JP2001129814A - Morter composite exterior finish material and method for producing it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an exterior finish material having a high adhering force of a metal core material to a mortar layer in a mortar composite exterior finish material formed by covering a front surface side of the core material with the mortar layer and a method for producing it. SOLUTION: The mortar composite exterior finish material comprises a metal core material P1 having a side plate part 2 molded of a metal plate material and bent toward a rear surface side and an engaging plate (mounting part) 3, and a mortar layer M1 molded to cover the overall surface of the front surface side of the material P1. In this case, the layer M1 is molded of a cement mixture mixed with a synthetic resin polymer, and the material P1 and the layer M1 are laminated and integrated through an adhesive layer made of the same material as the polymer coating the surface of the material P1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mortar composite exterior material used for exterior of buildings and a method for producing the same.

[0002]

2. Description of the Related Art As a conventional mortar-based composite exterior material (hereinafter sometimes simply referred to as "composite exterior material"), for example, the one disclosed in Japanese Patent Application Laid-Open No. H11-156827 is known. I have. This composite exterior material T 'is shown in FIG.
As shown in FIG. 5, a metal plate is bent to form a metal core 51 so that a fitting portion 51a bent inward in the cross section is formed at both ends, and the fitting portion 51a is formed. The entire outer surface of the metal core 51, including the outer surface of the metal core 51, is covered with a mortar layer 52 by extrusion molding or the like.
1 and a mortar layer 52 are integrated in shape. In FIG. 11, reference numeral 51b denotes an engaging portion obtained by bending the distal end of the fitting portion 51a of the metal core 51 further inward.

The above-mentioned composite exterior material T 'is made of a metal core 51
The metal core material 51 and the mortar layer 52 are partially fitted to each other by the two fitting portions 51a partially formed in Except for 51a, both are not joined. For this reason, the metal core 51 and the mortar layer 52 are likely to cause “relative displacement” along the longitudinal direction. In addition, since the metal core 51 is bent so as to have the fitting portion 51a, the cross-sectional shape is often complicated,
In this case, the processing becomes troublesome.

[0004]

SUMMARY OF THE INVENTION The present invention is directed to a mortar-based composite cladding material in which a mortar layer is covered on the surface side of a metal core material by increasing the bonding strength between the metal core material and the mortar layer. It is an object of the present invention to provide an exterior material which has solved the above problems and a method for producing the same.

[0005]

Means for Solving the Problems The present invention for solving the above-mentioned problems comprises a metal core material formed in an irregular cross section and a mortar layer formed so as to cover the surface side of the metal core material. A mortar-based composite exterior material comprising: the mortar layer is formed of a cement mixture in which a synthetic resin polymer is mixed, and the metal core material and the mortar layer are
It is characterized by being laminated and integrated via an adhesive layer made of the same material as the synthetic resin polymer applied to the surface of the metal core material.

A synthetic resin adhesive layer is applied to the surface side of the metal core, and the synthetic resin adhesive layer and the synthetic resin mixed in the cement mixture for forming the mortar layer are the same. Therefore, at the time of the curing, the two are firmly bonded. As a result, the metal core and the mortar layer covering the entire surface of the metal core are bonded by bonding over the entire surface of the metal core.

Further, when the metal core and the mortar layer are joined by a shape fitting in the cross section, the metal core and
The mortar layer laminated on the surface side is bonded by both the adhesive force by the above-mentioned synthetic resin adhesive layer and the shape fitting, so that the metal core material and the mortar layer are further strengthened. Is combined with

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in more detail with reference to examples. FIG. 1 shows a makeup cylinder difference T according to the present invention.
Is a partial perspective view of _one, FIG. 2 is a partial perspective view of a metal core P ₁ to configure this. As shown in FIGS. 1 and 2, the decorative cylinder difference T ₁ of the present embodiment is obtained by covering a metal core P ₁ formed by bending a metal plate and all parts on the surface side of the metal core P _1. It consists mortar layer M ₁ Tokyo to be, and has an elongate.

