JPH0662345B2 - Outer wall material having uneven pattern and method for manufacturing the same - Google Patents

Description

TECHNICAL FIELD The present invention relates to an outer wall material for a building, and more particularly to an outer wall material having an uneven pattern such as a brick tone or a stone tone on its surface, and a method for producing the same.

<< Prior Art >> In recent years, as an outer wall material of a building, a waterproof layer is formed on a wooden substrate, and a lightweight mixture layer obtained by kneading an inorganic binder and foamed synthetic resin particles is formed on the waterproof layer. , A lightweight construction base material that is excellent in strength, waterproofness, sound insulation, heat insulation and fire resistance is used.

Conventionally, these construction base materials have been developed mainly for simplifying the work of the base construction of the outer wall construction, and the surface finishing process of mortar, coating material, tile, etc. can be omitted. There wasn't.

Therefore, while taking advantage of the excellent performance of the above-mentioned conventional architectural base material, it is possible to further omit the surface finishing process which requires particularly skill in the outer wall construction, and it is desired to develop an outer wall material excellent in designability. In particular, there is an increasing demand for three-dimensional brick and stone tones.

Therefore, an attempt was made to form an uneven pattern with a template on the surface of a mixture layer formed by kneading the above-mentioned inorganic binder and expanded synthetic resin particles, but the surface property was poor, and the surface finishing step was omitted greatly. It was not possible.

<< Problems to be Solved by the Invention >> The inventors of the present invention have conducted extensive studies to solve the above problems, and as a result, an inorganic binder and a fine aggregate on a template having an uneven pattern formed on the surface. By coating a mixture layer obtained by kneading the above, and by configuring the above-mentioned architectural base material on the mixed layer, it is possible to form an uneven pattern on the surface of the architectural base material, and on the template. The present invention was found to find that a fine uneven pattern can be formed by vibrating the template with a vibrator after coating the mixture layer.

Therefore, a first object of the present invention is to provide an outer wall material having a fine uneven pattern which does not require surface finishing.

A second object of the present invention is to provide a method for manufacturing an outer wall material having a fine uneven pattern.

<< Means for Solving the Problems >> The above objects of the present invention are at least a lower layer formed by forming a waterproof layer on a wood-based substrate, an intermediate layer formed by kneading an inorganic binder and expanded synthetic resin particles, And an outer wall material obtained by sequentially laminating a surface layer formed by kneading an inorganic binder and fine aggregate, wherein the outer surface of the surface layer is provided with a concavo-convex pattern formed by a template. And the manufacturing method thereof.

Hereinafter, an outer wall material having an uneven pattern and a method for manufacturing the same according to the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view showing an example of an outer wall material having an uneven pattern according to the present invention.

In the figure, reference numeral (1) is a lower layer formed by forming a waterproof layer (2) on a wooden substrate, reference numeral (3) is an intermediate layer formed by kneading an inorganic binder and foamed synthetic resin particles, and a reference numeral (4) Is a surface layer formed by kneading an inorganic binder and a fine aggregate.

As the lower-layer (1) wood-based board, wood-based board materials such as plywood, fiberboard, particle board, wood wool board, and honeycomb core plywood can be used, but the present invention is not necessarily limited to wood-based board materials. Alternatively, a plate material made of another material may be used as long as it is light, has a relatively large bending stress, and can be easily cut.

The waterproof layer (2) can be appropriately selected and used from known waterproof substances generally used in coating film waterproofing methods, but it is waterproof and has good adhesiveness with cement, It is desirable to use a roll coater, a flow coater or the like that can be easily applied. The main ones are acrylic, ethylene / vinyl acetate, polypropylene and other synthetic resin emulsions; styrene / butadiene rubber, chloropyrene rubber, butyl rubber,
Synthetic rubber latex such as acrylonitrile butadiene rubber and methyl acrylate butadiene rubber; asphalt,
Examples thereof include bituminous emulsions such as tar and rubber algalt; mixtures of butyl rubber and bituminous emulsions; mixed emulsions of bituminous substances and polypropylene.

