JPH05331960A - Composite panel - Google Patents

Abstract

PURPOSE:To obtain a building material excellent in weatherproofness and decorativeness by forming a composite panel in which a resin film-laminated metal panel is connected with an inorganic panel by various methods. CONSTITUTION:A resin film-laminated metal panel 1, in which an adequate thickness of resin film such as fluororesin film, obtained by various methods, is hot-bonded to a metal plate such as aluminium plate, is laminated with an inorganic panel 2 such as non-cement or cement panel by using an adhesive. The composite material suitable for exterior or building part is obtained by preventing the falling-down or deformation or the metal panel by combined use of mechanical fixing method as needed. The composite panels consisting of the metal panel and the inorganic panel, having the same dimensions, so obtained, can be used for constructing walls for example.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel composite panel, more specifically, a composite panel excellent in weather resistance, stain resistance, heat resistance, workability, and excellent in design and suitable for exterior materials and construction materials. Regarding

[0002]

2. Description of the Related Art Heretofore, various metal panels having a resin layer have been applied to the surface thereof by coating or laminating a synthetic resin film with an adhesive or a heat fusion method. Proposed. When installing and installing these panels, after processing into so-called bent panels, attach the mounting brackets to the panel ends,
Further, it is necessary to fix the reinforcing aggregate on the back surface of the panel with stud bolts or an adhesive in order to prevent the panel from deforming or deforming due to thermal expansion. On the other hand, on the wall surface for panel construction, it is necessary to spread the base aggregate for attaching the bent panel along the four sides of the panel, which complicates and complicates the construction. There has been a demand for the development of new possible panels.

As an exterior material and a building material, general panels have problems in weather resistance, stain resistance, heat resistance and workability. The object of the present invention is to solve the problems of the prior art, and to provide a novel composite panel which has never been known.

[0004]

The present invention has been made to solve the above-mentioned problems, and provides a composite panel comprising a resin film laminated metal panel and an inorganic panel joined together. Preferably, the resin film is a composite panel which is a fluorine resin film, the resin film laminated metal panel is a composite panel which is a laminated metal panel obtained by heat-sealing the resin film, and the resin film laminated The present invention provides a composite panel in which the metal panel of the metal panel is an aluminum-based metal panel, the inorganic panel, and the cement-based panel is a lightweight foam concrete panel.

According to the present invention, however, a composite panel made of a composite metal plate can be simply installed and installed at a construction site and has very good workability, and moreover, has weather resistance, stain resistance, heat resistance and designability. It is excellent. The constituent factors of the present invention will be described in more detail below.

The "metal" of the present invention is not particularly limited, and any metal plate can be used.
In general, for example, iron-based, aluminum-based, copper-based, titanium-based and nickel-based metal plates, among them, iron-based, aluminum-based and copper-based metal plates are preferred, especially iron-based and aluminum-based metal Plates are preferred. The iron-based metal plate may be any metal plate as long as it is a metal plate mainly containing iron in composition, and specifically, for example, a cold rolled steel plate, a galvanized steel plate, a zinc alloy plated steel plate. , Aluminum-plated steel sheet, copper-plated steel sheet, stainless steel sheet, phosphoric acid-treated steel sheet, aluminum-zinc alloy-plated steel sheet, and the like. Among them, galvanized steel sheet, zinc alloy-plated steel sheet,
Aluminum plated steel sheets and aluminum-zinc alloy plated steel sheets are preferred.

Further, as the aluminum-based metal,
Any metal may be used as long as it is a metal mainly containing aluminum metal in composition, but in general, for example,
It is aluminum described on pages 13 to 22 of "Aluminum Handbook (Second Edition)" issued by Japan Light Metals Association on September 30, 1982, and specifically, pure aluminum, (Al-Cu) system,
(Al-Mn) system, (Al-Si) system, (Al-Mg) system, (Al-Mg-S
There are i) type and (Al-Zn-Mg) type, and among them, pure aluminum type, (Al-Mn) type and (Al-Mg) type are preferable.
Thus, as described above, various metals can be adopted, and among them, aluminum alone or various aluminum alloys such as duralumin, and aluminum-based metals such as aluminum metal containing a small amount of manganese, magnesium, etc. are preferable. In addition, iron-based metals, copper-based metals, titanium-based metals and the like can also be preferably used.