As shown in FIG. 2, the metal core material P ₁
Both ends in the width direction of the elongated metal plate material are bent into a U-shape in cross section, respectively, and are substantially perpendicular to the both ends in the width direction of the main body plate portion 1 with respect to the main body plate portion 1. Side plate portions 2 are connected to each other, and each side plate portion 2 has an internal space in the form of an engagement plate portion 3 that is folded back inward. In this embodiment, the metal core material P
The _first width direction the both engaging plate portion 3 formed at both ends of the mounting portion for mounting the decorative cylinder difference T ₁ of the building fixing bracket mounted on the outer surface 32 (see FIG. 7) is formed . In a state where the vertical width direction of the metal core P _1, the portion of the lower slightly than the center portion in the height direction of the main plate portion 1, for increasing the rigidity against bending and twisting core P ₁ A step portion 4 is provided. In an embodiment, the metal plate constituting the metal core P _1, using hot-dip galvanized steel sheet having a corrosion resistance in the thickness 0.5 mm. On the surface side of the main plate portion 1 and the side plate portion 2 of the metal core P ₁ described above, depending on the method of production described below, the mortar layer M ₁ are laminated integrally fixed by a synthetic resin adhesive layer.
This surface of the mortar layer M ₁ is stepped portion 5 corresponding to the stepped portion 4 of the metal core material P ₁ is provided, to enhance the shape aesthetics as a cosmetic cylinder difference T _1.

Next, a method of producing the above-described decorative cylinder difference T ₁ will be described. The molding material of the mortar layer M _1,
Portland cement (A), silica sand (B), lightweight aggregate (C), mineral fiber (D), glass fiber (E), methyl cellulose (F), epoxy resin (G), epoxy curing agent (H) and water ( I), later published

Cement mixtures mixed in the proportions shown in Tables 1 to 4 in Examples 1 to 4 were used. Note that the glass fiber is preferably subjected to an alkali resistance treatment. Here, silica sand (B) plays the action of preventing shrinkage during curing of the mortar layer M _1, lightweight aggregates (C) is for reducing the weight of the mortar layer M _1, mineral fibers (D) Acts to improve the fluidity of the molding raw material and to improve the strength of the formed mortar layer M ₁ , and the glass fibers (E) serve to improve the mortar layer M _1.
Acts to improve the strength of methyl cellulose (F)
Has the function of imparting tackiness to the molding raw material.

[0011]

[Table 1]

Further, six kinds of powdery materials ranging from Portland cement (A) to methyl cellulose (F) are used.

The components are blended in parts by weight shown in Examples 1 to 4 in Table 1.
Mixing and stirring were performed using a mixer so that the whole was uniform. Water (I) is added to a well-stirred mixture of each of the above six materials (A to F).

By mixing and kneading at the weight ratio shown in each of Examples 1 to 4 in the lowermost column of Table 1, a fluid intermediate molding raw material was produced. On the other hand, the epoxy resin (G) and the epoxy curing agent (H)

The mixture was previously mixed at the ratios shown in Examples 1 to 4 in Table 1, and the mixture was added to the above-mentioned fluidized intermediate molding raw material and kneaded again to obtain the final molding. Raw materials.

[0013] Then, by extrusion, by laminating a substantially constant thickness the molding material M 'on the surface side of the metal core P ₁ the entire surface in which the elongated, by curing and hardening,
To obtain a decorative cylinder difference T ₁ according to the present invention. That is, as shown in FIG. 3, the extrusion die 11, together with the passage hole 12 of the metal core P ₁ is provided through in the longitudinal direction, the supply hole 13 is an upper surface of the forming material M ' The openings 12 and 13 are provided at an opening, and merge at a portion of the extrusion port 14. Further, the cross-sectional shape of the forming material M 'in the portion of the extrusion port 14, a mortar layer M ₁ in the cross-sectional shape of the molded article.

