JPH01308622A - Material for construction and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain a material for construction having fire resistance, heat- insulating properties, sound-insulating properties and waterproofness by composing the material for construction of a cement external layer material layer and a foamed resin particle layer in which foamed resin particles are joined with the cement external layer material layer by resin aqueous emulsion. CONSTITUTION:A material for construction consists of a cement external layer material layer and a foamed resin particle layer in which foamed resin particles are joined with at least one surface of the cement external layer material by resin aqueous emulsion. At least one surface of the cement external layer material is coated with a foamed resin liquid containing the resin aqueous emulsion and the foamed resin particles, a coated surface is heated and the foamed resin particles are foamed, emulsion is dried and the foamed resin particles are cemented, and the foamed resin particle layer bonded with a cement group external layer material is formed, thus manufacturing the material for construction. An asbestos cement board and a pulp cement board are preferable as the cement external layer material. A resin, a minimum film forming temperature of which is brought to a heating temperature or lower, concretely, methacrylic acid n-propyl, styrene, etc., is used as a bonding resin.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application 1] 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 manufacturing the same.

[Prior Art] Conventionally, the exterior walls and roofs of buildings were generally finished by applying a cement-based outer layer material and then applying a glue coat such as acrylic lysine or a top coat coat such as acrylic paint. In addition, in order to provide these with waterproof and heat insulating properties, an asphalt waterproofing material is further applied or a foamed resin board such as a foamed polystyrene board is attached using an adhesive.

[Problems to be solved by the invention] However, construction of such external walls involves many steps and requires many types of materials.Furthermore, the installation of insulation boards must be done on-site, which takes many work days and is not economical. It could not be said that it was a financially 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 has 49 characteristics that it is composed of a cement-based outer material layer and a foamed resin particle layer in which foamed resin particles are bonded to at least one surface of the cement-based outer material layer by an aqueous resin emulsion. construction materials,
And, as a manufacturing method thereof, after applying a foamable resin liquid containing an aqueous resin emulsion and foamable resin particles to at least one surface of a cement-based outer layer material, the foamable resin solution is applied by heating the coated surface. Provided is a method for manufacturing a building material, which comprises foaming resin particles and drying the emulsion to bond the foamed resin particles to form a foamed resin particle layer adhered to a cement-based outer layer material. .

[Detailed Description of the Invention] (1) Cement-based outer layer material The cement-based outer layer material used in the building material of the present invention is formed by paper molding, extrusion molding, or casting using cement and other raw materials as main raw materials. For example, an asbestos slate board (JIS A-
5403), asbestos-cement perlite board (JIS
A-5413), asbestos cement calcium silicate board (JI
S A-5418), asbestos cement boards such as decorative asbestos cement boards and decorative tricalcium silica boards, and pulp cement boards made by paper-forming using cement, asbestos, pulp, and inorganic mixed materials as main raw materials (JIS A-5414), this Decorative pulp cement board (JIS A-
5420), wood chip cement board (JIS A-5417), compression molded using wood chips and cement as the main raw materials, wood wool cement board (JIS A-5417), compression molded using wood wool and cement.
There are wood cement boards such as IS A-5404), and among these, asbestos cement boards and pulp cement boards are preferable.

(2) Foamable resin liquid The foamable resin liquid applied to the cement-based outer layer material in the present invention basically contains an aqueous resin emulsion and expandable resin particles.

Adhesive resins used by dispersing in an aqueous medium in emulsion resin aqueous emulsions include resins whose minimum film-forming temperature is lower than the heating temperature. Tg 100℃),
Acrylonitrile (7g 100℃), ethyl methacrylate (Tg 105℃), methacrylic # (7g 130℃)
), itaconic acid (Tg 130℃), acrylamide (
Tg 153°C), 2-ethylhexyl acrylate (Tg
g-85°C), n-butyl acrylate (Tg-54°C)
), ethyl acrylate CTg-22°C), isopropyl acrylate (Tg-5°C), methacryl, 2-ethylhexyl acid (Tg-5°C), n-propyl acrylate (Tg-5°C)
g8'C), n-butyl methacrylate (Tg
20°C), vinyl acetate (Tg 30°C), ethyl methacrylate (Tg 85°C), vinyl chloride (Tg 79
°C), vinylidene chloride (Tg-1s °C), 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, diethylene glycol monoacrylate, glycidyl methacrylate, glycidyl Acrylate, N-methylolacrylamide, N-
Aqueous emulsion of homopolymer of methylol methacrylamide, butadiene, etc. or copolymer of two or more of these monomers [Tg shown in parentheses is the glass of homopolymer of these vinyl monomers or vinylidene chloride] transition point], and a mixture of an aqueous resin emulsion with a Tg higher than the heating temperature and an aqueous resin emulsion with a Tg lower than the heating temperature, and the lowest film forming temperature of the mixture is lower than the heating temperature.

