Method for manufacturing masonry structure and masonry structure
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ASTER CO LTD
- Filing Date
- 2026-01-15
- Publication Date
- 2026-07-30
Smart Images
Figure JP2026001108_30072026_PF_FP_ABST
Abstract
Description
Manufacturing Method of Assembled Structure and Assembled Structure
[0001] The present invention relates to a manufacturing method of an assembled structure and an assembled structure.
[0002] Conventionally, a technique for forming building materials such as walls by connecting a plurality of blocks via joint materials is known (for example, see Patent Document 1).
[0003] Japanese Patent Application Laid-Open No. 2007-032059
[0004] However, in the conventional construction method, there is a problem that the structure becomes complicated because joint materials are required for connecting the blocks.
[0005] Therefore, the present invention has been made in view of the above points, and an object thereof is to provide a manufacturing method of an assembled structure and an assembled structure that can reduce manufacturing costs with a simple configuration.
[0006] A manufacturing method of an assembled structure according to one aspect of the present invention includes a step of preparing an assembled wall in which a plurality of assembled materials are laminated, and a step of forming a reinforcing coating layer on a wall surface of the assembled wall. The step of forming the reinforcing coating layer includes applying a paint for forming the reinforcing coating layer to a coating region including at least a part of a boundary portion between a first assembled material and a second assembled material adjacent to each other among the plurality of assembled materials, a part of the first assembled material, and a part of the second assembled material, with at least a part of a wall surface of the first assembled material adjacent to the coating region and a wall surface of the second assembled material exposed.
[0007] The assembled wall is configured such that a first boundary portion corresponding to an arbitrary first assembled material among the plurality of assembled materials and a second boundary portion corresponding to a second assembled material adjacent to the first assembled material linearly extend along a stacking direction of the plurality of assembled materials or a direction intersecting the stacking direction. The step of forming the reinforcing coating layer may include linearly applying the paint along the stacking direction or along a direction intersecting the stacking direction so as to include the first boundary portion and the second boundary portion.
[0008] The step of forming the reinforcing coating layer includes applying the paint to a linear region extending in a direction inclined with respect to the stacking direction of the masonry material, wherein the linear region may be a region passing through a first side extending in the stacking direction of any masonry material and a second side intersecting the first side.
[0009] The pitch at which the multiple linear regions are arranged may be shorter than the length of the shorter side of the masonry material.
[0010] The step of forming the reinforcing coating layer may include applying the paint to a plurality of the masonry materials that are stacked in a predetermined stacking direction within a plane that intersects the vertical direction.
[0011] The step of preparing the masonry wall may include stacking the masonry materials without providing filler between them.
[0012] The step of forming the reinforcing coating layer may include applying the paint for the reinforcing coating layer using a roller having a zigzag convex pattern formed on its surface.
[0013] One embodiment of the present invention is a masonry structure comprising a masonry wall formed by stacking a plurality of masonry materials, and a reinforcing coating layer formed on the wall surface of the masonry wall, wherein the reinforcing coating layer includes a connection portion formed by applying paint for forming the reinforcing coating layer to a coating area that includes at least a portion of the boundary between a first masonry material and a second masonry material adjacent to each other, a portion of the first masonry material, and a portion of the second masonry material, while exposing at least one of the wall surfaces of the first masonry material and the second masonry material adjacent to the coating area.
[0014] According to the present invention, it is possible to provide a method for manufacturing a masonry structure and a masonry structure that can reduce manufacturing costs with a simple configuration.
[0015] This is a perspective view showing one embodiment of the masonry structure of the present invention. This is a front view of the masonry wall constituting the masonry structure of Figure 1. This is an enlarged view of a part of Figure 2. This is a diagram showing the configuration of the first modified example. This is a diagram showing the second modified example. This is an enlarged view of a part of Figure 5. This is a diagram showing the third modified example. This is a diagram showing an example of the shape of the connection part. This is a diagram showing an example in which a reinforcing coating layer is not formed over the entire area of the wall surface of the masonry wall.
[0016] An example of the present invention will be described below with reference to the drawings. Figure 1 is a perspective view showing a masonry structure according to one embodiment of the present invention. Figure 2 is a front view of the masonry wall constituting the masonry structure of Figure 1. Figure 3 is an enlarged view of a part of Figure 2. In Figure 1, the masonry structure S100 is depicted with a part of the reinforcing coating layer omitted. For example, reference numerals such as "11-1" and "12-1" may be simply shown as reference numerals "11" and "12".
[0017] In this application, the vertical direction corresponds to the vertical direction in each figure, and the horizontal direction corresponds to the horizontal direction. In this specification, when describing the structure and shape of a member, for example, with reference to the drawings, the member will be denoted by a reference numeral. However, when describing the material of a member, etc., without referring to the drawings, the reference numeral may be omitted.
[0018] As shown in Figure 1, the masonry structure S100 of this embodiment comprises a masonry wall 10 and a reinforcing coating layer 20. The masonry structure S100 is used as a wall material for a building, for example.
