JPS6158302B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a construction panel suitable for applying mortar at a construction site. Traditionally, when finishing the exterior walls of a wooden building with mortar, a wall framework was created, rough wood boards were nailed onto it, and asphalt-impregnated asphalt felt paper and metal lath were spread over the entire surface and fixed with rivets. A method of applying mortar is being implemented. However, since this conventionally known mortar finishing method involves riveting, it has the disadvantage that the mortar base layer has poor waterproof properties and is also poor in workability. Therefore, as a method to improve the drawbacks of conventionally known mortar finishing methods, a method has been proposed in which a mixture of rubber asphalt emulsion and clay emulsion is applied to the substrate surface, and then mortar mixed with an adhesive is applied. has been done. However, this construction method also has poor waterproof properties of the mixture coating layer.
In addition, the mixture of rubber asphalt emulsion and clay emulsion used in this construction method has low heat resistance, has a bad odor, and has low mortar adhesion, so a mixture of mortar and adhesive is used. However, it has the disadvantage that it is difficult to apply with a brush and must be sprayed when applying it to the substrate surface. In addition, a water-dispersed rubber system containing butyl recycled rubber emulsion as the main component may be applied to one side of single-layer or multi-layer boards of ready-made products such as plywood, asbestos boards, plaster boards, cement mortar boards, metal boards, and plastic boards. A method has been proposed in which a pressure-sensitive adhesive is applied, uncured cement mortar or gypsum mixed with water is applied, and the uncured material is cured and then made into an adhesive to produce a panel. A disadvantage of this manufacturing method is that after the water-dispersed rubber-based pressure-sensitive adhesive has been applied and dried, uncured cement mortar or plaster must be applied again. It takes a long time to apply and cure uncured cement mortar or plaster during the panel manufacturing process. It is necessary to use it. However, fast-setting cement mortar has a short usable life and causes variations in quality. The inventors completed this invention as a result of intensive research into building panels for on-site mortar construction that do not have the above-mentioned drawbacks. That is, this invention applies asphalt and 5 parts by weight of styrene-butadiene copolymer rubber to 100 parts by weight of asphalt on one side of a board such as a wood board or an asbestos board.
Apply an emulsion composition containing ~70 parts by weight, 30 to 200 parts by weight of a thermoplastic resin, 0.1 to 10 parts by weight of an anti-aging agent, and a nonionic or anionic surfactant at a rate of 0.4 to 2.0 Kg/ ^m2 . The present invention relates to a method for manufacturing architectural panels for on-site mortar construction, characterized by: The construction panel for on-site mortar construction obtained by this invention does not emit a bad odor during panel manufacturing, and there is no need to apply uncured cement mortar or plaster, resulting in improved productivity and economy. It is also very good. In addition, since the emulsion-based composition of the construction panel for on-site construction obtained by this invention has excellent weather resistance, even if cement mortar is applied after being left in the air for several months after the panel is made, it will not suffice. High adhesive strength can be obtained. There are no particular limitations on the board used in this invention, and examples include plywood, asbestos board, plaster board, cement mortar board, metal board, and plastic board. Among these, wooden boards such as plywood and asbestos boards are preferably used. In this invention, asphalt, 5 to 70 parts by weight of styrene-butadiene copolymer rubber, 30 to 200 parts by weight of thermoplastic resin, 0.1 to 10 parts by weight of anti-aging agent, and nonionic or anionic surfactant per 100 parts by weight of asphalt. It is necessary to use an emulsion-based composition containing the above-mentioned additives, and this makes it possible to obtain panels that can be mortared on-site after being left for a long period of time without applying cement mortar or plaster. be. The emulsion composition described above can be obtained by adding and mixing each component to water, but preferably contains each component and a nonionic or anionic surfactant. It can be obtained by mixing an asphalt emulsion, a styrene-butadiene copolymer rubber emulsion, a thermoplastic resin emulsion, and an anti-aging agent. When mixing