JPH04143360A - Manufacture of mortar bed plate - Google Patents

Abstract

PURPOSE:To efficiently manufacture the above mortar bed plate by coating kneading material on a base plate formed with a waterproof layer thereon in optional thickness, hereafter pressing a sheet having many air enclosed parts against it, and embedding the sheet into the kneading material. CONSTITUTION:A waterproof layer 2 is formed on a base plate 1, and kneading material 3' is coated on it in optional thickness. When the kneading material 3' is not yet hardened, a soft synthetic resin sheet 6 on which many independent air enclosing parts are projected and arranged on one side is plied on the not yet hardened kneading material 3'. This is pressed with a proper compressing device to embed the air enclosing parts 5 into the not yet kneading material 3', and the sheet 6 is separated in the hardened or semihardened condition to form a surface coated layer. Hereby, many traces of the embedded air enclosing parts are formed and hence a mortar bed plate formed with blind holes can efficiently be manufactured.

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention is directed to fixing on the outer wall structure base of a building and directly applying or spraying mortar, plaster, coating material, etc. The present invention relates to a novel method for manufacturing an architectural base plate suitable for pasting to form a wall surface.

<Prior art and the problem to be solved by the present invention> Traditionally, base processes such as lumber printing, pasting of lath base such as base plywood, waterproof sorting of felt and roofing, pasting of lath netting, and mortar undercoating were required. In place of the traditional wet wall coating method, various types of mortar base plates of the above-mentioned type have been proposed in recent years, which make it possible to immediately install wall materials by bonding them to the base structure of a building.

Some of these mortar base plates have a structure in which a plurality of holes and grooves are bored in the surface material so that the overcoat mortar adheres to them like anchors.
Publication No. 34 states, ``In a mortar base plate in which a board, a foamed synthetic resin body with a closed cell structure, and a waterproof sheet are sequentially laminated and integrally formed, a through hole is formed in the board, and a pilot hole in the form of a blind bow is formed in the foamed synthetic resin body. ``Mortar base plate characterized by coaxial holes and blind holes with a larger diameter than the through holes'' is described in Japanese Utility Model Publication No. 57-25935 as ``Synthetic resin foam is fixed to one side of plywood. A waterproof sheet is laminated and integrated underneath, a large number of holes are coaxially drilled in the plywood and the synthetic resin foam, and a hydraulic substance is mixed in the synthetic resin foam. ``Mortar base plate with characteristics'', and Japanese Utility Model Publication No. 58-7872 also describes ``a plurality of concave grooves, blind holes,
and at least one kind of through hole, a lump of a hydraulic composition is formed in the groove, and a waterproof layer is formed on the back surface of the synthetic resin foam. , are shown respectively.

In the mortar base board according to the first two conventional techniques, the mortar wall material to be overcoated passes through a through hole provided in the surface board (plywood) and enters a coaxial hole provided in the synthetic resin foam layer below. In addition to providing an anchoring effect, when the mortar wall material is press-fitted into the prepared hole, the inner surface of the prepared hole is expanded and the mortar wall material is filled to that extent, thereby increasing the connection force between the mortar wall material and the base plate. It is stated that it becomes more powerful. However, since the structure is such that the surface board protrudes from the upper edge of the pilot hole, which is formed coaxially with the through hole and has a large diameter, toward the opening, in reality,
It was difficult to completely push out the air in the prepared hole by applying and press-fitting the mortar wall material, and air pockets were likely to remain in the prepared hole. This residual air pocket substantially reduces the adhesion area between the mortar wall material and the base plate, which not only makes it impossible to obtain the desired anchoring effect, but also causes damage due to the influence of outside temperature after the mortar wall material is installed. The remaining air pocket repeatedly expands and contracts, and the resulting stress tends to cause cracks in the mortar wall material applied to the edge of the through hole.