[0019] (Masonry Wall 10) The masonry wall 10 is a wall composed of multiple masonry members 11. The masonry members 11 have a rectangular parallelepiped shape as shown in Figure 1. The masonry members 11 may be block members with through holes formed in them, or they may not have through holes formed in them, but in this embodiment they are block members without through holes formed in them. In the masonry structure S100, multiple masonry members 11 are arranged in the vertical and horizontal directions. The vertical and horizontal directions will be referred to as the vertical and horizontal directions below, respectively.
[0020] Multiple masonry members 11 are arranged such that the boundary lines 12 between adjacent masonry members 11 in the horizontal direction form a single line in the vertical direction. Furthermore, multiple masonry members 11 are arranged such that the boundary lines 13 between vertically stacked masonry members 11 form a single line in the horizontal direction. This arrangement method is known as "potato stacking."
[0021] The material of the masonry material 11 is not particularly limited and can be stone, brick, mortar, resin, wood, bamboo, metal, or composites thereof. The density of the masonry material 11 is, for example, 0.3 g / cm³. ３ 1.5g / cm or more ３ It is less than. The material of the masonry 11 may be wood as described above. The masonry 11 does not have to be relatively low in density as described above; for example, 1.5 g / cm³. ３ That's fine too.
[0022] A filler material such as mortar may or may not be provided between adjacent masonry pieces 11, but in the masonry structure S100 of this embodiment, no filler material is provided.
[0023] Furthermore, the masonry structure as a whole may have filler material only partially provided between adjacent masonry members. An example of a masonry structure as a whole with filler material partially provided between adjacent masonry members is as follows:
[0024] A masonry structure is composed of multiple masonry materials. If we focus on one specific masonry material from among these multiple materials and call it masonry material A, then masonry material A is adjacent to at least one other masonry material (let's call it masonry material B). In this case, if no filler material is provided between a certain masonry material B and masonry material A, then it can be said that masonry material B and masonry material A are adjacent without the intervening filler material. Conversely, if a filler material is provided between a certain masonry material B and masonry material A, then it can be said that masonry material B and masonry material A are adjacent via the filler material.
[0025] Here, if masonry material A is adjacent to at least one of the adjacent masonry materials B without any filler in between, then masonry material A is said to be masonry material A that does not have filler in at least a portion of it. Also, if masonry material A is adjacent to at least one of the adjacent masonry materials B via filler in between, then masonry material A is said to be masonry material A that has filler in at least a portion of it. It should be noted that a certain masonry material A may be both masonry material A that does not have filler in at least a portion of it and masonry material A that has filler in at least a portion of it.
[0026] Here, the case where a masonry structure as a whole has filler material partially provided between adjacent masonry members means that of all the masonry members constituting the masonry structure, at least a portion (preferably 10% to 100%, more preferably 50% to 100%) of the masonry members are masonry members A that do not have filler material at least partially, and at least a portion of all the masonry members constituting the masonry structure are masonry members A that have filler material at least partially.
[0027] (Reinforcement coating layer 20) The reinforcement coating layer 20 is a member formed on the wall surface of the masonry wall 10 to reinforce the masonry wall 10. In this example, the reinforcement coating layer 20 is formed over the entire area of the wall surface of the masonry wall 10. The reinforcement coating layer 20 may be formed on both sides of the masonry wall 10 or on one side, but in this embodiment it is formed on one side.
[0028] The reinforcing coating layer 20 is formed in the region covering the boundary lines 12 and 13 of the masonry material 11. Specifically, as shown in Figure 2, the reinforcing coating layer 20 includes vertical connection portions 21 and horizontal connection portions 22. The multiple vertical connection portions 21 and multiple horizontal connection portions 22 are arranged in a grid pattern that intersects with each other. In the region Sa (see Figure 2) where the vertical connection portions 21 and horizontal connection portions 22 are not formed, the wall surface of the masonry material 11 is exposed.
[0029] As shown in Figure 3, the vertical connection portion 21 is formed by a paint (hereinafter also simply referred to as "paint") that forms a reinforcing coating layer 20 applied to a coating area that includes at least a boundary line 12, a part 11a of the first masonry material 11-1, and a part 11b of the second masonry material 11-2. The boundary line 12 is the boundary between the first masonry material 11-1 and the second masonry material 11-2, which are adjacent to each other among the multiple masonry materials.
[0030] As shown in Figure 3, the lateral connection portion 22 is also formed by paint applied to a coating area that includes at least a boundary line 13, a part 11c of the first masonry material 11-1, and a part 11d of the other masonry material 11-3 located below the first masonry material 11-1, similar to the vertical connection portion 21.
[0031] Area Sa is not coated with paint, and the wall surface of the masonry material 11 is exposed. With respect to the first masonry material 11-1 and the second masonry material 11-2, the wall surface of the first masonry material 11-1 and the wall surface of the second masonry material 11-2 adjacent to the vertical connection section 21 are not coated with paint. The same is true when viewed with respect to the horizontal connection section 22; for example, the wall surface of the first masonry material 11-1 adjacent to the horizontal connection section 22 and the wall surface of the other masonry material 11-3 below the first masonry material 11-1 are not coated with paint.
