JP2004238999A - Exterior wall material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an exterior wall material having excellent design and flame resistance, lightweight and restrained from crack initiation. <P>SOLUTION: The exterior material made of resin includes at least thermosetting resin, an inorganic filler and inorganic fiber. The exterior material has at least one connection part of a rib whose ratio of long side to short side is 2 or more, and the radius of curvature R of the angle of the connection part is 2 mm to 200 mm. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an outer wall material excellent in strength, design, and workability as a building material.
[0002]
[Prior art]
Conventionally, when a general house has a wooden frame structure, its outer wall surface is generally finished with wood or mortar, and its surface is generally finished by spray painting. In the case of this wooden frame construction method, a curing period for mortar and a curing period for drying the paint are required, and therefore, this construction method is called a wet construction method. On the other hand, prefabricated construction methods, such as nailing plywood or panels to studs, nailing ceramic siding boards on the outside, or hanging tiles on horizontal rails, etc., are also common in houses called the two-by-four construction method. This method is called the dry method.
[0003]
For example, when the outer wall formed by the wet method is applied by spraying, there is a problem that an environmental load is increased due to scattering of a coating liquid fine powder to a neighboring house and volatilization of an organic solvent in the coating. In addition, the method of stacking or attaching bricks, tiles, and the like via a mortar still has a problem in that a long construction period is required for curing.
On the other hand, in the dry method, for example, when a ceramic siding board or a tile as disclosed in Patent Document 1 is used, the mass per unit area thereof is often excessive, and a design capable of withstanding a large mass is often used. Had to do. Furthermore, among houses with wooden frame structures, ceramic siding boards and tiles have been used in order to carry out the renovation (renovation) of the outer wall of a so-called second-hand house 10 years after construction without repainting. In such a case, the design strength of the existing outer wall materials and columns will be exceeded, and in many cases these large-mass ceramic siding boards and tiles cannot be used. Even if the renovation of the house itself was done, separate work such as removal of existing outer wall materials and strengthening of pillars occurred so that the design load of existing outer wall materials and columns was not exceeded, and renovation work was performed It was extremely inconvenient.
[0004]
Moreover, in the construction of ceramic siding materials, for example, a large flat panel of a 3 × 6 (about 90 cm × about 180 cm) plate is fixed by nailing, so that it is necessary to transport the panel, which is a heavy object, and use a wall. At present, the burden on the builder 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. This is because embossed irregularities are formed on the surface of a thin metal plate such as aluminum that constitutes the surface layer, and the inner layer is formed of urethane foam or the like. The method of attaching this to the existing outer wall surface by nailing is adopted. This method is disclosed, for example, in Patent Document 2. However, in terms of design, the uneven shape of the aluminum surface often lacks high-grade appearance due to excessive glossiness. In particular, since the melting point of aluminum is 660 ° C. on an aluminum surface, when an open flame comes into intense contact with the outer wall surface due to a fire or the like, the surface is melted and destroyed, and there is a problem in terms of fire protection. Similarly, as a lightweight outer wall material, a molded product made of a thermoplastic resin as a main material in a panel shape is disclosed in Patent Literature 3, and in order to further improve the mechanical strength of the panel, a front wall having a design surface and a front wall are designed. Patent Literature 4 proposes a plastic outer wall material having a hollow double-walled structure in which opposite back walls are joined by concave ribs at intervals, or a fitting structure in which the upper, lower, left, and right edges of the panel are sealed. Patent Document 5 proposes a decorative wall covering having the following. However, there is a problem that thermoplastic resin siding materials have poor fire resistance and cannot be used as outer wall materials in areas designated as fire prevention areas.
[0005]
On the other hand, as a thermosetting resin panel, a flame-retardant panel containing an inorganic filler and having excellent flame retardancy and workability (Patent Document 6), an outer wall panel (Patent Document 7), or a grid-like reinforcing rib is used. There has been proposed a wall panel (Patent Document 8) having a shape into which a joint member for joining panels can be inserted. However, since these thermosetting resin panels have higher rigidity than thermoplastic resin panels, they may not be able to correct slight distortion during construction, or cracks may occur if excessive force such as twisting the panel is applied. there were.
[0006]
[Patent Document 1]
JP-A-5-209454 [Patent Document 2]
JP-A-63-125770 [Patent Document 3]
JP-A-7-217059 [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]
Japanese Patent Application Laid-Open No. 2001-214599 [Patent Document 8]
Japanese Patent Application Laid-Open No. Hei 10-18481
[Problems to be solved by the invention]
An object of the present invention is to solve these problems and to provide an outer wall material which is excellent in design properties and flame retardancy, is lightweight, and hardly causes cracks.
