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DESCRIPTION
TITLE OF THE INVENTION: CONSTRUCTION STRUCTURE AND METHOD FOR
PRODUCING SAME
TECHNICAL FIELD
[0001]
The present invention relates to a construction structure
in which one or more panels are fitted to between a plurality
of lengthened members arranged side by side, and a method for
producing the construction structure.
BACKGROUND ART
[0002]
Hitherto, as a construction structure, known has been a
construction structure having the following: a plurality of
lengthened members (for example, columns) arranged side by side
in the widthwise direction of the members to make individual
longitudinal directions of the members parallel to each other;
and hard panels fittable to between the lengthened members (for
example, Patent Document 1). For example, the panels are each
a heat insulating member made of a synthetic resin.
[0003]
In this construction structure, the panels are required
to have a high dimension precision. Specifically, even when
the dimension of any one of the panels is slightly small, a gap
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is generated between the panel and ones adjacent thereto out
of the lengthened members. Contrarily, even when the dimension
of the panel is slightly large, the panel is not fitted to between
the adjacent lengthened members or the panel that has been
fitted to therebetween by force is damaged.
PRIOR ART DOCUMENT
PATENT DOCUMENT
[0004]
Patent Document 1: JP-A-2003-278290
SUMMARY OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0005]
Thus, in light of the situation, an object of the present
invention is to provide a construction structure making it
possible to fit its panel easily to between its lengthened
members, and prevent any gap from being generated between the
panel and one adjacent thereto out of the lengthened members.
[0006]
According to the present invention, there is provided a
construction structure, which includes:
a plurality of lengthened members located to make
individual longitudinal directions of the members parallel to
each other in a first direction and to be arranged side by side
in a second direction orthogonal to the first direction; and
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a panel fittable to between the lengthened members;
wherein the panel is a foam having a plurality of cells
formed lengthwise along a direction orthogonal to the second
direction to have elasticity in the second direction.
[0007]
According to the construction structure of the present
invention, its lengthened members are located to make
individual longitudinal directions of the members parallel to
each other in a first direction and to be arranged side by side
in a second direction orthogonal to the first direction. Its
panel is a foam having a plurality of cells formed lengthwise
along a direction orthogonal to the second direction, so as to
have elasticity in the second direction. Accordingly, the
panel compressed in the second direction is released from the
compression between ones adjacent of the lengthened members,
so as to be restored (or the panel is fitted to between the
adjacent lengthened members while compressed in the second
direction) , so that the panel is fitted to between the adjacent
lengthened members in the state of contacting the adjacent
lengthened members closely and pushing the adjacent lengthened
members.
[0008]
Also, the construction structure according to the present
invention may have a configuration in which:
the cells are formed lengthwise along the first direction
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to make the elastic modulus in the second direction of the panel
smaller than that in the first direction of the panel.
[0009]
According to this configuration, the cells are formed
lengthwise in the direction orthogonal to the second direction,
so that the elastic modulus in the second direction of the panel
becomes small. In this way, the panel has elasticity in the
second direction to be easily compressed in the second direction.
Furthermore, the cells are formed lengthwise along the first
direction out of directions orthogonal to the second direction.
Accordingly, the panel becomes large in elastic modulus in the
first direction. Thus, the panel has rigidity in the first
direction, so that the panel between the adjacent lengthened
members is stably held between the adjacent lengthened members.
[0010]
According to the present invention, there is
provided a method for producing a construction structure, which
includes:
preparing a plurality of lengthened members located to
make individual longitudinal directions of the members parallel
to each other in a first direction and to be arranged side by
side in a second direction orthogonal to the first direction;
and
fitting a panel to between the lengthened members, the
panel being a foam having a plurality of cells formed lengthwise
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along a direction orthogonal to the second direction to have
elasticity in the second direction.
[0011]
As described above, the present invention produces
excellent advantageous effects that the panel is easily
fittable to between the adjacent lengthened members and further
a gap is prevented from being generated between the panel and
the lengthened members adjacent thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012]
Fig. 1 illustrates a front view of a main portion of a
construction structure according to an embodiment of the
present invention.
Fig. 2 illustrates a sectional view taken on line II-II
in Fig. 1.
Fig. 3 illustrates a perspective view of the whole of the
panel according to the embodiment.
Fig. 4 illustrates an enlarged sectional view of a main
portion (of the panel) taken on line IV-IV in Fig. 3.
Fig. 5 illustrates a perspective view of a main portion
(of a panel workpiece) that is referred to for describing a
method for producing the panel according to the embodiment.
Fig. 6 illustrates a perspective view of a main portion
(of a structure workpiece) that is referred to for describing
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a method for producing the construction structure according to
the embodiment.
Fig. 7 illustrates a front view of a main portion of a
construction structure according to another embodiment of the
invention.
Fig. 8 illustrates a transversely sectional view of a main
portion of a construction structure according to still another
embodiment of the invention.
Fig. 9 illustrates a transversely sectional view of amain
portion of a construction structure according to a different
embodiment of the invention.
Fig. 10 illustrates a transversely sectional view of a
main portion of a construction structure according to a further
different embodiment of the invention.
Fig. 11 shows a table for evaluation of examples of the
invention.
MODE FOR CARRYING OUT THE INVENTION
[0013]
With reference to Figs. 1 to 6, a description will be made
about a construction structure according to an embodiment of
the present invention.
