JP2001316165A - Building wall structure - Google Patents

Abstract

(57) [Summary] [Problem] As a wall structure of a building such as a wooden detached house, particularly as a wall structure of an external heat insulating structure, cracks, warpage, undulations of the decorative finishing material, sagging of the outer wall material and opening of the outer wall joint,
Provide a wall structure without breaks in coking. SOLUTION: Water is added to an inorganic hydraulic composition containing an inorganic hydraulic material, a siliceous material, a fibrous material, and a lightweight aggregate, molded, cured, and cured to have a water content of 10% by weight or more. The rate of change in length between 5% by weight is 0.01
% Or less and a specific gravity of 1.1 or less are obtained, and used as a decorative finish base material or exterior material for the outer wall of a building having an external heat insulation structure.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wall structure of a building, and more particularly, to a structure of an outer wall of a building such as a wooden detached house.

[0002]

2. Description of the Related Art Conventionally, the exterior wall of a building is sprayed with a cement, siliceous, synthetic resin emulsion, synthetic resin solution, polymer cement, or other cosmetic finishing material at the construction site using an air spray or spray gun. It is often painted with a roller or a brush, and especially in wooden detached houses, it occupies an important position as a method of finishing the outer wall. As described above, cement mortar is most often used as a base material when a decorative finish is applied to the exterior wall of a building for finishing. For example, the wall structure shown in FIG. 5 includes a plywood 3 provided on the outside of a pillar 1 and a stud 2 located on the indoor side of a building.
A waterproof paper 4 is applied thereon, a mortar base 6 containing a lath wire mesh 5 is applied thereon, and the decorative finishing material 7 as described above is applied on the mortar base 6.

However, the application of the mortar base 6 requires an undercoat, an intermediate coat, an overcoat, and the like, and when applied on top of the mortar, it is necessary to dry the lower surface sufficiently, and it takes a very long time to perform the application. In addition, there is a problem in that the undercoating, the intermediate coating, and the topcoating also require a lot of labor for construction. Furthermore, when applying the decorative finishing material 7, the foundation 6 needs to be dried as much as possible, and the wet condition that can be applied is generally 8
% Or less, depending on the outside temperature, humidity, etc.,
When using cement mortar as a base material, it takes a considerable time to dry the mortar.

[0004] Further, cement mortar is usually cracked due to drying. Therefore, although the lath wire mesh 5 is placed in the mortar to perform the foundation work, cracking has not yet been completely prevented. Absent. When the mortar of the base 6 cracks in this way, the decorative finishing material 7
Cracks occur in the decorative finishing material 7 itself, moisture invades from the cracked parts, causing not only rain leakage, but also corrosion of the rims and columns inside the outer wall, thereby reducing the durability of the building. There is a danger of falling.

[0005] In recent years, the number of detached houses with external heat insulation specifications has been increasing. In general, there are two types of wall insulation methods for detached houses: an inner insulation method in which heat insulating material is installed between pillars and studs, and an outer heat insulation method in which pillars and studs are installed outside the room. In order to make it longer, the use of external insulation methods is increasing. For example, the wall construction method of the external heat insulation specification shown in FIG. 6 constructs the rim 9 on the outdoor side of the heat insulating board 8 provided on the outdoor side of the pillar 1 and the stud 2 located on the indoor side of the building,
The waterproof paper 4 is constructed on the plywood 3 provided on the waist edge 9,
A mortar base 6 containing a lath wire mesh 5 is constructed thereon,
The decorative finishing material 7 is applied on the mortar base 6. In the case of such an external heat insulation method, if the weight of the outer wall material such as the mortar base 6 and the decorative finishing material 7 as the decorative finishing base material is heavy, wall sagging or the like occurs. Therefore, the weight of the outer wall material has been required to be reduced. However, the mortar base 6 has a large mortar specific gravity of about 2.0 to 2.4, and a lath wire mesh 5 for preventing cracks.
Add it to make it even heavier. Therefore, at present, the mortar base 6 cannot cope with the weight reduction of the outer wall.

On the other hand, with respect to the outer wall of a building, the design and performance of the outer wall have been advanced, and the weight of the outer wall material has tended to increase accordingly, and the heat insulating material provided on the back surface of the outer wall material supports the outer wall material. Can not be done, and dripping of the outer wall material occurs frequently. For this reason, it is desired that the outer wall material used in the outer heat insulation method be as light as possible.

