JP2024078974A - Structure protection sheet - Google Patents

Abstract

To provide a structure protection sheet that is easy to handle when attached to the roof of a structure, and can protect the structure for a long period of time without causing wrinkles or forming gaps between the structure and the roof.
[Solution] A structure protection sheet to be attached to the roof of a structure, the structure protection sheet having a structure in which an adhesive layer, a reinforcing layer, a hardened polymer cement layer and a resin layer are provided in this order from the side to be attached to the roof of the structure, the hardened polymer cement layer has a reinforcing layer embedded therein, and the thickness of the reinforcing layer is 42 to 62% of the thickness of the hardened polymer cement layer.
[Selected Figure] Figure 1

Description

The present invention relates to a structure protection sheet. More specifically, the present invention relates to a structure protection sheet that is easy to handle when attached to the roof of a structure, and can protect the structure for a long period of time without wrinkles or gaps between the structure and the roof.

The roofs of structures such as residential homes and commercial buildings can deteriorate due to long-term exposure to wind and rain, or be damaged by disasters such as typhoons, which can cause leaks.
When the roof of a structure deteriorates or becomes damaged, emergency measures are required. Currently, emergency measures for the roof of a structure typically involve placing a blue tarp 31 to cover the damaged area of the roof 30, and placing multiple sandbags 32 on top of the blue tarp 31 as a weight, as shown in FIG. 4.
In addition to the method of placing the blue tarp 31 using weights such as sandbags 32, for example, Patent Documents 1 and 2 propose a method of fixing the blue tarp using bags filled with water.

Utility Model Registration No. 3225057 Utility Model Registration No. 3116572

However, while slate roofs are widely used as building roofs, slate roofs are non-flat, with a surface having multiple parallel steps. When repairing such roofs using conventional blue tarps, it is difficult to prevent the tarp from wrinkling, and there is also a problem that gaps exist between the tarp and the roof, making it impossible to prevent water from entering through these gaps.
In addition, blue tarps are usually not very weather resistant, so they deteriorate within a year or so and require replacement.

The present invention was made in consideration of the current situation, and its purpose is to provide a structure protection sheet that is easy to handle when attached to the roof of a structure, and can protect the structure for a long period of time without wrinkling or forming gaps between the structure and the roof.

As a result of intensive research into a structure protection sheet used to protect the roof of a structure, the inventors have found that a structure protection sheet having a laminated structure of an adhesive layer, a hardened polymer cement layer, and a resin layer, in which a reinforcing layer is embedded in the hardened polymer cement layer having a predetermined thickness, can eliminate gaps between the structure and the roof when attached to the roof of a structure, and can further impart performance to the structure protection sheet according to the characteristics of the roof, specifically, the structure protection sheet has conformability to follow cracks and expansion that occur in a slate roof, waterproofing that does not allow deterioration factors such as water and chloride ions to penetrate, salt insulation, neutralization prevention, and water vapor permeability that can discharge moisture in the roof as water vapor, and also has a layer that ensures the appropriate strength and elongation of the structure protection sheet itself, thereby completing the present invention. This technical concept can also be applied as a protection method using a structure protection sheet for members other than the roof of a structure, such as the walls, eaves, fences, gateposts, gates, and gate roofs of a structure.

The present disclosure (1) is a structure protection sheet to be attached to the roof of a structure, and has a structure in which an adhesive layer, a hardened polymer cement layer, and a resin layer are provided in this order from the side to be attached to the roof of the structure, and the hardened polymer cement layer has a reinforcing layer embedded therein, and the thickness of the reinforcing layer is 42 to 62% of the thickness of the hardened polymer cement layer.

According to this invention, by having a reinforcing layer embedded in a hardened layer of polymer cement, a structure protection sheet can be obtained that has appropriate tensile strength and elongation, which makes it easy to handle when attaching it to the roof of the structure, protects the structure for a long period of time without the occurrence of wrinkles or the formation of gaps between the structure and the roof, and further makes it possible to impart performance according to the characteristics of the structure's roof.
In addition, the structural protection sheet can be mass-produced using coating and drying processes on a factory production line, which reduces costs, significantly shortens on-site work time, and enables long-term protection of structures.
Furthermore, since an adhesive layer is formed in advance on the surface of the hardened polymer cement layer, it is possible to attach the structure protection sheet to the roof of the structure via the adhesive layer without applying adhesive at the work site to form an adhesive layer, resulting in extremely excellent work efficiency.

Disclosure (2) is a structure protection sheet as described in Disclosure (1) having a tensile strength of 5.0 MPa or more based on JIS L1913:2010 General Nonwoven Fabric Testing Method.

This invention provides sufficient tensile strength to prevent tearing even when pulled when attaching to the roof of a structure, and allows for gap-free attachment to roofs of various shapes.

Disclosure (3) is a structure protection sheet according to disclosure (1) or (2) having an elongation rate of 15.0% or less based on JIS L1913:2010 General Nonwoven Fabric Testing Method.

According to this invention, the structure protection sheet of the present invention exhibits moderate stretch when applied to the roof of a structure, making it easy to apply without gaps to roofs of various shapes.

Disclosure (4) is a structure protection sheet according to disclosure (1), (2), or (3), in which the reinforcing layer is unevenly distributed on the adhesive layer side in the thickness direction of the cured polymer cement layer.

According to this invention, the structure protection sheet according to the present invention can be easily obtained by embedding the reinforcing layer in the hardened layer of polymer cement before hardening, and the obtained structure protection sheet has an adhesive layer with sufficient adhesiveness.

The present disclosure (5) is a structure protection sheet according to the present disclosure (1), (2), (3), or (4) having an uneven shape on the surface of the adhesive layer side of the cured polymer cement layer.

This invention makes it possible to improve the adhesion between the adhesive layer and the hardened polymer cement layer.

The present disclosure (6) is a structure protection sheet according to the present disclosure (1), (2), (3), (4) or (5), in which the polymer cement cured layer is a layer containing a cement component and a resin, and the resin is contained in an amount of 10% by weight or more and 40% by weight or less.

According to this invention, the polymer cement hardened layer is a layer with excellent compatibility and excellent conformability, so the layer itself has excellent adhesion. Furthermore, the cement component contained in the polymer cement hardened layer on the structure side acts to increase adhesion with structures such as concrete.