[0014]
As illustrated in Figs. 1 and 2, the construction
structure according to the present embodiment, which is a
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construction structure 1, has a plurality of lengthened members
2 (two members are illustrated in each of Figs. 1 an 2) located
to make individual longitudinal directions of the members
parallel to each other, and to be arranged side by side in the
widthwise direction thereof; and a panel 3 fitted to between
adjacent ones 2, 2 of the lengthenedmembers. The construction
structure 1 has frame members 4, 4 fixed to ends of the lengthened
members 2, respectively, and a plate member 5 fixed to
respective sides of the lengthened members 2. In the present
embodiment, the construction structure 1 is a wall.
[0015]
Each of the lengthened members 2 has supporting surfaces
21, 21 for supporting one of the panels 3 and different one of
the panels 3, respectively, at both sides in the widthwise
direction of the member 2. Specifically, the lengthened member
2 has a cross section in a rectangular form. Any adjacent two
of the lengthened members 2 are arranged to face one of the
supporting faces 21 of one of the two members 2 to one of the
supporting faces 21 of the other member 2. In the present
embodiment, the lengthened members 2 are each a column, and the
column is arranged to make the longitudinal direction thereof
parallel to the height direction thereof.
[0016]
Each of the panels 3 is formed into a rectangular
parallelepiped form. In the state that the panel 3 is fitted
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to between adjacent ones 2, 2 of the lengthened members, the
longitudinal direction of the panel 3 is parallel to the
longitudinal direction of the lengthened members 2. The
widthwise direction of the panel 3 is parallel to the widthwise
direction of the lengthened members 2.
[0017]
In the present invention, a direction parallel to the
longitudinal direction of the lengthened members 2 is called
a first direction D1 of each of the construction structure 1,
the lengthened members 2 and the panels 3; a direction parallel
to the direction in which the lengthened members 2 are arranged
side by side is called a second direction D2 of each of the
construction structure 1, the lengthened members 2 and the
panels 3; and a direction orthogonal to the first direction D1
and the second direction D2 is called a third direction D3 of
each of the construction structure 1, the lengthened members
2 and the panels 3.
[0018]
In other words, in the present embodiment, the first
direction D1 of the panels 3 is the longitudinal direction
(lengthwise direction) of the panels 3; the second direction
D2 of the panels 3 is the widthwise direction of the panels 3;
and the third direction D3 of the panels 3 is the thickness
direction of the panels 3. Hereinafter, signs D1, D2 and D3
are attached, respectively, to respective directions
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corresponding to the first to third directions D1 to D3.
[0019]
As illustrated in Figs. 3 and 4, the panels 3 are each
made of a synthetic resin (for example, a urethane resin,
styrene resin or phenolic resin), and are each a foam having
elasticity. Specifically, the panel 3 is a foam having a
plurality of cells 31 formed lengthwise along a direction
orthogonal to the widthwise direction D2 to have elasticity in
the widthwise direction D2.
[0020]
In the present invention, it is unnecessary that all the
cells 31 are lengthwise formed along the direction orthogonal
to the second direction D2. For example, it is sufficient for
a half or more of the cells 31 to be lengthwise formed along
the direction orthogonal to the second direction D2 to cause
the panels 3 to have elasticity in the second direction D2. In
other words, as far as the panels 3 have elasticity in the second
direction D2, some of the cells 31 may be located to be formed
along the direction parallel to the second direction D2 in the
present invention.
[0021]
The panels 3 are each formed to make the elastic modulus
of the panel 3 in the widthwise direction D2 smaller than that
in the longitudinal Dl. The panel 3 is formed to make the
elastic modulus of the panel 3 in the widthwise direction D2
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substantially equal to that in the thickness direction D3.
[0022]
Specifically, in the panel 3, the cells 31 are lengthwise
formed along the longitudinal direction D1 out of directions
orthogonal to the widthwise direction D2, thereby being formed
to make the elastic modulus of the panel 3 in the widthwise
direction D2 smaller than that in the longitudinal direction
Dl. More specifically, the cells 31 are located to arrange the
respective maximum-dimension directions of the cells along the
longitudinal direction D1, thereby making the respective
elastic moduli in the widthwise direction D2 and the thickness
direction D3 of the panel 3 smaller than that in the longitudinal
direction D1 of the panel 3
[0023]
The elastic modulus is the following ratio when external
force is applied to the panel 3 to deform the panel 3: the ratio
between the stress and the strain (deformation amount) of the
panel in an elastic range of the panel. In other words, as the
panel is smaller in elastic modulus, the panel becomes larger
in deformation amount at the same stress (pressure).
[0024]
When the panel 3 does not deform elastically, the
dimension W2 in the widthwise direction D2 of the panel 3 is
larger than the separate distance W1 between adjacent ones 2,
2 of the lengthened members. Thus, in the state that the panel
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3 is compressed and deformed in the widthwise direction D2, the
panel 3 is fitted to between the lengthened members 2, 2. The
dimension W2 in the widthwise direction D2 of the panel 3 that
does not deform elastically is preferably from 101 to 115% of
the separate distance W1 between the lengthened members 2,2,
more preferably from 105 to 110% thereof.
[0025]
In the present embodiment, the panel 3 is a polyurethane
foam panel. The structure of the panel 3 will be described in
detail hereinafter.
[0026]
The panel 3 is a polyurethane foam panel which is obtained
by mixing a polyol composition comprising one or more polyol
compounds and a water as a foaming agent with a polyisocyanate
component, and causing these components to react with each other,
and which has a lengthwise direction (longitudinal direction)
D1, a widthwise direction D2, and a thickness direction D3. In
the panel 3, the foam density is 15 kg/m3 or less, and the ratio
of the 10% compressive strength SD1 in the lengthwise direction
D1 to the 10% compressive strength SD2 in the widthwise direction
D2 (Sp1/SD2) is set to 2 or more.
