Sealant leveling tool and sealing device

Abstract

To perform the work of filling a sealant into joints of an exterior wall with a simpler configuration.SOLUTION: The sealant leveling tool includes a support member extending in a first direction and a leveling member supported by the support member and extending in the first direction. The support member is formed of a first support member and a second support member divided into left and right halves with respect to a central axis along the first direction. The first support member and the second support member each have a first surface and a second surface that face each other. A leveling member is provided on each of the second surfaces of the first support member and the second support member, and the width of the leveling member increases as the first support member and the second support member open left and right.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a sealant leveling tool and a sealing device for filling sealant into joints in the exterior walls of a building. [Background technology]

[0002] When an exterior wall is constructed using multiple exterior wall panels, waterproofing sealants are applied to the joints formed between the panels. Manually filling the sealant requires the erection of scaffolding on the exterior wall or the hanging of a gondola. Furthermore, to prevent the sealant from adhering to the exterior wall panels, it is necessary to apply masking tape around the joints and smooth the surface of the applied sealant with a spatula (see Patent Documents 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-28450 [Patent Document 2] Japanese Patent Application Publication No. 2018-70822 Summary of the Invention [Problem to be solved by the invention]

[0004] However, this method requires applying masking tape around the joints, smoothing the surface of the sealant with a spatula, and then peeling off the masking tape, which increases the number of steps. Furthermore, smoothing the sealant with a spatula to make the surface smooth requires the skill of the installer.

[0005] The present invention has been made in consideration of such problems, and one of its objects is to provide a simpler configuration for filling the joints of an exterior wall with a sealant. [Means for solving the problem]

[0006] A sealant leveling device according to one embodiment of the present invention has a support member extending in a first direction, and a leveling member supported by the support member and extending in the first direction, the support member being composed of a first support member and a second support member divided into left and right halves with respect to a central axis along the first direction, the first support member and the second support member each having a first surface and a second surface facing each other, and a leveling member is provided on the second surface of the first support member and the second support member, and the width of the leveling member increases as the first support member and the second support member open left and right.

[0007] In the above sealant leveling tool, the first surface of the first support member and the first surface of the second support member may be disposed so as to face each other.

[0008] In the above sealant leveling tool, the first support member and the second support member may be configured to rotate about the tip of the first surface and open in the left and right directions.

[0009] In the above-described sealant leveling tool, the first support member and the second support member may be extended in the left-right direction so that the width of the leveling member is increased.

[0010] The above-described sealant leveling tool may further include a coating layer covering the first support member, the second support member, and the leveling member.

[0011] In the above sealant leveling tool, the first support member and the second support member may have an I-shape or an L-shape when viewed from the first direction.

[0012] In the above-described sealant leveling tool, the first support member and the second support member may have tapered surfaces on the outsides of the corners of the L-shape.

[0013] In the above sealant leveling tool, the support member may be divided into at least two parts along a second direction perpendicular to the first direction.

[0014] In the above-described sealant leveling tool, the support member and the leveling member may have through holes that pass through in a third direction that is perpendicular to the first direction and the second direction.

[0015] A sealing device according to one embodiment of the present invention includes the above-described sealant leveling tool. [Effects of the Invention]

[0016] According to one embodiment of the present invention, the task of filling the joints of an exterior wall with a sealant can be performed with a simpler configuration. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a perspective view showing a sealant leveling tool according to an embodiment of the present invention. FIG. [Figure 2] 1A is a perspective view illustrating the shape of a support member, and FIG. 1B is a perspective view illustrating the shapes of a first backer material and a second backer material that constitute a leveling member. [Figure 3] 1A and 1B are end views of a ceiling leveling tool as viewed from a first direction; [Figure 4] 1A is a plan view showing a method for forming a sealant using a sealant leveling tool according to an embodiment of the present invention, and FIG. 1B is a side view showing a method for forming a sealant using a sealant leveling tool according to the present invention. [Figure 5] 1 is a diagram showing an overview of a sealing device according to an embodiment of the present invention; [Figure 6] 1 is a front view showing the configuration of a sealing device according to an embodiment of the present invention. [Figure 7] 1 is a side view showing the configuration of a sealing device according to an embodiment of the present invention. [Figure 8] 2 is a perspective view showing the structure of a sealant filling unit in a sealing device according to one embodiment of the present invention; FIG. [Figure 9] 1 is a diagram showing the configuration of a sealing gun in a sealing device according to the present invention; [Figure 10] FIG. 1 is an isometric view of a sealant leveling tool and drive mechanism according to one embodiment of the present invention. [Figure 11] FIG. 2 is a side view of a sealant leveling tool and a drive mechanism according to an embodiment of the present invention. [Figure 12] FIG. 2 is a front view of a sealant leveling tool and a drive mechanism according to an embodiment of the present invention. [Figure 13] FIG. 2 is a top view of a sealant leveling tool and drive mechanism according to an embodiment of the present invention. [Figure 14] FIG. 2 is an enlarged view of a sealant leveling tool according to an embodiment of the present invention. [Figure 15] 10A and 10B are diagrams illustrating the relationship between an exterior wall panel and a joint and the configuration of a guide provided in the sealing device according to the present invention. [Figure 16] FIG. 4 is a cross-sectional view illustrating the configuration of a first guide. [Figure 17] 1A and 1B are side views showing a sealant leveling tool according to an embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the present invention can be implemented in many different forms, and should not be construed as being limited to the description of the embodiments exemplified below. In order to clarify the explanation, the drawings may show the width, thickness, shape, etc. of each part schematically compared to the actual form, but these are merely examples and do not limit the interpretation of the present invention. Furthermore, in this specification and each figure, elements similar to those previously described with reference to the previous figures are given the same reference numerals (or reference numerals with A, B, etc. suffixed thereto), and detailed explanations may be omitted as appropriate. Furthermore, the letters "first" and "second" attached to each element are convenient labels used to distinguish each element, and have no further meaning unless otherwise specified. In this specification and each figure, elements using the same material may be used as a reference numeral. Multiple elements may be distinguished and listed as "-1" and "-2".

[0019] 1.Sealant leveling tool FIG. 1 is a perspective view showing a sealant leveling tool 1062 according to this embodiment. The sealant leveling tool 1062 is used in the construction of filling sealant into the joints (hereinafter, unless otherwise specified, this refers to "vertical joints") between exterior wall panels when forming an exterior wall using multiple exterior wall panels. A highly viscous liquid sealant is filled into the joints of the exterior wall panels, and the sealant is leveled and hardened using the sealant leveling tool 1062 inserted into the joint, thereby flattening the surface of the sealant filled into the joint. In FIG. 1, the direction in which the sealant leveling tool 1062 extends is referred to as a first direction D1, the width direction of the sealant leveling tool 1062 is referred to as a second direction D2, and the height (thickness) direction of the sealant leveling tool 1062 is referred to as a third direction D3.

[0020] The sealant leveling device 1062 has support members 10622-1 and 10622-2 extending in the first direction D1, and a leveling member 10627 supported by the support members 10622-1 and 10622-2 and extending in the first direction D1.

[0021] The support members 10622-1 and 10622-2 are divided into left and right halves with respect to a central axis along the first direction D1. When the support members 10622-1 and 10622-2 are viewed from the first direction D1, their end faces have an L-shape or an I-shape. An L-shape is a shape having a portion extending in the second direction D2 and a portion extending in the third direction D3 when the support members 10622-1 and 10622-2 are viewed from the first direction D1. An I-shape is a shape having a portion extending in the third direction D3 when the support members 10622-1 and 10622-2 are viewed from the first direction D1. In FIG. 1, the end faces of the support members 10622-1 and 10622-2 are L-shaped when viewed from the first direction D1. The support members 10622-1 and 10622-2 each have a first surface and a second surface that face each other. The first surface of the support member 10622-1 and the first surface of the support member 10622-2 are arranged to face each other. In other words, the support members 10622-1 and 10622-2 are arranged with their L-shapes back to back.

[0022] The leveling member 10627 is supported by support members 10622-1 and 10622-2 and extends in the first direction D1. The leveling member 10627 includes a pair of first backer materials 10623-1 and 10623-2 arranged to sandwich the support members 10622-1 and 10622-2, and a pair of second backer materials 10624-1 and 10624-2 arranged to sandwich the first backer materials 10623-1 and 10623-2. The first backer materials 10623-1 and 10623-2 may be in direct contact with the second backer materials 10624-1 and 10624-2, or may be in contact with each other via an adhesive.

[0023] The support members 10622-1, 10622-2 and the leveling member 10627 may be covered with a coating layer 10626. In FIG. 1, the end surface of the leveling member 10627 is not covered with the coating layer 10626, but the end surface of the leveling member 10627 may be covered with the coating layer 10626.

[0024] The sealant leveling tool 1062 is also provided with a through hole 10628 that penetrates the support members 10622-1 and 10622-2 and the first backer materials 10623-1 and 10623-2. The through hole 10628 is provided to penetrate at least the support members 10622-1 and 10622-2 and the leveling member 10627 along the third direction D3. In FIG. 1, the through hole 10628 is formed to penetrate the coating layer 10626, the support members 10622-1 and 10622-2, and the first backer materials 10623-1 and 10623-2 along the third direction D3.

