JPH09195441A - Manufacture of lightweight heat insulating waterproof panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance waterproof performance by forming a panel by filling a foaming resin composition in a space of a core material such as a honeycomb arranged inside a frame body, and applying a waterproof applying material to the obverse and the reverse or the like of this panel. SOLUTION: A honeycomb structure 1 or a corrugated structure partitioned into plural spaces by kraft paper or an incombustible sheet on which frame retarding treatment is performed, is arranged in a frame body of an aluminum section. A foaming resin composition 2 by adding an inorganic agent and reinforcing short fiber to a resin material to which a foaming agent is added, is filled in a space of a core material composed of these honeycomb structure 1 and corrugated structure, and a panel 4 is molded. Next, a waterproof layer 3 is formed by applying an acrylic emulsion type waterproof coating film forming material to the frame body 5 on a surface or the obverse and reverse and a peripheral end part of this panel 4. Therefore, a lightweight heat insulating waterproof panel can be molded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a lightweight, heat-insulating and waterproof panel having a heat insulating property and a waterproof property, which is used for wall materials, roof materials, floor materials, etc. of buildings such as general buildings and houses. It is a thing.

[0002]

2. Description of the Related Art Conventionally, waterproofing work for buildings is a sheet waterproofing method in which metal plates or sheets are spread, an asphalt waterproofing method in which a waterproof layer is formed by using an aspart material, a mortar method in which mortar is applied, and a synthetic resin waterproofing method. There is a method of applying a material to form a waterproof coating film.

In any of the above methods, cracks occur due to deterioration over time due to repeated expansion and contraction due to wind and rain or temperature changes. The occurrence of cracks causes water leakage and forms a water channel, which is a factor of water leakage expansion. Moreover, these cracks could not be easily found, and it was very difficult to repair the water leaks.

Further, since the conventional waterproofing method completely covers the surface to be waterproofed, air generated from the surface to be waterproofed,
In some cases, peeling or floating may occur due to the influence of moisture or the like. Therefore, there is a problem that a degassing tower must be installed to degas and dehydrate.

[0005] Waterproofing work depends largely on the degree of skill of the worker, and for unskilled workers, there is a significant difference in the quality of the work. There is also a problem that it is not possible to work in rainy weather because of the large amount of outdoor construction, which is affected by the weather.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above problems, and a foamed resin composition is filled in the space of a core material such as a honeycomb produced at the factory to fill the panel. A lightweight heat-insulating waterproof panel in which a waterproof layer is formed by applying a waterproof coating material to the front surface or front and back surfaces and the peripheral edge frame. By laying this lightweight heat-insulating waterproof panel and filling the joints between the panels with a sealing material, on-site work such as draining gradient can be made extremely easy, and there is no concern about the quality of the finish due to the difference in the skill level of the workers, immediately after the rain. The purpose of the present invention is to provide a method for manufacturing a lightweight heat-insulating waterproof panel that can be immediately used for construction, saves waiting time for hands, and can completely prevent water leakage due to cracks in the coating film. I am trying.

[0007]

[Means for Solving the Problems] As a result of intensive research aimed at solving the above problems, as a result, flame-retardant kraft paper or /
And a foamed resin composition is filled in the space of the core material having a honeycomb structure or a corrugated structure with a non-combustible sheet, and a waterproof coating material is applied to the front surface or front and back surfaces and peripheral edges to form a waterproof layer. It was solved by a lightweight insulation waterproof panel.

[0008]

The present invention will be described below. The foamed resin composition is filled in the space of the honeycomb structure or the corrugated structure serving as the core material of the panel. The surface or front and back surfaces of the filled core material and the frame bodies at the peripheral end portions are coated with a waterproof coating material to make it lightweight, thereby providing a lightweight, heat-insulating waterproof panel. As the frame body forming the peripheral edge portion, any of inorganic, metal, and organic plate materials or mold materials can be used.