Further, the copper-based metal may be any metal as long as it is a metal mainly containing copper in composition, but generally, for example, pure copper-based, brass-based, bronze-based and brass. There are metals such as brass.

The metal plate to be laminated with the resin film may be laminated with any of the above metal plates depending on the purpose.
Considering workability, it is particularly preferable to laminate a resin film on an aluminum metal plate.

The thickness of the metal plate in the present invention is not particularly limited, but it is generally 0.15 to 4 m, for example.
m, preferably 0.2 to 2.2 mm. In order to improve the adhesion of the metal to the fluororesin film, the surface of the metal should be subjected to surface treatment such as cleaning treatment (degreasing cleaning) and roughening treatment (sand plast, chemical etching, etc.) in advance. Are generally preferred.

The "resin film" may be a fluororesin film, an acrylic resin film, a vinyl chloride resin, Keiron 6, nylon 12, polyethylene terephthalate, or the like, and a fluororesin film is particularly preferable.

In the present invention, the "fluorine-based resin" is not particularly limited as long as it is a thermoplastic resin containing fluorine in the molecular structural formula of the resin. Specifically, for example,
It is an ethylene tetrafluoride resin having four fluorine atoms in the molecular structure of the resin, an ethylene trifluoride resin, an ethylene difluoride resin, an ethylene monofluoride resin and a composite of these resins. Among them, tetrafluoroethylene-based resin and difluoroethylene-based resin are preferable, and tetrafluoroethylene-based resin is more preferable.

Here, the tetrafluoroethylene-based resin is specifically, for example, tetrafluoroethylene resin (PTFE), tetrafluoroethylene / perfluoroalkoxyethylene copolymer.
(PFA), tetrafluoroethylene / propylene hexafluoride / perfluoroalkoxyethylene copolymer (EPE) and tetrafluoroethylene / ethylene copolymer (ETFE) tetrafluoroethylene / hexafluoropropylene copolymer, etc. There is PF
A, ETFE and EPE are preferred, and ETFE is particularly preferred.

ETFE will be described in detail. Ethylene and tetrafluoroethylene are mainly used (the molar ratio of ethylene / tetrafluoroethylene is generally 40/60 to 60/40), and if necessary, a small amount thereof may be added. Third (usually 10 mol% or less)
In the present invention, the molar ratio of ethylene / tetrafluoroethylene is 40% or less.
/ 60-60 / 40, represented by preferably in the range of 45 / 55-55 / 45, and the formula _{CH 2 = CH-CnF 2n +} 1 ( where, n is an integer from 2 to 10) perfluoroalkyl vinyl monomer unit _{(e.g., CH 2 = CH-C 4} H 9 or CH ₂ = CH-C ₆ H
The content of units derived from ₁₃ ) is derived from the range of 0.3 to 10 mol%, preferably 0.3 to 5 mol%, and is preferably used.

This ETFE is known per se, and can be produced, for example, by the method described in JP-B-59-50163, and is commercially available from Asahi Glass Co., Ltd. under the name "Aflon R".
It is also possible to use a commercially available product under the trade name "COP".

The above trifluoroethylene resin is
Specifically, for example, trifluorochloroethylene resin (CTF
E) and trifluorochloroethylene / ethylene copolymer (E
CTFE) and the like, among which PCTFE is preferable. The above-mentioned ethylene difluoride-based resin and ethylene monofluoride-based resin are, for example, vinylidene fluoride resin (PVDF) and vinyl fluoride resin (PVF).

Further, the method for producing the fluororesin film is as follows:
The method is not particularly limited, and any conventionally used method can be used. For example, a heat melting method, a solution casting method, or the like, which is appropriately selected depending on the application of the composite metal plate of the present invention, the resin used, and the like. As the heat melting method, for example,
Examples of the solution casting method include a solvent casting method, an organosol casting method, a prestisol casting method, and the like.

