JPH0321700B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a base panel for wall/ceiling construction and a method for manufacturing the same.

Recently, this construction method for walls and ceilings has been improved, and a "base panel" is formed by forming an uneven coating material layer on the plate-shaped substrate that serves as an adhesive layer for the surface finishing material, and this base panel is used as a building material. A construction method has been adopted in which the panels are fixed to the base structure material and a surface finishing material such as cement mortar is applied seamlessly to the surface of the connected base panels over the entire wall of the building to form a so-called "large wall". I have reached the point where

As an example of this construction method, as disclosed in Japanese Patent Application Laid-open No. 54-150817, synthetic resin particles that have resilience even when deformed are mixed into the uneven coating layer of the base panel as aggregate, and the uneven coating layer has elasticity. It has already been proposed to provide a buffer layer between the surface finishing material and the underlying panel to absorb the expansion and contraction of the surface finishing material.

However, in this proposal, after the surface finishing material is applied, the bonding of the surface finishing material with the uneven coating layer depends only on the adhesive force and anchoring force between the two, so compared to the present invention, which will be described later, the surface finishing material and the uneven coating layer are The problem remains that the adhesive strength between the paint layer and the paint layer is poor. Note that the details of the reason will be described later.

The present invention relates to an improvement of the uneven coating material layer of such a base panel. That is, the base panel of the present invention is prepared by mixing fine particles 3 of synthetic resin foam with cement forming the uneven coating layer 5 as described below.
After coating on the primary unevenness 6, it is rapidly and forcibly dried in a drying device C. At this time, the cement near the surface of the primary unevenness 6 contracts, so that the primary unevenness 6 is coated with unevenness. The large uneven surface 7 in the final form of the membrane layer 5 and the fine particles 3 of the foam existing near the surface of the large uneven surface 7 protrude while being thinly coated with cement to form a small uneven surface 8. .

After the rapid drying, the drying of the uneven coating layer 5 is stopped when the hydration curing reaction is interrupted. Therefore, even after the surface finishing material S is applied, the hydration curing reaction continues and the surface finishing material is prevented from peeling or cracking.

Embodiments of the present invention illustrated in the drawings will be described below.

1 is a plate-like substrate, which is an inorganic material such as plywood, fiberboard, wood chip board, gypsum board, wood wool board, wood chip cement board, asbestos cement board, asbestos slate board, calcium silicate board, valve cement board, synthetic resin board, etc. Or it is an organic plate. The four circumferential surface edges of the substrate 1 may be chamfered as necessary to form the inclined surfaces 2.

The manufacturing process of the base panel of the present invention will be explained.

As shown in FIG. 2, the substrate 1 is transported by a transport device A such as a belt conveyor or a roll conveyor,
During the transportation process, the surface of the substrate 1 is mainly made of cement, mixed with synthetic resin, adhesive or latex, and fine particles 3 of highly elastic synthetic resin foam, and if necessary, fibers are added alone or mixed. The added coating material is applied using a coating device B such as a roll coater or a reverse coater so as to form a primary uneven pattern 6.

A waterproof layer 4 is formed on the surface of the substrate 1 by coating synthetic resin, adhesive, latex, or a mixture thereof, or by pasting a sheet-like material such as a synthetic resin sheet, resin-impregnated paper, or metal foil. A waterproof layer 4 may also be formed.

A coating material for forming the uneven coating layer 5 is applied to the primary uneven surface 6 as shown in FIG. 3 using the coating device B.

In the coating material, fine particles 3 of synthetic resin foam with high elasticity are incorporated in the primary unevenness 6 in a deformed state.

When the primary unevenness 6 is rapidly and forcibly dried in the drying device C, the fine particles 3 of the synthetic resin foam try to restore to their original shape before being mixed into the coating material due to their restoring force, and the cement When forming the uneven coating layer 5 in the final form by protruding in a thinly coated state, smaller uneven surfaces 8 are formed on the large uneven surface 7.

The thus formed uneven coating layer 5 has a rough surface, and the anchoring hardening of the surface finishing material S applied thereon to the uneven coating layer 5 is significantly improved.