In addition, in the latter case, the adhesion of the synthetic resin foam itself to the mortar material used as the surface board is poor and its strength is low, so the anchoring effect of the mortar material in the grooves etc. drilled in the foam material and the Even with the anchoring effect of the lumps of the hydraulic composition filled in or protruding from the grooves, it is still difficult to exhibit sufficient adhesion to the mortar material.

In view of these disadvantages of the prior art, the present applicant has made extensive efforts to develop a mortar base plate with a new structure that can exhibit great adhesion to the mortar wall material to be overcoated. Successful. An object of the present invention is to provide a method that can efficiently and inexpensively manufacture such a new mortar base plate.

<Means for Solving the Problems> The present invention was devised to achieve the above object, and after forming a waterproof layer on the surface of a substrate as necessary, a hydraulic inorganic material is applied to the entire surface of the substrate. The kneaded material, which is the main component, is applied to an arbitrary thickness, and while the applied kneaded material is in an uncured state, a soft synthetic resin/-t with a large number of independent air enclosing parts protruding from one side of the kneaded material is applied. Laminate the sheets so that the side on which the air-enclosed portion protrudes is in contact with the uncured kneaded material, and then press the synthetic resin sheet from the opposite side to bury the air-enclosed portion in the kneaded material and maintain this buried state. A method for producing a mortar base plate, comprising curing and curing the kneaded material to form a surface coating layer, and peeling off a soft synthetic resin sheet from the surface coating layer after the kneaded material has been semi-cured or hardened.

<Function> By press-contacting a large number of independent air-enclosed portions protruding from one side of the soft synthetic resin sheet to the uncured kneaded material, the tips or central portions of the air-enclosed portions expand due to this pressing force, and thus expand. It is deformed into a solid shape and embedded in the uncured kneaded material. The soft synthetic resin sheet is peeled off after the kneaded material is semi-cured or hardened to form a surface coating layer, but it has a shape that is enlarged at the tip or center in response to the compressive deformation of the air-filled part. Blind holes are left as traces in the surface coating layer. Therefore, the blind hole is formed so that the cross-sectional area at the bottom is larger than the opening area at the top, increasing the adhesive area with the mortar coating material, improving the anchoring effect and increasing the adhesion force.

<Specific description of the structure> The structure of the mortar base plate to be manufactured by the present invention will be described in detail below with reference to FIGS. 1 and 2. The substrate 1 of the mortar base plate 10 may be plywood, fiber board,
Particle board, inorganic board, etc. are used.

A waterproof layer 2 made of one or a mixture of synthetic resins, synthetic rubbers, etc. is provided on the surface of the substrate 1, if necessary.

A surface coating layer 3 is provided on the entire surface of the substrate 1 directly or via a waterproof layer 2. This surface coating layer 3 is mainly made of a hydraulic inorganic material such as cement, gypsum, slag, etc.
In addition, as necessary, aggregates such as silica sand, calcium carbonate, talc, clay, shirasu balloons, vermiculite, perlite, foamed or crushed synthetic resin particles, wood flour, fly ash, glass fiber, rock wool, bulbs, and wood fibers are added. , organic or inorganic fibers such as coconut fibers, nylon, vinylon, and polypropylene fibers, as well as admixtures such as polyvinyl alcohol, methyl cellulose, and synthetic resins, and waterproofing agents.

It is preferable that the surface coating layer 3 has a thickness of at least 3 mm or more. If it is thinner than this, the depth of the blind holes described below will be insufficient, making it impossible to obtain the desired anchoring effect. The upper limit of the thickness of the surface coating layer is not particularly limited, but
Considering the workability as a mortar base plate, it is 15 to 30.
The so-called shoulder level is realistic. The thickness of the surface coating layer is determined by applying one coat of mortar wall material, which will be described later, to the fire prevention structure wall, which is a fire prevention regulation for house construction as stipulated in the Building Standards Act, the Enforcement Order of the Act, and the Enforcement Regulations of the Act. It is preferable to make adjustments so that a wall with a structure equivalent to that of an earth-coated wall can be obtained.

