Lightweight self-supporting wall

Abstract

To provide a lightweight self-supporting wall having high weather resistance even when installed outdoors.SOLUTION: A lightweight self-supporting wall 1 erected on a foundation 10 includes an elongated hollow cylindrical or horizontal cross-sectional H-shaped support 15 made of aluminum, stainless steel, or carbon fiber plastic, which is fixed so as to stand vertically on the foundation 10, a foamed resin foam panel 20 in which an insertion hole 21 extending in a vertical direction into which the support 15 is inserted is formed, and a cement-based filler 30 filled into the insertion hole 21 in order to bond and fix the support 15 and the foam panel 20. The support column 15 is a hollow cylinder, and the cement filler 30 is filled in both an internal space of the support column 15 and an external space of the support column 15 in the insertion hole 21.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a lightweight freestanding wall using foamed resin. [Background technology]

[0002] Conventionally, concrete block walls have been installed at the boundaries between ordinary houses and adjacent properties or roads. However, due to the danger they pose when they collapse due to earthquakes or other reasons, lightweight freestanding walls made of polystyrene foam (expanded resin) or the like have been proposed in recent years as an alternative to concrete block walls, and are disclosed, for example, in Patent Documents 1 to 3 listed below. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-21328 [Patent Document 2] Japanese Patent Application Laid-Open No. 2004-239036 [Patent Document 3] Japanese Patent Publication No. 2020-29759 Summary of the Invention [Problem to be solved by the invention]

[0004] Here, the lightweight self-supporting walls made of polystyrene foam or the like disclosed in the above Patent Documents 1 to 3 use steel reinforcing bars (deformed steel bars) and anchor bolts as supports. However, because boundary walls are installed outdoors and exposed to wind and rain, if cracks occur due to the expansion and contraction of the structure and rainwater gets inside, there is a risk that the steel supports will rust and expand.

[0005] If the support posts rust and expand, the mortar around the support posts may explode, or the steel support posts may be damaged, causing the appearance of the lightweight freestanding wall to deteriorate and, in the worst case, causing it to collapse.

[0006] The present invention has been made in view of the above problems, and aims to provide a lightweight freestanding wall that is highly weather resistant even when installed outdoors. [Means for solving the problem]

[0007] In order to solve the above problem, the lightweight freestanding wall of the present invention is a lightweight freestanding wall that is erected on a foundation, and is characterized by comprising: a long, hollow cylindrical or H-shaped horizontal cross-section pillar made of aluminum, stainless steel, or carbon fiber plastic that is fixed so as to stand vertically on the foundation; a foam panel made of foamed resin that has a vertically extending through hole through which the pillar is inserted; and a cement-based filler that is filled in the through hole to adhesively fix the pillar and the foam panel. [Effects of the Invention]

[0008] According to the lightweight self-supporting wall of the present invention, even if rainwater gets inside, the support posts will not rust, and the lightweight self-supporting wall has high weather resistance. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view of a lightweight freestanding wall according to an embodiment of the present invention. [Figure 2] FIG. 2 is a diagram showing the configuration of a foam panel according to an embodiment of the present invention. [Figure 3] FIG. 3 is a horizontal cross-sectional view of a foam panel according to an embodiment of the present invention. [Figure 4] FIG. 4 is a perspective view showing the configuration of a foam panel according to an embodiment of the present invention. [Figure 5] FIG. 5 is an exploded perspective view of a foam panel according to an embodiment of the present invention. [Figure 6] FIG. 6 is a flowchart showing the construction procedure for a lightweight freestanding wall according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, a lightweight freestanding wall according to an embodiment of the present invention will be described in detail. In this embodiment, a styrene foam fence installed on the boundary of a general residential property will be described as an example of the lightweight freestanding wall.

[0011] The lightweight freestanding wall 1 includes base concrete 10 to be placed on the ground, aluminum supports 15, foam panels 20 made of expanded polystyrene, cement-based filler 30, and a surface layer 31. In this embodiment, a lightweight freestanding wall 1 composed of a total of nine foam panels 20 arranged in three rows and three columns will be described.

[0012] Fig. 2(a) is a front view showing the configuration of the foam panel 20, Fig. 2(b) is a side view showing the configuration of the foam panel 20, and Fig. 2(c) is a plan view showing the configuration of the foam panel 20. Figs. 2 to 4 show the foam panel 20 in an exposed state before the processes of undercoating, intermediate coating, and top coating, which will be described later, are performed.

