JPH01295955A - Construction material and manufacture thereof - Google Patents

Abstract

PURPOSE:To reduce the number of manufacturing processes and to make it possible to execute in a reduced working schedule by manufacturing a construction material having fire resistance and heat insulating efficiency formed of a gypsum plaster board layer and a foaming resin particle layer at a factory. CONSTITUTION:After applying foaming resin liquid containing resin water emulsion and foaming resin particle to at least one surface of a gypsum plaster board, the foaming resin particle is foamed by heating an applied surface. The emulsion is dried to join the foaming resin particle, and a foaming resin particle layer 3 is adhered to the gypsum plaster board. According to the constitution, such a material as has fire resistance and heat insulating efficiency, and as is equipped with the foaming resin layer 3 in the gypsum plaster board in advance can be manufactured at a factory, so that an adiabatic work at a construction field is not required, and an execution can be easily carried out.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field] The present invention relates to a building material, particularly a building material having heat insulating properties useful for wall materials, ceiling materials, etc., and a method for producing the same.

[Prior Art] Conventionally, the exterior walls of buildings are generally made by temporarily fixing glass fiber insulation material sandwiched between aluminum foil and resin film to a board nailed to a pillar, and then covering the board side with asphalt waterproof paper and metal lath. , a mortar finish is applied, and then glue such as acrylic lysine is applied on top to create an insulating exterior wall, plasterboard is pasted inside the insulation material, and wall materials such as vinyl cloth are attached. .

[Problems to be solved by the invention] However, such exterior wall construction involves many steps and requires many types of materials, and the installation of insulation materials, plasterboard, wallpaper, etc. must be done on-site. This method took many work days and could not be said to be an economically advantageous method.

Furthermore, since these exterior wall materials use many different materials, there is a problem in that the exterior walls tend to crack over time.

[Means for Solving the Problems] In view of the above-mentioned problems, the present inventors have conducted extensive research into building materials that require a small amount of materials, a small number of construction steps, and can be extremely easily used as exterior wall materials. As a result, we have arrived at the present invention.

That is, the present invention provides a building material comprising one gypsum board layer and a foamed resin particle layer in which foamed resin particles are bonded to at least one surface of the gypsum board layer by an aqueous resin emulsion. , and its manufacturing method: 1. After applying a foamable resin liquid containing an aqueous resin emulsion and foamable resin particles to at least one surface of a gypsum board, the foamable resin is heated by M heating the applied surface. This invention provides a method for producing architectural scrap materials, which comprises foaming the particles and drying the emulsion to bond the foamed resin particles to form a layer of foamed resin particles adhered to a gypsum board.

[Detailed Description of the Invention] (1) Gypsum board The gypsum board used as the building material of the present invention is a hydraulic gypsum such as hemihydrate gypsum treated with chemical gypsum or natural gypsum, and fibers and aggregates are added as necessary. After adding reinforcing materials such as and kneading with an appropriate amount of water, the core is coated on both sides with base paper for board to maintain its shape, formed to a certain thickness, and cured.
It is cut and dried until the moisture content is 3% or less.
For example, JIS-A8901 has a thickness of 9n+m and 12mm.
In addition to those specified as 15a+a, those thinner than that or those with a thickness of 20 mm can be used.

(2) Foamable resin liquid The foamable resin liquid applied to the gypsum board in the present invention basically contains the following resin aqueous emulsion and expandable resin particles.

