JP6855270B2 - Building materials - Google Patents

Description

The present invention relates to a building material that is used as a louver material, a floor material, a deck material, or the like and has a covering portion that covers the outer surface of the core material.

Conventionally, for example, benches, tables, Yatsubashi, boardwalks installed in promenades, park facilities, rest areas, etc., flooring materials and exterior materials used for bleachers in stadiums, balconies of houses, terrace decks, etc. Natural wood was used for the louver material used for the louver structure mainly for ensuring privacy and blocking the line of sight, but in consideration of long-term durability and surface discoloration, the outer surface of the metal mold material A molded body coated with resin has come to be used.

For example, in Patent Document 1, two or more coating layers made of synthetic resin are formed on the outer surface of an aluminum core material, and in the coating layer, the synthetic resin layer in contact with the core material is a polyester resin layer. As for the core material, at least in the coating layer forming region, an integrally extruded molded product that has been subjected to an alumite treatment without a sealing treatment is disclosed.

Further, as shown in Patent Document 2, the applicant also covers the tubular body in which the inwardly recessed concave surface is formed on the outer surface along the longitudinal direction and the outer surface including the recessed surface of the core material. A dovetail groove-shaped retaining groove is formed on the recessed surface of the core material toward the inside of the core material, and a part of the coating resin layer has entered the retaining groove. We are proposing a resin-coated long body.

Japanese Unexamined Patent Publication No. 2008-08753 Japanese Unexamined Patent Publication No. 2013-227777

By the way, when such a core material is coated with resin, it is generally formed by extrusion molding, but in the case of an aluminum profile material, there is a limit to the weight reduction of the core material even if a hollow portion is provided, and the shape is formed. If the material is extremely thin, it cannot withstand the molding pressure at the time of resin coating and may cause deformation or the like.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a building material having a core material coated with a covering portion, which is lightweight and has high strength.

In order to achieve the above object, the present invention has the following configuration.
That is, the building material according to the present invention is made of synthetic resin and has a long foam.
A core material having metal end members arranged at both side ends in the width direction of the foam, and
It is provided with a coating portion made of synthetic resin that covers the outer surface of the core material.
The foam is a molded product obtained by a thermoforming method.
A smooth surface on the surface of the molded product is arranged on at least the upper surface portion and the lower surface portion.
At least one of the side surface portions has a cut surface formed by cutting a part of the molded body.
It is characterized in that the covering portion formed by an extrusion molding method in which the core material is continuously supplied into a mold is provided so as to be in contact with the smooth surface of the molded body .

Further, in the building material according to the present invention, a core material having a long foam made of synthetic resin and metal end members arranged at both side ends in the width direction of the foam is formed in the width direction and thickness. A core material unit formed by arranging a plurality of core materials in at least one of the directions, and
It is provided with a coating portion made of synthetic resin that covers the outer surface of the core material unit.
The foam is a molded product obtained by a thermoforming method.
A smooth surface on the surface of the molded product is arranged on at least the upper surface portion and the lower surface portion.
At least one of the side surface portions has a cut surface formed by cutting a part of the molded body.
It is characterized in that the covering portion formed by an extrusion molding method in which the core material unit is continuously supplied into a mold is provided so as to be in contact with the smooth surface of the molded body .

In the present invention, the foam is a molded product obtained by a thermoforming method, and at least the upper surface portion and the lower surface portion are arranged with smooth surfaces on the surface of the molded product, and at least one of the side surface portions is. It may have a cut surface formed by cutting a part of the molded product.

According to the building material according to the present invention, a core material made of a synthetic resin and a long foam, metal end members arranged at both side ends in the width direction of the foam, and a core material outside the core material. Since it is provided with a coating portion made of synthetic resin that covers the surface, the weight of the building material can be reduced by the core material, and the bending of the building material in the length direction can be suppressed by the end member.