emulsions of each component, it is desirable that the same type of surfactant be blended. The asphalt emulsion used to obtain the emulsion-based composition used in this invention is made of known natural asphalt, petroleum asphalt such as straight asphalt or blown asphalt, or JIS-A6011 It is preferably an emulsion of asphalt for waterproofing work as defined in (1), in which the proportion of asphalt in the total amount of the emulsion is 40 to 70% by weight. As the nonionic surfactant, known surfactants such as polyoxyethylene alkyl ether, polyoxyethylene alkyl phenol ether, sorbitan fatty acid ester, polyoxyethylene sorbitan fatty acid ester, and polyoxyethylene alkylamine are used. Examples of anionic surfactants include fatty acid salts, alkyl sulfates, alkylbenzene sulfonates, alkylbenzene naphthalene sulfonates, alkyl sulfosuccinates, alkyl phosphate ester salts, polyoxyethylene alkyl sulfate ester salts, and formalin condensation of naphthalene sulfonate. things etc. are used. The asphalt emulsion can be obtained by a method known per se, for example, by stirring and mixing water containing the nonionic or anionic surfactant and molten asphalt. The nonionic or anionic styrene-butadiene copolymer rubber emulsion used to obtain the emulsion composition used in this invention preferably has a rubber content of 40 to 70% by weight based on the total amount of the emulsion. A polymer rubber having a styrene content of 5 to 70% by weight is used. The nonionic or anionic surfactant is preferably the same as the surfactant used in the nonionic or anionic asphalt emulsion. The nonionic or anionic thermoplastic resin emulsion used to obtain the emulsion composition used in this invention contains a nonionic or anionic surfactant and a thermoplastic resin. Preferably, the proportion of resin is 40 to 70% by weight. The nonionic or anionic surfactant used is the same as the nonionic or anionic surfactant used in the nonionic or anionic asphalt emulsion. Examples of the thermoplastic resin include polymers such as acrylic acid, methacrylic acid, methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate, copolymers thereof, copolymers of these and acrylonitrile, and vinyl acetate. Polymers, copolymers of vinyl acetate and ethylene, etc. are used. Antiaging agents used in this invention include known aromatic secondary amines, phosphoric acid esters, alkylphenols, benzimidazoles, thioureas, dithioic acid salts, reaction products of amines and ketones, The product name ``Sannotsuku, Sannotsuku N'' is used. The blending ratio of each component is 5 to 5 to 100 parts by weight of styrene-butadiene copolymer rubber per 100 parts by weight of asphalt.
70 parts by weight, preferably 10-50 parts by weight, the thermoplastic resin is 20-300 parts by weight, preferably 50-200 parts by weight, and the anti-aging agent is 0.1-10 parts by weight, preferably 0.3-5 parts by weight. Department. If the amount of styrene-butadiene copolymer rubber is outside the above range, the emulsion composition will become hard and may crack at low temperatures.
On the other hand, it becomes hard and causes problems such as a decrease in mortar adhesion, which is not preferable. If the amount of the thermoplastic resin is outside the above range, the mortar adhesion force when mortar is applied to a panel obtained using this emulsion composition will be reduced, and the waterproof property of the composition coating layer will be reduced. So I don't like it.
Further, if the amount of the anti-aging agent is outside the above range, mortar adhesion after the panel is left in the atmosphere for a long time (for example, several months) may decrease, and the cost of the panel may increase, which is undesirable. The emulsion composition in this invention includes:
Vulcanizing agents, vulcanization accelerators, vulcanization accelerators, as long as they do not impair the workability of the emulsion composition, the mortar adhesion of the emulsion composition, the mortar adhesion properties after being left for a long period of time, and the waterproof properties. Fillers, thickeners, desiccant agents, antifungal agents, etc. may be added. Colloidal sulfur is used as the vulcanizing agent. As the vulcanization accelerator, sodium di-n-
Butyldithiocarbamate, sodium diethyldithiocarbamate, sodium dimethyldithiocarbamate, zinc N-ethylphenyldithiocarbamate, zinc di-n-butyldithiocarbamate, zinc diethyldithiocarbamate,
Dithiocarbamate vulcanization accelerators such as zinc dimethyldithiocarbamate are used. As the vulcanization accelerator, zinc oxide, magnesium oxide, etc. are used. The mixing ratio of each component is 0.1 to 5 parts by weight of the vulcanizing agent and 0.1 to 5 parts by weight of the vulcanization accelerator per 100 parts by weight of the nonionic or anionic asphalt emulsion.
