Method for manufacturing building panels with openings and building panels with openings

Abstract

The object of the present invention is to provide a method for manufacturing a building panel with an opening, and a building panel with an opening, that allows for the easy and quick temporary fixing of a cover for the opening to the opening. [Solution] The manufacturing method for the building panel 100 with an opening comprises the steps of: (I) temporarily fixing a plurality of support members 5 to a panel frame 101 at a position that will become the opening side surface 21 of the opening 2 to be formed; (II) providing a facing material 104 on one side 101a of the panel frame 101 after step (I); (III) forming the opening 2 by cutting out the facing material 104 after step (II); and (IV) positioning and temporarily fixing the opening cover 4 to the plurality of support members 5 that have been temporarily fixed to the opening side surface 21 via an adjustment material 6 after step (III).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing an architectural panel with an opening and an architectural panel with an opening.

Background Art

[0002] Conventionally, it is known that openings are formed in floor panels for underfloor storage, sink inspection, bathroom inspection, etc. As a method for forming a floor panel with an opening, for example, as disclosed in Patent Document 1, first, a jig having an opening is brought into contact with a predetermined position of the floor panel. Then, while guiding the guided portion of the router by the inner surface of the opening of the jig, the floor material of the floor panel is cut by the cutting portion of the router. Thereby, an opening having a predetermined shape can be provided. And a lid is installed in the opening. However, since the lid installed in the opening described in Patent Document 1 is a formal lid, it may be damaged when the floor panel is transported to the site. Therefore, when the lid is damaged, it is necessary to separately replace the lid. Therefore, it is required to attach the formal lid at the site. However, if the panel with an opening is used with the opening left open without attaching a lid to the opening, there is a risk of accidentally falling into the opening during construction at the site. Therefore, it is desirable to provide a temporary lid for the opening.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present invention has been made in view of the above circumstances, and its purpose is to provide a method for manufacturing a building panel with an opening, and a building panel with an opening, that allows for easy and quick temporary fixing of a cover for the opening to the opening. [Means for solving the problem]

[0005] The invention described in claim 1 is a method for manufacturing an architectural panel 100 with an opening, which has an opening 2 formed through the thickness direction of the architectural panel 1, as shown in Figures 1 to 4, 6, 7, 10 and 11, for example. The process (I) involves temporarily fixing a plurality of support members 5 to the panel frame 101 at positions that will become the opening side surface 21 of the opening 2 that will be formed, After step (I), step (II) is performed to provide a facing material 104 to one surface 101a of the panel frame 101, After step (II) above, step (III) is performed to cut out the surface material 104 to form the opening 2, The present invention is characterized by comprising the step (IV) of positioning and temporarily fixing the opening cover 4 to the plurality of receiving members 5 that have been temporarily fixed to the opening side surface 21 via the adjustment member 6, after the above step (III).

[0006] According to the invention described in claim 1, the invention comprises the steps of: (I) temporarily fixing a plurality of support members 5 to a panel frame 101 at a position that will become the opening side surface 21 of the opening 2 to be formed; (II) providing a facing material 104 on one surface 101a of the panel frame 101 after step (I); (III) forming the opening 2 by cutting out the facing material 104 after step (II); and (IV) positioning and temporarily fixing the opening cover 4 to the plurality of support members 5 temporarily fixed to the opening side surface 21 via an adjustment material 6 after step (III). Specifically, in process (I), multiple support members 5 are temporarily fixed in advance at positions that will become the opening side surface 21 of the panel frame 101. Then, on the factory line, the process of installing the facing material 104 (II), forming the opening 2 (III), and temporarily fixing the opening cover 4 (IV) is carried out. Therefore, by performing step (I) in advance, existing factory lines that manufacture standard building panels with openings only need to add step (IV) to temporarily fix the opening cover 4. Thus, the opening cover 4 can be easily and quickly temporarily fixed to the opening 2 without significantly increasing the number of steps on the factory line, improving productivity. Furthermore, in step (IV), the opening cover 4 is positioned and temporarily fixed via the adjustment material 6. By adjusting the thickness H of the adjustment material 6, the upper surface 4a of the opening cover 4 and the upper surface 104a of the facing material 104 can be made to be at approximately the same height.

[0007] The invention described in claim 2 is, for example, as shown in Figures 1 to 3, a method for manufacturing the building panel 100 with an opening as described in claim 1, In step (I) above, the support member 5 is temporarily fixed at a position that will become the opening side surface 21, at a distance equal to the thickness of the adjustment member 6 from one surface 101a of the panel frame 101.