[0025] The support member 10621 may include a flat plate 10625 located adjacent to the through hole 10628 and on the opposite side to the first direction D1. The flat plate 10625 is provided in a region from the through hole 10628 to one end of the leveling member 10627. Although FIG. 1 shows an example in which the flat plate 10625 is provided below the coating layer 10626, the flat plate 10625 may be provided above the coating layer 10626.

[0026] The sealant leveling device 1062 can widen the width of the leveling member 10627 by opening the support members 10622-1 and 10622-2 in the second direction D2 (left and right direction).

[0027] FIG. 2(A) is a perspective view illustrating the shapes of the support members 10622-1 and 10622-2. The support members 10622-1 and 10622-2 are divided into at least two pieces along the second direction D2. FIG. 2(A) shows an example in which the support members 10622-1 and 10622-2 are divided into three pieces, but they may be divided into four or more pieces. In FIG. 2, the support member 10622-1 divided into three pieces is referred to as support members 10622-11 to 10622-13, respectively. The support member 10622-2 divided into three pieces is referred to as support members 10622-21 to 10622-23, respectively. The support members 10622-1 and 10622-2 divided into three pieces are referred to as a pair of support members 10621-1 to 10621-3.

[0028] The pair of support members 10621-1 to 10621-3 are connected to each other by hinges 10629-1 to 10629-3, respectively. For example, the tip of the first surface 10622-11a of the support member 10622-1 and the tip of the first surface 10622-21a of the support member 10622-2 can rotate around the center of rotation to open left and right, thereby widening the width of the leveling member 10627. This allows the pair of support members 10621-1 to 10621-3 to open left and right to different widths. In other words, only the pair of support members 10621-1, the support members 10622-11 and 10622-21, can open left and right, while the pair of support members 10621-2 and 10621-3 can remain closed. In this way, the width of the sealant leveling device 1062 can be varied depending on the region. Therefore, even if there are areas with different joint 202 widths in the joints 202 of the exterior wall panels, leakage of the sealant can be suppressed.

[0029] Although not shown, it is preferable to provide a through hole 10628 at the boundary between the pair of support members 10621-1 and the pair of support members 10621-2. Furthermore, if a flat plate 10625 is provided, it is preferable to provide it on the pair of support members 10621-2 and 10621-3.

[0030] FIG. 2(B) is a perspective view illustrating the shapes of first backer materials 10623-1 and 10623-2 and second backer materials 10624-1 and 10624-2 that constitute the leveling member 10627. The leveling member 10627 extends in the first direction D1. The leveling member 10627 is arranged to sandwich a pair of support members 10621-1 to 10621-3, which are divided into three pieces. Specifically, the first backer material 10623-1 is provided on the second surface side of the support members 10622-11 to 10622-13. Furthermore, the first backer material 10623-2 is provided on the second surface side of the support members 10622-21 to 10622-23. The second backer materials 10624-1 and 10624-2 extend in the first direction D1. Specifically, a second backer material 10624-1 is provided on a first backer material 10623-1, and a second backer material 10624-2 is provided on a first backer material 10623-2.

[0031] The pair of support members 10621 is divided into three pieces, but by arranging the first backer material 10623-1, 10623-2 and the second backer material 10624-1, 10624-2 across the three pairs of support members, it is possible to prevent the sealing material ejected from the through hole 10628 from leaking out from the gaps between the three pairs of support members 10621-1 to 10621-3.

[0032] Not only the pair of support members 10621-1, 10621-2, but also the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 may be divided into at least two pieces along the second direction D2. In this case, the number of pieces into which the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 are divided is the same as the number of pieces into which the pair of support members 10621 are divided. Also, the flat plate 10625 and the coating layer 10626 are not divided but are integrally formed. Alternatively, the pair of support members 10621-1, 10621-2 and the first backer materials 10623-1, 10623-2 may be divided into at least two pieces along the second direction D2. In this case, the number of divisions of the first backer materials 10623-1 and 10623-2 is the same as the number of divisions of the pair of support members 10621. In addition, the second backer materials 10624-1 and 10624-2, the flat plate 10625, and the coating layer 10626 are not divided but are configured as a single unit.

[0033] 1-1. Opening and closing mechanism of ceiling leveling device 1 Next, a mechanism for partially opening and closing the sealant leveling device 1062 will be described with reference to FIGS. 3(A) and 3(B). FIGS. 3(A) and 3(B) are end views of the sealant leveling device 1062 as viewed from the first direction D1. As shown in FIGS. 3(A) and 3(B), the support members 10622-11 and 10622-21 can be opened left and right by inserting an opening / closing member 10630 between the first surface of the support member 10622-11 and the first surface of the support member 10622-21. In FIGS. 3(A) and 3(B), an actuator is shown as the opening / closing member 10630.

[0034] The support members 10622-1 and 10622-2 are L-shaped, with the outer corners of the L-shape being chamfered. In Figures 3(A) and 3(B), the corners of the L-shape of the support member 10622-1 have tapered surfaces 10622-1c. The corners of the L-shape of the support member 10622-2 have tapered surfaces 10622-2c. Note that the outer corners of the L-shapes of the support members 10622-1 and 10622-2 are not limited to being tapered surfaces 10622-2c, and the outer corners of the L-shapes may be rounded. Furthermore, even if the support members 10622-1 and 10622-2 are I-shaped, the corners on the side where the first surface 10622-1 of the support member 10622-1 and the surface 10622-21a of the support member 10622-2 face each other may be chamfered, may have a tapered surface 10622-2c, or may be rounded, which makes it easier to insert the opening / closing member 10630 between the first surface 10622-11a of the support member 10622-1 and the first surface 10622-21a of the support member 10622-2.

[0035] When the support member 10622-1 and the support member 10622-2 are divided into at least two pieces along the second direction D2, it is preferable that the outer corners of the L-shape of each of the divided support members 10622-1 and 10622-2 are chamfered. Also, the outer corners of the L-shape of the support member 10622-1 and the support member 10622-2 may be chamfered along the first direction D1, or only the portion where the opening / closing member 10630 is inserted may be chamfered.

[0036] It is preferable that the opening / closing member 10630 has three pairs of support members 10621-1 to 10623-3 divided into three along the second direction D2 so that each pair can be opened and closed left and right. In other words, the number of divided pairs of support members 10621 is the same as the number of opening / closing members 10630.

[0037] 1-2. Method of forming sealant Next, a method for applying a sealant to a joint using the sealant leveling tool 1062 will be described. FIG. 4 is a diagram showing a method for applying a sealant using the sealant leveling tool 1062 according to the present invention. As shown in FIG. 4(A), when the first exterior wall panel 201A1 and the first exterior wall panel 201A2 are attached, a joint 202A is formed with a predetermined width. When the second exterior wall panel 201B1 and the second exterior wall panel 201B2 are attached on top of this, a joint 202B is formed with a predetermined width. In FIG. 4, the direction of travel of the sealant leveling tool 1062 is the first direction D1.

[0038] 4(A), the width of joint 202A between first exterior wall panel 201A1 and first exterior wall panel 201A2 is larger than the width of joint 202B between second exterior wall panel 201B1 and second exterior wall panel 201B2. If the width of joint 202A between first exterior wall panel 201A1 and first exterior wall panel 201A2 is larger than the width of the sealant leveling tool, there is a risk of sealant leaking from the gap between the sealant leveling tool and the exterior wall panel.

[0039] In a sealant leveling tool 1062 according to one embodiment of the present invention, a pair of support members 10621 open and close left and right in a direction perpendicular to the traveling direction of the sealant leveling tool 1062. Furthermore, by dividing the pair of support members 10621 into at least two pieces along the second direction D2, the pair of support members 10621 can be partially opened and closed. FIG. 4(A) shows an example in which the pair of support members 10621 are divided into two pieces along the second direction D2 near where the through-hole 10628 of the sealant leveling tool 1062 is provided. Furthermore, FIG. 4(A) shows the position where an opening / closing member 10630-1 is inserted to open and close one of the pair of support members 10621 divided into two along the second direction D2, and the position where an opening / closing member 10630-2 is inserted to open and close the other.

[0040] FIG. 4(B) shows a state in which a sealant leveling tool 1062 is fixed to a fixing member 10641 provided in a sealing device, which will be described in detail later. A backup material 204 is provided at the bottom of the joint 202. A bond breaker may be used as a tape-like material attached to the bottom of the joint 202 instead of the backup material 204. As shown in FIG. 4(B), a leveling member 10627 is inserted into the joint 202 to a predetermined depth. At this time, the leveling member 10627 is inserted so that there is a gap between the backup material 204 and the leveling member 10627. In addition, the sealant leveling tool 1062 is positioned so that the flat plate 10625 is located on the opposite side of the first direction D1 when the leveling member 10627 is inserted. A nozzle 10612 for supplying sealant is inserted into the through-hole 10628. The sealant 206 is discharged from the discharge port 10615 of the nozzle 10612 of the sealing device, which will be described later. The sealant 206 discharged from the discharge port 10615 fills the gap between the backup material 204 and the leveling member 10627. When the leveling member 10627 is moved in the first direction D1 along the joint 202 while the sealant 206 is being discharged from the discharge port 10615, the sealant 206 is leveled by the flat plate 10625, and the surface of the sealant 206 can be made smooth. The width of the sealant 206 is determined by the width of the leveling member 10627 formed by the pair of support members 10621, first backer materials 10623-1 and 10623-2, and second backer materials 10624-1 and 10624-2.