[0032] The line width of the vertical connection portion 21 and the horizontal connection portion 22 may be, for example, 10% or more, 15% or more, or 20% or more of the length L1 of the shorter side of the masonry material 11 (see Figure 3). The line width may be, for example, 10 mm or more, 25 mm or more, or 40 mm or more.
[0033] In the masonry structure S100 of this embodiment, the reinforcing coating layer 20 is formed with the wall surface of the masonry wall 10 exposed, thereby reducing the weight of the masonry wall 10. This technical effect is particularly useful when the masonry wall 10 is made of a relatively lightweight material such as wood.
[0034] The paint may be applied to the primer layer after the primer material has been applied to the masonry wall and dried. The reinforcing coating layer does not need to be a single layer, and may be formed by laminating multiple layers with different properties. Further layers may be formed on top of the reinforcing coating layer. Alternatively, further layers may be formed to cover both the areas with and without the reinforcing coating layer. These further layers may be, for example, decorative layers to improve the aesthetic appearance of the masonry wall 10.
[0035] (Regarding the material of the reinforcing coating layer 20) The reinforcing coating layer is formed, for example, by a paint in which fiber material is dispersed in a resin material. The reinforcing coating layer is formed, for example, by the curing of a resin material that contains fiber material and exhibits a slurry-like state.
[0036] The reinforcing coating layer preferably contains fibers of a predetermined length (hereinafter referred to as "specific length"). Inorganic fibers (such as glass fibers) are preferred because they offer superior weather resistance and reinforcing effects. Hereinafter, fibers of the specified length will be referred to as "specific fibers." In this specification, "length" of the fiber material refers to the actual length. The specific length is preferably 1 mm or more, more preferably 3 mm or more, even more preferably 6 mm or more, and particularly preferably 13 mm or more, from the viewpoint of superior reinforcing effects achieved by the reinforcing coating layer. From the viewpoint of workability (hereinafter also simply referred to as "workability") when applying a paint containing specific fibers (hereinafter referred to as "this paint") to form the reinforcing coating layer, the specific length is preferably 50 mm or less, more preferably 20 mm or less, and even more preferably 16 mm or less.
[0037] The content of specific fibers relative to the total mass of the reinforcing coating layer is preferably 0.1% by mass or more, more preferably 0.3% by mass or more, even more preferably 0.5% by mass or more, even more preferably 1.0% by mass or more, and particularly preferably 2.0% by mass or more, from the viewpoint of superior reinforcing effect. The content of specific fibers relative to the total mass of the reinforcing coating layer is preferably 75% by mass or less, more preferably 65% by mass or less, even more preferably 55% by mass or less, and particularly preferably 20% by mass or less, from the viewpoint of superior workability.
[0038] The content of specific fibers relative to the total mass of this paint is preferably 0.1% by mass or more, more preferably 0.3% by mass or more, even more preferably 0.5% by mass or more, and even more preferably 1.0% by mass or more, from the viewpoint of superior reinforcing effect. The content of specific fibers relative to the total mass of this paint is preferably 60% by mass or less, more preferably 50% by mass or less, even more preferably 40% by mass or less, and particularly preferably 18% by mass or less, from the viewpoint of superior workability.
[0039] The content of specific fibers relative to the total mass of the fibrous material contained in the reinforcing coating layer or this paint is preferably 50% by mass or more, more preferably 75% by mass or more, even more preferably 92% by mass or more, and particularly preferably 99% by mass or more, from the viewpoint of having a good balance between reinforcing effect and workability. There is no particular upper limit, and it is 100% by mass.
[0040] The fiber material may be inorganic fiber (glass fiber, carbon fiber, boron fiber, etc.) or organic fiber (aramid fiber, plant fiber, etc.), with inorganic fiber being preferred. In this embodiment, glass fiber is used as an example. The average diameter of the fiber material is, for example, 0.5 μm to 20 μm. By mixing the fiber material into an acrylic paint, a slurry in which the fiber material is suspended in the resin material can be obtained. The weight ratio of the fiber material to the weight of the paint is, for example, 1% to 40%. As for the glass fiber, for example, it may be obtained by removing the sizing agent (e.g., adhesive polymers such as PVA and methylcellulose) from chopped strands of glass fiber cut to a predetermined length using an organic solvent such as toluene or styrene. The fiber material may be surface-treated to adjust its adhesion to the resin. The fiber material content is preferably 0.75 to 4% by mass relative to the total mass of the reinforcing coating layer. The fiber material is not limited to one type, but may contain multiple types of fiber materials.
[0041] As the resin material, it may be a so-called elastic paint in which the coated surface exhibits a single-layer rubbery state. As the resin material, for example, an acrylic paint mainly composed of a crosslinkable acrylic emulsion is preferable. The content of the resin material is preferably, for example, 80 to 99.5% by mass based on the total mass of the reinforcing coating layer. The reinforcing coating layer is formed so as to adhere to the wall surface, thereby enhancing at least any one of the rigidity, strength, and deformation ability (these are collectively referred to as strength, etc. in this specification) of the laminated structure.