[0027]
The foam density (core density) of the panel 3 is
preferably 15 kg/m3 or less, more preferably 13 kg/m3 or less,
even more preferably 11 kg/m3 or less. The foam density is set
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into this range, for example, by adjusting the water as the
foaming agent into the range of 20 to 100 parts by weight (for
100 parts by weight of the polyol compound(s)). The foam
density is a value measured in accordance with JIS K7222.
[0028]
The foam density of the panel 3 is 15 kg/m3 or less to
be very low. Thus, the panel 3 has a high foaming expansion
ratio. Accordingly, the cells 31 are each stretched into the
lengthwise direction D1 to be made into an elliptic form. The
long diameter direction of the cell 31 in the elliptic form
becomes parallel to the lengthwise direction D1 of the panel
3, so that the panel 3 becomes high in foam strength in the
lengthwise direction D1 while the panel 3 becomes low in foam
strength in the widthwise direction D2 and the thickness
direction D3 of the panel 3. As a result, the panel 3 has
elasticity (flexibility) in the widthwise direction D2 and the
thickness direction D3.
[0029]
The panel 3 is formed to set the ratio of the 10%
compressive strength SD1 in the lengthwise direction D1 to the
10% compressive strength SD2 in the widthwise direction D2
(SD1/SD2) to 2 or more . The ratio of the 10% compressive strength
SD1 in the lengthwise direction D1 to the 10% compressive
strength SD2 in the widthwise direction D2 (SD1/SD2) is preferably
3 or more, more preferably 5 or more in order to make the panel
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compatible between workability when the panel 3 is fitted to
between the lengthened members 2, 2 and self-standing
performance when the panel 3 is being fitted thereto. The upper
limit of this ratio (Sp1/SD2) is not particularly limited, and
is, for example, about 7. The wording "X% compressive strength"
denotes a stress necessary for compressing the panel 3 to be
deformed by an amount of X%.
[0030]
In order to improve the workability when the panel 3 is
fitted to between the lengthened members 2, 2, it is necessary
that the panel 3 can easily be compressed in the widthwise
direction D2. Accordingly, the 10% compressive strength SD2 in
the widthwise direction D2 of the panel 3 is preferably 3 N/cm2
or less, more preferably 1 N/cm2 or less, in particular
preferably 0.5 N/cm2 or less.
[0031]
In order to improve the workability when the panel 3 is
fitted to between the lengthened members 2, 2, it is also
necessary that the compressed panel 3 is rapidly restored. It
is therefore preferred that even when compressed in the
widthwise direction D2 by 20%, the panel 3 is neither damaged
nor broken, and further after compressed in the widthwise
direction D2 by 20%, the panel 3 is restored into a dimension
of 90% or more of the pre-compression dimension in the widthwise
direction D2 of the panel when released from the compression.
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[0032]
In the panel 3, it is preferred that the foaming direction
of the cells 31 is substantially perpendicular to each of the
widthwise direction D2 and the thickness direction D3. The
wording "substantially perpendicular" specifically denotes 90
15 , in particular, 90 10 . The wording "foaming direction
of the cells" denotes the following when the shape of the
individual cells 31 is regarded as an elliptical shape: the long
diameter direction of the cells. The wording denotes, in
particular, the direction obtained in the case of measuring a
central region of the panel 3 (region extended from the center
of the panel in the lengthwise direction D1 and the widthwise
direction D2 to both sides thereof along the former direction
D1 by 10% of the dimension in the former direction D1 of the
panel, as well as to both sides thereof along the latter
direction D2 by 10% of the dimension in the latter direction
D2 thereof.
[0033]
Since the panel 3 is used as a heating insulating member,
the thermoconductivity X of the panel 3 is preferably 0.04 W/m=K,
or less. In this case, even when the panel 3 is a panel made
low in density, the panel 3 can exhibit a sufficient heat
insulating performance. The thermoconductivity herein is a
value measured in accordance with JIS A1412-2.
[0034]
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The independent cell proportion of the panel 3 is
preferably 15% or less, more preferably from 0 to 10%. When
the panel is made high in continuous cell proportion in this
way, the panel can ensure an excellent dimension stability. The
independent cell proportion herein is a value measured in
accordance with ASTM D2856.
[0035]
As described above, the panel 3 is obtained by mixing a
polyol composition containing one or more polyol compounds and
a water as a foaming agent with a polyisocyanate component, and
causing these components to react with each other.
[0036]
The polyol compound ( s ) preferably include (s) a polyether
polyol (A) that is a polymer having an average functional group
number of 2 to 4 and a weight-average molecular weight of 3000
to 8000 and made from an alkylene oxide, and a short glycol (B)
having a molecular weight less than 250.
[0037]
The polyether polyol (A) is a polyoxyalkylene polyol
yielded by causing an alkylene oxide to undergo ring-opening
addition polymerization to an initiator having 2 to 4 active
hydrogen atoms.
[0038]
Examples of the initiator include aliphatic polyhydric
alcohols (for example, glycols such as ethylene glycol,
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propylene glycol, diethylene glycol, dipropylene glycol,
1,4-butanediol, 1,3-butanediol, 1,6-hexanediol, neopentyl
glycol, cyclohexylene glycol and cyclohexanedimethanol,
triols such as trimethylolpropane and glycerin, and
tetrafunctional alcohols such as pentaerythritol); aliphatic
amines (for example, alkylenediamines such as ethylenediamine,
propylenediamine, butylenediamine, hexamethylenediamine and
neopentyldiamine, and alkanolamines such as monoethanolamine
and diethanolamine); and aromatic amines (for example,
2,4-toluenediamine, 2,6-toluenediamine,
diethyltoluenediamine, 4,4'-diaminodiphenylmethane,
p-phenylenediamine, o-phenylenediamine and
naphthalenediamine). These compounds may be used alone or in
any combination of two or more thereof. The initiator is
preferably an aliphatic alcohol, more preferably a triol, even
more preferably glycerin.