[0041] The sealing device is also provided with a joint width sensor. The joint width sensor 115 is an optical sensor and has the function of detecting the width of the joint 202. The pair of support members 10621 can be opened and closed left and right by moving the opening / closing members 10630-1 and 10630-2 inserted through openings in the fixing member 10641 along the third direction in accordance with the width of the joint 202 detected by the joint width sensor. As shown in FIG. 4(A), when the width of the joint 202B is narrow, the opening / closing member 10630-2 is inserted shallowly between the pair of support members, or the opening / closing member 10630-2 does not need to be inserted at all. When the width of the joint 202A is wide, the opening / closing member 10630-1 is inserted deeply between the pair of support members 10621. If the width of joint 202A is larger than the width of the sealant leveling tool, the width of sealant leveling tool 1062 can be increased by inserting opening / closing member 10632-2 into the other of the pair of divided support members 10621. This allows the width of each of the pair of divided support members 10621 to be changed even if the width of joint 202 varies, thereby preventing a gap from forming between sealant leveling tool 1062 and the joint. This prevents sealant from leaking from the gap between sealant leveling tool 1062 and the exterior wall panel.

[0042] 1-3. Materials for sealant leveling tools Next, the materials of each component that constitutes the sealant leveling tool 1062 will be described.

[0043] The support members 10622-1 and 10622-2 are formed of resin, such as polycarbonate, polyamide (Nylon (registered trademark)), polyvinyl chloride, polypropylene, or ABS resin. The support members 10622-1 and 10622-2 may be formed of metal, such as iron or aluminum. The hardness of the support members 10622-1 and 10622-2 is preferably harder than the first backer materials 10623-1 and 10623-2 and the second backer materials 10624-1 and 10624-2. The hardness of the support members 10622-1 and 10622-2 is preferably about 120 in Rockwell hardness (HRR). Alternatively, when the support members 10622-1 and 10622-2 are measured with a durometer, the Shore hardness (Hs) is 80 to 90.

[0044] The first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 preferably have elasticity and are formed of rubber such as urethane foam, polyethylene foam, natural rubber (NR rubber), etc. The material of the first backer materials 10623-1, 10623-2 and the material of the second backer materials 10624-1, 10624-2 may be the same or different.

[0045] The first backer materials 10623-1 and 10623-2 are preferably elastic, and the second backer materials 10624-1 and 10624-2 are preferably harder than the first backer materials 10623-1 and 10623-2. The Shore A hardness of the second backer materials 10624-1 and 10624-2 is preferably greater than the Shore A hardness of the first backer materials 10623-1 and 10623-2. The Shore A hardness of the first backer materials 10623-1 and 10623-2 is preferably 1 to 10 times, or 4 to 7 times, the Shore A hardness of the second backer materials 10624-1 and 10624-2. The Shore A hardness is determined using a measuring device conforming to ISO-7619. The Shore A hardness of the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 varies depending on their respective thicknesses. Therefore, the Shore A hardness of the first backer materials 10623-1, 10623-2 and the Shore A hardness of the second backer materials 10624-1, 10624-2 are not limited to the above ranges. In this embodiment, the Shore A hardness of the first backer materials 10623-1, 10623-2 is 9, and the Shore A hardness of the second backer materials 10624-1, 10624-2 is 42.

[0046] It is preferable to use a fluororesin such as PTFE (Poly tetrafluoro ethylene), PFA (Perfluoro alkoxy alkane), FEP (Perfluoro ethylene propylene copolymer), ETFE (Ethylene-tetrafluoroethylene), or ECTFE (Chlorotrifluoroethylene ethylene copolymer) for the coating layer 10626. These fluororesins have small static and dynamic friction coefficients. For example, the static friction coefficient of PTFE is 0.08 to 0.12, and the dynamic friction coefficient is 0.03 to 0.08. The static friction coefficient of ECTFE is 0.38 to 0.42, and the dynamic friction coefficient is 0.34 to 0.38. In this embodiment, for example, tape-shaped Teflon (registered trademark) is used for the coating layer 10626. For example, a tape-shaped Teflon (registered trademark) having a low friction coefficient such as Teflon (registered trademark) is used for the coating layer 10626. By using a material with a small number of particles, it is possible to easily insert the sealant leveling tool 1062 into the joint. It is also possible to easily move the sealant leveling tool 1062 in the first direction D1 relative to the joint. It is also preferable that the coating layer 10626 suppresses adhesion of the sealant. Because the side surface of the leveling member 10627 moves in the first direction D1 while being rubbed against the inside of the joint, it is preferable that the material used for the coating layer 10626 be a highly durable material.

[0047] As shown in FIG. 1 , when the leveling member 10627 is provided with a coating layer 10626, a through-hole 10628 is also provided in the coating layer 10626. The through-hole 10628 is provided for inserting a nozzle for supplying a sealant. Therefore, the diameter of the through-hole 10628 only needs to be larger than the diameter of the nozzle. The shape of the through-hole 10628 is circular, but is not limited thereto and may be polygonal. Note that when the through-hole 10628 is polygonal, the center of the circumferential circle of the polygon is defined as the center O of the through-hole 10628. Here, if the overall length of the leveling member 10627 is L1, the length from one end of the leveling member 10627 to the center O of the through-hole 10628 is defined as length L2, and the length from the center O of the through-hole 10628 to the other end of the leveling member 10627 is defined as length L3. The length of the portions of the pair of support members 10621 extending in the first direction D1 may be longer than the length L1 of the leveling member 10627.

[0048] The width W1 of the leveling member 10627 is determined by the thickness of the portion of the pair of support members 10621 extending in the third direction D3, the thickness of the first backer materials 10623-1 and 10623-2, the thickness of the second backer materials 10624-1 and 10624-2, and the thickness of the coating layer 10626. The width W1 of the leveling member 10627 is preferably larger than the width of the joints of the exterior wall panels. Because the first backer materials 10623-1 and 10623-2 are elastic, when the leveling member 10627 is inserted into the joints, the width W1 of the leveling member 10627 shrinks to match the width of the joints. If the width W1 of the leveling member 10627 is smaller than the width of the joints, the width W1 of the leveling member 10627 can be increased by widening the pair of support members 10621 to the left and right. The length in the second direction D2 of the portions of the pair of support members 10621 extending in the second direction D2 may be the same as or greater than the width W1 of the leveling member 10627. Furthermore, the thickness of the portions of the pair of support members 10621 extending in the third direction D3, the first backer materials 10623-1, 10623-2, and the second backer materials 10624-1, 10624-2 preferably satisfy the following relationship of thickness: thickness of the first backer materials 10623-1, 10623-2 > thickness of the portions of the pair of support members 10621 extending in the third direction D3 > thickness of the second backer materials 10624-1, 10624-2. By making the thickness of the first backer materials 10623-1 and 10623-2 greater than the thickness of the second backer materials 10624-1 and 10624-2, the cushioning properties of the first backer materials 10623-1 and 10623-2 can be improved.

[0049] The length L2 from one end of the leveling member 10627 to the through hole 10628 is longer than the length L3 from the through hole 10628 to the other end of the leveling member 10627. The length L2 from one end of the leveling member 10627 to the through hole 10628 may be longer than the length L3 from the through hole 10628 to the other end of the leveling member 10627. The ratio of the lengths L2 to L3 may be, for example, L2:L3 = 3:2, but is not limited thereto. By providing a flat plate 10625 in the region from one end of the leveling member 10627 to the through hole 10628, the area over which the sealant is leveled can be increased. Furthermore, the width W2 of the flat plate 10625 is greater than the thickness of the portion of the pair of support members 10621 extending in the third direction D3, thereby increasing the area over which the sealant is leveled.

[0050] The flat plate 10625 is preferably made of a material with a smooth surface, such as sheet-like Teflon (registered trademark). Alternatively, the flat plate 10625 may be made of plate-like aluminum. The thickness of the flat plate 10625 is preferably smaller than that of the second backer materials 10624-1 and 10624-2 and greater than that of the coating layer 10626. This is preferable because the position of the flat plate 10625 can be fixed by providing the flat plate 10625 on the portions of the pair of support members 10621 extending in the third direction D3 and then covering them with the coating layer 10626. The flat plate 10625 may be provided on the coating layer 10626 if the flat plate 10625 can be firmly adhered to the coating layer 10626.

[0051] As shown in FIG. 1, the upper surfaces of the first backer materials 10623-1 and 10623-2 are inclined at an angle θ1 (θ1<90°) with respect to a surface S1 that contacts the second surfaces of the support members 10622-1 and 10622-2. The second backer materials 10624-1 and 10624-2 are inclined at an angle θ2 (θ2<90°) with respect to a surface S2 that contacts the first backer materials 10623-1 and 10623-2. Here, the angle θ1 is the same as the angle θ2, but the angle θ1 may be different from the angle θ2. With this configuration, the surface S1 of the first backer materials 10623-1 and 10623-2 that contacts the second surfaces of the support members 10622-1 and 10622-2 has the largest area. Furthermore, the surface S2 of the second backer materials 10624-1, 10624-2 that contacts the first backer materials 10623-1, 10623-2 has the largest area. Furthermore, the area of ​​the first backer materials 10623-1, 10623-2 that contacts the flat plate 10625 may have a surface that is horizontal with respect to the surfaces of the support members 10622-1, 10622-2 that extend in the second direction D2. Because the width of the leveling member is larger than the width of the joint, it is difficult to insert the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 into the joint if they are horizontal with respect to the surfaces of the support members 10622-1, 10622-2 that extend in the second direction D2. Therefore, by having the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 inclined relative to the surfaces of the support members 10622-1, 10622-2 extending in the second direction D2, it is possible to easily insert the leveling member 10627 into the joint. Furthermore, when the leveling member 10627 is moved along the first direction D1, the inclination allows the sealant to adhere to the side walls of the joint, thereby increasing the contact area between the sealant and the side walls of the joint. This makes it possible to prevent the sealant from peeling off from the side walls of the joint.

