JP2585720B2 - Architectural material and method for producing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a building material having heat insulating properties useful for building materials, particularly wall materials, ceiling materials, and the like, and a method for producing the same.

[Prior Art] Conventionally, the exterior walls and roofs of buildings have generally been finished by applying a cement-based outer layer material and then applying a lysine coating such as acrylic lysine or a topcoat coating such as acrylic coating thereon. In addition, in order to impart waterproofing and heat insulating properties to these, further, asphalt waterproofing material is applied,
A foamed resin plate such as a foamed polystyrene board is stuck using an adhesive.

[Problems to be Solved by the Invention] However, the construction of such an outer wall requires a large number of steps, requires various kinds of materials, and the installation of the heat insulating plate is an on-site construction. It was not considered to be an economically advantageous method.

In addition, since these outer wall materials use various kinds of materials, there is a problem that the outer wall is easily cracked with age.

[Means for Solving the Problems] In view of the above problems, the present inventors have intensively studied a building material that can be used as an outer wall material extremely easily with a small number of materials and a small number of construction steps. As a result, the present invention has been achieved.

That is, the present invention is characterized by comprising a cement-based outer layer material layer and a foamed resin particle layer obtained by bonding foamed resin particles to at least one surface of the cement-based outer layer material layer with a resin aqueous emulsion. Building materials,
And, as a production method, a foamable resin liquid containing a resin aqueous emulsion and foamable resin particles is applied to at least one surface of a cement-based outer layer material, and then the foamable resin is heated by heating the applied surface. An object of the present invention is to provide a method for producing a building material, which comprises foaming resin particles and drying the emulsion to bond the foamed resin particles to form a foamed resin particle layer adhered to a cement outer layer material. .

[Specific description of the invention] (1) Cement-based outer layer material The cement-based outer layer material used for the building material of the present invention is a material obtained by forming, extruding, and casting using cement and other raw materials as main raw materials. For example, asbestos slate board (JIS A-540) which is formed by papermaking and molding using cement and asbestos as raw materials and cured under normal pressure or under autoclave curing.
3) Asbestos-cement pearlite plate (JIS A-541) formed by papermaking using cement, asbestos and pearlite as main raw materials
3) Asbestos cement calcium silicate plate (JIS A-5418), asbestos, calcareous raw material (including cement) and siliceous raw material, and autoclave-cured by paper forming and molding, asbestos cement plate, decorative calcium tricalcium plate Such as asbestos-cement board, and pulp-cement board paper-formed and formed from cement, asbestos, pulp and inorganic mixed materials as main raw materials (JIS
A-5414), decorative pulp cement board (JIS A-5420) with makeup applied thereto, wood chip cement board (JIS A-5417) compression-molded using wood chips and cement as main raw materials, wood wool and cement Compression molded wood wool cement board (JIS A-5
404) and the like, and among them, the asbestos cement board and the pulp cement board are preferable.

(2) Foamable resin liquid The foamable resin liquid applied to the cement outer layer material in the present invention basically contains a resin aqueous emulsion and foamable resin particles.

Resin aqueous emulsion The adhesive resin used in the aqueous resin emulsion by being dispersed in an aqueous medium is a resin having a minimum film-forming temperature of not higher than the heating temperature. Specifically, n-methacrylic acid n-
Propyl (Tg 81 ° C), styrene (Tg 100 ° C), acrylonitrile (Tg 100 ° C), methyl methacrylate (Tg 105
℃), methacrylic acid (Tg 130 ℃), itaconic acid (Tg 130
° C), acrylamide (Tg 153 ° C), 2-ethylhexyl acrylate (Tg -85 ° C), n-butyl acrylate (Tg
g-54 ° C), ethyl acrylate (Tg-22 ° C), isopropyl acrylate (Tg-5 ° C), 2-ethylhexyl methacrylate (Tg-5 ° C), n-propyl acrylate (Tg 8 ° C), methacryl N-butyl acid (Tg 20 ° C), vinyl acetate (Tg 30 ° C), ethyl methacrylate (Tg 65
° C), vinyl chloride (Tg 79 ° C), vinylidene chloride (Tg −
18 ° C.), 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, diethylene glycol monoacrylate, glycidyl methacrylate, glycidyl acrylate, N-methylol acrylamide, N-methylol Aqueous emulsions of homopolymers such as methacrylamide and butadiene or copolymers of two or more of these monomers [Tg shown in parentheses
Is the glass transition point of these vinyl monomers or homopolymers of vinylidene chloride), and Tg is a mixture of a resin aqueous emulsion at a heating temperature or higher and a resin aqueous emulsion at a heating temperature or lower, and Those having a minimum film-forming temperature equal to or lower than the heating temperature are exemplified.