3 parts by weight, and 0.1 to 5 parts by weight of the vulcanization accelerating aid. As the filler, pulverized calcium carbonate, silica sand, etc., with a particle size in the range of 0.1 to 400μ, and an average particle size of 50 to 200μ, are used. The amount of filler is asphalt emulsion 100
It is preferably 300 parts by weight or less, particularly 50 to 300 parts by weight. If the amount of the filler is outside the above range, mortar adhesion of the adhesive composition coating layer will be small and waterproofness will be reduced. As the thickener, known water-soluble thickeners such as methylcellulose, ethylcellulose, carboxymethylcellulose, and polyvinyl alcohol are used. The amount of viscosity increase is preferably 5 parts by weight or less per 100 parts by weight of the nonionic or anionic asphalt emulsion. If the amount of the thickener is outside the above range, the waterproof property of the composition coating layer will decrease. Ammonium carbonate is used as the desiccant. The amount of desiccant is preferably 10 parts by weight or less, particularly 0.1 to 10 parts by weight, per 100 parts by weight of the nonionic or anionic asphalt emulsion. If the amount of desiccant is outside the above range, air bubbles and
Cracks etc. enter, reducing waterproofness and mortar adhesion. As the fungicide, known fungicide such as para-chloro-meta-xylene, 2,4-dinitrophenol, 2-(4-thiazolyl)benzimidazole, etc. can be used. The amount of the fungicide is preferably 1 part by weight or less, particularly 0.05 to 1 part by weight, per 100 parts by weight of the nonionic or anionic asphalt emulsion. Even if the amount of the fungicide is outside the above range, the fungicide effect remains uneconomical. The construction panel for on-site mortar construction of this invention is
For example, the nonionic or anionic asphalt emulsion, the nonionic or anionic styrene-butadiene copolymer rubber emulsion,
After creating an emulsion-based composition by mixing the emulsion of a nonionic or anionic thermoplastic resin, each component of the anti-aging agent and, if necessary, the other components in the above-mentioned proportions by a method known per se, 1 m ² on one side of the single-layer or multi-layer board such as the wood board, plaster board, asbestos board, cement board, metal board, plastic board, etc. by a method known per se.
It is obtained by applying 0.4 to 2.0 kg per coat and drying it. The coating method may be a doctor knife method, a roll coater method, a spray method, or a brush method, and it is desirable to form an uneven pattern on the surface. Also, when curing and drying
It is desirable to leave it to dry for 20-24 hours at a temperature of 10-80 ° C. The panels obtained by the above method do not lose their mortar adhesion properties even after being left for a long period of time, have excellent water resistance, and are economically superior in terms of panel manufacturing costs. The construction panel for on-site mortar construction of this invention is
It can be used to mortar finish the exterior walls of houses built using panel construction, houses constructed using 2" x 4" construction, or houses built using conventional construction. Next, examples will be shown. In the examples, the mortar adhesion of the emulsion-based composition layer and the mortar adhesion after 6 months are the emulsion-based composition coated layers of the building panels for on-site mortar construction (immediately after creation or after being left for 6 months) manufactured according to the examples. For the mortar finished panel obtained by applying mortar with a sand:cement ratio of 3:1 (weight ratio) and water containing 65% by weight of cement to a thickness of 10 mm on the surface of the panel, and curing for 4 weeks,
This is the adhesion force between the plywood and the mortar coating layer, which was determined by cutting out a 4 cm x 4 cm sample and pulling it at 50 mm/min using a universal tensile tester. The heat resistance test of the emulsion composition coating layer was conducted as follows. A test piece for the mortar adhesion test with a weight attached to the center of the mortar coating layer was heated at 260°C with the weight at the lowest end.
The mortar coating layer peeled off from the plywood and the minimum load (g/m ² ) of the weight was determined when the weight fell. The larger the minimum load, the better the heat resistance of the emulsion composition coating layer. The drying time of the emulsion-based composition was determined by applying the emulsion-based composition to the water-resistant plywood at a rate of 1 kg/m ² using a roll brush, and applying the emulsion-based composition to the surface coated with the obtained emulsion-based composition at a wind speed of 5 m/sec at 80°C. It was determined by applying dry air. It is expressed as the time from the start of applying dry air until 80% of the water in the composition evaporates. In addition, the waterproof property of the emulsion-based composition coating layer was determined by applying the emulsion-based composition onto paper using a roller brush at a rate of 1 kg/m ² and leaving it to dry for one day and night. The surface of the material coating layer was covered with a caulking agent, water colored with red ink was added to the caulked areas, and the paper was left to stand for one week at room temperature, and the presence or absence of discoloration of the paper was judged. The waterproofness when the paper turned red was rated as ×, and the waterproofness when the paper did not change color was rated as ○. Example 1 A nonionic surfactant (polyoxyethylene lauryl ether) was used in 100 parts by weight of an asphalt emulsion in which the proportion of asphalt in the total amount of emulsion was 57% by weight. 25 parts by weight of a styrene-butadiene copolymer rubber emulsion in which the proportion of copolymer rubber in the total amount of the emulsion is 51% by weight and the proportion of styrene in the copolymer rubber component is 23% by weight, and a nonionic surfactant. Contains a copolymer with a molar ratio of methyl acrylate and methacrylic acid of 3:1, and the proportion of the copolymer of methyl acrylate and methacrylic acid in the total amount of the emulsion is 50%.
