JP2003094419A - Outer wall material excellent in weatherability and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cement extrusion product as an outer wall material rich in design effect, excellent in weatherability and antistaining properties and free from maintenance in order to be made economically inexpensive, and a method for manufacturing the same. SOLUTION: The method for manufacturing the cement extrusion product as the outer wall material includes an extrusion molding process for a cement slurry, a decoration process for dividing the obtained extrusion molded object and sprinkling one kind or one or more kinds of inorganic coloring materials over the surfaces of the divided extrusion molded objects to decorate the same, a press process for pressing a press mold to the obtained decorative molded object to pattern the same, a coating process for applying an in-line sealer to the surface of the patterned pressed decorative molded object, an ageing process for ageing the obtained patterned pressed molded object in an autoclave and a coating process for coating the surface of the obtained aged object with a clear paint.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a maintenance-free outer wall material having excellent weather resistance and rich in design, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, various types of outer wall materials made of cement molded products have been proposed.

Japanese Unexamined Patent Publication (Kokai) No. 3-112607 discloses a cement product with a concavo-convex pattern in which sand particles are scattered on the surface of a cement molded product, and after pressure molding, an emulsion synthetic resin is further applied.

In Japanese Patent Laid-Open No. 4-319405, a coloring material is prepared by adding an inorganic coloring material to a mixture of the same type as a cement kneaded material, and spraying the resulting mixture with a roller to bring it into close contact. It is disclosed to perform painting.

Japanese Unexamined Patent Publication (Kokai) No. 11-90912 discloses a method of patterning a cement-based green plate by pressing with a press molding machine.

[0006]

Since the living environment has changed drastically today, excellent design properties are required for cement extruded products, and further weather resistance and stain resistance are required for use as outer wall materials. And it is required to be maintenance-free to be economically inexpensive.

However, in the above-mentioned prior art, it was not possible to manufacture a product which satisfies all of these demands. In particular, recently, a product with excellent design has been strongly demanded as an outer wall material.

An object of the present invention is to provide an outer wall material and a method of manufacturing the same which enables the appearance patterning by a novel method which has never been found in the prior art. Further, an object of the present invention is to provide a cement extruded product as a maintenance-free outer wall material which is rich in designability, is excellent in weather resistance and stain resistance, and is economically inexpensive, and a manufacturing method thereof. Is.

[0009]

Means for Solving the Problems The present inventor has conducted various studies in order to solve the above problems, and sprays a powder of an inorganic coloring material on the surface of a cement extruded material, and imparts a concavo-convex pattern with a pressing machine, Next, the present invention has been completed by knowing that a cement product having an appearance and a designability which have not been seen so far can be obtained by applying a heat-crosslinking resin emulsion paint also as an in-line sealer.

Here, the present invention provides (1) an extrusion molding step of cement slurry, and the obtained extrusion molded body is divided, and 1 is formed on the surface of the divided extrusion molded body.
Makeup process of applying one or more kinds of inorganic coloring materials to make up, press process of press-molding the obtained makeup molding to give a pattern, and to the surface of the press makeup molding with a pattern A coating step of applying an in-line sealer, a curing step of curing the obtained patterned press decorative molding with an autoclave, and a coating step of coating a clear coating on the surface of the obtained curing body, Method of manufacturing outer wall material.

(2) The method for producing an outer wall material according to (1), wherein the inline sealer is a heat-crosslinking resin emulsion. (3) The method for manufacturing an outer wall material according to (1) or (2) above, wherein the inorganic coloring material is selected from brick scraps, natural minerals, inorganic pigments, and colored natural minerals. .

(4) The method for producing an outer wall material as described in any one of (1) to (3) above, wherein the clear paint is an organic clear paint and / or an inorganic clear paint.

(5) The outer wall according to any one of the above (1) to (4), further including a coloring step of partially coloring the living body obtained in the curing step before or after the coating step. Method of manufacturing wood.

(6) The above-mentioned (1) to (5), wherein partial coloring is carried out before applying the clear paint.
The method for manufacturing an outer wall material according to any one of 1. (7) A cementitious material layer extruded and provided with an uneven pattern by a press die, an inorganic colorant powder coating layer provided on the material layer, an inline sealer layer, and a clear coating layer were provided. The outer wall material characterized by.

[0015]

DETAILED DESCRIPTION OF THE INVENTION The present invention is a method of extrusion of a cement mixture, spraying of a brick powder, patterning by pressing, application of a resin-based emulsion paint, and curing, followed by optional coloring with further inorganic pigments. And then applying clear paint.

The cement product according to the present invention obtained through such a process can be sprayed with brick powder,
It can exhibit excellent designability, and its economic efficiency is particularly remarkable. Hereinafter, each step in the present invention will be specifically described.

Extrusion molding step: As a cement slurry, silica sand, perlite, pulp, mica, fibers, methylcellulose, etc. are appropriately blended with cement to prepare a cement slurry as a raw material. Particularly in the case of the present invention, the cement and other components may be the same as conventional ones, but the water content of the slurry is set to 35 to 45% by mass, which is smaller than the conventional one. Known cements such as Portland cement, blast furnace cement, and alumina cement can be used.