[0008]
[Means for Solving the Problems]
The present inventors have earnestly conducted trial production and evaluation in order to achieve the object of the present invention, and as a result, 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 an inorganic fiber, wherein the outer wall material has at least one connecting portion to which a rib having a ratio of a long side to a short side of 2 or more is bonded. A resin outer wall material, having a radius of curvature (R) of a corner of the connecting portion of 2 mm or more and 200 mm or less;
(2) The resin outer wall material according to (1), wherein the number of ribs directly connected to the opposing side wall of the outer peripheral portion is one or less in each of the vertical and horizontal directions.
(3) The resin outer wall material according to (1) or (2), wherein a fire-resistant paint is applied on at least one surface.
[0009]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in more detail with particular emphasis on its preferred embodiments.
First, the resin outer wall material of the present invention contains at least a thermosetting resin, an inorganic filler and an inorganic fiber. Thermosetting resins include phenolic resins, unsaturated polyester resins, urea resins, epoxy resins, alkyd resins, melamine resins, urethane resins, and mixtures thereof. Among them, a phenol resin and an unsaturated polyester resin are preferable because they show good moldability, and a phenol resin is particularly preferable because it has excellent flame retardancy.
[0010]
The phenolic resin used in the present invention is a resol type phenol resin synthesized with an alkali metal hydroxide or an alkaline earth metal hydroxide, a novolak 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, and among them, a resol-type phenol resin is preferable because of its particularly good moldability. For the purpose of increasing the degree of polymerization as required, these resins may be used by adding an acid catalyst for a resole type phenol resin or a basic catalyst for a novolak type phenol resin.
[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 reduced, and if it is too large, shape retention during combustion may be reduced. The preferable content of the resin is 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.
Examples of the inorganic filler of the present invention include calcium carbonate, kaolin clay, talc, microballoon, barium sulfide, silicic anhydride, diatomaceous earth, glass powder, mica, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zonotolite, Examples include tobermorite, wollastonite, silica sand and the like, and preferred are calcium carbonate, kaolin clay, and aluminum hydroxide. 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 large, the strength may be reduced, and if it is too small, the flame retardancy may be reduced. The preferred content of the inorganic filler is 20% by mass or more, more preferably 30% by mass or more, less than 80% by mass, and more preferably less than 60% by mass.
[0012]
As the inorganic fibers, glass fibers such as E-glass, C-glass, T-glass, AR-glass, and D-glass, carbon fibers, rock wool, and the like may be used. Glass is preferred. The glass fiber preferably has a fiber diameter of about 0.003 to 0.03 mm, more preferably 0.006 to 0.015 mm. Further, the inorganic fiber length in the present invention is preferably from 0.1 to 100 mm, more preferably from 3 to 30 mm. When the fiber length of the inorganic fiber is less than 0.1 mm, the reinforcing effect of the inorganic fiber is not sufficiently exerted, and as a result, the bending strength of the molded product is hardly exhibited. If the inorganic fiber length exceeds 100 mm, the flowability of the molding resin composition comprising the inorganic filler and the phenol resin tends to decrease, and the moldability tends to deteriorate. Although the content of the inorganic fiber is not particularly limited, a 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 poor.
[0013]
The resin outer wall material of the present invention has a base portion occupying most of the area and a rib integrally formed with the base portion.
The thickness of the substrate is preferably 0.5 mm or more and 20 mm or less. If the thickness of the base material portion is less than 0.5 mm, the strength is reduced and the material is easily broken, and if the thickness exceeds 20 mm, the mass increases and the workability may be impaired. A more preferable thickness of the base member is 1.5 mm or more and 15 mm or less. The base member can have any design by providing irregularities on the surface.
[0014]
The rib preferably has a thickness of at least twice the thinnest portion of the base portion, and has a short side of at least 2 mm 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 less likely to enter the rib during molding, and the strength of the rib may be reduced. If the ratio of the short side to the long side of the rib is smaller than 2, the mass of the rib portion may increase and the overall mass may increase, or the effect of reinforcing the rib may not be sufficiently 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 portion increases, and the overall mass increases, which may impair workability. For this reason, as a size that can be handled by one person, the short side of the rib is preferably 40 mm or less, more preferably 20 mm or less.
