JP2007138443A - Plate-like material for wall, its manufacturing method, and exterior wall structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To exert proper heat insulation without a deterioration in original function, even in a connecting part of a plate-like material, in a structure of a wall surface which is constructed by arranging a plate-like building material such as a tile material. <P>SOLUTION: This plate-like material W for the wall, which is composed of a molded article of ceramic material and which is constructed in the state of being arranged on the wall surface of the building, comprises: an approximately plate-like main body part 10: joint parts 22 etc. which are provided on the lateral side of the main body part 10, and which are connected to joint parts 22 etc., provided on the lateral side of another plate-like material W adjacently arranged in construction, in such a manner as to vertically overlap each other; upside joints 22 and 24, which are arranged on the top surface side of the main body part 10, among the joint parts; downside joints 32 and 34 which are arranged on the lateral side of the main body part 10, facing the upside joints 22 and 24, among the joint parts, and which are arranged on the undersurface side of the main body part 10; and a heat insulating material 40 which is composed of a molded article of a foamed resin, and which is joined in the state of close adhesion to the whole of the backside, except the backsides of the upside joints 32 and 34, of the main body part 10. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a wall plate material, a method of manufacturing the same, and an outer wall structure, and more specifically, to a wall plate material made of a cement-based hardened plate or the like that is applied in parallel on the outer wall surface of a house, and the like. The present invention is directed to a method of manufacturing a wall plate and an outer wall structure constructed using such a wall plate.

In a building such as a house, finishing of an outer wall surface is performed by arranging ceramic tile materials such as ALC plates and fired ceramic tiles. Compared to mortar-coated walls and the like, it is said that the outer wall structure is excellent in construction workability and excellent in appearance design and durability.
In order to enhance the heat insulation of the outer wall, a heat insulating material such as foamed styrene is also applied to the back surface side of the plate material for the outer wall as described above.
For example, Patent Document 1 discloses a technique for providing a heat insulating material on the back surface of a tile to be constructed on an outer wall base. In this technique, a heat insulating material is provided on the entire back surface of the tile except for a portion of a receiving metal fitting which is arranged at four corners of a flat plate-like tile and is attached and fixed to the base of the outer wall.

Apart from this, an outer wall surface constructed with tile materials arranged side by side requires a water stop function for preventing water such as rainwater from entering the walls through the gaps between the tile materials.
Patent Document 2 discloses a technique in which an overlapping joint for connecting tile materials in a surface direction is provided on opposite sides of a rectangular plate-like outer wall plate material. In the jointing joint, the sides of adjacent tiles are overlapped with each other at the joint, so the gap between the tiles is blocked and the water-stopping function that prevents intrusion of rainwater and the like into the interior is demonstrated. It becomes easy.
JP 2003-301585 A JP 2005-163444 A

In the conventional outer wall structure using the tile material, there is a problem that the heat insulating property is impaired at the connecting portion of the tile material even if the heat insulating material is provided on the back surface of the tile material.
In the technique of Patent Document 1, a place where a heat insulating material does not necessarily exist occurs at a place of a receiving metal fitting for fixing and fixing a tile material. If there is no heat insulating material and there is a metal metal fitting having high thermal conductivity, the portion will efficiently pass heat.
When tile materials are connected with a joint joint as in the technique of Patent Document 2, a heat insulating material is pasted on a recessed portion formed on the back surface of the tile material to form a joint joint. It is possible to attach it. However, in that case, there is no heat insulating material in the portion of the joint joint, and the heat insulating property in this portion is impaired.

  The object of the present invention is to provide a good heat insulating property without damaging the original function even in the connection part of the plate-like material in the structure of the wall surface in which the plate-like building materials such as the tile materials are arranged side by side. Is to be able to do it.

The wall plate material according to the present invention is a wall plate material to be constructed side by side on the wall surface of a building, and is composed of a ceramic body-shaped molded body, and is formed into a substantially plate shape, and the main body portion. A joint portion that is overlapped with each other and connected to each other on the side of another wall plate material that is disposed adjacent to the side wall during construction, and the main body among the joint portions. An upper joint disposed on the upper surface side of the part, a lower joint disposed on a lower side of the main body part and disposed on a side of the main body part facing the upper joint among the joint parts, and a foamed resin And a heat insulating material formed in close contact with the entire back surface of the main body portion except the back surface of the upper joint.
Each configuration will be described in detail.