In a preferred embodiment, in consideration of economic efficiency, continuous extrusion is performed, and then the product is cut into an appropriate size to obtain a predetermined product size. Cosmetic process : The extruded product thus obtained is then applied with a pulverized product of an inorganic coloring material such as natural stone. This improves the appearance design and further imparts weather resistance. Examples of the inorganic coloring material at this time include natural minerals, brick scraps, inorganic pigments, and colored natural minerals. The size of the crushed product varies depending on the desired design property, but considering the stain resistance, it is preferable to avoid a coarse product.

Since it is an outer wall material, it is preferable to use a material originally used as an outer wall material, for example, a crushed product of brick, natural mineral or the like. In particular, brick waste has a calm appearance and is excellent in terms of design.

Such inorganic coloring material is sprayed when the cement slurry extruded product is in a sufficiently soft state, and patterning, that is, uneven patterning, can be performed with a sufficiently low press pressure in the subsequent pressing step. It is preferable to do so. Specifically, the water content is 35 to 45% by mass so that the pressing step described later can be performed.

Pressing step : The press forming in the present invention is to press a mold having irregularities, and is for the purpose of patterning, and in combination with the presence of the inorganic coloring material scattered prior to this, the design Greatly contributes to the improvement of sex. The pressing pressure at this time is sufficient as low as 10 to 15 kgf / cm ² , which also makes the present invention excellent in economic efficiency.

The pressing step has been carried out even in the past, but in that case, the pressing pressure is 200 kgf / cm ² or 50 to 50% from the viewpoint of improving the adhesion of the colored layer.
Although a considerably high pressure such as 100 kgf / cm ² was used, in the case of the present invention, the material is clay-like and sufficiently soft,
Moreover, since the scattered material is only the amount necessary for coloring, the above-mentioned low pressure is sufficient because it is simply patterned.

Coating process : After press molding, a coating process of coating an in-line sealer is carried out. The content and purpose of the coating process are, for example, coating of an acrylic heat-crosslinking resin emulsion as an in-line sealer, and brick powder. Fixing of the inorganic colorant powder in the above and white flower generated in the subsequent process
(Efflorescence) is to be prevented. The emulsion paint in-line sealer may be before and after application of the colorant.

Conventionally, in-line sealers using a resin emulsion have been known, but in the case of the present invention, such in-line sealer material of the prior art is applied in that it has a fixing effect on the scattered material. To be distinguished. In other words, an in-line sealer is used to realize such a fixing effect of the scattered matter.

Curing process : After spraying the inorganic coloring material, the cement molded product is cured to cure it. Specific conditions for curing may be the same as those used in the present invention and are not particularly limited. For example, steam curing and autoclave curing.

Coloring step : Coloring at this stage is a desired step and may be carried out if necessary. For example, when reproducing "dirt" on the surface, finish coloring may be performed in advance using an inorganic coloring pigment (eg, iron oxide, carbon black, etc.).

Painting process : After curing and optionally coloring, the appearance of the product is protected using, for example, an inorganic and / or organic clear paint. Examples of these clear paints include silicon acrylic, alkoxysilane condensation, and special polysiloxane polymers.

The thus obtained outer wall material according to the present invention comprises a cementitious material layer extruded and provided with an uneven pattern by a press die, and an inorganic coloring material powder provided on the material layer. It has a coating layer, an inline sealer layer, and a clear coating layer.

Therefore, the outer wall material according to the present invention can maintain a natural texture for a long period of time without being deteriorated by ultraviolet rays unlike the enamel paint. In addition, by providing a clear coating layer, it is possible to prevent water and CO ₂ from entering, which has a higher protective effect and which impairs long-term performance.

Thus, according to the present invention, an outer wall material excellent in designability, weather resistance, and stain resistance can be obtained by an inexpensive means, and the obtained outer wall material is so-called maintenance-free. It has great practical significance.

Next, the effects of the present invention will be described more specifically with reference to Examples.

[0032]

[Example] After the cement mixture was kneaded at the raw material mixing ratio shown in Table 1, the thickness was 20 mm and the width was 480 mm by an extruder.
, Extrusion molding a flat plate with a length of 9500 mm, and further on the surface,
1 to 3 types of brick powder were mixed and scattered, and this was pressed with a mold having irregularities to give a pattern. Press pressure is 10-15kg
It was / cm ² . Brick powder made by Keiwa Furnace Co., Ltd. was used.

Further, a heat-crosslinking resin emulsion (Dainippon Paint Co., Ltd.) was applied to this surface. The purpose of applying this resin emulsion is to prevent efflorescence (efflorescence) generated in the subsequent steps and to fix brick powder.

The extruded material thus obtained was naturally cured for about 1 day, then autoclaved at 170 ° C., dried, and then colored on the surface with an inorganic coloring pigment. Further, an inorganic clear paint [Dainippon Paint] was used. Co., Ltd., silicon acrylic for intermediate coating, and special polysiloxane polymer for top coating] were applied and subjected to the following evaluation tests.