It should be noted that the fine particles 3 of the foam have cement attached to them and are rapidly and forcefully dried as they are, so that after rapid drying, the surface of the fine particles 3 is coated with a thin layer of cement.

The waterproof layer 4 described in 2. is a substrate made of a highly water-absorbing plate material such as an inorganic material, and when the coating material of the uneven coating layer 5 is applied to the surface, it prevents absorption of moisture in the coating material, and The bond between the substrate and the coating material is strengthened by the intermolecular attraction between the synthetic resin, adhesive, or latex mixed in the coating material and the inorganic component in the substrate. If the substrate 1 is a highly water-absorbing plate-like material, especially an inorganic plate-like material, if the coating material of the uneven coating layer 5 is immediately applied to the surface of the substrate 1, the water in the coating material will be absorbed and the coating will be applied at the interface. Moisture in the material becomes insufficient, and the adhesive strength to the substrate 1 decreases. In particular, when the base panel of the present invention is used for an outer wall, the uneven coating layer 5 may peel off from the substrate 1 because the substrate 1 absorbs a lot of moisture.

However, when the base panel of the present invention is used as an inner wall material, the waterproof layer 4 is not particularly necessary because the coating film 5 is also lightweight and there is no possibility that the uneven coating layer 5 will peel off.

The coating material of the uneven coating layer 5 applied to the surface is mainly composed of cement, mixed with an arbitrary amount of fine particles 3 of a highly elastic synthetic resin foam such as polystyrene, polyvinyl chloride, polyester, or urethane.

If necessary, synthetic resins or adhesives such as vinyl acetate, ethylene vinyl acetate, and epoxy resins, or latexes such as MBR, NBR, and SBR may be used.
Furthermore, if necessary, natural or synthetic fibers, and additives such as MC and PVA to increase viscosity and water retention may be mixed.

When forming inclined surfaces 2 on the four circumferential surface edges of the substrate 1, an uneven coating layer 5 is formed on the surface other than the inclined surfaces 2.
It is preferable to apply a coating material of

In this manner, the uneven coating layer 5 is applied to the substrate 1 in an uneven shape as the primary unevenness 6, and then rapidly and forcibly dried in the drying device C to form its final form. That is, the coating material of the uneven coating layer 5 is forcibly and quickly dried by the drying device C, and in order to release the moisture in the coating material, the hydration hardening reaction of the cement in the uneven coating layer 5 is interrupted. An uneven coating layer 5 is formed.

In addition, in the coating layer 5, due to the water retention capacity of the foamed fine particles 3, water remaining deep from the surface is absorbed by the fine particles 3.
This moisture causes a secondary cement hydration hardening reaction in the coating material to gradually proceed, forming a strong uneven coating layer 5.

In this way, the base panel 9 is completed and is stacked by the stacking device D.

The stacked base panels 9 are used as pillars, studs, etc.
These multiple base panels 9 are connected and fixed with nails to the trunk edge, etc., and then the surface finishing material S is cement mortar, decorative material, etc. Apply mortar. In addition, when forming the inclined surface 2 on the four circumferential surface edges, after fixing the base panel 9,
After applying a coating material having the same composition as the uneven coating layer 5 to the V-shaped groove formed in the butt portion, cement mortar as the surface finishing material S is applied.

When the cement mortar of the surface finishing material S is applied to the surface of the uneven coating layer 5, water in the mortar is supplied to the uneven coating layer 5, and the hydration reaction of the uneven coating layer 5 proceeds again. At this time, the cement of the uneven coating layer 5 and the cement of the cement mortar of the surface finishing material S react with each other while in contact with each other, forming a hydration product, and a strong adhesive force is obtained.

