JP3970653B2 - Fixed screw hole reinforcement panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a panel having excellent load resistance.
[0002]
[Prior art]
Conventionally, in a general house, in the case of a wooden frame structure, the outer wall surface is generally finished with wood or mortar whose surface is painted by spraying. In this case, a curing period of mortar and a drying period of paint are necessary, and this construction method is called a wet construction method. In addition, houses with a construction method called a two-by-four construction method such as nailing a plywood or panel to a stud and nailing a ceramic siding board to the outside or hooking a tile etc. to a horizontal rail are also common. The construction method is called the dry construction method.
[0003]
The above-mentioned wet construction method, for example, when painting by spraying on the outer wall surface, is not only a problem of increased environmental burden due to scattering of paint liquid fine powder to neighboring houses and volatilization of organic solvent in the paint, but also paint finish The outer wall surface due to has deteriorated the color tone and the surface resin layer in about 10 years, so that the appearance of the outer wall surface deteriorates, and therefore there is a problem that repainting is required. In addition, the construction method in which bricks, tiles and the like are stacked or pasted through mortar also has a problem that a long construction period is required for curing.
[0004]
On the other hand, in the dry construction method, for example, when using ceramic siding boards or tiles as disclosed in JP-A-5-209454, the weight per unit area is heavy and the weight may be excessive. Many designs had to be able to withstand a large weight from the design stage. In particular, in a wooden framed house, when trying to use ceramic siding boards or tiles to renovate the outer walls of so-called second-hand houses after the 10th year of construction without repainting. However, it will exceed the design strength of existing outer wall materials and pillars, and ceramic heavy siding boards and tiles, which are heavy in weight, are often not usable. Even if the house itself is remodeled using ceramic siding boards or tiles, it is necessary to remove existing outer wall materials and reinforce pillars so as not to exceed the design load of existing outer wall materials and columns. Construction was often necessary, and it was extremely inconvenient for the renovation work.
[0005]
Also, in the construction of ceramic siding materials, a large flat panel, usually 3 x 6 (about 90 cm x about 180 cm), is fixed by nailing. The burden placed on the installer during the positioning work is large.
Therefore, in recent years, lightweight siding materials such as metal siding have been developed as lightweight outer wall materials, which are embossed unevenness on the surface of a thin metal plate such as aluminum constituting the surface layer, and the inner layer is urethane foam or the like The construction method of attaching this to the existing outer wall surface by nailing is adopted. This construction method is disclosed in, for example, Japanese Patent Laid-Open No. 63-125770.
[0006]
However, the uneven shape of the aluminum surface often lacks a high-quality appearance because it is too glossy. Further, since aluminum has a melting point of 660 ° C., when an open flame is violently in contact with the surface of the outer wall due to a fire or the like, the surface is melted and destroyed, and there is a problem in terms of fire resistance.
Similarly, as a lightweight outer wall material, a panel molded from a thermoplastic resin as a main raw material is disclosed in JP-A-7-217059. However, thermoplastic resin-based siding materials have poor fire resistance, and there is a problem that they cannot be used as outer wall materials in areas designated as fire prevention areas.
[0007]
Also, in these dry constructions, it is usually necessary to screw the panel to the outer wall, so it is necessary to make the screw stopper part thick to some extent in order to give the screw stopper part sufficient strength. It was.
[0008]
[Problems to be solved by the invention]
In view of the above circumstances, an object of the present invention is to provide a panel that is easily attached to an outer wall of a general house with nails, screws, or the like and has excellent load resistance.
[0009]
[Means for Solving the Problems]
As a result of diligent research to solve the above-mentioned problems, the present inventors have fitted a tubular body made of, for example, a metal material as a reinforcing material along the inner peripheral surface of the fixing screw hole of the panel, so that the screw mounting portion is a panel. It has been found that it is possible to prevent deterioration and damage due to its own weight, and the present invention has been completed.
That is, the present invention is as follows.
[0010]
(1) A building panel having a fixed screw hole , molded using a molding resin composition containing at least a phenol resin, an inorganic filler, and inorganic fibers , wherein the fixed screw hole has a short side An elliptical or rectangular screw hole having a width of 2 mm to 10 mm, a long side length of 10 mm to 200 mm, a depth of 1 mm to 10 mm, and along the inner peripheral surface of the fixed screw hole A panel comprising a material selected from the group consisting of ceramic, iron alloy, stainless steel, and copper alloy and having a thickness of 0.1 mm or more and 10 mm or less .
( 2 ) The panel according to ( 1 ), wherein the inorganic filler is mainly composed of a mixture of aluminum hydroxide and kaolin clay.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail focusing on particularly preferred embodiments.