[0042] As the resin material, a urethane-based paint may be used instead of the acrylic paint. Part (preferably more than half by mass) or all of the resin contained in the fiber-reinforced resin that can constitute the reinforcing coating layer is preferably an elastic resin, and an acrylic resin, a silicone resin, an acrylic silicone resin, a urethane resin, or a natural resin (latex paint) is preferable.
[0043] (Manufacturing method of the laminated structure S100) As an example, the manufacturing method of the laminated structure S100 of the present embodiment includes a step of preparing the laminated wall 10 and a step of forming the reinforcing coating layer 20. In the following, it is exemplified that the entire laminated wall 10 is created in one step, but a part of the laminated wall 10 may be manufactured and then the reinforcing coating layer 20 may be formed, and then another part of the laminated wall 10 may be manufactured and then the reinforcing coating layer 20 may be formed.
[0044] In the step of preparing the laminated wall 10, the operator prepares a laminated wall 10 in which a plurality of laminated materials 11 are laminated. The operator may prepare the laminated wall 10 by stacking (i) a plurality of laminated materials 11 in the vertical direction, or may stack a plurality of laminated materials 11 by arranging (ii) a plurality of laminated materials 11, for example, on the floor (in an example, in a plane intersecting the vertical direction). Here, (ii) will be described.
[0045] In this specification, "laminating" is not limited to stacking objects in the vertical direction, but also means arranging objects in a plane intersecting the vertical direction.
[0046] The operator stacks a plurality of assembled materials 11 in a predetermined stacking direction within a plane intersecting the vertical direction. No filler is arranged between the assembled materials 11. The "plane intersecting the vertical direction" may be a horizontal plane or a plane inclined with respect to the horizontal plane (excluding the vertical plane). The plurality of assembled materials may be arranged side by side on an inclined plane so that the assembled materials abut against each other and no gap is generated between the assembled materials, and paint may be applied to the wall surface. From the viewpoints of ease of work and difficulty of the paint flowing down, the inclined plane may be inclined at an angle of 10° or more and 45° or less with respect to the horizontal plane.
[0047] In the step of forming the reinforcing coating layer 20, a plurality of vertical connecting portions 21 and a plurality of horizontal connecting portions 22 as shown in FIG. 2 are formed. In the configuration of the present embodiment, as shown in FIG. 3, one vertical connecting portion 21 linearly extends in the vertical direction so as to include the first boundary line 12-1 and the second boundary line 12-2. The operator applies the paint linearly so as to include the first boundary line 12-1 which is the first boundary portion and the second boundary line 12-2 which is the second boundary portion. Specifically, the operator applies the paint linearly along the stacking direction of the plurality of assembled materials 11. The operator also applies the paint linearly in the horizontal direction intersecting the stacking direction.
[0048] The paint for forming the reinforcing coating layer is applied to the assembled wall by, for example, a roller, a brush, a brush or a spray and adheres to the wall surface. In the present embodiment, as an example, it is applied by a roller.
[0049] When the applied paint cures, the vertical connecting portion 21 and the horizontal connecting portion 22 are formed. The curing of the paint may be curing by drying or curing by a curing agent. In addition, the paint may be a paint in which the heat-melted paint cures (solidifies) as it cools, or a paint that cures by reacting with components (such as moisture) in the atmosphere. The curing of the paint may be curing using a combination of a plurality of curing methods (such as curing by combining drying and a curing agent).
[0050] The worker may form the vertical connection sections 21 one by one, or several vertical connection sections 21 in a single operation. The same applies to the horizontal connection sections 22. When several connection sections are formed simultaneously, the roller may have two or more ring-shaped protrusions (annular protrusions that project radially from the outer surface of the roller and encircle the outer surface of the roller) so that paint can be applied in two or more straight lines that extend parallel to each other (the width between one protrusion and the other protrusion corresponds to the distance between the boundaries of the masonry materials).
[0051] After the paint has hardened, the masonry wall 10 on which the reinforcing coating layer 20 has been formed in the steps up to this point is lifted and raised from the floor surface to create the masonry structure S100 of this embodiment. Alternatively, the paint may also be applied to and hardened on the opposite side of the created masonry structure S100 to create a masonry structure S100 with the reinforcing coating layer 20 formed on both sides. The application of the paint on the opposite side may be carried out in the same manner as the application of the paint already performed, or in a different manner.
[0052] (Effects of the masonry structure S100) In the masonry structure S100 of this embodiment, configured as described above, the reinforcing coating layer 20 is not formed to cover the entire surface of the masonry wall 10 (a state in which the paint is applied without exposing the wall surface), but rather to cover the boundary lines 12 and 13 while partially exposing the wall surface. The masonry materials 11 are fixed together by the reinforcing coating layer 20, and the overall strength of the masonry structure S100 is ensured. With this configuration, unlike the conventional technology, the masonry structure S100 can be manufactured with a simple structure without using joint materials, and the manufacturing cost can be reduced.