In places around the bathroom where the humidity is high and particularly strict waterproofing is required, use a waterproof sheet for butyl rubber, synthetic resin such as rubberized asphalt, etc. What was stuck on the base material can also be used.

The inorganic binder used in the middle layer (3) and the surface layer (4) is, in addition to ordinary Portland cement, gypsum, etc., if it has production line aptitude, high-alumina such as ultra-rapid hardening cement, thermosetting cement, etc., High gypsum quick-setting cement may be used. Also, depending on the application, the bonding strength of cement,
When it is necessary to increase the flexibility, an aqueous dispersion such as a synthetic resin emulsion or a synthetic rubber latex can be added and mixed within the range of 20% by weight of the solid content.

If the thickness of the middle layer (3) is equal to or larger than the thickness of the lower layer (1), warpage may occur or the bending strength of the entire base material may decrease, but in this case, the mixture layer contains It is preferable to mix a fiber material such as glass fiber, synthetic fiber or vegetable fiber in an amount of 0.2 to 5% based on the weight of cement.

The foamed synthetic resin particles can be appropriately selected and used from resins capable of forming foams such as styrene type, urea type, phenol type, urethane type, vinyl chloride and polyethylene. Among them, the expansion ratio It is preferable to use those having a high degree of closed cells and closed cells because the heat insulating property and the fire prevention performance can be further improved. In particular, expanded synthetic resin particles of polystyrene and polyethylene are used in packaging materials and containers in large amounts because polystyrene, polyethylene, etc. are used in large quantities, so it is extremely cheap to crush and use defective products and waste that are generated during manufacturing. Can be manufactured.

The particle size of the expanded synthetic resin particles is related to the thickness and specific gravity of the middle layer (3), but those in the range of 0.2 to 10 mm are used.
When aiming for low specific gravity, it is necessary to densely fill the expanded synthetic resin particles, and the smaller the particle size, the better. However,
If there are too many small diameters, the contact area between the cement paste and the expanded synthetic resin particles will increase, and part of the cement paste will be absorbed by the foam, so the shape of the minute voids will decrease and the specific gravity will not decrease as expected. . Therefore, it is preferable to mix foamed resin particles having an appropriately different particle size within the above range rather than mixing foamed synthetic resin particles having the same particle size.

The uneven pattern provided on the surface of the surface layer (4) may be a brick pattern, a stone pattern, or the like. It is preferable that the concave and convex grooves have a depth of about 4 mm in order to form a three-dimensional pattern. Further, silica sand is usually used as the fine aggregate of the surface layer (4), but if fine aggregate such as Farai ash or silica fume is used, the fluidity is increased and a good uneven surface can be obtained. Further, a fiber material such as glass fiber, synthetic fiber or plant fiber may be added to the surface layer (4) to increase the strength.

The outer wall material having a concavo-convex pattern of the present invention has at least the above-mentioned constitution, but the concavo-convex surface of the surface layer (4) can be further subjected to finish coating.

Further, the outer wall material of the present invention can be used not only as an outer wall material but also as an interior material.

Next, the method for manufacturing the outer wall material of the present invention will be described in detail below.

FIG. 2 is a cross-sectional view 1 showing a method for manufacturing an outer wall material of the present invention.
Here is an example.

In the figure, reference numeral (10) is a template having an uneven pattern.

First, a release agent is applied to the upper surface of the template (10). The template (10) used in the present invention can be appropriately selected and used from known materials.

The release agent can be appropriately selected and used from known release agents composed of polyethylene, fatty acids, mineral oils and the like.

Next, the surface layer (4) obtained by kneading the inorganic binder and the fine aggregate is applied onto the template (10), and the template (10) is vibrated by a vibrator. Thereby, the air between the template (10) and the surface layer (4) can be removed, and the finished surface of the uneven surface can be improved.

A wood-based substrate obtained by applying an intermediate layer (3) obtained by kneading an inorganic binder and expanded synthetic resin particles on the surface layer (4) and then applying a waterproof layer (2) on the intermediate layer (3). Is placed with the waterproof layer (2) facing down, and pressure is applied for a predetermined time with a pressing machine.