As an adhesive resin used by dispersing it in an aqueous medium in a resin aqueous emulsion, n-propyl methacrylate (
7381℃), styrene (Tg 100℃), acrylonitrile (Tg 1o (1℃), methyl methacrylate (
Tg 105°C), methacrylic acid (Tg 130°C),
itaconic acid (Tg 130℃), acrylamide (Tg
153°C), 2-ethylhexyl acrylate (Tg-
85℃), n-butyl acrylate (Tg-54℃), ethyl acrylate (Tg-22℃), isopropyl acrylate (Tg-5℃), 2-ethylhexyl methacrylate (Tg-5℃), acrylic acid n-propyl (Tg 8℃
), n-butyl methacrylate (Tg 20℃), vinyl acetate (Tg 30℃), ethyl methacrylate (Tg 8
5℃), vinyl chloride (Tg 79℃), vinylidene chloride (Tg -18℃), 2-hydroxyethyl acrylate,
2-hydroxypropyl acrylate, butadiene, 2-hydroxyethyl methacrylate, 2-methacrylate
Aqueous emulsions of homopolymers such as hydroxypropyl, diethylene glycol monoacrylate, glycidyl acrylate, glycidyl methacrylate, N-methylol acrylamide, N-methylol methacrylamide, or copolymers of two or more of these monomers [shown in parentheses] Tg is the glass transition point of these vinyl monomers or vinylidene chloride homopolymers.

The resin solid concentration in the aqueous emulsion of these resins is usually 20 to BO weight 2, and the diameter of the dispersed resin particles is usually 10 tiles or less, preferably 0.05 to 1.0.
This is River I.

The foamable resin particles contained in the foamable resin liquid include styrene containing a polymerization initiator, and if necessary, vinyl monomers such as methyl methacrylate, vinylbenzene, and acrylic acid in water. Distribute and add? 8 to polymerize a vinyl monomer such as styrene, and then inject a swelling agent such as butane or heptane into the suspension in which the polymer particles are dispersed, and add a volatile swelling agent to the polymer particles. 1～
Expandable polystyrene particles manufactured by impregnation at a ratio of 2 parts by weight of 1O2, or by polymerizing while supplying the expansion agent to the suspension during suspension polymerization of vinyl monomers such as styrene. , or expandable α-methylstyrene-styrene copolymer particles produced by coexisting α-methylstyrene with the above styrene, or expandable acrylonitrile Φ butadiene 9-styrene copolymer produced by coexisting acrylonitrile and butadiene with the above styrene. Resin (foamable ABS) or the like can be used.

These expandable resin particles generally have a particle size of t, 5+u
+ or less, preferably 0.2 to 0.8 ts. If the above particle size exceeds 1.51, the workability of mixing with the aqueous resin emulsion will be poor, and the expandable resin particles will not form in the upper layer of the emulsion liquid. This is undesirable because it tends to migrate and separate, which deteriorates the storage stability of the foaming resin liquid itself.Also, if the diameter of the resin particles is large, it becomes difficult to apply it to the gypsum board and the coating properties decrease. This is undesirable, and furthermore, the foamed resin particles tend to fall off after the foamed resin liquid is applied to the gypsum board and dried.

118,110 groups In addition to the above essential ingredients, if necessary, cement, calcium carbonate, aluminum hydroxide, clay, talc,
Extender pigments such as barium sulfate, foamed fillers such as shirasu and glass, pigments such as red iron oxide and titanium oxide, glass am
, synthetic fibers, inorganic fibers, metal fibers, flame retardants, iron powder, iron oxide, colorants such as carbon and dyes, DOP, BB
Plasticizers such as P, GDP, and XDP, toluene,
Coating aids such as nasal spleen spirit, thickeners such as methyl ethyl cellulose and polyvinyl alcohol, antifreeze agents,
Antifoaming agent 1 A dispersing agent, an aziridine compound, a hydrazine compound, a melamine, a urea compound, an amine compound as a crosslinking agent, a foaming agent, a wetting agent, an emulsifier, etc. can be blended. It is also preferable to use expandable resin particles that have undergone flame retardant treatment.

1 amount of expandable resin particles is added to the resin aqueous emulsion in an amount of 50 to 100 parts by weight per 100 parts by weight of resin in the emulsion.
oo parts by weight, preferably 150 to 600 parts by weight.

(3) Application By applying the foamable resin liquid to at least one surface of the gypsum board, the board paper of the gypsum board is impregnated with the resin aqueous emulsion in the foamable resin liquid, and the foamed resin layer and the gypsum board layer This improves the adhesion between the two layers, making it difficult for the two layers to separate.