[0008] According to the invention described in claim 2, in step (I), the support member 5 is temporarily fixed at a position that will become the opening side surface 21, spaced by the thickness of the adjustment member 6 from one surface 101a of the panel frame 101. Therefore, as shown in Figure 7, when inserting the tool R into the surface material 104 and cutting out the opening in step (III), there is a space between the lower surface 104b of the surface material 104 and the upper surface 5a of the support member 5. As a result, the blade Ra at the tip of the tool R is prevented from coming into contact with the support member 5. Thus, the surface material 104 can be smoothly cut out without the support member 5 getting in the way, and the opening 2 can be easily formed.

[0009] The invention described in claim 3 is, for example, as shown in Figures 1, 2, 8 and 10, a method for manufacturing the building panel 100 with an opening as described in claim 1, In step (IV) above, the adjustment member 6 is assembled into a frame shape, the opening cover 4 is attached to the frame-shaped adjustment member 6 (for example, the adjustment frame member 60), and the opening cover 4 is then positioned and temporarily fixed to the plurality of receiving members 5 via the adjustment member 6.

[0010] According to the invention described in claim 3, in step (VI), the adjustment member 6 is assembled into a frame shape, the opening cover 4 is attached to the frame-shaped adjustment member 6, and then the opening cover 4 is positioned and temporarily fixed to the multiple receiving members 5 via the adjustment member 6. In other words, by attaching the opening cover 4 to the frame-shaped adjustment member 6 in advance, on the factory line, it is only necessary to attach the opening cover 400 with the adjustment frame member onto the receiving members 5. Therefore, the number of steps on the line can be further reduced, and time can be shortened.

[0011] The invention described in claim 4 is, for example, as shown in Figures 1, 2, and 5, a method for manufacturing the building panel 100 with an opening as described in claim 1, The method is characterized by providing an anti-termite sheet 106 on the other surface 101b of the panel frame 101 after step (II) and before step (III).

[0012] According to the invention described in claim 4, since the termite-proof sheet 106 is provided on the other surface 101b of the panel frame 101 after step (III) and before step (IV), the termite-proof sheet 106 can prevent termites and other pests from entering the building panel 100 with an opening.

[0013] The invention described in claim 5 is, for example, as shown in Figure 13, a method for manufacturing the building panel 100 with an opening as described in claim 1, The present invention is characterized by having a step (V) of removing the plurality of support members 5 after the above step (IV).

[0014] According to the invention described in claim 5, since the process includes step (V) of removing the multiple support members 5 after step (IV), permanent support members can be installed on-site in place of the multiple support members 5 that were temporarily fixed.

[0015] The invention described in claim 6 is, for example, a building panel 100 with an opening, which has an opening 2 formed through the building panel 1 in the thickness direction, as shown in Figures 1 and 2. A plurality of receiving members 5 are temporarily fixed to the opening side surface 21 of the opening 2. An opening lid 4 is temporarily fixed to the plurality of receiving members 5 temporarily fixed to the opening side surface 21 via an adjusting member 6.

[0016] According to the invention described in claim 6, a plurality of receiving members 5 are temporarily fixed to the opening side surface 21 of the opening 2, and an opening lid 4 is temporarily fixed to the plurality of receiving members 5 temporarily fixed to the opening side surface 21 via an adjusting member 6. Therefore, by temporarily fixing the receiving members 5 to the opening side surface 21 in advance, in the existing factory line for manufacturing ordinary building panels with openings, it is only necessary to temporarily fix the opening lid 4 via the adjusting member 6. Thus, the opening lid 4 can be easily and quickly temporarily fixed to the opening 2 without significantly increasing the number of processes on the factory line, improving productivity. In addition, since the opening lid 4 is temporarily fixed via the adjusting member 6, by adjusting the thickness H of the adjusting member 6, the upper surface 4a of the opening lid 4 and the upper surface 104a of the facing material 104 can be made substantially at the same height position.

Effects of the Invention

[0017] According to the present invention, it is possible to provide a method for manufacturing a building panel with an opening and a building panel with an opening, which can easily and quickly temporarily fix an opening lid to the opening.

