JPH1058414A - Manufacture of outer-wall panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To give large indentations to the surface side and to eliminate a gap between the surface side and a lining material. SOLUTION: A surface material 1 being prepared by forming an indented steel sheet in the shape of a box, a slurry-like raw material 5 of a lining material prepared by blending inorganic light-weight aggregate, water, plaster and resin is poured into the box shape of the steel sheet, solidified and made integral with the steel sheet and thereby an outer-wall panel is obtained. Since the lining material in conformity with the shape of the surface material is formed, accordingly, depression of the indentation given to the surface layer material 1 is prevented.

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 an outer wall panel used for an outer wall of a building or a building.

[0002]

2. Description of the Related Art As an outer wall panel, a steel plate obtained by applying a design to a flat plate by painting or a steel plate obtained by applying a design by embossing is used as a surface material. This surface material is lined with an inorganic board such as a gypsum board or a calcium silicate board or an organic foam such as urethane or phenol.

[0003]

In the case of an outer wall panel in which an inorganic gypsum board or the like is lined with a steel sheet having irregularities, the convexities are dented when a force is applied from the surface side because the surface has irregularities. Although dents on the front surface can be prevented by embedding resin or the like from the back surface side, the cost of the resin used and the increase in the process cost increase the cost of the outer wall panel obtained. If the irregularities on the steel plate are reduced, dents on the surface can be suppressed without the need for resin filling,
Surface irregularities are smaller than ceramic panels, resulting in poor design. Also, the gypsum board is water-absorbing, which is a disadvantage of the obtained outer wall panel.

On the other hand, an outer wall panel using an organic foam as a backing material is inferior in heat resistance to an inorganic backing material, so that a gypsum board, a calcium silicate plate or the like must be further attached to the back side of the panel. There is. Therefore, the number of steps for manufacturing the panel increases, and the obtained outer wall panel becomes expensive. The present invention has been devised in order to solve such a problem. By pouring a slurry-like backing material into a surface material formed into a box and curing the material, the surface material along the irregularities attached to the surface material is formed. An object of the present invention is to provide an outer wall panel which is formed with a backing material and has excellent design without protruding portions even when a force is applied from the front side.

[0005]

In order to achieve the object, a method for manufacturing an outer wall panel according to the present invention is to form a surface material by forming a steel plate having irregularities into a box shape, and to use inorganic lightweight aggregate, water, gypsum and the like. It is characterized in that a slurry-like backing material containing a resin is poured into a steel box, and the backing material is solidified and integrated with the steel sheet. When a backing material to which a water repellent is added is used, water absorption resistance is imparted to the inside, surface, and the like of the backing material.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An outer wall panel according to the present invention is, as shown in FIG.
The backing material 2 is provided on the back side. The outer wall panel is reinforced by an iron frame 3, and a backing paper 4 is attached to a backing material 2. As the surface material 1, a steel sheet having a thickness of 0.2 to 2 mm is used, and examples thereof include a surface-treated steel sheet, a galvalume steel sheet, a stainless steel sheet, an enameled steel sheet, a painted steel sheet, a galvanized steel sheet, an aluminum-plated steel sheet, and a copper-plated steel sheet. The steel plate is provided with irregularities of 0.5 to 10 mm by embossing, pressing, or the like to impart designability. The concavo-convex pattern can be applied simultaneously when the steel sheet is formed into a box shape. With less than 0.5 mm unevenness, it is not enough to improve the design by unevenness, but it is almost impossible to provide unevenness over 10 mm by processing, and it is expensive equipment to actually pattern by processing Is required, which causes an increase in cost.

