Plate-shaped concrete member, method for manufacturing plate-shaped concrete member, and exterior wall plate

Abstract

To provide a plate-shaped concrete member, a manufacturing method of the plate-shaped concrete member, and an exterior wall plate which can increase variations in exterior finishing.SOLUTION: A plate-shaped concrete member 1 includes: a body plate part 2 in which a fluid material is cured with the lapse of time; and a substrate member 3 in which a recessed part 31 entering the inside of the body plate part 2 from one surface side of the body plate part 2 is fixed by the curing of the body plate part 2 and which serves as a place for fixing a surface plate 4 arranged on the one surface side by a fixing member 5.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a plate-shaped concrete member, a method for manufacturing a plate-shaped concrete member, and an exterior wall panel. [Background technology]

[0002] Patent Document 1 discloses a concrete wall body that includes a concrete wall body and tiles adhered to the surface thereof. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 9-234715 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the concrete wall structure is composed of a concrete wall body and tiles adhered to its surface, which means that the exterior finish is limited to the tiles that can be adhered to the concrete wall body. In addition, other than the tile finish, a painted finish is generally used.

[0005] In view of the above circumstances, an object of the present invention is to provide a plate-shaped concrete member, a method for manufacturing a plate-shaped concrete member, and an exterior wall panel that enable a wide variety of exterior finishes to be achieved. [Means for solving the problem]

[0006] In order to solve the above problems, the plate-shaped concrete member according to the present invention comprises a main plate portion in which a fluid material has hardened over time; The present invention is characterized by comprising a base member in which a concave portion extending from one side of the main body plate portion into the interior of the main body plate portion is fixed by the hardening of the main body plate portion, and which serves as a location for fixing the surface plate placed on the one side of the main body plate portion with a fixing member.

[0007] With the above configuration, the surface panel can be fixed to the base member using the fixing member, thereby allowing the exterior finishing of the plate-shaped concrete member to be carried out, and since various materials such as wood, resin, steel, etc. can be used for the surface panel, a wide variety of exterior finishes can be achieved.

[0008] The base member may have a flat plate portion that contacts the one surface and protrudes from the recessed portion. This allows the base member to be stably placed with the flat plate portion facing downwards on the bottom side of the formwork for the plate-shaped concrete member, making it easier to manufacture the plate-shaped concrete member.

[0009] The recessed portion may have a groove shape that is wider at its innermost portion than at its opening portion, thereby enabling the recessed portion to be firmly fixed to the main body plate portion.

[0010] The recess may contain a wood or resin member into which the fixing member fits, thereby allowing the surface panel to be fixed to the base member by the fixing member even if the fixing member does not penetrate the recess.

[0011] A wooden or resin member into which the fixing member fits may be embedded inside the main body plate portion on the back side of the portion of the recess into which the fixing member fits. In this way, the fixing member penetrates the recess and fits into the wooden or resin member, thereby increasing the pull-out resistance of the fixing member.

[0012] A burring portion that protrudes into the interior of the main body plate portion in a generally cylindrical shape and into which the threaded portion of the fixing member is screwed may be formed at a location of the recessed portion where the fixing member fits. In this way, the burring portion can increase the fixing force of the main body plate portion to the recessed portion, and the threaded portion of the fixing member can be screwed into the burring portion, thereby increasing the pull-out resistance of the fixing member.

[0013] A nut portion may be fixed to the back side of the recessed portion at a location where the fixing member is screwed. In this way, the fixing member is screwed onto the nut portion, thereby increasing the pull-out resistance of the fixing member.

[0014] The present invention also provides an exterior wall panel using any of the above-mentioned plate-shaped concrete members, characterized in that a ventilation layer is formed between the surface panel and the one side, allowing water and moisture to be discharged to the outside through the ventilation layer.

[0015] The present invention also provides an exterior wall panel using any of the above-mentioned plate-shaped concrete members, characterized in that a heat insulating material is provided between the surface panel and the one surface, thereby easily realizing an external heat insulating structure.

