JP2646153B2 - Method of manufacturing mortar base plate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial application field> The present invention relates to a method of fixing a building on an external wall structure foundation and directly applying or spraying a mortar, a plaster, a coating material, or the like, or attaching a tile thereon. The present invention relates to a novel method of manufacturing an architectural base board suitable for forming a wall surface.

<Prior art and problems to be solved by the present invention> A tradition that required a base process such as lath base application such as lathing or base plywood, waterproof sheet application such as felt or roofing, lath net application, and mortar undercoat. In recent years, various types of mortar base plates of the above-described type have been proposed in place of a conventional wet wall coating method, in which a wall material can be immediately applied by being attached to a base structure of a building.

As such a mortar base plate, there is a mortar base plate in which a plurality of holes or grooves are formed in the surface material so that the overcoat mortar is in close contact with an anchor, and for example, Japanese Utility Model Publication No. 57-25934 discloses `` Board, In a mortar base plate formed by sequentially laminating a foamed synthetic resin body having a closed cell structure and a waterproof sheet and integrally forming the same, a through hole is formed in the board, and a blind hole-shaped lower hole is formed coaxially in the foamed synthetic resin body. The mortar base plate is characterized by being drilled to a diameter larger than the through-hole, but Japanese Utility Model Publication No. 57-25935 states that a synthetic resin foam is fixed to one side of the plywood, and a waterproof sheet underneath. A mortar base plate, wherein a plurality of holes are coaxially formed in the plywood and the synthetic resin foam, and a hydraulic substance is mixed in the synthetic resin foam. " But also No. 58-7787 The report states that "at least one of a plurality of grooves, blind holes, and through-holes is provided on the surface of a synthetic resin foam to form a lump of a water-curable composition in the grooves and the like, The mortar base plate, wherein a waterproof layer is formed on the back surface of the foam, is shown.

In the former two mortar base plates, the mortar wall material to be overcoated passes through a through hole provided in a surface board (plywood) and enters a lower hole provided coaxially with a synthetic resin foam in the lower layer. And the mortar wall material expands when the mortar wall material is pressed into the prepared hole, and the mortar wall material is filled by that amount to connect the mortar wall material and the base plate. Is described as being more powerful. However, since the surface board protrudes from the upper edge of the lower hole formed coaxially with the through hole and having a large diameter toward the opening, the mortar wall material is actually applied by press-fitting. As a result, it was difficult to completely extrude the air in the pilot hole, and an air reservoir easily remained in the pilot hole. This residual air reservoir substantially reduces the adhesion area between the mortar wall material and the base plate, so that not only the intended anchoring effect cannot be obtained, but also due to the influence of the outside air temperature after the mortar wall material is installed. There is a problem that the residual air reservoir repeats expansion and contraction, and the stress easily causes cracks in the mortar wall material applied on the edge of the through hole.

In the latter case, the synthetic resin foam used as the surface board has poor adhesion to the mortar material and low strength. Therefore, the anchoring effect of the mortar material into the groove or the like formed in the foam and the concave effect are obtained. Even with the anchoring effect due to the lump of the water-curable composition filling or projecting into the groove or the like, it was still difficult to sufficiently exert the adhesion to the mortar material.

In view of these disadvantages of the prior art, the present applicant has eagerly devised to develop a mortar base plate having a novel configuration capable of exhibiting a large adhesion to a mortar wall material to be overcoated. Successful. An object of the present invention is to provide a method for efficiently and inexpensively manufacturing such a new mortar base plate.

<Means for Solving the Problems> The present invention has been devised to achieve the above object, and is an air filter of a soft synthetic resin sheet having a large number of independent air-filled portions protruding on one side thereof. On the surface on the side where the sealing portion is protruded, a kneaded material containing a hydraulic inorganic material as a main component is applied to a thickness sufficient to bury the air sealing portion, and the applied kneaded material is further uncured. After laminating a substrate thereon, curing and forming a surface coating layer of the kneaded material, and peeling the soft synthetic resin sheet from the surface coating layer after the kneaded material is semi-cured or cured. And a method for manufacturing a mortar base plate.

<Function> Since the kneaded material is applied so as to bury the independent air encapsulation portions formed on one side of the soft synthetic resin sheet so as to be buried, the leading end or the central portion of the air encapsulation portion is pressed or applied during application. Later, the pressing force given from the upper surface side of the substrate or the pressing force given by its own weight during the deposition curing causes the substrate to be enormously deformed into an enlarged shape and buried in the uncured kneaded material. The soft synthetic resin sheet is peeled after the kneaded material is semi-cured or cured to form a surface coating layer, but has a shape whose tip or center is enormously enlarged corresponding to the compressive deformation of the air-filled portion. Blind holes are left as traces in the surface coating. Therefore, the blind holes are formed so that the cross-sectional area at the lower part is larger than the opening area at the upper part, and the adhesive area with the mortar coating material increases, thereby improving the anchoring effect and increasing the adhesion.