The film thickness of these fluororesin films is not particularly limited, and any film thickness may be used, but it is generally 5 to 500 μ, preferably 10 to 200 μ, and more preferably 20 to 100 μ. ..

Further, by adding a colorant to the fluorine-containing resin film or by printing on the front surface and / or the back surface of the fluorine-containing resin film, the function of distinguishing the function by the color of the interior material according to the present invention can be improved. The decorativeness can be improved. The colorant used in the present invention is a colorant generally added and blended, and is not particularly limited,
For example, there are white, red, vermilion, yellow, green, blue, violet, and black colorants.

Next, the process of joining and coating the fluorine resin film on the metal plate according to the present invention will be described. The heating and fusion bonding of the fluorine resin film can be carried out by a conventional method.

The process steps will be specifically described below, but generally, for example, the pretreatment process, the heating process, the lamination of the fluorine-containing resin film, the pressurizing process, the reheating process, the cooling process and the like are performed. ,Obtainable.

(1) Pretreatment Step This step is a step that is performed as necessary to more strongly coat the metal plate and the fluorine-containing resin film.

Pretreatment Step of Metal Plate The purpose of the pretreatment step of the metal plate is to remove oily substances, foreign matters, oxide film, etc. adhering to the surface by washing, and to expose the bare metal to the surface by polishing or the like. Further, surface plating, surface treatment such as acid treatment, and if necessary, surface roughness are performed.

A. Surface cleaning is not particularly limited, and a cleaning method conventionally performed with a specific metal is used.For example, as a degreasing method,
Degrease and wash with an organic solvent, alkaline aqueous solution, surfactant, etc.

B. Surface polishing It is possible to expose the bare metal to the surface by surface polishing, for example, by mechanical and scientific polishing.

C. Surface treatment If necessary, the surface of the film to be coated may be subjected to a plating treatment, a coating treatment for providing a metal oxide film layer, and a chemical conversion treatment such as a rust preventive treatment. For example, specific examples of the chemical conversion treatment of the iron-based metal include phosphate treatment of zinc phosphate, calcium phosphate and the like, and chromate treatment by reactive chromate and coating chromate.

D. Surface Roughening The surface can be roughened by a surface roughening method by a physical means such as brushing, sand plast or shot plast, or a surface roughening method by a chemical electrochemical etching method or a combination thereof.

Film pretreatment step: Removal of oily substances, foreign matters, etc. adhering to the film surface, addition of an oxide film, etc. by corona discharge treatment, chemical treatment, etc. A treatment such as applying a treatment agent such as aminosilane, vinylsilane, or mercaptosilane can be performed.

(2) Heating step This is a step of heating a pretreated metal plate in the air or in an atmosphere substantially free of oxygen, and the latter is preferred in the present invention, and the film is optionally used. Is also heat-treated at the same time.

Heating atmosphere The above-mentioned “atmosphere substantially free of oxygen” means
There is no particular limitation as long as it is an atmosphere in which the surface conditions of the metal plate and film that have undergone the pretreatment step can be heated while substantially maintaining them, but specifically, the oxygen content is 1
% Or less, preferably 0.5% or less, more preferably 0.2%
The atmosphere is particularly preferably 0.01% or less.
In order to obtain this heating atmosphere, it can be filled with an inert gas or can be heated in a vacuum state. Any type of inert gas may be used, but nitrogen gas and argon gas are generally preferred.

The vacuum state is 5 Torr or less, preferably 1 Torr or less, more preferably 0.1 Torr or less.

Heating Temperature The heating temperature is appropriately determined depending on the types of the composite resin film and the metal plate to be coated, but in general, the softening point temperature (mp) of the resin film of the second layer to be directly joined is generally determined. ) Or higher, preferably (mp + 30) ° C. or higher, more preferably (mp + 50) ° C. or higher and thermal decomposition temperature or lower. Specifically, the fluorine-containing resin film is generally 260 to 260 ° C. for ETFE. 370 ° C, preferably 280-330
280-400 ℃ for PFA, 220 for CTFE
~ 350 ° C, and PVDF is 250 to 300 ° C.