The resin solid content concentration in the aqueous emulsion of these resins is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is usually 10 lm or less, preferably 0.05 to 1.0 m.
It is gm.

Button 7 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 dispersed in water. By heating this, a vinyl monomer such as styrene is polymerized, and then an expanding agent such as butane or heptane is injected into the suspension in which the polymer particles are dispersed, and the polymer particles are volatilized. In the case of suspension polymerization of vinyl monomers such as styrene, polymerization is carried out while supplying the swelling agent to the suspension. The produced expandable polystyrene particles, or the expandable α- produced by coexisting α-methylstyrene with the above styrene
Methylstyrene/styrene copolymer particles or a foamable acrylonitrile/butadiene/styrene copolymer resin (foamable ABS) produced by coexisting acrylonitrile and butadiene with the above styrene can be used.

These expandable resin particles generally have a particle size of 1.5 mm.
If the particle size exceeds 1.5 mm, the workability of mixing with the aqueous resin emulsion will be poor, and one expandable resin particle will be in the upper layer of the emulsion liquid. It becomes easier to move to the part and shunt 1
This is undesirable because the storage stability of the foamable resin liquid spout deteriorates. Also, if the diameter of the resin particles is large, it becomes difficult to coat onto the cement-based outer layer material and the four-sided property is undesirable. Furthermore, after the foamable resin liquid is applied to the cement-based outer layer material and dried, the foamed resin particles tend to fall off.

Since the expandable resin particles used are finer than those used in the molding of ordinary foamed products, non-standard products can be utilized in the process of manufacturing expandable resin particles.

Length: 10,110 L In addition to the above essential ingredients, if necessary, extender pigments such as calcium carbonate, water-stained aluminum, clay, talc, barium sulfate, pigments such as Portland cement, red iron oxide, titanium oxide, and carbon, glass fiber, Synthetic fiber,
Light aggregates such as inorganic fibers, metal fibers, shirasu balloons, perlite, and vacuum light, flame retardants, dyes, iron powder, iron oxide, plasticizers such as DOP, BBP, CDP, and XDP, and film formation such as toluene and mineral spirits. auxiliary agent,
Methyl ethyl cellulose, polyvinyl alcohol, other thickeners, antifreeze agents, antifoaming agents, dispersants, wood generators, wetting agents, emulsifiers, etc. can be blended.

Further, as a crosslinking agent, an aziridine compound, a hydrazine compound, a melamine, a urea compound, or an amine compound may be used in combination.

Basics Add 50 to 8 parts of foamable resin particles to the aqueous resin emulsion based on 100 parts by weight of resin in the emulsion.
00 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 cement-based outer layer material, the cement-based outer layer material is impregnated with the resin aqueous emulsion in the foamable resin liquid, and the foamed resin layer and the cement-based outer layer material are impregnated with the resin aqueous emulsion in the foamable resin liquid. It has good adhesion with the outer material layer, making it difficult for the two layers to separate.

The foamable resin liquid is generally applied using rolls, spray foam coating, etc., and the emulsion is impregnated into the cement-based outer material layer by pressing with nip rolls.

The amount of foaming resin liquid applied is generally 100 to 100% as solid content.
1,700 g/m', preferably 300-1,300
g/m'.

(4) Shape-retaining material After applying the foaming resin liquid onto the cement-based outer layer material, apply a shape-retaining material on the surface of the foaming resin liquid if necessary while the foaming resin liquid is still wet. It is desirable to set the

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 moisture in the emulsion has evaporated and the foamable resin particles have foamed. be able to. Specifically, woven fabrics, nonwoven fabrics, resin films, sheets, paper, inorganic fiber layers,
Breathable materials such as metal mesh or foil,
Materials with pores are used, and among these materials, 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 256°C.
The fibers are thermoplastic resin fibers and composite fibers thereof, and may be thin or thick depending on the purpose, but are usually 3 denier or more, and the Fa fiber length is preferably 8 mm or more from the entanglement surface. It is obtained by intertwining the resin TA fibers by a method such as a spun-pounding method or a needle punching method. In addition, fibrous webs obtained by carding, etc., fibrous webs fixed with binders, needle felts mainly made of recycled fibers commonly called felts, phenol felts, etc. = It may be made of molten felt, glass cloth sheet, or other inorganic fibers. The basis weight is 6 to 800 g/m', preferably 10 to 500
g/m''.