[0053] Furthermore, the configuration of this embodiment is advantageous for reducing the overall weight of the building, and therefore the overall design of the building can be reviewed, which can lead to reductions in materials and costs during construction, as well as a reduction in carbon dioxide emissions.
[0054] Furthermore, in the manufacturing method of this embodiment, the vertical connection portion 21 and the horizontal connection portion 22 can be formed by linearly applying paint along the stacking direction of the masonry material 11 and along the direction intersecting the stacking direction, making the work easy. In addition, in the manufacturing method of this embodiment, since the paint is applied from the top side to the masonry wall which is laid on its side, problems such as paint dripping are less likely to occur.
[0055] (Modification 1) Figure 4 shows the configuration of the first modification. In the masonry structure S101 of Figure 4, a plurality of masonry materials 11 are stacked in a so-called staggered stacking manner. In the masonry structure S101, the boundary line 12 of a predetermined layer (for example, boundary line 12-1) is not aligned in a straight line with the boundary line 12 of an adjacent layer (for example, boundary line 12-2) in the height direction. On the other hand, a plurality of horizontal boundary lines 13 (for example, boundary lines 13-1 and boundary line 13-2) are aligned in a straight line in the horizontal direction.
[0056] Even for a masonry wall 10 constructed using this staggered stacking method, a reinforcing coating layer 20 is formed which includes multiple vertical connection parts 21 and multiple horizontal connection parts 22, and in which a portion of the masonry material 11 is not coated with paint, leaving the wall surface exposed. This provides the effect of reinforcing the masonry wall with a simple structure without using joint materials.
[0057] As shown in Figure 4, in a configuration where a first boundary portion 13-1 corresponding to any first masonry material (e.g., masonry material 11-1) and a second boundary portion 13-2 corresponding to a second masonry material adjacent to the first masonry material (e.g., masonry material 11-2) extend linearly, a lateral connection portion 22 extending laterally along this linear region can be formed by applying paint linearly along this linear region. Therefore, the work process is simplified, and the reinforcing coating layer 20 can be formed efficiently.
[0058] (Modification 2) Figure 5 shows a second modification. Figure 6 is an enlarged view of a part of Figure 5. In all of the above examples, the connection portion was formed along the boundary line 12 and boundary line 13, but the connection portion may be inclined with respect to the boundary line 12 and boundary line 13. The masonry structure S102 in Figure 5 has a reinforcing coating layer 20A formed on the wall surface of the masonry wall.
[0059] The reinforcing coating layer 20A includes a plurality of inclined connection portions 23, a lateral connection portion 24, and a vertical connection portion 25. The material of the reinforcing coating layer 20A is the same as in the embodiment described above, so its description is omitted.
[0060] The inclined connection portion 23 is inclined at a predetermined angle with respect to the stacking direction of the masonry material 11. Multiple inclined connection portions 23 are, for example, parallel to each other and of the same width. As shown in Figure 6, the inclined connection portion 23 is formed in such a shape that, with respect to any one masonry material 11 (here, masonry material 11-1), it intersects both a part of the first side 11s and a part of the second side 11t of that masonry material 11 (in other words, it passes through the first side 11s and the second side 11t). The first side 11s is a side that extends in the vertical direction (stacking direction). The second side 11t is a side that extends in the horizontal direction and intersects the first side 11s.
[0061] The inclined connection portion 23 is also formed, similar to the embodiment described above, by applying paint to a coating area that includes at least a portion of the boundary between the adjacent first masonry material (e.g., masonry material 11-1) and the second masonry material (e.g., masonry material 11-2), a portion 11a of the first masonry material, and a portion 11b of the second masonry material. In the area adjacent to the inclined connection portion 23, the wall surface of the first masonry material 11-1 and the wall surface of the second masonry material 11-2 are exposed.
[0062] The inclined connection portion 23 can be formed, for example, by linearly applying paint to a linear region extending in a direction inclined with respect to the stacking direction of the masonry material. With this configuration, the reinforcing coating layer 20A can be formed with good workability.
[0063] The pitch p between the inclined connection parts 23 is arbitrary. The pitch p between the inclined connection parts 23 can be set appropriately considering the strength required for the masonry structure and the material of the reinforcing coating layer 20. As for the relationship between the length of a predetermined reference portion of the masonry material 11 and the pitch p, in one embodiment, it is preferable that the pitch p is shorter than the length L1 of the first side 11s, which is the short side of the masonry material 11. The line width of the inclined connection part 23 may be, for example, 10% or more of the length L1, 15% or more, or 20% or more.
