixed at a position of a predetermined height while sliding vertically. During traveling, the living room 1B is lowered as shown in Fig. 13(A) to ensure traveling stability. When arriving at the site and using the living room 1B, as shown in Fig. 13(B), by lifting the upper peripheral wall portion and fixing the position with bolts or the like, a living room space with a high and wide roof can be secured.

[0044] Fig. 14 shows a soundproof room 1C as another example of a structure using the panel for the structure of the present invention in a perspective view. As described above, due to the characteristic part of the present invention in which a frame body is sandwiched between two plastic corrugated boards to form a three-layer structure containing a lot of air, it has excellent internal and external heat insulation functions. The soundproof room 1C of this embodiment is characterized in that it also has excellent soundproof performance due to its three-layer structure. Its structure is assembled by attaching panels 10 and 10F to a skeleton made of aluminum square columns 20 and 23 in the same manner as the prefabricated house 1 described above, and assembly and disassembly can be completed in a short time.

[0045] Fig. 15 shows a cross-sectional view of an example of a joint for connecting aluminum square columns of a structure using the panel for the structure in the above-described embodiment to form a frame. For example, when connecting aluminum square columns with a joint and fixing the connection state using a screw of steel material at its insertion portion, if the screwing operation is performed a plurality of times, it is conceivable that the thread of the screw hole formed on the aluminum square column side is crushed and the fixing force is reduced.

[0046] Therefore, as shown in Fig. 15(A), through holes 455 and 456 with a diameter larger than that of ordinary screw holes are formed in insertion portions 45a and 45b, which are small-diameter portions for inserting the joint into the aluminum square column 24. A spring 450 bent in a Z shape is provided inside, and a locking convex portion 451 and a fixing convex portion 452 are provided. It is preferable to use a joint 45 provided by inserting the locking convex portion 451 through the through hole 455 and the fixing convex portion 452 through the through hole 456.

[0047] In this case, as shown in Fig. 15(A), the locking convex portion 451 provided on the spring 450 protrudes from the tip side of the through hole 455. An inclined surface that becomes lower toward the tip side of the insertion portion 45a is formed on the upper surface of the locking convex portion 451. By inserting the aluminum square column 24 into the insertion portion 45a, the tip hits the inclined surface of the locking convex portion 451 and elastically sinks it, and as shown in Fig. 15(B), the aluminum square column 24 is inserted to the fixed position.

[0048] Then, at the fixed position where the through hole 455 and the through hole 240 are aligned, the locking convex portion 451 protrudes again due to the elastic repulsive force of the spring 450 and locks into the through hole 240, so that the connected state can be fixed. As a result, in addition to making the connection and separation operations between the joint 45 and the aluminum square column 24 extremely easy, the fixing force during connection does not decrease even after performing the connection and separation operations many times.

[0049] As described above, regarding the structure panel that constitutes the outer surface side of the structure, according to the present invention, it is possible to ensure the waterproof performance of the structure without requiring excessive labor and cost, and to be lightweight and excellent in strength.

Explanation of Reference Numerals

[0050] 1 Prefabricated house, 1B Living room, 1C Soundproof room, 2 Frame, 10, 10D, 10E, 10F Panels, 10a, 10b, 10c, 10d Connecting grooves, 11 Frame body, 12 Inner panel, 13 Outer panel, 20, 21, 22, 23, 24 Aluminum corner posts, 25, 35, 45, 46 Screw insertion holes, 30 Nut member, 40, 41 Connecting ridges, 42 Connecting member, 45 Joint, 70 Screw, 100 Weather-resistant sheet, 200 Light truck, 240, 241, 455, 456 Insertion holes, 450 Spring, 451 Locking convex part, 452 Fixed convex part

Claims

1. It is attached to a frame forming the skeleton of a structure and partitions the inner and outer spaces while forming the outer peripheral surface and / or the upper surface of the structure. Connecting grooves are formed longitudinally at intermediate positions in the thickness direction of the upper, lower, left, and right end faces. By inserting and fitting a connecting ridge or a connecting member having a shape that fits into the connecting groove, in a panel for a structure in which the connection between the panel and the frame and / or between the panels is reinforced, the inner panel constituting the inner surface thereof and the outer panel constituting the outer surface thereof are made of rectangular plastic corrugated cardboard, and the outer panel and the inner panel having sizes larger in the vertical and horizontal directions than those are attached and fixed to both the front and back surfaces of a frame body formed by assembling square timbers into a rectangular contour so that the upper, lower, left, and right edges thereof protrude from the upper, lower, left, and right edges of the frame body by a predetermined width. The connecting groove is formed with a groove width that matches the thickness of the frame body. A panel for a structure, characterized in that.

2. At least one of the upper, lower, left, and right end faces of the frame body has screw insertion holes for screw fixation formed by arranging nut members, and is used for screw fixation to reinforce and fix the connection by the connecting ridge or the connecting member. The panel for a structure according to claim 1, characterized in that.

3. It is used as a component constituting the outer wall and / or the roof of a prefabricated house. The panel for a structure according to claim 1 or 2, characterized in that.

4. A prefabricated house formed by attaching and assembling the panel for a structure according to claim 3 to the frame to form a space inside.

5. The connecting ridge and / or the connecting member is made of unpainted wood. The prefabricated house according to claim 4, characterized in that.

6. A structure formed by attaching and assembling the panel for a structure according to claim 1 or 2 to the frame to form a space inside.

7. The connecting ridge and / or the connecting member is made of unpainted wood. The structure according to claim 6, characterized in that.

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