JPH03232777A - Outside wall material having uneven pattern and production thereof - Google Patents

Abstract

PURPOSE:To obtain an outside wall material having beautiful uneven pattern without requiring surface finishing process by successively laminating a lower layer on which a water proof layer is formed, middle layer consisting of an inorganic binding material and foaming synthetic resin grains and surface layer consisting of an inorganic binder and fine aggregate on a wooden substrate and forming uneven pattern on the outside face of the surface layer by a template. CONSTITUTION:A lower layer 1 on which a waterproof layer 2 is formed of a synthetic resin emulsion, synthetic rubber latex, bituminous emulsion, etc., middle layer 3 obtained by kneading an inorganic binder such as portland cement or gypsum with a foaming synthetic resin grains and surface layer 4 obtained by kneading an inorganic binder with a fine aggregate are successively laminated on a wooden substrate such as a laminated board, fiber board or particle board and brick-like or stone surface-like uneven pattern is applied on the outside face of the surface layer 4 by a template to provide the outside wall material.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to an exterior wall material for a building, and more particularly to an exterior wall material whose surface has an uneven pattern such as a brick-like or stone-like pattern, and a method for manufacturing the same.

(Prior art) In recent years, as an exterior wall material for buildings, a waterproof layer is formed on a wooden substrate, and a lightweight mixture layer made by kneading an inorganic binder and foamed synthetic resin particles is formed on the waterproof layer. , lightweight building materials with excellent strength, waterproofness, sound insulation, heat insulation, and fireproofing properties are used.

In the past, these building materials were developed primarily to simplify the work of foundation work in exterior wall construction, and were not able to omit surface finishing processes such as mortar, coating materials, and tiles. There wasn't.

Therefore, there is a need for the development of an exterior wall material that can take advantage of the excellent performance of the above-mentioned conventional building base materials, while also omitting the surface finishing process that requires special skill in exterior wall construction, and that also has an excellent design. In particular, the demand for three-dimensional brick-like and stone-grained designs is increasing.

Therefore, an attempt was made to form an uneven pattern on the surface of a mixture layer made by kneading the above-mentioned inorganic binder and foamed synthetic resin particles using a template, but the surface properties were poor and it was difficult to omit the surface finishing step. It was not something I could do.

(Problems to be Solved by the Invention) As a result of intensive studies to solve the above problems, the present inventors have discovered that an inorganic binder and fine aggregate are placed on a template with an uneven pattern formed on its surface. By applying a layer of a mixture obtained by kneading and composing the above-mentioned architectural base material on the mixture layer, it is possible to form an uneven pattern on the surface of the base material for construction. The inventors have discovered that after coating the mixture layer, a beautiful uneven pattern can be formed by vibrating the template with a pipe rake, and have thus arrived at the present invention.

Therefore, a first object of the present invention is to provide an exterior wall material having a beautiful uneven pattern that does not require surface finishing.

A second object of the present invention is to provide a method for manufacturing an exterior wall material having a beautiful uneven pattern.

(Means for Solving the Problems) The above aspects of the present invention include at least a lower layer formed by forming a waterproof layer on a wooden substrate, a middle layer formed by kneading an inorganic binder and foamed synthetic resin particles, and a surface layer made by kneading an inorganic binder and fine aggregate, which are successively laminated, the surface layer having an uneven pattern formed by a template on the outer surface of the surface layer. This has been achieved by an exterior wall material and a method for manufacturing the same.

EMBODIMENT OF THE INVENTION Hereinafter, the exterior wall material having an uneven pattern and its manufacturing method of the present invention will be explained in detail based on the drawings.

FIG. 1 is a sectional view showing an example of an exterior wall material having an uneven pattern according to the present invention.

In the figure, code (1) is a lower layer formed by forming a waterproof layer (2) on a wooden substrate, code (3) is a middle layer made by kneading an inorganic binder and foamed synthetic resin particles, and code (4) is a lower layer formed by forming a waterproof layer (2) on a wooden substrate. is a surface layer made by kneading an inorganic binder and fine aggregate.

As the wood-based substrate of the lower layer (1), wood-based board materials such as plywood, fiberboard, particle board, wood wool board, and honeycomb core plywood can be used, but the present invention is not necessarily limited to wood-based board materials. Other materials may be used as long as they are light, have relatively high bending stress, and can be easily cut.