Before the metal core material P ₁ enters the extrusion mold 11, the hardener mixed with the molding material of the mortar layer M ₁ is applied to the entire surface of the main body plate 1 and the side plates 2. An adhesive made of the same resin as the used epoxy resin is applied. The mortar layer M ₁ is laminated on the surface side of the metal core material P ₁ via an adhesive layer made of an epoxy resin by the extrusion molding of the molding material M ′ at the extrusion port 14 of the extrusion mold 11. Te is supported on the core material P _1, without or deformed such bending, extruded as it is.

After the mortar layer M ₁ is laminated on the surface side of the metal core material P ₁ and extruded, the extruded product having the decorative cylinder difference T ₁ is cured. That is, the extruded product is kept at room temperature for about 2 hours.
And standing time, mainly to cure the epoxy resin during this period, so there is no trouble in handling such as movement of the molded article in the primary hardening of the mortar layer M _1, and then allowed to cure at 80 ° C for about 2 hours was mainly mortar layer M ₁ is cured secondary hydration reaction of cement. Further, by leaving the product at room temperature for one week, a product having a decorative cylinder difference T ₁ whose outer peripheral surface was constituted by a mortar layer M ₁ was obtained.

Here, the mortar layer M₁At the time of its curing
During the primary curing, the epoxy resin cures itself
The shape of the mortar is preserved without breaking
Layer M ₁It is estimated that the evaporation of moisture in the water is also suppressed. Also,
Mortar layer M₁Shrinks slightly, but the mortar layer M
₁Is a core material P made of a metal plate material₁In a laminated state on the surface side of
Due to the integration, shrinkage along the width direction is suppressed.
At the same time as it shrinks along its width.
Metal core material P₁Is slightly deformed in the opening direction
Mortar layer M during liquefaction₁Is absorbed. this
As a result, the mortar layer M₁Generates large shrinkage stress inside
No longer occurs, the water evaporation is suppressed, and the epoxy resin
Cracks, cracks, etc. almost occur on the surface in conjunction with the
Will not be born. The mortar layer M₁Dude when curing
The shrinkage along its length
M₁And metal core material P₁Are phases along their length.
On the other hand, the mortar layer M₁The longitudinal direction of
The stress generated along the width direction is generated along the width direction.
Cracks, cracks, etc.
It is presumed that it is unlikely to cause the above.

Further, the makeup cylinder difference T₁When using
If a tensile force acts on this, most of this tensile force
Metal core material P₁Mortar layer M₁Burden
The mortar layer M₁Is
It is reinforced by the incorporation of epoxy resin. For this reason,
Cosmetic body difference T₁Mortar layer M ₁
Cracks and the like are less likely to occur. On the other hand, compressive force was applied
Mortar layer M which is strong against compression₁Is the compression force
Of the metal core material P₁The compressive force acting on
The metal core material P₁Bending, buckling, etc.
Will not be repelled. Furthermore, when bending force is applied,
Almost as in the case of tension, the metal core material P₁Is mainly this
Mortar layer M₁Overstress
Mortar layer M to prevent₁Is prevented from being damaged.

Next,

As shown in Table 2 and FIG. 4, the decorative cylinder difference T ₁ (composite exterior material) according to the present invention formed by the above method is as follows.
In all of "bending strength", "adhesive strength" and "water permeability", the improvement was confirmed with respect to "Comparative Example" in which the synthetic resin polymer was not mixed into the molding material. Also, the overall width of the cosmetic cylinder difference T ₁ (W), the thickness of the end portion in the width direction (K ₁₎ and the thickness of the other end (K ₂₎ [both see FIG. 1], respectively 75 mm, 15 mm, a 13 mm, the thickness of the mortar layer M ₁ is about almost constant 7.5
mm. The thickness of the metal core P ₁ are as 0.5mm described above. In addition, the test method of the “adhesion strength” is as shown in FIG. 5 in accordance with JIS A1408, and the decorative cylinder difference T ₁ is cut into a length of 160 mm to form a test piece, and the opening thereof is directed upward. horizontally disposed, one side part of each step portion 4, 5 of the metal core P ₁ and mortar layer M ₁ and fixed using a pair of fixing jigs 21 and 22,
The other side is made cantilevered, and in this state, a force S _{1 is applied} to the end face 6 of the mortar layer M ₁ via the holding jig 23 to separate the mortar layer M ₁ from the metal core material P _1. the force S ₁ at the start was carried out by measurement. In addition, the test method of “water permeability” is based on the above-mentioned makeup cylinder difference T according to JIS A5422.
It was cut to ₁ length 200mm and the test piece was conducted height of water penetrating the mortar layer M ₁ in the test piece (water reduction height) was measured.

