JP2558205B2 - Exterior panel manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an exterior panel used when constructing an outer wall of a building.

[0002]

2. Description of the Related Art As a conventional exterior panel, one having a plurality of bubbles inside the panel is widely known for the purpose of weight reduction and soundproofing. In addition, in this type of panel manufacturing method, firstly styrofoam is mixed with cement material and water is added, and then the styrofoam is melted by heating after curing to a predetermined shape so that bubbles are formed in the panel. What has been done is proposed.

[0003]

However, in the above-mentioned conventional example, since the specific gravity of the styrofoam is extremely small, when the styrofoam is mixed with the cement material and water is added, the styrofoam floats up and the desired bubble distribution inside the panel is obtained. There was a problem that I could not get. In particular, in the case of panel molding using a papermaking method, the styrofoam floats on the water surface, making manufacture itself difficult.

Further, because of the flexibility of the styrofoam, when the styrofoam is laminated and pressed in several layers, the styrofoam once contracted is gradually restored over time, which significantly reduces the adhesion between the layers. , Was a cause of the peeling phenomenon. Further, for the same reason, the strength until the panel is completely cured becomes weaker as the amount of expanded polystyrene mixed increases, so there is also the disadvantage that the amount of expanded polystyrene cannot be increased too much in consideration of the transfer work in the manufacturing process. It was

The present invention has been made to solve the above problems, and an object thereof is to provide a desired air bubble distribution inside the panel and to ensure high adhesion between the layers of the inorganic plate material. It is to provide a method for manufacturing a panel.

[0006]

The present invention has been made in order to achieve the above-mentioned object, and at the time of manufacturing a panel, resin beads having a high specific gravity and a high hardness are mixed with a cement material, and water is added thereto. The first step of manufacturing an uncured lightweight inorganic plate material, and stacking the uncured reinforcing inorganic plate materials on both sides of the uncured lightweight inorganic plate material, and pressure-curing the stacked laminated board materials. And an integrated panel including a second step of heating the integrated laminated plate material to melt the resin beads to form bubbles inside the lightweight inorganic plate material. Is a manufacturing method.

[0007]

In the method of manufacturing the exterior panel of the present invention, the resin beads having high specific gravity and high hardness and the cement material are mixed in the first step to obtain the uncured lightweight inorganic plate material. The beads are prevented from floating when water is added, and the resin beads are prevented from being deformed at the time of pressing (pressing) in the second step. In the second step, the interface between the plate materials laminated in the uncured state is pressure-bonded by pressure curing without using an adhesive or the like. Furthermore the third
In the process (1), the resin beads are melted by heating, so that air bubbles are formed inside the lightweight inorganic plate material corresponding to the distribution of the beads.

[0008]

Embodiments of the present invention will now be described in detail with reference to the drawings. FIG. 1 is a schematic sectional view showing an embodiment of a method for manufacturing an exterior panel according to the present invention. First, in the first step, as shown in FIG. 1A, a resin bead 2b having a high specific gravity and a high hardness and a cement material are mixed, and an appropriate amount of water is added to the mixture to add an uncured lightweight inorganic plate material, For example, the lightweight slate 2 is manufactured. The specific gravity of the resin beads 2b used here is at a level close to the specific gravity of the cement material used for panel molding, and its hardness is ensured so that it will not be deformed by the pressure treatment described later.
Further, in this embodiment, a paper-making method is adopted as the panel forming method, and two light-weight slate 2 having a thickness of about 15 mm is manufactured by this paper-making method, and these are stacked to have a thickness of 3
A lightweight slate 2 of about 0 mm is integrally formed.

Incidentally, when the resin beads 2b and the cement material are mixed in the first step, the resin beads 2
If the cement material is sufficiently adhered to the outer surface of b in advance, it is possible to more reliably prevent the beads from rising when water is added.

Then, in the second step, as shown in FIG. 1B, uncured reinforcing inorganic plate materials, for example, reinforcing slate 3 are superposed on both sides of the uncured lightweight slate 2 and the slate 3 is superposed. The combined laminated plate materials are pressure-cured and integrated. At this time, when the lightweight slate 2 and the reinforcing slate 3 laminated in the uncured state are pressed, the interfaces between the layers are not hardened gradually and are pressure-bonded to each other, and finally, they are completely joined. As a result of this joining action, the laminated plate material constituted by both slates 2 and 3 is integrated.

Subsequently, in the third step, as shown in FIG. 1C, the laminated plate material integrated by pressure is heated to
Resin beads 2 mixed with cement material in the first step
b is melted, thereby forming a plurality of bubbles 2a inside the lightweight slate 2. At that time, about 130 ° C. is sufficient as the heating temperature for melting the resin beads 2b, but in the present embodiment, autoclave curing (condition: 180)
The resin beads 2b were melted at (° C, 15 atm, high humidity).