A plurality of blind holes 4 are formed on the surface of the surface coating layer 3. The blind holes 4 have the function of allowing the mortar wall material to be overcoated to adhere in an anchor-like manner and increasing the adhesion force by expanding the bonding area to the mortar wall material. In order to effectively exhibit this effect, it is preferable that the blind hole 4 is formed so that the cross-sectional area at the bottom is larger than the opening area at the top. It is preferable to form a trapezoidal cross section with an opening area of 65% to 95%. If it is less than 65%, the adhesive area will increase, but the opening will become narrower, making it difficult for the air in the blind hole to be pushed out from inside when applying mortar wall material, and causing cracks to occur due to the expansion of the remaining air. This is likely to be the cause. Moreover, if it exceeds 95%, the problem of residual air will not occur, but the inner wall of the blind hole will become approximately vertical, and the effect of increasing the bonding area will be diminished.

The cross-sectional shape of the blind hole 4 is not limited to a trapezoidal shape, but any shape having an internal cross-sectional area larger than the opening area can exhibit the same effects as described above. Figure 3(a)
-(d) illustrate other preferred cross-sectional shapes.

In addition, the approximately drum shape shown in the same figure (a) or the same figure (b)
In the case of the approximately hexagonal shape shown in , the central part has the largest cross-sectional area, so the opening area and/or bottom area is formed in a range of 65 to 95% of the cross-sectional area of the central part. It is preferable.

The method of the present invention for manufacturing the mortar base plate 10 having such a structure consists of the following one culm. That is, as shown in FIG. 4, after forming a waterproof layer 2 on the surface of a substrate 1 as necessary, a kneaded material 3 containing a hydraulic inorganic substance as a main component is applied to the entire surface of the waterproof layer 2.
Apply ° to any desired thickness. When the applied kneaded material is in an uncured state, a large number of independent air enclosing portions 5 are formed on one side of the kneaded material.
Using a soft synthetic resin sheet 6 arranged in a protruding manner, the side on which the air enclosing part is formed protrudingly is stacked so that it is in contact with the uncured kneaded material 3', and then the synthetic resin sheet 6 is laminated by hand or from the opposite side. The air enclosing portion 5 is buried in the kneaded material by pressing using an optional pressing device. Since the synthetic resin sheet 6 is a soft material, by stacking it with the air enclosing part 5 in contact with the surface of the uncured kneaded material and pressing it from the opposite side, the air enclosing part 5 is pressed by the pressing force. The tip portion or the center portion is enlarged, and the enlarged shape is buried in the uncured kneaded material by 3 degrees.

Next, the protruding air enclosing portion 5 of the synthetic resin sheet 6 is inserted into the kneaded material 3.
The kneaded material is cured while being buried in the water to form a mixture layer. Curing is carried out by ordinary temperature curing or steam curing. After the kneaded material is semi-cured or hardened by curing, the synthetic lubricant sheet 6 is peeled off. Synthetic resin sheet 6
At the time of peeling, the air-enclosed portion 5 buried in the kneaded material is stretched and extracted from the semi-cured or hardened kneaded material. Thus, the traces of the air enclosing part 5, which had been buried in the uncured kneaded material in the enlarged shape described above, have a relatively small opening area at the top and a relatively small cross-sectional area at the center or bottom. A plurality of large blind holes are formed in the mixture layer. Thus, the surface coating layer 3 has a plurality of blind holes 4 formed on its surface.
is obtained, and the mortar base plate 10 is manufactured.

As the soft synthetic resin sheet 6, a polyethylene sheet, which has been widely used as a packaging material, can be suitably used. A plurality of air sealing parts 5 formed on one surface of this polyethylene sheet have a substantially cylindrical shape with rounded upper edges, but when pressed against the uncured kneaded material, the cylindrical upper end expands. , thus being press-fitted into the kneaded material with a substantially trapezoidal cross section. Therefore, by peeling off the polyethylene sheet after the kneaded material is semi-cured or hardened, a plurality of blind holes 4 having a substantially trapezoidal cross section can be easily formed in the surface coating layer 3.

