JPH10245925A - Cement panel and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cement panel of no warp or crack resulting from drying shrinkage when a moisture impermeable decorative material is stuck on the surface of a cement base material and partial dry is produced on the back side. SOLUTION: A cement panel 1 is composed of a cement base material 2 stuck with a moisture impermeable decorative material 3 on the surface 2a and a composite sheet 6 formed by a hydrophilic property sheet 4 and a steam impermeable film 5, while the back 2b of the cement base material 2 is stuck with the hydrophilic property sheet 4 through an adhesive 7 and covered with the composite sheet 6. Thus sudden dry originating from the back 2b side is restrained and warps and cracks attributable to dry shrinkage are prevented from generating on the back 2b side.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cement panel used as an interior / exterior material of a building such as a tunnel or a building, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, thin cement-based panels have been used for finishing exterior walls of buildings, inner walls of tunnels, or the like or for renovation finishing. When such a thin panel for finishing is used, a decorative material such as a tile, a porcelain plate or a decorative stone material is stuck on the surface of the panel base material to mainly provide a design effect (in the case of a road side wall such as a tunnel, a vehicle is used). There is also a viewpoint of driving safety).

[0003] These thin panels are basically formed by the following method. First, a cosmetic material is placed in a predetermined mold with its surface facing down. Next, a prepared cementitious slurry is poured into a mold. Furthermore, after curing and hardening so that the mold can be removed, the mold is removed, and the room temperature state or 40-8
It is hardened and stabilized by heating to about 0 ° C or curing with high temperature and high pressure steam.

[0004]

In general, a cement-based substrate is not only cured during curing to form it into a required shape, but also after the moisture is contained in the air for a required period after being applied to a building or the like as a product. Release into and dry. Also,
When the contained water is rapidly released, drying shrinkage occurs in the substrate.

When such a cement-based substrate is formed into a so-called panel shape and an impermeable material such as a tile is stuck on the surface of the panel, moisture is released on the side of the stuck material (the surface side). ), It is inevitably biased toward the back side where the decorative material is not applied, and drying shrinkage occurs on the back side. There is no problem in use and storage under normal conditions, but under conditions where the environment changes rapidly such as exposure to direct sunlight, drying on the back side becomes sharp, and the difference between the moisture content on the back side and inside As a result, a large contraction force is generated on the back surface, and warpage or cracking may occur.

In order to prevent such warping and cracking, it is conceivable to add a shrinkage reducing agent to the cementitious slurry or to apply a resin coating or the like to the outer surface. In the case where a moisture-permeable makeup material is stuck, the expected effect cannot be obtained because the difference in drying between the front and back surfaces is large (particularly, in a thin panel).

[0007] Therefore, an object of the present invention is to provide a cement-based base material having a moisture-impermeable decorative material attached to the front surface side, in which uneven water release occurs on the rear surface side, and warpage due to drying shrinkage occurs. An object of the present invention is to provide a cement-based panel that does not cause cracking.

[0008]

Means for Solving the Problems The above object is achieved by a composite comprising a cement-based substrate having a moisture-impermeable decorative material adhered on the surface side, a hydrophilic sheet and a water vapor-impermeable film. A cement sheet, wherein the hydrophilic sheet is adhered to the back surface of the cement-based substrate via an adhesive, and the back surface of the cement-based substrate is covered with the composite sheet. It is a system panel.

The water-vapor-impermeable film is, for example,
It is a synthetic resin film or a metal foil selected from a polyethylene film, a polypropylene film, a polyester film or a polyamide film. When formed from these materials, the transmission of water vapor can be reliably suppressed. The hydrophilic sheet is a sheet formed of, for example, a paper material, a woven fabric, a nonwoven fabric, or a mesh sheet. If such a sheet is used, the bond with the cement-based substrate through the adhesive becomes more reliable and strong,
Peeling of the composite sheet can be suppressed more reliably.