The waterproof layer (2) can be appropriately selected from among the known waterproof materials that are generally used in paint film waterproofing methods. It is desirable that the coating can be easily applied using a coating device such as a roll coater or a flow coater. The main ones include synthetic resin emulsions such as acrylic, ethylene/vinyl acetate, and polypropylene; synthetic rubber latex such as styrene/butadiene rubber, chloropyrene rubber, butyl rubber, acrylonitrile butadiene rubber, and methyl acrylate butadiene rubber; Examples include bituminous emulsions such as asphalt, tar, and rubber alphalt; mixtures of butyl rubber and bituminous emulsions; and mixed emulsions of bituminous materials and polypropylene.

In addition, in areas where there is high humidity and particularly strict waterproofing is required, such as around bathrooms, use a waterproof sheet made of synthetic resin such as butyl rubber or rubberized asphalt using a primer, etc. It is also possible to use one attached to a base material.

Inorganic binders used in the middle layer (3) and the surface layer (4) include ordinary Portland cement, gypsum, etc., as well as high alumina cement such as ultra-fast hardening cement, thermosetting cement, etc., if suitable for the production line. High gypsum, fast setting cement may be used. Also, depending on the application, the bonding strength of cement,
If it is necessary to increase the flexibility, an aqueous dispersion such as a synthetic resin emulsion or synthetic rubber latex may be added and mixed in an amount within 20% by solid weight.

If the thickness of the middle layer (3) is equal to or larger than the thickness of the lower layer (1), warping may occur or the bending strength of the entire base material may decrease. It is preferable to mix fiber materials such as glass fibers, synthetic fibers, and vegetable fibers in an amount of 0.2 to 5% based on the weight of cement.

The foamed synthetic resin particles can be appropriately selected from resins that can form foams, such as styrene, urea, phenol, urethane, vinyl chloride, and polyethylene. It is preferable to use a material with a high level of closed cell structure because it can improve heat insulation and fire prevention performance. In particular, polystyrene and polyethylene foamed synthetic resin granules are extremely inexpensive because polystyrene, polyethylene, etc. are used in large quantities in packaging materials and containers, and by pulverizing and reusing defective products and waste generated during the manufacturing of these materials. can be manufactured.

The particle size of the foamed synthetic resin particles is related to the thickness and specific gravity of the middle layer (3), but those in the range of 0.2 to 10 mm are used. When aiming for a material with low specific gravity, it is necessary to densely pack the foamed synthetic resin particles, and the smaller the particle size, the better. However, if there are too many small-diameter particles, the contact area between the cement paste and the foamed synthetic resin particles will increase, and some of the cement paste will be absorbed into the foam, reducing the shape of the fine voids and reducing the specific gravity as expected. Does not decrease. Therefore, rather than mixing foamed synthetic resin particles with the same particle size, it is preferable to mix foamed resin particles with moderately different particle sizes within the above range.

The uneven pattern provided on the surface of the surface layer (4) may be arbitrary, such as a brick pattern or a stone pattern. It is preferable that the depth of the uneven grooves be approximately 4 mm in order to form a three-dimensional pattern. Silica sand is usually used as the fine aggregate for the surface layer (4), but if fine aggregate such as fara ash or silica hume is used, fluidity will increase and a good uneven surface can be obtained. Furthermore, in order to increase the strength, a fibrous material such as glass fiber, synthetic fiber, or vegetable fiber may be added to the surface layer (4).

The exterior wall material having an uneven pattern of the present invention has at least the above-mentioned configuration, but the uneven surface of the surface layer (4) can also be further coated with a finishing coat.

Moreover, the exterior wall material of the present invention can be used not only as an exterior wall material but also as an interior material.

Next, the method for manufacturing the exterior wall material of the present invention will be described in detail below.

FIG. 2 is a cross-sectional view showing the method for manufacturing exterior wall materials of the present invention.
This is an example.

In the figure, reference numeral (10) is a template on which an uneven pattern is formed.

First, a release agent is applied to the upper surface of the template (10).

The template (10) used in the present invention can be appropriately selected from known materials.

The release agent can be appropriately selected from known release agents such as polyethylene, fatty acids, mineral oil, and the like.

Next, a surface layer (4) made by kneading an inorganic binder and fine aggregate is applied onto the template (10), and the template (lO) is vibrated with a vibrator. As a result, air between the template (lO) and the surface layer (4) can be removed and the uneven surface can be finished in a good manner.