<Specific Description of Configuration> Hereinafter, the configuration of the mortar base plate to be manufactured by the present invention will be described in detail with reference to FIG. 1 and FIG.
As the substrate 1 of the mortar base plate 10, plywood, fiberboard,
Particle hods, inorganic substances and the like are used.

On the surface of the substrate 1, a waterproof layer 2 made of a synthetic resin, a synthetic rubber, or the like, alone or in combination, is provided as necessary.

Directly on the entire surface of the substrate 1 or via the waterproof layer 2
A surface coating layer 3 is provided. The surface coating layer 3 is mainly composed of a hydraulic inorganic material such as cement, gypsum, slag, etc., and if necessary, silica sand, calcium carbonate, talc, clay, shirasu balloon, vermiculite, pearlite, synthetic resin expanded particles or Aggregates such as crushed grains, wood flour, fly ash, glass fiber, rock wool, pulp,
Organic or inorganic fibers such as wood fibers, coconut fibers, nylon, vinylon, and polypropylene fibers; and admixtures such as polyvinyl alcohol, methyl cellulose, and synthetic resins;
A waterproofing agent or the like is added.

The surface coating layer 3 preferably has a thickness of at least 3 mm or more. If the thickness is smaller than this, the depth of the blind holes described below is insufficient, and the intended anchoring effect cannot be obtained. The upper limit of the thickness of the surface coating layer is not particularly limited,
Considering the workability as a mortar base plate, it is practical to be about 15 to 30 mm. The thickness of the surface coating layer is determined by applying a single coating of mortar wall material, which will be described later. It is preferable to make adjustments so as to obtain a wall having the same structure as a soil-coated wall.

A plurality of blind holes 4 are formed on the surface of the surface coating layer 3. The blind holes 4 have the effect of anchoring the overcoated mortar wall material in an anchoring manner and increasing the adhesive strength by expanding the bonding area to the mortar wall material.
In order to effectively exert this effect, it is preferable that the blind hole 4 is formed to have a larger cross-sectional area below the opening area at the upper part, and more specifically, to form the upper part with respect to the bottom area at the lower part. Is preferably formed in a trapezoidal cross-section having an opening area of 65 to 95%. If it is less than 65%, the bonding area will increase, but the opening will be narrower and the air in the blind holes will be less likely to be pushed out from the interior when applying the mortar wall material, and cracks will occur due to the expansion of the residual air. Easy to cause. If it exceeds 95%, the problem of residual air does not occur, but the inner wall of the blind hole becomes substantially vertical, and the effect of expansion of the bonding area is reduced.

The cross-sectional shape of the blind hole 4 is not limited to a trapezoidal shape, and the same effect as described above can be exerted as long as the shape has an internal cross-sectional area larger than the opening area. 3 (a) to 3 (d) illustrate other preferable cross-sectional shapes. In the case of the substantially drum shape shown in FIG. 4A or the substantially hexagonal shape shown in FIG. 4B, the central area has the largest cross-sectional area, so that the opening area and / or low area is smaller than that of the central area. Preferably, it is formed so as to be in the range of 65 to 95% with respect to the cross-sectional area.

The method of the present invention for producing the mortar base plate 10 having such a configuration includes the following steps. That is, a soft synthetic resin sheet having a large number of independent air enclosing portions on one side thereof is laid with the side on which the air enclosing portions are protruded as an upper surface,
Next, a kneaded material containing a hydraulic inorganic material as a main component is applied to the surface thereof to completely bury the air-filled portion. Since the kneaded material used here is cured and cured to become the surface coating layer 3, as described above, it is mainly composed of a hydraulic hard inorganic material such as cement, and an aggregate, a fibrous material, an additive, etc. Are mixed and kneaded.

Next, the substrate 1 is laminated in a state where the kneaded material applied to a thickness sufficient to completely bury the air-filled portion of the synthetic resin sheet is in an uncured state. On the back side of the substrate 1, if necessary, a waterproofing agent obtained by mixing one or a plurality of synthetic resins, synthetic rubbers or the like on one side (the side in contact with the kneaded material) is applied to form the waterproof layer 2 as described above. Can be formed in advance and used.

The obtained laminate is put into a curing room,
The kneaded material is cured and hardened in a state in which the protruding air enclosing portion of the synthetic resin sheet is buried in the kneaded material to form a mixture layer. Curing is carried out by ordinary room temperature curing or steam curing. After the kneaded material is semi-cured or cured by curing, the synthetic resin sheet is peeled off. When the synthetic resin sheet is peeled off, the air-filled portion buried in the kneaded material is drawn out from the semi-cured or cured kneaded material while being stretched.

