JP3232329U - Lightweight wall material to replace block walls - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wall material which is lightweight, does not collapse or collapses, maintains an independent structure, and can ensure the safety of passersby, etc., instead of a block wall. SOLUTION: The flat wall material having at least one kind of foamed synthetic resin selected from the group consisting of expanded polystyrene, foamed polyurethane, foamed polyethylene and foamed vinyl chloride as a core material 1 and reinforcing at least one side thereof. A wall material comprising a high-strength fiber mesh cloth 3 and a resin layer made of a polyurea resin that covers both sides of the core material and the high-strength fiber mesh cloth. [Selection diagram] Fig. 1

Description

The present invention relates to a lightweight and durable wall material as an alternative to a block wall.

The block wall made by stacking concrete blocks is used as an outer wall of the site, but its side surface is almost unreinforced, and there is a risk of collapse due to an earthquake or collision with a car or the like. In addition, the construction of a block wall requires a lot of manpower and work time because it is an on-site work of stacking concrete blocks and fixing them with mortar.

In recent years, the concrete block wall installed as the outer wall of the site has had an accident in which the old block wall collapsed due to the earthquake, and passersby were sometimes involved in the accident.

Patent Document 1 describes a core material in which the outer shell structural material is made of an unsinkable material containing air, and a polyurea resin layer in which a polyurea resin is laminated so as to cover substantially the entire outer surface of the core material. A floating shelter with water is disclosed. It is also disclosed that the outer surface side of the core material of the outer shell structural material is reinforced with mesh-sized impact-resistant fibers.

Synthetic resin foam (foamed styrol, etc.) is used as the core material made of the above non-settling material, and the impact-resistant fibers are para-aramid fiber, ultra-high molecular weight polyethylene, polyarylate fiber, and PBO (polyparaphenylene benzobis). Oxazole) fibers, carbon fibers and the like are disclosed.

By using the method disclosed in Patent Document 1, it is possible to easily form an outer shell structural material for a floating shelter in which a non-sinking material, a mesh-sized impact-resistant fiber, and a polyurea resin layer are integrated. .. As a result, even in a high temperature environment such as a water fire, the outer shell does not melt due to heat and the inside of the shelter does not become hot, so the floating shelter on the water does not easily affect the personnel inside the shelter. Can be. When not in use, it can also be used as a soundproof room (karaoke room, musical instrument practice room, etc.) or a heat storage tank for other purposes. However, it is not stated that the above shelter can be used as a substitute for a block wall.

JP-A-2015-51732

The present invention has been made in view of the above circumstances, and provides a wall material that is lightweight, does not collapse or collapse, maintains an independent structure, and can ensure the safety of passers-by, etc., instead of a block wall. The task is to do.

In order to solve the above problems, the present inventor is a flat plate-shaped wall material having at least one type of foamed synthetic resin selected from the group consisting of foamed polystyrene, foamed polyurethane, foamed polyethylene and foamed vinyl chloride as a core material. A wall material comprising: a high-strength fiber mesh cloth for reinforcing at least one side thereof, and a resin layer made of a polyurea resin covering both sides of the core material and the high-strength fiber mesh cloth. I will provide a.

According to the present invention, a wall that replaces a block wall can be constructed with a small amount of labor and in a short period of time, and a self-supporting structure can be maintained without the wall collapsing even in the event of an earthquake. In addition, the safety of the site can be maintained without collapsing even in the event of a collision with a car or the like. As a result, it is possible to ensure the safety of passers-by and prevent damage to the facilities inside the wall from an accident in which the block wall collapses or collapses.
The block wall weighs 200 to 250 kg / m ² , while the wall material made of foamed synthetic resin ^{is as light as 20 kg / m 2} (when the thickness is 120 mm), so the wall is 3 m high without a buttress. Can be made. It is also possible to construct from the top of the existing block, and the cost and time to remove and dispose of the existing block can be reduced.
Since the foamed synthetic resin material is used for the core material, it is possible to finish the design freely, such as adding a curved shape or attaching a small window according to the design. Since its own weight is light, special foundation and formwork work is not required, and construction costs can be reduced. Since the wall material is made of a lightweight material with excellent elasticity, it does not easily fall under its own weight, it does not easily collapse in the event of an earthquake, and even in the unlikely event of a collapse, the danger can be minimized.