[Building walls]
As a building, it can be applied to various types of buildings represented by general detached houses. This includes apartment buildings, commercial buildings, and public buildings.
As a wall surface of a building, in addition to an outer wall that partitions an indoor space and an outdoor space of a building, it can be applied to a wall surface of a structure such as a pillar, a partition wall, or a fence installed outdoors. There is also a wall surrounding the courtyard inside the building. It can also be applied to the inner wall portion that partitions each room indoors.
In addition to the case where the wall surface is a flat plane, a curved surface, a step surface, and an uneven surface in which a plurality of planes are combined are also included. There are also curved surfaces such as cylindrical surfaces. There is also a combination wall surface of a plane and a curved surface.

[Plate for wall]
The wall plate-like material can be basically provided with the same material and shape structure as those of a normal wall plate-like material.
Generally, it has a substantially rectangular flat plate shape. However, a polygon other than a rectangle or a curved outer shape may be adopted depending on the form of the wall surface to be constructed or for the purpose of an external design effect. There are not a flat plate, but a bent plate, an uneven plate, and a curved plate.
(Main body)
This constitutes the main structure of the wall plate. Basically, the same material, shape, structure, and manufacturing technology as those of a normal wall plate material are applied.

A main-body part is comprised with the molded object of ceramic material. Ceramic materials include hydraulic materials such as cement as binders. May include aggregates such as fine aggregates and lightweight aggregates. It may contain a curable resin. It may also contain fiber materials such as glass fibers and inorganic particles. A colorant may be blended. In addition, various additives that are blended in ordinary ceramic building materials may be blended. By molding and curing such a ceramic material, a main body portion of the wall plate material can be obtained. Conventionally, cement-based hardened materials used for various building materials can be used.
The shape of the main body is substantially plate-shaped. In general, the planar shape is a square or a rectangle. However, it may not have a simple flat plate shape but may also have a three-dimensional shape such as a concavity and convexity and a hole constituting a connection structure such as a joint part, a structure for fixing with a nail or the like. If the joint surface with the heat insulating material has irregularities, the joint integrity with each other can be improved. There are polygons other than rectangles, curved outer shapes, bent plate shapes, uneven plate shapes, and curved plate shapes.

It is preferable that the main body is relatively thin and lightweight. Of course, even if it is lightweight, it is necessary to have the required rigidity and structural strength. Although it varies depending on the composition of the ceramic material as a raw material, it can be set to 0.4 to 1.0 cm at the thinnest part and 1.0 to 3.0 cm at the thickest part. As a whole, those having a weight per area of 15 to 22 kg / m ² are preferable.
A wrinkle finish layer can be provided or colored coating can be provided on the upper surface of the main body exposed to the outside in the construction state. If a coloring material such as a pigment is added to the material of the main body, the entire main body can be colored. If a reflective coating layer that reflects sunlight, particularly heat rays, is provided, it is possible to suppress the transmission of solar heat to the back side of the main body, and the heat insulation function can be further enhanced.

(Fitting part)
It is on the side of the main body. It is connected with the joint part which has on the side of another plate-like material arrange | positioned adjacent at the time of construction up and down mutually.
Basically, it is equipped with a splice joint structure for ordinary building materials.
The joint portion is composed of a combination of an upper joint and a lower joint. The upper joint is disposed on the upper surface side of the main body. The lower joint is disposed on the lower surface side of the main body. Usually, the thickness of the upper joint and the lower joint is set to half the total thickness of the main body. Of the plurality of side edges present in the main body, one set of opposing sides is arranged with an upper joint on one side and a lower joint on the other side. The widths of the upper joint and the lower joint are set to be approximately the same.

As the upper joint and the lower joint, those having a strip shape can be adopted. In addition, an uneven structure that is positioned so as to mesh with each other in the vertical direction or in the horizontal direction can be added to the opposing portions.
An attachment hole for attaching and fixing the wall plate-like material can be arranged in the lower joint. When a nail or a screw nail is attached to the attachment hole of the lower joint, the attachment hole or the nail can be hidden by covering the upper joint of another wall plate material on the lower joint. It is also possible to prevent rainwater and the like from entering through the mounting hole. It is possible to prevent a metal nail head or the like from being exposed to the outside and impairing the heat insulation. Appearance design and appearance are also improved.