[0016] In addition, the method for manufacturing a plate-shaped concrete member of the present invention is characterized by including the steps of placing the base member at the bottom of the formwork so that the opening side of the concave portion faces the bottom, and pouring a fluid material that will become the main plate portion into the formwork.

[0017] The manufacturing method may include a step of applying a release agent to at least the area where the base member is not disposed, whereby the flowable material exposed in the area where the base member is not disposed is appropriately released after hardening. [Effects of the Invention]

[0018] The plate-shaped concrete member of the present invention can be made of a variety of materials, such as wood, resin, and steel, as the surface panel that forms the exterior finish of the plate-shaped concrete member, thereby achieving the effect of increasing the variety of exterior finishes. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is an explanatory diagram showing a plate-shaped concrete member of an embodiment and a precast exterior wall panel produced by attaching a surface panel to this plate-shaped concrete member. FIG. [Figure 2] FIG. 2 is a schematic, partially enlarged, vertical cross-sectional view of the precast exterior wall panel shown in FIG. [Figure 3] 2 is an explanatory view showing a method for manufacturing the plate-shaped concrete member shown in FIG. 1 and a formwork. FIG. [Figure 4] 2 is a front view of a plate-shaped concrete member having a base member in a form different from that of the plate-shaped concrete member shown in FIG. 1. FIG. [Figure 5] FIG. 10 is a schematic, partially enlarged, vertical cross-sectional view of a precast exterior wall panel according to a modified example in which a wooden member is provided on the back side of a base member. [Figure 6] FIG. 10 is a schematic, partially enlarged, vertical cross-sectional view of a precast exterior wall panel according to a modified example in which the base member has a burring portion. [Figure 7] FIG. 10 is a schematic, partially enlarged, vertical cross-sectional view of a precast exterior wall panel according to a modified example, which has nuts on the back side of the base member. [Figure 8] FIG. 10 is a partial enlarged schematic vertical cross-sectional view of a precast exterior wall panel according to a modified example in which the recessed portion of the base member is T-groove-shaped. [Figure 9] FIG. 9 is a schematic, partially enlarged, vertical cross-sectional view of a precast exterior wall panel according to a modified example in which a wooden member is provided in a recessed portion of the base member shown in FIG. 8. [Figure 10] FIG. 10 is a partial enlarged schematic vertical cross-sectional view of a modified precast exterior wall panel in which a ventilation layer is formed between the surface panel and the main panel portion. [Figure 11] 10 is an explanatory diagram showing a base member in which a ventilation layer is formed between the surface plate and the main plate portion, and the bending process thereof. FIG. [Figure 12] FIG. 10 is a partial enlarged schematic vertical cross-sectional view of a modified precast exterior wall panel in which an insulating material is provided between the surface panel and the main panel portion. DETAILED DESCRIPTION OF THE INVENTION

[0020] An embodiment of the present invention will now be described with reference to the accompanying drawings. As shown in Figure 1, a plate-shaped concrete member 1 of this embodiment comprises a main body plate 2 and a plurality of base members 3 provided on one side of the main body plate 2. A surface plate 4 is provided on the plate-shaped concrete member 1 to produce a precast exterior wall panel 10.

[0021] The main body plate 2 is made of a fluid material containing aggregates (coarse aggregates, fine aggregates), hardening materials (cement, etc.), and water that hardens over time. The thickness of the main body plate 2 is, for example, about 100 mm. Reinforcing bars 2a (see Figure 3) are arranged in a mesh pattern within the main body plate 2.

[0022] 2, the base member 3 is made of a metal plate formed by bending, for example, with a recessed portion 31 and two flat plate portions 32 that protrude from both edges of the recessed portion 31 and contact the one surface of the main body plate portion 2. The base member 3 has, for example, a length that is approximately the same as the width of the main body plate portion 2, and is arranged at a predetermined interval in the vertical direction with the recessed portions 31 extending horizontally.