When manufacturing the outer wall panel, first, the surface material 1 is formed into a box shape as shown in FIG. A raw material 5 in which lightweight aggregate, gypsum, water, resin and the like are kneaded in a slurry state in advance is poured from a hopper 6 into the box of the surface material 1. The backing material 5 is prepared by kneading an inorganic lightweight aggregate such as perlite or vermiculite, gypsum, a binder resin, etc., and preparing a slurry. The backing material 5 may be added with a reinforcing fiber, a water repellent, a fluidizing agent, and the like, if necessary. In order to improve the conformability of the backing material 5 to the surface material 1, an adhesive may be applied to the back surface of the surface material 1. As the adhesive, an aqueous emulsion adhesive such as acrylic or vinyl acetate or a solvent-based resin adhesive such as epoxy or phenol is used. Paper, as required
A nonwoven fabric or the like may be attached to the back surface of the surface material 1. After charging the raw material, the surface material 1 is vibrated so that the slurry-like backing material 5 is distributed evenly and uniformly. Next, the backing material 4 is placed on the backing material 5 and dried and solidified to form the backing material 2. Thereafter, the iron frame 3 is mounted, and the outer wall panel is assembled.

[0008]

【Example】

Example 1 A steel plate having a thickness of 0.4 mm is provided with irregularities and has a width of 50 mm.
A box formed with 0 mm, 700 mm in length and 40 mm in depth was used as the surface material 1, and an acrylic resin adhesive was applied to the back surface. Inside the box of the surface material 1, plaster 100
Parts by weight, 8.5 parts by weight of perlite, vinyl acetate resin 3
The backing material 5 was kneaded into a slurry at a mixing ratio of 150 parts by weight of water to 150 parts by weight of water. The surface material 1 was vibrated, and the poured backing material 5 was evenly distributed inside the box. Then, the backing paper 4 was stretched on the smoothed backing material 5. This state is maintained at room temperature for 24 hours,
The backing material 5 was dried and solidified. After drying, when the smoothness of the backing paper 4 was measured, the unevenness was within ± 1 mm. Observation of the cross section of the obtained outer wall panel revealed that the backing material 2 had no gap between itself and the surface material 1 and filled the back side irregularities of the surface material 1. Therefore, even when the convex portion of the surface material 1 was pressed from the front side of the outer wall panel, no dent was generated.

Example 2: A backing kneaded in a slurry at a mixing ratio of 100 parts by weight of gypsum, 8.5 parts by weight of perlite, 3 parts by weight of vinyl acetate resin, 150 parts by weight of water, and 10 parts by weight of silicone water repellent. The raw material material 5 was poured into the surface material 1 formed into a box shape and solidified to produce an outer wall panel.
The obtained outer wall panel is 100 mm × 100 mm × 9.5.
After being cut into mm and dried sufficiently, it was immersed in water for 24 hours. Then, the weight change before and after the immersion was measured, and the water absorption was determined from the measured value. FIG. 3 shows the results of the investigation. Note that FIG.
Then, gypsum boards of the same dimensions were compared as a comparative example. As is clear from FIG. 3, the outer wall panel to which the water repellent was added had a water absorption of 1/5 or less as compared with the gypsum board, and was found to be excellent in water absorption resistance.

[0010]

As described above, in the present invention, the raw material of the slurry-like backing material is poured into the surface layer material formed into a box shape of a steel sheet having irregularities and solidified, thereby following the irregularities of the steel sheet. A backing material having a bent shape is formed. In the obtained outer wall panel, since the solidified backing material supports the surface material from the back side, the convex portion is not dented by pressure from the surface side. Therefore, a steel plate having large irregularities can be used as a surface material, and an outer wall panel excellent in design is provided.

[Brief description of the drawings]

FIG. 1 is an exterior wall panel manufactured in accordance with the present invention.

Fig. 2 Slurry-like backing material that is poured into the inside of the box of the surface material

Fig. 3 Effect of water repellent on water absorption resistance of exterior wall panels

[Explanation of symbols]

1: Surface material 2: Backing material 3: Iron frame
4: Backing paper 5: Backing material 6: Hopper

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hiroshi Iwata 7-1 Takayashinmachi, Ichikawa-shi, Chiba Nisshin Steel Co., Ltd.

Claims (2)

[Claims] 1. A steel plate having irregularities is formed into a box to form a surface material, and a slurry-like backing material containing inorganic lightweight aggregate, water, gypsum and resin is poured into the steel box. A method of manufacturing an outer wall panel in which a backing material is solidified and integrated with a steel plate. 2. The method according to claim 1, wherein a backing material to which a water repellent is added is used.