[0013] The base concrete 10 is a foundation that is poured by digging a predetermined depth into the ground over the entire area where the foam panel 20 will be installed. Support holes (not shown) are formed at predetermined intervals in the base concrete 10 where the foam panel 20 will be installed to secure the aluminum supports 15 that support the foam panel 20. The support holes may be drilled with an excavator after the base concrete 10 is poured, or may be drilled using a sleeve method in which a void is created in advance and then the base concrete 10 is poured.

[0014] The aluminum pillar 15 is a hollow, elongated rectangular cylinder made of aluminum, and is set upright with its lower part supported by the base concrete 10. The height of the aluminum pillar 15 is approximately the same as the height of the lightweight self-supporting wall 1. The lower end of the aluminum pillar 15 is inserted into a pillar hole in the base concrete 10 and fixed in place with mortar.

[0015] Normally, aluminum supports have lower strength than steel supports, and therefore cannot be used as supports for supporting heavy objects such as concrete blocks due to insufficient strength. In contrast, as in this embodiment, even aluminum supports 15 can stably support lightweight foam panels 20. In particular, in this embodiment, the aluminum supports 15 are formed as hollow rectangular tubes, thereby increasing the strength of the supports.

[0016] The foam panel 20 is a rectangular parallelepiped panel made of expanded polystyrene foam with a 50% expansion rate. Of course, the expansion rate can be changed as needed. In this embodiment, the foam panel 20 has different shapes and the presence or absence of the support insertion holes 21, vertical connection protrusions 22a, and vertical connection recesses 22b depending on the installation location, and six types of foam panel 20 structures are available.

[0017] The post insertion holes 21 are holes formed by vertically penetrating the foam panel 20, and are holes through which aluminum posts 15 pass vertically to support the foam panel 20. The post insertion holes 21 include single post insertion holes 21a formed entirely within one foam panel 20, and combined post insertion holes 21b formed at the boundary between two adjacent foam panels 20, where a recess on one side of the post through hole 21 is formed in each foam panel 20 and the two panels are combined to form one post through hole 21 (see FIG. 5, etc.).

[0018] The undersides of the foam panels 20-1, 20-2, and 20-3 installed on the lower level of the lightweight self-supporting wall 1 are flat surfaces that are adhered to the surface of the base concrete 10, and the upper surfaces are formed with upper and lower connecting protrusions 22a that connect to the undersides of the adjacent middle level foam panels 20-4, 20-5, and 20-6 above.

[0019] The lower surfaces of the foam panels 20-4 to 20-6 installed in the middle of the lightweight freestanding wall 1 are formed with upper and lower connection recesses 22b that fit with the upper and lower connection protrusions 22a of the adjacent lowermost foam panels 20-1 to 20-3, and the upper surfaces are formed with upper and lower connection protrusions 22a that connect with the adjacent uppermost foam panels 20-7, 20-8, 20-9 above.

[0020] The foam panels 20-7 to 20-9 installed in the upper stage of the lightweight freestanding wall 1 have lower surfaces formed with vertical connection recesses 22b that fit with the vertical connection protrusions 22a of the adjacent foam panels 20-4 to 20-6 in the middle stage below, and the upper surfaces are flat.

[0021] The foam panels 20-1, 20-4, and 20-7 installed in the leftmost row of the lightweight freestanding wall 1 have a single support insertion hole 21a formed inside near the left end and a recess for a combined support insertion hole 21b formed at the right end, which integrates with the recess for the combined support insertion hole 21b of the foam panels 20-2, 20-5, and 20-8 adjacent to the right to form a support insertion hole 21 at the boundary portion.

[0022] The foam panels 20-2, 5, and 8 installed in the central row of the lightweight freestanding wall 1 have recesses for the insertion holes 21b for the combined supports formed on both the left and right ends, which integrate with the recesses for the insertion holes 21b for the combined supports of the foam panels 20 adjacent to the left and right to form the insertion holes 21 for the supports at the boundary portions.

[0023] The foam panels 20-3, 20-6, and 20-9 installed in the rightmost row of the lightweight freestanding wall 1 are installed symmetrically to the foam panels 20-1, 4, and 7 installed in the leftmost row, but have the same shape.When viewed from the front, an insertion hole 21b for a combined support is formed at the left end, and an insertion hole 21a for a single support is formed inside near the right end.

[0024] Here, when bonding the undersides of the lowest foam panels 20-1 to 20-3 of the lightweight self-supporting wall 1 to the surface of the base concrete 10, pressure cement is used. The upper and lower connecting protrusions 22a and the upper and lower connecting recesses 22b of the foam panels 20 that fit adjacent to each other in the vertical direction are bonded with a silicone-based sealant.