Through the above steps, the heat insulating property is as follows:
The lightweight exterior panel 1 having excellent fire resistance and the like can be obtained. That is, in the exterior panel 1 obtained by the manufacturing method of the present example, the lightweight slate 2 has a two-layer structure, and each has a plurality of bubbles 2a inside. Each layer is manufactured by the papermaking method as described above, and its thickness is about 15 mm (2
It is about 30 mm in layers). Also, individual bubbles 2
The size of “a” is set to approximately φ2 mm, and the mixing amount with respect to the cement material is appropriately set within the range of 5 to 50% by weight. On the other hand, reinforcement slate 3
Are laminated on the upper and lower surfaces of the lightweight sley 2,
The thickness of each reinforcing slate 3 is set to about 3 mm, which is thinner than that of the lightweight slate 2. Therefore, the total thickness of the exterior panel 1 is about 36 mm.

As described above, in the exterior panel 1 obtained by the manufacturing method of this embodiment, the inside of the panel is constituted by the lightweight slate 2 having a plurality of bubbles 2a, and the reinforcing slate 3 is laminated on the upper and lower surfaces thereof to form one sheet. Since it is integrated as a panel, it is lightweight and has a high soundproofing effect, and by providing the reinforcing slate 3 on the surface part, high panel strength is obtained, and it is also waterproof, heat insulating and fire resistant. But it will be excellent.

As described above, in the panel manufacturing method of this embodiment, since the resin beads 2b having high specific gravity are mixed with the cement material, the beads are prevented from floating when water is added to the cement material. To be done. Therefore, even when a general papermaking method is adopted, a desired bubble distribution can be easily obtained inside the lightweight slate 2.

Further, in this embodiment, since the resin beads 2b having high specific gravity and high hardness are mixed with the cement material, a considerably large panel strength can be obtained even in the uncured lightweight slate 2. Therefore, the amount of the resin beads 2b mixed with the cement material can be freely set. Moreover, even if the slate is pressed in the second step, the bead itself does not deform (shrink) because of its high hardness. Therefore, extremely high adhesion can be secured between the layers of the lightweight slate 2 and the reinforcing slate 3 that are laminated and integrated.

Further, in the ordinary papermaking method, only the maximum thickness of about 15 mm could be produced from the viewpoint of panel strength, but the slate laminated in the uncured state was pressure-cured as in the production method of this example. 20m by integrating
Even a considerably thick panel of m or more can be built with almost the same level of panel strength as the one body.

In the panel manufacturing method of this embodiment, the case of manufacturing the exterior panel 1 in which the reinforcing slate 3 is laminated on the upper and lower surfaces of the lightweight slate 2 has been described, but the present invention is not limited to this, and for example, FIG. As shown in Fig. 7, a reinforcing slate (reinforcing inorganic plate material) 3 is laminated on each of the upper and lower surfaces of the lightweight slate (lightweight inorganic plate material) 2 and the central portion thereof, and the panel itself is further strengthened as the overall plate thickness is increased. It is also applicable when manufacturing a panel.

[0018]

As described above, according to the method of manufacturing the exterior panel of the present invention, the resin beads having a high specific gravity are mixed with the cement material to manufacture the lightweight inorganic plate material, thereby preventing the resin beads from floating. Therefore, even if it is a papermaking method, a desired bubble distribution can be formed inside the panel. In addition, since the resin beads with high specific gravity and high hardness are mixed with the cement material, sufficient panel strength can be obtained even with an uncured lightweight inorganic plate material. Can be set freely.
Furthermore, since the beads themselves do not deform even when the plate materials are pressed against each other, high adhesion can be maintained between the layers of the inorganic plate material. As a result, by stacking the uncured inorganic plate materials on each other and integrating them by pressure curing, it is possible to manufacture a considerably thick panel with almost the same level of panel strength as the integrated body.

[Brief description of drawings]

FIG. 1 is a schematic sectional view showing an embodiment of a method of manufacturing an exterior panel according to the present invention.

FIG. 2 is a schematic sectional view showing another application example of the present invention.

[Explanation of symbols]

 1 Exterior Panel 2 Lightweight Slate (Lightweight Inorganic Plate Material) 2a Bubbles 2b Resin Beads 3 Reinforced Slate (Reinforced Inorganic Plate Material)

Claims (1)

(57) [Claims] 1. A first step of mixing a resin bead having a high specific gravity and a high hardness with a cement material and adding water to the mixture to produce an uncured lightweight inorganic plate material, and the uncured lightweight inorganic material A second step of superimposing uncured reinforcing inorganic plate materials on both sides of the plate material, and pressure-curing the integrated laminated board materials to integrate them, and heating the integrated laminated board materials to form the resin. And a third step of forming bubbles inside the lightweight inorganic plate material by melting the beads.