[Insulation]
It consists of a molded body of foamed resin, and is in close contact with the entire back surface except the back surface of the upper joint among the back surfaces of the main body.
As the foamed resin, various foamed resins used for heat insulation in the field of building technology can be employed. For example, polyolefin-based foamed resins such as polystyrene and polypropylene can be used. In the foamed resin molded body, those having closed cells are superior to those having open cells in terms of heat insulation and water-stopping properties.
The larger the expansion ratio of the foamed resin molded article, the better the heat insulation, elastic deformation, lightness, and the like. In order to increase the water-stopping property, mechanical strength, rigidity, etc., a smaller foaming ratio is better. Usually, it is desirable to set the expansion ratio to 5 to 20 times.

As the shape of the heat insulating material, it is sufficient that the overall shape of the wall plate-like material is configured by being combined with the main body portion and can be used as the wall plate-like material.
Since the heat insulating material is attached so as to be fitted on the back side of the main body portion, the shape of the upper side of the heat insulating material corresponds to the back surface shape of the main body portion. If there is substantially no gap between the main body portion and the heat insulating material, the integral connection between them will be enhanced. In addition, partial gaps and passages can be provided in order to improve air permeability and moisture discharge.
A part of the structure of the heat insulating material can fulfill a part of the function of the joint part in the main body part. Specifically, the heat insulating material can be integrated with the lower joint of the main body portion to perform the function of the joint, or the end side of the heat insulating material can constitute the inner end edge of the upper joint of the main body portion.

The bottom surface of the heat insulating material constitutes the bottom surface of the wall plate-like material. Usually, it is a flat surface. Irregularities, grooves, holes, etc. can be provided on a part of the flat surface. For example, a groove used for draining or venting may be provided, or an uneven shape that engages with a mounting bracket or a positioning member may be provided.
The thickness of a heat insulating material changes with combinations with the shape of a main-body part. Usually, the portion arranged on the back surface of the lower joint has the smallest thickness. The portion corresponding to the back surface of the main body other than the lower joint is thicker. Specifically, the total thickness including the main body portion and the heat insulating material is 1.5 to 4.0 cm, whereas the thickness of the heat insulating material is set to 0.00 on the back surface of the lower joint where the thickness is the thinnest. It can be set to 5-1.5 cm.

[Manufacture of plate materials for walls]
The plate material for walls having the structure described above can be manufactured by applying a manufacturing technology for plate materials such as various building tile materials. Basically, a general ceramic manufacturing tile material manufacturing technique and a heat insulating material manufacturing technique may be combined.
Method (I) (II) combining the following steps can be employed as a method for producing a wall plate material in combination with the main body and the heat insulating material. -Manufacturing method (I)-
<Process (a): Molding of main body>
A ceramic material is press-molded to obtain a molded body having the shape of the main body.

Normal ceramics tile manufacturing technology can be applied.
A method of press-molding ceramic materials including cement can be employed. The press molding apparatus and molding conditions may be the same as in the case of normal tile material production. For example, the molding pressure can be set to a molding pressure of 9.8 to 14.7 MPa (100 to 150 kgf / cm ² ). It can also be heated during press molding.
The molded body obtained by molding has the shape of the main body, but is not yet cured. If force is applied, it may be deformed or cracked.
The formed body after press molding can be immediately supplied to the next step.

<Process (b): Integration of main body and heat insulating material>
The molded body of the main body portion, which is obtained in the previous step (a) and is in a deformable state, is fitted into a heat insulating material made of a molded body of foamed resin that is molded in advance and integrated.
About a heat insulating material, a normal foam molding technique is applied and manufactured beforehand.
If the heat insulating material is placed on a rigid support base or support plate with the flat bottom surface of the heat insulating material applied, the heat insulating material is stably supported and the work can be easily performed.
If the main body and the heat insulating material have the shape as designed, the main body is smoothly fitted into the heat insulating material. Even if the shape of the main body and heat insulating material do not match exactly due to manufacturing variations or dimensional errors, if the main body that can be deformed before curing is slightly deformed, it can be easily fitted with the heat insulating material. It is.