[0064] The lateral connection portion 24 is formed to extend laterally at the upper and lower ends of the region where the plurality of inclined connection portions 23 are formed. The vertical connection portion 25 is formed to extend vertically at both lateral ends of the region where the plurality of inclined connection portions 23 are formed. In this example, the lateral connection portion 24 is formed not on the outer perimeter of the masonry wall, but at the boundary between the first and second layers of masonry from the top and the boundary between the first and second layers of masonry from the bottom. The present invention is not limited to this configuration, and the lateral connection portion 24 may also be formed on the outer perimeter of the masonry wall.
[0065] As described above, in a configuration where the pitch p of the multiple inclined connection parts 23 is shorter than the length L1 of the first side 11s, which is the short side of the masonry material 11, the multiple inclined connection parts 23 are formed at a relatively high density on the wall surface of the masonry wall 10, thus providing the effect of effectively reinforcing the masonry structure.
[0066] In one embodiment, it is preferable that the multiple inclined connection portions 23 are arranged such that, in the region where the multiple inclined connection portions 23 are formed, there are no masonry members 11 that are not in contact with the inclined connection portions 23 (in other words, that at least one of the inclined connection portions 23 is in contact with every masonry member 11).
[0067] (Modification 3) Figure 7 shows a third modification. Figure 7(a) is a front view, and Figure 7(b) is a top view. In the masonry structure S103 of Figure 7, a plurality of masonry members 11B formed to be long in the vertical direction are provided. The masonry members 11B are plate-shaped panels. A masonry wall 10B is formed by arranging a plurality of masonry members 11B. A reinforcing coating layer 20B is formed on the masonry wall 10B. The reinforcing coating layer 20B includes a plurality of vertical connection parts 21B and a plurality of horizontal connection parts 22B.
[0068] As shown in Figure 7(b), in this example, another wall material 18 is provided on the back of the masonry wall 10B. The vertical connection portions 21B on both sides of the masonry wall 10B are formed to cover the connection portion between the masonry wall 10B and the wall material 18.
[0069] Even in the configuration shown in Figure 7, the formation of the reinforcing coating layer 20B allows for the creation of a reinforced masonry structure S103 without the use of joint materials. Furthermore, since the reinforcing coating layer 20B is not formed to cover the entire surface of the masonry wall 10B, manufacturing costs are reduced, which is advantageous for reducing the weight of the masonry structure S103.
[0070] Figure 8 shows an example of the shape of the connection portion. In the embodiment described above, a linear connection portion (for example, a vertical connection portion 21 and a horizontal connection portion 22, etc.) was described, but the connection portion formed as the reinforcing coating layer 20 may have a shape other than a linear shape.
[0071] In Figure 8(a), the connecting portion 21-1 is a zigzag-shaped line having a predetermined width. In Figure 8(b), the connecting portion 21-2 is a curved, meandering line having a predetermined width. The connecting portion 21-1 is formed with a shape and line width that covers the boundary line 12. The same applies to the connecting portion 21-2. In Figure 8(c), the connecting portion 21-3 is a zigzag-shaped line having a predetermined width. In Figure 8(d), the connecting portion 21-4 is a curved, meandering line having a predetermined width. The connecting portion 21-3 is formed with a shape and line width such that a part of it does not cover the boundary line 12 and moves away from the boundary line 12. The same applies to the connecting portion 21-4.
[0072] Although Figure 8 depicts all connection points as extending in the vertical direction, the connection points may be formed as vertical, horizontal, or inclined connection points. The line width of the connection points is not limited to a constant value, and the line width of some parts of the connection point may differ from that of other parts. The connection points are not limited to a regularly bent shape as shown in the example in Figure 8, but may also have an irregularly bent shape.
[0073] In one embodiment of the present invention, a roller having a convex pattern formed on its surface corresponding to the shape of any of the connecting portions 21-1, 21-2, 21-3, or 21-4 may be used, and the paint for forming the connecting portion may be applied by rolling the roller along the boundary line 12. The convex pattern may be a zigzag pattern that meanders in a curved shape with a predetermined width, or a zigzag pattern in which line segments extending in a first inclination direction and line segments extending in a second inclination direction are alternately followed.
[0074] Furthermore, the reinforcing coating layer may be formed in a shape other than linear. For example, it may be a dot-shaped reinforcing coating layer, and it is preferable that the dot-shaped reinforcing coating layer is formed to cover the points where three or more masonry members meet. The shape of the "dot shape" is arbitrary and may be circular, elliptical, polygonal, or a combination of two or more of these shapes.
[0075] In the embodiments described above, connection portions of linearly extending reinforcing coating layers (for example, vertical connection portion 21 and horizontal connection portion 22, etc.) were explained, but these connection portions do not necessarily have to be continuously connected from one end of the wall surface to the other (for example), and may be interrupted in the middle.
[0076] Figure 9 shows an example where the reinforcing coating layer is not formed over the entire surface of a masonry wall. As shown in Figure 9, in the present invention, the reinforcing coating layer 20 does not necessarily have to be formed over the entire surface of the masonry wall 10. In the region of Figure 9, the reinforcing coating layer 20 is formed only in region Sb.
