JP4094449B2 - Exterior wall material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an outer wall material excellent in strength, designability, and workability as a building material.
[0002]
[Prior art]
Conventionally, when a general house has a wooden frame structure, the outer wall surface is generally finished with wood or mortar, and the surface is usually finished by spraying. In the case of this wooden frame construction method, a curing period for mortar and a curing period for drying paint are necessary, and this construction method is called a wet construction method. On the other hand, houses with a construction method called the prefabrication method or the two-by-four method, such as nailing plywood or panels to the studs and nailing a ceramic siding board on the outside or hooking tiles etc. to the horizontal rail, are also common. This method is called dry method.
[0003]
For example, when the outer wall by the wet construction method is applied by spraying, there is a problem of an increase in environmental load due to scattering of paint liquid fine powder to neighboring houses and volatilization of organic solvent in the paint. In addition, there is a problem that a long construction period is required for curing even in a construction method in which bricks, tiles and the like are stacked or pasted through mortar.
On the other hand, in the dry method, for example, when using ceramic siding boards or tiles as disclosed in Patent Document 1, the mass per unit area is often excessive, and the design can withstand a large mass. Had to do. Furthermore, especially in wooden framed houses, we tried to use ceramic siding boards and tiles to renovate the outer walls of so-called second-hand houses after 10 years of construction without repainting. In such a case, the design strength of the existing outer wall materials and pillars will be exceeded, and ceramic mass siding boards and tiles with large masses cannot be used in many cases. Even if the house itself has been remodeled, the renovation work will be carried out due to other work such as removal of the existing outer wall material and reinforcement of the pillar so as not to exceed the design load of the existing outer wall material and pillar. It was extremely inconvenient.
[0004]
Moreover, in the construction of ceramic siding materials, for example, a large flat panel of 3 × 6 (about 90 cm × about 180 cm) plates is fixed by nailing, so that the panel, which is a mass, can be transported or The current situation is that the burden placed on the installer during the positioning work is large. Therefore, in recent years, lightweight siding materials such as metal siding have been developed as lightweight outer wall materials, which are embossed unevenness on the surface of a thin metal plate such as aluminum constituting the surface layer, and the inner layer is urethane foam or the like A construction method is adopted in which this is attached to the existing outer wall surface by nailing. This construction method is disclosed in Patent Document 2, for example. However, in terms of design, the uneven shape on the aluminum surface often lacks a high-quality appearance due to excessive glossiness. In particular, on the aluminum surface, since the melting point of aluminum is 660 ° C., when an open flame violently comes into contact with the outer wall surface due to a fire or the like, the surface is melted and broken, and there is a problem in terms of fire resistance. Similarly, as a lightweight outer wall material, a panel molded from thermoplastic resin as a main raw material is disclosed in Patent Document 3, and in order to further improve the mechanical strength of the panel, the front wall and the front wall having a design surface are disclosed. A plastic outer wall material having a hollow double wall structure in which the opposite back walls are joined with a concave rib is proposed in Patent Document 4, or a fitting structure in which the upper, lower, left and right edge portions of the panel are sealed Patent Document 5 proposes a decorative wall covering material having However, the thermoplastic resin-based siding material has poor fire resistance, and there is a problem that it cannot be used as an outer wall material in a district designated as a fire prevention area.
[0005]
On the other hand, as a thermosetting resin panel, a flame retardant panel (Patent Document 6), an outer wall panel (Patent Document 7), or a lattice-shaped reinforcing rib that contains an inorganic filler and has excellent flame retardancy and workability. A wall panel (Patent Document 8) having a shape into which a joint member for joining the panels can be inserted has been proposed. However, these thermosetting resin panels have higher rigidity than thermoplastic resin panels, so it may not be possible to correct slight distortion during construction, or cracks may occur if an excessive force such as twisting the panel is applied. there were.
[0006]
[Patent Document 1]
JP-A-5-209454 [Patent Document 2]
JP 63-125770 A [Patent Document 3]
JP 7-217059 A [Patent Document 4]
JP-A-11-131751 [Patent Document 5]
Japanese Patent Publication No. 6-509613 [Patent Document 6]
JP 2002-187247 A [Patent Document 7]
JP 2001-214599 A [Patent Document 8]
Japanese Patent Laid-Open No. 10-18481
[Problems to be solved by the invention]
An object of the present invention is to provide an outer wall material that solves these problems, is excellent in design and flame retardancy, is lightweight and does not easily crack.
