JP2013231276A - Siding material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a siding material having an excellent design quality, light weight, and durability.SOLUTION: A siding material 10 includes a base plate 12 made of a synthetic resin and a design layer 14 formed on the base plate 12. The design layer 14 includes a primer layer 28 formed on the base plate 12, an intermediate coating layer 30 made of a resin composition including inorganic particles dispersed in a synthetic resin formed on the primer layer 28, and a top coating layer 32 formed on the intermediate coating layer 30.

Description

  The present invention relates to a siding material made of synthetic resin.

  As exterior materials for buildings, etc., ceramic siding materials made by mixing raw materials such as cement, calcium silicate, fibers and admixtures, pouring into molds and molding at high temperature and high pressure, and ALC plates molded by foaming concrete Is widely used. In these ceramic siding materials and ALC boards, for the purpose of obtaining an excellent design, a spraying material in which natural crushed stones or aggregates are blended with a synthetic resin emulsion is coated on the surface to form a natural stone-like pattern. (For example, patent document 1).

  However, since these ceramic siding materials and ALC plates are repeatedly expanded and contracted by freezing and thawing of water contained in concrete in a cold region, they are likely to crack. In addition, since it is heavy, it is necessary to reinforce the structural material in order to increase earthquake resistance.

JP 2010-5836 A

  An object of the present invention is to provide a siding material having excellent design properties, light weight and excellent durability.

  The siding material of the present invention has a synthetic resin substrate and a design layer formed on the substrate, and the design layer is formed on the primer layer and the primer layer. And an intermediate coating layer made of a resin composition in which inorganic particles are dispersed in a synthetic resin.

In the siding material of the present invention, it is preferable that the design layer further has a topcoat layer formed on the intermediate coating layer.
Moreover, it is preferable that the siding material of the present invention does not break even if a 1 kg steel ball is dropped from a height of 1 m at 23 ° C. and −30 ° C.
The substrate is, JIS K7111 impact strength at 23 ° C. in Charpy impact test specified is 18 kJ / ^{m 2} or more and an impact strength at 0 ℃ is 12 kJ / ^{m 2} or more.
The substrate preferably has an impact strength at 23 ° C. of 800 kJ / m ² or more in a tensile impact test specified by JIS K7160.

  The siding material of the present invention has an excellent design, is lightweight and has excellent durability.

It is a side view of the siding material of the present invention. It is the front view which looked at the siding material of the present invention from the surface side. It is the rear view which looked at the siding material of the present invention from the back side. It is sectional drawing when the siding material of FIG. 1 is cut | disconnected by the straight line I-I '.

  In this specification, the “front surface” is a surface that becomes the outdoor side when the siding material is attached to the outer wall or the like of the building, and the “back surface” is the opposite side, that is, the surface that becomes the building side. In addition, “upper” at the upper edge, upper end, and the like refers to a side that becomes upper when a siding material is attached to an outer wall or the like of a building.

Hereinafter, an example of the siding material of the present invention will be described with reference to FIGS.
As shown in FIGS. 1 to 3, the siding material 10 includes a rectangular substrate 12 made of synthetic resin and a design layer 14 formed on the surface of the substrate 12.
The siding material 10 has an upper end surface portion 16 extending perpendicularly from the upper end of the substrate 12 to the surface of the substrate 12 and on the opposite side to the design layer 14 side; An upper edge 18 extending in parallel to the surface of the substrate 12 from the end and extending to the opposite side of the substrate 12; and a protrusion protruding from the design layer 14 side on the upper surface of the upper end surface 16 to the opposite side of the substrate 12 A ridge 20; a bent portion 22 that protrudes perpendicularly from the vicinity of the lower end of the substrate 12 to the side opposite to the design layer 14 side, and bends perpendicularly to the lower end direction of the substrate 12 in the middle; And two ridges 24, 24 provided along (long side direction). A groove portion 26 is formed by the bent portion 22 and the substrate 12 on the lower end side of the siding material 10.