Brief Description of the Drawings

[0018] [Figure 1] It is an exploded perspective view of a building panel with an opening. [Figure 2] It is a cross-sectional view taken along the line ii-ii of FIG. 1. [Figure 3] It is an external perspective view showing step (I). [Figure 4] It is an external perspective view showing step (II). [Figure 5] It is an external perspective view showing the step of attaching an anti-termite sheet after step (II). [Figure 6] It is an external perspective view showing step (III). [Figure 7] This is a cross-sectional view taken along the line vii-vii in Figure 6. [Figure 8] This is an external perspective view showing process (IV). [Figure 9] This is an external perspective view showing process (IV). [Figure 10] This is an external perspective view showing process (IV). [Figure 11] This is an external perspective view showing process (IV). [Figure 12] This is an external perspective view showing process (V). [Figure 13] This is an external perspective view showing process (V). [Figure 14] This is a perspective view of the jig and support material as seen from above. [Figure 15] This is a perspective view of the jig and support material as seen from below. [Figure 16] This is an external perspective view illustrating the procedure for attaching a support member to the side of an opening using a jig. [Figure 17] This is an external perspective view illustrating the procedure for attaching a support member to the side of an opening using a jig. [Figure 18] This is a cross-sectional view taken along the line xviii-xviii in Figure 17. [Figure 19] This is an exploded perspective view of a modified architectural panel with an opening. [Modes for carrying out the invention]

[0019] Embodiments will be described below with reference to the drawings. The features and technical effects of the embodiments will be understood from the following detailed description and drawings. However, the scope of the present invention is not limited to the embodiments disclosed below. The scope of the present invention is not limited to the examples shown in the drawings, as the drawings are provided for illustrative purposes only.

[0020] [Manufacturing method for building panels with openings] Figure 1 is an exploded perspective view of an architectural panel with an opening. Figure 2 is a cross-sectional view taken along the line ii-ii in Figure 1. The building panel 100 with an opening is preferably a floor panel used for, for example, an underfloor storage compartment, a washroom inspection area, a bathroom inspection area, or an attic inspection area, or a roof panel for a skylight. The following description will use the application of the panel to a floor panel for an underfloor storage compartment as an example, but the present invention is not limited thereto.

[0021] The building panel 100 with an opening has an opening 2 formed by penetrating the building panel 1 in the thickness direction. The opening 2 is rectangular in plan view. In Figure 1, the opening 2 is approximately square in plan view.

[0022] Multiple support members 5 are temporarily fixed to the opening side surface 21 that forms the opening 2. An opening cover 4 is positioned and temporarily fixed on the multiple support members 5 via an adjustment member 6.

[0023] The support member 5 and the adjustment member 6 are rod-shaped timbers. The length M4 of the support member 5 is shorter than the length M6 of the adjustment member 6. The width W3 of the support member 5 is approximately equal to the width W4 of the adjustment member 6. Therefore, the adjustment member 6, which is placed on the support member 5, is securely held by the support member 5.

[0024] The opening cover 4 has a shape similar to that of the opening 2, and in plan view, it is roughly square. The opening cover 4 is sized to fit on the adjustment material 6, and is slightly smaller than the dimensions of the opening 2. The thickness of the opening cover 4 is preferably approximately equal to the thickness of the facing material 104, which will be described later. Also, the thickness H of the adjustment material 6 is approximately equal to the height from the lower surface 104b of the facing material 104 to the upper surface 5a of the supporting material 5 when it is placed on the supporting material 5. Furthermore, the upper surface 4a of the opening cover 4, which is placed on the supporting material 5 via the adjustment material 6, and the upper surface 104a of the facing material 104 are at approximately the same height.

[0025] The manufacturing method for the building panel 100 with an opening is described below. The building panel 100 with an opening is manufactured, for example, in a factory through the following steps (I) to (IV).

[0026] Step (I): Multiple support members 5 are temporarily fixed to the panel frame 101 at positions that will become the opening side surface 21 of the opening 2 to be formed. Step (II): A facing material 104 is provided on one side 101a of the panel frame 101. Step (III): The facing material 104 is cut out to form the opening 2. Step (IV): The opening cover 4 is placed and temporarily fixed to the multiple support members 5 that are temporarily fixed to the opening side surface 21 via the adjustment member 6.

[0027] <Process (I)> Figure 3 is an external perspective view showing process (I). In step (I), as shown in Figure 3, multiple support members 5 are temporarily fixed to the panel frame 101 at positions that will become the opening side surface 21 of the opening 2 to be formed. The panel frame 101 is formed by pre-assembling vertical frame members 102 and horizontal frame members 103 in a rectangular frame shape. Multiple reinforcing core members 105 are attached to the panel frame 101, arranged vertically and horizontally, except at the positions that will become openings 2.

[0028] The longitudinal length M4 of the support member 5 is shorter than the length M5 of the opening side surface 21. Therefore, in the case of multiple support members 5 temporarily fixed to the opening side surface 21, a gap C1 is formed between the ends of adjacent support members 5. A crowbar B, which is used to remove the opening cover 4, is inserted into the gap C1, as will be described later (see Figure 12).