[0007] As a method other than the mortar foundation described above, a panel such as asbestos slate may be used as a decorative base material for the outer wall. For example, cement-based, gypsum-based, molded plates manufactured from a composition mainly composed of an inorganic hydraulic material such as calcium silicate-based, conventionally, exterior materials of houses, ceilings, interior materials and widely used. I have. However, in the panel used conventionally, the molded plate expands due to moisture absorption due to humidity in the air, water absorption due to rainwater intrusion, and the like, and thereafter, the molded plate contracts due to drying. When the moisture content in the formed plate changes in this way, the formed plate repeatedly expands and contracts, causing the formed plate to warp or undulate. When warping or swelling occurs in the molded plate, not only does the appearance deteriorate, but also the gap between the molded plates and the clearance between the molded plate and the sash etc. is empty, making it a decorative finish material applied on the molded plate. Cracks are entered, and rainwater etc. intrudes from the gap,
Corrosion of the hull and columns in the wall causes a decrease in structural strength,
This leads to reduced durability of the whole building. In the case of mortar coating, cracks occur on the entire wall surface. However, when a panel made of the molded plate is used as a base material, the cracks concentrate on joints and the width of the cracks increases. Therefore, when using a panel made of a molded plate as the base material, it is necessary to use a panel having excellent dimensional stability.

[0008] Further, with respect to the exterior material of the exterior wall of the building such as the exterior wall panel, the dimensional change causes gaps in the sagging of the exterior wall panel and the vertical joint sealing portion and the horizontal joint sealing portion. It is the present situation that intrusions and the like have adversely affected the structure. Generally, when a molded plate is used as an outer wall material, the water content is about 5%.
The weight change is between 10% and 5% by weight, but the change in length between 10% and 5% by weight of the water content of the inorganic lightweight compact conventionally used for ceramic siding is generally 0%. It is usually about 0.02 to 0.03% or more. Accordingly, a molded article having good dimensional stability is also desired for an exterior material of a building outer wall such as an outer wall panel.

[0009] Further, the formed plate conventionally used as an outer wall material has a large problem in processing, transportation, and construction because of its excessive weight. When used for a house of the outer heat insulation method, a particularly lightweight formed body is desired. Therefore, attempts to reduce the weight of these inorganic molded bodies have been made for a long time, and a mixture of a hydraulic material, a fine aggregate, a fibrous material, and the like, an inorganic lightweight aggregate such as a pearlite, a shirasu balloon, and a polystyrene foam are added. The weight of inorganic molded articles has been reduced by the addition of organic lightweight aggregates such as particles and synthetic resins having water absorption performance.

However, among these lightening methods, the addition of an inorganic lightweight aggregate made of a foam of an inorganic substance such as pearlite is liable to be broken by an external force exerted during mixing, kneading and extrusion, so that a sufficient light weight is obtained. Was difficult to achieve.

As a lightweight aggregate, for example, Japanese Patent Publication No. 63-63
As described in Japanese Patent No. 1276, there has been proposed a method for reducing the weight by blending an organic lightweight aggregate such as expanded polystyrene beads, which has been industrially manufactured and conventionally known. However, when a predetermined amount or more of organic light-weight aggregate is added, these organic light-weight aggregates have a poor affinity and tend to be easily released from the kneaded material, and also a spring generated when the molding pressure is removed. Due to the back phenomenon, there is a problem that fine cracks and defects are generated inside the molded body, and the strength tends to be reduced. Furthermore, when only organic light-weight aggregates such as polystyrene expanded particles (EPS) are mixed to reduce the weight, for example, when a predetermined amount or more of an organic material such as EPS, cellulosic, or fibrous is added, the incombustibility of the molded plate deteriorates. However, it is difficult to use it as a non-combustible material.

When a water-absorbent resin is used as disclosed in Japanese Patent Publication No. 6-84268, the water-absorbent resin itself is destroyed by an external force received during mixing, kneading and extrusion, and the particle size of the water-absorbent resin is reduced. Due to the wide distribution, the range of porosity in the product is widened and the nailing performance is deteriorated, and the mixing of a large amount of water causes a delay in the curability of the hydraulic material, resulting in low initial strength. There was a problem. If the initial strength is low, there is a risk that the molded product may be cracked or chipped during transportation during the curing process after molding. Further, there is a problem that the resin in a water-absorbing state is easily aggregated during mixing and kneading, and it is difficult to produce an inorganic molded body in a uniformly dispersed state.