The resin solids concentration in the aqueous emulsion of these resins is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is usually 10 μm or less, preferably 0.05 to 1.0 μm.

Foamable resin particles As the foamable resin particles contained in the foamable resin liquid, styrene containing a polymerization initiator, methyl methacrylate if necessary, vinylbenzene, vinyl monomers such as acrylic acid are dispersed in water. By heating this, a vinyl monomer such as styrene is polymerized, and then a swelling agent such as butane or hebutane is pressed into a suspension in which the polymer particles are dispersed, and volatilized into the polymer particles. When the suspension monomer is produced by impregnating a swelling agent at a ratio of 1 to 10% by weight or when a vinyl monomer such as styrene is subjected to suspension polymerization, polymerization is performed while supplying the swelling agent to the suspension. The produced expandable polystyrene particles, or the expandable α- produced by allowing α-methylstyrene to coexist with the above styrene.
Methylstyrene-styrene copolymer particles, or an expandable acrylonitrile-butadiene-styrene copolymer resin (expandable ABS) produced by coexisting acrylonitrile and butadiene with the above-mentioned styrene can be used.

These expandable resin particles generally have a particle size of 1.5 mm or less, preferably 0.2 to 0.8 mm.If the particle size exceeds 1.5 mm, the workability with the aqueous resin emulsion is poor, and the foaming resin particles are expanded. The resin particles move to the upper layer of the emulsion liquid and are easily separated, and the storage stability of the foamable resin liquid itself deteriorates, which is not preferable. On the other hand, if the diameter of the resin particles is large, it is difficult to apply the resin particles to the cement-based outer layer material, and the coatability is deteriorated. Further, the foamed resin particles are likely to fall off after the foamable resin liquid is applied to the cement-based outer layer material and dried.

Since the expandable resin particles to be used are finer than those used for the molding of a normal expanded product, nonstandard products in the production process of the expandable resin particles can be used.

Other components In addition to the essential components, if necessary, further extenders such as calcium carbonate, aluminum hydroxide, clay, talc, barium sulfate, Portland cement, red iron oxide,
Pigment such as titanium oxide and carbon, glass fiber, synthetic fiber, inorganic fiber, metal fiber, lightweight aggregate such as shirasu balloon, perlite, vacuum light, flame retardant, dye, iron powder, iron oxide, DOP, BBP, CDP, Plasticizers such as XDP, film forming aids such as toluene and mineral spirits, methyl ethyl cellulose, polyvinyl alcohol, other thickeners, antifreeze agents, defoamers, dispersants, foaming agents, wetting agents, emulsifiers, etc. Can be blended. Further, an aziridine compound, a hydrazine compound, a melamine, a urea compound, or an amine compound may be used in combination as a crosslinking agent.

Blending to the aqueous resin emulsion, expandable resin particles, based on 100 parts by weight of the resin in the emulsion, 500 to 800 parts.
It is added at a ratio of 150 parts by weight, preferably 150 to 600 parts by weight.

(3) Application By applying the foamable resin liquid to at least one surface of the cement-based outer layer material, the cement-based outer layer material is impregnated with the aqueous resin emulsion in the foamable resin liquid, and the foamable resin layer and the cement Adhesion with the system outer layer material layer is improved so that peeling between the two layers is difficult.

The application of the foamable resin liquid is generally performed using a roll, spray foam coating, or the like, and the emulsion is impregnated into the cement-based outer layer material layer by pressing with a nip roll.