In order to solve the above-mentioned problems, a step of laying a moisture-impermeable decorative material in a predetermined form with the surface facing downward and arranging a reinforcing material such as a mesh bar is provided. Casting a cementitious slurry into the mold, curing and curing, and then removing the mold, and forming a hydrophilic sheet on the back surface of the formed cement-based substrate on which the moisture-impermeable decorative material is not provided. And bonding the composite sheet formed of a water vapor impervious film with an adhesive so that the hydrophilic sheet side is attached thereto, and covering the back surface of the cement-based substrate with the composite sheet. This is a method for manufacturing a system panel.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A cement panel according to the present invention will be described below with reference to an embodiment shown in FIGS.
FIG. 1 is a perspective view of one embodiment of the cement panel of the present invention, and FIG. 2 is a partially cross-sectional enlarged view of the cement panel shown in FIG.

FIG. 2 shows a cement panel 1 of this embodiment.
As shown in FIG. 3, the cement base 2 has a moisture-impermeable decorative material 3 stuck on the surface 2a side, and a composite sheet 6 formed of a hydrophilic sheet 4 and a water vapor impervious film 5. . Then, the hydrophilic sheet 4 is adhered to the back surface 2b of the cement-based substrate 2 via an adhesive 7, and the cement-based substrate 2
Is covered with the composite sheet 6.

[0013] In the cement panel of the present invention, a composite sheet obtained by laminating a hydrophilic sheet and a water vapor impervious film is adhered to the back surface of the cement substrate. In the case where a suitable cosmetic material is stuck, the uneven release of moisture from the back side is suppressed, and the occurrence of warpage and cracks due to drying shrinkage is prevented. Less than,
Each configuration will be sequentially described in detail.

The cement panel 1 of this embodiment is a rectangular panel having a long side dimension of 1832 mm and a short side dimension of 620 mm, and a thickness of 24 mm (cement base material:
15 mm, tile: 9 mm). In addition,
The size is not limited to this. As for the warpage of the panel, the relationship between the thickness of the panel and the dimension of the side is an important factor. If the dimensions of the sides of the panel are small, warpage does not pose a practical problem. When the side dimension is increased as in the above example, the amount of warpage at both ends of the panel is increased, which poses a practical problem.
Therefore, in order to suitably implement the present invention, it is necessary to consider the relationship between the thickness of the panel and the side dimension (the longest side dimension in the case of a rectangle). That is, as a result of the examination, it has been found that a cement panel capable of suitably implementing the present invention is particularly effective when the ratio between the thickness and the length of the cement substrate is 1:10 or more.

The cement-based substrate 2 is a polymer cement plate (PCM plate), specifically, a cementitious slurry [a hydraulic material (eg, Portland cement, white cement, mixed cement, alumina cement), aggregate) (For example, silica sand, sand), a main material composed of an expansive material and a polymer, and an admixture composed of a water reducing agent and the like, which are kneaded by adding water]. In addition, as a cement base material, a glass fiber reinforced cement board (GRC)
Alternatively, it may be a concrete plate.

The polymers include styrene butadiene rubber (SBR) and polyacrylate (PA).
E), ethylene vinyl acetate copolymer (EVA), vinyl acetate versatate copolymer, polyvinyl acetate (PVA)
One or a mixture selected from C), ethylene vinyl acetate, vinyl chloride copolymer and the like can be suitably used.

On the surface 2a side of the cement base 2, a moisture-impermeable decorative material 3 is attached. In particular,
As shown in FIG. 1, a tile group formed by adjoining four tiles vertically and horizontally is defined as one block, and joints are provided between the blocks, and a plurality of blocks are juxtaposed and attached. However, the shape or arrangement of the moisture-impermeable decorative material is not limited to this, and any form may be used as long as it is attached to the surface 2a side of the cement-based substrate 2. Also,
As the impermeable decorative material, a decorative stone material such as a ceramic plate, a natural stone plate, or a synthetic stone plate may be used.

The composite sheet 6 is obtained by laminating a hydrophilic sheet 4 to be adhered to the back surface 2b side of the cement-based substrate 2 and a water vapor-impermeable film 5 covering the hydrophilic sheet 4. The hydrophilic sheet 4 is formed by coating the steam-impermeable film 5 described below with the back surface 2 b of the cement-based substrate 2.
And is formed of a paper material (for example, kraft paper). The hydrophilic sheet 4 is also an adhesive auxiliary sheet for attaching the water vapor impervious film 5 to the cement-based substrate. As the hydrophilic sheet, in addition to those described above, for example, a woven fabric, a nonwoven fabric, a mesh sheet, or the like formed of cotton, cellulose, or the like may be used.