On the other hand, as a lightweight building material, a concrete plate generally called ALC is manufactured. However, although ALC is lightweight, it has a drawback that it has high water absorption and extremely poor frost damage resistance.

In the production of an inorganic molded article, asbestos has conventionally been added as a fibrous raw material. Asbestos has a water retention ability to retain the added water in the system and a shape retention force to maintain the shape after molding, so that the addition of excessive moisture impairs the moldability and shape retention. Thus, it was possible to produce a molded article without any problem, and it was easy to reduce the weight of the molded article due to dissipation of the added excess moisture. However,
In recent years, the use of asbestos has been greatly reduced due to the harmfulness of the asbestos to the human body, and a method for producing a light-weight molded article by adding no asbestos has been studied.

As described above, various attempts have been made to reduce the weight of a molded article used as an exterior wall material of a building. However, the required dimensional stability and nonflammability without asbestos have been added. At present, a satisfactory light-weight molded product has not been obtained.

[0016]

SUMMARY OF THE INVENTION In view of the above-mentioned problems of the prior art, an object of the present invention is to provide an outer wall material of a building such as a decorative finish base material for an outer wall of a building or an outer wall panel as an exterior material. The use of an inorganic lightweight molded body that has excellent dimensional stability, is lightweight, has no asbestos added, and is nonflammable in the base material test of Ministry of Construction Notification No. 1828, prevents sagging of the outer wall material and shrinkage of the outer wall material. An object of the present invention is to provide a wall structure capable of preventing a deterioration in the appearance of a building due to warping, undulation, and the like, and preventing a deterioration in the durability of the building due to intrusion of rainwater or the like.

[0017]

Means for Solving the Problems The present inventors have conducted a detailed study on the outer wall material of a building, and found that the outer wall material has a length change between 10% by weight and 5% by weight. By using an inorganic lightweight molded article having a ratio of 0.01% or less and a specific gravity of 1.1 or less, the exterior wall material, which has been a problem in the past, or a decorative finish is applied to a building wall, and then a base material. Shrinkage, warping, undulation, etc. due to the drying of the wall will not only deteriorate the appearance of the wall, but also cause cracks in the decorative finishing material, dripping of the exterior material such as the outer wall panel, and breakage of joints due to rainwater, etc. The present invention can solve the problem that the durability of the building itself is reduced due to the corrosion of the rim and the pillars caused by the penetration of the steel, and the present invention has been completed.

The change in length in the inorganic lightweight molded body is a phenomenon in which the molded body expands due to moisture absorption due to humidity in the air, infiltration of rainwater, and the like, and contracts due to subsequent drying. In the present invention, as a building exterior wall material, for example, a decorative finishing base material, or an exterior wall panel as an exterior material, the length change rate is 0.01% when the water content is between 10% by weight and 5% by weight. % Or less of an inorganic lightweight molded body. When the rate of change in length is 0.01% or less, more preferably 0.05% or less, the shrinkage amount is 0.3 mm even at the longest standard (3030 mm) of a commonly used molded plate.
In the following, even when it is 0.15 mm or less, when such a molded body is used as a decorative finishing material, cracking occurs in the decorative finishing material due to the influence of the underlying material regardless of what kind of decorative finishing material is used. In addition, when this molded body is used as an outer wall panel as an exterior material, rainwater or the like may enter due to the occurrence of a gap in the molded body horizontal joint caulking part and the joint caulking cut of the vertical joint caulking part. It is thought that the problem of deterioration in the durability of the building itself due to corrosion of the rim and columns can be solved.

As described above, by using a molded body having a length change rate of less than 0.01% as an outer wall material of a building,
Cracking, moisture absorption due to humidity in the air, expansion due to intrusion of rainwater, and subsequent shrinkage due to drying are unlikely to occur, and the formation of gaps in the joints of the molded body eliminates adverse effects on the structure due to intrusion of rain and snow from the gaps . On the other hand, in the case of a molded body in which the change in length of the inorganic lightweight molded body was greater than 0.01%, this was used as an exterior wall material such as a decorative base material for a building exterior wall or an exterior wall panel as an exterior material. In such a case, expansion due to moisture absorption due to the humidity in the air and intrusion of rainwater and subsequent shrinkage due to drying become severe, causing problems such as generation of gaps in the caulking portion of the horizontal joint and breakage of the coking portion of the vertical joint. Furthermore, the penetration of rain, snow, or the like from those portions may cause corrosion of the structure and a decrease in the strength of the structure due to the corrosion.