The present disclosure (7) is a structure protection sheet according to the present disclosure (1), (2), (3), (4), (5), or (6), in which the reinforcing layer is made of cheesecloth.

This invention makes it easy to set the tensile strength and elongation of the structure protection sheet according to the present invention within the above-mentioned ranges, and allows for extremely efficient attachment to the roof of the structure.

The present invention relates to a structure protection sheet used on the surface of a roof of a structure. When a conventional structure protection sheet was actually applied to the roof of a structure, it had a problem that it was easily torn and difficult to apply because it was applied by pulling it slightly by hand. For example, when a nonwoven fabric was laminated on the structure protection sheet, the occurrence of tearing when pulled by hand was greatly improved, but it was found that the amount of elongation was larger than expected and it was difficult to apply.
Therefore, the present invention provides a structure protection sheet that has a reinforcing layer, such as cheesecloth, that can impart appropriate tensile strength and elongation, thereby making it easier to apply to the surface of a structure's roof and improving efficiency by laminating the sheet with a reinforcing layer that can impart appropriate tensile strength and elongation, resulting in less elongation and sufficient tensile strength.
According to the present invention, a structure protection sheet can be provided which has excellent handleability when attached to the roof of a structure and can protect the structure for a long period of time without causing wrinkles or forming gaps with the roof of the structure.
In particular, it is possible to provide a structure protection sheet that can be provided with performance that corresponds to the characteristics of the surface of the structure, can accommodate cracks and expansion that occur on the surface of the structure, can prevent deterioration factors such as water and chloride ions from penetrating the surface of the structure, can have permeability that allows moisture and deterioration factors to be expelled from within the structure, and can improve strength.
Furthermore, at the construction site, the paint for repairing leaks has the advantage of improving the stability and uniformity of quality compared to the method of manually applying multiple layers.

1A and 1B are cross-sectional configuration diagrams showing an example of a structure protection sheet according to the present invention. 1A and 1B are schematic diagrams showing how the structure protection sheet according to the present invention is attached to a structure. 1A and 1B are schematic diagrams showing an example of a reinforcing layer of a structure protection sheet according to the present invention. FIG. 1 is an explanatory diagram of a conventional roof repair method.

The structure protection sheet of the present invention and the application method of the structure protection sheet will be described below with reference to the drawings. Note that the present invention is not limited to the following description and the forms shown in the drawings, and various modifications are possible as long as the technical characteristics are maintained.

[Structure protection sheet]
The structure protection sheet according to the present invention is used by being attached to the roof of a structure, and when attached to the roof of the structure, a resin layer is provided on the outermost surface.
As shown in Fig. 1, the structure protection sheet 10 according to the present invention has an adhesive layer 14, a hardened polymer cement layer 12, and a resin layer 13 provided in this order, with a reinforcing layer 15 embedded in the hardened polymer cement layer 12. Both the hardened polymer cement layer 12 and the resin layer 13 may be formed as single layers as shown in Fig. 1(A) or may be formed as a laminate as shown in Fig. 1(B). Depending on the required performance, another layer may be provided between the hardened polymer cement layer 12 and the resin layer 13.

The structure protection sheet 10 according to the present invention preferably has a water vapor transmission rate of 10 to 50 g/m ² ·day. Since the polymer cement cured layer 12 contains a cement component, it is expected to have a certain degree of water vapor transmission rate, but it is assumed that the resin layer 13 provided on the polymer cement cured layer 12 will have a poor water vapor transmission rate. However, such a problem does not occur in the present invention, and since the water vapor transmission rate of the entire structure protection sheet 10 is within a predetermined range, the water vapor inside can be suitably transmitted and discharged to the outside after being attached to the roof of a structure such as concrete, so that the occurrence of blisters can be suitably prevented, and further, the deterioration of adhesiveness can be prevented. The advantage of having a water vapor transmission rate within a predetermined range is that the structure allows steam to escape easily, which tends to suppress corrosion of metals (e.g., reinforcing bars) in the structure. Furthermore, when the structure protection sheet 10 is applied to the roof of a structure on a rainy day, the roof of the structure gets wet and the structure itself is moistened during application, but since the structure protection sheet 10 has the above water vapor transmission rate, moisture that has soaked into the structure after application (after the reinforced structure is manufactured) can easily escape to the outside. Furthermore, concrete immediately after hardening contains a lot of moisture inside, and the structure protection sheet 10 of the present invention can be suitably used on such concrete as well.
Another advantage of the structure protection sheet 10 according to the present invention is that, because its water vapor transmission rate can be controlled, it can be attached to the roof of a structure even when the cement of the structure is not yet hardened. In other words, if moisture is rapidly lost when molding and hardening cement, the cement becomes porous and the strength of the structure tends to decrease, but by attaching the structure protection sheet 10 according to the present invention to cement before it hardens, it is possible to control the speed at which moisture is removed when the cement hardens, which has the advantage of making it easier to avoid the formation of the porous structure.
If the water vapor transmission rate is less than 10 g/ ^m2 ·day, the structure protection sheet 10 according to the present invention cannot transmit water vapor sufficiently, and the blistering phenomenon after application to the roof of the structure cannot be prevented, resulting in insufficient adhesion. If it exceeds 50 g/ ^m2 ·day, the speed of water removal during cement hardening becomes excessively fast, which may cause the hardened cement to become porous. The preferred range of the water vapor transmission rate is 20 to 50 g/ ^m2 ·day.
The structure protection sheet 10 according to the present invention having such a water vapor permeability can be obtained, for example, by using a hardened polymer cement layer 12 described below and a resin having a predetermined water vapor permeability for the resin layer 13.
The water vapor transmission rate in the present invention can be measured by the method described below.

The structure protection sheet according to the present invention may be used in a state where two or more layers are stacked together, so that the roof of a structure protected by the structure protection sheet according to the present invention can be further protected by stacking the layers together, and for example, when two structure protection sheets according to the present invention are attached side by side, another structure protection sheet according to the present invention can be attached so as to cover the boundary between these structure protection sheets.
In the structure protection sheet 10 according to the present invention, the hardened polymer cement layer 12 contains a cement component and a resin component, and therefore exhibits suitable adhesion to the resin layer 13 of the structure protection sheet 10 according to the present invention that has been previously applied to the roof of a structure. Therefore, the structure protection sheet 10 according to the present invention can be suitably used in a layered state.