[0039]
About the polyether polyol (A), the average functional
group number is from 2 to 4, more preferably from 2.5 to 3.5.
About the polyether polyol (A), the weight-average molecular
weight thereof is more preferably from 3000 to 5000.
[0040]
Examples of the alkylene oxide include ethylene oxide,
propylene oxide, 1,2-butylene oxide, 2,3-butylene oxide,
styrene oxide, and cyclohexene oxide. It is preferred to use,
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out of these compounds, ethylene oxide and propylene oxide
together, and cause these oxides to undergo ring-opening
addition polymerization to the initiator. At this time, it is
preferred to set the proportion of ethylene oxide ("ethylene
oxide"/"ethylene oxide" + "propylene oxide") into the range of
to 30%.
[0041]
The hydroxyl value of the polyether polyol (A) is
preferably from 20 to 100 mgKOH/g, more preferably from 30 to
60 mgKOH/g. If this hydroxyl value is less than 20 mgKOH/g,
the viscosity ratio of the polyol composition to the
polyisocyanate component is high so that when this composition
is mixed with the polyisocyanate component, a stirring failure
is caused. Conversely, if the value is more than 100 mgKOH/g,
an appropriate toughness is not easily given to the resultant
polyurethane foam. The hydroxide value is a value measured in
accordance with JIS K1557-1:2007.
[0042]
Examples of the short glycol (B), which has a molecular
weight less than 250, include ethylene glycol (molecular
weight: 62), propylene glycol (molecular weight: 76),
diethylene glycol (molecular weight: 106), dipropylene glycol
(molecular weight: 134), 1, 4-butanediol (molecular weight: 90),
1,3-butanediol (molecular weight: 90), 1,6-hexanediol
(molecular weight: 118), glycerin (molecular weight: 92), and
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tripropylene glycol (molecular weight: 192). Of these
examples, preferred are diethylene glycol, dipropylene glycol
and glycerin, and particularly preferred is diethylene glycol
in order to make the foam high in resin strength with a higher
certainty. The molecular weight of the short glycol (B) is
preferably from 62 to 200 mgKOH/g, more preferably from 90 to
150 mgKOH/g.
[0043]
It is preferred that the polyol composition used as one
of the raw materials further contains, as one of the polyol
compounds, a polyether polyol (C) having an average functional
group number of 2 to 4 and a weight-average molecular weight
of 3000 to 5000 and made from propylene oxide. The polyether
polyol (C) is a polyoxyalkylene polyol obtained by causing only
propylene oxide to undergo ring-opening addition
polymerization to an initiator having 2 to 4 active hydrogen
atoms. Examples of the initiator include above-mentioned
aliphatic polyhydric alcohols, aliphatic amines, and aromatic
amines. However, the initiator is not particularly limited.
The initiator is in particular preferably glycerin.
[0044]
The polyol composition used as one of the raw materials
preferably contains 10 to 80 parts by weight of the polyether
polyol (A) and 10 to 60 parts by weight of the short glycol (B)
in 100 parts by weight of the polyol compounds, and more
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preferably contains 15 to 70 parts by weight of the polyether
polyol (A) and 10 to 50 parts by weight of the short glycol (B)
therein in order to attain the production of the polyurethane
foam panel 3 excellent in heat insulating performance while the
panel 3 is made low in density. When the polyol composition
contains the polyether polyol (C) , the composition preferably
contains 10 to 30 parts by weight of the polyether polyol (A) ,
to 60 parts by weight of the short glycol (B) and 30 to 70
parts by weight of the polyether polyol (C) , and more preferably
contains 15 to 25 parts by weight of the polyether polyol (A) ,
10 to 50 parts by weight of the short glycol (B) and 40 to 60
parts by weight of the polyether polyol (C) .
[0045]
Water is blended as a foaming agent into the polyol
composition. The foaming agent is preferably water alone. The
blend amount thereof is from 20 to 100 parts by weight for 100
parts by weight of the polyol compound (s) , more preferably from
30 to 90 parts by weight therefor, even more preferably from
40 to 80 parts by weight therefor. Such a blend of water in
a large amount makes it possible to make the panel 3 low in
density.
[0046]
Usually, a flame retardant, a catalyst and a foam adjustor
are further blended into the polyol composition. Moreover,
thereinto may be further blended a colorant, an antioxidant,
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and various other additives.
[0047]
Examples of the flame retardant include organic
phosphates, halogen-containing compounds, and metal compounds
such as aluminum hydroxide. Particularly preferred are
organic phosphates since these compounds have an effect of
lowering the viscosity of the polyol composition. Examples of
the organic phosphates include halogenated alkyl esters of
phosphoric acid, alkyl esters of phosphoric acid, aryl esters
of phosphoric acid, and phosphonates. Specific examples
thereof include tris(chloropropyl) phosphate (TMCPP,
manufactured by Daihachi Chemical Industry Co., Ltd.),
tributoxyethyl phosphate (TBEP), tributyl phosphate, triethyl
phosphate, trimethyl phosphate, and cresyldiphenyl phosphate.
The blend amount of the flame retardant is preferably from 10
to 50 parts by weight, more preferably from 15 to 40 parts by
weight for 100 parts by weight of the polyol compound(s). In
order to prevent the brittleness-deterioration of the foam, it
is particularly preferred that the polyol composition contains
the flame retardant in an amount of 20 parts or more by weight
for 100 parts by weight of the polyol compound(s), besides the
polyether polyol (A) and the short glycol (B).