[0015]
One or more ribs are present in each of the vertical and horizontal directions, and have at least one or more connecting portions (points including intersections of the ribs), and corners of the connecting portions (corners formed by the intersection of the ribs). Has a radius of curvature (R) of 2 mm or more and 200 mm or less. If R of the connecting portion is smaller than 2 mm, cracks may be generated in the connecting portion even when stress is concentrated and slight deformation is applied. On the other hand, if R exceeds 200 mm, the volume of the rib becomes large, the total mass increases, and the workability may be impaired. More preferably, R of the connecting portion is 3 mm or more and 100 mm or less.
[0016]
Further, it is preferable that the rib has a slope that becomes smaller in the thickness direction from a portion connected to the resin outer wall material base portion, because the mold releasability from the mold is improved when the rib is formed.
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 that rises at an angle of 45 degrees or more in a direction perpendicular to the surface, and the area surrounded by the outer peripheral side wall is at least 50% of the base material part. Preferably occupy the area of In addition, when the ribs on the outer peripheral portion are directly connected to many ribs, the resin outer wall material becomes rigid, and it becomes difficult to correct a slight distortion during construction. It is preferable that the number of ribs is not more than one in each of the vertical and horizontal directions, and it is more preferable that there is no rib directly connecting the side walls of the outer peripheral portion facing each other.
[0017]
In addition, when connecting the rib and the side wall rising in the vertical direction to the surface, not only the outer peripheral portion, it is preferable that the connecting portion also has an R. The preferred range of R is 2 mm or more and 200 mm or less, and more preferably 3 mm or more and 100 mm or less.
The surface of the resin outer wall material of the present invention is preferably coated in order to keep the color tone constant during long-term use. Here, the surface refers to one or both of the front and back surfaces of the resin outer wall material. As the paint used for coating the surface, a light-resistant paint is preferred, and any of acrylic silicone, urethane, silicone, and fluororesin may be used, but acrylic silicone is preferred from the viewpoint of cost. In addition, in the case of the resin outer wall material of the present invention, it is more preferable to use a coating material having fire protection performance as a paint, because the fire protection performance of the resin outer wall material is further improved.
[0018]
The coating material having fire prevention performance refers to a coating material that exerts an 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 calorific value suppression effect was measured using a corn calorimeter test device (for example, a corn calorimeter III of Toyo Seiki Co., Ltd.) and based on the "Fireproof Performance Test / Evaluation Business Method Book" edited by the Japan Building Research Institute. The determination can be made by evaluating the total calorific value in a combustion test carried out by the following method. Examples of coating materials having fire protection performance include antimony trioxide, zirconium oxide, barium metaborate, ammonium polyphosphate, melamine, pentaerythritol, zinc borate, phosphate esters, tricresyl phosphate, and the like in the coating materials. Paints. These coating materials can be used alone or in combination. Alternatively, a fire-resistant coating material and an acrylic silicon-based light-resistant paint may be applied to form two or more coating films.
[0019]
Next, an example of a method for producing the resin outer wall material of the present invention will be described.
A paste is prepared by mixing the phenolic resin and the inorganic filler at a desired ratio. At this time, a flame retardant, an ultraviolet absorber, and an internal release agent are added to impart a viscosity increase to the phenolic resin, and to impart flame retardancy, weather resistance, mold release property of the mold at the time of molding to the obtained molded product. It is preferable to add additives such as a mold agent and a thickener, and it is particularly preferable to include an internal mold release agent. The addition amount of the internal release agent is preferably from 0.1 to 5 parts by mass, more preferably from 1 to 3 parts by mass, based on 100 parts by mass of the total mass of the phenol resin, the inorganic filler and the inorganic fibers. Examples of the internal release agent include aliphatic hydrocarbon-based ones, higher aliphatic alcohol-based ones, fatty acid amide-based ones, metal soap-based ones, and phosphoric acid-based ones. Hydrophobic alcohols are preferred. In particular, it is preferable to use a neutralizing phosphoric acid alcohol (trade name “Zelek NE”) manufactured by DuPont, because the fixability of the coating material is good. Without the use of the internal mold release agent, during molding using a mold, the molded article adheres firmly to the inner wall of the mold, and when the mold is opened, the molded article tends to be torn and broken. However, there is a possibility that the yield of the molded product may be reduced.
[0020]
Using the paste and the inorganic fibers, a resin outer wall material can be manufactured by a method such as sheet molding compound molding, bulk compound molding, or hand lay-up molding.