The structure protection sheet 10 according to the present invention preferably has a thickness distribution within ±100 μm. With the thickness distribution within the above range, even an unskilled worker can stably provide a layer with little thickness variation on the roof of a structure with the structure protection sheet 10. Furthermore, by controlling the thickness distribution within the above range, it becomes easier to uniformly reinforce the structure.
The polymer cement hardened layer 12 provided on the roof side of the structure has excellent adhesion to the roof of the structure, and the resin layer 13 provided on the polymer cement hardened layer 12 can easily be imparted with excellent properties such as waterproofing, salt resistance, and neutralization prevention.
Furthermore, the structure protection sheet 10 of the present invention can be mass-produced by coating and drying processes on a factory production line, which reduces costs, significantly shortens on-site work time, and achieves long-term protection of the structure's roof.

Furthermore, structure protection sheet 10 according to the present invention has reinforcing layer 15 embedded in hardened polymer cement layer 12. The presence of reinforcing layer 15 brings the tensile strength and elongation of structure protection sheet 10 according to the present invention into an appropriate range when applied to the roof of a structure, making it possible to prevent tearing and suppressing elongation when pulled, allowing the sheet to be attached to the roof of a structure without gaps.
In this specification, the "reinforcing layer" refers to a layer that can impart appropriate tensile strength and elongation to the structure protection sheet according to the present invention.

The structure protection sheet 10 according to the present invention having such a reinforcing layer 15 preferably has a tensile strength of 5.0 MPa or more based on JIS L1913:2010 General Nonwoven Fabric Testing Method. When the tensile strength is 5.0 MPa or more, the structure protection sheet 10 according to the present invention has sufficient strength and can be suitably prevented from breaking even when pulled when attached to the roof of a structure. The tensile strength is more preferably 5.6 MPa or more, and even more preferably 6 MPa or more.
In addition, the structure protection sheet 10 according to the present invention preferably has an elongation percentage of 15.0% or less based on JIS L1913:2010 General Nonwoven Fabric Testing Method. By having the elongation percentage of 15.0% or less, it is possible to suitably prevent the structure protection sheet 10 according to the present invention from being excessively elongated when pulled when attaching it to the roof of a structure, resulting in the generation of a gap between the roof. A more preferable upper limit of the elongation percentage is 11.2%.

The structure protection sheet 10 according to the present invention also has an adhesive layer 14 between the reinforcing layer 15 and the roof of the structure. By providing the adhesive layer 14, there is no need to apply an adhesive at the work site to form an adhesive layer, and even non-expert craftsmen can easily attach the sheet to the roof of the structure via an adhesive layer of uniform thickness. As a result, the construction time required for attaching the sheet to the roof of the structure can be significantly reduced, and the roof of the structure can be protected for a long period of time.

Specific examples of each component are explained in detail below.

[roof]
There are no particular limitations on the structure having a roof to which the structure protection sheet according to the present invention can be attached, and examples include ordinary houses, and large structures such as gymnasiums, hospitals, and public facilities.
The shape of the roof of the above-mentioned structure is not particularly limited, and any shape such as a gabled roof, hipped roof, square roof, flat roof, single-pitch roof, beckoning roof, and semi-cylindrical roof can be used.
Specific examples of the roofs of the above-mentioned structures include slate roofs, roofs made of Galvalume steel sheet (registered trademark), tin roofs (roofs made of zinc-plated steel sheet), metal roofs made of painted iron, and concrete roofs including flat roofs (called "rikuyane" or "rokuyane").
Slate is a material that has an inorganic coating applied to an inorganic decorative (cement) layer provided on a cement layer, with an inorganic coating layer interposed between the inorganic coating and the cement layer, and is widely used as a roofing material for ordinary houses because it has a simple appearance, a wide variety of colors, is light, and is inexpensive. However, slate roofs are more likely to crack than roofs made of Galvalume Steel Sheets (registered trademark), and have lower durability and waterproofing than roofs made of other materials, making them more susceptible to problems such as breakage, making them particularly suitable as roofs to which the structure protection sheet of the present invention is attached.
In the following description, the roof of a structure will also be referred to as a "slate roof, etc."
The surface of the roof of the above-mentioned structure may be flat, or may have irregularities to the same extent as a typical slate roof, etc. In particular, in the present invention, a structure protection sheet having a specific configuration is applied to the roof of the structure, so that even if the roof of the structure has an irregular surface such as a slate roof, no gaps are formed.
In addition, by applying the structure protection sheet of the present invention to the roof of a structure, it is possible to follow any cracks or expansion that occur in the roof of the structure, and it has the special advantage of being able to discharge moisture inside the roof of the structure as water vapor without allowing deterioration factors such as water and chloride ions to penetrate into the interior of the roof of the structure. In particular, in the case of slate roofs and the above-mentioned flat roofs, which are materials that tend to accumulate rainwater, the ability to discharge water vapor is highly effective in preventing deterioration of the material.

(polymer cement hardened layer)
The hardened polymer cement layer 12 is a layer disposed on the roof side of the structure relative to the resin layer 13. This hardened polymer cement layer 12 may be a single layer as shown in Fig. 1(A) or a laminated layer as shown in Fig. 1(B), but whether it is a single layer or a laminated layer is arbitrarily set in consideration of the overall thickness, the functions to be imparted (following ability, adhesion to the structure, etc.), the production line of the factory, production costs, etc., and for example, when the production line is too short to achieve the desired thickness with a single layer, it can be formed by applying two or more layers. For example, when applying two layers, the second layer is formed after the first layer is dried.
The hardened polymer cement layer 12 may be configured by laminating layers of different properties. For example, by forming a layer having a higher ratio of resin components on the resin layer 13 side, the layer with a higher resin component will adhere to the resin layer, and the layer with a higher cement component will adhere to the concrete structure, resulting in excellent adhesion to both layers.