Further, according to the building material according to the present invention, the core material composed of a long foam made of synthetic resin and metal end members arranged at both side ends in the width direction of the foam is formed in the width direction and Since it is provided with a core material unit formed by arranging a plurality of core material units in at least one direction in the thickness direction and a synthetic resin covering portion that covers the outer surface of the core material unit, the core materials can be combined. It is possible to produce a building material composed of core material units having various shapes.

In the present invention, the foam is a molded product obtained by a thermoforming method, and at least the upper surface portion and the lower surface portion are arranged with smooth surfaces on the surface of the molded product, and at least one of the side surface portions is. If it has a cut surface formed by cutting a part of the molded body, when the outer surface of the core material is coated by thermoforming with a coating portion, secondary foaming may occur in the foam. In the thickness direction, the smooth surfaces of the upper surface and the lower surface suppress the swelling outward, and in the width direction, the swelling tends to be outward from the cut surface, and the swelling can be suppressed by the end member.

It is a perspective view which shows one Embodiment of the extrusion-molded article which concerns on this invention. It is an enlarged sectional view of the main part of the line AA of FIG. It is sectional drawing of the main part which shows the deformation example of the building material shown in FIG. It is sectional drawing of the main part which shows the other embodiment of the building material which concerns on this invention. It is sectional drawing of the main part which shows the deformation example of the building material shown in FIG. It is sectional drawing of the main part which shows the deformation example of the building material shown in FIG. It is sectional drawing of the main part which shows another modification of the building material shown in FIG. It is sectional drawing of the main part which shows still another modification of the building material shown in FIG. It is sectional drawing of the main part which shows the deformation example of the building material shown in FIG. It is sectional drawing of the main part which shows another modification of the building material shown in FIG. It is sectional drawing of the main part which shows still another embodiment of the building material which concerns on this invention. It is sectional drawing of the main part which shows still another embodiment of the building material which concerns on this invention. It is sectional drawing of the main part which shows the deformation of the building material shown in FIG. It is sectional drawing which shows the other embodiment of the intermediate member. It is sectional drawing of the main part which shows the deformation of the building material shown in FIG. It is sectional drawing of the main part which shows still another embodiment of the building material which concerns on this invention.

Next, the best mode for carrying out the present invention will be specifically described with reference to the drawings.
FIG. 1 is a perspective view showing an embodiment of a building material according to the present invention, and FIG. 2 is an enlarged cross-sectional view of a main part of the line AA of FIG. The building material P according to this embodiment includes a core material 10 and a synthetic resin covering portion 40 that covers the outer surface thereof. The core material 10 has a long foam 20 made of synthetic resin and metal end members 30 arranged at both side ends of the foam 20 in the width direction. In the present embodiment, the foam 20 is used by appropriately cutting a sheet-like material made of a polystyrene foam having a predetermined thickness in the length direction and the width direction.

As a result, the weight of the building material P can be reduced. Further, since the building material P can suppress the bending in the longitudinal direction by the both end members 30, for example, when the building material P is used as the deck material, the joists that support the deck material are compared with the case where the both end members 30 are not used. Sufficient strength can be obtained even if the installation interval is widened.

The material of the foam 20 is not limited to polystyrene shown in the present embodiment, and examples thereof include styrene resins such as ABS resin, AAS resin and AES resin, polyolefins such as polyethylene and polypropylene, polyurethane and vinyl chloride resin. However, a foam made of synthetic resin made of polystyrene, which is relatively inexpensive and has a low water absorption rate, is preferably used.

Further, in the present embodiment, the foam 20 is used by cutting a sheet-shaped molded body obtained by a thermoforming method into an appropriate size, and the upper and lower surfaces corresponding to the thickness direction are on the surface of the molded body. The formed smooth surface is used as it is, and both side surfaces corresponding to the width direction are cut to a predetermined width, and at least one side surface is the cut surface.

As a result, the upper surface portion 21 and the lower surface portion 22 of the foam 20 have a smooth surface on the outer surface, and at least one of the side surface portions 23 has a cut surface on the outer surface. Where secondary foaming occurs when heat is applied to the foam 20 by thermoforming, swelling is easily suppressed by the upper surface portion 21 and the lower surface portion 22 having smooth surfaces in the thickness direction, and the cut surface is relatively cut. The swelling of the foam 20 can be suppressed by the end member 30 where it is easy to swell outward from the side surface portion 23 having the above.