[0029] As a method for temporarily fixing the support member 5, first, the support member 5 is placed in the panel frame 101 at a position that will become the opening side surface 21 of the opening 2 to be formed in a later process. Then, the support member 5 is temporarily fixed with the fixing material S2. As shown in Figure 2, the mounting position of the support member 5 is on the opening side surface 21, spaced downward by an amount H equal to the thickness of the adjustment member 6 to be installed in a later process, from one surface 101a of the panel frame 101. In other words, it is spaced downward by an amount H equal to the thickness of the adjustment member 6 from the lower surface 104b of the facing material 104 to be installed in a later process. By attaching the support member 5 to a position lower than one of the surfaces 101a of the panel frame 101 in this manner, when the surface material 104 is cut out with a tool R in a subsequent process to form the opening 2, the blade Ra of the tool R and the support member 5 do not come into contact, allowing the surface material 104 to be cut out smoothly (see Figure 7).

[0030] For example, screws, nails, or staples can be used as the fixing material S2. Since it is for temporary fixing and easy to remove, it is preferable to use screws, nails, or staples as the fixing material S2 without using adhesive. From the viewpoint of saving time, it is preferable to fix the support material 5 at two points on both ends of the support material 5 with the fixing material S2. Furthermore, in step (I), it is preferable from the viewpoint of work efficiency to attach the support member 5 to the opening side surface 21 using a dedicated jig 3, which will be described later.

[0031] <Process (II)> Figure 4 is an external perspective view showing process (II). In step (II), as shown in Figure 4, a facing material 104 is provided on one side 101a of the panel frame 101. Specifically, adhesive is applied to one side 101a of the panel frame 101. Then, the facing material 104 is bonded and fixed to the side 101a of the panel frame 101 to which the adhesive has been applied.

[0032] Figure 5 is an external perspective view showing the process of attaching the termite-proof sheet after process (II). As shown in Figure 5, it is preferable to attach the termite-resistant sheet 106 to the other surface 101b of the panel frame 101 before step (III) after the facing material 104 has been bonded and fixed. Specifically, after attaching the facing material 104 to the panel frame 101, the panel frame 101 is inverted so that the side with the facing material 104 attached faces downwards, and the other side 101b of the panel frame 101 faces upwards. Next, adhesive is applied to the other surface 101b of the panel frame 101. Then, the termite-resistant sheet 106 is attached and fixed to the other surface 101b of the panel frame 101 to which the adhesive has been applied. After attaching the termite-resistant sheet 106, the termite-resistant sheet 106 is cut out in the area where the opening 2 will be formed. Then, the panel frame 101 is inverted so that the side with the termite-resistant sheet 106 attached faces downwards, and the panel frame 101 is positioned so that one side 101a faces upwards. By inverting it in this way, the facing material 104 faces upwards.

[0033] <Process (III)> Figure 6 is an external perspective view showing process (III). Figure 7 is a cross-sectional view taken along the line vii-vii in Figure 6. In step (III), as shown in Figures 6 and 7, the tool R is inserted into the surface material 104 to a depth above the mounting position of the support member 5 to cut out the surface material 104 and form the opening 2. Note that the tool R is not shown in Figure 6 due to drawing limitations. Specifically, a tool R is placed at a predetermined position on the surface material 104 where an opening 2 is to be formed. Examples of tools R include cutting tools such as routers and trimmers. When using a router R, the protrusion length of the router blade Ra is adjusted. The protrusion length of the router blade Ra should be such that it does not come into contact with the upper surface 5a of the support material 5. This allows the router blade Ra to smoothly cut out the surface material 104 and form the opening 2 without coming into contact with the support material 5. Next, the surface material 104 is cut out using a tool R to form the opening 2. It is preferable to use the cut-out surface material 104 for the opening cover 4, which will be described later, in order to simplify the work. Reference numeral 42 denotes a processing hole formed when the surface material 104 is cut out with a router or the like.

[0034] <Process (IV)> Figures 8 to 11 are external perspective views showing process (IV). In step (IV), the opening cover 4 is placed and temporarily fixed to the multiple support members 5 that are temporarily fixed to the opening side surface 21 via the adjustment member 6. As shown in Figure 8, the adjustment member 6 is pre-assembled into a rectangular frame to form the adjustment frame member 60. Then, as shown in Figure 9, it is preferable to attach the opening cover 4 to one side of the adjustment frame member 60. It is preferable to temporarily fix the adjustment frame member with the opening cover 400, which has the adjustment frame member 60 and opening cover 4 attached in advance, on a plurality of support members 5 in order to improve work efficiency.