It is explanatory drawing (front view (a) and back view (b)) explaining the wall material which is one Embodiment of this invention, polyurea resin is sprayed on both sides of the core material of a wall, and the mesh made of high-strength fiber only on one side. This is an example of adhering cloth. It is explanatory drawing (front view (a) and back view (b)) explaining the wall material which is one Embodiment of this invention, and is an example which reinforced both sides of the core material of a wall with a high-strength fiber mesh cloth. It is explanatory drawing explaining the space ratio, the opening and the thread width of the high-strength fiber mesh cloth of this invention.

Hereinafter, the present invention will be specifically described with reference to the drawings.

1 and 2 are embodiments of the wall material of the present invention, and are views for explaining a wall material in which a polyurea resin and a high-strength fiber mesh cloth are adhered to a flat plate-shaped core material made of a foamed synthetic resin. Is. In FIGS. 1 and 2, 1 is a core material made of foamed synthetic resin, 2 2a is a resin layer made of polyurea resin, 3 is a high-strength fiber mesh cloth, and 10 is a wall material.

The wall material 10 according to the present invention can be formed by the following method.
First, the polyurea resin 2 is sprayed on the entire surface of one side of the foamed synthetic resin core material 1 (FIG. 1 (a)).
On the other hand, on the opposite surface of the core material 1, first, an appropriate amount of polyurea resin 2a is sprayed on the entire surface, and immediately after that, the high-strength fiber mesh cloth 3 is attached to the entire surface. After crimping with a roller to firmly bond the cloth 3 to the core material, the polyurea resin 2 is sprayed onto the high-strength fiber mesh cloth 3 to completely bond the high-strength fiber mesh cloth 3 to the core material ( FIG. 1 (b).
When installing the wall material, it is up to you whether the surface reinforced with the high-strength fiber mesh fabric is inside or outside the site.

Further, a high-strength fiber mesh cloth may be attached to both sides of the core material 1 to form a reinforcing structure. As in the case of single-sided reinforcement of the core material 1, polyurea resin is sprayed on one side of the core material 1, and immediately after that, a high-strength fiber mesh cloth 3 is attached to the entire surface, and the cloth 3 is firmly adhered to the core material 1. After that, the polyurea resin is further sprayed onto the high-strength fiber mesh cloth 3 (FIG. 2 (a)). Similarly, on the opposite surface, the polyurea resin is sprayed on the entire surface, immediately after that, the high-strength fiber mesh cloth 3 is attached to the entire surface, the cloth 3 is firmly adhered to the core material 1, and then the polyurea resin is applied to the high strength. It is sprayed onto the fiber mesh cloth 3 to completely adhere the high-strength fiber mesh cloth 3 to the core material 1 (FIG. 2 (b)).

The wall material of the present invention is reinforced with a core material made of foamed synthetic resin having a small specific gravity, and due to the high tensile strength and high tensile elasticity of the high-strength fiber mesh fabric, the core material has bending strength, shear strength, and resistance. It improves impact resistance.

The core material 1 is made of a foamed synthetic resin.
As the expanded synthetic resin, at least one type of expanded synthetic resin selected from the group consisting of expanded polystyrene, expanded polyurethane, expanded polyethylene, and expanded vinyl chloride is used. Expanded polystyrene is preferable from the viewpoint of light weight, economy, and workability. The thickness of the foamed synthetic resin may be any thickness that can be used as a wall material, and is preferably 20 mm or more and 200 mm or less. It is more preferably 50 mm or more and 180 mm or less, and further preferably 100 mm or more and 150 mm or less.

The polyurea resin not only has high adhesive strength to the side surface of the core material, but also improves bending strength, shear strength, and impact resistance as a wall material, similar to high-strength fiber mesh fabric. Further, since it has a high affinity (wetting property) with high-strength fibers, it is not necessary to perform a pretreatment on the high-strength fiber mesh fabric to enhance the adhesiveness to the polyurea resin, which is economically excellent.

In the wall material of the present invention, when the high-strength fiber mesh cloth 3 is not used, the thickness of the polyurea resin layer 2 formed on the side surface of the core material 1 is preferably 1 mm or more, preferably 1.5 mm or more. It is more preferable, and it is particularly preferable that it is 2 mm or more. If the thickness is insufficient, the toughness of the resin film becomes insufficient, and it becomes difficult to maintain the wall structure against a large bending force or impact force.

On the other hand, when the high-strength fiber mesh cloth 3 is used, the thickness of the polyurea resin layer 2 formed on the high-strength fiber mesh cloth 3 adhered to the core material 1 via the polyurea resin 2a is 1 mm. The above is preferable, 1.5 mm or more is more preferable, and 2 mm or more is particularly preferable. In this case, the thickness of the polyurea resin 2a sprayed on the core material 1 in advance is not particularly limited, but is preferably a thickness that can cover the entire surface of one side of the core material 1, for example, about 0.5 mm or more and 1 mm or less. ..