[0023] The recessed portion 31 extends into the interior of the main body plate 2 from the one surface side of the main body plate 2, and is fixed to the main body plate 2 as the fluid material hardens. The recessed portion 31 is the location where the surface plate 4, which is placed on the one surface side, is fixed by the fixing member 5. The recessed portion 31 has a generally trapezoidal dovetail shape in which the space is wider at the back side than at the opening side of the recessed portion 31, for example.

[0024] The surface panel 4 is made of wood, resin, steel, etc. In the illustrated example, the surface panel 4 is made by arranging multiple vertically long wooden pieces horizontally, and screws as fixing members 5 are driven into the front side of each wooden piece at the intersections between each wooden piece and each recessed portion 31, with the tips of these screws penetrating the metal plate portion of each recessed portion 31 and reaching the inside of the main body plate portion 2.

[0025] With a plate-shaped concrete member 1 having the above-described configuration, the surface panel 4 can be fixed to the base member 3 with the fixing member 5, thereby enabling the exterior finishing of the plate-shaped concrete member 1. Since various materials such as wood, resin, and steel can be used for the surface panel 4, a wide variety of exterior finishes can be achieved.

[0026] If the base member 3 has a flat plate portion 32 that contacts the one surface, the base member 3 can be stably placed on the bottom side of the formwork 6 (described later) with this flat plate portion 32 facing downwards, facilitating the production of the plate-shaped concrete member 1. Note that it is also possible to use a base member that does not have a flat plate portion 32.

[0027] Furthermore, if the recessed portion 31 has a groove-like shape that is wider at the back side than at the opening side of the recessed portion 31, the fixing strength of the recessed portion 31 by the main body plate portion 2 can be increased. In other words, the deterrent force against the base member 3 falling off from the main body plate portion 2 can be increased. Note that it is also possible to use a base member that does not have a groove-like shape that is wider at the back side as described above.

[0028] Next, we will explain the method for manufacturing the plate-shaped concrete member 1. As shown in Figure 3, a release agent is applied to the entire bottom surface of a formwork 6, which has an inner surface shape that matches the outer shape of a precast exterior wall panel or the like, and base members 3 are placed at predetermined intervals so that the openings of the recesses 31 face the bottom. Furthermore, the reinforcing bars 2a are placed so that they float above the base members 3. Note that the base members 3 are placed with the flat plate portions 32 facing downwards, allowing for stable placement of the base members 3, as described above.

[0029] Next, ready-mixed concrete (fluid material) containing coarse aggregate and fine aggregate that will become the main plate portion 2 is poured into the formwork 6, and the ready-mixed concrete is cured to harden, thereby producing the plate-shaped concrete member 1.

[0030] In this manufacturing method, a release agent is applied to the bottom side of the formwork 6, and the fluid material exposed in areas where the base member 3 is not placed is properly released after hardening. Note that the base member 3 may be attached to the bottom side of the formwork 6 with double-sided tape or the like to prevent the base member 3 from shifting when the ready-mixed concrete is poured.

[0031] The face plate 4 may be attached to the plate-shaped concrete member 1 in a factory, or may be attached to the plate-shaped concrete member 1 at the construction site. When attaching the face plate 4 to the plate-shaped concrete member 1 at the construction site, the face plate 4 can be positioned at the joint between adjacent plate-shaped concrete members 1, making the joint less noticeable. In addition, both in the factory and on the construction site, the tolerance for deviation in the fixing position of the fixing member 5 on the base member 3 can be widened, making it easier to align the face plate 4.

[0032] In the plate-shaped concrete member 1, the base member 3 has the concave portions 31 extending horizontally and arranged at a predetermined interval in the vertical direction, but this is not limited to this, and the base member 3 may have the concave portions 31 extending vertically and arranged at a predetermined interval in the horizontal direction.