[0035] The opening cover 400 with the adjustment frame material can be formed by the following procedure. Specifically, as shown in Figure 8, first, the longitudinal ends of the four adjustment members 6 are butted together to form a rectangular frame. At this time, it is preferable to fix the longitudinal ends of adjacent adjustment members 6 together with staples S4 or the like. It is preferable to drive the staples S4 so that they straddle the longitudinal end of one adjustment member 6 and the longitudinal end of the other adjustment member 6, in order to secure them firmly. The four adjustment members 6 are assembled in this way to form the adjustment frame member 60.

[0036] Next, as shown in Figure 9, the opening cover 4 is placed on the adjustment frame material 60, and the fixing material S5 is driven into the adjustment frame material 60 from the upper surface 4a of the opening cover 4. This forms the opening cover 400 with the adjustment frame material. For fastening material S5, for example, screws, nails, or staples can be used.

[0037] Next, as shown in Figure 10, the opening cover 400 with the adjustment frame is positioned so that the adjustment frame 60 rests on the support member 5. This brings the upper surface 4a of the opening cover 4 and the upper surface 104a of the facing material 104 to approximately the same height. Furthermore, a second gap C2 is formed between the side surface 4b of the opening cover 4 and the opening side surface 21 (see Figures 2 and 11). In step (V) described later, it is preferable to remove the opening cover 4 by inserting a crowbar B using the second gap C2 and the gap C1 formed between the ends of adjacent support members 5, due to the length M4 of the support member 5 being shorter than the length M5 of the opening side surface 21 (see Figure 12).

[0038] Next, as shown in Figure 11, the opening cover 4 is temporarily fixed to the support member 5. The opening cover 4 is fixed to the support member 5 at predetermined intervals using fixing materials S3 from the upper surface 4a of the opening cover 4. The fixing materials S3 can be the same as the fixing materials S2 used to fix the support member 5. For example, screws, nails, or staples can be used as fixing materials S3. Since it is for temporary fixing and easy to remove, it is preferable to use screws, nails, or staples as fixing materials S3 without using adhesive. Furthermore, in addition to fastening with screws, nails, or staples, although not shown in the diagram, hazard tape may also be attached so as to span the side edges of the opening cover 4 and the side edges of the facing material 104.

[0039] In the above explanation, an opening cover 400 with an adjustment frame was prepared in advance and attached to the support member 5. However, this is not the only option; after attaching each adjustment member 6 to multiple support members 5, the opening cover 4 may be placed on the adjustment member 6 and temporarily fixed in place. In this case, the adjustment members 6 may be assembled in advance to form an adjustment frame 60, the adjustment frame 60 may be attached to multiple support members 5, and then the opening cover 4 may be placed on the adjustment frame 60 and temporarily fixed in place.

[0040] It is preferable to perform steps (I) to (IV) above in the factory, and then transport the building panel 1 with the opening cover 4 temporarily fixed to the site before performing step (V) below. Furthermore, it is preferable that the support members 5 are attached to the panel frame 101 in advance at the factory in step (I), and that steps (II) to (IV) are performed on the factory line. This avoids heavy lifting work such as inverting the panel frame 101.

[0041] <Process (V)> Figures 12 and 13 are external perspective views showing process (V). After step (IV), step (V) is performed to remove multiple support members 5. In step (V), as shown in Figure 12, a crowbar B is inserted into the gap C1 formed by the portion of the support member 5 that is shorter than the opening side surface 21, the opening cover 4 is removed, and the opening 2 is opened. Specifically, a second gap C2 is located above gap C1, between the opening cover 4 and the opening side surface 21. Therefore, the opening cover 4 is removed by inserting a crowbar B through the second gap C2 located above gap C1 (see Figure 12). The crowbar B can be easily inserted into gap C1 and the second gap C2 by striking its tip with, for example, a hammer. Furthermore, to remove the opening cover 4, instead of using gap C1 and the second gap C2, one may use, for example, the processing hole 42 formed in the opening cover 4. The opening cover 4 may also be removed by inserting a crowbar B into this hole 42.

[0042] After removing the opening cover 4, remove the multiple support members 5 as shown in Figure 13. It is preferable to remove the multiple support members 5 using a removal tool such as a crowbar, in the same manner as the opening cover 4.

[0043] After step (V), a formal support member is attached to the side of the opening 21, and a formal cover is also attached to the opening 2.