The coating amount of the foaming resin liquid is generally 100 to 100% as a solid content.
1,700g / m ^2, preferably 300~1,300g / m ² approximately.

(4) Shape Retaining Material After applying the foamable resin liquid on the cement-based outer layer material, while the foamable resin liquid is in an undried state, the shape retaining material is placed on the surface of the foamable resin liquid as necessary. It is desirable to place them.

As the shape maintaining material, any material can be used as long as it can maintain the shape so that the expandable resin particles do not peel off even after the water in the emulsion evaporates and the expandable resin particles expand. Can be. Specifically, woven fabric, nonwoven fabric, resin film, sheet, paper, inorganic fiber layer,
Like a metal net, foil, etc.
Although those having pores are used, it is particularly preferable to use paper or nonwoven fabric among these.

As the non-woven fabric, non-woven fabrics made of thermoplastic resin fibers are preferably used, and polyethylene, polypropylene, linear polyester, polyamide or other thermoplastic resin fibers having a melting point of 80 to 256 ° C., and composite fibers thereof. ,
Although it may be thin or thick depending on the purpose, it is usually 3 denier or more, and the fiber length is preferably 8 mm or more from the surface of the entanglement,
This resin fiber is obtained by entanglement by a technique such as a spun bond method or a needle punch. Further, a fiber web obtained by a card or the like, a fiber web fixed with a binder, a needle felt mainly composed of regenerated fibers generally called a felt, a phenol felt, a felt containing a hot melt fiber, a glass cloth sheet ,
Other inorganic fibers may be used. The basis weight is 6 ~
800 g / m ^2, preferably from 10 to 500 g / m ^2.

The architectural material of the present invention on which such a shape maintaining material is placed, when a nonwoven fabric, a wire mesh, or the like is used as the shape maintaining material,
A lysine coating such as acrylic lysine can be performed directly thereon, and the applied lysine is entangled with the nonwoven fabric fibers, so that the adhesion of the lysine to the foamed resin particle layer is improved.

(5) Heating The foamable resin liquid applied to the cement-based outer layer material is heated to foam the foamable particles and dry the emulsion. Heating is performed by heating means such as an infrared heater, a suction dryer, and a hot air dryer. The heating is generally performed at a temperature higher than the foaming temperature of the foamable resin particles in the foamable resin liquid (50 to 180 ° C, preferably 100 to 180 ° C).
(140 ° C.) and in a short time (5 to 15 minutes) from one side to dry the aqueous emulsion and expand the expandable resin particles in the expandable resin liquid.

By this heating, the expandable resin particles foam about 2 to 50 times and form a foam resin layer having a particle size of 0.5 to 4.5 mm, preferably 1 to 3 mm, and the expanded resin particles in the foam resin layer are foamed. Are adhered to each other by the film formed by the aqueous resin emulsion contained in the hydrophilic resin liquid.

(6) Architectural material The architectural material of the present invention produced by applying the above-mentioned means to the above-mentioned material is specifically a cement-based outer layer material layer having a structure shown in FIG. 1 and FIG. Resin particle layer,
It is basically composed of a shape holding material layer formed as required.

Cement-based outer layer material The cement-based outer layer material in the building material of the present invention is basically the same as a commercially available cement-based outer layer material. The resin particle layer 3 is formed, and the resin aqueous emulsion of the expandable resin liquid applied when the foamed resin particle layer is formed adheres tightly to the cement-based outer layer material layer 2 to make it difficult to peel them off. .

The gypsum board layer has an effect of improving soundproofing property, moisture absorbing property, heat insulating property and water resistance when the building material is used as a wall material.

Foamed Resin Particle Layer The foamed resin particle layer is formed by connecting foamed resin particles 2 to 50 times foamed covered with an emulsion resin film, which are connected to each other by the adhesive force of the emulsion resin film. .

This foamable resin particle layer has a density of generally 0.03 to 0.6 g / c.
because it is the bubble layer of m ^3, on which the effect of improving the thermal insulation and acoustic insulation when used as a building wall member, will form the foamed resin particles is covered with emulsion resin film, emulsion resin film Since a continuous film is formed, the cement-based exterior material is provided with waterproofness and moistureproofness.