[0052] Sandwiching the elastic first backer materials 10623-1 and 10623-2 between the portion 10622 extending in the third direction D3 of the pair of support members 10621 and the rigid second backer materials 10624-1 and 10624-2 allows the first backer materials 10623-1 and 10623-2 to function as cushions. Contraction of the first backer materials 10623-1 and 10623-2 makes it easier to insert the leveling member 10627 into the joint 202 shown in FIG. 4(A). After inserting the sealant leveling tool 1062 into the joint 202, the repulsive force of the first backer materials 10623-1 and 10623-2 presses the second backer materials 10624-1 and 10624-2 against the sides of the joint 202. Because the second backer materials 10624-1 and 10624-2 have a higher Shore A hardness than the first backer materials 10623-1 and 10623-2, the second backer materials 10624-1 and 10624-2 can improve adhesion to the joints 202. Furthermore, the sealant 206 filled in the joints 202 can be prevented from overflowing from the joints 202 without succumbing to the pressure of the sealant 206 discharged from the through holes 10628. This eliminates the need to apply masking tape around the joints to prevent the sealant from adhering to the exterior wall panels, thereby simplifying the process of filling the sealant. Furthermore, because the first backer materials 10623-1 and 10623-2 are elastic, the width W1 of the leveling member 10627 can flexibly follow the width of the joint 202 when moved in the first direction D1, even if the width is not constant due to manufacturing errors in the exterior wall panels or misalignment of the exterior wall panels. Furthermore, because the surface of the flat plate 10625 is smooth, the surface of the sealant can be smoothed. Furthermore, covering the flat plate 10625 with a coating layer 10626 improves the sliding properties of the sealant filled in the joint. The sealant is discharged from the discharge port through the through-hole of the sealant leveling tool 1062 to fill the sealant down to the bottom of the joint, and the surface of the sealant is smoothed by moving the leveling member along the first direction D1, simultaneously, thereby efficiently forming a smoothed sealant 206.Furthermore, a sealant with a smooth surface can be easily formed regardless of the skill level of the installer. As described above, the sealant leveling tool 1062 of the present invention can improve the finish of the sealant, which is related to the application quality and stability.

[0053] In this embodiment, the thickness of the first backer materials 10623-1 and 10623-2 is greater than the thickness of the second backer materials 10624-1 and 10624-2. However, this embodiment is not limited to this. The leveling member 10627 only needs to have elasticity that allows the width of the leveling member 10627 to conform to the width of the joint even if the joint width is not constant, and sealing properties that prevent the sealant from spilling out of the joint by adhering to the side walls of the joint. Therefore, the thicknesses of the first backer materials 10623-1 and 10623-2 and the second backer materials 10624-1 and 10624-2 may be determined based on the balance between the elasticity and adhesiveness of the leveling member 10627. Therefore, depending on the material of the first backer materials 10623-1, 10623-2 and the material of the second backer materials 10624-1, 10624-2, the thickness of the second backer materials 10624-1, 10624-2 may be greater than the thickness of the first backer materials 10623-1, 10623-2.

[0054] In the present embodiment, the length L2 from one end of the leveling member 10627 to the through hole 10628 is longer than the length L3 from the through hole 10628 to the other end of the leveling member 10627, but one embodiment of the present invention is not limited to this. The lengths L2 and L3 may be approximately equal, or the length L3 may be longer than the length L2. Furthermore, the lengths L2 and L3 may be set appropriately to match the sealing device described later.

[0055] Next, a method for forming the sealant leveling tool 1062 will be described. Through holes may be formed in advance in the pair of support members 10621 to match the shape of the through hole 10628. The first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 are cut to a predetermined shape. The first backer materials 10623-1, 10623-2 may be cut in advance to match the shape of the through hole 10628. The first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 are bonded together. At this time, the second backer materials 10624-1, 10624-2 and the first backer materials 10623-1, 10623-2 are bonded together so that the surface S2 having the largest area of ​​the second backer materials 10624-1, 10624-2 contacts the first backer materials 10623-1, 10623-2. Next, the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 are placed on the pair of support members 10621 so that the surface S1 having the largest area of ​​the first backer materials 10623-1, 10623-2 contacts the first surfaces 10622-11a and 10622-21a. This forms a leveling member 10627 on the pair of support members 10621. Next, a flat plate 10625 is placed on the pair of support members 10621 and the first backer materials 10623-1 and 10623-2. Finally, the leveling member 10627 and the flat plate 10625 are covered with a coating layer 10626, thereby forming the sealant leveling tool 1062.

[0056] In the present embodiment, an example has been described in which the flat plate 10625 is provided on the pair of support members 10621 and then the coating layer 10626 is wrapped around it, but this is not limiting. The leveling member 10627 may be covered with the coating layer 10626, and then the flat plate 10625 may be attached to the coating layer 10626. Also, the process of covering the leveling member 10627 with the coating layer 10626 and attaching the flat plate 10625 may be omitted. Alternatively, the process of attaching the flat plate 10625 to the pair of support members 10621 and the first backer materials 10623-1 and 10623-2 and then forming the coating layer 10626 may be omitted.

[0057] According to the configuration of the sealant leveling tool 1062 of the present invention, repeated use of the sealant leveling tool 1062 makes it easy to replace the first backer materials 10623-1, 10623-2 and the second backer materials 10624-1, 10624-2 with new ones, even if they become worn out, which is preferable.

[0058] 2. Sealing system Next, a sealing system to which the sealant leveling tool 1062 of the present invention can be applied will be described with reference to FIGS. 5 to 16. FIG. 5 shows the overall configuration of a sealing system 100 according to this embodiment. The sealing system 100 includes a sealing device 102 and a drive device 104. FIG. 5 schematically shows the configuration of the sealing system 100, and in addition to a state in which an exterior wall 200 is viewed from the side, an inset view of the exterior wall 200 viewed from the front is also shown. The exterior wall 200 is formed by a plurality of exterior wall panels, and joints 202 are formed at the joints between the exterior wall panels. The sealing system 100 is used in construction work to fill the joints 202 (hereinafter, this refers to "vertical joints" unless otherwise specified) with sealant.

[0059] The sealing device 102 includes a sealant filling unit 106, a roller unit 108, a support 110, and sensors 112 (first sensor 112A and second sensor 112B). The sealant filling unit 106 and the roller unit 108 are attached to the support 110. The sealant filling unit 106 has the function of filling the sealant into the joints 202. The roller unit 108 is provided to ensure that the sealing device 102 moves smoothly over the exterior wall 200. The support 110 is further provided with a first sensor 112A and a second sensor 112B. The first sensor 112A has the function of detecting the upper end of the exterior wall 200, and the second sensor 112B has the function of detecting the lower end of the exterior wall 200.

[0060] The driving device 104 includes a winch 1042, a pulley 1046, a wire 1048, and a control unit 1044 that controls the operation of the winch 1042. The winch 1042 is used to wind up and lower the wire 1048. The pulley 1046 is supported by the support 105 and is disposed above the exterior wall 200. There are no particular limitations on the mounting structure of the pulley 1046, and for example, the pulley 1046 may be disposed above the exterior wall 200 while being suspended by a crane. A connector 113 is provided on the upper part of the support 110, and the wire 1048 is looped around the pulley 1046 and connected to the connector 113.

[0061] Although there is no particular limitation on the location where the driving device 104 is installed, the winch 1042 is installed at a lower position than the pulley 1046. For example, the winch 1042 is installed on the ground. Alternatively, the winch 1042 may be installed on the roof of a building. An electric motor or a hydraulic motor is used as the power source for the winch 1042. The winch 1042 winds up and down the wire 1048, thereby pulling up and down the sealing device 102 along the surface of the exterior wall 200. Note that while FIG. 5 shows a fixed pulley as the pulley 1046, the configuration of the pulley 1046 is not limited to this, and any configuration that can drive the sealing device 102 up and down along the surface of the exterior wall 200 is not limited to the configuration shown in the figure. For example, the pulley 1046 may be a combination of a fixed pulley and a movable pulley. Furthermore, the winding up and down of the wire 1048 is not limited to the winch 1042, and other wire winding mechanisms may be used.

[0062] The operation of the winch 1042 is controlled by a control unit 1044. The control unit 1044 has an inverter built in, which controls the speed at which the winch 1042 winds up and lowers the wire. The winch 1042 may have an encoder built in, which may control the height at which the sealing device 102 is lifted. Furthermore, the height of the sealing device 102 may be determined by controlling the operation of the winch 1042 to wind up and lower the wire 1048 based on detection signals from a first sensor 112A that detects the upper end of the exterior wall and a second sensor 112B that detects the lower end. Furthermore, the operation of the winch 1042 may be controlled by an encoder, the first sensor 112A, and the second sensor 112B.