The building material of the present invention on which such a shape-retaining material is mounted can be coated with a glue such as acrylic lysine directly on the shape-retaining material when a non-woven fabric, wire mesh, etc. is used as the shape-retaining material. The lysine is entangled with the non-woven 1uta fibers, resulting in good adhesion of the lysine to the foamed resin particle layer.

(5) Heating 1i1 The foamable resin liquid coated on the cement-based outer layer material is heated to foam the foamable particles and dry the emulsion. Heating is performed using heating means such as an infrared heater, a suction dryer, and a hot air dryer. Heating is generally performed from one side at a temperature higher than the foaming temperature of the expandable resin particles in the expandable resin liquid (50 to 180°C, preferably 100 to 140°C) and for a short time (5 to 15 minutes). While drying the emulsion, the foamable resin particles in the foaming resin liquid are foamed.

By this heating, the expandable resin particles expand approximately 2 to 50 times, and each particle size becomes 0.5 to 4.5 arms, preferably 1 to 3 cm.
The foamed resin layer becomes a foamed resin layer, and the foamed resin particles in the foamed resin layer are adhered to each other by a film formed by the aqueous resin emulsion contained in the foamed resin liquid.

(6) Building material The building material of the present invention manufactured by subjecting the material to the above-mentioned method specifically includes a cement-based outer layer material layer having the structure shown in FIGS. 1 and 2, a foamed It basically consists of a resin particle layer and a shape-retaining material layer formed as necessary.

Cement: The cement-based outer material layer in the building material of the present invention is basically the same as the commercially available cement-based outer material layer, but at least one side of the cement-based outer material layer 2 is provided with a foamed resin particle layer bonded with a resin emulsion. 3 is formed, and the resin aqueous emulsion liquid in the foamable resin liquid applied when forming the foamed resin particle layer adheres closely to the cement-based outer material layer 2, making it difficult to separate them.

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

L This milk 1 Enyu 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.
83/am'', 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 Since the resin film forms an i!I continuous film, it imparts waterproof and moisture-proof properties to the cement-based exterior material.

A shape-retaining material layer made of a nonwoven fabric bonded with the emulsion layer is optionally formed on the opposite side of the foamed resin particle layer from the cement-based outer material layer. This shape-retaining material layer prevents the particles of the expandable resin particle layer from peeling off.

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 spraying exterior materials such as mastic,
The building material of the present invention has this shape-retaining material layer because it facilitates the adhesion of glue coatings such as acrylic lysine and has a stronger adhesion strength than both, preventing cracks from occurring over time. Also, when applying cement mortar, polymer cement mortar finishing, cement filler, etc. on non-woven fabric or wire mesh, or adjusting the unevenness, it also contributes to adhesion. 0 When using the building material of the present invention as a ceiling material In this case, the foamable resin particle layer becomes the ceiling surface and the outer wall does not require any shape retention, so this shape retention material is not necessarily required.

In the case of a ceiling material, it is preferable to further adhere a decorative paper such as vinyl cloth to the surface of the cement exterior material.Furthermore, the foam layer of the present invention can be patterned by thermoforming after the foam layer is formed. This can be done by heating the foam layer to 120 to 180°C and pressing or hot pressing to create an arbitrary uneven pattern. In this case, a nonwoven fabric is preferable as the shape-retaining material, and it is good to use it as it is or to paint it as a ceiling, interior and exterior material.

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

The building material of the present invention can be directly used as a siding board and attached to a frame such as a pillar by nailing at a construction site for a wooden house or the like. The walls can also be completed by spraying exterior materials such as acrylic lysine, mastic, or cement-based materials from the outside.

Furthermore, instead of using acrylic lysine, the curtain wall construction method may be used.

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

Example 1 Styrene (80 mm%) and n-butyl acrylate (2
To 100 parts by weight of a resin aqueous emulsion produced by emulsion polymerization of 0 weight 2) [resin average particle size 0.2 ILm, solid content 50%, glass transition point 80°C], a particle size of 0.5 + sm was added.
250 parts by weight of "Styropol IRE" (Mitsubishi Yuka Verdice Co., Ltd.'s mounting product name, containing 5.8z butane) of expandable polystyrene particles with the following (average particle size 0.33 mm) are blended, and further, Mitsubishi Oil Co., Ltd. Contains the thickener “Latecol °゛” (trade name) manufactured by Kapardice Co., Ltd.
Foaming resin liquid 3 adjusted to have a viscosity of 3000 cpS at 5°C
a on the back side of Ichisaka's cement-based outer layer material 2 placed on a manufacturing device as shown in FIG.