[0019]

[Table 2]

It has been found that the "bending strength" increases almost in proportion to the increase in the amount of the epoxy resin mixed with the molding material. This is because the mixed synthetic resin reinforces the brittleness of the mortar-based raw material and the core material P
₁ and slip between the mortar layer M ₁ (relative movement) is prevented, it is believed that a synergistic effect greater than the strength both have alone is obtained. For this reason, it is particularly effective for a long exterior material such as a trunk. Also,
It was also found that the "adhesive strength" also increased almost in proportion to the increase in the amount of the epoxy resin mixed with the molding material. This is a synthetic resin which is mixed into the molding material M ', for the synthetic resin of the pre-applied adhesive on the surface side of the metal core P ₁ is the same, at the time of curing, both integral This is probably due to the formation of a strong bond.
Furthermore, since the "water permeability (water absorption)" decreases almost in proportion to the mixing amount of the epoxy resin with the molding raw material, the deterioration of the mortar layer due to the absorption of moisture is prevented, and the life of the composite exterior material is prolonged. Become.

Here, the mixing ratio of the epoxy resin to the molding material is as follows:

It is desirably about 5 to 20% by weight (about 4 to 15% by weight based on the whole fixed matter including the curing agent) based on the composition of each of the materials A to F shown in Table 1. If the amount is less than 4% by weight based on the entire fixed component, the above-mentioned "bending strength"
In addition, the effects of improving the "adhesion strength" and reducing the "water permeability" are not sufficiently exhibited, and if the content exceeds 15% by weight, smoke and flammability are generated at the time of flame, and nonflammability is a characteristic. This is because the advantage of the mortar-based exterior material is lost.

Next, the above-mentioned makeup cylinder difference T₁Usage examples
Will be described. FIG. 6 shows the makeup cylinder difference T ₁Building with
FIG. 7 is a perspective view of an object, and FIG.₁In use
FIG. As shown in FIG.
Makeup body difference T according to₁Between the first and second floors of the building
When attached, the whole is recognized as a mortar
And the outer mortar layer M₁Is good with the outer wall panel 31
At the same time, a sense of luxury and elegance is exhibited. Also of the building
Makeup body difference T to outer wall panel 31₁To fix
As shown in FIG. 7, stainless steel, spring steel, elastic rigidity
A plurality of fixtures 32 made of resin or the like
Previously fixed to the outer wall panel 31 via the
Makeup body difference T for fitting 32₁Push in the fixing bracket
An engaged portion 32a formed at the upper and lower ends of the
Difference T₁Metal core material P₁Is engaged with the engagement plate portion 3 of
Makeup body difference T₁Is fixed to the plurality of fixing brackets 32.
You. Makeup body difference T₁In the fixed state, the fixing bracket 32
Is the core material P₁Mortar layer M₁To
The core material P₁Compare to
Brittle mortar layer M₁Can be lost
No.

Further, with respect to the method for producing a composite exterior material according to the present invention, the method for producing a long exterior material having an extremely large length to width ratio, such as the above-mentioned decorative body difference, body edge, and sideding, etc. Furthermore, according to the extrusion molding, since continuous molding is possible, there is an advantage that a long composite exterior material can be easily molded. On the other hand, compression molding as shown in FIG. 8 is effective for forming a panel-shaped composite exterior material having a width and a length substantially equal to each other or a length several times as large as the width. That is, an adhesive made of the same or the same resin as the synthetic resin mixed with the molding material M ′ is applied to the surface side of the metal core material P ₂ , and the molding material M ′ is put in the compression mold 41. put, thereon, an opening is placed the metal core member P ₂ so as to face upward, further arranged to push plate 42 on the metal core member P _2, compressive force to the pressing plate 42 while the addition of S _2, allowed to stand for a predetermined time. As a result, the mortar layer M ₂ is adhered to the surface side of the metal core material P ₂ , and the compression molded product is taken out from the inside of the molding die 41 and cured to form a panel-shaped composite exterior material T _2. .