[0063] When performing sealing work, the sealing device 102 is pulled up from below the exterior wall 200 while suspended by the wire 1048, and moves downward while filling the sealant into the joints 202 of the exterior wall 200. As shown in the inset of Fig. 5, the sealing device 102 moves from top to bottom along the joints 202 while suspended by the wire 1048. As the sealing device 102 moves from top to bottom along the joints 202, the sealant filling unit 106 fills the sealant into the joints 202.

[0064] 5, the sealing device 102 may be equipped with a sealant supply unit that supplies sealant to the sealant filling unit 106. The sealant supply unit may be disposed on the ground or above the exterior wall 200, and the sealant may be supplied to the sealant filling unit 106 by a hose or the like.

[0065] 3. Sealing device The configuration of the sealing device 102 will be described with reference to Figures 6 and 7. Figure 6 shows a front view of the sealing device 102 (as seen from the exterior wall side), and Figure 7 shows a side view of the sealing device 102.

[0066] 3-1. Overall structure The sealing device 102 includes a support 110, a sealant filling unit 106, roller units 108 (first roller unit 108A, second roller unit 108B, third roller unit 108C, fourth roller unit 108D, fifth roller unit 108E, sixth roller unit 108F), a first sensor 112A and a second sensor 112B, a connector 113, a suction unit 114 (first suction unit 114A, second suction unit 114B, third suction unit 114C, fourth suction unit 114D), and a guide 107 (first guide 107A, second guide 107B, third guide 107C, fourth guide 107D).

[0067] The support 110 is used to support the sealant filling unit 106 and has, for example, a cubic shape assembled by a frame. The sealant filling unit 106 is suspended from the support 110. The roller units 108 (first roller unit 108A, second roller unit 108B, third roller unit 108C, fourth roller unit 108D, fifth roller unit 108E, sixth roller unit 108F), the suction units 114 (first suction unit 114A, second suction unit 114B, third suction unit 114C, fourth suction unit 114D), the first sensor 112A, the second sensor 112B, and the connector 113 are attached to various locations on the support 110. The support 110 may also be provided with a sealant supply unit 116 that supplies sealant to the sealant filling unit 106. Furthermore, the support 110 may be provided with a control panel 118 for controlling the operation of the sealant filling unit 106 and the sealant supply unit 116 .

[0068] 3-1-1.Support The support 110 has a structure in which frames are assembled into a box shape. There is no limitation on the material of the frame, and various frames such as an aluminum frame, a steel frame, and a carbon frame can be used. Note that although FIGS. 6 and 7 show an example in which the support 110 is formed by a frame, it may be replaced with another structure as long as it has a structure that supports the sealant filling unit 106 and attaches the roller unit 108 and the like. For example, the support 110 is not limited to a frame structure, and may be replaced with a box-shaped housing.

[0069] A connector 113 is provided on the upper part of the support 110. The connector 113 is provided to connect the support 110 and the wire 1048. There are no particular limitations on the structure of the connector 113, and various types of hanging hardware can be used as long as they have a load-bearing capacity that allows the sealing device 102 to be hung.

[0070] 3-1-2. Roller unit A roller unit 108 is provided on the support 110. The roller unit 108 is attached at a position facing the exterior wall 200 when the support 110 is placed against the exterior wall 200. The roller units 108 are preferably provided at four or more locations on the support 110 so that the sealing device 102 can move smoothly on the surface of the exterior wall 200. For example, the roller units 108 are preferably provided at four locations, namely, the top, bottom, left, and right of the support 110. Furthermore, the roller units 108 may also be provided on the left and right of the center of the support 110.

[0071] FIG. 6 shows an example in which roller units 108 are provided at two locations on the upper left and right of the support body 110 (first roller unit 108A, second roller unit 108B), two locations on the lower left and right of the support body 110 (third roller unit 108C, fourth roller unit 108D), and two locations on the center left and right of the support body 110 (fifth roller unit 108E, sixth roller unit 108F). Note that FIG. 6 is just an example, and the fifth roller unit 108E and sixth roller unit 108F provided at the two locations on the center left and right may be omitted. By providing roller units 108 at four or more locations on the support body 110, tilting, bending, and twisting of the support body 110 can be prevented, and the sealing device 102 can be moved parallel to the surface of the exterior wall 200 while in contact with the surface.

[0072] 3-1-3.Suction unit When the sealant is filled into the joint 202, the sealing device 102 is subjected to a reaction force from the exterior wall 200. Furthermore, when sealing work is performed outdoors, the sealing device 102 may become unstable due to the influence of wind. Therefore, it is necessary to use the suction unit 114 to prevent the support 110 from separating from the exterior wall 200, thereby maintaining the stability of the sealing device 102.

[0073] The suction unit 114 is provided on the surface of the support 110 facing the exterior wall 200. The suction unit 114 is preferably provided so as not to come into direct contact with the exterior wall 200, so as not to scratch the surface of the exterior wall 200 due to the movement of the sealing device 102. For example, the suction unit 114 is preferably attached to the support 110 so as not to protrude outward beyond the roller unit 108 and to be spaced apart from the exterior wall 200. Furthermore, the suction unit 114 may be attached so that a soft member such as a woven fabric is used on the surface that comes into contact with the exterior wall 200, and so as to come into contact with the exterior wall 200 with enough strength not to impede the movement of the sealing device 102, and to slide on the surface of the exterior wall.

[0074] When the exterior wall 200 is made of a ferromagnetic material such as a steel plate, a magnet can be used as the suction unit 114. A permanent magnet or an electromagnet can be used as the magnet. Furthermore, even when the exterior wall is made of reinforced concrete, since the wall contains rebar inside, a magnet can also be used as the suction unit 114. By applying the magnetic force of the suction unit 114 to the exterior wall, it is possible to prevent the sealing device 102 from separating from the exterior wall. Furthermore, instead of using a magnetic force, a suction type suction unit 114 that uses the suction force of a vacuum pump can be used as the suction unit 114.

[0075] The suction unit 114 is provided at least at one location, and preferably at multiple locations, on the support body 110. Fig. 6 shows an example in which the suction units 114 are provided at two locations on the upper left and right sides of the support body 110 (first suction unit 114A, second suction unit 114B) and two locations on the lower left and right sides of the support body 110 (third suction unit 114C, fourth suction unit 114D). By providing the suction units 114 symmetrically on the left and right sides of the support body 110 in this way, the sealing device 102 can be prevented from moving away from the exterior wall 200 and can be maintained in a stable state.

[0076] 3-1-4. Sealant filling unit The sealant filling unit 106 is attached to the support 110 so that the sealant discharge port can be displaced to follow the joint 202. For example, the sealant filling unit 106 is provided in a suspended state from the support 110 so that it can swing and be displaced in the left-right direction. The sealant filling unit 106 includes a sealing gun 1061 and a first drive mechanism 1063A. The first drive mechanism 1063A has a function of controlling the sealing gun 1061 to a standby position (a position where sealant is not discharged) and a working position (a position where sealant is discharged).

[0077] The sealant filling unit 106 is provided with a sealant leveling tool 1062 and a second drive mechanism 1063B of the present invention. The sealant leveling tool 1062 is provided at the tip of the sealing gun 1061. The second drive mechanism 1063B has a function of controlling the sealant leveling tool 1062 between a standby position and a working position.

[0078] The sealant filling unit 106 may be provided with a joint width sensor 115. The joint width sensor 115 is an optical sensor and has the function of detecting the width of the joint 202. The sealing device 102 can prevent sealant from leaking from the gap between the sealant leveling tool and the exterior wall panel by opening and closing a pair of support members left and right depending on the width of the joint 202 detected by the joint width sensor 115. The sealing device 102 may also have the function of controlling the amount of sealant dispensed from the sealing gun 1061 depending on the width of the joint 202 detected by the joint width sensor 115. Details of the sealant filling unit 106 having such a configuration will be described later.

[0079] 3-1-5. Guide A plurality of guides 107 (first guide 107A, second guide 107B, third guide 107C, and fourth guide 107D) are provided to assist the sealing device 102 in moving along the joint 202. FIGS. 6 and 7 show an example in which the first guide 107A and the second guide 107B are provided on the sealant filling unit 106, and the third guide 107C and the fourth guide 107D are provided on the support body 110. The first guide 107A and the second guide 107B are disposed on the vertical center line of the discharge port of the sealing gun 1061. The third guide 107C and the fourth guide 107D are disposed below the sealant filling unit 106 and overlap the vertical center lines of the first guide 107A and the second guide 107B in the initial state. The multiple guides (first guide 107A, second guide 107B, third guide 107C, fourth guide 107D) are positioned so that their tip portions are inserted into the joint 202 when the sealing device 102 fills the sealant.