[0077] In areas other than region Sb, for example, multiple masonry members 11 may be fixed to each other with a filler such as mortar. Alternatively, in areas other than region Sb, the wall surface of the masonry wall 10 may be entirely coated with a paint similar to the reinforcing coating layer 20 (in this case, only region Sb will have a grid-like reinforcing coating layer 20).
[0078] The area of region Sb is, for example, 30% or more, 50% or more, or 70% or more of the total surface area of the masonry wall 10. In the example in Figure 9, region Sb is located in the central part of the masonry wall 10, but the region where the reinforcing coating layer 20 is formed may be adjacent to the upper end, lower end, or side end of the masonry wall 10.
[0079] (Measurement of the content of specific fibers) When determining the content of fibrous materials and specific fibers contained in this paint, an appropriate method should be used considering the composition and properties of the paint. In particular, when this paint consists of a resin material, a solvent, and a fibrous material (including specific fibers) which is an inorganic fiber (preferably glass fiber), the content of fibrous materials and specific fibers contained in this paint can be determined, for example, by performing the following procedures (A) and (B).
[0080] (A) An organic solvent compatible with the resin material is added to the paint to reduce its viscosity, and the resulting mixture is filtered. The resulting filtrate is thoroughly washed with the organic solvent and then dried, and the resulting dried material is obtained as the fibrous material contained in the paint. The mass of the obtained dried material (fibrous material) is taken as the fibrous material content of the paint.
[0081] (B) Observe the dried material (fibrous material) obtained in (A) above with a magnifying glass or microscope and separate it based on the length of the fibers to obtain specific fibers (fibrous material having a specific length). The mass of the obtained specific fibers shall be taken as the content of the specific fibers contained in the paint.
[0082] Furthermore, if the paint contains solid materials other than fibrous materials (such as fillers), an additional step may be taken to redisperse the dried material obtained in (A) above in a suitable liquid and then separate the solid materials from the fibrous materials by centrifugal separation. The content of fibrous materials and specific fibers in the paint should be determined by an appropriate method according to the composition of the paint.
[0083] The method for measuring the content of fibrous material and specific fibers contained in the reinforcing coating layer should also be appropriate, taking into account the composition and properties of the reinforcing coating layer. In particular, when the reinforcing coating layer consists of a resin material and a fibrous material (including specific fibers) which is an inorganic fiber (preferably glass fiber), the content of fibrous material and specific fibers contained in the reinforcing coating layer can be determined, for example, by performing the following procedures (a) and (b).
[0084] (a) The resin material is dissolved in an organic solvent in the reinforcing coating layer, and the resulting mixture is filtered. The resulting filtrate is thoroughly washed with the organic solvent and then dried. The dried material is obtained as the fibrous material contained in the reinforcing coating layer. The mass of the obtained dried material (fibrous material) is taken as the fibrous material content in the reinforcing coating layer.
[0085] (b) Observe the dried material (fibrous material) obtained in (a) above with a magnifying glass or microscope and separate it based on the length of the fibers to obtain specific fibers (fibrous material having a specific length). The mass of the obtained specific fibers shall be taken as the content of the specific fibers contained in the reinforcing coating layer.
[0086] If there is no organic solvent capable of dissolving the resin material contained in the reinforcing coating layer, the reinforcing coating layer may be heat-treated in air to remove the resin material and obtain the dried material (fiber material). The heat treatment conditions should be appropriately determined according to the properties of the resin components and fiber material, but for example, heating at 400°C for 10 hours in an atmospheric environment is a possible method.
[0087] If the reinforcing coating layer contains a solid material (such as a filler) different from the fibrous material, the content of the fibrous material and specific fibers in the reinforcing coating layer can be determined by an appropriate method depending on the composition of the reinforcing coating layer, such as adding a step to redisperse the dried material (the dried material obtained in (a) above or the dried material obtained by the heat treatment above) in a suitable liquid and then separate the solid material from the fibrous material by centrifugal separation.
[0088] From the viewpoint of balancing the strength and cost of the masonry structure, in the masonry structure of the present invention, the lower limit of the ratio of the area on which the reinforcing coating layer is formed (the area where the paint is present) to the total area of the surface on which the reinforcing coating layer is formed is preferably 1% or more, more preferably 2% or more, and even more preferably 5% or more. The upper limit of the above area ratio is preferably 60% or less, preferably 50% or less, and even more preferably 40% or less.
[0089] For example, in a configuration where the reinforcing coating layer 20 is formed only on a part of the wall surface of the masonry wall 10, as shown in Figure 9, the "said surface" refers not to the entire wall surface of the masonry wall 10, but to the region enclosed by the outer edge of the reinforcing coating layer 20.
[0090] A masonry wall may have a reinforcing coating layer formed on only one side, or on both sides. If a reinforcing coating layer is formed on both sides, the reinforcing coating layers on each side may be formed similarly or in different forms. If a reinforcing coating layer is formed on both sides, one side may have the reinforcing coating layer formed over its entire surface or substantially over its entire surface (preferably 80% to 100%, more preferably 90% to 100%, and even more preferably 95% to 100%).