Heating Time The heating time is not particularly specified, and it is necessary that at least the surface of the metal plate reaches the heating temperature, and it is appropriately determined according to the type and thickness of the metal plate. However, it is generally 1 to 20 minutes, preferably 3 to 15 minutes, and more preferably 5 to 10 minutes.

(3) Laminating Step In this step, the composite resin film is placed on the heated metal plate,
It is a process of coating by laminating and pressing.

Laminating Atmosphere Although the laminating atmosphere is not particularly limited, it is desirable that the atmosphere is substantially free of oxygen at least until the film is laminated and placed on the heated metal plate. The atmosphere is preferably based on the previous step (2), *.

Pressing the film stacked and placed on the heated metal plate, for example, 2
It is a step of continuously pressing with a book roll or the like for strong coating. Here, the roll in contact with the film is preferably a roll not sticking to the film such as a rubber roll or a metal roll, and the pressing force is 5 to 30 kg / cm2, preferably 10
~ 20kg / cm2.

(4) Reheating Step In this step, a reheating step is carried out, if necessary, in order to further strengthen the fusion force between the metal plate and the film of the film-coated metal plate obtained in the previous factory. Is. The * heating atmosphere in this step can be carried out according to the heating step in (2) above.

Heating Temperature The heating temperature is appropriately determined depending on the types of the fluororesin film and the metal plate to be coated, but generally, the softening point temperature (mp) of the fluororesin film is determined. Or higher, preferably (mp + 30) ° C. or higher, more preferably (mp + 50) ° C. or higher and lower than the thermal decomposition temperature. Specifically, in the case of a fluororesin-based film containing no colorant, For example, 260-370 for ETFE
℃, preferably 280 ~ 330 ℃, PFA generally 280 ~ 400
℃, typically 220-350 ℃ for CTFE and 250-3 for PVDF
For example, 00 ° C.

Further, in the case of a film containing the above colorant, it is necessary to further raise the temperature above the above temperature, and it is desirable to raise the temperature further depending on the colorant to be added. ℃, 20 for inorganic colorants
It is desirable to raise the temperature to ~ 50 ° C.

Heating Time The heating time is not particularly limited, and it is necessary that at least the surface of the metal plate reaches the heating temperature, and it is appropriately determined according to the type and thickness of the metal plate. If the second layer does not contain a coloring material, it is generally 1 to 20 minutes, preferably 3 to 15 minutes, and more preferably 5 to 10 minutes, but when the coloring material is contained. It is important to extend for at least 2 minutes or more.

(5) Cooling Step This step is a step of cooling the reheated film laminated metal plate to room temperature, and can be cooled by, for example, an air cooling fan, water or the like. If uneven cooling is performed here, the plate may be distorted or deformed. Therefore, uniform cooling is desirable.

The resin film-laminated metal panel thus obtained can be used as a pre-processed panel according to the purpose by a conventional method of processing a metal plate. For example, the composite metal plate is cut, and then the exposed metal part is oxidized and anticorrosion treated to improve the durability of the metal. In this case, when the metal is aluminum or an aluminum-based alloy, alumite processing, chromate processing, anticorrosion coating, etc. are suitable processing methods.

When the metal is an iron-based metal, phosphate treatment, chromate treatment, anticorrosion coating and the like are suitable treatment methods.

As the inorganic panel used in the present invention, both a cement panel and a non-cement panel can be used. In the present invention, the cement-based panel is a concrete panel or a lightweight foam concrete panel (AL
C panel), asbestos cement board extrusion molded cement board, glass fiber reinforced cement panel (GRC panel), asbestos cement pearlite board and the like. Examples of the non-cement panel in the present invention include gypsum board and calcium silicate board.

The "cement panel" is not particularly limited, but specifically, for example, JIS
Portland cement specified in R5210, JI
Blast furnace cement specified by SR5211, JIS R
5212 silica cement and JIS
Fly ash cement specified in R5213 can be used.

In addition, JIS A
5002 Structural lightweight concrete aggregate, J
Crushed stone for concrete specified in IS A5004,
Aggregates such as crushed stone for concrete specified in JIS A5005, fiber materials such as glass fiber and carbon fiber, expansive materials, chemical admixtures, admixtures such as rust preventives can be contained. ..