After adding 100 parts by weight of a thermoplastic resin emulsion and mixing with stirring, 1.0 parts by weight of trisnonylphenol phosphite was added and mixed with stirring to prepare an emulsion composition.
1.0 cm of emulsion composition per ¹ m2 of plywood
After applying it with a roller brush to a weight of 1.5 kg, it was dried using a hot air dryer at 50 to 80°C for 1 hour to produce a construction panel for on-site mortar construction. The results are summarized in Table 1. Example 2 A panel was manufactured in the same manner as in Example 1 except that asbestos board was used instead of plywood. The results are summarized in Table 1. Example 3 100 parts by weight of a nonionic asphalt emulsion having the same composition as that used in Example 1, 25 parts by weight of a styrene-butadiene copolymer rubber emulsion having the same composition as used in Example 1, and Example 1
After adding 100 parts by weight of a thermoplastic resin emulsion with the same composition as that used in 1. -1.0 parts by weight of n-butyl dithiocarbamate, 3.0 parts by weight of zinc oxide, 1.0 parts by weight of colloidal sulfur and 3.0 parts by weight of ammonium carbonate were added and stirred, followed by 1.3 parts by weight of methylcellulose (400 centipoise) and 0.3 parts by weight of parachloromethaxylene. The emulsion-based composition was prepared by adding 1.0 kg of emulsion-based composition to a 90 cm x 180 cm plywood board at a concentration of 1.0 kg per 1 m ² with a roller brush, and then dried for use in on-site mortar construction. Manufactured architectural panels. The results are summarized in Table 1. Example 4 A panel was manufactured in the same manner as in Example 3 except that asbestos board was used instead of plywood. The results are summarized in Table 1. Example 5 Anionic asphalt emulsion with the same composition as used in Example 1 (however, sodium lauryl sulfate was used as the anionic surfactant)
100 parts by weight, 25 parts by weight of anionic styrene-butadiene copolymer rubber emulsion having the same composition as used in Example 1, and 100 parts by weight of anionic thermoplastic resin emulsion having the same composition as used in Example 1. 200 parts by weight of crushed calcium carbonate with an average particle size of 100μ, 1.0 parts by weight of trisnonylphenol phosphite, and 1.0 parts by weight of sodium di-n-butyldithiocarbamate.
After adding and stirring 3.0 parts by weight of zinc oxide, 1.0 parts by weight of colloidal sulfur, and 3.0 parts by weight of ammonium carbonate, methyl cellulose (400 centipoise) was added.
1.3 parts by weight and 0.3 parts by weight of parachloromethaxylene were added and mixed with stirring to prepare an emulsion-based composition, and the emulsion composition was applied to a 90 cm x 180 cm plywood board using a roller brush so that the emulsion composition was 1.0 kg per ¹ m2. After drying, construction panels for on-site mortar construction were manufactured. The results are summarized in Table 1. Example 6 A panel was manufactured in the same manner as in Example 5, except that asbestos board was used instead of plywood. The results are summarized in Table 1. 【table】

Claims (1)

[Claims] 1. Add asphalt and styrene to 100 parts by weight of asphalt on one side of a board such as a wood board or asbestos board.
An emulsion composition containing 5 to 70 parts by weight of butadiene copolymer rubber, 30 to 200 parts by weight of a thermoplastic resin, 0.1 to 10 parts by weight of an antiaging agent, and a nonionic or anionic surfactant is mixed at 0.4 to 2.0 kg/ A method for producing architectural panels for on-site mortar construction, characterized in that they are applied at a rate of ^m2 .