If an adhesive or a curable material is applied to the contact surface between the main body and the heat insulating material, the main body and the heat insulating material are strongly bonded. However, since the main body portion is cured and cured later, the main body portion is bonded to the heat insulating material, so that an adhesive or the like may not be used.
The main body part fitted with the heat insulating material can be pressed against the heat insulating material side. The main body portion is deformed, and there is no gap left between the main body and the heat insulating material, or the bondability with the heat insulating material is increased. The integrity of the main body portion and the heat insulating material is improved by deforming the surface of the main body portion in accordance with the fine irregularities on the surface of the heat insulating material made of the foamed resin molding.
If the main body is placed on the heat insulating material and the main body is pressed against the heat insulating material, the main body is easily deformed and firmly joined to the heat insulating material.

In addition, a main-body part can be mounted on a support stand, and it can also integrate by inserting a heat insulating material from the upper part of a main-body part.
<Process (c): Curing of the main body>
The molded body of the main body united with the heat insulating material is cured and cured.
As the curing curing treatment apparatus and treatment conditions, a technique common to curing curing in the production of ordinary cement tile materials can be applied.
In the known tile material manufacturing, the tile material molded body is loaded on a curing device and supported during curing while being placed on a support base that can be supported so as not to lose its shape. If the molded body of the tile material has a three-dimensional shape, the support base also needs a three-dimensional shape. If the shape of the tile material is changed, the design of the support base also needs to be changed.

On the other hand, the main body supported by the heat insulating material does not require a support base having the above three-dimensional shape. The heat insulating material that supports the main body can be handled as it is and sent to the curing device. Even if you place the bottom surface of the heat insulating material that supports the main unit on a support plate made of a flat plate, it will be in a stable mounting state, and even if it is subject to vibration or tilting slightly during handling, it will fall or be shaped There will be no collapse.
As the curing treatment, heating in a processing chamber with a heater or the like, application of heated air, or steam curing with heated steam can be performed. The heating atmosphere can be replaced with a gas other than air. When heating is performed, the heating temperature is set so as not to exceed the heat resistance temperature of the heat insulating material. Natural curing is possible by leaving it in the air or placing it in a well-ventilated place without heating or adjusting the atmosphere.

In the curing treatment, the entire main body is cured by the action of a curable material such as cement contained in the material of the main body. When the main body portion is cured, a wall plate material in which the main body portion and the heat insulating material are integrally joined is obtained. It can be taken out from the curing device and used for construction work.
<Other processes>
In addition to the above-described steps, various processing and processing steps that are employed in the production of ordinary plate materials for construction can be performed.
For example, the surface of the cured main body can be polished, unnecessary portions such as molding burrs can be removed, and the surface can be cleaned. The surface of the main body can be finished or coated. It is also possible to attach metal fittings necessary for the construction of the plate material for the wall, or to additionally process the mounting holes and the uneven structure for mounting.

-Manufacturing method (II)-
In this method, the main body is molded and cured and cured, and then integrated with the heat insulating material.
<Process (m): Molding of main body>
A ceramic material is press-molded to obtain a molded body having the shape of the main body.
A technique common to the step (a) of the manufacturing method (I) is applied.
<Step (n): Curing curing of main body>
Curing and curing the molded body of the main body.
Although it is basically the same as the step (c) of the production method (I), it is different in that the main body is cured and cured independently. A support base that supports the molded body of the main body is used as necessary. Since there is no heat insulating material, it is not necessary to consider the heat resistance of the heat insulating material, and conditions such as an appropriate temperature and atmosphere can be set for curing and curing the main body.

<Process (o): Integration of main body and heat insulating material>
The cured and cured main body portion is fitted into a heat insulating material made of a foamed resin molded body and integrated.
Although it is basically the same as the step (b) of the production method (I), it differs in that the main body is cured and cured.
In this case, the main body part cannot be deformed so much, but the main body part and the heat insulating material can be brought into close contact with each other by utilizing the deformability of the heat insulating material. The main body portion and the heat insulating material may be joined only by a physical fitting action. However, in order to ensure the joining, it is effective to perform the joining using an adhesive or a curable material.