Further, when the specific gravity of the inorganic lightweight molded article is 1.1 or less, the specific gravity of the inorganic lightweight molded article is about 1 in comparison with the mortar base material.
Even when used for an outer wall of an external heat insulation specification, the wall can be prevented from sagging at a specific gravity of / 2.

Therefore, in the wall structure of a building according to the present invention, the inorganic lightweight molded body can be used as an outer wall material such as a decorative finish base material for an outer wall of a building or an outer wall panel as an exterior material. Further, an exterior wall material such as a decorative base material or an exterior wall panel made of the inorganic lightweight molded body may be used on the outside of the heat insulating material to form a wall structure of a detached outdoor heat insulation method.

The inorganic lightweight molded article having the above-mentioned properties is a composition containing an inorganic hydraulic material, a siliceous material, a fibrous material, and a lightweight aggregate. A composition obtained by adding water to an inorganic hydraulic composition that satisfies at least one of the compositions, and then curing the composition is preferably used. 1) exceeds the specific surface area 5000 cm ² / g as siliceous materials, of less than 8000 cm ² / g, and the content of SiO ₂ is used silica powder is 90 wt% or more, Ca in the composition
The molar ratio of O / SiO ₂ is in the range of 0.5 to 1.2. 2) The fiber material contains water-absorbing natural mineral fibers other than asbestos and / or water-absorbing inorganic artificial fibers in a total amount of 5% by weight or more and 50% by weight or less.

As the water-absorbing natural mineral fiber, at least one fiber selected from the group consisting of wollastonite, sepiolite and attapulgite can be used, and as the water-absorbing inorganic artificial fiber, rock is used. Wool can be used. As the lightweight aggregate, expanded thermoplastic resin particles having an expansion ratio of 10 times or more and 100 times or less can be used. The thermoplastic resin expanded particles have a particle size of 10 μm or more and 1
Those having a size of 300 μm or less are preferred. As the thermoplastic resin foam particles, at least one kind of foam particles selected from the group consisting of acrylonitrile resin foam particles, vinylidene chloride resin foam particles, and styrene resin foam particles can be used. As the styrene-based resin expanded particles, those having an expansion ratio of 20 times or more and 50 times or less and an average particle size of 300 μm or more and 1300 μm or less are suitably used, and more preferably an expansion ratio of 20 times or more and 50 times or less.
The average particle size is 300 μm or more and 700 μm or less. As the lightweight aggregate, in addition to the thermoplastic resin foam particles, an average particle diameter of 50 μm or more
It can contain an inorganic lightweight aggregate containing an aluminum oxide component of not more than 00 μm, a bulk specific gravity of 0.1 or more and 0.7 or less, a pressure resistance of 8 MPa or more, and 20% by weight or more and 50% by weight or less. Furthermore, it is more preferable that the inorganic lightweight molded article is obtained by adding water to the inorganic hydraulic composition, mixing the resulting mixture, molding the mixture, and then curing the mixture in an autoclave.

[0024]

1 and 2 show an example of a wall structure of a building according to the present invention using the inorganic lightweight molded article as a decorative finish base material. First, in the wall structure shown in FIG. 1, waterproof paper 4 is applied to the outside of a pillar 1 and a stud 2 located on the indoor side of a building, and a decorative finish base material 10 made of an inorganic lightweight molded body is provided thereon. , The decorative finish base material 1
From above, a decorative base material 7 made of a material such as cement, siliceous, synthetic resin emulsion, synthetic resin solution, or polymer cement is sprayed with an air spray or a spray gun, or with a roller or brush. It is made by painting. FIG. 2 shows an example of a wall structure in a case where the external heat insulation method is adopted. A heat insulating board 8 is provided on the outside of the pillars 1 and the studs 2, and a rim 9 is provided on the outside of the room. The decorative base material 10 made of an inorganic lightweight molded body is provided on the body edge 9, and the decorative finish material 7 similar to the above is applied from above the decorative finish base material 10.