The fixing screw hole in the present invention is a hole into which a screw is driven in order to attach the panel to the outer wall portion using a screw, and the shape of the fixing screw hole can be easily fixed by the screw, and the fixing portion is constant. Any width can be selected, but the shape of the fixing screw hole is oval or rectangular so that the screw can be easily fixed, and the fixing part has a degree of freedom and the fixing location can be selected. Therefore, it is preferable. An example of the shape of the fixing screw hole is shown in FIG.
[0012]
The width of the short side of the fixing screw hole in the present invention is preferably 1 mm or more and 20 mm or less, more preferably 2 mm or more and 10 mm or less from the viewpoint of facilitating fixing of the screw. It is necessary to use a screw that is inserted into the fixed screw hole and is fixed in size according to the width of the short side of the fixed screw hole. If the fixed screw hole has a width of 1 mm or more, the fixed screw is used. If the load resistance of the screw matched to the hole is sufficient, and the width is 20 mm or less, the design of the panel is not impaired. The width of the short side of the fixed screw hole here refers to the width of a in the fixed screw hole illustrated in FIG. 1, and when the shape is changed, it is set to the narrowest maximum width.
[0013]
Further, the length of the long side of the fixing screw hole in the present invention is preferably 5 mm or more and 300 mm or less, more preferably 10 mm or more and 200 mm or less. If the length of the long side of the fixing screw hole is 5 mm or more, sufficient freedom is obtained in the fixing position by the screw at the time of panel construction, and if it is 300 mm or less, the load resistance of the panel is not adversely affected. A panel that is satisfactory in terms of load resistance can be obtained. The length of the long side of the fixed screw hole here refers to the width of b in the fixed screw hole illustrated in FIG. 1, and when the shape changes, the longer maximum width is used.
[0014]
The depth of the fixing screw hole in the present invention is preferably 0.5 mm or more and 20 mm or less, more preferably 1 mm or more and 10 mm or less. If the depth of the fixing screw hole is 0.5 mm or more, sufficient load resistance is obtained, and if it is 20 mm or less, the appearance of the panel is not impaired.
In the present invention, the fixing screw hole reinforcing material is a ceramic, iron alloy, gold, silver, copper, aluminum, aluminum alloy, stainless steel, copper alloy, etc. Any of them may be used, but ceramic, iron alloy, stainless steel, and copper alloy are more preferable from the viewpoint of strength and economy. The fixed screw hole and the same type may be of the same type that can be fitted into the fixed screw hole, and need not be exactly the same type.
[0015]
The reinforcing member for the fixed screw hole in the present invention preferably has a tubular shape whose outer peripheral surface is along the inner peripheral surface of the fixed screw hole, and its thickness is preferably 0.1 mm or more and 10 mm or less. If the thickness is 0.1 mm or more, a sufficient reinforcing effect is obtained, and if it is 10 mm or less, the aesthetic appearance of the panel is not impaired. It is preferable that the height of the reinforcing material (width in the panel thickness direction) substantially matches the thickness of the panel.
An example of attachment of the tubular reinforcing material is shown in FIG. The reinforcing material is desirably fixed to the panel with an adhesive or the like, but is not necessarily fixed completely. An example of fixing the panel with screws is shown in FIG.
[0016]
The phenolic resin in the present invention may be a resol type phenolic resin or a novolac type phenolic resin. In addition, for the purpose of increasing the degree of polymerization to these resins as necessary, For acid catalysts and novolak-type phenol resins, basic catalysts may be added, but resol-type phenol resins that are liquid at room temperature can be used without a catalyst, and the productivity can be increased. It is preferable from the point of being.
[0017]
Further, the content of the phenol resin in the panel is preferably 10 wt% or more from the viewpoint of durability as an outer wall material, and preferably 60 wt% or less from the viewpoint of fire resistance. When the content of the phenol resin is 10 wt% or more, the molded panel does not become brittle, and an outer wall material that is satisfactory in terms of durability can be obtained. Moreover, if content of a phenol resin is 60 wt% or less, since the outer wall material which has sufficient fire prevention property is obtained, the area range which can be used as an outer wall material is not limited. Further, the content of the phenol resin in the panel is preferably 15 wt% or more and 30 wt% or less.
[0018]
Examples of the inorganic filler used in the present invention include kaolin clay, aluminum hydroxide, dosonite, calcium aluminate, zinc borate, calcium carbonate, talc, microballoon, barium sulfide, anhydrous silicic acid, diatomaceous earth, glass powder, mica, carbonic acid. Examples thereof include magnesium, antimony trioxide, zonotlite, tobermorite, wollastonite, silica sand, gypsum and the like. Among them, an inorganic filler having an endothermic peak in a temperature range of 200 ° C. to 600 ° C. such as kaolin clay, aluminum hydroxide, dosonite, calcium aluminate, and zinc borate is preferable because it has a large effect of improving the fire resistance of the panel. In particular, kaolin clay, aluminum hydroxide, and zinc borate are preferable because they have a greater effect of improving the fire resistance of the panel.