<Other processes>
After the main body and the heat insulating material are integrated, a necessary processing operation can be performed in the same manner as in the manufacturing method (I).
[Outer wall structure]
The outer wall structure of a building can be constructed by using the wall-shaped plate material having the above structure. Basically, a technique common to the outer wall structure by normal tile finishing can be applied.
Specifically, wall plate materials are arranged side by side on the outer wall base surface to be constructed on the outer wall surface of the building.

The outer wall base surface may be the same as the outer wall structure in a normal building. A frame structure itself such as a concrete frame or a steel frame may be used, or a base plate such as a siding board may be pasted thereon. Crosspieces may be arranged at intervals in the vertical and horizontal directions. A film or sheet that becomes a waterproof layer or a moisture-impermeable layer can be attached, or a coating treatment can be applied. In addition, in the conventional outer wall construction, it is not necessary to perform the pasting of the heat insulating sheet which has been performed before the outer wall tile material is pasted. Of course, the heat insulation layer similar to a normal heat insulation wall structure may be provided inside the wall structure.
The wall plate-like material is disposed so that the bottom surface of the heat insulating material contacts the outer wall base surface. Normally, internal condensation can be prevented by preventing a gap between the heat insulating material and the outer wall base surface. Further, there is a case where moisture is expelled by providing a ventilation gap between the heat insulating material and the outer wall base surface.

The wall plate-like material is attached in order from one side of the wall surface to the other side. The wall plate material attached first is fixed to the outer wall base material using an adhesive or a nail. It arrange | positions so that the upper side joint of the wall-plate material attached next may rest on the lower joint of the wall-plate material attached previously.
On a vertical wall surface or an inclined wall surface, a wall plate-like material is arranged and attached from the lower side to the upper side of the wall surface. Accordingly, the lower joint of the lower wall plate is attached so as to cover the upper joint of the upper wall plate. Rainwater and the like flowing along the upper wall plate-like material are difficult to enter the gap through the joint.
A water-stopping material can be applied to the contact surfaces between the joints, or a water-stopping film can be sandwiched between them. A caulking material can be filled around the mounting holes and nails for fixing the wall plate material to the outer wall base material, or a waterproof treatment or a rust prevention treatment can be applied. Eliminating gaps in order to improve water stopping performance also leads to improved heat insulation.

  After wall plate-like materials are attached to the specified area of the wall continuously and side by side, if necessary, install edge material on the edge of the construction area or perform water stop treatment at the edge. Can do. The entire surface of the applied wall plate can be coated or painted.

The plate member for wall according to the present invention is provided with an upper joint or a lower joint on the side of the main body portion formed of a ceramic material molded body, fulfills a connection function and a water stop function by a lap joint, A heat insulating material made of a foamed resin molded body is provided on the back surface of the part to achieve a heat insulating function.
In particular, since the heat insulating material is not provided on the back surface of the upper joint among the back surfaces of the main body part, but provided on the entire other back surface including the lower joint, the heat insulating material interferes with the function of the joint joint. There is no. In addition, in the state where the wall plate-like materials are connected by the joint joint, the end surfaces of the heat insulating materials of the adjacent wall plate-like materials are closely arranged without leaving a gap on the back surface of the main body portion. become.

  As a result, the wall surface on which the wall plate-like material has been constructed can exhibit good heat insulation on the entire surface. The problem of local heat insulation function deterioration due to the mounting bracket and the connecting structure is solved. In addition, the construction of the plate material for the wall itself can be performed easily and accurately using a splice joint, so that construction workability is high and it is possible to construct a highly functional wall structure economically. .

[Plate for wall]
The wall-shaped plate material W shown in FIGS.
The main body 10 is made of a cement-based hardener and has a structure in which an upper board portion 20 having a rectangular plate shape and a lower board portion 30 having an L-shaped plate shape are vertically stacked. The lower board part 30 has the same thickness as the upper board part 20, is joined to the back side of two adjacent sides of the upper board part 20, and projects outward. A plurality of mounting holes 36 are formed through the lower board portion 30 along the orthogonal sides.
Of the upper board part 20, the two sides far from the lower board part 30 are the upper joints 22 and 24. Of the lower board part 30, the two sides far from the upper board part 20 are the lower joints 32 and 34. The upper side joint 22 and the lower side joint 32 or the upper side joint 24 and the lower side joint 34 are arranged so as to face each other on the opposite sides of the main body 10, thereby forming a so-called lap joint. Yes.