[0048]
The catalyst is not particularly limited as far as the
catalyst is a catalyst for promoting the urethanizing reaction.
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The catalyst is preferably a reactive amine catalyst, which can
react with isocyanate groups of the polyisocyanate component.
Examples of the reactive amine catalyst include
N,N-dimethylethanolamine, N,N-dimethylaminoethoxyethanol,
N,N,N'-trimethylaminoethylethanolamine,
N,N,N',N'-tetramethy1-2-hydroxypropylenediamine,
N-hydroxyethylmorpholine, N-methyl-N-hydroxyethylpiperazine,
and N,N-dimethylpropylenediamine.
[0049]
An ordinary tertiary amine catalyst is also usable.
Examples of the tertiary amine catalyst include
N,N,W,N'-tetramethylethylenediamine,
N,N,N',N'-tetramethylhexamethylenediamine,
N,N,N',N',N"-pentamethyldiethylenetriamine,
diazabicycloundecene, N,N-dimethylcyclohexylamine,
triethylenediamine, and N-methylmorpholine.
[0050]
The blend amount of the catalyst is preferably from. 2 to
parts by weight, more preferably from. 3 to 8 parts by weight
for 100 parts by weight of the polyol compound(s).
[0051]
The foam adjustor may be, for example, the following out
of known foam adjustors for a polyurethane foam: a graft
copolymer made from a polyoxyalkylene glycol, which is a polymer
made from ethylene oxide or propylene oxide, and a
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polydimethylsiloxane. The foam adjustor is preferably a
silicone foam adjustor in which the content by percentage of
oxyethylene groups in a polyoxyalkylene is from 70 to 100% by
mole. Specific examples thereof include products SH-193,
SF-2937F and SF-2938F (manufactured by Dow Corning Toray Co.,
Ltd.), B-8465, B-8467 and B-8481 (manufactured by Evonik
Degussa Japan Co., Ltd.), and L-6900 (manufactured by the
company Momentive). The blend amount of the foam adjustor is
preferably from 1 to 10 parts by weight for 100 parts by weight
of the polyol compound(s).
[0052]
The polyisocyanate component, which is mixed with the
polyol composition to be caused to react therewith, thereby
producing the polyurethane foam panel 3, maybe a polyisocyanate
compound that has two or more isocyanate groups and that may
be of various types, such as aromatic, alicyclic and aliphatic
types. The polyisocyanate component is preferably a liquid
diphenylmethane diisocyanate (MDI) since this compound is easy
to handle, large in reaction rate and low in costs, gives a
polyurethane foam excellent in physical properties, and
produces other advantages. Examples of the liquid MDI include
crude MDIs (c-MDIs) (44V-10, 44V-20, etc." (manufactured by
Sumitomo Bayer Urethane Co., Ltd.), "MILLIONATE MR-200"
(manufactured by Nippon Polyurethane Industry Co., Ltd., ) , and
urethonimine-containing MDIs "MILLIONATE MTL" (manufactured
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by Nippon Polyurethane Industry Co. , Ltd.,) . Together with the
liquid MDI, a different polyisocyanate compound may be used.
As the polyisocyanate compound used together therewith, a
polyisocyanate compound known in the technical field of
polyurethanes is usable without any restriction.
[0053]
When the polyisocyanate component is mixed with the
polyol composition to be caused to react therewith for the panel
3, the isocyanate index (NCO index) is set preferably to 30 or
less, more preferably to less than 30. The lower limit of the
isocyanate index is, for example, 20. By setting the isocyanate
index into the range, the polyurethane foam panel 3 can be
rendered a panel low in density and excellent in elasticity and
heat insulating performance. The isocyanate index herein
denotes an index representing, in the unit of percentage, the
ratio by equivalent of isocyanate groups of the polyisocyanate
component to all active hydrogen groups (provided that a
calculation therefor is made under a condition that water as
the foaming agent is regarded as a bifunctional active hydrogen
compound) contained in the polyol composition (the ratio of the
equivalent of the isocyanate groups to 100 equivalents of the
active hydrogen groups) .
[0054]
A method for producing the panel 3 is preferably a method
for producing the panel 3 that is a polyurethane foam panel
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obtained by using, as a raw material therefor, a foaming stock
solution composition which contains a polyol composition
containing one or more polyol compounds and water as a foaming
agent, and further which contains a polyisocyanate component,
in which: the polyol composition contains, as the polyol
compound (s) , for example, polyol compounds including a
polyether polyol (A) that is a polymer made from an alkylene
oxide and has an average functional group number of 2 to 4 and
a weight-average molecular weight of 3000 to 8000, and a short
glycol (B) having a molecular weight less than 250; water is
contained in an amount of 20 to 100 parts by weight for 100 parts
by weight of the polyol compounds; and when the polyisocyanate
component is mixed with the polyol composition to be caused to
react therewith, the isocyanate index is less than 30. In order
to form a plurality of cells 31 lengthwise in the lengthwise
direction D1 of the panel 3 to cause the panel 3 to have
elasticity in the widthwise direction D2, the method preferably
has, as illustrated in Fig. 5, an injecting step of injecting
the foaming stock solution composition into a mold 7 having the
above-defined lengthwise direction D1, widthwise direction D2
and thickness direction D3 to render planes (of the resultant
panel) extended along the widthwise direction D2 and the
thickness direction D3 a bottom surface 71 thereof; and a
reaction step of subjecting the foaming stock solution
composition after the injecting step to reaction.