The hardened polymer cement layer 12 is obtained by forming a resin (resin component) containing a cement component into a paint and applying the paint.
Examples of the cement component include various cements, limestones containing a component made of calcium oxide, clays containing silicon dioxide, etc. Among them, cement is preferable, and examples thereof include Portland cement, alumina cement, high-early-strength cement, and fly ash cement. The cement to be selected is selected according to the characteristics that the polymer cement hardened layer 12 should have, for example, the degree of conformability to the concrete structure is taken into consideration. In particular, Portland cement as specified in JIS R5210 is preferable.

Examples of the resin component include acrylic resin, acrylic urethane resin, acrylic silicone resin, fluororesin, soft epoxy resin, polybutadiene rubber, acrylic resin exhibiting rubber properties (e.g., synthetic rubber having acrylic ester as a main component), etc. From the viewpoint of enhancing adhesion between the hardened polymer cement layer 12 and the resin layer 13, it is preferable that such a resin component is the same as the resin component constituting the resin layer 13 described below.
The resin component may be any of a thermoplastic resin, a thermosetting resin, and a photocurable resin. The term "cured" in the polymer cement cured layer 12 does not mean that the resin component is limited to a resin that cures and polymerizes, such as a thermosetting resin or a photocurable resin, but means that a material that cures when it becomes a final layer may be used.

The content of the resin component is adjusted appropriately depending on the materials used, etc., but is preferably 10% by weight or more and 40% by weight or less based on the total amount of the cement component and the resin component. If it is less than 10% by weight, there may be a tendency for the adhesion to the resin layer 13 to decrease and for it to become difficult to maintain the polymer cement hardened layer 12 as a layer, and if it exceeds 40% by weight, the adhesion to the structure may be insufficient. From the above viewpoint, the content of the resin component is more preferably in the range of 15% by weight or more and 35% by weight or less, and even more preferably 20% by weight or more and 30% by weight or less.

The coating material for forming the hardened polymer cement layer 12 is preferably a coating liquid in which a cement component and a resin component are mixed in a solvent. The resin component is preferably an emulsion. For example, an acrylic emulsion is polymer fine particles obtained by emulsion-polymerizing a monomer such as an acrylic acid ester using an emulsifier. A preferred example is an acrylic acid polymer emulsion obtained by polymerizing a monomer or a monomer mixture containing one or more of an acrylic acid ester and a methacrylic acid ester in water containing a surfactant.
The content of the acrylic acid ester and the like constituting the acrylic emulsion is not particularly limited, but is selected within the range of 20 to 100% by mass. A surfactant is also blended in an amount according to need, and the amount is not particularly limited, but an amount of the surfactant sufficient to form an emulsion is blended.

The hardened polymer cement layer 12 is formed by applying the coating liquid onto a release sheet and then drying and removing the solvent (preferably water). For example, a mixed composition of a cement component and an acrylic emulsion is used as the coating liquid to form the hardened polymer cement layer 12. Note that, on the release sheet, the resin layer 13 may be formed after the hardened polymer cement layer 12 is formed, or the resin layer 13 may be formed on the release sheet and then the hardened polymer cement layer 12 is formed.
Specifically, for example, the resin layer composition described below is coated onto a process paper serving as a release sheet, and after drying, a coating liquid for a polymer cement is applied. Reinforcing layer 15 is attached in a wet state before drying and then dried, and then adhesive layer 14 is formed on the surface of reinforcing layer 15, thereby producing structure protection sheet 10 according to the present invention.
The structure protection sheet according to the present invention may have a structure in which a coating liquid for forming a hardened polymer cement layer is further applied to the surface to which reinforcing layer 15 is bonded, and then dried, so that the reinforcing layer is present inside the hardened polymer cement layer.
It is also possible to obtain a structure protection sheet in which a reinforcing layer is present in a polymer cement cured layer by coating the resin layer composition on a process paper as a release sheet, drying the coating liquid for the polymer cement cured layer, laminating the reinforcing layer in the wet state before drying, and then coating the coating liquid for the polymer cement cured layer on the surface to which the reinforcing layer is laminated without going through a drying step, forming an adhesive layer 14, and then drying the entire structure.

In the present invention, the thickness of the hardened polymer cement layer 12 is appropriately adjusted so that the relationship with the thickness of the reinforcing layer 15 satisfies the relationship described below, and is preferably, for example, 360 to 500 μm. If the thickness is less than 360 μm, the reinforcing layer 15 may be embedded in the hardened polymer cement layer 12 unevenly, and the reinforcing layer 15 may become an interface with the adhesive layer 14, causing the adhesive layer to adhere insufficiently to the hardened polymer cement layer 12. Furthermore, when the reinforcing layer 15 is exposed from the surface of the hardened polymer cement layer 12 and the reinforcing layer 15 is a cheesecloth described below, the uneven shape of the cheesecloth may appear on the surface of the adhesive layer 14, exposing gaps, and moisture may enter the gaps due to capillary action. On the other hand, if the thickness exceeds 500 μm, air entrapped when the reinforcing layer 15 is embedded in the hardened polymer cement layer 12 cannot be discharged, and voids may be formed between the hardened polymer cement layer 12 and the resin layer 13.
The more preferable lower limit of the thickness of the hardened polymer cement layer 12 is 400 μm, and the more preferable upper limit is 450 μm.

Due to the presence of the cement component, water vapor can easily pass through this polymer cement hardened layer 12 compared to the resin layer 13 described below. The water vapor transmission rate at this time is, for example, about 20 to 60 g/ ^m2 ·day. Furthermore, the cement component has good compatibility with the cement component constituting concrete, for example, and can have excellent adhesion to the concrete surface. Furthermore, since the structure protection sheet 10 has the adhesive layer 14, the polymer cement hardened layer 12 containing the cement component adheres to the adhesive layer 14 with good adhesion. Furthermore, since the polymer cement hardened layer 12 has extensibility, it can follow the changes in the concrete even if cracks or expansion occur in the roof of the structure.

(Reinforcing layer)
The present invention has a reinforcing layer 15 embedded in the hardened polymer cement layer 12 .
By providing the structure protection sheet 10 according to the present invention with the reinforcing layer 15, the structure protection sheet according to the present invention can have sufficient strength and an appropriate elongation rate.