The foamed resin composition includes a resin material added with a foaming agent or a resin material added with a foaming agent, to which an inorganic material and reinforcing short fibers are added and filled. Any foaming method can be used for foaming the resin material, for example, a method of foaming by adding a foaming agent, a foaming agent is added to a liquid resin during the polymerization reaction, the foam is stirred and foamed, and the foam does not disappear. A method of solidifying the material, a method of generating a foamed resin by generating gas in the polymerization reaction process, a process of producing a molding material by polymerizing by including a low boiling point solvent such as propane and butane in the polymerization process, and heating the molding material A foam compression molding method can be used.

The resin material used for the foamed resin is a thermoplastic resin such as polystyrene, polyethylene, polypropylene, foamed vinyl chloride resin, polyurethane or the like, or a thermosetting resin such as phenol, urea, epoxy or hard polyurethane.

The inorganic agent added and filled in the resin material added with the foaming agent can improve the mechanical strength of the foamed resin and impart flame retardancy and self-extinguishing property of the foamed resin. As the inorganic agent, a heat-decomposable inorganic agent or an inorganic refractory agent such as aluminum hydroxide, calcium carbonate, silicon oxide, calcium silicate, magnesium hydroxide, barium sulfate, gypsum, dolomite, talc, clay, mica, antimony trioxide, borax. Powder such as can be arbitrarily used.

To make the foamed resin composition tough, organic or inorganic short fibers are added. When using organic short fibers, vinylon fibers, polypropylene fibers, polyethylene fibers, which are short fibers in the range of 1 to 20 mm,
Although pulp fibers and the like can be used, vinylon fibers are more preferably used in consideration of impact strength. When inorganic short fibers are used, glass fibers of 5 mm or less, rock wool, wollastonite, sepiolite,
Carbon fiber or the like can be used.

When organic short fibers are used, the amount is 8 parts by weight or less based on the total weight of the molded panel. Addition of more than this will impair moldability. Preferably it is 0.5 to 5 parts by weight. When organic short fibers and short inorganic fibers are used in combination, the organic short fibers are in the range of 0.5 to 3 parts by weight and the short inorganic fibers are in the range of 0.5 to 8 parts by weight. To do. When using only inorganic short fibers without using organic short fibers, the amount is 1 to 10 parts by weight.

As the core material having a honeycomb structure and a corrugated structure, a core material formed of kraft paper and / or a non-combustible sheet subjected to a flame retardant treatment is used. As one method of making the kraft paper flame-retardant, the kraft paper immersed in water glass or a suspension of water glass and aluminum hydroxide is dried by hot air at about 100 ° C. Even if the kraft paper that has been subjected to the flame-retardant treatment is ignited, crystal water is generated from the aluminum hydroxide to take heat, and it does not burn. After that, the oxidized rusty aluminum remains and the kraft paper is carbonized. Further, the state of being covered with water glass can easily carbonize the kraft paper.

As the non-combustible sheet used when the core material having the honeycomb structure and the corrugated structure is formed of a non-combustible sheet, an inorganic mineral fiber sheet made of calcium silicate, magnesium silicate or the like is used.
By using flame-retardant kraft paper or non-combustible sheet as the core material of the lightweight heat-insulating waterproof panel, it is possible to improve the fire resistance, bending strength, and impact strength.

The waterproof layer coating material, which is a waterproof coating material applied to the front surface or the front and back surfaces and peripheral edges of the panel in which the foamed resin composition is filled in the space of the core material, is a waterproof layer using an asphalt-based material. Either a waterproof layer using a rubber or synthetic resin sheet or a waterproof layer in which a synthetic resin liquid material is applied or sprayed while a reinforcing cloth and a mesh are attached.

The lightweight heat-insulating waterproof panel in which a waterproof coating is applied only on the surface of the panel to form a waterproof layer is used as an outer wall material / roof material or a floor material of a balcony. It is possible to easily form the draining gradient of the roof material or the balcony floor material by forming a notched slope on the back surface of the panel and laying the panel. Moreover, since the panel itself has high heat insulation and high waterproofness, it suffices to fill the joints between the panels with a sealing material for on-site construction.