24
CA 02897479 2015-07-07
[0055]
Specifically, in the method for producing the panel 3,
the foaming stock solution composition, which contains the
polyol composition and the polyisocyanate component, is
injected from a mixing head 8 to render the surface (of the
resultant panel) extended in the widthwise direction D2 and the
thickness direction D3 the bottom surface 71 (injecting step) .
After the injection, the foaming stock solution composition is
subjected to reaction while foamed (or expended) in the
lengthwise direction D1. In this way, a foam is formed
(reaction step) . In this reaction step, the mold 7 may be wholly
or locally heated as required.
[0056]
The configuration of the construction structure 1
according to the present embodiment is as described above, and
a description will next be described about a method for
producing the construction structure 1 according to the
embodiment with reference to Fig. 6.
[0057]
As illustrated in Fig. 6, plural lengthened members 2,
2 are arranged side by side in the widthwise direction D2 to
make the respective longitudinal directions D1 parallel to each
other. When external force is applied to each panel 3, the panel
3 is compressed in the widthwise direction D2. In this way,
the dimension W2 in the widthwise direction D2 of the panel 3,
CA 02897479 2015-07-07
which is larger than the separate distance W1 between the
lengthened members 2, 2, is made smaller than the separate
distance W1 between the lengthened members 2, 2.
[0058]
The panel 3 compressed in the widthwise direction D2 is
positioned between the lengthened members 2, 2, and then the
applied external force is cancelled to restore the panel 3.
Even after the panel 3 is brought into contact with respective
supporting surfaces 21 of the lengthened members 2, the panel
3 is forced to be further restored by elasticity. Thus, in the
state that the panel 3 contacts the lengthened members 2
adjacent thereto closely and further pushes the lengthened
members 2, the panel 3 is fitted to between the lengthened
members 2, 2.
[0059]
As described above, in the construction structure 1
according to the present embodiment, the lengthened members 2
are located to make individual longitudinal directions of the
members 2 parallel to each other in the first direction D1 and
to be arranged side by side in the second direction 2 orthogonal
to the first direction D1. The panels 3 are each a foam, which
has the cells 31 formed lengthwise along the direction
orthogonal to the second direction D2, to have elasticity in
the second direction D2.
[0060]
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Accordingly, each of the panels 3 compressed in the second
direction D2 is released from the compression between adjacent
ones 2, 2 of the lengthened members to be restored. In this
way, the panel 3 is fitted to between the lengthened members
2, 2 in the state of adhering closely to the (adjacent)
lengthened members 2 and pressing the (adjacent) lengthened
members 2. Thus, in the construction structure 1 according to
the present embodiment, the panels 3 can each be fitted with
ease to between the lengthened members 2, 2, and further the
generation of any gap can be prevented between the panels 3 and
the lengthened members 2.
[0061]
Moreover, according to the construction structure 1 of
the present embodiment, the cells 31 are formed lengthwise along
the direction orthogonal to the second direction D2, so that
the panel 3 is small in elastic modulus in the second direction
D2. Thus, the panel 3 is easily compressed in the second
direction D2 since the panel 3 has elasticity in the second
direction D2.
[0062]
Furthermore, the cells 31 are lengthwise formed along the
first direction D1 out of directions orthogonal to the second
direction D2, so that the panel 3 is large in elastic modulus
in the first direction Dl. Thus, the panel 3 has rigidity in
the first direction D1; thus, the panel 3 fitted to between the
27
CA 02897479 2015-07-07
lengthened members 2, 2 is stably held between the lengthened
members 2, 2, so that the panel 3 can alone stand.
[ 0063]
Additionally, the cells 31 are lengthwise formed along
the first direction D1 out of the directions orthogonal to the
second direction D2, so that the panel 3 can be improved in heat
insulating performance in the third direction D3.
[0064]
The present invention is not limited to the configuration
of the above-mentioned embodiment. Effects and advantages
thereof are not limited to the above-mentioned effects and
advantages. Of course, in the invention, the embodiment may
be variously modified as far as the modified embodiments do not
depart from the subject matters of the invention. For example,
it is needless to mention that any constituent or manner, or
any other that is related to various modified examples that will
be described below may be selected at will to be adopted for
one of the constituents, manners and others that are related
to the above-mentioned embodiment.
[0065]
The construction structure 1 according to the
above-mentioned embodiment has a configuration in which each
of the panels 3 is fitted to between adjacent ones 2, 2 of the
lengthened members. However, the present invention is not
limited to this configuration. As illustrated in Fig. 7, the
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CA 02897479 2015-07-07
invention may have, for example, a configuration in which panels
3 are arranged side by side in the first direction D1, and are
each fitted to between adjacent ones 2, 2 out of lengthened
members. As illustrated in Fig. 8, the invention may have a
configuration in which panels 3 are arranged side by side in
the second direction D2, and are each fitted to between adjacent
ones 2, 2 out of lengthened members.
[0066]
When the construction structure shown in Fig. 7, which
is a construction structure 1, is formed to render the first
direction D1 a height direction thereof, it is preferred that
each of the panels 3 is formed to make the elastic modulus in
the widthwise direction D2 smaller than that in the longitudinal
direction D1 by forming cells 31 lengthwise along the first
direction D1. In this way, the panel 3 has rigidity in the first
direction D1. Thus, the panel 3 fitted to between the
lengthened members 2, 2 can alone stand, and further the panel
3 can stably support a panel arranged above the panel 3, out
of the panels 3, from below the above-arranged panel.