Polyurea resin is a compound formed by a chemical reaction between an isocyanate compound (main agent) and an amine compound (curing agent) having active hydrogen. Examples of the polyurea resin include Extreme 11-50 (manufactured by Rhino Lining Co., Ltd.) and the like. It is presumed that the polyurea resin adheres the core material and the high-strength fiber mesh fabric and forms a film having high toughness and high elongation on the surface of the core material.

Examples of the method for applying the polyurea resin include a method of applying or spraying the polyurea resin on the core material with a predetermined thickness, but spraying is desirable because it is excellent in workability. As a spraying device for spraying the polyurea resin onto the core material, a known spraying device can be used. The polyurea resin is produced by subjecting a polyisocyanate compound (main agent) and an amine compound having active hydrogen (curing agent) to a collision mixture with a spray gun to cause a chemical reaction. The spraying device is a device in which a polyisocyanate compound and an amine compound are collision-mixed to form a mist and sprayed onto a core material.

The spraying device heats a tank containing a polyisocyanate compound, a tank containing an amine compound, a pump that delivers the compound from each tank, a high-pressure metering pump that applies sufficient pressure to the compound to deliver a predetermined amount, and a compound to be transported. A heater, a hose with a heater that holds the temperature of a compound, a spray gun that collides and mixes both compounds and ejects them in a mist state, a control device that changes the mixing ratio of both compounds, a control device that changes the heating temperature, etc. Can be used. Both compounds are heated to a predetermined temperature by a heater and sent to a spray gun while being held at a predetermined temperature by a hose with a heater, and the spray gun collides and mixes both compounds and ejects them in the form of mist. Both compounds form a polyurea resin by a chemical reaction and solidify on the surface of the object to be sprayed to form a coating film. Therefore, there is an advantage that the working time can be extremely short.

As the high-strength fiber mesh fabric, at least one selected from woven fabrics, knitted fabrics, knitted fabrics, lattice sheets and honeycomb-shaped materials is preferably used, depending on the shape of the wall material and the reinforcing effect required for the wall material. , One type may be used, or two types or three or more types of fabrics may be used in combination. From the viewpoint of high tensile strength of the high-strength fiber mesh fabric, a woven fabric or a honeycomb-like material is preferable. The woven fabric structure is preferably plain weave, twill weave, satin weave, etc., and may be a general biaxial woven fabric, or a multiaxial woven fabric such as a triaxial woven fabric or a quadrilateral woven fabric. Further, the high-strength fiber mesh fabric used for the front surface and the back surface of the core material may have the same type and fineness of the high-strength fiber and the type and shape of the fabric may be the same or different.

The high-strength fiber may be at least one selected from the group consisting of glass fiber, boron fiber, ceramic fiber, aramid fiber, polyparaphenylene benzbisoxazole fiber, high-strength polyethylene fiber and total aromatic polyester fiber. preferable. Aramid fibers are particularly preferable because of their high strength and high elastic modulus. The aramid fiber is a meta-type aramid fiber, a para-type aramid fiber, or a copolymer thereof. Specific examples include fibers made of polyparaphenylene terephthalamide, polymetaphenylene isophthalamide, poly-3,4'-oxydiphenylene terephthalamide copolymer and the like. The fineness of the high-strength fiber is preferably 100 to 8,000 dtex, more preferably 100 to 6,300 dtex.

If the high-strength fibers constituting the high-strength fiber mesh fabric are untwisted, yarn disorder and yarn spread are likely to occur when the polyurea resin is sprayed, and the fabric strength is likely to decrease or the space ratio is likely to change. In order to prevent them, it is preferable that the high-strength fibers are twisted. The preferred twist coefficient (lower twist coefficient) is 0.1 to 5.0, more preferably 0.1 to 2.2, and even more preferably 0.1 to 1.6. If the twist coefficient exceeds 5.0, the strength decreases and the twisted yarn becomes thicker, which may not be preferable from the viewpoint of ensuring the space ratio and lightness. The twist coefficient is calculated by the following formula (1).

The high-strength fiber mesh fabric preferably has 0.5 or more and 10 or less warp and weft threads per inch. More preferably, it is 7 or less. When the number of threads is less than 0.5, it becomes difficult to play a role as a ripstop depending on the fineness, so it is more preferably 1 to 7 threads / inch.