The synthetic resin constituting the substrate 12 is preferably a thermoplastic resin from the viewpoint of moldability and the like. Examples of the thermoplastic resin include polyolefin resins such as vinyl chloride resin, polycarbonate resin, polyethylene, and polypropylene. Of these, vinyl chloride resin is preferred in that it has moisture permeability and hardly undergoes freezing destruction and has high resistance to salt damage, acid and alkali.
The synthetic resin may be blended with additives such as fillers, reinforcing materials, pigments, processing aids, heat stabilizers, and ultraviolet absorbers as necessary.

The substrate 12 may be a single layer or a multilayer.
When the substrate 12 is a single layer, the substrate 12 may be a synthetic resin foam or a non-foam. A foam is preferable in terms of weight reduction, and a non-foam is preferable in terms of strength.
When the substrate 12 is a multilayer, the synthetic resin constituting each layer may be the same or different. Moreover, you may combine the layer which consists of a foam, and the layer which consists of a non-foam.

  The thickness of the substrate 12 is preferably 2 to 5 mm, and more preferably 3 to 4 mm. If the thickness of the substrate 12 is equal to or greater than the lower limit value, the substrate 12 has sufficient strength to form the design layer 14 on the surface thereof, and problems such as deformation are hardly generated during coating in the formation of the design layer 14. Moreover, the design of the surface of the siding material 10 to be obtained is excellent in profound feeling and texture. If the thickness of the substrate 12 is less than or equal to the upper limit value, the weight of the siding material 10 is light and the workability and the like are good.

Since the siding material 10 is used for an outer wall of a building or the like, it is preferable that the siding material 10 is not easily deformed by a wind during a typhoon or damaged by an impact of a flying object.
The siding material 10 is preferably not damaged at a positive pressure of 3000 Pa or a negative pressure of 1600 Pa in a wind pressure resistance performance test defined in JIS A1414, which is a test assuming a wind during a typhoon.
Further, the substrate 12 preferably has an impact strength at 23 ° C. of 18 kJ / m ² or more in a Charpy impact test defined in JIS K7111. The impact strength at 0 ° C. in the Charpy impact test is preferably 12 kJ / m ² or more.
In addition, the substrate 12 preferably has an impact strength at 23 ° C. of 800 kJ / m ² or more in a tensile impact test defined by JIS K7160.
Moreover, it is preferable that the siding material 10 is not damaged even if a 1 kg steel ball is dropped from a height of 1 m at 23 ° C. and −30 ° C., and it is not damaged even if a 1 kg steel ball is dropped from a height of 1.5 m. It is more preferable that no occurs.

  The working width W of the substrate 12 (the length in the vertical direction when attached to the attachment surface. FIG. 2), and the length L (the length in the horizontal direction when attached to the attachment surface. FIG. 2) are: Each is not particularly limited, and the working width and length of a commonly used siding material can be appropriately employed. Usually, the working width W is in the range of 300 to 600 mm, and the length L is in the range of 1500 to 5000 mm.

  2 and 3, the upper edge 18 is provided with a plurality of mounting holes 18a for mounting the siding material 10 to a mounting surface such as an outer wall of a building. The siding material 10 is fixed to the mounting surface by bringing the back surface of the upper edge 18 into contact with the mounting surface and screwing, nailing or the like using the mounting hole 18a.

  The bent portion 22 is formed such that the width and depth of the groove portion 26 are equal to or greater than the width and height of the ridge 20. Accordingly, when the plurality of siding materials 10 are continuously attached to the attachment surface in the vertical direction, the groove portion 26 of the siding material 10 and the ridges 20 of the other siding materials 10 attached to the lower side thereof are engaged. It is like that. By engaging the groove 26 and the ridge 20, the upper and lower siding materials 10 are not easily separated. The siding material 10 is usually attached from the bottom to the top of the attachment surface.