[0091] From the standpoint of the strength of the masonry structure, it is also preferable that, on the surface where the reinforcing coating layer is formed, the reinforcing coating layer is formed on at least a portion of the boundary between adjacent masonry materials (or, in the case of adjacent masonry materials, the boundary with at least one of them) of substantially all (for example, 80% to 100%, preferably 90% to 100%, more preferably 97% to 100%) of the masonry materials constituting the masonry structure.
[0092] However, in cases where a reinforcing coating layer is not formed over the entire surface of a masonry wall, as shown in Figure 9, it is also preferable to have less than 100% (for example, 20% to 80% of the masonry materials constituting the masonry structure) of the masonry materials on which the reinforcing coating layer is formed at least a portion of the boundary with adjacent masonry materials.
[0093] Although the present invention has been described above using embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments, and various modifications and changes are possible within the scope of its gist. For example, all or part of the apparatus can be configured by functionally or physically distributing and integrating in any unit. Furthermore, new embodiments resulting from any combination of multiple embodiments are also included in the embodiments of the present invention. The effects of the new embodiments resulting from the combinations are combined with the effects of the original embodiments.
[0094] Furthermore, in masonry structures where filler is partially provided between adjacent masonry members, or where no filler is provided between adjacent masonry members as a whole, a reinforcing coating layer is formed on the entire or substantially entire surface (preferably 80% to 100%, more preferably 90% to 100%, and even more preferably 95% to 100%) of at least one surface of the masonry structure, a method for manufacturing a masonry structure and a masonry structure that can reduce manufacturing costs with a simple configuration can also be provided. On the opposite side of the surface on which the reinforcing coating layer is formed on the entire or substantially entire surface of such a masonry structure, the reinforcing coating layer may be formed on the entire or substantially entire surface, partially, or not formed at all. Examples of embodiments in which the coating layer is formed on a portion of the surface include any of the embodiments shown in the embodiments of the present invention.
[0095] 10 Masonry wall 11 Masonry material 11s First side 11t Second side 12 Boundary line 13 Boundary line 18 Wall material 20 Reinforcement coating layer 21 Vertical connection 22 Horizontal connection 23 Inclined connection 24 Horizontal connection 25 Vertical connection p Pitch S100-S103 Masonry structure Sa area Sb area
Claims
1. A method for manufacturing a masonry structure, comprising the steps of: preparing a masonry wall in which a plurality of masonry materials are stacked; and forming a reinforcing coating layer on the wall surface of the masonry wall, wherein the step of forming the reinforcing coating layer includes applying a paint for forming the reinforcing coating layer to a coating area that includes at least a portion of the boundary between a first masonry material and a second masonry material adjacent to each other, a portion of the first masonry material, and a portion of the second masonry material, while exposing at least one of the areas of the wall surface of the first masonry material and the wall surface of the second masonry material adjacent to the coating area.
2. The method for manufacturing a masonry structure according to claim 1, wherein the masonry wall is configured such that a first boundary portion corresponding to any first masonry material among the plurality of masonry materials and a second boundary portion corresponding to a second masonry material adjacent to the first masonry material extend linearly along the stacking direction of the plurality of masonry materials or in a direction intersecting the stacking direction, and the step of forming the reinforcing coating layer includes applying the paint linearly along the stacking direction or in a direction intersecting the stacking direction so as to include the first boundary portion and the second boundary portion.
3. The method for manufacturing a masonry structure according to claim 1, wherein the step of forming the reinforcing coating layer includes applying the paint to a linear region extending in a direction inclined with respect to the lamination direction of the masonry material, the linear region being a region passing through a first side extending in the lamination direction of any masonry material and a second side intersecting the first side.
4. The method for manufacturing a masonry structure according to claim 3, wherein the pitch at which the plurality of linear regions are arranged is shorter than the length of the short side of the masonry material.
5. The method for manufacturing a masonry structure according to claim 1 or 2, wherein the step of forming the reinforcing coating layer includes applying the paint to a plurality of masonry materials stacked in a predetermined stacking direction in a plane intersecting the vertical direction.
6. The method for manufacturing a masonry structure according to claim 1 or 2, wherein the step of preparing the masonry wall includes stacking the plurality of masonry materials without providing a filler material between them.
7. The method for manufacturing a masonry structure according to claim 1 or 2, wherein the step of forming the reinforcing coating layer includes applying the paint for the reinforcing coating layer using a roller having a zigzag convex pattern formed on its surface.
8. A masonry structure comprising: a masonry wall formed by stacking a plurality of masonry materials; and a reinforcing coating layer formed on the wall surface of the masonry wall, wherein the reinforcing coating layer includes a connection portion formed by applying paint for forming the reinforcing coating layer to a coating area that includes at least a portion of the boundary between a first masonry material and a second masonry material adjacent to each other among the plurality of masonry materials, a portion of the first masonry material, and a portion of the second masonry material, while exposing at least one of the wall surfaces of the first masonry material and the second masonry material adjacent to the coating area.