The end member 30 is made of metal, and aluminum alloy, stainless steel, steel, copper, titanium and the like are used. Among them, an aluminum alloy that is lightweight and easy to mold is preferably used. Further, in the present embodiment, the aluminum profile has a rectangular cross section and is composed of a thin-walled portion having a hollow portion inside, and the strength of the building material P can be increased while reducing the weight.

In this embodiment, the end member 30 is not connected to the foam 20 but is simply arranged at the side ends 23 and 23 of the foam 20, but for example, although not shown, it is made of an adhesive. It may be attached to the side surface portions 23, 23 of the foam 20 via an adhesive layer.

The covering portion 40 is formed on the outer surface of the foam 20 and the end member 30 except for the portion where they are overlapped with each other, and the first covering portion 41 that covers the outer surface derived from the foam 20 in the foam 20. And a second covering portion 42 that covers the outer surface derived from the end member 30, and the first covering portion 41 and the second covering portion 42 are continuously formed.

Here, by using a synthetic resin that adheres or welds to at least one of the foam 20 and the end member 30 as the covering portion 40, the covering portion 40 can be either the first covering portion 41 or the second covering portion 42. Since one of them is in a state of being adhered to either one of the foam 20 and the end member 30, even if it is not adhered to the other, the foam 20 or the end due to thermal expansion / contraction of the covering portion 40 It is possible to suppress peeling from the member 30.

The material of the covering portion 40 is not particularly limited, and for example, a polyolefin such as polypropylene, an ethylene-vinyl acetate copolymer resin, an ethylene-acrylic acid copolymer resin, a modified polyolefin such as an ethylene-methacrylic acid copolymer resin, etc. Examples thereof include thermoplastic synthetic resins such as polyester, polycarbonate, polyvinyl chloride, polystyrene, acrylic resin, ABS resin, AAS resin, and urethane resin, and thermosetting synthetic resins. Among these, by thermoforming such as extrusion molding and injection molding, polystyrene is easily welded to the foam 20 and modified polyolefin is easily adhered to the metal end member 30, so these are preferably used. can do. In this embodiment, an ethylene-acrylic acid copolymer resin is used as the material of the covering portion 40 in the modified polyolefin that can be thermoformed at a relatively low temperature. If polyethylene is used instead of polystyrene as the material of the foam 20 with respect to this embodiment, the covering portion 40 can be easily adhered to both the core material 20 and the end member 30.

In this embodiment, the covering portion 40 is formed on the outer surface of the core material 10 by an extrusion molding method. That is, in a state where the end members 30 are arranged on both side ends of the foam 20, they are put into a thermoforming mold to form a covering portion 40 in the mold. It is not always necessary to connect the end member 30 to the end member 30, and any material that can be continuously supplied into the mold as the core material 10 is sufficient, so that the building material P can be easily produced.

Further, the covering portion 40 may contain an additive such as a filler. As the filler, at least one type may be selected from the group of calcium carbonate, talc, mica, silica, aluminum hydroxide, magnesium hydroxide, glass or glass fiber, clay, wood flour, carbon fiber, montmorillonite, and fly ash. Good. Further, the core member may also contain a similar additive such as a filler.

FIG. 3 is a cross-sectional view of a main portion showing a modified example of the building material shown in FIG. 2, and in this embodiment, it is not a form having a hollow portion inside as in the end member 30 shown in FIG. The difference is that they are formed in the shape of a vertical plate.

FIG. 4 is a cross-sectional view of a main part showing another embodiment of the building material according to the present invention. Compared with the building material P shown in FIG. 2, the form of the end member 30 is mainly different, the different parts are mainly described, and the same components as those already described are designated by the same reference numerals. The description thereof will be omitted.