[0008]
[Means for Solving the Problems]
As a result of intensive trial manufacture and evaluation in order to achieve the object of the present invention, the present inventors have completed the present invention. That is, the present invention
(1) A resin outer wall material containing at least a thermosetting resin, an inorganic filler, and inorganic fibers, the outer wall material having one or more ribs extending in the vertical and horizontal directions and integrally formed therewith. At least one connecting portion that intersects and joins, and the corner radius of curvature (R) of the connecting portion is 2 mm or more and 200 mm or less , while the outer wall material has a rectangular shape and has an outer peripheral portion. A resin outer wall material, characterized in that it has a side wall, and the ribs directly connected to the side walls of the outer peripheral portion facing each other are one or less each in length and width ,
(2) The resin-made outer wall material according to claim 1, wherein there is no rib directly connected to the side wall of the opposing outer peripheral portion,
(3) The resin outer wall material according to (1) or (2), wherein a fire-proof paint is applied to at least one surface.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in more detail, particularly focusing on preferred embodiments thereof.
First, the resin outer wall material of the present invention contains at least a thermosetting resin, an inorganic filler, and inorganic fibers. Thermosetting resins include phenolic resins, unsaturated polyester resins, urea resins, epoxy resins, alkyd resins, melamine resins, urethane resins, and mixtures thereof. Of these, phenol resins and unsaturated polyester resins are preferable because they exhibit good moldability, and phenol resins are particularly preferable because they are excellent in flame retardancy.
[0010]
The phenol resin used in the present invention includes a resol type phenol resin synthesized with an alkali metal hydroxide or an alkaline earth metal hydroxide, a novolac type phenol resin synthesized with an acid catalyst, and an ammonia resol type phenol resin synthesized with ammonia. Or a benzyl ether type phenol resin synthesized with lead naphthenate or the like. Among them, a resol type phenol resin is particularly preferable because of its good moldability. In addition, for the purpose of increasing the degree of polymerization as necessary, an acid catalyst may be added to these resins, and a basic catalyst may be added to novolac type phenol resins.
[0011]
The content of the thermosetting resin is not particularly limited, but if it is too small, the strength of the outer wall material may be lowered, and if it is too much, the shape retention during combustion may be lowered. The resin content is preferably 10% by mass or more, more preferably 20% by mass or more, preferably less than 80% by mass, more preferably less than 60% by mass.
As the inorganic filler of the present invention, calcium carbonate, kaolin clay, talc, microballoon, barium sulfide, silicic anhydride, diatomaceous earth, glass powder, mica, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zonotlite, Tobermorite, wollastonite, silica sand and the like can be mentioned, and calcium carbonate, kaolin clay and aluminum hydroxide are preferable. These can be used alone or as a mixture of two or more. The content of the inorganic filler is not particularly limited, but if it is too much, the strength may be lowered, and if it is too little, the flame retardancy may be lowered. The content of the inorganic filler is preferably 20% by mass or more, more preferably 30% by mass or more, and less than 80% by mass, more preferably less than 60% by mass.
[0012]
As the inorganic fiber, glass fiber such as E-glass, C-glass, T-glass, AR-glass, D-glass, carbon fiber, rock wool, etc. may be used. Glass is preferred. The fiber diameter of the glass fiber is preferably about 0.003 to 0.03 mm, more preferably 0.006 to 0.015 mm. Moreover, it is preferable that the inorganic fiber length in this invention is 0.1-100 mm, and it is more preferable that it is 3-30 mm. When the fiber length of the inorganic fiber is less than 0.1 mm, the reinforcing effect by the inorganic fiber is not sufficiently exhibited, and as a result, the bending strength of the molded product is hardly exhibited. If the inorganic fiber length exceeds 100 mm, the fluidity of the molding resin composition composed of the inorganic filler and the phenol resin is lowered, and the moldability tends to be inferior. The content of the inorganic fiber is not particularly limited, but the preferable content of the inorganic fiber is 3% by mass or more and less than 40% by mass, more preferably 8% by mass or more and less than 30% by mass. If the content of the inorganic filler is less than 3% by mass, the strength may be insufficient, and if it is 40% by mass or more, the moldability may be inferior.