Incidentally, for comparison, those not coated with a resin-based emulsion after pressing, those not sprinkled with bricks,
Each one was manufactured by applying ordinary acrylic coating. Using these, a coating film durability test by a metal weather test, a freeze-thaw test, and a coating film adhesion test by hot water immersion were carried out.

The metal weather test uses a test equipment manufactured by Dai Brown Co., Ltd., and the irradiation with a light amount of 63 mw / cm ² is performed for 16 hours.
(Temperature 65 ° C, Humidity 70%), Rest 2 hours (Temperature 65 ° C, Humidity 70%), Condensation 6 hours (Temperature 30 ° C, Humidity 98%), Shower 1 cycle each before and after condensation This was performed 30 cycles, and after the test, the presence or absence of abnormality in the test material was investigated.

The freeze-thaw test was conducted according to JIS A5422.
This is because the test material is immersed in water at about 20 ° C for 24 hours, put in a freeze-thaw tester, frozen for 2 hours in air at -20 ° C, and thawed for 1 hour in water at 20 ° C for one cycle. As a result, the presence or absence of abnormality of the test material after 300 cycles was investigated.

The hot water immersion test was carried out by immersing the sample in hot water at 50 ° C. for 10 days to examine changes in the appearance of the test material and the adhesion state of the coating film.
These results are summarized in Table 1.

[0039]

[Table 1]

[0040]

As described above, according to the present invention, there is provided an outer wall material made of a cement extruded product having the following characteristics which could not be satisfied at the same time, and an economical manufacturing method thereof. , Its significance today.

(1) Designability: The steepness of the pattern by press molding was observed, and the designability with an excellent texture by spraying brick powder was realized. (2) Weather resistance: Excellent weather resistance could be realized without ultraviolet deterioration due to the inorganic colored layer which does not depend on enamel and the inorganic clear paint on the surface layer.

(3) Contamination resistance: The inorganic clear paint was able to realize stain resistance excellent in hydrophilicity. (4) Economical efficiency: Because it is made up with inexpensive raw materials such as brick powder and natural minerals, it is possible to achieve equivalent or superior durability performance without using expensive inorganic paints, and also as bricks and natural stones as outer wall materials. It is possible to provide a maintenance-free and economical outer wall material that can realize the texture of.

In this respect, the prior art, for example, Japanese Patent Laid-Open No. 3-11
In the invention disclosed in JP 2607, the weather resistance and stain resistance are not sufficient, and the invention disclosed in JP-A-4-319405 is
The color layer produced separately is pressure-bonded by roll, and the designability is not sufficient, and the invention disclosed in JP-A-11-90912 has sufficient designability and economy (because the coating material is expensive). Not.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B28B 3/20 B28B 3/20 D 4G055 C04B 41/71 C04B 41/71 E04F 13/14 102 E04F 13/14 102A (72) Inventor Keizo Yabumoto 4-1, Higashitakasu-cho, Amagasaki-shi, Hyogo Sumikin F.R.C. Co., Ltd. F term (reference) CB06 CB21 CB36 DA06 DB12 DC02 EA01 EA07 EA13 EA39 EA43 EB22 EB43 EC11 4G028 FA03 4G052 DA01 DB12 DC01 DC04 DC06 4G054 AA01 AA15 AB01 AC04 BA00 4G055 AA01 AB01 AC01 AC09 BA36 BA38 BA44

Claims (7)

[Claims] 1. An extrusion molding step of cement slurry and a makeup step of dividing the obtained extrusion molded body and applying one or more kinds of inorganic coloring materials to the surface of the divided extrusion molded body for makeup. And a press step of applying a pattern to the obtained decorative molded article by press embossing, an applying step of applying an in-line sealer on the surface of the patterned decorative cosmetic article, and the obtained patterned press decorative article. A method for producing an outer wall material, comprising: a curing step of curing a molded body in an autoclave, and a coating step of applying a clear coating to the surface of the obtained curing body. 2. The method for producing an outer wall material according to claim 1, wherein the inline sealer is a heat-crosslinking resin emulsion. 3. The method for producing an outer wall material according to claim 1, wherein the inorganic coloring material is selected from brick scraps, natural minerals, inorganic pigments, and colored natural minerals. 4. The method of manufacturing an outer wall material according to claim 1, wherein the clear paint is an organic clear paint and / or an inorganic clear paint. 5. The method of manufacturing an outer wall material according to claim 1, further comprising a coloring step of partially coloring the cured body obtained in the curing step before or after the coating step. . 6. The method of manufacturing an outer wall material according to claim 1, wherein partial coloring is carried out before applying the clear paint. 7. A cementitious material layer extruded and provided with an uneven pattern by a press die, an inorganic colorant powder coating layer provided on the material layer, an in-line sealer layer, and a clear coating layer. Outer wall material characterized by that.