In each of the above embodiments, an epoxy resin is used as an example of a synthetic resin mixed with a molding material or constituting an adhesive layer. An acrylic resin emulsion can be used. Furthermore, not only synthetic resin but also SB
It seems that synthetic rubbers such as R and latex can be used.

When a metal core is formed by bending a metal plate, as shown in FIG. 9, the metal core P is formed by bending the metal plate so that an undercut portion 45 is provided. _{Use 3} and do the same as above,
Over the whole surface on the front side of the metal core member P ₃ by molding the mortar layer M _3, when the decorative body difference T ₃ are adhered to each other via a synthetic resin adhesive layer extruded metal core member P ₃ and mortar Layer M
₃ is bonded together by both the adhesive force of the synthetic resin adhesive layer and the shape fitting, so that the fixing force between them is further increased.

Extrusion molded products such as aluminum alloys can be used as the metal core material, as long as it has greater toughness than the mortar layer, instead of bending the metal plate material. In this case, as shown in FIG. 10, at the time of molding of the metal core P ₄ consisting of extrusion, it is possible to form an undercut portion 46 in the portion to be the front surface side thereof. Also according to this method, the metal core material P ₄ and the mortar layer M ₄ constituting the decorative cylinder difference T ₄ are joined together by both the adhesive force and the form fitting by the synthetic resin adhesive layer.

In each of the embodiments shown in FIGS. 9 and 10, each of the metal cores P ₃ and P ₄ is connected to the metal cores P ₃ and P ₄ by the undercut portions 45 and 46 provided in the metal cores P ₃ and P ₄ . This is an example in which the mortar layers M ₃ and M ₄ are fitted to each other in shape.
6, the fitting portions 51a provided at both ends in the width direction of the metal core member 51 as shown in FIG.
Accordingly, a configuration in which the metal core material 51 and the mortar layer 52 are fitted is also included.

Further, as another means for forming a shape between the metal core material and the mortar layer, a large number of holes or slits are provided in the metal core material so that one of the molding raw materials can be used when forming the mortar layer. Some parts are filled in the holes or slits.

[0029]

According to the composite armor material of the present invention, the metal core and the mortar layer coated on the surface of the metal armor are made of the same material as the synthetic resin polymer mixed in the raw material for forming the mortar layer. The metal core and the mortar layer are firmly fixed because they are laminated and integrated via the agent layer. Thus, since the metal core and the mortar layer are fixed by the synthetic resin adhesive layer, it is not necessary to provide the metal core with an undercut portion, an uneven portion, and the like. It can also be a simple shape. Furthermore, since the metal core material and the mortar layer are fixed on the entire surface of the contact portion, even if any force acts on the exterior material, the relative movement between the two does not occur.
Bending strength is also improved.

Further, when the metal core material and the mortar layer are joined by shape fitting in the cross section, the metal core material and the mortar layer are combined with both the adhesive force by the synthetic resin adhesive layer and the shape fitting. Therefore, since they are connected to each other, the fixing force between them is further increased.

According to the extrusion molding method of the sixth aspect of the present invention, there is provided a method for producing a composite exterior material according to the present invention.
According to the compression molding method according to claim 7, it is possible to easily form the long body difference without deforming the mortar layer at the time of molding or at the time of handling. The formed exterior material can be easily formed.

[Brief description of the drawings]

1 is a partial perspective view of a decorative cylinder difference T ₁ according to the present invention.

2 is a partial perspective view of a metal core P ₁ constituting the cosmetic cylinder difference T _1.

3 is a cross-sectional view showing the principle of the extrusion molding method of a decorative cylinder difference T ₁ according to the present invention.