After coating the middle layer (3) made by kneading an inorganic binder and foamed synthetic resin particles on the surface layer (4) above, a wooden substrate is provided with a waterproof layer (2) on the middle layer (3). is placed with the waterproof layer (2) facing down, and pressurized with a press for a predetermined period of time.

Finally, the template (10) is demolded to produce the exterior wall material having the uneven pattern of the present invention.

(Effects of the Invention) As described above in detail, the exterior wall material having the uneven pattern of the present invention can omit surface finishing on site, so that the construction period can be shortened.

Furthermore, since the template is vibrated by pie-breaking, the air between the template and the surface layer is removed and a beautiful uneven pattern can be formed.

Furthermore, if a fine aggregate such as fly ash or silica fume is used as the fine aggregate in the surface layer, an uneven surface can be smoothed.

(Examples) Hereinafter, the present invention will be explained in more detail with reference to Examples, but the present invention is not limited thereto.

Example 1 On a 455 m x 1.820 a* FRP template coated with cement release agent at about 102 g/m (diluted with water), surface cement was kneaded at the mixing ratio shown in Table 1, and the coating amount was about 3.0 g/m.
It was coated at a weight of 8 kg/%.

Next, after applying the middle layer cement mixed at the mixing ratio shown in Table 2 at a coating amount of 10.2 kg/rrf,
Waterproofed and 7.5mm thick, 280ma+X28
When a structural plywood of 0m+o was placed and removed from the mold by applying pressure with a press for a predetermined period of time, an exterior wall material having the uneven surface of the template could be obtained. In this case, holes were observed that were thought to be caused by air trapped between the template and the surface layer.

Table 1 (All units in the table below, including the above table, are parts by weight.

) Table 2 Example 2 After applying surface cement in the same manner as in Example 1, FR
Vibration was applied to the P-type plate using a pipe rake.

Next, the middle layer cement and structural plywood were laminated in the same manner as in Example 1, and when the mold was removed by applying pressure with a press for a predetermined period of time, the surface was smoother than that of the exterior wall material obtained in Example 1. It has been demonstrated that an improved exterior wall material can be obtained by applying vibration after coating the surface layer and having a small number of holes.

Example 3 External wall material was manufactured in the same manner as in Example 2 except that the surface cement was kneaded at the mixing ratio shown in Table 1. As a result, the small holes caused by air almost completely disappeared, and the unevenness was very good. It was possible to obtain an exterior wall material having a surface. This is because the use of fine aggregate such as fly ash instead of silica sand increases the fluidity of the surface cement and improves its compatibility with the FRP template. The resulting exterior wall material was approximately 30% heavier than conventional architectural base materials.

Example 4 The middle layer cement was kneaded at the mixing ratio shown in Table 2, and the coating amount of the surface layer cement was 3.2 kg/% and the coating amount of the middle layer cement was 8.3 kg/m. When an external wall material was manufactured in the same manner as in Example 3, it had a beautiful uneven pattern similar to that in Example 3, but it had almost the same weight and strength as conventional architectural base materials. We were able to obtain exterior wall materials.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing an example of an exterior wall material having an uneven pattern according to the present invention. FIG. 2 is a cross-sectional view showing a method of manufacturing an exterior wall material having an uneven pattern according to the present invention.・Lower layer・Waterproof layer・Middle layer・Surface layer・Template

Claims (1)

[Claims] 1) At least a lower layer formed by forming a waterproof layer on a wooden substrate, a middle layer formed by kneading an inorganic binder and foamed synthetic resin particles, and an inorganic binder and fine aggregate. 1. An exterior wall material having an uneven pattern, characterized in that the exterior wall material is made by sequentially laminating a surface layer formed by kneading, and the outer surface of the surface layer is provided with an uneven pattern formed by a template. 2) Applying a mold release agent onto the template on which the uneven pattern is formed, and applying a surface layer made by kneading an inorganic binder and fine aggregate;
After vibrating the template with a vibrator to remove air between the template and the surface layer, applying an intermediate layer made by kneading an inorganic binder and foamed synthetic resin particles on the surface layer,
A method for manufacturing an exterior wall material having an uneven pattern, characterized in that a wooden substrate is then placed on the intermediate layer via a waterproof layer and pressurized for a predetermined period of time using a press. 3) The method for manufacturing an exterior wall material having an uneven pattern according to claim 2, wherein the fine aggregate in the surface layer is fly ash or silica fume.