[0044] [jig] In step (IV), when temporarily fixing the support member 5 to the opening side surface 21, it is preferable from the viewpoint of work efficiency to use a dedicated jig 3. The configuration of the dedicated jig 3 will be described below. Figure 14 is a perspective view of the jig and support member as seen from above. Figure 15 is a perspective view of the jig and support member as seen from below. In the following explanation, "top surface" refers to the upper side (front surface) of the building panel 1 in Figure 1, and "bottom surface" refers to the lower side (back surface) of the building panel 1 in Figure 1. As shown in Figure 14, the jig 3 comprises a jig body 31, an intermediate member 32, and a leg member 33. The jig body 31, intermediate member 32, and leg member 33 are plate-shaped members. The intermediate member 32 is provided on the lower surface 311 of the jig body 31, and the leg member 33 is provided on the lower surface 321 of the intermediate member 32.

[0045] The width W2 of the intermediate member 32 and the width W2 of the leg member 33 are approximately equal. The width W2 of the intermediate member 32 and the width W2 of the leg member 33 are smaller than the width W1 of the jig body 31. An intermediate member 32 is provided on one of the side edges of the lower surface 311 of the jig body 31, along the longitudinal direction. One side surface 312 of the jig body 31 along the longitudinal direction and one side surface 322 of the intermediate member 32 along the longitudinal direction are flush with each other. Furthermore, as shown in Figure 15, the lower surface 311 of the jig body 31 has a lower surface portion 313 where the intermediate member 32 is not provided.

[0046] Leg members 33 are provided at both ends of the longitudinal direction on the lower surface 321 of the intermediate member 32. One side surface 322 of the intermediate member 32 along the longitudinal direction and one side surface 332 of the leg member 33 along the longitudinal direction are flush (see Figure 14). The other side surface 323 of the intermediate member 32 along the longitudinal direction and the other side surface 333 of the leg member 33 along the longitudinal direction are flush (see Figure 15).

[0047] The longitudinal length M1 of the jig body 31 and the longitudinal length M2 of the intermediate member 32 are approximately equal. Furthermore, the lengths M1 of the jig body 31 and M2 of the intermediate member 32 are approximately equal to the length M5 of the opening side surface 21 of the opening 2. The longitudinal length M3 of the leg member 33 is shorter than the longitudinal length M2 of the intermediate member 32. On the lower surface 321 of the intermediate member 32, the space between the two leg members 33 is a holding portion 34 for holding the support member 5, which will be described later. Therefore, the length between these two leg members 33 is approximately equal to the longitudinal length M4 of the support member 5.

[0048] The jig body 31, the intermediate member 32, and the leg member 33 are stacked in this order and then fixed to the jig body 31 from the lower surface 331 of the leg member 33 with fasteners S1 such as screws, nails, or staples.

[0049] A positioning portion 35 is formed relative to the upper surface (one surface 101a) of the panel frame 101 by the lower surface 313 of the jig body 31 where the intermediate member 32 is not provided, the other side surface 323 along the longitudinal direction of the intermediate member 32, and the other side surface 333 along the longitudinal direction of the leg member 33. That is, as shown in Figures 17 and 18 described later, the jig 3 is positioned by bringing the positioning portion 35 into contact with the upper surface (one surface 101a) of the panel frame 101.

[0050] Using the jig 3 described above, the opening cover 4 is temporarily fixed to the opening 2 of the building panel 1. Figures 16 and 17 are external perspective views illustrating the procedure for attaching the support member to the opening side using a jig. Figure 18 is a cross-sectional view taken along the line xviii-xviii in Figure 17. As a method for temporarily fixing multiple support members 5, first, the support members 5 are held by the holding portion 34 of the jig 3 (see Figure 16). That is, the support members 5 are positioned between the two leg members 33 on the lower surface 321 of the intermediate member 32 of the jig 3. With the support members 5 held between the two leg members 33 in this manner, the positioning portion 35 of the jig 3 is brought into contact with the upper surface (one side 101a) of the panel frame 101, and the jig 3 and the support members 5 are brought into contact with the opening side surface 21 at the same time (see Figures 17 and 18). Next, the support member 5 is temporarily fixed to the opening side surface 21 with the fixing member S2. Afterward, the jig 3 is removed, releasing the support member 5 from its position. In this way, the support members 5 are temporarily fixed to each of the four opening sides 21 using the jig 3. The four temporarily fixed support members 5 each have their upper surfaces 5a horizontal.