FIG. 4 is a graph showing a relationship between “bending strength”, “adhesion strength”, and “water reduction height” of a molded product with respect to a mixing ratio of an epoxy resin to a molding raw material.

FIG. 5 is a sectional view showing a test method of “adhesive strength”.

FIG. 6 is a perspective view of a building with makeup trunk difference T ₁ is attached.

7 is a transverse sectional view of the state of use of the cosmetic cylinder difference T _1.

8 is a sectional view showing the principle of a panel-like composite compression molding method of the outer package T ₂ according to the present invention.

9 is a cross-sectional view of another cosmetic cylinder difference T ₃ according to the present invention.

10 is a cross-sectional view of another cosmetic cylinder difference T ₄ according to the present invention.

FIG. 11 is a cross-sectional view of a conventional mortar-based composite exterior material T ′.

[Explanation of symbols]

P _{1 to} P ₄ : metal core material T ₁ , T ₃ , T ₄ : decorative body difference (mortar composite exterior material) T ₂ : panel-like composite exterior material (mortar composite exterior material) 2: side plate of metal core material Part 3: Engagement plate part (attachment part) of metal core material 11: Extrusion mold 32: Fixture 41: Compression mold 45, 46: Undercut part (shape fitting part) 51a: Fitting of metal core material Part (shape fitting part)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04F 13/14 102 E04F 13/14 102A // B32B 13/06 B32B 13/06 (72) Inventor Kei Sugiura 4-1-1 Nagane-cho, Obu City, Aichi Prefecture F-term (reference) in Tokai Kogyo Co., Ltd. GB32W GB42Z GB54W 4F100 AB01A AB04 AB10 AE01B AG00H AK01B AK01C AK25 AK25G AK53B AK53G BA02 BA03 BA06 BA10A BA10B CA23B CB00 DE01B EC102 EH46C EJ651 GB07 JK01 JK06 JL11A01B01A01A014G05 A0101

Claims (7)

[Claims] 1. A mortar-based composite exterior material comprising a metal core formed into a cross-section with an irregular shape, and a mortar layer formed so as to cover the surface side of the metal core, wherein the mortar layer comprises: The metal core and the mortar layer are formed by a cement mixture in which a synthetic resin polymer is mixed, and the metal core and the mortar layer are formed through an adhesive layer made of the same material as the synthetic resin polymer applied to the surface of the metal core. A mortar-based composite exterior material that is laminated and integrated. 2. The mortar-based composite cladding material according to claim 1, wherein the metal core material and the mortar layer are joined by shape fitting in a cross section. 3. An attachment portion is provided on the metal core material,
The mortar-based composite exterior material according to claim 1, wherein the attachment portion is attachable to a fixture attached to an outer surface of a building. 4. The mortar layer is a mixture of Portland cent, aggregate and fiber as a main component, to which a synthetic resin polymer and water are added.
The mortar-based composite cladding material according to any one of claims 1 to 3, wherein the amount is 4.5 to 15% by weight of the solid component of the mixture. 5. The mortar-based composite cladding material according to claim 1, wherein the synthetic resin polymer is an epoxy resin. 6. A method for producing a mortar-based composite exterior material provided with a mortar layer so as to cover a surface side of a metal core material, wherein the mortar layer is formed on the surface side of a long core material. An adhesive made of the same substance as the synthetic resin polymer constituting the cement mixture to be applied was applied, and the synthetic resin polymer was mixed on the surface side while the core material was passed through an extrusion mold. A method for producing a mortar-based composite exterior material, comprising: laminating and integrating a mortar layer on the surface side of a metal core material by extruding a cement mixture. 7. A method for producing a mortar-based composite exterior material provided with a mortar layer so as to cover a surface side of a metal core material, comprising a cement mixture for forming a mortar layer on the surface side of the core material. An adhesive made of the same substance as the synthetic resin polymer is applied, and the cement mixture is arranged on the surface side of the metal core material, and both are accommodated in a compression mold, A method for producing a mortar-based composite exterior material, wherein a mortar layer is laminated and integrated on the surface side of a core material by compression molding a cement mixture.