The foaming resin liquid is generally applied using a roll, spray, foam coating, etc. After application, the emulsion is impregnated into the gypsum board by pressing with a nip roll.

The amount of foaming resin liquid applied is generally 100 to 100% as solid content.
1.700 g/m', preferably 300-1.300
It is about g/rn'.

(4) Shape-retaining material After applying the foamable resin liquid onto the gypsum board, place a shape-retaining material on the surface of the foamable resin liquid if necessary while the foamable resin liquid is still undried. This is desirable.

As the shape-retaining material, any material can be used as long as it can maintain the shape so that the foamable resin particles do not peel off even after the water in the emulsion evaporates and the foamable resin particles foam. I can do it. Specifically, breathable materials such as woven fabrics, non-woven fabrics, resin films, sheets, paper, inorganic fibers, metals, nets, and foils, as well as materials with reduced pores to make them breathable, are used. Among these, it is particularly preferable to use paper or nonwoven fabric.

As the nonwoven fabric, a nonwoven fabric made of thermoplastic resin fibers is preferably used, and polyethylene, polypropylene, linear polyester, polyamide, etc. have a melting point of 80 to 258°C.
mll11 of thermoplastic resin, or composite m#I of these materials, which may be thin or thick depending on the purpose, but are usually 3 denier or more, and the fiber length is 81 mm in terms of entanglement. The above is preferable and can be obtained by intertwining the resin fibers by a method such as a spun-pounding method or a needle bunching method. Alternatively, a fiber web obtained by carding or the like or a fiber web fixed with a binder may be used, and the basis weight is 8 to 800 g/m', preferably 10 to 500 g/m'.
In addition, needle felt, phenol felt, and hot-melt fiber felt, which are mainly made of recycled fibers and generally called felt, can be used. Furthermore, there are those made of glass cloth or sheets.

The building material of the present invention on which such a shape-retaining material is placed has the following properties:
A glue such as acrylic lysine can be directly applied thereon, and the coated glue becomes entangled with the nonwoven fabric fibers, resulting in good adhesion of the lysine to the foamed resin particle layer.

(5) Heating The foamable resin liquid coated on the gypsum board is heated to foam the foamable particles and dry the emulsion. Heating is performed using a heating means such as an infrared heater, a suction dryer, or a hot air dryer. Heating is generally carried out at a temperature higher than the foaming temperature of the expandable resin particles in the expandable resin liquid (50-180°C, preferably 100-180°C).
at 40°C).

Moreover, it is carried out in a short period of time (5 to 15 minutes) from the foaming resin liquid coating side, thereby drying the aqueous emulsion and foaming the foaming resin particles in the foaming resin liquid.

By this heating, the foamable resin particles are expanded to about 2 to 50 times the size, resulting in a foamed resin layer with a particle size of 0.5 to 4.5 layers, preferably 1 to 31 layers, and the foamed resin in the foamed resin layer is expanded. The particles are adhered to each other by a film formed by an aqueous resin emulsion contained in the foamable resin liquid.

(6) Building material The building material of the present invention produced by subjecting the material to the above-mentioned means specifically includes a gypsum board layer having the structure shown in FIGS. 1 and 2, and foamed resin particles. It basically consists of a shape-retaining material layer formed as necessary.

5.1 The gypsum board layer in the building material of the present invention is basically the same as a commercially available gypsum board, but at least one side of the gypsum board layer 2 is provided with a foamed resin particle layer 3 bonded with a resin emulsion. is formed, and the resin aqueous emulsion liquid in the foamable resin liquid applied when forming the foamed resin particle layer is impregnated into the board paper 2a of the gypsum board layer 2,
A resin-impregnated board paper layer 2a' as shown in FIGS. 1 and 2 is formed on a part of the gypsum board layer, and this resin-impregnated board paper layer 2a' provides good adhesion between both layers. This makes it difficult to separate the two.