On the other hand, the above-mentioned prior art Japanese Unexamined Patent Publication No.
No. 150817, the uneven resin mortar mixed with synthetic resin granules used as a base material for construction does not interrupt the hydration hardening reaction by forced rapid drying as in the present invention, but by drying. , the hydration hardening reaction of cement in the uneven resin mortar has been completed. For this reason, even if a surface finishing material is applied to the surface of the uneven coating layer, the hydration hardening reaction of the cement in the surface finishing material only proceeds independently. The adhesion force generated by the formation of a mutual hydration product between the adhesive and the adhesive is significantly inferior to that generated by the formation of a mutual hydration product between the adhesive and the adhesive.

[Effects of the Invention] In the method for manufacturing a base panel of the present invention, the fine particles 3 of the synthetic resin foam are formed in a deformed form in the coating material applied to the substrate 1 in an uneven shape as the primary unevenness 6. When the fine particles 3 are forcibly dried in the drying device C, they try to restore their original shape before being mixed into the coating material due to their restoring force, and they protrude while being thinly coated with cement. , a smaller uneven surface 8 is formed on the large uneven surface 7. At the same time, the moisture in the coating material is evaporated by rapid drying, and the uneven coating layer 5 is formed in a state where the hydration hardening reaction of the cement in the coating material is interrupted.

In this way, after the surface finishing material S is applied, the secondary hydration curing reaction continues, so that the surface finishing material S is integrally bonded to the uneven coating layer 5, thereby preventing minute cracks and peeling of the surface finishing material S. This is what I am trying to do.

The uneven coating layer 5 of the base panel of the present invention is a rough surface consisting of a large uneven surface 7 and a small uneven surface 8 protruding from this large uneven surface, and its excellent anchoring effect makes it easy to coat the surface. A strong bond is created between the surface finishing material and the surface finishing material. Furthermore, when the cement mortar of the surface finishing material S is applied to the surface of the uneven coating layer 5, the water in the surface finishing material is replenished into the uneven coating layer 5, and the cement water in the interrupted uneven coating layer 5 is replenished. The curing reaction proceeds again. At this time, the cement of the uneven coating layer 5 and the cement mortar of the surface finishing material S react with each other while in contact with each other to form a hydration product, resulting in a very strong adhesive force.
The synergistic effect with the bonding force caused by the anchor hardening of the rough surface prevents delamination between the two.

[Brief explanation of drawings]

Figure 1: Cross-sectional view of the base panel of the present invention, Figure 2:
Manufacturing process diagram of the base panel of the present invention, Figure 3: Cross-sectional view of the base panel of the present invention before foaming, Figure 4: Partially enlarged sectional view of the base panel of the present invention, 1: Substrate, 2: Chamfered slope, 3 : fine particles of synthetic resin foam, 4: waterproof layer, 5: uneven coating layer,
6: Primary unevenness, 7: Large uneven surface, 7a: Large depression, 7b: Large unevenness, 8: Small uneven surface, 8a: Small depression, 8b: Small unevenness, 9:
Base panel of the present invention.

Claims (1)

[Scope of Claims] 1. An uneven coating layer 5 is formed on the surface of an inorganic or organic plate-like substrate 1 using a coating material mainly composed of cement and mixed with fine particles 3 of synthetic resin foam, The uneven coating layer 5 forms a small uneven surface 8 along the surface of the large uneven surface 7 with the synthetic resin foam particles 3 covered with a thin film of cement, and the uneven coating layer 5 has the following characteristics: A base panel for wall and ceiling construction, characterized in that the hydration curing reaction is suspended. 2. A coating material mainly composed of cement and mixed with fine particles 3 of synthetic resin foam is applied to the surface of an inorganic or organic plate-like substrate 1 so as to form a primary uneven pattern 6, and then this is applied. First order unevenness 6
The coating material of the paint film applied to the surface is forcibly and quickly dried, and the cement shrinks to form a large uneven surface 7 where the primary unevenness 6 becomes the final form of the uneven coating layer 5, and a thin coating of cement. Fine particles 3 of synthetic resin foam covered with a film protrude along the surface of the large uneven surface 7 to form a small uneven surface 8, and the final form of the uneven coating layer 5 is formed by a hydration curing reaction. A method for producing a base panel for wall/ceiling construction, characterized in that the base panel is formed in a state where is interrupted.