In the present embodiment, the end member 30 connects a vertical plate-shaped base portion 31 that covers the side surface portion 23 of the foam 20, a fitting portion 32 that fits the foam 20, and the base 31 and the fitting portion 32. It is provided with a connecting portion 33. More specifically, the fitting portion 32 includes an upper piece portion 34 and a lower piece portion 35 formed in the same direction at intervals from the upper and lower end portions of the base portion 31 via the connecting portion 33. The cross section is U-shaped, and the side end portion of the foam 20 can be fitted between the upper piece portion 34 and the lower piece portion 35 to integrate the foam 20 and the end member 30. Further, when the covering portion 40 is formed on the outer surface of the core material 10 by thermoforming, swelling occurs in the vertical direction from between the side surface portion 23 and the base portion 31 of the foam 20 due to the influence of the secondary foaming of the foam 20. Since the upper piece portion 34 and the lower piece portion 35 are connected to the base portion 31 via the connecting portion 33, the above-mentioned swelling in the vertical direction can be suppressed.

FIG. 5 is a cross-sectional view of a main portion showing another modification of the building material shown in FIG. 4, and in this embodiment, both end portions of the upper surface portion 21 and the lower surface portion 22 of the foam 20 in the width direction. The foam 20 and the end member 30 are formed by fitting the upper portion 24 and the lower portion 25 formed along the longitudinal direction with the upper piece portion 34 and the lower piece portion 35, which are the fitting portions 32 of the end member 30. Is integrated with. In this embodiment, the outer surfaces of the upper surface portion 21 and the upper piece portion 34 and the outer surfaces of the lower surface portion 22 and the lower piece portion 35 are substantially flush with each other, so that the covering portion 40 is less likely to have uneven thickness and is thinned. It will be easier.

The upper portion 24 and the lower portion 25 may be formed by cutting out a part of the foam 20 or may be formed at the time of molding the foam 20.

FIG. 6 is a cross-sectional view of a main portion showing a modified example of the building material shown in FIG. 5, and in the present embodiment, the end member 30 is connected from the lower end portion of the base portion 31 via the connecting portion 33. It has an L-shaped cross section with only one piece 35, and the foam 20 has a lower part 25 formed but an upper part 24 not formed, and the lower part 25 is a lower piece 35. By fitting, the foam 20 and the end member 30 are integrated.

FIG. 7 is a cross-sectional view of a main portion showing another modification of the building material P shown in FIG. 4, in which the end member 30 has an upper piece portion 34 as compared with the end member 30 shown in FIG. It has an L-shaped cross section.

FIG. 8 is a cross-sectional view of a main portion showing still another modification of the building material P shown in FIG. 4, in which the end member 30 is a foam 20 as compared with the end member 30 shown in FIG. The end member 30 arranged at one side end portion does not have the upper piece portion 34 and has an L-shaped cross section, and the end member 30 arranged at the other side end portion of the foam 20 has an L-shaped cross section. It does not have a lower piece 35 and has an inverted L-shaped cross section.

FIG. 9 is a cross-sectional view of a main portion showing a modified example of the building material P shown in FIG. 6, wherein one side end portion of the foam 20 includes a lower portion 25 on a lower surface portion 22 and a base portion 31. A side end portion 30 having a lower piece portion 35 is fitted, and the other side end portion has an upper portion 24 on an upper surface portion 21 instead of the lower portion 25, and a base portion 31 and an upper piece portion 34. It is a form in which the end member 30 provided with and is fitted.

FIG. 10 is a cross-sectional view of a main portion showing another modification of the building material shown in FIG. 6, wherein the foam 20 is formed from the vertical intermediate portion of both side surface portions 23 toward the central portion of the foam 20. The fitting piece portion 36, which is a fitting portion 32, is provided with a fitting groove portion 26 extending in the longitudinal direction, and the end member 30 is connected to a position corresponding to the fitting groove portion 26 from the base portion 31 via the connecting portion 33. It is formed in an inverted T-shape with a cross section.