In the case of the lattice-shaped mesh sheet, the space ratio of the mesh fabric is preferably 70% or more, more preferably 75% or more. When the space ratio is 70% or more, the impact resistance of the wall material can be further improved in combination with the effect of improving the adhesiveness of the polyurea resin to the core material. On the other hand, if the space ratio becomes too high, the strength of the high-strength fiber mesh fabric itself decreases and the reinforcing effect becomes insufficient. Therefore, the space ratio is preferably 93% or less, more preferably 90% or less. Is.

In the case of a general biaxial woven fabric, the space ratio is calculated by the following formula (2).

Further, in a multi-axis woven fabric such as a triaxial woven fabric and a quadruple woven fabric, the spatial ratio can be obtained by using an image analysis device. Simply, a black-and-white copy is taken with an electrophotographic (ZEROX) type copier, and it can be obtained by using the copied image (area of the black portion / area of the entire effective portion) × 100.

FIG. 3 is a diagram for explaining the spatial ratio, the opening, and the thread width when the high-strength fiber mesh fabric of the present invention is a lattice-shaped mesh sheet. The opening (Me, Mf) of the warp and weft is the length between adjacent fibers. The widths of the warp and weft (We, Wf) are both the widths of the fibers constituting the mesh fabric. The width of the fiber is related to the degree of fiber opening, widening / flattening, and the number of twists. The width of the fiber increases as the width / flattening of the fiber progresses, and decreases as the number of twists increases.

In the case of high-strength fiber mesh fabric, by reducing the number of fibers per inch and reducing the width of the fibers used, the opening of the fabric can be increased, and as a result, the space ratio is increased. be able to. In order to reduce the width of the fiber while maintaining the strength of the mesh fabric, it is effective to use a high-strength fiber that is hard to cut even if it is thin.

The wall material 10 of the present embodiment is made of a core material 1 made of a foamed synthetic resin, a high-strength fiber mesh cloth 3 for reinforcing at least one side of the core material 1, and both sides of the core material 1 and the high-strength fiber. It includes a resin layer 2 made of a polyurea resin that covers the mesh cloth 3.

That is, the presence of the core material 1 and the resin layer 2 having extremely high toughness significantly improves the bending strength and shear strength of the wall material. Further, even when an impact is applied from the outside, the high-strength fiber mesh fabric 3 having high strength and elastic modulus exists without breaking, so that the impact from the outside is alleviated and the impact on the core material 1 is applied. It is weakened. At the same time, the high-strength fiber mesh fabric 3 freely expands and contracts or bends in accordance with the deformation of the resin layer 2, so that the movement of the resin layer 2 is appropriately relaxed. As a result, even if a large impact is applied to the wall material at the time of a collision of a car or the like, the resin layer 2 expands and contracts following the deformation of the core material 1 and the high-strength fiber mesh cloth 3, and the wall material becomes self-supporting without being destroyed. It is possible to keep the state.
Even in the absence of the high-strength fiber mesh fabric 3, the resin layer 2 made of polyurea resin having extremely high toughness bends following the deformation of the core material 1 to prevent the wall material from breaking. can do.
When the high-strength fiber mesh fabric 3 is subjected to a strong impact, the resin and the fiber surface are peeled off. Therefore, when reinforcing only one side with the high-strength fiber mesh fabric, it is better to arrange it on the opposite surface that receives the impact. High effect can be expected.

Further, in the present invention, the surface of the core material 1 may be subjected to a primer treatment as long as the effect of the wall material is not hindered. By the primer treatment, the adhesion between the core material 1 and the polyurea resin 2a can be improved.

Further, in the present invention, a finishing material (paint) may be sprayed or applied to the surface of the polyurea resin 2. Finishing materials are polyurethane-based, acrylic silicone-based, fluorine-based, epoxy-based, vinyl-based, polyester-based, melamine-based, aminoalkyd-based, from the viewpoints of weather resistance, scratch resistance, abrasion resistance, workability, appearance, etc. A resin material such as urea can be appropriately selected and used. The form of the resin material is not particularly limited, such as water-based, emulsion, and solvent-based. As for the curing method, a one-component type, a two-component type, an ultraviolet curing method, or the like can be appropriately selected and performed. Known additives (gloss adjuster, ultraviolet absorber, light stabilizer, antibacterial agent, fungicide) may be added to the paint.

Alumina, silica, silicon nitride, silicon carbide, glass beads and the like may be added to the paint from the viewpoint of improving the design. Alternatively, it can be tiled.

The wall material described in the above embodiment is an example for embodying the technical idea of the present invention, and the shape, dimensions, etc. of each material are not limited to those of this embodiment. Various changes can be made within the scope of the present invention.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to the following Examples.