The total content of the inorganic filler contained in the panel is preferably 20 wt% or more from the viewpoint of fire resistance and cost, and is preferably 80 wt% or less from the viewpoint of moldability of the panel. More preferably, it is 40 wt% or more and 60 wt% or less.
[0019]
In the present invention, it is preferable to use a mixture of two or more inorganic fillers from the viewpoint of shape retention during combustion and moldability during panel molding, rather than using a single type of inorganic filler as the inorganic filler. In particular, when only kaolin clay is used, the moldability tends to be reduced. In the present invention, it is most preferable to use a mixture of kaolin clay and aluminum hydroxide. Among inorganic fillers having an endothermic peak in the range of 200 ° C. to 600 ° C., using a mixture of kaolin clay and aluminum hydroxide not only suppresses heat generation during combustion but also causes cracks in the panel during combustion. Without generating, extremely excellent fireproof performance can be expressed. Further, there is no decrease in moldability during molding. The mixing ratio in this case is preferably a mass ratio of kaolin clay: aluminum hydroxide in the range of 1: 5 to 5: 1, more preferably in the range of 1: 3 to 3: 1. In the present invention, the main component of the mixture of aluminum hydroxide and kaolin clay is that the mixture contains 60% or more of the inorganic filler.
[0020]
The panel of the present invention preferably contains inorganic fibers. Inorganic fibers refer to glass fibers, metal fibers, mineral fibers, and the like, and these can be used alone or in combination. Among these, glass fiber is preferable because it has high strength and is advantageous in terms of cost. As a kind of glass fiber, any kind of glass such as E-glass, C-glass, T-glass, AR-glass, and D-glass may be used, but E-glass is preferable from the viewpoint of cost.
[0021]
Moreover, the fiber diameter of a glass fiber has a preferable fiber diameter of 3-30 micrometers, More preferably, it is 6-15 micrometers. The fiber length of the glass fiber is preferably 0.1 to 100 mm, and more preferably 3 to 30 mm. When the fiber diameter of the glass fiber is 3 μm or more and the fiber length is 0.1 mm or more, the reinforcing effect by the glass fiber is exhibited, and as a result, the molded product can obtain sufficient bending strength. If the glass fiber diameter is 30 μm or less and the glass fiber length is 100 mm or less, the fluidity of the molding resin composition comprising the glass fiber, the inorganic filler and the phenol resin is lowered and the moldability is inferior. Absent.
[0022]
The glass fiber content in the panel is preferably 3 wt% or more from the viewpoint of the strength of the panel, and preferably 40 wt% or less from the viewpoint of formability. More preferably, it is 8 wt% or more and 25 wt% or less.
In the production of the panel of the present invention, it is preferable to add additives such as fire retardant, ultraviolet absorber, internal mold release agent, thickener, etc., in order to impart fire resistance, weather resistance, mold release properties, etc. . In particular, it is preferable to add an internal release agent in order to improve moldability. The internal mold release agent is added so that the content in the panel is preferably 0.1 wt% or more and 10 wt% or less, more preferably 0.5 wt% or more and 5 wt% or less. Examples of the internal mold release agent include aliphatic hydrocarbons, higher aliphatic alcohols, fatty acid amides, metal soaps, and phosphates. Among them, zinc stearate, A compatible phosphate alcohol is preferable because of its high release effect.
[0023]
Moreover, when calcium hydroxide and magnesium hydroxide are not included as an inorganic filler, it is preferable to add calcium hydroxide as a thickener in order to improve moldability during molding. In this case, the amount of calcium hydroxide added is preferably 0.1 wt% or more and 5 wt% or less, more preferably 0.2 wt% or more and 3 wt% or less as the content in the panel.
The panel in the present invention refers to a flat plate having a flat surface, a surface having a design molded by a molding resin composition for a panel, or a panel-shaped molded body decorated by painting. The panel obtained by the present invention can be used as a building material such as an outer wall material, an inner wall material, a flooring material, a roofing material, a ceiling material, etc., but particularly as an outer wall material for renovation because of its durability, fire resistance, and design. Is preferred. For this reason, it is preferable that the structure of the panel can be devised to make it easier and more robust.
[0024]
If the thickness of the panel is too thin, the shape retention and strength reduction of the panel after combustion become remarkable, so the average thickness of the panel is preferably 0.5 mm or more and 20 mm or less, more preferably 1 mm or more and 5 mm or less. From the viewpoint of workability, the size of one panel is preferably 0.1 m ² or more and 4 m ² or less, more preferably 0.2 m ² or more and 1 m ² or less. Further, the mass of one panel is preferably 0.1 kg or more and 10 kg or less, more preferably 0.5 kg or more and 6 kg or less, and it is also recommended to have a fitting structure on the upper, lower, left and right parts of the panel. Here, the fitting structure refers to a structure in which a convex portion is provided in a part of a panel and a concave portion is provided in a part of another panel, and the convex portions and the concave portions of two panels are fitted and the panels can be added.