The heat insulating material 40 is made of a polystyrene extruded foam having an expansion ratio of 5 to 20 times, and is integrally joined to the back surface side of the main body 10. The heat insulating material 40 is disposed on the inner peripheral end surface and the back surface of the lower board portion 30 from the back side of the upper board portion 20 of the main body portion 10. The heat insulating material 40 does not exist on the back surfaces of the upper joints 22 and 24 of the main body 10, and the outer end surface of the heat insulating material 40 constitutes the inner end edges of the upper joints 22 and 24. On the back side of the lower joints 32, 34, the outer peripheral end surface of the heat insulating material 40 is disposed up to the same position as the outer peripheral end surfaces of the lower joints 32, 34. The bottom surface of the heat insulating material 40 is a rectangle having the same shape as the upper board portion 20 and is slightly shifted in the diagonal direction.
<Dimension example of wall plate>
Upper board portion 20: rectangle of 30 cm length x 45 cm width, thickness 1.0 cm.

Lower board part 30: L-shaped, 29.7 cm long x 44.7 cm wide, 5.8 cm wide on each side, 1.0 cm thick.
Heat insulating material 40: rectangular bottom surface of 29.7 cm in length × 44.7 cm in width, total thickness of 1.5 cm, thickness of lower joints 32 and 34 is 0.5 cm.
The overhang of the upper joints 22 and 24 from the end face of the heat insulating material 40 is 3.3 cm.
The protruding amount of the lower board part 30 from the end face of the upper board part 20 is 3.0 cm.
[Outer wall structure]
As shown in FIG. 4, a wall plate-like material W is used for finishing the outer wall 50 of a house or the like.

The outer wall 50 includes a framework structure, a heat insulating layer, internal piping, and the like that are not shown, and an outer wall base plate 52 made of a siding board or the like is affixed to a surface on the outdoor side.
The outer wall 50 is a vertical wall surface, and the wall plate-like material W is attached from the lower side to the upper side.
The wall plate-like material W is disposed on the outer wall base plate 52 in such a posture that the lower joint 34 faces upward and the upper joint 24 faces downward. The bottom surface of the heat insulating material 40 hits the surface of the outer wall base plate 52. If an adhesive is applied to the contact surface between the heat insulating material 40 and the outer wall base material 52, the heat insulating material 40 can be bonded to the outer wall base material 52.
In this state, the mounting screw 60 is inserted through the mounting hole 36 formed through the lower board portion 30 and screwed into the outer wall base material 52. The attachment screw 60 may be screwed to the outer wall 50 main body portion through the outer wall base material 52. The wall plate-like material W shown in the upper part of FIG. 4 has the mounting holes 36 penetrating from the lower board portion 30 to the heat insulating material 40, but the heat insulating material 40 has the mounting holes 36 formed therein. It doesn't matter. If the mounting screw 60 is screwed from the mounting hole 36 of the lower board portion 30, it is easy to screw the outer wall base material 52 through the relatively soft heat insulating material 40.

The wall plate-like material W is fixed to the outer wall base material 52 by screwing attachment screws 60 into the outer wall base material 52 through a plurality of mounting holes 36.
The next wall plate-like material W is arranged on the wall plate-like material W attached first. Next, the upper joint 24 existing on the lower side of the wall plate member W to be attached is connected to the lower joint 34 of the wall plate member W to which the wall plate W has already been attached, and the connection is made by the joint joint. Is called. The head of the mounting screw 60 is exposed in the mounting hole 36 of the lower board portion 30, but the mounting hole 36 and the mounting screw 60 are completely covered by the upper joint 24 of the next wall plate-like material W. Hidden.
If such an operation is repeated from the bottom to the top of the wall surface 50, the wall plate W can be attached to the entire wall surface 50. Although illustration is omitted, the wall plate-like material W is attached sequentially from the left side to the right side in the horizontal direction of the wall surface 50.