Shape Retaining Material Layer On the side of the expanded resin particle layer opposite to the cement-based outer layer material layer, a shape retaining material layer formed of a nonwoven fabric or the like bonded by the emulsion layer is formed as necessary. The shape maintaining material layer prevents the particles of the expandable resin particle layer from peeling off.

In addition to preventing the particles of the expandable resin particle layer from peeling off, the shape-retaining material layer also has an acrylic lysine or mastic on the expanded resin particle layer side of the present building material when the present building material is used as a wall material. When spraying exterior materials such as materials,
Since the lysine coating such as acrylic lysine is easily adhered and becomes stronger than the adhesion strength between the two, it is possible to prevent the occurrence of cracks due to aging. Is preferred. In addition, when a cement mortar or a polymer cement mortar is finished on a nonwoven fabric or a wire mesh, or when a base such as a cement filler is adjusted or irregularities are adjusted, it also contributes to adhesion. When the architectural material of the present invention is used as a ceiling material, the expandable resin particle layer is located under the ceiling and does not need to maintain the same shape as the outer wall. In the case of a ceiling material, a decorative paper such as a vinyl cloth may be further adhered to the surface of the cement exterior material. The foamed layer of the present invention can be patterned by thermoforming after the foamed layer is formed. By heating the foamed layer to 120 to 180 ° C. and pressing or hot pressing, an arbitrary uneven pattern can be formed. In this case, a non-woven fabric is preferable for the shape-retaining material, and it is preferable to apply it as it is or as a ceiling or interior / exterior material.

(7) Construction The building material of the present invention is optimally used as the wall material. However, since it has water resistance, fire resistance, sound insulation and heat insulation, it is used as it is or as a pattern. Then, it can be used as an interior material or a ceiling material.

The building material of the present invention can be directly attached as a siding board to a frame such as a pillar at a construction site such as a wooden house by nailing or the like. Further, the wall can be completed by a method such as spraying an exterior material such as acrylic lysine, mastic or cement material from the outside.

Further, instead of using acrylic lysine, it may be constructed by a curtain wall method.

[Examples] Hereinafter, the building materials of the present invention will be specifically described with reference to examples.

Example 1 Aqueous resin emulsion prepared by emulsion polymerization of styrene (80% by weight) and n-butyl acrylate (20% by weight) [average particle diameter of resin: 0.2 μm, solid content: 50%, crow transition point: 8
0 ° C] 100 parts by weight, particle size 0.5 mm or less (average physical diameter 0.33 m
m) Expandable polystyrene particles, “Styropor IBE”
[Mitsubishi Yuka Birdsie Co., Ltd. product name, butane 5.8
% Containing] 250 parts by weight, and a thickener "Latecol" (trade name) manufactured by Mitsubishi Yuka Birdsushie Co., Ltd.
The foamable resin liquid 3a prepared to have a viscosity of 3000 cps at 25 ° C. by blending is mixed on a back surface of a commercially available cement-based outer layer material 2 placed on a manufacturing apparatus as shown in FIG.
The foamable resin liquid layer 3a was formed by applying the liquid at a concentration of 500 g / m ² (solid portion).

Next, on this foamable resin liquid layer 3a, a polyester nonwoven fabric 4 manufactured by Nippon Lutravir Co., Ltd. was placed at 100 g / m ² .

Then, the laminate is heated in a hot air drying and foaming machine 8 at 140 ° C. for 10
After heating and drying for 1 minute, a foamed resin layer in which the expandable polystyrene particles were foamed about 10 times was formed, and a building material 1a of the present invention shown in FIG. 1 was obtained.

When the water permeability of this building material 1a was measured in accordance with the water permeability test of JIS A-9610, it was 0.5 ml or less, and it was found that the water permeability was excellent.

When the polystyrene foam particles in the foamed resin layer in this building material 1a were measured, the particle diameter was 0.5 to 1.5 mm and the bulk density was about 0.10 g / cm ² .