It should be noted that the wall structure of the present invention is not limited to the wall structure described above. Further, the heat insulation board 8 to be constructed includes a polystyrene type, a urethane type and the like, but it is also applicable to other board-shaped heat insulating materials. Further, the decorative finishing material 7 is not particularly limited, and those generally used conventionally can be used. Cement-based, siliceous-based, synthetic resin emulsion-based, synthetic resin solution-based, polymer cement-based There are various kinds of materials, such as thin finish, multi-layer finish, thick finish, etc., but there is no particular problem using any material and specification. Regarding the construction method of decorative finishing materials,
Although there are spraying, construction using a roller, construction using a brush, etc., there is no particular problem using any construction method. In addition, when the base material adjustment is necessary, the base adjustment material is not particularly limited, and there are a synthetic resin-based sealer, a synthetic resin putty, a cement-based adjustment coating material, a synthetic resin emulsion-based coating material, and the like. There is no particular problem even if used.

As described above, the decorative base material 10 in the wall structure of the building has a moisture content of 10% by weight to 5% by weight.
By using an inorganic lightweight molded body having a length change ratio of 0.01% or less between weight% and a specific gravity of 1.1 or less, the problem of the drying time of cement mortar, which was a problem in the conventional method, was found. Prevents the appearance of the decorative finishing material 7 from cracking due to the cracking of the cement mortar due to drying, thereby preventing the leakage of water due to the intrusion of water such as rainwater and the durability of the building, and the occurrence of wall sagging due to the weight of the outer wall material. can do.

FIG. 3 shows an example of an external heat insulation method using the inorganic lightweight molded article as an exterior material of an outer wall of a building. In this wall structure, waterproof paper 4 is installed on the outdoor side of a heat insulating board 8 provided on the outdoor side of the pillar 1 and stud 2 located on the indoor side of the building, and the rim 9 is installed thereon. next,
Exterior wall panel 1 made of inorganic lightweight molded body as exterior material
1 is installed on the rim 9.

As described above, as the outer wall panel 11 of the exterior material in the wall structure of the building, the rate of change in the length between the water content of 10% by weight and 5% by weight is 0.01% or less, and the specific gravity is By using an inorganic lightweight molded body of 1.1 or less, sagging of the outer wall panel 11 due to the weight of the outer wall panel 11 which has been a problem in the conventional method is eliminated, and the caulking portion 12 of the vertical joint generated due to dimensional change of the outer wall panel 11. Problems such as joint cracking of the joint and opening of the joint of the lateral joint caulking part 13 and breakage of the caulking are prevented, rain and snow intrusion from the joint part are prevented, and the pillars 1 and the studs 2, the rim 9, and the base 14 due to moisture are prevented. It is possible to prevent body decay.

Further, as another embodiment of the present invention, a perspective view of a tile dry construction method using an external heat insulation construction method is shown in FIG. In this wall structure, a decorative finish base material 10 made of the inorganic lightweight molded body is provided on a body edge 9 of an outer wall of an external heat-insulating specification, and a decorative finish by a tile dry method is applied thereon. As described above, when the inorganic lightweight molded body is used as the decorative finishing base material 10 of the tile dry method, there is no problem such as peeling of the tile 15 due to a dimensional change of the decorative finishing base material 10, dropping, cracking of the tile 15, and the like. The tile state at the time of construction can be preserved for a long time. In addition, in the tile dry method, the tiles 15 are applied to the surface of the decorative finish base material 10 after the decorative finish base material 10 is applied, so that the total weight of the outer wall increases. As a result, in a building constructed by employing the external heat insulation method, the load on the heat insulating board 8 increases, and problems such as sagging or displacement of the decorative finish base material 10 occur. However, as the decorative finish base material 10, the moisture content is 10% by weight to 5% by weight.
Is less than 0.01% and the specific gravity is 1.1
By using the following inorganic lightweight molded body, it is possible to reduce problems such as sagging and displacement of the outer wall.