In a state in which the wall plate member W is attached to the entire wall surface 50, the main body 10 of the wall plate member W exists on the surface exposed to the outside. The heat insulating material 40 is not exposed. And the heat insulating material 40 exists between the main-body part 10 and the outer wall base material 52, without interrupting the whole surface direction. There is no place where the outer wall base material 52 and the main body 10 are in direct contact.
Outdoor cold or strong solar radiation contacts the main body 10 existing on the surface of the wall plate W to cool or heat the main body 10, but the outer wall base completely separated by the heat insulating material 40. Heat transfer to the inside of the material 52 and the outer wall 50 is suppressed.

In addition, there is a possibility that heat transfer is easily performed from the main body 10 to the outer wall base material 52 via the mounting screw 60 only at the location of the mounting screw 60. However, as long as only the mounting screws 60 are present in the form of dots, the heat insulating function of the entire wall surface 50 is not significantly impaired. In particular, since the mounting screw 60 is covered with the upper joints 22 and 24 of the main body 10, outdoor heat is not directly transferred from the mounting screw 60 to the inside of the wall.
Water may flow on the surface of the wall plate W due to rainfall or water spray. Water flows down the surface of the main body 10. Since water flows from the tip of the upper joint 24 on the lower side of the main body 10 to the surface of the lower wall plate W, it is difficult for water to enter the gap between the wall plates W. Even if water enters inside from the lower end surface of the upper joint 24, the lower joint 34 of the lower plate portion 30 of the wall plate W disposed on the lower side on the back side of the upper joint 24 is in the vertical direction. Since it constitutes a wall, further penetration is difficult. Furthermore, even if water has soaked up from the surface of the lower joint 34 to the upper end surface, the end surface of the lower joint 34 is the end surface of the heat insulating material 40 of the wall plate W disposed on the upper side. Therefore, the water does not penetrate into the inside beyond the contact point with the heat insulating material 40.

[Manufacture of plate materials for walls]
FIG. 5 shows the steps of manufacturing the wall plate W in stages (a) to (e).
<Step (a)>
The main body 10 is molded. A pair of upper and lower molds 70 and 72 is supplied with a molding material 80 in a dumpling shape by kneading a raw material such as cement. The molds 70 and 72 have mold surfaces corresponding to the shape of the main body 10.
<Step (b)>
When the molds 70 and 72 are closed and a press pressure is applied, the molding material 80 is molded into a shape corresponding to the cavity shape of the molds 70 and 72, that is, the shape of the main body 10.

After molding, the molds 70 and 72 are opened, and the molded main body 10 is taken out.
However, the main body 10 immediately after molding is not yet cured and is in a state of remaining plasticity. Handling must be performed carefully so that the soft main body 10 is not deformed or damaged.
<Step (c)>
On the support base 76, the heat insulating material 40 previously resin-molded is placed. For the manufacture of the heat insulating material 40, a normal mold foam molding technique may be applied. A part of the foamed block-like foam may be cut or cut to produce a predetermined heat insulating material 40 shape.

Since the flat bottom surface 32 of the heat insulating material 40 is placed on the flat support base 76, the heat insulating material 40 is placed in a stable state without being inclined or deformed.
On the heat insulating material 40, the main body 10 molded in the previous step (b) is disposed. Since the back surface shape of the main body portion 10 corresponds to the outer shape of the heat insulating material 40, the main body portion 10 fits into the heat insulating material 40 exactly. In particular, the main body 10 is not yet completely cured and is in a state where it can be deformed to some extent. Therefore, the main body 10 is slightly deformed according to the shape of the heat insulating material 40, so that the fitting work can be performed. It is easy and the gap with the heat insulating material 40 can be eliminated. If each part of the main body 10 is strongly pressed against the heat insulating material 40, the adhesion between the main body 10 and the heat insulating material 40 becomes extremely good. If the back surface of the main body portion 10 is pressed and fitted into the fine irregularities or holes of the foam constituting the heat insulating material 40, the integrity of the two becomes stronger.

If necessary, if the adhesive is applied to the contact surface between the heat insulating material 40 and the main body 10 or the same cement slurry as the molding material of the main body 10 is applied, the main body 10 and the heat insulating material 40 become stronger, and the integrity is enhanced.
<Step (d)>
With the heat insulating material 40 and the main body 10 integrated, the main body 10 is cured and cured.
Curing and curing are usually performed in a curing room 78 in which the inside can be heated or heated steam can be supplied. Before the curing process in the curing chamber 78, a drying process for removing excess water from the main body 10 may be performed. The drying process is natural drying or forced drying by a drying oven.