The ridges 24 serve to increase the strength of the siding material 10.
The cross-sectional shape of the ridges 24 is a rectangle as shown in FIG.
The width D ₂ (length in the direction perpendicular to the surface of the substrate 12) of the ridges 24 is the same as the width D ₁ of the upper end surface portion 16. By width D ₂ of the ridge 24 is the same as the width D ₁ of the upper end face portion 16, when fitted with a siding 10 to the mounting surface, also the tip end surface of the projections 24 as well as the rear surface of the upper edge 18 Touch the mounting surface. Thereby, since the board | substrate 12 is supported by the protruding item | line 24, the outstanding stability is acquired.
The number of ridges 24 is not limited to two and may be one or three or more.
The upper end surface portion 16, the upper edge portion 18, the ridges 20, the bent portions 22, and the ridges 24 and 24 are formed of the same synthetic resin as the substrate 12.

  The design layer 14 is a layer that is formed on the surface side of the substrate 12 and imparts excellent design properties. As shown in FIG. 4, the design layer 14 in this example was formed on the primer layer 28 formed on the substrate 12, the intermediate coating layer 30 formed on the primer layer 28, and the intermediate coating layer 30. A top coat layer 32. That is, the design layer 14 is a laminate having a three-layer structure in which the primer layer 28, the intermediate coating layer 30, and the topcoat layer 32 are sequentially laminated from the substrate 12 side. The top coat layer 32 is a layer provided for the purpose of further improving the weather resistance. The design layer in the siding material of the present invention may not have a topcoat layer.

The primer layer 28 is a layer that improves the adhesion between the substrate 12 and the intermediate coating layer 30.
The primer agent used for forming the primer layer 28 may be any primer that can enhance the adhesion between the substrate 12 and the intermediate coating layer 30, and either a water-based primer agent or a solvent-based primer agent can be used. For example, various primer agents such as urethane-based, acrylic-based, ethylene-vinyl acetate copolymer system, and vinyl chloride acetate copolymer system can be used. Examples of the solvent-based two-component primer agent include those using a polyisocyanate-based or amine-based curing agent.
Further, the primer layer 28 may contain titanium oxide, a pigment, or the like as necessary.

  The thickness of the primer layer 28 is preferably 0.05 to 0.2 mm, and more preferably 0.07 to 0.15 mm. If the thickness of the primer layer 28 is more than a lower limit, the adhesiveness of the board | substrate 12 and the design layer 14 will be excellent. If the thickness of the primer layer 28 is less than or equal to the upper limit value, the amount of material used can be suppressed and drying can be accelerated.

The intermediate coating layer 30 is a layer made of a resin composition in which inorganic particles are dispersed in a synthetic resin. A design (grained pattern or the like) is imparted to the design layer 14 depending on the type, size, dispersion state, and the like of the inorganic particles contained in the intermediate coating layer 30.
The synthetic resin used for forming the intermediate coating layer 30 is not particularly limited and satisfies the weather resistance, solvent resistance, water resistance, adhesiveness, flexibility, water absorption resistance, impact resistance, etc. required for the siding material. Those that do are preferred. Examples of such synthetic resins include acrylic resins, silicone resins, urethane resins, and fluororesins.

The inorganic particles used for forming the intermediate coating layer 30 are not particularly limited, and the type and size can be appropriately set according to a desired design (natural stone pattern or the like).
Examples of the inorganic particles include natural crushed stones, pebbles, mica, silica sand, glass, colored aggregates, ceramic chips (chromium oxide, titanium oxide, zirconium oxide, aluminum oxide, tungsten carbide, chromium carbide, etc.). Can be mentioned. These inorganic particles may be used alone or in combination of two or more.

The size of the inorganic particles varies depending on the target design and the thickness of the intermediate coating layer 30, but is preferably 0.01 to 3 mm.
In the present invention, it is particularly preferable that the size of the inorganic particles is smaller than the thickness of the intermediate coating layer 30. When the size of the inorganic particles is reduced, the inorganic particles are less likely to protrude from the surface of the formed intermediate coating layer 30, so that the resin composition forming the intermediate coating layer 30 can have a high viscosity. Further, even when a concavo-convex pattern (such as a streak or an indefinite shape) is formed on the surface of the intermediate coating layer 30 by trowel finishing, roller finishing, or the like after coating, it can be easily formed into a desired shape.