If the kneaded material has a relatively large viscosity, a required pressing force acts on the protruding air enclosing portion of the synthetic resin sheet at the time of application, and the air enclosing portion receives this pressing force. Thus, the central portion or the tip portion is in an enormously deformed state, and the enormous air enclosing portion is buried in the kneaded material. When the viscosity of the kneaded material is relatively small, such pressing force is not given,
After the substrates 1 are laminated, a pressing force is applied from the upper surface side by a press roll or the like, or a plurality of laminated materials in a state where the substrates 1 are laminated are deposited and put into a curing room to utilize a required weight by using its own weight. It is necessary to give a pressing force.
Thus, the trace of the air-filled part buried in the uncured kneaded material as an enlarged shape at the center or tip has a relatively small opening area at the top, and the cross-sectional area at the center or bottom is compared. A plurality of blind holes are formed in the mixture layer. Thus blind hole 4
The surface coating layer 3 having a plurality of openings formed on the surface thereof is obtained, and the mortar base plate 10 is manufactured.

As the soft synthetic resin sheet 6, a polyethylene sheet which has been widely used as a packing material in the past can be suitably used. The plurality of air enclosing portions 5 formed on one surface of the polyethylene sheet have a substantially cylindrical shape with a rounded upper edge, but when pressed against an uncured kneaded material, the upper end of the cylindrical shape expands. Then, it is pressed into the kneaded material in a substantially trapezoidal cross section. Accordingly, by peeling the polyethylene sheet after the kneaded material is semi-cured or cured, a plurality of blind holes 4 having a substantially trapezoidal cross section can be easily formed in the surface coating layer 3.

The synthetic resin sheet such as a polyethylene sheet for packing used in the above-mentioned manufacturing process may be peeled off before shipment of the mortar base plate. It can also serve as a surface curing sheet for the coating layer. The synthetic resin sheet used as the curing sheet in this way is, after shipping,
Peeled off before or after the mortar base plate at the construction site.

As shown in FIG. 4, the mortar base plate 10 is used by a plurality of base mortars 11 such as pillars and pouring, butted against each other with a nail 12 and fixed. After fixing, the jointed part is jointed by applying joint tape or applying jointing agent.
After the step 13, the mortar wall material 14 is sprayed on the surface, and the mortar wall material 14 is applied by ironing or the like so as to fill the inside of the blind hole 3. When the wall surface is to be tiled, the tile can be attached after the mortar wall material is applied, or the tile can be directly attached.

As described above, the mortar base plate manufactured by the method of the present invention requires only one coating of the mortar wall material on the surface of the mortar base plate. It is possible to obtain a fire prevention structure or a structure equivalent to earthen wall, which is a fire prevention regulation accompanying house construction. Here, "one-time application of mortar wall material" means that the mortar wall material to be applied on the base material (mortar base plate) generates dripping and dripping cracks after coating and before curing. This means a coating step that does not occur, and generally has a coating thickness of about 10 to 12 mm. In addition, in the case of obtaining a coating thickness of 10 to 12 mm by one ironing, after applying to a thickness of 5 to 6 mm by the first ironing, in a basic wet state before curing and curing. Apply the second iron coating to a coating thickness of 5 to 6 mm for a total of 10 to 1
When obtaining a coating thickness of 2 mm (so-called chase-coating in the so-called plastering term), the above-mentioned "single coating of mortar wall material"
include.

According to the experiments of the present inventors, it is necessary to have a coating thickness of about 13 mm or more in the case of ordinary mortar and about 10 mm or more in the case of special mortar to obtain a soil-coated wall equivalent structural wall. Approximately 18mm in case of ordinary mortar to obtain fire protection structure wall
In the case of the special mortar, the coating thickness of about 15 mm or more was required. The numerical values of the respective coating thicknesses described above mean the sum of the thickness of the surface coating layer of the mortar base plate and the thickness of the mortar top coating layer formed by coating on the surface. Therefore, assuming that ordinary mortar is used, if the thickness of the surface coating layer is 3 mm or more, a wall of the same structure as the earth-painted wall can be obtained by one coating of the mortar wall material, and 8 m
If it is at least m, a fireproof structure wall can be obtained by a single application of the mortar wall material. If the surface coating layer is less than 3 mm, the depth of the blind holes is insufficient and the intended anchoring effect is not obtained, and it is difficult to obtain the above-mentioned stable coating thickness, as described above. It is. In the case of using special mortar, by applying a surface coating layer having a thickness of 3 mm or more, a single coating of the mortar wall material will result in a soil-coated wall equivalent structural wall,
When the thickness is 5 mm or more, a fireproof structure wall can be obtained with a single application of the mortar wall material.