[0067]
In the construction structure illustrated in Fig. 8,
which is a construction structure 1, adjacent ones 32, 32, out
of ends of the panels, contact each other at a position outside
the position between the lengthened members 2, 2. Panel ends
33, 33 at respective sides of the panels that are reverse to
29
CA 02897479 2015-07-07
the end 32, 32 sides thereof are each positioned between the
lengthened members 2, 2, and contact the lengthened members 2,
2 and a plate member 5. When the panels 3 receive external force
to position the adjacent panel ends 32, 32 between the
lengthened members 2, 2, the panels 3 are fitted to between the
lengthened members 2, 2 while compressed in the second direction
D2.
[0068]
The construction structure 1 according to the
above-mentioned embodiment has a configuration in which each
of the panels 3 is formed to make the dimension in the first
direction D1 larger than that in the second direction D2.
However, the present invention is not limited to this
configuration. As has been illustrated in Fig. 7, the invention
may have, for example, a configuration in which each of the
panels 3 is formed to make the dimension in the first direction
D1 smaller than that in the second direction D2.
[0069]
The above-mentioned embodiment has a configuration in
which the lengthened members 2 are columns, and the construction
structure 1 is a wall. However, the present invention is not
limited to this configuration. The invention may have, for
example, a configuration in which the lengthened members 2 are
each a floor stringer in which the first direction (longitudinal
direction) D1 is a horizontal direction, and the construction
CA 02897479 2015-07-07
structure 1 is a floor. The invention may have a configuration
in which the lengthened members 2 are each a ceiling stringer
in which the first direction (longitudinal direction) D1 is a
horizontal direction, and the construction structure 1 is a
ceiling. Furthermore, the invention may have a configuration
in which the lengthened members 2 are each a rafter in which
the first direction (longitudinal direction) D1 is a direction
inclined to vertical and horizontal directions, and the
construction structure 1 is a roof. In short, in the invention,
the first to third directions D1, D2 and D3 are not limited to
specified directions.
[0070]
In the above-mentioned embodiment, the panels 3 are
produced, using the mold 7. However, the present invention is
not limited to this manner. In the invention, for example, the
foaming stock solution composition is sprayed onto a conveyer,
and the panels 3 are cut into the form of rectangular
parallelepipeds to render the vertical direction the first
direction D1 thereof.
[0071]
As illustrated in Fig. 9, the present invention may have
a configuration in which each of two ends in the second direction
D2 of each panel 3 has a taper portion 34 inclined to the third
direction D3. The panel 3 is formed to make the dimension
thereof in the second direction D2 gradually large by the taper
31
CA 02897479 2015-07-07
portion 34. By pushing the panel 3 in the third direction D3,
the panel 3 is fitted to between adjacent ones 2, 2 out of
lengthened members 2 while compressed in the second direction
D2. The taper portion 34 may be located in only one of the (two)
ends.
[0072]
As illustrated in Fig. 10, the present invention may have
a configuration in which fixing portions 6 are located to be
projected in the second direction D2 from lengthened members
2, ones opposed to each other out of the fixing portions 6 being
for fixing a panel 3 fitted to between adjacent ones 2, 2 of
the lengthened members . The opposed fixing portions 6 each have
an engaging moiety 61 with which the panel 3 fitted to between
the adjacent lengthened members 2, 2 is engaged in the second
direction D2, and an inclined moiety 62 inclined to the third
direction D3.
[0073]
According to this configuration, the panel 3 is pushed
in the third direction D3 to be compressed into the second
direction D2 through the respective inclined moieties 62 of the
opposing fixing portions 6. The panel 3 rides over the opposing
fixing portions 6 to be fitted to between the lengthened members
2, 2. The panel 3 fitted to between the lengthened members 2,
2 is engaged with the opposed fixing portions 6 to be prevented
from dropping away from between the lengthened members 2, 2.
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CA 02897479 2015-07-07
[0074]
The present invention may have a configuration in which
the front surface of each panel 3 is covered with a film (for
example, a shrinkable film made of polyvinyl. This
configuration makes the panel 3 easy to handle when the panel
3 is held by worker' s hand or the panels 3 are stacked onto each
other.
EXAMPLES
[0075]
Hereinafter, the present invention will be described in
more detail by way of examples thereof. However, the invention
is not limited to these examples.
[0076]
<Preparation of polyol compositions>
Formulations shown Fig. 11 were each used as raw materials
for a polyurethane foam panel 3 species to prepare a polyol
composition. Details of the individual components shown in Fig.
11 are as follows:
[0077]
(1) Polyol compounds
Polyether polyol (A) -1: trade name "EXCENOL-820"
(manufactured by Asahi Glass Co., Ltd. ) , i.e., a polyether
polyol (weight-average molecular weight = 4900; hydroxyl value
(OHV) = 34 mgKOH/g) obtained by addition-polymerizing ethylene
33
=
CA 02897479 2015-07-07
oxide and propylene oxide, using glycerin as an initiator,
Polyether polyol (A)-2: trade name "EXCENOL-850"
(manufactured by Asahi Glass Co., Ltd.), i.e., a polyether
polyol (weight-average molecular weight = 7000; hydroxyl value
(OHV) = 25 mgKOH/g) obtained by addition-polymerizing ethylene
oxide and propylene oxide, using glycerin as an initiator,
Short glycol (B)-1: diethylene glycol (DEG)
(manufactured by Nacalai Tesque, Inc.; molecular weight = 106,
and hydroxyl value (OHV) = 1058 mgKOH/g), and
Polyether polyol (C): trade name "T-3000S" (manufactured
by Mitsui Chemicals, Inc.), i.e., a polyether polyol
(weight-average molecular weight = 3000; hydroxyl value = 56
mgKOH/g) obtained by addition-polymerizing only propylene
oxide, using glycerin as an initiator.