The reinforcing layer 15 may be embedded inside the hardened polymer cement layer 12, but is preferably unevenly distributed on the adhesive layer 14 side in the thickness direction of the hardened polymer cement layer 12. By having the reinforcing layer 15 unevenly distributed on the adhesive layer 14 side in the hardened polymer cement layer 12, an appropriate uneven shape is formed on the surface of the hardened polymer cement layer 12 on the adhesive layer 14 side, which ensures sufficient adhesion of the adhesive layer 14 and provides excellent adhesion to the roof of the structure.
In this specification, “biasedly located on the adhesive layer side in the thickness direction of the polymer cement hardened layer” means that the middle part of the thickness of the reinforcing layer 15 is located closer to the adhesive layer 14 side than the middle part of the thickness of the polymer cement hardened layer 12.

In the present invention, it is preferable that the surface of the polymer cement cured layer 12 on the adhesive layer 14 side has an uneven shape. The uneven shape can improve the adhesion between the polymer cement cured layer 12 and the adhesive layer 14. The uneven shape is preferably an uneven shape derived from the reinforcing layer 15 embedded in the polymer cement cured layer 12. When the reinforcing layer 15 is completely embedded in the polymer cement cured layer 12, the uneven shape derived from the reinforcing layer 15 is hardly formed. However, when the reinforcing layer 15 is embedded near the surface of the polymer cement cured layer 12 on the adhesive layer 14 side or when a part of the reinforcing layer 15 is exposed from the surface of the polymer cement cured layer 12 on the adhesive layer 14 side, the uneven shape derived from the reinforcing layer 15 is formed.

Specifically, the uneven shape formed on the hardened polymer cement layer 12 preferably has an arithmetic mean roughness Ra of 5.0 to 8.5 μm and a maximum height roughness Rz of 45 to 80 μm as specified in JIS B0601 (2013). By having an uneven shape that satisfies the above-mentioned Ra and Rz, it is possible to improve the adhesion between the hardened polymer cement layer 12 and the adhesive layer 14, and to provide excellent adhesion to structures.

The reinforcing layer 15 may have a structure in which warp and weft fibers are arranged in a lattice pattern, as shown in FIG.
The above-mentioned fibers are preferably composed of at least one type of fiber selected from the group consisting of polypropylene-based fibers, vinylon-based fibers, carbon fibers, aramid fibers, glass fibers, polyester fibers, polyethylene fibers, nylon fibers, and acrylic fibers, and among these, polypropylene fibers and vinylon fibers can be preferably used.
The shape of the reinforcing layer 15 is not particularly limited, and in addition to the biaxially woven fabric shown in FIG. 3, any reinforcing layer 15 such as a triaxially woven fabric can be used.
The reinforcing layer 15 may be made of high-strength vinylon mesh for civil engineering, vinylon for agricultural use, or cheesecloth made of polyester or the like.

The reinforcing layer 15 desirably has a line pitch of 50 mm to 1.2 mm (line density of 0.2 to 8.0 lines/cm). If the pitch is less than 1.2 mm, the material constituting the hardened polymer cement layer 12 will not be sufficiently filled between the fibers constituting the reinforcing layer 15, which may result in insufficient surface strength of the structure protection sheet 10. If the line pitch exceeds 50 mm, the surface strength of the structure protection sheet 10 will not be adversely affected, but the tensile strength may be weakened.
In the structure protection sheet 10 according to the present invention, there is a trade-off between tensile strength and surface strength, and the reinforcing layer 15 suitable for use in the present invention has a line pitch in the range of 50 mm to 1.2 mm.

Reinforcing layer 15 may be large enough to cover the entire surface of hardened polymer cement layer 12 when viewed from the top side of hardened polymer cement layer 12 , or may be smaller than hardened polymer cement layer 12 .
That is, the area of the reinforcing layer 15 in plan view may be the same as or smaller than the area of the hardened polymer cement layer 12 in plan view, but the area of the reinforcing layer 15 in plan view is preferably 60% or more and 95% or less of the area of the hardened polymer cement layer 12 in plan view. If it is less than 60%, the tensile strength of the structure protection sheet 10 according to the present invention may be insufficient, the elongation rate may be large, and the strength may vary. If it exceeds 95%, in the case of a configuration in which the hardened polymer cement layer 12 is laminated via the reinforcing layer 15, the adhesive strength between the hardened polymer cement layers 12 may be poor, and when the structure protection sheet 10 according to the present invention is applied to the roof of a structure, the risk of peeling off the hardened polymer cement layer 12 increases. The area of the reinforcing layer 15 and the like in plan view can be measured by a known method.

In the structure protection sheet 10 according to the present invention, the thickness of the reinforcing layer 15 is 42 to 62% of the thickness of the hardened polymer cement layer 12. By having the above-mentioned relationship between the thickness of the reinforcing layer 15 and the thickness of the hardened polymer cement layer 12, the structure protection sheet 10 according to the present invention can have excellent adhesion between the adhesive layer 14 and the hardened polymer cement layer 12, appropriate tensile strength and elongation, excellent handling when attached to the roof of the structure, and can protect the structure for a long period of time without the occurrence of wrinkles or the formation of gaps with the roof of the structure. The lower limit of the range of the thickness of the reinforcing layer 15 relative to the thickness of the hardened polymer cement layer 12 is preferably 45%, and the upper limit is preferably 55%.

(Resin Layer)
The resin layer 13 is a layer that is disposed on the opposite side of the structure from the roof and appears on the surface. The resin layer 13 may be, for example, a single layer as shown in FIG. 1(A), or may be a laminate consisting of at least two layers as shown in FIG. 1(B). The decision as to whether to form a single layer or a multilayer is made in consideration of the overall thickness, the functions to be imparted (waterproofing, salt blocking, neutralization prevention, water vapor permeability, etc.), the length of the factory production line, production costs, etc., and, for example, if the production line is too short to achieve a predetermined thickness with a single layer, two or more layers can be applied in layers. In addition, in the case of applying multiple layers, the second layer is applied after the first layer is dried. The second layer is then dried.

The resin layer 13 is obtained by applying a coating material that is flexible, can follow cracks and fissures that occur on the roof of the structure, and has excellent waterproofing, salt-proofing, neutralization prevention, and water vapor permeability. Examples of resins that make up the resin layer 13 include acrylic resins that exhibit rubber properties (e.g., synthetic rubbers that have acrylic esters as their main component), acrylic urethane resins, acrylic silicone resins, fluororesins, soft epoxy resins, and polybutadiene rubber. This resin material is preferably the same as the resin components that make up the hardened polymer cement layer 12 described above. In particular, it is preferable that the resin contains an elastic film-forming component such as rubber.