This gypsum board layer has the effect of improving sound insulation, moisture absorption, heat insulation, water resistance, etc. when this building material is used as a wall material.

Color Konomaruke 1 King 1 The foamed resin particle layer is formed by foamed resin particles covered with an emulsion resin film and expanded 2 to 50 times more and connected to each other by the adhesive force of the emulsion resin film. It is something.

This foamable resin particle layer generally has a density of 0.03 to 0.
Since the foam layer is 8g/cm'', it has the effect of improving heat insulation and soundproofing properties when used as a building wall material, and the foamed resin particles are covered with an emulsion resin film, making the emulsion resin Since the membrane forms a continuous membrane, it provides waterproof and moisture-proof properties to the gypsum board.

L1KYUJILI On the opposite side of the foamed resin particle layer from the gypsum board layer, a shape-retaining material layer made of a nonwoven fabric or the like bonded with the emulsion layer is formed as necessary.

In addition to preventing the particles of the foamable resin particle layer from peeling off, this shape-retaining material layer also prevents the particles of the foamable resin particle layer from peeling off.When this building material is used as a wall material, acrylic lysine or When spraying exterior materials such as mastic,
The building material of the present invention uses this shape-retaining material layer because it facilitates the adhesion of the glue and acrylic lysine and has a stronger adhesion strength than the two, which prevents cracks from occurring over time. It is also preferable to have 0.
When the building material of the present invention is used as a ceiling material, the foamable resin particle layer is placed on the ceiling and the outer wall does not require any shape retention, so this shape retention material is not necessarily required for the ceiling material. If so, it is a good idea to attach a decorative paper such as vinyl cloth to the surface of the board paper.

Further, the foamed layer of the present invention can be patterned by thermoforming after the formation of the two foamed layers. This means that the foam layer is 120 to 180℃.
Any desired uneven pattern can be obtained by heating and pressing or hot pressing.

In this case, a nonwoven fabric is preferable as the shape-retaining material, and it is preferable to use it as it is for the ceiling, interior and exterior, or to use it as a decoration.

(7) Construction The building material of the present invention is used at the construction site of a wooden house, etc., by attaching wood to a frame such as a pillar, and applying acrylic lysine from the outside.
Exterior walls can be completed by methods such as spraying cladding materials such as mastic or cement-based materials. Also, instead of using acrylic lysine, you may use the curtain wall construction method or nail the sizing board.

The building material of the present invention is best used as the above-mentioned wall material, but since it has water resistance, fire resistance, soundproofing and heat insulation properties, it can be used as it is or patterned to be used as an interior material. It can also be used as ceiling material.

[Example] The building material of the present invention will be specifically explained with reference to Examples below.

Example 1 Styrene (80 weight tons) and n-butyl acrylate (2
0 weight 2) [average particle size of resin 0.2 gm, solid content 50%, glass transition point 80°C] 1 particle size is 0.5 or less in 100 parts by weight. (Average particle size 0.33 mm) expandable polystyrene particles, 250 parts by weight of ``Styro Ball IBE'' [part name manufactured by Mitsubishi Yuka Verdice Co., Ltd., containing 5.8z butane], and further added to this A foamable resin liquid 3a prepared by adding a thickener "Latechol" (trade name) manufactured by Bardatessie Co., Ltd. to have a viscosity of 3000 cps at 25°C,
A licker roller 7 is applied to the surface of a commercially available gypsum board 2 placed on a manufacturing device as shown in FIG.
(solid content) by coating the foaming resin liquid layer 3a.
was formed.

Next, on this foamable resin liquid layer 3a, a polyester nonwoven fabric 4 manufactured by 1 Nippon Lutrabil ■ was placed at a weight of 100 g/m'.

Then, this laminate was heated in a hot air drying foaming machine 8 at 140°C.
It was heated and dried for 0 minutes to form a foamed resin layer in which the expandable polystyrene particles were expanded to about 10 times the size, thereby obtaining the building material 1a of the present invention shown in FIG.