[0013]
The resin outer wall material of the present invention has a base material portion that occupies most of the area, and a rib that is integrally formed with the base material portion.
As for the thickness of a base material part, 0.5 mm or more and 20 mm or less are preferable. If the thickness of the base material portion is less than 0.5 mm, the strength tends to decrease and breakage easily, and if the portion exceeding 20 mm increases, the mass increases and the workability may be impaired. A more preferable thickness of the base material portion is 1.5 mm or more and 15 mm or less. The base material portion can be made into an arbitrary design by providing irregularities on the surface.
[0014]
The rib preferably has a thickness that is twice or more that of the thinnest part of the base material, preferably has a shape with a short side of 2 mm or more and a long side having a length of at least twice the short side.
If the length of the short side of the rib is smaller than 2 mm, the inorganic fibers are difficult to enter the rib during molding, and the strength of the rib may be reduced. On the other hand, if the ratio of the long side to the short side of the rib is smaller than 2, there is a possibility that the mass of the rib portion increases and the overall mass becomes large, or the rib reinforcing effect cannot be fully exhibited. There is no particular upper limit on the length of the short side of the rib. However, if the short side of the rib is too long, the area of the rib with respect to the base material portion increases, and the overall mass increases and the workability may be impaired. For this reason, as a size which a person can handle alone, the short side of the rib is preferably 40 mm or less, more preferably 20 mm or less.
[0015]
There are one or more ribs in the vertical and horizontal directions. Each rib has at least one connecting portion (a portion including the intersection of the rib and the rib), and a corner of the connecting portion (a corner formed by intersecting the rib and the rib). The curvature radius (R) is 2 mm or more and 200 mm or less. If the R of the connecting portion is less than 2 mm, the stress may concentrate and cracks may occur in the connecting portion even when a slight deformation is applied. On the other hand, if R exceeds 200 mm, the volume of the ribs increases, the overall mass increases, and the workability may be impaired. R of the more preferable connection part is 3 mm or more and 100 mm or less.
[0016]
Furthermore, it is preferable that the rib has an inclination that decreases in the thickness direction from the portion connected to the resin outer wall material base material portion, since the releasability from the mold is improved when the rib is molded.
The resin outer wall material of the present invention preferably has a side wall on the outer peripheral portion. The outer peripheral side wall referred to here is the outermost side wall standing up at an angle of 45 degrees or more in the direction perpendicular to the surface, and the area surrounded by the outer peripheral side wall is at least 50% of the base material portion. It is preferable to occupy the area. Also, if the outer peripheral side wall and many ribs are directly connected, the resin outer wall material becomes stiff and it becomes difficult to correct slight distortion during construction, so the rib that directly connects the opposite outer peripheral side wall is One or less each in length and breadth is preferable, and more preferably, there is no rib that directly connects the side walls of the opposing outer peripheral portions.
[0017]
Moreover, when connecting the side wall and rib which stand | start up not only in an outer peripheral part but in the orthogonal | vertical direction with respect to the surface, it is preferable to take R also in a connection part. The range of R is preferably 2 mm or more and 200 mm or less, more preferably 3 mm or more and 100 mm or less. The resin outer wall material of the present invention is preferably coated on the surface in order to make the color tone constant during long-term use. Here, the front surface refers to one or both of the front surface and the back surface of the resin outer wall material. The paint used for the surface coating is preferably a light-resistant paint, and any of acrylic silicon, urethane, silicon, and fluororesin may be used, but acrylic silicon is preferred from the viewpoint of cost. Moreover, in the case of the resin outer wall material of the present invention, it is more preferable to use a coating material having fireproof performance as the paint because the fireproof performance of the resin outer wall material is further improved.