Of these, it is preferable that the acrylic resin exhibiting rubber characteristics is made of an aqueous emulsion of an acrylic rubber copolymer, because of its excellent safety and coatability. The proportion of the acrylic rubber copolymer in the emulsion is, for example, 30 to 70% by mass. The acrylic rubber copolymer emulsion is obtained, for example, by emulsion polymerization of monomers in the presence of a surfactant. The surfactant may be anionic, nonionic, or cationic.

The resin layer 13 may be formed, for example, by preparing a mixed coating liquid of the above-mentioned resin and a solvent, applying the coating liquid to a release sheet, and then drying and removing the solvent. The solvent may be water or a water-based solvent, or an organic solvent such as xylene or mineral spirits. In the examples described below, a water-based solvent is used, and the resin layer 13 is made of an acrylic rubber composition. The order of the layers formed on the release sheet is not limited, and may be, for example, the resin layer 13 and the hardened polymer cement layer 12 as described above, or the hardened polymer cement layer 12 and the resin layer 13.

The thickness of the resin layer 13 is set arbitrarily depending on the type of use, age, shape, etc. of the roof of the structure. As an example, the thickness is set to any value within the range of 50 to 200 μm, and it is preferable that the thickness variation is within ±50 μm. This level of thickness precision is impossible to achieve by on-site coating, but can be achieved reliably on a factory production line.

This resin layer 13 has high waterproofing, salt-proofing, and carbonation-preventing properties, but is preferably permeable to water vapor. The water vapor transmission rate at this time is desirably about 10 to 50 g/ ^m2 ·day, for example. This allows the structure protection sheet 10 to have high waterproofing, salt-proofing, carbonation-preventing properties, and a predetermined water vapor transmission property. Furthermore, by being composed of the same type of resin component as the hardened polymer cement layer 12, it is possible to provide a sheet with good compatibility with the hardened polymer cement layer 12 and excellent adhesion. The water vapor transmission property was measured in accordance with JIS Z0208 "Test method for moisture transmission property of moisture-proof packaging material".

Furthermore, the resin layer 13 may contain a pigment from the viewpoint of providing the structure protection sheet 10 with a wide range of color variations.
The resin layer 13 may contain an inorganic substance. By containing an inorganic substance, scratch resistance can be imparted to the resin layer 13. The inorganic substance is not particularly limited, and examples thereof include conventionally known materials such as metal oxide particles such as silica, alumina, and titania.
Furthermore, the resin layer 13 may contain a known antifouling agent. Since the structure protection sheet 10 is usually used to repair concrete structures installed outdoors, the resin layer 13 is often contaminated, but by containing an antifouling agent, it is possible to suitably prevent contamination of the structure protection sheet 10. The above-mentioned antifouling agent is not particularly limited, and examples thereof include conventionally known materials.
Furthermore, the resin layer 13 may contain additives capable of imparting various functions, such as cellulose nanofiber.

(Adhesive layer)
In the present invention, structure protection sheet 10 has adhesive layer 14 provided on the surface of hardened polymer cement layer 12 opposite resin layer 13 (surface facing the roof of the structure).
By providing the adhesive layer 14 on the surface of the hardened polymer cement layer 12, when attaching the structure protection sheet 10 to the roof of the structure, there is no need to apply an adhesive at the work site to form the adhesive layer 14, resulting in extremely excellent work efficiency, and furthermore, the structure protection sheet 10 can be attached to the roof of the structure via the adhesive layer 14 of uniform thickness without the need for a skilled craftsman. Furthermore, by providing the adhesive layer 14, the adhesive layer 14 can be made to fit along the linear steps formed on the roof of the structure, thereby improving the adhesion of the structure protection sheet 10.

The adhesive is not particularly limited, and examples thereof include known adhesives such as acrylic adhesives, silicone adhesives, urethane adhesives, and rubber adhesives, but in the present invention, the adhesive layer is preferably composed of an acrylic adhesive. Acrylic adhesives allow easy adjustment of the adhesive strength to the roof of the structure, provide high freedom in material design, and are also excellent in transparency, weather resistance, and heat resistance, so that the structure protection sheet 10 can more suitably protect the roof of the structure.
The acrylic adhesive is not particularly limited, and a commercially available product can be used. For example, Olivine (registered trademark) BPS6574 (manufactured by Toyochem Co., Ltd.) can be mentioned.

The thickness and lamination amount of the adhesive layer made of the acrylic adhesive is preferably 80 to 120 μm in thickness and 20 g/ ^m2 or more and 250 g/ ^m2 or less in amount, so that sufficient adhesion to the surface of a structure such as concrete can be exhibited.
Furthermore, the adhesive strength when attached to the surface of a structure via the adhesive layer is preferably 0.5 N/ ^mm2 or ^more . If it is less than 0.5 N/mm2, the adhesion of the structure protection sheet 10 to the roof of the structure may be insufficient.

(Release sheet)
In order to protect the surface of the adhesive layer 14, the structure protection sheet 10 preferably has a release sheet 16 attached to the side of the adhesive layer 14 opposite the reinforcing layer 15. Such a release sheet 16 is peeled off when attaching the structure protection sheet 10 to the roof of the structure 21, as shown in Fig. 2(A). Then, as shown in Fig. 2(B), after the adhesive layer 14 is exposed, the structure protection sheet 10 is attached to the roof of the structure 21 from the adhesive layer 14.
Such a release sheet 16 is not particularly limited, and examples thereof include a sheet having a base layer and a release layer.
Examples of materials constituting the base layer include polyesters such as polyethylene terephthalate and polyethylene naphthalate, polyolefins such as polyethylene, polypropylene and polymethylpentene, polyamides such as nylon 6, vinyl resins such as polyvinyl chloride, acrylic resins such as polymethyl methacrylate, cellulose resins such as cellulose acetate, and synthetic resins such as polycarbonate. The base layer may be formed mainly of paper. Furthermore, the base layer may be a laminate of two or more layers.