The steam-impermeable film 5 is for suppressing rapid drying due to the release of moisture from the back surface 2b of the cement-based substrate 2, and has a completely moisture-impermeable property or a slight moisture-permeable property. Can be used. Here, a polyethylene film which is a polyolefin film is used. Further, as the water vapor-impermeable film, a synthetic resin film such as a polyolefin film such as a polypropylene film, a polyester film (for example, a polyethylene terephthalate film), or a polyamide film, or a metal foil such as an aluminum foil may be used.

The back surface 2b of the cement base 2 is
As shown in FIG. 2, the hydrophilic sheet 4 of the composite sheet 6 is attached via an adhesive 7,
b is covered with the composite sheet 6. This allows
Sudden and uneven release of moisture from the back side is suppressed, and warpage and cracking due to drying shrinkage can be prevented.
As described above, by covering the back surface 2b of the cement-based substrate 2 with the composite sheet 6, the moisture in the cement-based substrate 2 is gradually released from the fore-edge surface of the substrate, and drying is slow. As a result, warpage and cracking can be prevented.

As the adhesive 7, an adhesive having both a hydrophilic sheet (for example, a paper material) and a cement-based substrate is used. Specifically, natural polymer adhesives such as soy paste (starch paste), dextrin, natural rubber, acrylic adhesives (eg, polyacrylate), and vinyl acetate adhesives (eg, polyvinyl acetate) , Ethylene-vinyl acetate copolymer, vinyl acetate-acrylate copolymer), vinyl alcohol-based adhesive (for example, polyvinyl alcohol, ethylene-vinyl alcohol copolymer), polyvinyl ether, synthetic rubber-based adhesive ( For example, nitrile rubber, styrene-butadiene rubber), cellulose derivatives (for example, cellulose-nitrate) and the like are used.

Next, a method for manufacturing the cement panel of the present invention will be described. Cement-based panel 1 of the present invention
Is a step of laying the moisture-impermeable decorative material 3 in a predetermined formwork with the surface facing downward, arranging a reinforcing material such as a mesh streak, and placing a cementitious slurry into the formwork. When,
A step of demolding after curing and curing, and a step of forming a composite sheet 6 formed of a hydrophilic sheet 4 and a water vapor-impermeable film 5 on the back surface 2b of the formed cement-based base material 2 using a cement-based The cement-based substrate 2 is manufactured through a process of covering the entire rear surface 2b of the cement-based substrate 2 with the composite sheet 6 so as to be attached to the rear surface 2b of the substrate 2 via an adhesive. Hereinafter, each step will be sequentially described.

First, in the step of laying the moisture-impermeable decorative material 3 in a predetermined formwork and arranging the reinforcing material, a required number of the moisture-impermeable decorative materials 3 are arranged in the formwork in parallel. In this case, since the cementitious slurry is later poured from the back side of the moisture-impermeable decorative material 3, the surface of the moisture-impermeable decorative material 3 is set to the lower side, and the back side is exposed to the upper surface. Above it, a reinforcing material, for example, a mesh streak is provided.

In the step of casting the cementitious slurry into the mold, the cementitious slurry is kneaded with a mixer and then uniformly poured into the mold. Further, the cementitious slurry is spread to a state where it can be automatically scraped by conveying the mold. Examples of cementitious slurries include hydraulic substances (eg, Portland cement, white cement, mixed cement, alumina cement), aggregates (eg, silica sand,
A mixture obtained by adding water to an admixture consisting of a sand), an expanding material and a polymer and a water reducing agent or the like and kneading the mixture is used.