It is also possible to use a ready-mix concrete defined in JIS A5308. Furthermore, the "cement-based panel" in the present invention is JIS
It is also possible to use a lightweight air bubble concrete panel (ALC panel) specified in A5416.

This ALC panel is an autoclave-cured material mainly composed of calcareous raw materials and siliceous raw materials, and is preferably a panel reinforced with reinforcing bars for buildings. As the calcareous raw material, lime, Portland cement, blast furnace cement, Celica cement, or fly ash cement or high siliceous cement with these cements as a main raw material can be exemplified, and as the siliceous raw material, silica stone, silica sand, Blast furnace slag, fly ash, etc. that do not contain harmful components such as mud, dust, and organic substances in a harmful amount are preferable.

Further, it is also possible to use a foaming agent, an admixture material, a rust preventive and the like. Further, as a reinforcing bar used for the ALC panel, a rolled steel material for general structure specified in JIS G 3101, a steel bar for reinforcing bar concrete specified in JIS G 3112, and JIS G 3532 are used.
An example is a normal iron wire defined in 1.

The method for producing the "cement-based panel" is not particularly limited, and specific examples thereof include a cast molding method and an extrusion molding method.

In the present invention, the "panel" is a composite metal plate cut into a certain shape and processed, and its shape is not particularly limited, and may be rectangular, circular, or the like.
It may have any shape such as an oval shape or a polygonal shape, but a rectangular shape is preferable. Any size is acceptable, but in general
It is 3m x 2m ~ 20mm x 20mm.

In the present invention, the method of joining the "resin film laminated metal panel" and the "inorganic panel" is not particularly limited as long as both the panels are firmly joined and there is no practical problem. However, specifically, a method of bonding the composite metal panel and the inorganic panel with an adhesive, a mechanical fixing method such as metal nails or anchor bolts, or a stud on a composite metal panel that has been preformed. An example is a method of forming an inorganic panel by a casting method after applying a means such as fixing reinforcing metal bars by a method such as a welding method.

As the adhesive used for joining the two panels in the present invention, rubber-based, epoxy-based, acrylic-based, modified acrylic-based, urethane-based, olefin-based, vinyl acetate-based adhesives, etc. are used. Of these, rubber-based and epoxy-based vinyl acetate are preferable.

Further, when using the adhesive, it is preferable to preliminarily surface-treat the surface of the inorganic panel with a primer or the like. As the primer, an epoxy resin, a vinyl acetate resin, an acrylic resin, a urethane resin, a silicone resin, or the like can be used.

As the mechanical fixing method used for joining the two panels in the present invention, a method of fixing the metal panel to the end surface or the surface of the inorganic panel by metal nails, anchor bolts, ALC nails, through bolts, or the like, or It is possible to adopt a method in which a stud bolt welded to a rough metal panel is fixed with a nut through a through hole formed in a cement-based panel.

Further, in the present invention, it is preferable to adopt both the joining method using an adhesive and the mechanical fixing method in order to ensure the prevention of the falling and deformation of the metal panel.

The "metal panel" and the "inorganic panel" in the present invention are joined by a method in which a composite panel obtained by joining a composite metal panel and an inorganic panel of the same size is used as a wall body, in the form of small pieces. Examples are a method of constructing a composite panel in which cut and processed composite metal panels are arranged and joined in a brick shape or a tile shape as a wall body, or a method of joining a composite metal panel to a cement-based panel wall surface that has been previously constructed as a wall structure. To be done.

[0058]

EXAMPLES The present invention will be described in more detail with reference to the following examples, but it goes without saying that the present invention is not limited to the examples.

Example A (Preparation of Composite Metal Plate) Ethylene tetrafluoride / ethylene content molar ratio was 53/47, flow start temperature 280 ° C., thermal decomposition start 350 ° C., 300
An ethylene-tetrafluoroethylene copolymer (ETFE) having a volumetric flow rate at 90 ° C. of 90 mm ² / sec was obtained by an extruder to obtain ETFE pellets. The pelletizing conditions at this time are temperature 300
The temperature was 100 ° C. and the rotation speed was 100 rpm L / D = 30. A non-porous ETFE film having an average thickness of 50 μm, which was formed from the pellets by a hot melt extrusion method, was prepared.