Examples of materials constituting the release layer include silicone resins, melamine resins, and fluorinated polymers. The release layer can be formed by a coating method in which a coating liquid containing the material constituting the release layer and an organic solvent is applied to the substrate layer by a known method such as gravure coating, roll coating, comma coating, or lip coating, and then dried and cured. In addition, when forming the release layer, the laminated surface of the substrate layer may be subjected to a corona treatment or an easy-adhesion treatment.

The method of installing the structure protection sheet of the present invention involves attaching the above-mentioned structure protection sheet of the present invention to the roof of a structure, so that the structure protection sheet of the present invention can be attached to the roof of the structure without any gaps.
In addition, it can also expel moisture from structures such as concrete, and can protect concrete structures for a long period of time. In particular, it is possible to impart performance to the structure protection sheet according to the characteristics of the structure, to allow it to follow cracks and expansion that occur in the roof of the structure, to prevent deterioration factors such as water and chloride ions from penetrating the roof of the structure, and to impart permeability that allows deterioration factors in the roof of the structure to be expelled.
Furthermore, because these structural protection sheets can be manufactured in factories, they can be mass-produced with stable, high-quality properties. As a result, they can be installed without relying on the skills of craftsmen, shortening construction time and reducing labor costs.

In the method for applying the structure protection sheet according to the present invention, a primer layer containing a curable resin material may be formed on the surface of the roof of the structure.
The curable resin material is not particularly limited as long as it has the property of being cured into a resin by heat curing, photocuring or other methods, but preferably includes an epoxy compound. In this case, the cured primer layer formed by curing the primer layer becomes an epoxy cured product. An epoxy cured product is generally obtained by curing an epoxy compound having two or more epoxy groups with a curing agent. Hereinafter, an example will be described in which an epoxy cured product is used as a primer layer.

Examples of the epoxy compound include bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol S type epoxy resins, ortho-cresol novolac type epoxy resins, alicyclic epoxy resins, aliphatic epoxy resins, diglycidyl ethers of phenols, and diglycidyl ethers of alcohols.
In addition, the curing agent may include polyfunctional phenols, amines, polyamines, mercaptans, imidazoles, acid anhydrides, phosphorus-containing compounds, etc. Among these, the polyfunctional phenols may include monocyclic bifunctional phenols such as hydroquinone, resorcinol, and catechol, polycyclic bifunctional phenols such as bisphenol A, bisphenol F, naphthalenediols, and biphenols, as well as their halides and alkyl group-substituted derivatives. Furthermore, novolacs and resols, which are polycondensates of these phenols and aldehydes, may be used. As the amines, aliphatic or aromatic primary amines, secondary amines, tertiary amines, quaternary ammonium salts, and aliphatic cyclic amines, guanidines, and urea derivatives may be used.
Among the above examples, examples of the material for the primer layer (including the curable resin material) include an epoxy resin primer that uses, for example, a bisphenol A type epoxy or bisphenol F type epoxy base agent and a polyamine or mercaptan curing agent. The epoxy resin primer may contain, in addition to the base agent and curing agent, a coupling agent, a viscosity modifier, and a curing accelerator. For example, Toagosei's two-liquid reactive curing water-based epoxy resin emulsion "Aronbull Coat P-300" (product name, "Aronbull Coat" is a registered trademark of Toagosei) can be used as such a primer layer.

The primer layer is generally used as a primer for the roof of a structure. For example, the primer may be a solvent-type epoxy resin solvent solution, or an epoxy resin emulsion or other general emulsion, or an adhesive, etc., applied to the surface of the structure. In this case, the primer may be applied in a normal manner, for example, by applying the primer to the surface of the structure to be prevented from deterioration with a brush or roller, or by applying the primer to the surface of the structure to be prevented from deterioration with a general method such as spraying with a spray gun, etc., to form a coating film.
The thickness of the primer layer is not particularly limited, but can be preferably within the range of 50 μm or more and 300 μm or less in a wet state. By making it 50 μm or more, it is easy to make the thickness of the primer layer uniform while taking into consideration the penetration of the material of the primer layer into the structure such as concrete, and it is easy to ensure the adhesion between the roof of the structure and the structure protection sheet. The upper limit of the thickness of the primer layer is not particularly limited, but it is preferably 300 μm or less in terms of ease of application, minimizing the misalignment of both layers during adhesion, and optimizing the amount of material used. The primer layer provided as an undercoat layer on the roof of the structure acts to increase the mutual adhesion between the roof of the structure and the structure protection sheet, so if the primer layer is made to the above thickness, the structure protection sheet can easily reinforce and protect the roof of the structure stably for a long period of time.
In addition, if cracks or defects are present on the roof of the structure, it is preferable to repair the cracks or defects before applying the primer layer. The repair method is not particularly limited, but the repair is usually performed using cement mortar, epoxy resin, or the like.

The present invention will be explained in more detail with examples and comparative examples.

(Example 1)
A resin layer-forming composition containing an acrylic resin was applied onto a 130 μm-thick release sheet made of PP laminate paper and dried to form a single resin layer having a thickness of 110 μm.
Next, a composition for forming a cured polymer cement layer was applied onto the resin layer so as to have a thickness of 450 μm after curing, thereby forming a coating film.
Next, #600 cheesecloth (Cremona, manufactured by Kuraray Co., Ltd., thickness: 230 μm, material: Vinylon) was pressed onto the formed coating film so as to be embedded unevenly on the side opposite the resin layer side of the coating film, and then the coating film was dried and hardened to form a hardened polymer cement layer with the cheesecloth embedded in it.

The arithmetic mean roughness Ra and maximum height roughness Rz of the uneven surface of the adhesive layer side of the formed hardened polymer cement layer were determined according to JIS B0601 (2013), and the results were Ra 8.0 μm and Rz 69.5 μm.

Thereafter, 100 parts by mass of an acrylic adhesive (Olivine (registered trademark) BPS5762K (manufactured by Toyochem Co., Ltd.)) was mixed with 5 parts by mass of an isocyanate curing agent (BHS8515 (manufactured by Toyochem Co., Ltd.)) to prepare an adhesive mixture with a gel fraction of 57%. This adhesive mixture was applied to the surface of the polymer cement cured layer and dried to form an adhesive layer with a thickness of 100 μm, and a structure protection sheet with a total thickness of 600 μm was produced. Note that the ratio of the thickness of the reinforcing layer to the thickness of the polymer cement cured layer of the obtained structure protection sheet was 51%.
This structure protection sheet was continuously produced in a factory controlled at about 25° C., and taken up into a roll including a PP laminated paper release sheet to give the configuration shown in FIG.
The adhesive strength of the obtained structure protection sheet was measured in accordance with JIS A6909 (2014) and was found to be 1.3 N/ ^mm2 .