As a result, when the covering portion 40 is formed on the outer surface of the core material 10 by thermoforming, the opening width of the fitting groove portion 26 in the vertical direction is likely to be deformed due to the influence of the secondary foaming of the foam 20. Therefore, the fitting piece portion 36 to be fitted in the fitting groove portion 26 is less likely to come off from the foam 20, the foam 20 and the end member 30 can be easily integrated, and the coating layer 40 can be easily thermoformed.

FIG. 11 is a cross-sectional view of a main part showing still another embodiment of the building material according to the present invention. Compared with the building material P shown in FIG. 2, the form of the end member 30 is mainly different, the different parts are mainly described, and the same components as those already described are designated by the same reference numerals. The description thereof will be omitted.

In the building material P according to the present embodiment, the end members 30 are connected to each other by the horizontal plate member 50 to form an H-shaped horizontally long cross section, and the space between the end members 30 is vertically divided and divided by the horizontal plate member 50. By arranging the foam 20 in the upper and lower spaces, the end members 30 are arranged at both side ends of the foam 20.

As a result, when the covering portion 40 is formed on the outer surface of the core material 10 by thermoforming, in the case of the wide horizontally elongated rectangular foam 20 as in this embodiment, the secondary foaming of the foam 20 is performed. Due to the influence, the end members 30 are connected to each other where the expansion tends to be larger in the width direction than in the thickness direction, so that the expansion of the foam 20 in the lateral direction can be effectively suppressed.

FIG. 12 is a cross-sectional view of a main part showing still another embodiment of the building material according to the present invention. Compared with the building material P shown in FIG. 4, the difference is that a plurality of foams 20 are mainly arranged in the width direction, and the different parts are mainly described, and the same components as those already described are used. The same reference numerals are given, and the description thereof will be omitted.

The building material P according to the present embodiment is an intermediate member 60 having a fitting portion 61 for fitting both foams 20 to facing side surface portions 23 of adjacent foams 20 in a plurality of foams 20 arranged in the width direction. Is arranged, and the end member 30 is arranged on the other side surface portion 23 of the foam 20. In this embodiment, the intermediate member 60 has an upper piece portion 64 and a lower piece portion 65 formed at intervals in the vertical direction from both side portions of the vertical plate-shaped base portion 62 via the connecting portion 63. It has a character shape, and the foams 20 are connected to each other to form the core material 10 by fitting the foams 20 between the upper piece 64 and the lower piece 65, respectively. As a result, by combining the foam 20, the pair of end members 30, and the intermediate member 60, the dimensions of the core material 10 in the width direction can be arbitrarily set, and the bending in the longitudinal direction can be further suppressed. it can.

FIG. 13 is a cross-sectional view of a main part showing the deformation of the building material shown in FIG. 12, in which the upper piece portion 64 and the lower piece of the intermediate member 60 are attached to the upper part 24 and the lower part 25 of the adjacent foam 20. The portion 65 is fitted.

In the building material P shown in FIGS. 12 and 13, the intermediate member 60 is, in this embodiment, an aluminum alloy profile in which the base portion 62, the upper piece portion 64, and the lower piece portion 65 are integrally formed. For example, the bases 31 of the two end members 30 may be connected to each other to form an intermediate member 60.

FIG. 14 is a cross-sectional view showing another embodiment of the intermediate member 60. The shape of the intermediate member 60 is not limited to that shown in FIGS. 12 and 13, and as shown in FIG. 14 (a), the upper piece portion is formed as a fitting portion 61 on both side surfaces of the base portion 62. It may have a T-shaped cross section having only 64, and as shown in FIG. 14 (b), a fitting portion 61 is provided with respect to the base portion 62, and an upper piece portion 64 is provided on one surface portion. The other surface portion may have a lower piece portion 65 and may have a Z-shaped cross section. As shown in FIG. 14 (c), the other surface portion is fitted as a fitting portion 61 near the central portion in the vertical direction of both side portions of the base portion 62. It may have a cross-sectional cross shape provided with the splicing portion 66. Further, the foam 20 into which the intermediate member 60 shown in FIGS. 14A and 14 is fitted may or may not be provided with the upper portion 24 on the upper surface portion 21, and may or may not be provided on the lower surface portion. Similarly, the lower surface portion 25 of 22 may or may not be provided. Further, when the intermediate member 60 shown in FIG. 14 (c) is used, the foam 20 may be provided with the fitting groove portion 26 shown in FIG.