Further, in the step of demolding after curing and curing, a mold in which a cementitious slurry is poured is placed in a curing chamber, and curing is performed at a predetermined temperature for a predetermined time while maintaining a wet state. Alternatively, it is heated in a normal temperature state or about 40 to 80 ° C. Thereafter, the binding bolt attached to the peripheral frame portion of the mold is removed, and the mold is removed using a suction-type remover.

A composite sheet 6 formed of a hydrophilic sheet 4 and a water vapor impervious film 5 is attached to the back surface 2b of the cement base 2, and the back surface 2b of the cement base 2 and the hydrophilic sheet 5 are adhered to each other. Attach in the state to be attached, cement-based substrate 2
In the step of covering the entire back surface 2b of the cement-based substrate 2 with the composite sheet 6, the adhesive 7 is applied to the back surface 2b of the cement-based substrate 2 or the adhesive is applied to the hydrophilic sheet 4, and then the cement-based substrate 2 and the hydrophilic sheet 5 are adhered. Through the above steps, the cement panel 1 of the present invention in which the entire back surface 2b of the cement substrate 2 is covered with the composite sheet 6 is produced.

[0027]

DESCRIPTION OF THE PREFERRED EMBODIMENTS According to the above-described method, the dimension of the long side is 1832.
mm, a rectangular panel with a short side dimension of 620 mm, a thickness of 24 mm (cement base material: 15 mm, tile: 9 mm), and a tile (long side dimension of about 227 mm, short side dimension of about 60 mm) ) On the front side, and the cement-based panel of the present invention in which the entire back surface was covered with the composite sheet was produced. As the composite sheet, a sheet obtained by laminating a polyethylene film, which is a water vapor impervious film, on kraft paper was used. The composite sheet was bonded to a cement-based substrate of a cement-based panel using an adhesive [shofu paste (starch paste)].

(Comparative Example) The same method and the same material as in the example were used except that the coating with the composite sheet was not performed.
A cement panel was produced.

(Experiment) The cement panel of the example and the cement panel of the comparative example were left outdoors for about one month, and then their warpage was measured. As a result, a warp of 6 mm was confirmed in the panel of the comparative example, but no warp was confirmed in the cement-based panel of the example. Also, no cracks occurred.

[0030]

According to the cement panel of the present invention, when a moisture-impermeable decorative material is attached to the front side of the cement base material, uneven release of moisture from the back side is suppressed, and drying shrinkage occurs. Warpage and cracks caused by the cracks can be prevented.
Further, according to the method for manufacturing a cement-based panel of the present invention,
A cement panel exhibiting the above effects can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a perspective view of one embodiment of a cement panel of the present invention.

FIG. 2 is an enlarged partial cross-sectional view of the cement panel shown in FIG.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 cement-based panel 2 cement-based substrate 2 a front surface 2 b back surface 3 moisture-impermeable decorative material 4 hydrophilic sheet 5 water-vapor-impermeable film 6 composite sheet 7 adhesive

Claims (5)

[Claims] 1. A cement-based substrate having a moisture-impermeable decorative material adhered to a front surface thereof, and a composite sheet formed of a hydrophilic sheet and a water-vapor-impermeable film. Wherein the hydrophilic sheet is adhered via an adhesive, and a back surface of the cement-based substrate is covered with the composite sheet. 2. The cement panel according to claim 1, wherein the water vapor-impermeable film is a synthetic resin film or a metal foil selected from a polyethylene film, a polypropylene film, a polyester film, and a polyamide film. 3. The cement panel according to claim 1, wherein the hydrophilic sheet is a sheet formed of a paper material, a woven fabric, a nonwoven fabric, or a mesh sheet. 4. The cement-based panel according to claim 1, wherein the cement-based substrate has a thickness-to-length ratio of 1:10 or more. 5. A step of laying a moisture-impermeable decorative material in a predetermined form with the surface facing down and arranging a reinforcing material, and casting a cementitious slurry into the form. A step of removing the mold after curing and curing, and a composite formed by a hydrophilic sheet and a water vapor impervious film on the back surface of the formed cement-based substrate on which the moisture-impermeable decorative material is not provided. Bonding the sheet via an adhesive so that the hydrophilic sheet side is adhered thereto, and covering the back surface of the cement-based substrate with the composite sheet. .