[0018]
The coating material having fireproof performance refers to a coating material that exhibits the effect of suppressing the amount of heat generated when the resin outer wall material is burned by applying the coating material to the resin outer wall material. The suppression effect of calorific value is based on the “Corporate Calorimeter III of Toyo Seiki Co., Ltd.” and “The Fire Protection Performance Test / Evaluation Work Method” edited by Japan Building Research Institute. Can be determined by evaluating the total calorific value in a combustion test. Examples of coating materials having fireproof performance include antimony trioxide, zirconium oxide, barium metaborate, ammonium polyphosphate, melamine, pentaerythritol, zinc borate, phosphate ester, tricresyl phosphate, etc. A paint is mentioned. These coating materials can be used alone or in combination. Moreover, a fire-proof coating material and an acrylic silicon type light-resistant coating material can each be apply | coated, and a coating film can also be made into two or more layers.
[0019]
Next, an example of a method for producing the resin outer wall material of the present invention will be described.
A phenol resin and an inorganic filler are mixed in a desired amount ratio to prepare a paste. At this time, in order to impart thickening to the phenolic resin, or to impart flame retardancy, weather resistance, mold releasability during molding, etc. to the obtained molded product, flame retardant, ultraviolet absorber, internal release It is preferable to add additives such as molds and thickeners, and it is particularly preferable that an internal mold release agent be included. The addition amount of the internal mold release agent is preferably 0.1 to 5 parts by mass, more preferably 1 to 3 parts by mass with respect to 100 parts by mass of the total mass of the phenol resin, the inorganic filler, and the inorganic fiber. Examples of the internal mold release agent include aliphatic hydrocarbons, higher aliphatic alcohols, fatty acid amides, metal soaps, and phosphoric acids. Among these, zinc stearate, A compatible phosphate alcohol is preferred. In particular, it is preferable to use neutralizing phosphate alcohol (trade name “Zelec NE”) manufactured by DuPont because the fixability of the paint is good. Without using an internal mold release agent, when molding using a mold, the molded product adheres firmly to the inner wall of the mold, and when the mold is opened, the molded product tends to tear and break. There is a possibility that the yield of the molded product is lowered.
[0020]
A resin outer wall material can be produced by a method such as a sheet molding compound molding method, a bulk compound molding method, and a hand layup molding method using the paste and inorganic fibers.
<Adjustment of molding material A>
100 parts by mass of a resole phenolic resin (made by Showa High Polymer Co., Ltd., trade name “BRL-240”), 1 part by mass of calcium hydroxide (made by Kanto Chemical Co., Ltd., reagent grade) as a thickener, internal mold release As an agent, zinc stearate (manufactured by Kanto Chemical Co., Ltd., reagent grade 1) 3 parts by mass, aluminum hydroxide (manufactured by Showa Denko Co., Ltd., trade name “Hijilite H32”) 83 parts by mass, kaolin clay (manufactured by ENGELHARD, Trade name "ASP-400P") 83 parts by weight, average fiber length 3 mm glass fiber (manufactured by Nitto Boseki Co., Ltd., trade name "CS-3SK") 67.0 parts by weight Omnimixer (Chiyoda Giken Co., Ltd.) The product name “OM-5”) was mixed and stirred for about 1 minute, and the resulting composition was sandwiched between polypropylene films having a thickness of 0.04 mm, and a thickness of about 3 using a hand roller. m and a sheet was heat treated for 4 hours at 80 ° C. from (referred to as molding material A).
[0021]
<Adjustment of molding material B>
100 parts by mass of a resole phenolic resin (product name “BRL-240”, manufactured by Showa Polymer Co., Ltd.), 1 part by mass of calcium hydroxide (special grade manufactured by Kanto Chemical Co., Ltd.) as a thickener, an internal release agent 3 parts by weight of zinc stearate (first grade reagent manufactured by Kanto Chemical Co., Inc.), 83 parts by weight of aluminum hydroxide (manufactured by Showa Denko KK, trade name “Hijilite H32”), kaolin clay (manufactured by ENGELHARD, trade name) 83 parts by weight of “ASP-400P”) was mixed with a hand mixer (trade name “BMV-150A” manufactured by Shibaura Seisakusho) for 10 minutes to obtain a raw material paste.