The composition for forming a polymer cement hardened layer is a water-based acrylic emulsion containing 45 parts by mass of a cement mixture. The cement mixture contains at least 70±5 parts by mass of portland cement, 10±5 parts by mass of silicon dioxide, 2±1 parts by mass of aluminum oxide, and 1 to 2 parts by mass of titanium oxide. The acrylic emulsion contains at least 53±2 parts by mass of an acrylic acid-based polymer obtained by emulsion-polymerizing an acrylic acid ester monomer using an emulsifier, and 43±2 parts by mass of water. The polymer cement hardened layer obtained by applying and drying the composition for forming a polymer cement hardened layer containing these is a composite layer containing 50% by mass of portland cement in the acrylic resin. On the other hand, the composition for forming a resin layer is an acrylic silicone resin. This acrylic silicone resin is an emulsion composition containing 60 parts by mass of an acrylic silicone resin, 25 parts by mass of titanium dioxide, 10 parts by mass of ferric oxide, and 5 parts by mass of carbon black.

Example 2
A structure protection sheet was manufactured in the same manner as in Example 1, except that the cheesecloth used was ES cheesecloth, ES2000, 210 μm thick, made of polyester, manufactured by Toyobo STC, and the adhesive mixture was prepared by mixing 100 parts by mass of an acrylic adhesive (Olivine (registered trademark) BPS5213K (manufactured by Toyochem Co., Ltd.)) with 5 parts by mass of an isocyanate curing agent (BHS8515 (manufactured by Toyochem Co., Ltd.)) to prepare an adhesive mixture with a gel fraction of 57%. The ratio of the thickness of the reinforcing layer to the thickness of the hardened polymer cement layer of the obtained structure protection sheet was 47%.
The adhesive strength of the obtained structure protection sheet was measured in the same manner as in Example 1 and was found to be 1.3 N/mm ² .

(Example 3)
A structure protection sheet was produced in the same manner as in Example 1, except that 520 mesh cheesecloth (Unitika Trading Co., Ltd., V520, thickness: 220 μm, material: vinylon) was used as the cheesecloth, and 100 parts by mass of an acrylic adhesive (Olivine (registered trademark) BPS6574 (Toyochem Co., Ltd.)) was mixed with 6 parts by mass of an isocyanate curing agent (BHS8515 (Toyochem Co., Ltd.)) to prepare an adhesive mixture having a gel fraction of 57%. The ratio of the thickness of the reinforcing layer to the thickness of the hardened polymer cement layer of the obtained structure protection sheet was 49%.
The adhesive strength of the obtained structure protection sheet was measured in accordance with JIS A6909 (2014) and was found to be 1.3 N/ ^mm2 .

(Comparative Example 1)
A hardened polymer cement layer with cheesecloth embedded therein was formed in the same manner as in Example 1, except that the thickness of the hardened polymer cement layer was set to 350 μm.
The arithmetic mean roughness Ra and maximum height roughness Rz of the uneven shape of the surface of the formed cured polymer cement layer on the side on which the adhesive layer was formed were determined in accordance with JIS B0601 (2013), and the Ra was 11.3 μm and the Rz was 99.9 μm.
Thereafter, a structure protection sheet was produced in the same manner as in Example 1. The ratio of the thickness of the reinforcing layer to the thickness of the cured polymer cement layer of the obtained structure protection sheet was 63%.
The adhesive strength of the obtained structure protection sheet was measured in accordance with JIS A6909 (2014) and was found to be 1.0 N/ ^mm2 .

(Comparative Example 2)
A hardened polymer cement layer with cheesecloth embedded therein was formed in the same manner as in Example 1, except that the thickness of the hardened polymer cement layer was set to 550 μm.
The arithmetic mean roughness Ra and maximum height roughness Rz of the uneven shape of the surface of the formed cured polymer cement layer on the side on which the adhesive layer was formed were determined in accordance with JIS B0601 (2013), and the Ra was 9.1 μm and the Rz was 67.3 μm.
Thereafter, a structure protection sheet was produced in the same manner as in Example 1. In the obtained structure protection sheet, the ratio of the thickness of the reinforcing layer to the thickness of the cured polymer cement layer was 40%.
The adhesive strength of the obtained structure protection sheet was measured in accordance with JIS A6909 (2014) and was found to be 1.0 N/ ^mm2 .

REFERENCE SIGNS LIST 10 Structure protection sheet 12 Hardened polymer cement layer 13 Resin layer 14 Adhesive layer 15 Reinforcing layer 16 Release sheet 21 Structure 30 Roof 31 Blue sheet 32 Sandbag

Claims (7)

A structure protection sheet used by being attached to the roof of a structure,
The laminate has a structure in which an adhesive layer, a hardened polymer cement layer, and a resin layer are provided in this order from the side to be attached to the roof of the structure,
The hardened polymer cement layer has a reinforcing layer embedded therein,
A structure protection sheet, wherein the thickness of the reinforcing layer is 42 to 62% of the thickness of the hardened polymer cement layer. The structure protection sheet according to claim 1, which has a tensile strength of 5.0 MPa or more based on JIS L1913:2010 general nonwoven fabric testing method. The structure protection sheet according to claim 1 or 2, which has an elongation rate of 15.0% or less based on JIS L1913:2010 general nonwoven fabric testing method. The structure protection sheet according to claim 1 or 2, wherein the reinforcing layer is unevenly distributed on the adhesive layer side in the thickness direction of the hardened polymer cement layer. The structure protection sheet according to claim 1 or 2, in which the surface of the adhesive layer side of the hardened polymer cement layer has an uneven shape. The structure protection sheet according to claim 1 or 2, wherein the polymer cement cured layer is a layer containing a cement component and a resin, and the resin is contained in an amount of 10% by weight or more and 40% by weight or less. 3. The structure protection sheet according to claim 1, wherein the reinforcing layer is made of cheesecloth.

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