[0051] This embodiment provides the following excellent effects. The manufacturing method for the building panel 100 with an opening comprises steps (I) to (IV). Specifically, in step (I), a plurality of support members 5 are temporarily fixed in advance at the positions that will become the opening side surface 21 of the panel frame 101. Then, on the factory line, steps (II) of installing the facing material 104, step (III) of forming the opening 2, and step (IV) of temporarily fixing the opening cover 4 are performed. Therefore, by performing step (I) in advance, existing factory lines that manufacture standard building panels with openings only need to add step (IV) to temporarily fix the opening cover 4. Thus, the opening cover 4 can be easily and quickly temporarily fixed to the opening 2 without significantly increasing the number of steps on the factory line, improving productivity. Furthermore, in step (IV), the opening cover 4 is positioned and temporarily fixed via the adjustment material 6. By adjusting the thickness H of the adjustment material 6, the upper surface 4a of the opening cover 4 and the upper surface 104a of the facing material 104 can be made to be at approximately the same height.

[0052] In step (I), the support member 5 is temporarily fixed at a position that will become the opening side surface 21, spaced by the thickness of the adjustment member 6 from one surface 101a of the panel frame 101. Therefore, in step (III), when inserting the tool R into the surface material 104 to cut out the opening, there is a space between the lower surface 104b of the surface material 104 and the upper surface 5a of the support member 5 equal to the thickness of the adjustment member 6. This prevents the blade at the tip of the tool R from coming into contact with the support member 5. Thus, the surface material 104 can be cut out smoothly without the support member 5 getting in the way, and the opening 2 can be easily formed.

[0053] In step (VI), the adjustment member 6 is assembled into a frame shape, the opening cover 4 is attached to the frame-shaped adjustment member 6, and then the opening cover 4 is positioned and temporarily fixed to multiple support members 5 via the adjustment member 6. In other words, by attaching the opening cover 4 to the frame-shaped adjustment member 6 in advance, on the factory line, it is only necessary to attach the opening cover 400 with the adjustment frame to the support members 5. Therefore, the number of steps on the line can be further reduced, and time can be shortened.

[0054] Since the termite-proof sheet 106 is installed on the other side 101b of the panel frame 101 after step (III) and before step (IV), the termite-proof sheet 106 prevents termites and other pests from entering the building panel 100 with an opening. Since the process includes step (V) of removing multiple support members 5 after step (IV), permanent support members can be installed on-site in place of the temporarily fixed support members 5.

[0055] In the building panel 100 with an opening, multiple support members 5 are temporarily fixed to the opening side 21 of the opening 2, and the opening cover 4 is temporarily fixed to the multiple support members 5 temporarily fixed to the opening side 21 via an adjustment member 6. Therefore, by temporarily fixing the support members 5 to the opening side 21 in advance, in existing factory lines that manufacture normal building panels with openings, it is only necessary to temporarily fix the opening cover 4 via the adjustment member 6. Thus, the opening cover 4 can be easily and quickly temporarily fixed to the opening 2 without significantly increasing the number of processes on the factory line, improving productivity. Furthermore, since the opening cover 4 is temporarily fixed via the adjustment material 6, the upper surface 4a of the opening cover 4 and the upper surface 104a of the facing material 104 can be made to be at approximately the same height by adjusting the thickness H of the adjustment material 6.

[0056] Furthermore, in recent years, there has been a growing demand for the realization of a decarbonized society through the promotion of carbon neutrality, which aims to reduce carbon dioxide emissions to virtually zero, and for the achievement of the Sustainable Development Goals (SDGs). In the construction industry, efforts are also being made to use wood in buildings, which reduces carbon dioxide emissions. The above-mentioned building panels and other materials utilize wood-based materials, and therefore can contribute to the realization of a decarbonized society through the promotion of carbon neutrality and the achievement of the SDGs.

[0057] [Differentiation] The embodiments to which the present invention can be applied are not limited to those described above, and can be modified as appropriate without departing from the spirit of the invention. Modifications are described below. The following modifications may be combined as much as possible. Furthermore, in each of the following modifications, elements common to the above-described embodiments are denoted by the same reference numerals, and their descriptions are omitted or simplified.

[0058] Figure 19 is an exploded perspective view of a modified architectural panel with an opening. In the above embodiment, the opening 2 is approximately square in plan view, but it may also be approximately rectangular as shown in Figure 19. When the opening 2 is approximately rectangular in plan view, it is preferable to temporarily fix two support members 5 to each of the four opening sides 21, specifically the opening sides 22 on the longer side. It is also preferable to temporarily fix one support member 5 to each of the four opening sides 21, specifically the opening sides 23a and 23b on the shorter side. Hereinafter, the opening side on the longer side will be referred to as the long-side opening side 22, and the opening sides on the shorter side will be referred to as the short-side opening sides 23a and 23b. In the step of temporarily fixing the support member 5 to the long-side opening surface 22 and the short-side opening surfaces 23a and 23b, it is preferable to use a jig 3 similar to that of the above embodiment.