The mixing ratio of the synthetic resin and the inorganic particles is preferably 20 to 100 parts by mass and more preferably 30 to 70 parts by mass with respect to 100 parts by mass of the inorganic particles.
The intermediate coating layer 30 may contain a filler, a film-forming aid, a thickener, a pH adjuster, an antifoaming agent, and the like as necessary.

The surface of the intermediate coating layer 30 may be provided with a concavo-convex pattern (such as a streak or an indefinite shape).
The thickness of the intermediate coating layer 30 is preferably 0.5 to 4 mm, and more preferably 1 to 2 mm. If the thickness of the intermediate coating layer 30 is equal to or greater than the lower limit value, the design has a profound feeling and texture. If the thickness of the intermediate coating layer 30 is 4 mm or less, the siding material 10 will be lightweight.
When the uneven pattern is formed on the surface of the intermediate coating layer 30, the thickness of the intermediate coating layer 30 means the thickness of the thinnest portion.

The topcoat layer 32 is a layer that is formed of a transparent resin and plays a role of improving the weather resistance and durability of the siding material 10.
Examples of the transparent resin include acrylic-silicon resin and fluororesin. Of these, acrylic-silicon resin and fluororesin are preferable.
Further, the top coat layer 32 may contain a matting agent or the like as necessary.

The thickness of the top coat layer 32 is preferably 0.05 to 0.3 mm, and more preferably 0.1 to 0.2 mm. If the thickness of the topcoat layer 32 is equal to or greater than the lower limit value, the weather resistance and durability of the siding material 10 are excellent. If the thickness of the topcoat layer 32 is not more than the upper limit value, the glossiness is improved.
When the topcoat layer 32 has an uneven pattern, the thickness of the topcoat layer 32 means the thickness of the thinnest part.

The thickness of the design layer 14 is preferably 0.6 to 4.5 mm, and more preferably 1.18 to 2.35 mm. If the thickness of the design layer 14 is equal to or greater than the lower limit value, the design will have a profound feeling and texture. If the thickness of the design layer 14 is less than or equal to the upper limit value, the siding material 10 becomes light.
When the design layer 14 has an uneven pattern, the thickness of the design layer 14 means the thickness of the thinnest part.

[Production method]
Hereinafter, a method for manufacturing the siding material 10 will be described. However, the manufacturing method of the siding material 10 is not limited to the method shown below. As a manufacturing method of the siding material 10, the method which has the following formation process and a decoration process is mentioned, for example.
Molding step: a step of forming a molded product in which the substrate 12, the upper end surface portion 16, the upper edge portion 18, the ridges 20, the bent portions 22 and the ridges 24 are integrated.
Decoration process: A process of forming the design layer 14 by sequentially forming the primer layer 28, the intermediate coating layer 30 and the topcoat layer 32 on the surface of the substrate 12.

(Molding process)
As a method of molding the molded product, a known molding method such as extrusion molding or injection molding can be employed.
At the time of molding, a synthetic resin may be foamed to form a foam. Thereby, a molded product can be reduced in weight. As a method for foaming a synthetic resin, for example, a method in which an inorganic foaming agent (such as carbonate) or an organic foaming agent (thermal decomposition type or reaction type) is added and heated to a decomposition temperature to generate gas is known. It has been.

(Decoration process)
First, a primer agent is applied to the surface of the substrate 12 and dried to form the primer layer 28. The method for applying the primer agent is not particularly limited, and coating by roll coater, knife coater, or reciprocating spraying is preferable.
The drying method is not particularly limited, and examples thereof include drying using a drying furnace.