Finally, the template (10) is released from the mold to manufacture the outer wall material having the uneven pattern of the present invention.

<< Effects of the Invention >> As described above in detail, since the surface finish of the outer wall material having the uneven pattern of the present invention can be omitted in the field, the work period can be shortened.

Further, since the template is vibrated by the vibrator, the air between the template and the surface layer is removed, and a fine uneven pattern can be formed.

Furthermore, if fine aggregate such as fly ash or silica fume is used for the fine aggregate of the surface layer, the uneven surface can be finished smoothly.

<< Examples >> The present invention will be described in more detail below with reference to Examples, but the present invention is not limited thereto.

Example 1 A surface layer cement, which was kneaded at a compounding ratio shown in Table 1, on a 455 mm × 1,820 mm FRP template coated with a cement release agent at about 102 g / m ² (water diluted solution) was applied at an amount of about 3 .8
The coating was performed so that it would be kg / m ² .

Next, after applying middle layer cement kneaded in the mixing ratio shown in Table 2 so that the coating amount becomes 10.2 kg / m ² , it is waterproofed and has a thickness of 7.5 mm and a structure of 280 mm × 280 mm. When the plywood was placed and depressurized by a pressing machine for a predetermined time, the outer wall material having the uneven surface of the template could be obtained. In this case, the formation of holes, which is probably due to the air trapped between the template and the surface layer, was observed.

(All units in the tables below, including the above table, are parts by weight.) Example 2 After coating surface cement in the same manner as in Example 1, FR
Vibration was applied to the P-shaped plate using a biplateer.

Next, when the middle layer cement and the structural plywood were laminated in the same manner as in Example 1 and depressurized by pressing with a pressing machine for a predetermined time, a smoother surface than the surface of the outer wall material obtained in Example 1 was obtained. It was proved that an improved outer wall material can be obtained by vibrating after coating the surface layer while having the small number of holes while having the holes.

Example 3 An outer wall material was produced in the same manner as in Example 2 except that the surface cement was kneaded at the mixing ratio shown in Table 1. Fine holes due to air disappeared almost completely, resulting in very good unevenness. An outer wall material having a surface could be obtained. This is because the use of fine aggregate such as fly ash instead of silica sand increased the fluidity of the surface cement and improved the compatibility with the FRP template. The obtained outer wall material was about 30% heavier than the conventional building base material.

Example 4 The middle layer cement was kneaded at the compounding ratio shown in Table ² , and the coating amount of the surface layer cement was 3.2 kg / m ² , and the coating amount of the middle layer cement was 8.3 kg / m ² , except that When an outer wall material was manufactured in the same manner as in Example 3, the weight was almost the same as that of the conventional building base material and the strength was the same as that of the conventional building base material, even though the outer wall material had the same excellent uneven pattern as in Example 3. It was possible to obtain an outer wall material having

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of an outer wall material having an uneven pattern according to the present invention. FIG. 2 is a cross-sectional view showing a method for manufacturing an outer wall material having an uneven pattern according to the present invention. 1 ... Lower layer 2 ... Waterproof layer 3 ... Middle layer 4 ... Surface layer 10 ... Template

Claims (3)

[Claims] 1. At least a lower layer formed by forming a waterproof layer on a wood-based substrate, an intermediate layer formed by kneading an inorganic binder and foamed synthetic resin particles, and an inorganic binder and a fine aggregate. An outer wall material having a concavo-convex pattern characterized in that the outer surface of the surface layer is provided with a concavo-convex pattern formed by a template. 2. A surface layer formed by coating a mold release agent on a template having an uneven pattern and kneading an inorganic binder and fine aggregate, and vibrating the template with a vibrator. After removing air between the template and the surface layer, an intermediate layer formed by kneading an inorganic binder and foamed synthetic resin particles is applied on the surface layer, and then a waterproof layer is formed on the intermediate layer. A method of manufacturing an outer wall material having an uneven pattern, which comprises placing a wood-based substrate through the substrate and pressing it with a pressing machine for a predetermined time. 3. The method for producing an outer wall material having an uneven pattern according to claim 2, wherein the fine aggregate in the surface layer is fly ash or silica fume.