[0022]
This raw material paste was set in an SMC manufacturing apparatus (manufactured by Tsukishima Kikai Co., Ltd.). A 0.040 mm thick polypropylene film was used as a carrier film, and this raw material paste was coated at a thickness of 1 mm and was run from two places above and below the apparatus. At this time, glass fiber robingu (manufactured by Nittobo Co., Ltd., trade name “RS240PB549AS”) was added so as to be sandwiched between two carrier films while cutting to an average fiber length of 25 mm. The addition amount at this time was adjusted so that the content of the glass fiber in the resulting molding material was 20 mass percent. The molding material obtained continuously became a sheet having a thickness of about 3 mm. This was wound up into a roll and then heat treated at 80 ° C. for 4 hours (this is referred to as molding material B).
[0023]
[Example 1]
The molding material A was loaded on the surface chrome plating mold 1 mounted on a pressure press heated to 180 ° C. When the mold 1 was closed and heated and pressed at 5 × 10 ⁶ Pa for 3 minutes, the average thickness was 2 mm, the mass per unit area was 6 kg / m ² , and the same shape as the inner shape of the mold having a sidewall structure on the outer periphery The outer wall material made of resin was obtained. There were no cracks in the molded product, and no cracks were generated even when it was strained several millimeters by hand. The outline of the obtained resin outer wall material is shown in FIGS. The radius of curvature (R) of the corner formed by intersecting the ribs of the resin outer wall material molded by the mold 1 is 6 mm.
[0024]
[Example 2]
Except having changed the molding material A into the molding material B, it carried out exactly like Example 1, and obtained the resin-made outer wall material. There were no cracks in the molded product, and no cracks were generated even when it was strained several millimeters by hand.
[0025]
[Comparative Example 1]
A resin outer wall material was obtained in exactly the same manner as in Example 1 except that the mold 1 was changed to the mold 2 (the same material as the mold 1 and the mold shape was different). When removed from the mold 2, two microcracks were generated at the rib connecting portion. The molded product was hardly distorted by hand. The outline of the obtained resin outer wall material is shown in FIGS. The radius of curvature (R) of the corner formed by the ribs of the resin outer wall material molded by the mold 2 intersecting is 1 mm.
[0026]
[Comparative Example 2]
Except having changed the molding material A into the molding material B, it carried out exactly like the comparative example 1, and obtained the resin-made outer wall material. When it was removed from the mold, five microcracks were generated at the connecting portion of the rib. The molded product was hardly distorted by hand.
[0027]
【The invention's effect】
According to the present invention, it is possible to provide an outer wall material that is excellent in design and flame retardancy, is lightweight, and has excellent workability.
[Brief description of the drawings]
FIG. 1 is a schematic plan view showing the surface of a resin outer wall material manufactured in Example 1. FIG.
2 is a schematic plan view showing the back surface of the resin outer wall material manufactured in Example 1. FIG.
3 is a partially enlarged plan view showing a rib connecting portion of the resin outer wall material manufactured in Example 1. FIG.
4 is a schematic side view showing a long side surface of a resin outer wall material manufactured in Example 1. FIG.
5 is a schematic side view showing a short side surface of the resin outer wall material manufactured in Example 1. FIG.
6 is a schematic plan view showing the back surface of the resin outer wall material manufactured in Comparative Example 1. FIG.
7 is a partially enlarged plan view showing a rib connecting portion of the resin outer wall material manufactured in Comparative Example 1. FIG.
[Explanation of symbols]
1: Base material part 2: Rib 3: Rib coupling part 4: Side wall of outer peripheral part

Claims (3)

A resin-made outer wall material containing at least a thermosetting resin, an inorganic filler, and inorganic fibers, the outer wall material having one or more ribs extending in the vertical and horizontal directions integrally formed therewith and intersecting the ribs. The connecting wall has at least one connecting portion and the corner has a radius of curvature (R) of 2 mm or more and 200 mm or less , while the outer wall material has a rectangular shape and has a sidewall on the outer periphery thereof. A resin-made outer wall material, characterized in that it has one or more ribs that are directly connected to the opposite side walls of the outer periphery . The resin-made outer wall material according to claim 1, wherein the resin-made outer wall material has a structure in which a rib directly connected to a side wall of an opposing outer peripheral portion does not exist .   The resin outer wall material according to claim 1 or 2, wherein a fireproof paint is applied to at least one surface.

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