In the wall structure of the building according to the present invention as described above, the length change when the water content of the decorative base material 10 and the outer wall panel 11 as the outer wall material is between 10% by weight and 5% by weight. The inorganic lightweight molded body having a ratio of 0.01% or less and a specific gravity of 1.1 or less is a composition containing an inorganic hydraulic material, a siliceous material, a fibrous material, and a lightweight aggregate, and The composition can be produced by adding water to an inorganic hydraulic composition satisfying at least one of the requirements (2) and (3), molding the composition, and then curing the composition. 1) exceeds the specific surface area 5000 cm ² / g as siliceous materials, of less than 8000 cm ² / g, and the content of SiO ₂ is used silica powder is 90 wt% or more, Ca in the composition
The molar ratio of O / SiO ₂ is in the range of 0.5 to 1.2. 2) The fiber material contains water-absorbing natural mineral fibers other than asbestos and / or water-absorbing inorganic artificial fibers in a total amount of 5% by weight or more and 50% by weight or less.

As the inorganic hydraulic material in the inorganic hydraulic composition, ordinary portland cement, low alkali type portland cement, early strength portland cement,
Examples include cements such as ultra-high strength Portland cement, blast furnace cement, silica cement, fly ash cement, magnesia cement, and alumina cement, and calcareous materials such as hemihydrate or anhydrous gypsum and gypsum. These may be used alone or in combination of two or more. However, like the siliceous material, a material having a large specific surface area, for example, a material having a specific surface area of 3000 cm ² / g or more is preferable.

That is, as a method for obtaining a high-strength molded article without using asbestos, conventionally, a method in which water is added to a mixed composition, the mixture is molded, cured, hardened and cured in an autoclave. Has been done. This is because a very stable crystal called tobermorite is formed in a molded article by curing at high temperature and pressure such as autoclave curing, and when all the products in the molded article are this crystal, It is known that a molded article having the highest dimensional stability, the highest strength, and the excellent freeze-thaw resistance can be obtained. If the specific surface area of the inorganic hydraulic material is large, the reaction amount for producing tobermorite increases,
Furthermore, the more the CaO component in the inorganic hydraulic material,
A large amount of tobermorite can be produced with a small amount of contamination. Therefore, as the inorganic hydraulic material, ordinary Portland cement and early-strength Portland cement containing a large amount of CaO component are suitable.

The amount of the inorganic hydraulic material is in the range of 20% by weight to 90% by weight, preferably 25% by weight to 80% by weight, based on 100% by weight of the solid content of the composition. . The amount of the inorganic hydraulic material is 25
When the amount is less than 90% by weight, the strength of the molded body tends to decrease due to the shortage of the hardening material. In the present invention, the solid content of the composition,
It refers to inorganic hydraulic materials, siliceous materials, fibrous materials, aggregates, admixtures, admixtures, etc., other than water and thickeners.

One of the technical means adopted in the present invention is that
Specific surface area 5000cm ^Two/ G, 8
000cm^Two/ G and SiO_Two90% by weight
% Or more, and CaO / SiO in the composition is used.
_TwoIs in the range of 0.5 to 1.2, preferably
The range is 0.6 to 1.0.

The content of the inorganic hydraulic material and the siliceous material is adjusted to adjust the content of CaO (calcium oxide) / Si in the composition.
It is said that by setting the molar ratio of O ₂ (silicon dioxide) in the range of 0.7 to 1.0, a large amount of tobermorite can be produced. However, ordinary Portland cement, which is generally used as an inorganic hydraulic material, and early-strength Portland cement have a specific surface area of about 3000 to 5000 cm ² / g, and the difference in specific surface area due to the type difference is small. Silica sand, silica stone powder, fly ash, etc. used as siliceous materials
The component ratio and specific surface area of SiO ₂ vary greatly depending on the type, and only by specifying the molar ratio of CaO / SiO ₂ in the composition to the above range, required flexural strength, dimensional stability, freeze-thaw resistance and the like are required. It was difficult to obtain a molded body having performance.

That is, in general, the process in which particles react is expanding from the surface to the inside, and since the thickness of the formed phase is the same for both large and small particles, the smaller the particles, the larger the surface area. , The reaction will be fast.
In particular, the autoclave curing is performed in a short time unlike the hydration reaction, and it is considered that the reaction amount increases as the number of fine particles increases. On the other hand, conventionally used silica sand has a large particle size, even the finest No. 8 silica sand has a particle size of about 50 μm to 200 μm, and a specific surface area of about 1500 cm ² / g.
It is considered that the amount of reaction between the silica sand and the inorganic hydraulic material is small, and the formation of tobermorite is insufficient, and a molded article having sufficient dimensional stability and bending strength cannot be obtained.