[0080] Sensors The support body 110 is provided with a first sensor 112A that detects when the sealing device 102 has reached the upper end of the exterior wall 200, and a second sensor 112B that detects when the sealing device 102 has reached the lower end. For example, the first sensor 112A is provided on the upper part of the support body 110, and the second sensor 112B is provided on the lower part. The first sensor 112A may be a contact sensor that detects whether or not there is contact with the exterior wall 200, or an optical sensor that measures the distance to the exterior wall 200. The second sensor 112B may be a contact sensor that detects whether or not there is contact with the ground, or a non-contact sensor that measures the distance to the ground. The contact sensor may be a contact output type sensor having a microswitch or a relay contact, and the non-contact sensor may be an optical sensor (e.g., a laser displacement meter) or an ultrasonic sensor that can detect the distance to an object.

[0081] By providing the first sensor 112A and the second sensor 112B, it is possible to detect the start point and end point of work by the sealing device 102. That is, the first sensor 112A is provided to detect the upper end of the exterior wall 200 (the work start point), and the second sensor 112B is provided to detect the lower end of the exterior wall 200 (the work end point).

[0082] The sealing device 102 maintains a constant distance from the support 110 to the exterior wall 200 because the roller unit 108 is in contact with the exterior wall 200. Therefore, when the sealing device 102 has not yet reached the top of the exterior wall 200, the signal detected by the first sensor 112A is constant or within a predetermined range. Since the first sensor 112A is provided above the support 110 (at a position higher than the upper first roller unit 108A and second roller unit 108B), when the sealing device 102 reaches the top of the exterior wall 200, the first sensor 112A does not detect the exterior wall, and the detection signal changes significantly. The change in the signal output from the first sensor 112A makes it possible to detect that the sealing device 102 has reached the top of the exterior wall 200.

[0083] The second sensor 112B measures whether or not the sealing device 102 has contacted the ground (or the basement) or the distance from the mounting position of the support 110 to the ground (or the basement). When the sealing device 102 is pulled up above the exterior wall 200, the second sensor 112B does not detect contact with the ground (or the basement) or detects that the distance to the ground (or the basement) is far away. When the sealing device 102 is at the bottom of the exterior wall 200 (the end point of the work), the second sensor 112B detects contact with the ground (or the basement) or detects the distance to the ground (or the basement). Therefore, by determining that the second sensor 112B has detected the ground (or the basement) or that the distance to the ground (or the basement) is a specified value (or within a predetermined range), it is possible to detect that the sealing device 102 has reached the bottom.

[0084] 3-1-7. Sealant supply unit The support 110 may be provided with a sealant supply unit 116 that supplies sealant to the sealant filling unit 106. The sealant supply unit 116 may be configured, for example, with a sealing pump unit including a sealing tank 1162, a compression plate 1164 that seals the upper surface of the sealing tank 1162 and compresses the interior space, and a pump 1166 that raises and lowers the compression plate 1164. By filling the sealing tank 1162 with sealant and lowering the compression plate 1164 using the pump 1166, the highly viscous sealant can be supplied to the sealing gun 1061 through a tube 1168. The pump 1166 can also adjust the speed at which the compression plate 1164 descends, thereby controlling the amount of sealant supplied to the sealing gun 1061. The sealing tank 1162 can have a large capacity, allowing a large amount of sealant to be loaded into the sealing device 102. This allows work to be carried out without interruption in the supply of sealant midway through the joint, even in high-rise buildings, thereby improving work efficiency.

[0085] 3-1-8.Control Panel The control panel 118 houses a control circuit that drives the sealant filling unit 106 and the sealant supply unit 116. The control panel 118 may be disposed anywhere, and may be provided on the side of the support 110, for example.

[0086] Next, the sealant filling unit 106 attached to the support 110 will be described in detail.

[0087] 3-2. Sealant filling unit Fig. 8 shows a perspective view of the sealant filling unit 106. In the description referring to Fig. 8, the front-to-rear direction refers to the direction [A] shown in the figure, the horizontal direction refers to the direction [B] shown in the figure, and the swinging direction refers to the direction [C]. Also, "forward" in Fig. 8 refers to the direction in which the sealing device 102 faces the wall surface, "rear" refers to the opposite direction, "upward" refers to the upward direction when the sealing device 102 is upright, and "downward" refers to the opposite direction.

[0088] The sealant filling unit 106 includes a sealing gun 1061 and a first drive mechanism 1063A. The first drive mechanism 1063A includes, for example, a first actuator 1064A and a first linear guide 1065A. The sealant filling unit 106 also includes a sealant leveling tool 1062 and a second drive mechanism 1063B. The second drive mechanism 1063B includes, for example, a second actuator 1064B and a second linear guide 1065B. In addition to these elements, the sealant filling unit 106 also includes parts such as a first support plate 1066A and a second support plate 1066B to which the first drive mechanism 1063A and the second drive mechanism 1063B are attached.

[0089] The first drive mechanism 1063A displaces the sealing gun 1061 in the front-to-rear direction and inserts the sealing gun 1061 into the joint. The first drive mechanism 1063A includes a first actuator 1064A and a first linear guide 1065A, which are fixed to a first support plate 1066A. The first linear guide 1065A is composed of a guide rail 10652A and a block 10654A, and the longitudinal direction of the guide rail 10652A is arranged in the front-to-rear direction as shown in the figure. The block 10654A slides on the guide rail 10652A by the first actuator 1064A. The sealing gun 1061 is connected to the block 10654A and displaces in the front-to-rear direction by the first actuator 1064A. Note that the sealing gun 1061 is positioned between the first drive mechanism 1063A and the second drive mechanism 1063B, and is therefore not shown in FIG. 8.

[0090] The second drive mechanism 1063B displaces the sealant leveling tool 1062 in the front-to-rear direction, inserting the sealant leveling tool 1062 into the joint. The second drive mechanism 1063B includes a second actuator 1064B and a second linear guide 1065B, and is fixed to the first support plate 1066A. The second linear guide 1065B is composed of a guide rail 10652B and a block 10654B, and the longitudinal direction of the guide rail 10652B is arranged in the front-to-rear direction as shown. The block 10654B slides on the guide rail 10652B due to the second actuator 1064B. The sealant leveling tool 1062 is connected to the block 10654B, and is driven by the second actuator 1064B to change its position in the front-to-rear direction.

[0091] In the sealant filling unit 106, the first drive mechanism 1063A and the second drive mechanism 1063B work in conjunction with each other to simultaneously displace the sealing gun 1061 and the sealant leveling tool 1062 in the front-to-rear direction. The sealant filling unit 106 can also displace the position of only one of the sealing gun 1061 and the sealant leveling tool 1062 by individually driving the first drive mechanism 1063A and the second drive mechanism 1063B. Note that, while Fig. 8 shows a configuration in which the front-to-rear positions of the sealing gun 1061 and the sealant leveling tool 1062 are controlled by individual drive mechanisms, the present invention is not limited to such a configuration, and the positions of both may be controlled by a single drive mechanism.

[0092] FIG. 9 is a side view of a sealing gun 1061. The sealing gun 1061 includes a main body 10611, a nozzle 10612, and a flow rate control valve 10613. The nozzle 10612 extends forward from the main body 10611, and its tip serves as a sealant outlet 10615. The flow rate control valve 10613 adjusts the amount of sealant dispensed by restricting its size. An electromagnetic or pneumatic valve can be used as the flow rate control valve 10613. The sealing gun 1061 shown in FIG. 9 is provided with a handle 10614 for operating the flow rate control valve 10613, and the handle 10614 is operated by a third actuator 1064C. The sealing gun 1061 is fixed to a mounting part 1067 for mounting to a first linear guide 1065A.

[0093] A tube 1168 is connected to the main body 10611 of the sealing gun 1061. Although not shown in FIG. 9, the other end of the tube 1168 is connected to the sealant supply unit 116 (see FIG. 7). The sealant is supplied from the sealant supply unit 116 to the sealing gun 1061 through the tube 1168. The sealant is continuously supplied from the sealant supply unit 116 and continuously discharged from the tip of the discharge port 10615 provided in the nozzle 10612. The amount of sealant discharged is adjusted by the supply pressure of the sealant supply unit 116 and the throttling amount of the flow rate adjustment valve 10613.

[0094] The structure and shape of the sealing gun 1061 can be selected as appropriate and are not limited to the configuration shown in Fig. 10. For example, the handle 10614 may be omitted, or may be replaced with an automatic opening and closing valve.

[0095] 3-3.Sealant leveling tool and drive mechanism FIG. 10 is an isometric view of a sealant leveling tool 1062A and a drive mechanism 1063 according to one embodiment of the present invention. FIG. 11 is a side view of the sealant leveling tool 1062A and a drive mechanism 1063 according to one embodiment of the present invention. FIG. 12 is a front view of the sealant leveling tool 1062A and a drive mechanism 1063 according to one embodiment of the present invention. FIG. 13 is a top view of the sealant leveling tool 1062A and a drive mechanism 1063 according to one embodiment of the present invention. FIG. 14 is an enlarged view of the sealant leveling tool 1062A according to one embodiment of the present invention. The sealant leveling tool 1062A is fixed to fixing members 10641 and 10643.

[0096] 10 to 14 show a sealant leveling tool 1062A having a different configuration from the sealant leveling tool 1062 described in FIG. 1 and elsewhere. The sealant leveling tool 1062A has a first backer material 10623 provided to cover a pair of support members 10621-2. That is, the first backer material 10623 is provided on second surfaces 10622-1b and 10622-2b of the support members 10622-1 and 10622-2. Second backer materials 10624-1 and 10624-2 are provided on the respective side surfaces of the first backer material 10623 along the first direction D1. The first backer material 10623 and the second backer materials 10624-1 and 10624-2 form a leveling member. A coating layer 10626 is provided to cover the first backer material 10623 and the second backer materials 10624-1 and 10624-2.