<Adjustment of molding material A>
100 parts by mass of a resole-based phenolic resin (trade name "BRL-240" manufactured by Showa Polymer Co., Ltd.), 1 part by mass of calcium hydroxide (manufactured by Kanto Chemical Co., Ltd., reagent grade) as a thickener, internal release As an agent, 3 parts by mass of zinc stearate (manufactured by Kanto Kagaku Co., Ltd., first grade reagent), 83 parts by mass of aluminum hydroxide (manufactured by Showa Denko KK, trade name "Heidilite H32"), kaolin clay (manufactured by ENGELHARD, 83 parts by mass of trade name "ASP-400P" and 67.0 parts by mass of glass fiber having an average fiber length of 3 mm (manufactured by Nitto Boseki Co., Ltd., trade name "CS-3SK") are manufactured by Omni Mixer (Chiyoda Giken Kogyo Co., Ltd.). After mixing and stirring for about 1 minute under the trade name "OM-5"), the obtained composition is sandwiched between polypropylene films having a thickness of 0.04 mm, and the thickness is adjusted to 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-based phenolic resin (trade name "BRL-240" manufactured by Showa Polymer Co., Ltd.), 1 part by mass of calcium hydroxide (special grade of reagent manufactured by Kanto Chemical Co., Ltd.) as a thickener, an internal mold release agent 3 parts by mass of zinc stearate (first grade reagent, manufactured by Kanto Chemical Co., Ltd.), 83 parts by mass of aluminum hydroxide (manufactured by Showa Denko KK, trade name "Heidilite H32"), kaolin clay (manufactured by ENGELHARD, trade name) 83 parts by mass of “ASP-400P”) were mixed for 10 minutes with a hand mixer (trade name “BMV-150A” manufactured by Shibaura Seisakusho) to obtain a raw material paste.
[0022]
This raw material paste was set in an SMC manufacturing device (manufactured by Tsukishima Kikai Co., Ltd.). The raw material paste was coated at a thickness of 1 mm using a 0.040 mm thick polypropylene film as a carrier film, and was run from two upper and lower portions of the apparatus. At this time, a glass fiber Robbing (trade name “RS240PB549AS” manufactured by Nitto Boseki Co., Ltd.) was added so as to be sandwiched between two carrier films while being cut into an average fiber length of 25 mm. The amount added at this time was adjusted so that the content of glass fiber in the obtained molding material was 20% by mass. The molding material obtained continuously became a sheet having a thickness of about 3 mm. This was wound into a roll and heat-treated at 80 ° C. for 4 hours (this is referred to as molding material B).
[0023]
Embodiment 1
The molding material A was loaded into a mold 1 having a surface chrome plating finish 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 side wall structure on the outer periphery. Was obtained. There were no cracks in the molded product, and no cracks occurred even if the product was distorted by several millimeters by hand. The outline of the obtained resin outer wall material is shown in FIGS. The radius of curvature (R) at the corner formed by the intersection of the ribs of the resin outer wall material formed by the mold 1 is 6 mm.
[0024]
Embodiment 2
A resin outer wall material was obtained in exactly the same manner as in Example 1 except that the molding material A was changed to the molding material B. There were no cracks in the molded product, and no cracks occurred even if the product was distorted by 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 a mold 2 (the same material and a different mold shape as the mold 1). When the mold was removed from the mold 2, two minute cracks were generated at the connection portions of the ribs. The molding 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 crossing of the ribs of the resin outer wall material formed by the mold 2 is 1 mm.
[0026]
[Comparative Example 2]
A resin outer wall material was obtained in exactly the same manner as in Comparative Example 1 except that the molding material A was changed to the molding material B. After being removed from the mold, five minute cracks had occurred at the connecting portions of the ribs. The molding was hardly distorted by hand.
[0027]
【The invention's effect】
According to the present invention, it is possible to provide an outer wall material which is excellent in design and flame retardancy, lightweight, and excellent in 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 connection portion of the resin outer wall material manufactured in Example 1.
FIG. 4 is a schematic side view showing a long side surface of the 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 connection portion of a resin outer wall material manufactured in Comparative Example 1.
[Explanation of symbols]
1: base member 2: rib 3: rib connecting portion 4: outer peripheral side wall

Claims (3)

A resin outer wall material containing at least a thermosetting resin, an inorganic filler and an inorganic fiber, wherein the outer wall material has at least one connecting portion to which a rib having a ratio of a long side to a short side of 2 or more is bonded. And a resin outer wall material, wherein a radius of curvature (R) of a corner of the connecting portion is 2 mm or more and 200 mm or less. The resin outer wall material according to claim 1, wherein the number of ribs directly connected to the opposed outer peripheral side wall is one or less in each of the vertical and horizontal directions. The resin outer wall material according to claim 1 or 2, wherein a fire-resistant paint is applied on at least one surface.

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