[0025]
As a method for producing the panel of the present invention, a mold which can be separated into upper and lower parts having a target panel shape is prepared, and the molding resin composition described above is injected into the mold in a necessary amount, heated and pressurized, and thereafter A panel molded body is manufactured by a normal press molding method or injection molding method in which a mold is opened and a target panel molded body is taken out, and then metal reinforcement is performed along the inner peripheral surface of the fixed screw hole in the fixed screw hole portion of the panel. It can be manufactured by inserting a material.
[0026]
Hereinafter, the present invention will be described based on examples.
[Example 1]
20.0 parts by mass of a resole phenolic resin (trade name “BRL-240” manufactured by Showa Polymer Co., Ltd.), 0.3 parts by mass of calcium hydroxide (reagent special grade manufactured by Kanto Chemical Co., Ltd.) as a thickener, inside As a mold release agent, zinc stearate (reagent grade 1 manufactured by Kanto Chemical Co., Ltd.) 1.0 part by mass, aluminum hydroxide (produced by Showa Denko KK, trademark “Hijilite H32”) 35.0 parts by mass, kaolin clay ( ENGELHARD, trademark “ASP-400P”) 35.0 parts by mass, fiber length 3 mm, fiber diameter 10 μm glass fiber (manufactured by Nitto Boseki Co., Ltd., trademark “CS-3SK”) 10.0 parts by mass (Made by Chiyoda Giken Co., Ltd., trademark “OM-5”) was mixed and stirred for about 1 minute to obtain a molding resin composition. The steel resin mold having a surface chrome plating finish mounted on a pressure press heated to 180 ° C. was quickly charged with the molding resin composition, and the mold was closed and heated and pressurized (180 ° C., 1.17 × 10 ⁷ Pa), a panel molded body having the same shape as that in the mold was obtained. The shape of this panel is shown in FIGS. The average thickness is 2 mm, the mass per unit area is 5 kg / m ² , the horizontal width is 900 mm, the vertical width is 350 mm, and there are six fixing screw holes in the upper part. The screw hole has a long side length of 80 mm and a short side width of 8 mm.
[0027]
A stainless steel tubular reinforcing material (average thickness 0.3 mm, height 2 mm) having an outer peripheral surface of the same type as the inner peripheral surface of the fixed screw hole is fitted into the fixed screw hole portion of the panel molded body, fixed with an adhesive, and evaluated. A panel for was obtained.
Screws are passed through the screw holes of this panel molded body, and both ends of the screws are fixed to the upper part of a tensile testing machine (trademark “TCM-500 universal tensile compression testing machine” manufactured by Minebea Co., Ltd.), and the lower part of the panel is pulled. By fixing to the lower part of the machine and performing a tensile test, a load was applied to the screw hole and a load resistance test was performed three times. However, no cracks, cracks, etc. occurred in any panel.
[0028]
[Comparative Example 1]
When the same load resistance test was performed three times on the panel in which the reinforcing material was not fitted, cracks occurred in the screw fixing portions in the two panels.
[0029]
【The invention's effect】
According to the present invention, it is possible to provide a panel having excellent load resistance.
[Brief description of the drawings]
FIG. 1 (a) is a plan view of a panel showing an embodiment of the present invention, and FIG. 1 (b) is a cross-sectional view taken along line AA ′ of FIG. 1 (a).
FIG. 2 is a perspective explanatory view showing an example of attaching a reinforcing material.
3A is a plan view showing an example of a state in which the panel is screwed, and FIG. 3B is a cross-sectional view taken along the line BB ′ of FIG. 3A.
[Explanation of symbols]
1 Panel 2 Fixing screw hole 3 Reinforcing material

Claims (2)

A building panel having a fixed screw hole formed using a molding resin composition containing at least a phenol resin, an inorganic filler, and an inorganic fiber , wherein the fixed screw hole has a short side width of 2 mm. 10 mm or less, a long side length of 10 mm or more, 200 mm or less, a depth of 1 mm or more and 10 mm or less of an elliptical or rectangular screw hole, and ceramic along the inner peripheral surface of the fixed screw hole A building panel comprising a tubular reinforcing material having a thickness of 0.1 mm or more and 10 mm or less, which is made of a material selected from the group consisting of iron alloy, stainless steel and copper alloy . The panel according to claim 1 , wherein the inorganic filler is mainly composed of a mixture of aluminum hydroxide and kaolin clay.

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