The water permeability of this building material 1a was measured according to the water permeability test of JIS A-8910, and it was found to be 0.5 mQ.
It was found that the water resistance was excellent.

When the polystyrene foam particles in the foamed resin layer in this building material were measured, the particle size was 0.5 to 1.5 mm.
The bulk density was approximately 0.10 g/cni'.

Furthermore, this building material was used as an exterior wall material for a wooden house, and 1,0% of acrylic lysine 5 was applied to the nonwoven surface of this material.
00 g/m'' to form the outer wall 6a shown in FIG.

When the adhesiveness and heat insulation properties of the outer wall 6a were measured using the following method, good results were obtained as shown in Table 1.

Cut the outer wall of the funeral home into 4cm x 4cm pieces with a cutter knife.
(a) The adhesive force between the acrylic lysine layer and the foamed resin particle layer and (b) The adhesive force between the foamed resin particle layer and the gypsum board were measured using an Eastron universal testing machine.

Wataru Nijizume Measured according to JIS A-1412.

Table 1 Example 2 The second example was carried out in the same manner as in Example 1 except that the nonwoven fabric was not placed on the foamable resin liquid layer in Example 1.
A building material 1b of the present invention shown in the figure was obtained. This building material 1b was treated with 1,0 acrylic lysine 5 in the same manner as in Example 1.
00 g/rn' was sprayed to form the outer wall 6b shown in FIG. 4, and the adhesion and heat insulation properties of the outer wall 6b were measured in the same manner as in Example 1. As a result, good results were obtained as shown in Table 1.

Example 3 The building material 1a produced in Example 1 was heated at 180°C for 2 minutes using a press 1/s, and the height difference was 2.0+.
After forming a head cut texture pattern having U+ unevenness, an elastic mastic paint was sprayed over the pattern.

[Effects of the Invention] The building material of the present invention has a gypsum board layer and a foamed resin particle layer, so it has fire resistance, heat insulation, sound insulation, and water resistance, and can be used for building materials such as wall materials and ceiling materials. It has extremely excellent performance as a material for industrial use.

In particular, the building material of the present invention is produced in a factory with a foamed resin layer applied to the gypsum board in advance, so there is no need for insulation work at the construction site, and when used on external walls, ricin is applied directly to the hill. Finishing treatments such as
Compared to conventional exterior wall materials, it requires fewer steps, requires less material, and can be constructed in an extremely short number of work days.

[Brief explanation of the drawing]

FIG. 1 is a cutaway sectional view of a building material according to an embodiment of the present invention.
Figure 2 is a cutaway cross-sectional view of the building material of another example, and Figures 3 and 4 are cutaway cross-sections of an external wall made of the building material of Figures 1 and 2 with external wall materials. FIG. 5 is a sectional view of an apparatus for manufacturing the building material of the present invention. la, lb: Building material 22 gypsum board calendar 2a: Board paper layer 2a°: Resin-impregnated board paper layer 3: Foamed resin particle layer 3a: Foamed resin liquid layer 4: Shape-retaining material layer 5: Exterior material 6a, 6b: Exterior wall material 7: Ritzker roller 8: Hot air drying foaming machine

Claims (4)

[Claims] (1) A building material comprising a gypsum board layer and a foamed resin particle layer in which foamed resin particles are bonded to at least one surface of the gypsum board layer by an aqueous resin emulsion. (2) The building material according to claim 1, wherein a shape-retaining material layer is formed on the foamed resin particle layer. (3) After applying a foamable resin liquid containing an aqueous resin emulsion and foamable resin particles to at least one surface of the gypsum board, the foamable resin particles are foamed by heating the applied surface; A method for producing a building material, which comprises drying the emulsion and bonding the foamed resin particles to form a layer of foamed resin particles adhered to a gypsum board. (4) The method for manufacturing a building material according to claim 3, wherein a shape-retaining material is placed on the coated surface before heating the coated surface.