[0097] The support member 10621 of the sealant leveling device 1062A is divided into two in the first direction D1. The fixed member 10643 is provided with opening / closing guides 10645-1 to 10645-8 for opening and closing the pair of support members 10621-1 and 10621-2. The opening / closing guides 10645-1 to 10645-4 fix the pair of support members 10621-1, and the opening / closing guides 10645-5 to 10645-8 fix the support member 10621-2. Spacers 10646-1 and 10646-2 are provided between the fixed member 10641 and the fixed member 10643. A second drive mechanism 1063B is fixed to the underside of the fixed member 10641.

[0098] The fixing member 10641 has rectangular openings 10642-1 and 10642-2 and a circular opening 10642-3 formed along the first direction D1. The circular opening 10642-3 is formed between the rectangular openings 10642-1 and 10642-2. Although not shown in FIGS. 10 to 12, the fixing member 10643 also has two rectangular openings and a circular opening formed along the first direction D1, and these openings are arranged to overlap with the two rectangular openings 10642-1 and 10642-2 and the circular opening 10642-3 of the fixing member 10641. Opening and closing members 10630-1 and 10630-2 are provided to pass through the rectangular openings 10642-1 and 10642-2 of the fixing members 10641 and 10643. 10 to 14, plate-like members are shown as opening and closing members 10630-1 and 10630-2. Nozzle 10612 of the sealing gun is provided so as to penetrate the circular openings of fixing members 10641 and 10643. Nozzle 10612 penetrates through through-hole 10628 of sealant leveling tool 1062A.

[0099] The sealing device 102 must move down the surface of the exterior wall 200 along the joints 202 in the first direction D1, and the sealant filling unit 106 must accurately fill the sealant into the joints 202. As described in FIG. 7, the sealing device is provided with a joint width sensor 115. The joint width sensor 115 is an optical sensor and has the function of detecting the width of the joint. If the width of the joint 202 detected by the joint width sensor 115 is large, at least one of the opening / closing members 10630-1, 10630-2 is inserted between the pair of support members 10622-1, 10622-2 in the third direction D3. 14 as an example, when the opening / closing member 10630-2 is moved in the third direction D3 inside the openings 10642-2 and 10644-2, the opening / closing guides 10645-7 and 10645-8 open left and right, and the opening / closing guides 10645-5 and 10645-6 (not shown) open left and right. This causes the support members 10622-12 and 10622-22 to open left and right as well. By inserting the opening / closing member 10630-2 between the support members 10622-12 and 10622-22, the width of the sealing material leveling device 1062A can be increased. Note that the position at which the opening / closing member 10630-2 is inserted preferably does not exceed the height of the support members 10622-11 and 10622-21 in the third direction D3.

[0100] In Figure 15(A), when first exterior wall panel 201A1 and first exterior wall panel 201A2 are attached, joint 202A is formed with a specified width. When second exterior wall panel 201B1 and second exterior wall panel 201B2 are attached on top of this, joint 202B is formed with a specified width. Ideally, joint 202A and joint 202B have the same width and horizontal position, but in actual buildings, some tolerance is allowed. For example, if joint width W1 is 19 mm to 25 mm, then misalignment width W2 of joint 202A may be allowed between 0 mm and 3 mm.

[0101] The sealant leveling tool 1062A has a vertically elongated shape that fits into the joint 202. As shown in Fig. 15(B), when the sealant leveling tool 1062A is provided, the nozzle 10612 is provided so that it passes through a through-hole 10628 of the sealant leveling tool 1062A and exposes the discharge port 10615. With this configuration, after the sealant is discharged from the nozzle 10612 into the joint 202, the surface of the sealant can be leveled and the shape adjusted.

[0102] As shown in Figure 15(B), the sealant leveling tool 1062A is inserted to a predetermined depth into the joint 202 when filling the sealant 206. The depth to which the sealant leveling tool 1062A is inserted into the joint can be adjusted appropriately, taking into account the thickness of the sealant 206. That is, the insertion depth D2 to which the sealant leveling tool 1062A is inserted into the joint 202 is shallower than the joint depth D1, and is controlled to a depth that ensures a contact width that can withstand pressure when filling the sealant and allows the sealant to have a predetermined thickness (e.g., 10 mm or more). Note that a backup material 204 is provided in the joint 202, and the depth of the joint 202 is the depth from the surface of the exterior wall panel 201 to the backup material 204. By adjusting the insertion depth D2 of the sealant leveling tool 1062A into the joint 202, the sealant 206 filled in the joint 202 can be leveled, and the sealant can be leveled so that it adheres closely to the side wall surface of the exterior wall panel 201.

[0103] The sealant 206 is applied to joints 202 on the wall surface by inserting a leveling member 10627 into the joint and moving it in the first direction D1, so that the central portion of the cross-sectional shape of the sealant 206 in the joint 202 is thin due to the cross-sectional shape of the leveling member 10627, and the sealant 206 that comes into contact with the wall materials on both sides that form the joint 202 is thicker than the central portion. In other words, the sealant 206 whose surface has been smoothed by the sealant leveling tool 1062A has two end portions (also referred to as first regions) that come into contact with the side walls of the joint along the first direction D1, and a central portion (also referred to as second region) sandwiched between the two end portions. The width of the sealant 206 is determined by the width of the leveling member 10627 formed by the portions of the pair of support members 10621 extending in the third direction D3, the first backer materials 10623-1 and 10623-2, and the second backer materials 10624-1 and 10624-2. When the wall material is cut in a direction intersecting the direction in which the joints extend, the thickness of the central region is smaller than the thickness of the two end regions. Furthermore, the surface of the central region is smooth relative to the bottom of the joint, while the end regions are inclined relative to the side walls of the joint. This increases the contact area between the end of the sealant and the side walls of the joint, improving the finish of the sealant, which affects application quality and stability.

[0104] Note that Figure 15(B) shows a structure in which the nozzle 10612 is inserted into the sealant leveling tool 1062A, but the arrangement of the sealing gun 1061 and the sealant leveling tool 1062A is not limited to this configuration, and the nozzle 10612 may be arranged below the sealant leveling tool 1062A.

[0105] As shown in FIG. 8, the first support plate 1066A, to which the first drive mechanism 1063A and the second drive mechanism 1063B are attached, has one end connected to the second support plate 1066B and the other end rotatable. The second support plate 1066B is connected to a bearing 1104 inserted through a fixed shaft 1102. The bearing 1104 is configured as a plain bearing or a rolling bearing and is rotatable around the fixed shaft 1102. Therefore, the first support plate 1066A is provided so that the other end rotates around the fixed shaft 1102. The fixed shaft 1102 is attached to a block 11064 of a fourth linear guide 1106 that slides horizontally. The block 11064 is movable horizontally on the guide rail 11062. With this configuration, the first support plate 1066A can swing like a pendulum (direction [C] shown in FIG. 8) and can also be displaced horizontally (direction [B] shown in FIG. 8). The sealant filling unit 106 is not fixed in a fixed position within the support 110, but is capable of swinging and displacing horizontally.

[0106] By having such an attachment structure, the sealant filling unit 106 can be displaced to match the joint 202 even if the linearity of the joint 202 is unstable. In other words, when the sealing device 102 descends along the joint 202 of the exterior wall 200, the tip of the sealing gun 1061 and the sealant leveling tool 1062 can descend smoothly along the joint 202 without coming off the joint. In other words, when the sealing device 102 moves from top to bottom of the exterior wall 200, even if the position of the support 110 fluctuates horizontally (left and right), or even if the joint 202 is undulating, the sealing gun 1061 and the sealant leveling tool 1062 can be prevented from coming off the joint.

[0107] The first support plate 1066A is provided with a joint width sensor 115 that detects the width of the joint 202. For example, a laser displacement sensor is used as the joint width sensor 115. The amount of sealant supplied from the sealing gun 1061 can be adjusted by detecting the width of the joint with the joint width sensor 115 and controlling the opening / closing amount of the flow rate adjustment valve (see FIG. 9) with the third actuator 1064C based on the detection signal.

[0108] 3-4. Guide The sealing device 102 must be lowered along the surface of the exterior wall 200 along the joints 202, and the sealant filling unit 106 must accurately fill the joints with sealant. Therefore, as shown in FIG. 8, a first guide 107A is preferably provided at the tip (the rotating side) of the first support plate 1066A. FIG. 16 is a cross-sectional view illustrating the configuration of the first guide 107A. As shown in FIG. 16, the first guide 107A has a structure in which a cam follower 1074 is provided at the tip of a support member 1072. The first guide 107A is provided at a position where it protrudes forward from the first support plate 1066A and is inserted into the joint 202. The diameter of the cam follower 1074 is set slightly smaller than the width of the joint 202 so that friction does not occur even when it comes into contact with the side of the joint.