On the other hand, JIS H-4000 with a thickness of 1.0 mm
After sandblasting one surface of the A5052 series aluminum rolled plate shown in 1) to an average unevenness depth of 10 to 15 μm (surface roughness) and an unevenness cycle of 10 to 20 μm, the sandblasted surface is electrolytically etched. This electrolytic etching treatment was carried out at a temperature of 40 ° C. with an electrolytic density of 4 amperes / dm ^{2 and an} energization amount of 35 clones / cm ² using an aqueous solution of 13% NaC.

After the etching surface was washed with water and dried, the aluminum plate was preheated to 310 ° C., the film was placed on the etching surface so that the printing surface of the printing film was in contact with the metal surface, and pressure was applied with a pressure of 20 kg / cm ^2. Then, it was reheated at 310 ° C. for 10 minutes and heat-sealed to obtain a composite metal plate of the present invention in which a fluorine resin layer was formed on the aluminum plate.

Example B (Preparation of Composite Panel) Example 1 The resin film laminated metal plate obtained in Example A was 492 mm × 1.
Cut to 042 mm and bend four sides to a width of 20 mm to form a folded panel. The bent panel was formed with an anodized film of 9 μm in an alumite layer.

The light-weight foam concrete having a width of 450 mm, a length of 1000 mm and a thickness of 40 mm was subjected to a primer treatment (Konishi Bond E-200P, manufactured by Konishi Co., Ltd.), and then the bent panel was bonded with an adhesive (Konishi Co., Ltd.). Konishi Bond EMS-20
Was used).

Further, an ALC nail was driven from the bent portion of the bent panel to mechanically fix the bent panel and the ALC panel to obtain a composite panel of the present invention. The obtained composite panel was an exterior material excellent in weather resistance, stain resistance, heat resistance, designability, and workability.

Example 2 The width of the bent panel (resin film laminated metal panel) having the anodized film formed by the method of Example 1 on the back surface of the panel.
Primer treatment of 450mm, 1000mm long, 12mm thick calcium silicate (Konishi Bond E-200P)
Then, the adhesive (Konishi Co., Ltd. Konishi Bond EMS-2
0) was used to bond the composite panel of the present invention.

The obtained composite panel has weather resistance, stain resistance, and
It was a building material with excellent heat resistance, design, and workability.

[0067]

INDUSTRIAL APPLICABILITY The novel composite panel of the present invention is excellent in weather resistance, stain resistance, heat resistance, workability, and excellent in design, and is suitable for exterior materials and construction materials.

[Brief description of drawings]

FIG. 1 is a sectional view showing a sectional structure of one mode of a composite panel obtained in Example 1 of the present invention.

FIG. 2 is a cross-sectional view showing the structure of one mode of the composite panel obtained in Example 1 of the present invention.

FIG. 3 is a sectional view showing a sectional structure of a composite panel obtained in Example 2 of the present invention.

[Explanation of symbols]

 1 Resin Film Laminated Metal Panel 2 ALC Panel 3 Fluororesin Film 4 Metal Plate (Aluminum Plate) 5 ALC 6 Fixing Nail 7 Adhesive 8 Resin Film Laminated Metal Panel 9 Adhesive 10 Calcium Silicate Plate

Claims (6)

[Claims] 1. A composite panel comprising a resin film laminated metal panel and an inorganic panel joined together. 2. The composite panel according to claim 1, wherein the resin film is a fluororesin film. 3. The composite panel according to claim 1, wherein the resin film laminated metal panel is a laminated metal panel obtained by heat-sealing a resin film. 4. The composite panel according to claim 1, wherein the metal panel of the resin film laminated metal panel is an aluminum-based metal panel. 5. The composite panel according to claim 1, wherein the inorganic panel is a cement panel. 6. The composite panel according to claim 5, wherein the cement-based panel is a lightweight foam concrete-based panel.