[0033] Furthermore, in the plate-shaped concrete member 1, the base member 3 has a length approximately equal to the width of the main plate portion 2, but this is not limited to this. As shown in Figure 4, base members 3 with a short width may be provided in a scattered arrangement (for example, a staggered pattern). When using base members 3 with a short width, it is preferable to place plate materials on both sides of the base member 3 as lids to prevent the above-mentioned fluid material from entering.

[0034] 5, a wooden member 33 into which the fixing member 5 is driven may be embedded inside the main body plate 2 on the back side of the portion of the recess 31 where the fixing member 5 is driven. In this way, the fixing member 5 penetrates the metal plate portion of the recess 31 and is driven into the wooden member 33, thereby increasing the pull-out resistance of the fixing member 5. In manufacturing the plate-shaped concrete member 1, the wooden member 33 adhered to the back side of the portion of the recess 31 where the fixing member 5 is driven may be placed on the bottom side within the formwork 6. Instead of the wooden member 33, a resin member may also be used.

[0035] 6, the base member 3 may have a burring portion 31a at the location of the recessed portion 31 where the fixing member 5 is driven, which protrudes into the interior of the main body plate portion 2 in a generally cylindrical shape and into which the threaded portion of the fixing member 5 is screwed. In this way, the burring portion 31a can increase the fixing strength of the recessed portion 31 by the main body plate portion 2, and the threaded portion of the fixing member 5 is screwed into the burring portion 31a, thereby increasing the pull-out resistance of the fixing member 5.

[0036] 7, the base member 3 may have a nut portion 36 fixed to the back side of the recessed portion 31 into which the fixing member 5 (bolt) is screwed. In this way, the fixing member 5 is screwed into the nut portion 36, thereby increasing the pull-out resistance of the fixing member 5.

[0037] Furthermore, in the above example, the spatial shape of the recessed portion 31 was a generally trapezoidal dovetail groove shape in which the innermost portion was wider than the opening portion of the recessed portion 31, but this is not limited thereto, and the spatial shape of the recessed portion 31 may also be a T-shaped T-groove shape as shown in Figure 8.

[0038] 9, a wooden member 35 having a rectangular cross section or the like into which a fixing member 5 is driven may be accommodated within the space of the recessed portion 31. In this case, the surface panel 4 can be fixed to the base member 3 by the fixing member 5 even if the fixing member 5 does not penetrate the metal plate portion of the recessed portion 31. When using the above-mentioned short-width base member 3, if the wooden member 35 is embedded in advance, this wooden member 35 can replace the plate material that serves as the lid. The wooden member 35 can also be accommodated in a recessed portion 31 with a dovetail groove shape. A resin member can also be used instead of the wooden member 35.

[0039] As shown in FIG. 10, the precast exterior wall panel 10 may have a ventilation layer 1a formed between the surface panel 4 and one of the surfaces of the main panel 2. This allows water and moisture to be discharged to the outside through the ventilation layer 1a. A base member 3A may be used to create a structure with the ventilation layer 1a. This base member 3A supports the surface panel 4 with protruding portions 37 protruding from each flat plate portion 32 of the base member 3, thereby forming the ventilation layer 1a between the surface panel 4 and the main panel 2. Note that the protruding portions 37 are not long enough to span the entire width of the plate-shaped concrete member 1, but are short, and the space between adjacent protruding portions 37 forms a vertical space.

[0040] In producing the plate-shaped concrete member 1 using the base member 3A, for example, after producing the plate-shaped concrete member 1 shown in FIG. 1, a substantially Z-shaped member that will become the protrusion 37 is fixed with a screw 37a.

[0041] Alternatively, the base member 3A may be formed from one portion of each flat plate portion 32 itself. For example, as shown in Fig. 11, two notches 37b are formed at a distance from each other in each flat plate portion 32, and after the flowable material is poured and the main plate portion 2 hardens, the portion of each flat plate portion 32 between the two notches 37b is separated from the main plate portion 2 and bent to form the protrusion 37. It is desirable to provide, for example, a release sheet at the location of the portion of the portion that is separated from the main plate portion 2.