Next, the intermediate coating layer 30 is formed by applying a mixture of the synthetic resin emulsion and the inorganic particles on the primer layer 28 and drying the mixture.
The coating method of the mixture is preferably coating by gun spraying. Examples of the supply pump used for gun spraying include a plunger pump, a snake pump, a gear pump, a diaphragm pump, and a squeeze pump.
The diameter of the gun is preferably 3 to 10 mm. By adjusting the aperture, uneven patterns having different sizes can be formed on the surface of the intermediate coating layer 30. Specifically, the concave / convex pattern is finer as the aperture is smaller, and the concave / convex pattern is rougher as the aperture is larger.
The drying method is not particularly limited, and examples thereof include drying using a drying furnace.
In addition, after coating the mixture and before drying the formed coating layer, if necessary, the surface of the coating layer is concavo-convex pattern (streaks, irregular shape, etc.) by trowel finishing, roller finishing, etc. May be formed.

  The synthetic resin emulsion may be an emulsion of a synthetic resin constituting the intermediate coating layer 30. The siding material 10 is excellent in weather resistance, solvent resistance, water resistance, adhesion, flexibility, water absorption resistance, impact resistance, and the like. From the viewpoint of obtaining an acrylic resin emulsion, a silicone resin emulsion, a urethane resin emulsion, and a fluororesin emulsion.

The viscosity of the mixture of the synthetic resin emulsion and the inorganic particles is preferably 10 to 30 Pa · s, and more preferably 15 to 20 Pa · s. The viscosity is a value measured at 23 ° C. with a B-type viscometer. If the viscosity of the mixture of the synthetic resin emulsion and the inorganic particles is equal to or higher than the lower limit, the intermediate coating layer 30 having a desired pattern can be easily formed, and the thickness of the intermediate coating layer 30 can be reduced. Furthermore, it becomes easy to form an uneven | corrugated pattern in the surface of the intermediate coating layer 30, and it can also suppress that a crack arises during drying. If the viscosity of the mixture of the synthetic resin emulsion and the inorganic particles is not more than the upper limit value, the supply of the synthetic resin emulsion by the supply pump becomes easy in the gun spray coating.
You may add a filler, a film-forming aid, a thickener, a pH adjuster, an antifoamer, etc. to a synthetic resin emulsion as needed. Moreover, in order to adjust a viscosity, you may add water, a solvent, etc. suitably.

  The mixing ratio of the synthetic resin emulsion to the inorganic particles is preferably 20 to 100 parts by mass, more preferably 30 to 70 parts by mass with respect to 100 parts by mass of the inorganic particles. .

Next, a coating material in which the above-described transparent resin is dissolved or dispersed in a solvent is applied on the intermediate coating layer 30 and dried to form the topcoat layer 32.
The coating method of the paint is not particularly limited, and coating by roll coater, knife coater, or reciprocating spraying is preferable.
The drying method is not particularly limited, and examples thereof include drying using a drying furnace.

The siding material of the present invention described above is provided with a primer layer and a design layer having an intermediate coating layer made of a resin composition in which inorganic particles are dispersed in a synthetic resin emulsion on the substrate surface. The design has a profound feeling and texture.
In addition, since the substrate is made of synthetic resin, it is lighter than ceramic siding materials and ALC plates, and it has excellent durability and is resistant to rust caused by salt damage and cracks caused by freezing and thawing. It is. Also, the adhesion between the substrate and the design layer is good.

The siding material of the present invention is not limited to the siding material 10.
For example, in the siding material 10, a structure corresponding to the upper end surface part 16, the upper edge part 18, and the protrusions 20 is provided on one of the side edges of the substrate 12, and a structure corresponding to the bent part 22 and the groove part 26 on the other side edge. May be a siding material. In the case of the siding material, attachment is performed from left to right or from right to left of the attachment surface.

EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited by the following description.
[Example 1]
As a synthetic resin, a vinyl chloride resin (trade name “TK-1000”, manufactured by Shin-Etsu Chemical Co., Ltd.) is blended with a stabilizer (Ca—Zn stabilizer) and an impact modifier (MBS modifier), and extrusion molding is performed. A substrate having a width of 16 mm, a working width of 450 mm and a thickness of 4 mm, corresponding to the substrate 12 of the siding material 10 illustrated in FIG.
An acrylic urethane resin primer and an isocyanate curing agent were mixed, applied onto the substrate with a spray gun, and dried at room temperature for 12 hours to form a primer layer having a thickness of 0.10 mm. 50 parts by mass of ceramic aggregate particles (particle size 0.05 mm) and colored silica sand (particle size 0.05 mm) as inorganic particles are mixed with 30 parts by mass of fluororesin emulsion, and the viscosity of the mixture is adjusted to 15 Pa · s. did. Using a snake pump, the mixture was applied onto the primer layer with a spray gun having a diameter of 6 mm, and dried at room temperature for 24 hours to form a 1.5 mm thick intermediate coating layer to obtain a siding material. It was.

The obtained siding material was subjected to an impact resistance test in which 1 kg of steel balls were dropped from a height of 1 m and 1.5 m at 23 ° C. and −30 ° C., respectively. I couldn't.
Moreover, when the Charpy impact test prescribed | regulated to JISK7111 was performed with respect to the said board | substrate using the Charpy impact test machine (the Toyo Seiki Seisakusho make, impact test machine), it is 22 kJ / m < ² >, 0 degreeC in 23 degreeC. It was 13 kJ / ^{m 2} at.
Moreover, when the tensile impact test prescribed | regulated to JIS K7160 was done with respect to the said board | substrate using the tensile test machine (the Toyo Seiki Seisakusho make, impact test machine), it was 900 kJ / m < ² > at 23 degreeC. .

[Example 2]
In the same manner as in Example 1, a substrate having a width of 450 mm, a working width of 1 m, and a thickness of 4 mm was produced. A primer layer and an intermediate coating layer were formed on the substrate in the same manner as in Example 1 to obtain a siding material.
Using a dynamic wind pressure test apparatus (Honda Kogyo Co., Ltd.), a wind pressure resistance performance test defined in JIS A1414 was performed. A vertical column was supported at a pitch of 450 mm on a 2 m square wooden frame member, and a total of eight siding members, two in the horizontal direction and four in the vertical direction, were attached to obtain a test specimen. When the test body was installed in a dynamic wind pressure test apparatus and the situation was confirmed with respect to deformation and breakage of the siding material when 3000 Pa was applied as a positive pressure, the maximum deformation amount was 15 mm and was not damaged. Moreover, when the situation was confirmed about the deformation | transformation and damage of a siding material when pressurizing 1600 Pa as a negative pressure, the maximum deformation amount was 35 mm and it was not damaged.

  DESCRIPTION OF SYMBOLS 10 ... Siding material, 12 ... Board | substrate, 14 ... Design layer, 16 ... Upper end surface part, 18 ... Upper edge part, 18a ... Mounting hole, 20 ... Projection, 22 ...... Bent part, 24 ... projection, 26 ... groove, 28 ... primer layer, 30 ... intercoat layer, 32 ... topcoat layer.

Claims (5)

A synthetic resin substrate and a design layer formed on the substrate;
A siding material in which the design layer has a primer layer formed on the substrate, and an intermediate coating layer formed on the primer layer and made of a resin composition in which inorganic particles are dispersed in a synthetic resin.   The siding material according to claim 1, wherein the design layer further includes a topcoat layer formed on the intermediate coating layer.   3. The siding material according to claim 1, wherein at 23 ° C. and −30 ° C., no damage occurs even if a 1 kg steel ball is dropped from a height of 1 m. The said board | substrate is 18 kJ / m < ² > or more in 23 degreeC impact strength in the Charpy impact test prescribed | regulated to JISK7111, The impact strength in 0 degreeC is 12 kJ / m < ² > or more. Siding material. 3. The siding material according to claim 1, wherein the substrate has an impact strength at 23 ° C. of 800 kJ / m ² or more in a tensil impact test defined by JIS K7160.

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