Synthetic resin sheets such as polyethylene sheets for packaging used in the above manufacturing process may be peeled off before shipping the mortar base plate, but by shipping them in a laminated state, the surface of the mortar base plate It can also serve as a surface curing sheet for the coating layer and prevent damage to the surface.

The synthetic resin sheet used as the curing sheet in this manner is peeled off at the construction site before or after construction of the mortar base plate after being shipped.

As shown in FIG. 5, the mortar base plates 10 are used by abutting a plurality of mortar base plates 10 onto a base structural material 11 such as a pillar or stud and fixing them with nails 12.

After fixing, apply joint tape to the butt joints, apply joint sealant, etc. to treat the joints 13, then spray mortar wall material 14 on the surface, and fill blind holes 3 by troweling, etc.
Apply to fill the inside.

If the wall surface is to be tiled, the tiles can be attached after applying the mortar wall material, or the tiles can be directly connected.

As mentioned above, the mortar base plate manufactured by the method of the present invention can meet the requirements specified in the Building Standards Act, the Enforcement Order of the Act, and the Enforcement Regulations of the Act by simply applying mortar wall material once on its surface. It is possible to obtain a fireproof structure or a structure equivalent to earth-coated walls, which is compliant with fire prevention regulations associated with house construction. Here"
"One-coat mortar wall material" refers to a coating that does not cause sag or sag cracks in the mortar wall material that is applied on the base material (mortar base plate) from the time it is applied to the time it cures and hardens. This refers to the coating process, and the coating thickness is generally limited to about 10 to 1211. In addition to obtaining a coating thickness of 10 to 12 degrees with one trowel coating, it is also possible to obtain a coating thickness of 5 to 61 degrees with the first trowel coating, and then apply a wet coating before curing and curing. Apply the second coat with a trowel to a coating thickness of 5 to 5'*ml:
A case where a total coating thickness of 10 to 12 coats is obtained by coating (so-called follow-up coating in plastering terminology) is also included in the above-mentioned "single coating of mortar wall material".

According to experiments by the present inventors, in order to obtain a wall with a structure equivalent to that of an earth-coated wall, a coating thickness of approximately 131 mm or more is required in the case of ordinary mortar, and approximately 10 mm in the case of special mortar. In order to obtain a fireproof structural wall, a coating thickness of about 181 m or more is required for ordinary mortar, and about 15 m or more for special mortar.
A coating thickness of m- or more was required in each case. The numerical values of each coating thickness mentioned above mean the sum of the thickness of the surface coating layer of the mortar base plate and the thickness of the mortar top coating layer applied and formed on the surface. Therefore, if normal mortar is used, the thickness of the surface coating layer should be 3. , or above, a wall with a structure equivalent to that of an earth-coated wall can be obtained by one coat of mortar wall material, and if it is 8 or more, a fire-resistant structural wall can be obtained by one coat of mortar wall material. It should be noted that if the surface coating layer is less than 3mm thick, the depth of the blind hole will be insufficient and the desired anchoring effect will not be obtained, and as mentioned above, it will be difficult to obtain the prescribed coating thickness. That's exactly what I did. When using special mortar, by using a surface coating layer with a thickness of 3 layers or more, a single coat of mortar wall material can create a wall with the same structure as an earthen wall, and by using a layer of 5 m or more, mortar can be used. A fireproof structural wall can be obtained with one coat of wall material.

When attempting to obtain a wall surface structure equivalent to an earth-coated wall using a mortar base plate manufactured by the method of the present invention, for example, a mortar base plate with a surface coating layer formed to a thickness of 3 mm is used as an external wall base structure. After nailing and fixing on top, ordinary mortar is applied to the surface, the blind holes are filled with the ordinary mortar, and a 7 mm thick overcoat layer of the ordinary mortar is further formed on the surface of the surface coating layer. shall be taken as a thing. As a result, the surface coating layer thickness (3I) and the top coating layer thickness (7 Rintoge = 101) are obtained, so the structural performance range is equivalent to that of an earthen wall.In addition, the surface coating layer is 10mm thick By applying ordinary mortar sufficient to fill the blind holes on the surface of the mortar base plate formed in the above, a mortar coating thickness of 10 m1 can be secured, resulting in a structural performance range equivalent to that of an earth-coated wall.