Further, the foam 20 and the end member 30 used for the building material P shown in FIGS. 12 and 13 are not limited to this embodiment, and are shown in, for example, FIGS. 2, 3, and 6 to 10. The foam 20 and the end member 30 may be used.

FIG. 15 is a cross-sectional view of a main portion showing deformation of the building material shown in FIG. 13, in which both side surface portions 23 of adjacent foams 20 are overlapped with each other. As a result, it is not necessary to use the intermediate member 60 shown in FIG. 13, so that the dimensions of the foam 20 in the width direction can be set more easily.

FIG. 16 is a cross-sectional view of a main part showing still another embodiment of the building material according to the present invention. Compared with the building material P shown in FIG. 10, the building material P is produced by using a plurality of foams 20 having end members 30 arranged at both side ends, and the different parts will be mainly described.

In the building material P according to the present embodiment, the outer surface of the core material unit 70 formed by arranging a plurality of core materials 10 shown in FIG. 6 in the width direction and arranging a plurality of core materials 10 in the thickness direction is coated with a synthetic resin. It is covered with the part 40.

As a result, if there is one type of foam 20 and one type of end member 30, the building material P made of core material units 70 having various shapes can be produced by combining the core materials 10 with the core material 10 as one unit. The foam 20 and the end member 30 are not limited to this embodiment, and are, for example, the foam 20 and the foam 20 shown in FIGS. 5, 6, 9, 10, 11, 13, and 15. The end member 30 may be used.

Although the building material P of the present invention has been described above based on the embodiments, the present invention is not limited to these embodiments. The scope of the present invention also includes various modifications that can be conceived by those skilled in the art within the scope of the present invention.

According to the present invention, in a building material coated with a core material, the core material includes a foam and metal end members at both ends thereof, so that the weight of the building material can be reduced and the building material can be prevented from bending. It can be suitably used for flooring materials, wall materials, bench seats and backrests, pillar materials, handrail materials, and the like.

10 Core material 20 Foam 21 Upper surface 22 Lower surface 23 Side surface 24 Upper 25 Lower 26 Fitting groove 30 End member 31 Base 32 Fitting 33 Connection 34 Upper piece 35 Lower piece 36 Fitting piece 40 Covering part 41 First covering part 42 Second covering part 50 Horizontal plate material 60 Intermediate member 61 Fitting part 62 Base part 63 Connection part 64 Upper piece part 65 Lower piece part 70 Core material unit P Building material

Claims (2)

Made of synthetic resin with a long foam and
A core material having metal end members arranged at both side ends in the width direction of the foam, and
It is provided with a coating portion made of synthetic resin that covers the outer surface of the core material.
The foam is a molded product obtained by a thermoforming method.
A smooth surface on the surface of the molded product is arranged on at least the upper surface portion and the lower surface portion.
At least one of the side surface portions has a cut surface formed by cutting a part of the molded body.
A building material characterized in that the covering portion formed by an extrusion molding method in which the core material is continuously supplied into a mold is provided so as to be in contact with the smooth surface of the molded body. A core material having a long foam made of synthetic resin and metal end members arranged at both side ends in the width direction of the foam is directed toward at least one of the width direction and the thickness direction. A core material unit formed by arranging multiple units and
It is provided with a coating portion made of synthetic resin that covers the outer surface of the core material unit.
The foam is a molded product obtained by a thermoforming method.
A smooth surface on the surface of the molded product is arranged on at least the upper surface portion and the lower surface portion.
At least one of the side surface portions has a cut surface formed by cutting a part of the molded body.
A building material characterized in that the covering portion formed by an extrusion molding method in which the core material unit is continuously supplied into a mold is provided so as to be in contact with the smooth surface of the molded body.

Images