The lightweight heat-insulating waterproof panel in which the front and back surfaces of the panel and the peripheral edge portions are coated with a waterproof coating material to form a waterproof layer is used, for example, for rooftop waterproofing work. A lightweight heat-insulating and waterproof panel is attached to the surface of the building to be waterproofed using attachment fasteners or adhesives, the joints between the panels are sealed with a sealing material, and the top surface of the sealing material is coated with a waterproof material if necessary. To do.

[0019]

Embodiments of the present invention will be described below.

Example A paper honeycomb having a cell size of 50 mm and a core material thickness of 30 mm was subjected to a flame-retardant treatment to obtain a core material for a lightweight heat-insulating waterproof panel. The extruded aluminum material was used for the frame at the peripheral edge. The foaming resin was polystyrene, and a foaming resin composition was prepared by adding an inorganic material and inorganic short fibers to a molding material prepared by polymerizing a low boiling point solvent such as propane or butane.

The foaming resin composition is blended in such a manner that 15 parts by weight of an inorganic material powder prepared by mixing 70 parts by weight of aluminum hydroxide and 30 parts by weight of calcium silicate with 100 parts by weight of a polystyrene molding material and inorganic short fibers are used. Is 0.5 ~
5 parts by weight of glass fiber having a denier of 40 and a length of 0.5 to 3 mm.

The foamed resin composition is filled in the space of the flame-retardant paper honeycomb core material inside the frame of the aluminum mold material,
It is heated to 100 ℃ and integrally molded, and the surface of this panel is coated with an acrylic emulsion type waterproof coating material (Toyo Exterior Co., Ltd. "Reball Mighty") to form a waterproof layer to make a lightweight heat-insulating waterproof panel. It was used as a floor material for a residential balcony by forming a diagonal notch on the back surface. The joints between the panels were sealed with a modified silicone type sealing material (“Hibon 2000” manufactured by Hitachi Chemical Polymer Co., Ltd.).

[0023]

The method for manufacturing a lightweight heat-insulating and waterproof panel according to the present invention uses a core material having a honeycomb structure or a corrugated structure made of a flame-retardant treatment or a non-combustible sheet disposed inside the frame at the peripheral end as a reinforcing core. A foamed resin composition is filled in the space to form a panel. A lightweight heat-insulating waterproof panel is constructed by applying a waterproof coating material to the front surface or front and back surfaces of this panel and the frame bodies at the peripheral edges to form a waterproof layer.

[0024] Lightweight heat-insulating and waterproof panels are used as roofing materials for buildings, balconies, balconies, etc., or as interior and exterior wall materials by attaching metal fittings or adhesives to the waterproof construction surface of the body and filling the joints between the panels with coating. It is possible to easily and surely carry out waterproofing work by simply doing it, and it is also very suitable for repair work.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view of a lightweight heat-insulating waterproof panel of the present invention.

FIG. 2 is a construction sectional view of an embodiment.

[Explanation of Codes] Honeycomb structure 2. 2. foamed resin composition Waterproof layer 4. Lightweight insulation waterproof panel 5. Frame body at the peripheral edge 6. Plywood 7. Joists 8. Draining 9. 10. Outer wall 11. handrail

Claims (4)

[Claims] 1. A lightweight heat-insulating and waterproof panel having a frame body at a peripheral end and a core material as a reinforcing core inside the frame body, and a foamed resin composition is filled in a space of the core material to form a panel. A method for manufacturing a lightweight heat-insulating and waterproof panel, characterized in that a waterproof coating material is applied to the front surface or front and back surfaces of the panel and the peripheral edge portions. 2. The method for manufacturing a lightweight heat-insulating and waterproof panel according to claim 1, wherein the core material has a honeycomb structure or a corrugated structure partitioned into a plurality of spaces. 3. The lightweight heat-insulating waterproof panel according to claim 1, wherein the honeycomb structure and the corrugated structure are formed of flame-retardant kraft paper. 4. The method for manufacturing a lightweight heat-insulating and waterproof panel according to claim 1, wherein the honeycomb structure and the corrugated structure are formed of an incombustible sheet.