[0109] As shown in FIGS. 6 and 7, the first guide 107A is located below the sealant filling unit 106. That is, when the sealing device 102 moves from the upper side to the lower side of the exterior wall, the first guide 107A is located forward in the direction of movement of the sealant filling unit 106 and near the tip of the rotating side of the first support plate 1066A. With this configuration, the first guide 107A can adjust the angle and horizontal position of the first support plate 1066A to fit the joint, ensuring that the sealant is properly filled into the joint. There may be only one first guide 107A, but multiple guides may also be provided. For example, as shown in FIG. 8, in addition to the first guide 107A, a second guide 107B may be arranged vertically next to the first guide 107A. The vertical centerlines of the first guide 107A and the second guide 107B are aligned and further aligned with the vertical centerline of the discharge port 10615 of the sealant filling unit 106. With this configuration, the angle and horizontal position of the first support plate 1066A can be adjusted by the first guide 107A and the second guide 107B so that it fits along the joint, and the sealant filling unit 106 can be controlled so that it does not come off the joint. Also, as shown in Figure 8, by providing a joint width sensor 115 between the first guide 107A and the second guide 107B, the width of the joint 202 can be accurately detected.

[0110] In addition to the first guide 107A and the second guide 107B provided on the first support plate 1066A, a third guide 107C and a fourth guide 107D may be provided on the support body 110 as shown in FIGS. 6 and 7. The third guide 107C and the fourth guide 107D are also provided protruding from the support body 110 so as to be inserted into the joint 202. The third guide 107C and the fourth guide 107D are provided below the first guide 107A and the second guide 107B. While the first guide 107A and the second guide 107B are provided near the tip of the first support plate 1066A, the third guide 107C and the fourth guide 107D are fixed to the support body 110. The third guide 107C and the fourth guide 107D are provided on an extension of the vertical center line of the first guide 107A and the second guide 107B. The third guide 107C and the fourth guide 107D control the support 110 so that it passes through the center of the joint. Furthermore, the first guide 107A and the second guide 107B change the angle and horizontal position of the first support plate 1066A, so that even if the linearity of the joint is unstable, the position of the sealant filling unit 106 can be finely adjusted so that it does not deviate from the joint.

[0111] The elements that make up the sealing system 100 work together to automatically fill the vertical joints in the exterior walls of a building with sealant. The worker simply hangs the sealing device 102 from a pulley and places it at the position of the vertical joint, and the sealant is then filled into the vertical joint, reducing the labor required and ensuring safety by reducing the need to work at height. Furthermore, these functions make it possible to provide an automatic sealant filling robot that can uniformly fill the joints in the exterior walls of high-rise buildings with sealant.

[0112] 4. Opening and closing mechanism of the sealant leveling device 2 Next, another mechanism for partially opening and closing the sealant leveling tool 1062 will be described with reference to Figures 17(A) and 17(B). Figure 17(A) is a side view showing the state before the sealant leveling tool 1062 is inserted into the joint 202, and Figure 17(B) is a side view showing the state after the sealant leveling tool has been inserted into the joint 202.

[0113] 17(A) and 17(B), the support members 10622-1 and 10622-2 have an I-shape when viewed from the first direction D1. Although not shown, the pair of support members 10621 are divided into at least two pieces, and a cam follower 134 is provided for each of the support members 10622-1 and 10622-2 of the divided pair of support members 10621. In other words, when the pair of support members 10621 are divided into two along the second direction D2, the cam followers 134 are provided so that the divided pair of support members 10621 open and close independently.

[0114] Support member 10622-1 and support member 10622-2 are rotatably fastened at fulcrum 140, with the leveling member side functioning as the point of application and the opposite side functioning as the force point, centered on fulcrum 140. Specifically, first backer materials 10623-1, 10623-1, second backer materials 10624-1, 10624-2, and a coating layer 10626 are provided at the tips of support member 10622-1 and support member 10622-2, and cam followers 134 (134A, 134B) are provided at the opposite ends. The sealant leveling tool 1062B having this configuration can be controlled by a cam 132 moved back and forth by a cylinder 130 to ensure that the coating layer 10626 adheres closely to the side of joint 202.

[0115] 17(A), before sealant leveling tool 1062B is inserted into joint 202, the wide portion of cam 132 is interposed between cam follower 134A and cam follower 134B. A tensile force is applied by spring 136 between cam follower 134A and cam follower 134B, but the presence of cam 132 keeps support member 10622-1 and support member 10622-2 parallel to each other.

[0116] As shown in FIG. 17(B), when sealant leveling tool 1062B is inserted into joint 202, cylinder 130 displaces cam 132, narrowing the gap between cam follower 134A and cam follower 134B. Support members 10622-1 and 10622-2 rotate around fulcrum 140, displacing support members 10622-1 and 10622-2 at their distal ends by an angle θ1. In other words, support members 10622-1 and 10622-2 displace such that the gap between leveling members 10627 widens on both sides as the gap between cam follower 134A and cam follower 134B narrows. The magnitude of displacement angle θ1 can be set as appropriate; for example, angle θ1 can be set within a range of 0.5 to 5 degrees.

[0117] 17(A) and 17(B), the sealant leveling tool 1062B can be brought into close contact with the side wall of the joint 202 (the side edge of the exterior wall 200), allowing the sealant to be applied evenly to the side wall of the joint 202. The width by which the leveling member 10627 spreads can be adjusted by the cam 132, allowing for flexible adaptation to exterior walls 200 with different widths of joint 202. [Explanation of symbols]

[0118] 100: sealing system, 102: sealing device, 104: drive device, 105: support, 106: sealant filling unit, 107: guide, 107A: first guide, 107B: second guide, 107C: third guide, 107D: fourth guide, 108: roller unit, 108A: first roller unit, 108B: second roller unit, 108C: third roller unit, 108D: fourth roller unit, 108E: fifth roller unit, 108F: sixth roller unit, 110: support, 112: sensor, 112A: first sensor, 112B: second sensor sensor, 113: connector, 114: suction unit, 114A: first suction unit, 114B: second suction unit, 114C: third suction unit, 114D: fourth suction unit, 115: joint width sensor, 116: sealant supply unit, 118: control panel, 130: cylinder, 132: cam, 134: cam follower, 134A, 134B: cam follower, 136: spring, 140: fulcrum, 200: exterior wall, 201: exterior wall panel, 201A1, 201A2: first exterior wall panel, 201B1, 201B2: second exterior wall panel, 202, 202A, 202B: joint, 20 4: backup material, 206: sealing material, 1042: winch, 1044: control unit, 1046: pulley, 1048: wire, 1061: sealing gun, 1062: sealing material leveling tool, 1062A: sealing material leveling tool, 1063A: first drive mechanism, 1063B: second drive mechanism, 1064A: first actuator, 1064B: second actuator, 1064C: third actuator, 1065A: first linear guide, 1065B: second linear guide, 1066A: first support plate, 1066B: second support plate, 1067: mounting part, 1072: support Component, 1074: cam follower, 1102: fixed shaft, 1104: bearing, 1106: fourth linear guide, 1114D: fourth suction unit, 1162: sealing tank, 1164: compression plate, 1166: pump, 1168: tube, 10611: main body, 10612: nozzle, 10613: flow rate adjustment valve, 10614: handle, 10615: discharge port, 10621, 10621-1 to 10621-3: pair of support members, 10622: part, 10622-1, 10622-11: support member, 10622-11a: first surface, 10622-11b: second surface,10622-11c: tapered surface, 10622-12, 10622-13: support member, 10622-2, 10622-21: support member, 10622-21a: first surface, 10622-21b: second surface, 10622-21c: tapered surface, 10622-22, 10622-23: support member, 10623-1, 10623-2: first backer material, 10624-1, 10624- 2: second backer material, 10625: flat plate, 10626: coating layer, 10627: leveling member, 10628: through hole, 10629-1 to 10629-3: hinge, 10630: opening and closing member, 10641: fixing member, 10652A, 10652B: guide rail, 10654A, 10654B: block, 11062: guide rail, 11064: block,

Claims

1. a support member extending in a first direction; a leveling member supported by the support member and extending in the first direction; and the support member is composed of a first support member and a second support member that are divided into left and right halves with respect to a central axis along the first direction, The first support member and the second support member each have a first surface and a second surface facing each other, the leveling member is provided on the second surface of the first support member and the second support member, The first support member and the second support member are opened in the left-right direction, thereby widening the width of the leveling member. Sealant leveling tool.

2. The first surface of the first support member and the first surface of the second support member are arranged to face each other. The sealant leveling tool according to claim 1.

3. The first support member and the second support member rotate around the tip of the first surface and open in the left and right directions. The sealant leveling tool according to claim 2.

4. The first support member and the second support member expand in the left-right direction so that the width of the leveling member increases. The sealant leveling tool according to claim 2.

5. The sealant leveling tool of claim 1 , further comprising a coating layer covering the first support member, the second support member, and the leveling member.

6. The first support member and the second support member have an I-shape or an L-shape when viewed from the first direction. The sealant leveling tool according to claim 1.

7. The first support member and the second support member have tapered surfaces on the outer sides of the corners of the L-shape. The sealant leveling tool according to claim 6.

8. The support member is divided into at least two parts along a second direction perpendicular to the first direction. The sealant leveling tool according to claim 6.

9. a through hole penetrating the support member and the leveling member in a third direction perpendicular to the first direction and the second direction; The sealant leveling tool according to claim 5.

10. A sealant leveling device according to any one of claims 1 to 9, Sealing device.

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