In any case, the integrated body of the heat insulating material 40 and the main body portion 10 is transferred and carried into the curing chamber 78 while being placed on the support base 76. Handling is easy without touching the main body part 10 or applying a force to peel off the main body part 10 and the heat insulating material 40.
In the curing chamber 78, the main body portion 10 heated at a predetermined temperature for a predetermined time becomes a main body portion 10 made of a cured body by curing a hardening material such as cement contained in the molding material. At the same time as the main body 10 is cured, the main body 10 is also strongly bonded to the heat insulating material 40.
<Step (e)>
When the curing and curing process is completed, the wall plate member W composed of the cured main body 10 and the heat insulating material 40 is completed.

The wall plate W may be left on the support stand 76 until the main body 10 heated by heating is sufficiently cooled.
After the main body 10 is sufficiently cooled, the wall plate W may be removed from the support base 76 and sent to operations such as packing and shipping. If necessary, remove the burrs and the like remaining in the main body 10 from the wall plate material W, scrape the surface, attach metal fittings necessary for construction, or attach holes for metal fittings. It is also possible to perform processing such as forming grooves and grooves. A finish coating can be applied to the surface of the main body 10.

  The wall plate-like material of the present invention is used, for example, for finishing an outer wall of a house. Construction is simple and efficient, and the wall surface after construction is superior in performance such as heat insulation and water-stopping properties, and has a good appearance.

The perspective view of the plate-shaped material for walls showing embodiment of this invention Front view Same as above Cross-sectional view of the outer wall structure with wall plate material Schematic diagram showing step by step the manufacturing process of the wall plate

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Main body part 20 Upper board part 22, 24 Upper joint 30 Lower board part 32, 34 Lower joint 36 Mounting hole 40 Heat insulating material W Wall plate

Claims (5)

It is a plate material for walls that is constructed side by side on the wall of a building,
It consists of a molded body of ceramic material, and has a main body that is roughly plate-shaped,
A joint part that is on the side of the main body part, and is connected to the joint part that is disposed on the side of another wall plate material that is disposed adjacent to the main body part so as to overlap each other.
Among the joint parts, an upper joint disposed on the upper surface side of the main body part,
Among the joint parts, disposed on the side of the main body part facing the upper joint, a lower joint disposed on the lower surface side of the main body part,
A heat insulating material comprising a molded body of foamed resin, and in close contact with the entire back surface except the back surface of the upper joint, of the back surface of the main body, and
A plate-like material for walls. The molded body of the ceramic material used as the main body portion is made of a cement-based cured material, and the weight per area is 15 to 22 kg / m ² .
The molded body of the foamed resin that becomes the heat insulating material is composed of a closed-cell polystyrene foam having an expansion ratio of 5 to 20 times,
The total thickness including the main body and the heat insulating material is 1.5 to 4.0 cm,
The thickness of the heat insulating material has 0.5 to 1.5 cm on the back surface of the lower joint,
The plate member for walls according to claim 1. A method for producing the wall plate according to claim 1,
A step (a) of obtaining a molded body having the shape of the main body by press-molding the ceramic material;
A step (b) of fitting the molded body of the main body obtained in the previous step (a) into a heat insulating material made of a molded body of a foamed resin that has been molded in advance;
The manufacturing method of the plate-shaped material for walls including the process (c) which cure-hardens the molded object of the said main-body part integrated at the said heat insulating material obtained by the said process (b). A method for producing the wall plate according to claim 1,
A step (m) of obtaining a molded body having the shape of the main body by press-molding the ceramic material;
The step (n) for curing the molded body of the main body obtained in the step (m) and the main body obtained in the previous step (n) are made of a foamed resin molded body. A step of fitting and integrating with the material (o);
The manufacturing method of the plate-shaped material for walls containing this. An outer wall structure of a building using the wall plate according to claim 1,
An outer wall foundation surface constructed on the outer wall surface of the building;
On the outer wall base surface, the bottom of the heat insulating material is brought into close contact with the outer wall base surface, and the wall plate-like material laid to be connected to each other front and rear and left and right by the joint portion, and
The heat insulating materials of the adjacent wall plate-like materials are continuously arranged in the horizontal direction,
Exterior wall structure.

Images