A foamable resin liquid layer 3a was formed by coating with a licker roller 7 at a concentration of 500 g/rn'' (solid content).

Next, a polyester nonwoven fabric 4 manufactured by 1 Japan Lutravil Co., Ltd. was placed on the foamable resin liquid layer 3a at a length of long/rn'.

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.

When the water permeability of this building material 1a was measured according to the water permeability test of JIS A-9610, it was found to be 0.5 mQ or less, indicating excellent water-blocking properties.

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

Separately, this building material 1a is used as an inner wall material, and acrylic lysine 5 is applied to the nonwoven fabric surface of this building material 1a.1.
000 g/m' to obtain an exterior wall material 6a shown in FIG.

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

Cut the Ll upper outer wall into 4CIIX 4C11 pieces with a cutter knife, and measure (a) the adhesive strength between the acrylic lysine layer and the foamed resin particle layer, and (b) the adhesive strength between the foamed resin particle layer and the cement-based outer layer material using an Instron universal testing machine. It was measured with

The thermal insulation properties of the foam layer were measured according to JIS A-1412.

Table 1 Example 2 Example 2
71 tons of the uninvented building material 1b shown in the figure was used. This building material ib was treated with acrylic lysine 5 1 in the same manner as in Example 1.
,000 g/m'' 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 with a press at 180°C for 2 minutes to form a head cut texture pattern having unevenness with height differences in the direction of the IO layer, and then an elastic mastic was applied on top of this. It was constructed by spraying the paint Ultra Soft (manufactured by Kikusui Chemical Co., Ltd.).

[Effects of the Invention] The building material of the present invention has a cement-based outer layer and a foamed resin particle layer, so it has fire resistance, heat insulation, sound insulation, and waterproof properties, and is suitable for wall materials 1, especially siding boards. It has extremely excellent performance as a construction material.

In particular, the building material of the present invention is produced in a factory with a foamed resin layer on the cement-based outer layer material, which eliminates the need for insulation work at the building site. Since it can be finished with ricin coating, it requires fewer steps and requires less material compared to conventional wall materials, so it 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.
FIG. 2 is a cutaway sectional view of a building material according to another embodiment, and FIG. 3 is a sectional view of an apparatus for manufacturing the building material of the present invention. la, lb: Building material 2: Cement-based outer material layer 2a: Resin impregnated layer 3: Foamed resin particle layer 3a: Foamed resin liquid layer 4: Shape-retaining material layer 5: Exterior material 6a, 6b: External wall material 7: Ritzker Roller 8: Hot Air Drying and Foaming Machine No.: Go-Z Stomach-・4 Figure 3 Figure 4 Hand Correction Form (Method) September 5, 1988 1, Incident Indication 1988 Patent Application No. 141266 No. 2, Name of the invention Building materials and manufacturing method thereof 3. Person making the amendment! Relationship with 19 cases Patent applicant address 1000 Yojiri-cho, Yokkaichi City, Mie Prefecture Name (05
7) Mitsubishi Yuka Badetsushi Co., Ltd. Representative Masao Isono 4, Agent Postal code 160 Address Miyako Building, 7-11-15 Nishi-Shinjuku, Shinjuku-ku, Tokyo Telephone (03) 389-2835 Name (7)
808) Patent attorney Katsura Atsuta Part 5, date of amendment order August 3, 1988 (shipment date August 30, 1988) 6
, the number of inventions increased by the amendment 7, the subject of the amendment (1 Nori daily rule blue 15ZIμt %LL"L4 (TV no prisoner J) 1 piece "Figure 3 shows the production of the building material of the present invention Figures 3 and 4 are partially cutaway sectional views of an exterior wall constructed of the building materials shown in Figures 1 and 2 with exterior materials;
The figure is a cross-sectional view of one manufacturing apparatus for the building material of the present invention. ” is corrected.

Claims (3)

[Claims] (1) Architectural use characterized by being composed of a cement-based outer material layer and a foamed resin particle layer in which foamed resin particles are bonded to at least one surface of the cement-based outer material layer with an aqueous resin emulsion. material. (2) After applying a foamable resin liquid containing an aqueous resin emulsion and foamable resin particles to at least one surface of the cement-based outer layer material, the foamable resin particles are foamed by heating the applied surface. A method for manufacturing a building material, comprising: drying the emulsion to bond the foamed resin particles to form a foamed resin particle layer adhered to the cement-based outer layer material. (3) The method for producing a building material according to claim 2, wherein a shape-retaining material is placed on the coated surface before heating the coated surface.