[0025] The aluminum support 15 that passes through the support insertion hole 21 of the foam panel 20 is bonded and fixed to the foam panel 20 by filling the support insertion hole 21 with a cement-based filler 30. At this time, as shown in the horizontal cross-sectional view of Figure 3, the hollow aluminum support 15 is positioned in the center of the support insertion hole 21, and the cement-based filler 30 is filled into the support insertion hole 21.

[0026] In this embodiment, within the support insertion hole 21, the space inside the aluminum support 15 is filled with a mortar filler 30a made of a mixture of sand, perlite, cement, and water as the cement-based filler 30, and the space outside the aluminum support 15 is filled with a grout filler 30b made of a mixture of perlite, cement-based non-shrink grout, and water.

[0027] The reason why a highly fluid grout filler 30b is used in the space outside the aluminum support 15 is that, as shown in Figure 3, the space inside the support insertion hole 21 is narrower on the outside of the aluminum support 15 than on the inside, allowing the cement-based filler 30 to flow smoothly into the gap between the aluminum support 15 and the foam panel 20 and be distributed throughout.

[0028] In this embodiment, the foam panels 20 adjacent in the horizontal direction are bonded and connected and fixed by the grout filler 30b filled in the joint support insertion holes 21b located at the boundary.

[0029] In this embodiment, horizontally adjacent foam panels 20 are bonded together using cement-based filler 30 filled in the through holes 21b for the combined support formed at the boundary, thereby not only bonding and fixing the aluminum support 15 to the foam panels 20, but also firmly connecting and fixing the horizontally adjacent foam panels 20 to each other.

[0030] In addition, in this embodiment, the foam panels 20-1, 3, 4, 6, 7, and 9 installed at the left and right ends of the lightweight freestanding wall 1 also have a single support insertion hole 21a formed therein, which allows the foam panel 20 and the aluminum support 15 to be more firmly adhered and fixed.

[0031] The surface layer 31 is a layer that covers the entire surface of the foam panel 20 (front, rear, both left and right sides, and top surface (top)), and is composed of a top coat material, mesh sheet, intermediate coat material, and top coat material, which will be described later.

[0032] The configuration of the lightweight freestanding wall 1 has been described above. Next, a construction method for the lightweight freestanding wall 1 will be described with reference to the flowchart shown in Fig. 6. In this embodiment, a case where a lightweight freestanding wall 1 consisting of a total of nine foam panels 20 in three rows and three columns, as shown in Fig. 2 etc., will be described.

[0033] First, in S1, concrete is poured and cured on the ground on which the lightweight self-supporting wall 1 will be installed to create base concrete 10. After the base concrete 10 is completed, in S2, cylindrical holes for the aluminum posts 15 are drilled (not shown) using a drilling machine at positions (four locations) in the base concrete 10 where the aluminum posts 15 will be erected.

[0034] In S3, the aluminum posts 15 are placed vertically in the post holes, and mortar is poured into them and allowed to harden, thereby erecting the four aluminum posts 15. In S4, the lower foam panels 20-1 to 20-3 are installed, and the undersides of the foam panels 20-1 to 20-3 are bonded to the surface of the base concrete 10 with pressure cement. When installing the foam panels 20-1 to 20-3, the aluminum posts 15 are installed so that they pass through each of the four post insertion holes 21 in the foam panel 20.

[0035] Next, proceeding to S5, the middle foam panels 20-4 to 20-6 and the upper foam panels 20-7 to 20-9 are stacked and installed in this order. The vertical connection protrusions 22a and the vertical connection recesses 22b of vertically adjacent foam panels 20 are firmly bonded together with a silicone-based sealant.

[0036] After all the foam panels 20 have been installed, in S6, cement-based filler 30 is filled into the four support through-holes 21 to firmly bond all the foam panels 20 to the aluminum supports 15. At this time, before filling with mortar, tape is applied to the outer surfaces of the boundaries between horizontally adjacent foam panels 20 to seal them and prevent the filled cement-based filler 30 from leaking out through gaps at the boundaries. The sealing tape is removed after the cement-based filler 30 has cured.

[0037] After the cement-based filler 30 is filled, the lightweight freestanding wall 1 is subsequently surface-finished in S7 and thereafter to form the surface layer 31. First, in S7, a primer is applied to the entire exposed surface of the foam panel 20 (front, rear, both left and right sides, and top surface (crown)) to prepare a base for the plastered wall. For example, a water-soluble resin can be used as the primer, and the primer is applied to a thickness of about 1 mm.