As described above, only the CaO /
It is difficult to obtain a molded body having sufficient physical properties only by defining the molar ratio of SiO ₂ , and it is necessary to use silica powder having predetermined properties as in the present invention, and to further improve the C content in the composition.
By setting the molar ratio of aO / SiO ₂ to a predetermined range,
By generating a lot of very stable crystals, called tobermorite, in the molded article during autoclave curing, the rate of change in the length of the molded article can be reduced, and high bending strength can be obtained. If the molded article is lightened using lightweight aggregates,
The bending strength decreases in proportion to the specific gravity, and there is a danger of cracking or cracking during transportation or construction. On the other hand, in the present invention, the use of silica powder under the above conditions increases the strength of the matrix portion other than the aggregate, so that a sufficient reduction in the weight of the molded body can be realized.

In the present invention, silica powder having a specific surface area of more than 5000 cm ² / g and less than 8000 cm ² / g is used as the siliceous material. This means that the specific surface area is 5000 cm ²
/ G or less, the amount of reaction with the inorganic hydraulic material (calcical material) is reduced, and sufficient tobermorite is not generated, so that the effect of autoclave curing is not exhibited and the dimensional stability of the molded product is reduced. In addition, the bending strength and the freeze-thaw resistance of the molded product are also reduced. On the other hand, the specific surface area is 8
When it is 000 cm ² / g or more, not only does the flowability when extruding by adding water decrease, the moldability deteriorates, but also the structure of the molded product becomes too dense and the specific gravity of the molded product increases. Further, in order to obtain silica stone powder having a large specific surface area, processing is troublesome, and the material cost is increased. Therefore, when viewed from the performance and cost aspects, as the specific surface area of the silica stone powder beyond 5000 cm ² / g, it is suitable which fall within the scope of less than 8000 cm ² / g.

The specific surface area of the siliceous material was measured according to J
The test was performed using a Blaine air permeation apparatus in accordance with the specific surface area test of IS R5201 “Physical Testing Method of Cement”.

Further, as the siliceous material, SiO ₂
Used is a silica powder having a content of 90% by weight or more. If the content of SiO _{2 in} the silica powder is low, it must be mixed in a large amount, and the specific gravity of the molded product increases. In addition, as components other than SiO ₂ , various components such as calcium oxide, aluminum oxide, iron oxide, potassium oxide, sodium oxide, and ignition loss (sometimes expressed as Ig.loss.) May be included. . These components are not separately mixed but are components contained in the silica powder.

The mixing amount of the inorganic hydraulic material and the siliceous material in the inorganic hydraulic composition is determined by the content of CaO in the inorganic hydraulic material, the content of SiO _{2 in} the siliceous material, and the content of CaO / Although it depends on how the molar ratio of SiO ₂ is defined, for example, inorganic hydraulic materials 20 to 7
0% by weight and about 10 to 60% by weight of the siliceous material are exemplified.

By the way, as the siliceous material, there is fly ash which has been generally used conventionally. However, the content of SiO _{2 in} fly ash is about 55% by weight, and in order to make the SiO ₂ component in the composition using fly ash the same as that using silica powder, it is necessary to compare with silica powder. Therefore, it is necessary to mix a large amount of fly ash, and the fly ash contains a small amount of unburned coal, which is not preferable because the non-combustibility of the molded article is reduced.

The mixing amount of the inorganic hydraulic material and the silica stone powder in the inorganic hydraulic composition is such that the molar ratio of CaO / SiO ₂ in the composition is 0.5 to 1.2, preferably 0.6 to 1. 0
And a mixture ratio falling within the range. If the above molar ratio is larger than 1.2, CaO becomes larger than SiO ₂ , so that lime becomes excessive, and products other than tobermorite are generated, and the strength of the molded body is reduced. On the other hand, when the above molar ratio is less than 0.5, silica becomes excessive and stable tobermorite can be formed, but unreacted silica remains as aggregate as it is. The molar ratio is 0.5 to 1.2, preferably 0.6 to 1.0
In the range, only tobermorite is formed in the molded product, which is the most preferable state.

Further, other technical means employed in the present invention include:
As an alternative to asbestos, an inorganic fiber having a water absorbing property other than asbestos is used. That is, a total of 5% by weight or more and 50% by weight or less of a natural mineral fiber having water absorbency and / or an artificial artificial fiber having water absorbency as a fibrous material is contained in the composition (when the solid content is 100% by weight). It is to do.