Further, for example, after nailing and fixing the mortar base plate of the present invention having a surface coating layer of 5 mm thickness on the outer wall base structure, a special mortar is applied to the surface of the mortar base plate of the present invention, and the blind holes are formed using the special mortar. Assuming that the special mortar overcoat layer is filled with 10 mm thick on the surface of the coating layer, a mortar coating thickness of 5 mm + 1 (b = 15 mm) will be obtained. As a result, a wall surface with fire protection structure performance range is obtained.

Also, 25. When using a mortar base plate having a surface coating layer with a thickness of 25 m, a fireproof structural wall can also be obtained by filling the blind holes with ordinary mortar to ensure a mortar coating thickness of 25 m.

<Effects of the Invention> According to the present invention, a suitable method for efficiently and inexpensively manufacturing a mortar base plate provided with a surface coating layer in which a plurality of blind holes are formed on the surface of the substrate is provided. Ru. The mortar base board manufactured by the method of the present invention can be immediately coated with mortar wall material after being nailed and fixed onto the base structure material. The coated mortar wall material enters a plurality of blind holes formed in the surface coated layer of the mortar base plate and is tightly attached like an anchor. Since the blind hole has a lower cross-sectional area larger than the surface opening area at the top, the anchoring effect is improved and the adhesion area to the mortar wall material is increased, so the adhesion strength is significantly improved. Since the blind holes are opened directly on the surface of the mortar base plate, the mortar wall material is filled throughout the blind holes, and no air remains in the blind holes, so the remaining air shrinks. Cracks that occur due to expansion can be prevented. Furthermore, by using the mortar base plate manufactured by the method of the present invention, a fireproof structural wall or a structural wall equivalent to an earth-coated wall can be easily obtained by applying mortar wall material in one coat.

[Brief explanation of drawings]

FIG. 1 is a perspective view schematically showing the structure of a mortar base plate manufactured by the method of the present invention, FIG. 2 is a partially enlarged sectional view thereof, and FIG. FIG. 4 is a partially enlarged cross-sectional view showing a modified example of the shape of the hollow hole; FIG. 4 is a perspective view showing a preferred method of manufacturing a mortar base plate according to the present invention; FIG. 5 is a cross-sectional view showing an example of construction of a mortar base plate. It is. Explanation of symbols 1...Substrate 2...Waterproof layer 3...Surface coating layer 4...
・Blind hole 5...Air sealing part 6...Synthetic resin/-
G10... Mortar base plate Figure 3 (a) (b) (c)
(d) Figure 5

Claims (1)

[Claims] (1) After forming a waterproof layer on the surface of the substrate as necessary,
A kneaded material mainly composed of hydraulic inorganic substances is applied to the entire surface to a desired thickness, and when the applied kneaded material is in an uncured state, it becomes a soft material with many independent air-filled parts protruding from one side. Synthetic resin sheets are laminated so that the side on which the air-enclosed portion protrudes is in contact with the uncured kneaded material, and then the air-enclosed portion is buried in the kneaded material by pressing from the opposite side of the synthetic resin sheet. A mortar, characterized in that the kneaded material is cured and cured to form a surface coating layer while maintaining the buried state, and the soft synthetic resin sheet is peeled from the surface coating layer after the kneaded material is semi-cured or hardened. Method of manufacturing base plate. (2) The method for manufacturing a mortar base plate according to claim 1, wherein a polyethylene packing sheet is used as the soft synthetic resin sheet. (3) The method for manufacturing a mortar base plate according to claim 1, wherein the soft synthetic resin sheet is used as a curing sheet for the surface coating layer of the mortar base plate, and is peeled off at the construction site.