Separately, this building material 1a was used as an inner wall material, and acrylic lysine 5 was applied to the nonwoven fabric surface of this building material 1a at 1,000 g / m
^By spraying ^two , an outer wall material 6a shown in FIG. 3 was obtained.

When the adhesiveness and heat insulation of the building material 1a and the outer wall material 6a were measured by the following methods, good results as shown in Table 1 were obtained.

Adhesiveness Cut the outer wall to 4cm x 4cm with a cutter knife. (B) Adhesive strength between acrylic lysine layer and foam resin particle layer and (b)
The adhesive strength between the foamed resin particle layer and the cement-based outer layer material was measured with an Instron universal testing machine.

Heat insulation The heat insulation of the foam layer was measured according to JIS A-1412.

Example 2 In Example 1, except that the nonwoven fabric was not placed on the foamable resin liquid layer, the same method as in Example 1 was carried out to obtain a building material 1b of the present invention shown in FIG. Was. Acrylic lysine 5 of 1,000 g / m ² was used for this building material 1b in the same manner as in Example 1.
The outer wall 6b shown in FIG. 4 was sprayed to measure the adhesiveness and heat insulation of the outer wall 6b in the same manner as in Example 1. As a result, good results were obtained as shown in Table 1.

Example 3 The architectural material 1a produced in Example 1 was heated at 180 ° C. for 2 minutes by a press to form a headcut texture pattern having unevenness with a height difference of 10 mm, and then an elastic mastic paint was applied thereon. A piece of Ultrasoft (manufactured by Kikusui Chemical Industry Co., Ltd.) was sprayed on for construction.

[Effects of the Invention] The building material of the present invention has water resistance, heat insulation, soundproofing, and waterproofness since a cement-based outer layer material layer and a foamed resin particle layer are formed, and is a wall material, particularly a siding board. It has extremely excellent performance as a building material.

In particular, since the building material of the present invention is manufactured at the factory in advance with a cement-based outer layer material provided with a foamed resin layer, thermal insulation work at the building site is unnecessary, and when used for an outer wall, it is directly applied on the outer wall. Since a finishing process such as lysine coating can be performed, the number of steps is small and the amount of materials is small as compared with the conventional wall material, so that the work can be performed in an extremely small number of working days.

[Brief description of the drawings]

FIG. 1 is a cutaway sectional view of a building material according to an embodiment of the present invention.
FIG. 2 is a cutaway sectional view of a building material of another embodiment, and FIGS. 3 and 4 are partially cutouts of an outer wall in which an exterior material is applied to the building material of FIGS. 1 and 2. FIG.
The figure is a cross-sectional view of an apparatus for producing a building material according to the present invention. 1a, 1b: Building materials 2: Cement-based outer layer material layer 2a: Resin impregnated layer, 3: Foamed resin particle layer 3a: Foamable resin liquid layer 4: Shape retaining material layer, 5: Exterior material 6a, 6b: Exterior wall material , 7: Ricker roller 8: Hot air drying and foaming machine

 ──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Hideo Okamoto 1000 Kawajiri-cho, Yokkaichi-shi, Mie Inside Mitsubishi Yuka Birdsie Co., Ltd. (56) References JP-A-59-111966 (JP, A) JP-A-52- 41632 (JP, A) JP-A-60-59183 (JP, A) JP-A 1-295955 (JP, A)

Claims (3)

(57) [Claims] 1. A cemented outer layer material layer, and a foamed resin particle layer in which foamed resin particles are bonded to at least one surface of the cemented outer layer material layer with a resin aqueous emulsion. Building materials. 2. A foamable resin liquid containing a resin aqueous emulsion and foamable resin particles is applied to at least one surface of a cement-based outer layer material, and the coated surface is heated to form the foamable resin particles. And foaming the emulsion and drying the emulsion to bond the foamed resin particles to form a foamed resin particle layer adhered to the cement-based outer layer material. 3. The method for producing a building material according to claim 2, wherein a shape-retaining material is placed on the application surface before heating the application surface.