[0038] In S8, after the base is formed in S7, a mesh sheet is attached to the entire surface to reinforce foam panel 20. As the mesh sheet, for example, an alkali-resistant glass fiber net having a thickness of about 1 mm can be used.

[0039] Next, in S9, an intermediate coat is applied to the entire surface of the foam panel 20, followed by a finishing top coat. The intermediate coat can be a water-soluble resin, similar to the primer, and is applied to a thickness of approximately 1 mm. The intermediate coat covers the entire mesh sheet.

[0040] The top coat is exposed on the surface to define the exterior appearance, so the installer can select the appropriate plaster material and paint based on their preferences. For example, a 2mm thick plaster containing an inorganic photocatalyst can be applied. Using a photocatalytic plaster can prevent the surface of the foam panel 20 from becoming dirty.

[0041] The surface layer 31 is formed from the primer S7, the mesh sheet S8, and the intermediate and top coats S9. In Figure 4, the surface layer 31 is represented by a two-dot chain line around the foam panel 20. Finally, in S10, the entire panel is dried to complete the lightweight freestanding wall 1 with no seams on the surface as shown in Figure 1.

[0042] This embodiment has been described in detail above. According to this embodiment, aluminum pillars 15 are used as the pillars 15 that support the lightweight foam panels 20. Therefore, even if rainwater or the like penetrates into the interior of the lightweight freestanding wall 1, the aluminum pillars 15 do not rust, and the lightweight freestanding wall 1 has high weather resistance.

[0043] Furthermore, by using lightweight aluminum supports 15, the lightweight freestanding wall 1 can be made lighter than conventional walls supported by steel bars or the like, and even if the lightweight freestanding wall 1 were to collapse, the danger to the surrounding area can be greatly reduced.

[0044] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the present invention. For example, the size, shape, and material of each member constituting the lightweight freestanding wall can be changed as appropriate, and the shape, height, and width of the lightweight freestanding wall can also be changed as appropriate to suit the site. The lightweight freestanding wall may be not only flat, but also curved.

[0045] In addition, in the above embodiment, polystyrene foam (expanded polystyrene) was used as the material for the foam panel, but other materials such as foamed polyurethane, foamed polyethylene, foamed polypropylene, etc., which are lightweight foamed synthetic resins (foamed plastics), can be used as appropriate.

[0046] Furthermore, the support pillars are not limited to being made of aluminum, and any suitable material can be used as long as it is lightweight, rust-proof, and has a certain degree of strength. For example, the support pillars can be made of stainless steel or carbon fiber plastic (CFRP).

[0047] The shape of the support pillars can be any shape that can maintain a certain level of strength, and as long as they are hollow and cylindrical, they can be not only rectangular but also triangular or cylindrical. Support pillars with an H-shaped horizontal cross section, such as H-beams, are also acceptable. [Explanation of symbols]

[0048] 1. Lightweight freestanding wall 10 Base concrete 15 Aluminum support 20 Foam Panel 21 Support hole 21a Single support hole 21b Insertion hole for combined support 22a Upper and lower connection protrusions 22b Upper and lower connection recess 30 Cement-based filler 30a Mortar filler 30b Grout filler 31 Surface layer

Claims

1. In a lightweight self-supporting wall erected on a foundation, A thin and long hollow cylinder or a horizontal cross section H-shaped support pillar made of aluminum, stainless steel, or carbon fiber plastic, which is fixed to stand vertically on the foundation; a foam panel made of foam resin having a through hole extending in a vertical direction into which the support post is inserted; A lightweight self-supporting wall characterized by comprising: a cement-based filler filled in the insertion hole to adhesively fix the support and the foam panel.

2. The support is a hollow cylinder, 2. The lightweight self-supporting wall according to claim 1, wherein the cement-based filler is filled in both the internal space of the support and the external space of the support within the insertion hole.

3. a plurality of the foam panels each having a rectangular parallelepiped shape, the foam panels being connected and fixed adjacent to each other in the lateral direction; The lightweight freestanding wall according to claim 1, characterized in that the foam panels have recesses formed on both opposing side surfaces at the boundary between adjacent foam panels, and the insertion hole is a combined insertion hole formed by the combination of two of the recesses.

4. 4. The lightweight freestanding wall according to claim 3, wherein the foam panel further has a single through-hole formed therein as the through-hole, the single through-hole being entirely located within the single foam panel.

5. 5. The lightweight self-supporting wall according to claim 1, wherein the support pillars are rectangular tubes made of aluminum.

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