[0078]
(2) Flame retardant: trade name "TMCPP" (manufactured by
Daihachi Chemical Industry Co., Ltd.)
(3) Foam adjustor:
Foam-adjustor-1: silicone nonionic surfactant, i.e.,
trade name "SF-2938F" (manufactured by Dow Corning Toray Co.,
Ltd.)
(4) Catalysts
Catalyst-1: tertiary amine catalyst, i.e., trade name
"TOYOCAT-ET" (manufactured by Toso Co., Ltd.), and
Catalyst-2: N,N-dimethylaminoethoxyethanol, i.e.,
34
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trade name "KAO No. 26" (manufactured by Kao Corp.).
[0079]
Panel evaluation:
Examples 1 to 3
Using a polyol composition prepared in accordance with
a formulation shown in Fig. 11, and a polyisocyanate component
(c-MDI ("SUMIDULE 44V-10", manufactured by Sumitomo Bayer
Urethane Co., Ltd.); NCO%: 31%) (in each of these examples),
a foaming stock solution composition was prepared which had an
isocyanate index (NCO index) adjusted as shown in Fig. 11. This
composition was injected from the mixing head 8 onto the bottom
surface 71 of the mold 7 shown in Fig. 5 (the dimension in the
lengthwise direction D1: 900 mm; the dimension in the widthwise
direction D2: 500 mm; and the dimension in the thickness
direction D3: 500 mm). Thereafter, a polyurethane foam panel
3 obtained by subjecting the foaming stock solution composition
to reaction was cut into pieces on cutting planes of the foam
panel 3 along the lengthwise direction D1 and the widthwise
direction D2. In this way, panels 3 were produced about each
of which the panel thickness direction D3 was substantially
perpendicular (90 ) to the foaming direction of the cells 31
(the dimension of the panel 3 in the lengthwise direction D1:
700 mm; the dimension of the panel 3 in the widthwise direction
D2: 400 mm; and the dimension of the panel 3 in the thickness
direction D3: 60 mm). Results thereabout are shown in Table
CA 02897479 2015-07-07
1.
[0080]
<Weight-average molecular weight>
The weight-average molecular weight (of any polymer in
each of the examples) was obtained by making a measurement
therefor by GPC (gel permeation chromatography) and then
calculating out a value in terms of that of standard
polystyrene.
GPC apparatus: LC-10A, manufactured by Shimadzu Corp.
Columns: the use of the following three columns linked
to each other: columns (PLgel, 5 gm, 500 A), (PLgel, 5 gm, 100
A) and (PLgel, 5 gm, 50 A) manufactured by Polymer Laboratories
Ltd.
Flow rate: 1.0 mL/min.
Concentration: 1.0 g/L
Injected amount: 40 gL
Column temperature: 40 C
Eluent: Tetrahydrofuran
[0081]
<Foam density>
The foam density (in the example) was obtained in
accordance with JIS K 7222.
[0082]
<Thermoconductivity>
The thermoconductivity of any one of the panels 3 (of the
36
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example) in the thickness direction D3 was measured in
accordance with JIS A1412-2 (Method for Measuring Thermal
Resistance and Thermoconductivity of Heat Insulating Material
- Section 2: Heat Flow Meter Method) (HFM method) on the basis
of JIS A9526 (Spray-Applied Rigid Urethane Foam for Thermal
Insulation for Buildings) .
[0083]
<10% Compressive Strength>
A cube 50 millimeters square was cut out as a foam specimen
from a central region of any one of the polyurethane foam panels
3 (the dimension in the lengthwise direction D1: 700 mm; the
dimension in the widthwise direction D2: 400 mm; the dimension
in the thickness direction D3: 60 mm) produced by the
above-mentioned method (in the example) (the central region:
region extended from the center of the panel in the lengthwise
direction D1 and the widthwise direction D2 to both sides
thereof along the former direction D1 by 10% of the dimension
in the former direction D1 of the panel, as well as to both sides
thereof along the latter direction D2 by 10% of the dimension
in the latter direction D2 thereof) . An autograph, AG-X plus
(manufactured by Shimadzu Corp.) was used to measure the 10%
compressive strength of the specimen at a compression rate of
mm/min.
[0084]
[Fitting workability of each polyurethane foam panel for being
37
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fitted into predetermined shape]
When any one of the panels 3 (of the example), the
dimension of which was 400 mm in the widthwise direction D2,
was compressed into the widthwise direction D2 by 5% to be easily
fittable to between adjacent ones 2, 2, out of lengthened
members, having a separate distance of 380 mm, the panel was
judged to have a flexibility for the predetermined width. Thus,
this panel 3 was judged to be good in fitting workability ("0"
in Fig. 11).
[0085]
From the results in Fig. 11, it is understood that the
panels 3 of each of Examples 1 to 3 are low in density and small
in brittleness, and have an excellent heat insulating
performance in the thickness direction D3. It is also
understood that the panels 3 each have a difference in
compressive strength between the lengthwise direction D1 and
the lateral direction D2 and further have an excellent
flexibility in the widthwise direction D2 to be excellent also
in fitting workability.
DESCRIPTION OF REFERENCE SIGNS
[0086]
1: Construction structure, 2: Lengthened member, 3: Panel,
4: Frame member, 5: Plate member, 6: Fixing portion, 7: Mold,
8:Mixing head, 21: Supporting surface, 31: Cell, 32: Panel end,
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33: Panel end, 34: Taper portion, 61: Engaging moiety, 62:
Inclined moiety, 71: Bottom surface, D1: First direction, D2:
Second direction, and D3: Third direction.
39