[0042] 12, the precast exterior wall panel 10 may have a heat insulating material 1b between the surface panel 4 and the one surface of the main panel 2. This allows for relatively easy construction of the external heat insulation structure. The heat insulating material 1b may be pre-attached to the plate-shaped concrete member 1 at a factory, or may be pre-attached to the surface panel 4. Alternatively, the heat insulating material 1b may be attached during on-site construction. In addition, when the surface panel 4 is configured to consist of multiple vertically elongated members, the heat insulating material 1b is not attached individually to each vertically elongated member of the surface panel 4, but is sized to cover the entire one surface of the plate-shaped concrete member 1.

[0043] Furthermore, in the above examples, the fixing members were fastening members such as screws and bolts, but this is not limited to this. For example, the fixing member may be an engaging member having a head that engages with a U-cut portion formed in the base member 3, or it may be an adhesive fixing member that fits into a hole formed in the wooden member 35 and is adhered with adhesive.

[0044] Although the embodiments of the present invention have been described above with reference to the drawings, the present invention is not limited to the illustrated embodiments. Various modifications and variations can be made to the illustrated embodiments within the same scope as the present invention or within an equivalent scope. [Explanation of symbols]

[0045] 1: Plate-shaped concrete member 1a: Ventilation layer 1b: Insulation material 2: Main body plate (fluid material) 2a: Reinforced concrete 3: Base material 3A: Base material 4: Surface plate 5: Fixing member 6: Formwork 10: Precast exterior wall board (exterior wall board) 31: Concave part 31a: Burring section 32: Flat plate part 33:Wooden materials 35:Wooden materials 36: Nut part 37: Protruding part 37a: Bis 37b: Cut

Claims

1. a main body plate portion in which the fluid material has hardened over time; A plate-shaped concrete member characterized by comprising a base member in which a concave portion extending from one side of the main plate portion into the interior of the main plate portion is fixed by the hardening of the main plate portion, and which serves as a point to fix a surface plate placed on the one side of the main plate portion using a fixing member.

2. 2. The plate-shaped concrete member according to claim 1, wherein the base member has a flat plate portion extending from the recessed portion and positioned in contact with the one surface.

3. 2. The plate-shaped concrete member according to claim 1, wherein the recessed portion has a groove-like shape that is wider at its innermost portion than at its open end.

4. 2. The plate-shaped concrete member according to claim 1, wherein the recessed portion accommodates a wooden or resinous member into which the fixing member is inserted.

5. 2. The plate-shaped concrete member according to claim 1, wherein a wooden or resin member into which the fixing member fits is embedded inside the main body plate portion on the back side of the portion into which the fixing member fits in the recessed portion.

6. 2. The plate-shaped concrete member according to claim 1, characterized in that a burring portion is formed at the location of the recessed portion where the fixing member is inserted, which protrudes approximately cylindrically toward the inside of the main plate portion and into which the threaded portion of the fixing member is screwed.

7. 2. The plate-shaped concrete member according to claim 1, wherein a nut portion is fixed to the back side of the recessed portion at the location where the fixing member is screwed.

8. An exterior wall board using the plate-shaped concrete member according to any one of claims 1 to 7, wherein an air-permeable layer is formed between the surface board and the one surface.

9. An exterior wall board using the plate-shaped concrete member according to any one of claims 1 to 7, characterized in that a heat insulating material is provided between the surface board and the one surface.

10. A method for manufacturing a plate-shaped concrete member as described in any one of claims 1 to 7, characterized in that it includes the steps of: placing the base member at the bottom of the formwork so that the opening side of the concave portion faces the bottom; and pouring a fluid material that will become the main plate portion into the formwork.

11. 11. The method for manufacturing a plate-shaped concrete member according to claim 10, further comprising the step of applying a release agent at least to areas where the base member is not placed.

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