[0059] When the opening 2 is substantially rectangular in plan view, it is preferable to use two adjustment frame members 60, each assembled in a groove shape in plan view by butting the longitudinal ends of three adjustment members 6 against each other. It is preferable to pre-fix the opening cover 4 onto the two groove-shaped adjustment frame members 60. At this time, a gap C3 is formed between each end of the two groove-shaped adjustment frame members 60. The opening cover 4, with the two adjustment frame members 60 attached in this manner, is then placed on the support member 5 and temporarily fixed in place.

[0060] Alternatively, the two groove-shaped adjustment frame members 60 may not be fixed to the opening cover 4 in advance. Instead, the two groove-shaped adjustment frame members 60 may be arranged on the support member 5 so that they form a roughly rectangular shape in plan view, and then the opening cover 4 may be placed on the adjustment frame members 60 and temporarily fixed in place. In this case as well, a gap C3 will be formed between the ends of the two groove-shaped adjustment frame members 60. Since this gap C3 is located between the ends of adjacent support members 5, a crowbar B can be inserted into the gap C3, and the opening cover 4 can be easily removed.

[0061] Furthermore, instead of pre-assembling each adjustment member 6 as an adjustment frame member 60, the adjustment members 6 may be placed on the support member 5 and then fixed in place.

[0062] Furthermore, in the above embodiment, the number of support members 5 is provided on each of the four opening sides 21, but for example, they may be provided only on two opposing opening sides 21, and the number of support members 5 can be changed as appropriate, as long as the opening cover 4 does not bend due to the load from above. Furthermore, the shape of opening 2 may not be rectangular. Furthermore, to remove the opening cover 4, instead of using gap C1 or the second gap C2, for example, a processing hole 42 formed in the opening cover 4 may be used. The opening cover 4 may also be removed by inserting a crowbar B into this hole 42.

[0063] In the above embodiment and modified examples, the support member 5 is pre-attached to the panel frame 40 before forming the opening 2. However, for example, after forming the opening 2, the support member 5 may be temporarily fixed to the opening side surface 21, and the opening cover 4 may be placed and temporarily fixed to the support member 5 via the adjustment member 6. [Explanation of Symbols]

[0064] 1. Building panels 2 openings 4 Opening lid 5 Received material 6 Adjustment material 100 Architectural panels with openings 101 Panel frame 101a One side 101b The other side 104 Surface material 104b Bottom side 106 Termite-proof sheet

Claims

1. A method for manufacturing an architectural panel with an opening, the architectural panel having an opening formed through the thickness direction, The panel frame comprises a step (I) of temporarily fixing multiple support members to positions that will become the opening sides of the opening that will be formed, After step (I), step (II) is to provide a facing material to one side of the panel frame, After step (II) above, step (III) is performed to cut out the surface material to form the opening, The process includes, after step (III), step (IV) of positioning and temporarily fixing the opening cover to the plurality of support members temporarily fixed to the side surface of the opening via an adjustment member. A method for manufacturing an architectural panel with an opening, characterized by the following:

2. In step (I) above, the support member is temporarily fixed at a position that will become the side of the opening, at a distance equal to the thickness of the adjustment member from one side of the panel frame. A method for manufacturing an architectural panel with an opening, as described in claim 1.

3. In step (IV) above, the adjustment member is assembled into a frame shape, the opening cover is attached to the frame-shaped adjustment member, and then the opening cover is positioned and temporarily fixed to the multiple receiving members via the adjustment member. A method for manufacturing an architectural panel with an opening, as described in claim 1.

4. After step (II) and before step (III), an anti-termite sheet is provided on the other side of the panel frame. A method for manufacturing an architectural panel with an opening, as described in claim 1.

5. The process includes step (IV) followed by step (V) of removing the plurality of support members. A method for manufacturing an architectural panel with an opening, as described in claim 1.

6. A building panel with an opening, having an opening formed that penetrates the building panel in the thickness direction, Multiple support members are temporarily fixed to the opening side of the aforementioned opening. A lid for the opening is positioned and temporarily fixed to a plurality of support members that are temporarily fixed to the side surface of the opening via an adjustment member. A building panel with an opening, characterized by the features described above.

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