When it is intended to obtain a wall structure equivalent to a clay-coated wall using the mortar base plate manufactured by the method of the present invention, for example, a mortar base plate having a surface coating layer formed to a thickness of 3 mm is formed on the outer wall base structure. After nailing and fixing, the surface is coated with ordinary mortar, the blind holes are filled in the ordinary mortar, and the ordinary mortar overcoat layer is formed to a thickness of 7 mm on the surface of the surface coating layer. I do. Thereby, the coating thickness of the surface coating layer thickness (3 mm) + the top coating layer thickness (7 mm) = 10 mm can be obtained, and the structural performance range is equivalent to that of the earth coating wall. Also, by applying ordinary mortar sufficient to fill the blind holes on the surface of the mortar base plate with a surface coating layer formed to a thickness of 10 mm, a mortar coating thickness of 10 mm is secured, equivalent to earth coating Structural performance range.

Further, for example, after the mortar base plate of the present invention having a surface coating layer formed to a thickness of 5 mm is nailed and fixed on the outer wall base structure, a special mortar is applied to the surface thereof, and blind holes are formed in the special mortar. Assuming that the outer special mortar overcoat layer is formed to a thickness of 10 mm on the surface of the coating layer, the mortar coating thickness of 5 mm + 10 mm = 15 mm will be obtained, The walls are obtained. Further, when a mortar base plate having a surface coating layer having a thickness of 25 mm is used, the fireproof structure wall can be obtained by filling the blind holes with ordinary mortar to secure a mortar coating thickness of 25 mm.

<Effects of the Invention> According to the present invention, there is provided a preferable method for efficiently and inexpensively manufacturing a mortar base plate provided with a surface coating layer having a plurality of blind holes formed on a surface of a substrate. You. The mortar base plate manufactured by the method of the present invention can be immediately coated with the mortar wall material after the mortar base plate is nailed and fixed on the base structure material. The applied mortar wall material is formed in a plurality of layers on the surface coating layer of the mortar base plate, penetrates into the blind hole, and adheres in an anchoring manner. Since the blind hole is formed to have a larger cross-sectional area below the surface opening area at the upper part thereof, the anchoring effect is improved and the bonding area to the mortar wall material is increased, so that the adhesion is greatly improved. Since the blind holes are opened directly on the surface of the mortar base plate, the mortar wall material is filled over the entire blind holes, so that no air remains in the blind holes, and consequent shrinkage of the remaining air. Cracks generated due to expansion can be prevented. In addition, by using the mortar base plate manufactured by the method of the present invention, a fireproof structure wall or a structure wall equivalent to a clay-coated wall can be easily obtained by a single coating of the mortar wall material.

[Brief description of the drawings]

FIG. 1 is a perspective view schematically showing the structure of a mortar base plate manufactured by the method of the present invention, FIG. 2 is a partially enlarged cross-sectional view thereof, and FIG. 3 is formed on a surface coating layer of the mortar base plate. FIG. 4 is a partially enlarged cross-sectional view showing a modification of the shape of the blind hole, and FIG. 4 is a cross-sectional view showing a working example of the mortar base plate. DESCRIPTION OF SYMBOLS 1 ... substrate 2 ... waterproof layer 3 ... surface coating layer 4 ...
Blind hole, 10 ... Mortar base plate

Continued on the front page (51) Int.Cl. ⁶ Identification number Reference number in the agency FI Technical display location E04B 1/94 E04B 1/94 L

Claims (4)

(57) [Claims] 1. A soft synthetic resin sheet having a plurality of independent air-filled portions protruding on one side thereof, and a kneading material containing a hydraulic inorganic material as a main component on a surface on which the air-filled portions protrude. The kneaded material is applied to a thickness sufficient to embed the air-filled portion, and the applied kneaded material is further cured after laminating a substrate thereon in an uncured state to form a surface coating layer of the kneaded material. And, after the kneaded material is semi-cured or cured, peeling the soft synthetic resin sheet from the surface coating layer,
A method for manufacturing a mortar base plate. 2. The method according to claim 1, wherein a polyethylene packing sheet is used as the soft synthetic resin sheet. 3. The method for manufacturing a mortar base plate according to claim 1, wherein the soft synthetic resin sheet is used as a curing sheet for a surface coating layer of the mortar base plate and is peeled off at a construction site. 4. The method for manufacturing a mortar base plate according to claim 1, wherein a waterproof layer is formed in advance on a side of said substrate in contact with the kneaded material.