(Example 1)
Polyurea resin (Extreme 11-50 manufactured by Rhino Lining Co., Ltd.) is applied to the surface of a flat core material (width 2 m, height 1.8 m, thickness 10 cm) made of Styrofoam, and the amount applied is approximately 2.2 kg / m ^2. It was sprayed so as to be (Fig. 1 (a)).
On the other hand, on the back side of the core material, first, the same polyurea resin as above is ^{sprayed so that the coating amount is about 0.5 kg / m 2,} and immediately after that, a mesh cloth made of aramid fiber (aramid fiber; Toray DuPont Co., Ltd.) Kevlar (R) made of cloth, with a texture of cloth; 45 g / m ² , space ratio; 90%) was attached. After the fabric was firmly adhered to the core material, the polyurea resin ^{was sprayed onto the mesh fabric so that the coating amount was about 2.2 kg / m 2} (FIG. 1 (b)).
The upper surface of the wall material was sprayed with polyurea resin so that the coating amount was about 2.2 kg / m ^2.
Acrylic resin was applied to the front surface, back surface, and upper surface of the wall material as a finishing material.

(Example 2)
A polyurea resin (Extreme 11-50 manufactured by Rhino Linings Co., Ltd.) was applied to the surface of a flat core material made of the same foamed styrol as that used in Example 1 (the surface on which an impact object hits), and the amount applied was about 0.5 kg. It was sprayed so as to be / m ^2, and immediately after that, a mesh cloth made of aramid fiber (aramid fiber; Kevlar (R) manufactured by Toray DuPont Co., Ltd., cloth grain; 45 g / m ² , space ratio; 90%) was pasted. .. After the fabric was firmly adhered to the core material, the polyurea resin ^{was sprayed onto the mesh fabric so that the coating amount was about 2.2 kg / m 2} (FIG. 2 (a)).
On the other hand, on the back surface of the core material, as with the front surface of the core material, the same polyurea resin as above is ^{sprayed so that the coating amount is about 0.5 kg / m 2,} and immediately after that, a mesh cloth made of aramid fiber (aramid fiber). Kevlar (R) manufactured by Toray DuPont Co., Ltd., with cloth grain; 45 g / m ² , space ratio; 90%) is pasted, and after the cloth is firmly adhered to the core material, the amount of polyurea resin applied is about. It was sprayed onto the mesh cloth so as to be 2.2 kg / m ^{2 (FIG. 2 (b)).}
The upper surface of the wall material was sprayed with polyurea resin so that the coating amount was about 2.2 kg / m ^2.
Acrylic resin was applied to the front surface, back surface, and upper surface of the wall material as a finishing material.

According to the wall material of the present invention, it is possible to construct a lightweight and durable wall instead of a block wall or a concrete wall in which concrete blocks are stacked. Therefore, in public facilities such as schools and hospitals, houses, sites, etc. By providing it in the surroundings, it is possible to prevent internal equipment from external collisions and provide a safe environment where there is no risk of collapse in the event of an earthquake.

1 Core material 2 Resin layer (coating layer) made of polyurea resin
2a Resin layer made of polyurea resin (adhesive layer)
3 High-strength fiber mesh fabric 10 Wall material

Claims (6)

A flat wall material having at least one type of expanded synthetic resin selected from the group consisting of expanded polystyrene, expanded polyurethane, expanded polyethylene, and expanded vinyl chloride as a core material.
A wall material comprising: a high-strength fiber mesh cloth that reinforces at least one side thereof, and a resin layer made of a polyurea resin that covers both sides of the core material and the high-strength fiber mesh cloth. The wall material according to claim 1, wherein the thickness of the core material made of the foamed synthetic resin is 20 mm or more and 200 mm or less. The wall material according to claim 1 or 2, wherein the high-strength fiber mesh fabric is at least one selected from a woven fabric, a knitted fabric, a knitted fabric, and a honeycomb-shaped fabric. The claim that the high-strength fiber is at least one selected from the group consisting of glass fiber, boron fiber, ceramic fiber, aramid fiber, polyparaphenylene benzbisoxazole fiber, high-strength polyethylene fiber and total aromatic polyester fiber. The wall material according to any one of 1-3. The wall material according to any one of claims 1 to 4, wherein the high-strength fiber is an aramid fiber. The invention according to any one of claims 1 to 5, wherein the high-strength fiber mesh fabric has a space ratio of 70% or more and the number of warp threads and weft threads per inch is 0.5 to 10. Wall material.

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