The natural mineral fibers include, for example, wollastonite, sepiolite, attapulgite, halloysite, fibrous gypsum (gypsum), mordenite (zeolite), and the like, and the mineral artificial fibers include rock wool. These are appropriately selected according to the required physical properties of the molded article so that the characteristics can be utilized.
Since these inorganic fibers have a large surface area and a large tensile strength, when mixed into a molded article, they restrict expansion or contraction of the paste portion in the molded article, thereby reducing the rate of change in the length of the molded article. Can be. In addition, these inorganic fibers have many needle-like crystals, and a molded article using the inorganic fibers has excellent bending strength and impact resistance.

On the other hand, the amount of cellulosic fiber, thermoplastic resin blended for weight reduction, and synthetic fiber blended for improving impact resistance is limited because they are combustible. It was necessary to sacrifice weight reduction and impact resistance. On the other hand, the inorganic fiber can be mixed in an amount sufficient to improve the dimensional stability, bending strength and impact resistance without decreasing the incombustibility of the molded article even if the mixed amount is increased.

These natural mineral fibers and inorganic artificial fibers are not limited as long as they are water-absorbing and are not limited by type, material, properties, etc., but may be 30% by weight or more, preferably 100% by weight or more. Those having water absorbency are preferred. These water-absorbing natural mineral fibers and water-absorbing inorganic artificial fibers are only required to be contained in the composition in a range of 5% by weight to 50% by weight in total.
Both may be used together or used alone.

Among the above-mentioned natural mineral fibers and inorganic artificial fibers, wollastonite, sepiolite and attapulgite are used as natural mineral fibers having water absorption, and rock wool is used as inorganic artificial fibers having water absorption. Is preferably used.

Wollastonite is a calcium metasilicate, also called wollastonite, and is acicular in shape and has excellent heat resistance.
It has the characteristic that the coefficient of thermal expansion is small. There are many types of wollastonite having different shapes, fiber lengths, and fiber diameters, but wollastonite used in the present invention is not particularly limited.

Sepiolite is a hydrous magnesium silicate that is porous, has a large specific surface area, and has hydroxyl groups on its surface, so that it has good affinity for water and alcohol, has good heat resistance, and has a heat resistance of about 1200 ° C. It has the feature of maintaining its properties as a fibrous substance.

Attapulgite is a hydrated magnesium aluminum silicate having a hollow needle-like crystal structure, a large cation substitution capacity and a large specific surface area, so that it has excellent water absorbency and good heat resistance.

Rock wool includes those using rock as a main raw material and those using slag, both of which have good incombustibility.

The characteristics of each inorganic fiber are as follows: wollastonite and rock wool have a slightly higher specific gravity of 2.5 to 2.9 and a smaller water absorption than sepiolite.
The reinforcing effect is high, and the dimensional stability and bending strength of the molded product can be greatly improved. Sepiolite and attapulgite have a specific gravity of about 2 to 2.2 and a large specific surface area, so they have a large water absorption and a large weight saving effect.

Further, these water-absorbing inorganic fibers are:
Since it has water retention, it retains the water in the slurry, gives lubricity to the inorganic hydraulic composition at the time of extrusion, improves extrusion moldability, and also provides reinforcement and mold retention at the time of uncuring. As a result, the hollow portion does not sag when extruded into a hollow shape, and a shape as designed can be obtained. Further, these inorganic fibers having water absorbability also make it possible to reduce the weight of the molded body due to dissipation of the added excess moisture.

The amount of the water-absorbing inorganic fiber in the inorganic hydraulic composition is determined such that the solid content weight of the composition is 1%.
00% by weight, 5% by weight or more and 50% by weight or less,
More preferably, it is in the range of 10% by weight or more and 35% by weight or less. If the amount of the inorganic fiber is less than 5% by weight, the water retention performance is not exhibited, and the effect of improving the moldability is hardly obtained.
Further, it is difficult to obtain the effects of improving the dimensional stability of the molded product, the bending strength of other properties, and the impact resistance. 50% by weight
When the ratio exceeds, the ratio of components other than the inorganic fibers becomes too low, and the surface property of the molded product deteriorates. In particular, a decrease in the component ratio of the inorganic hydraulic material leads to a decrease in bending strength.

In the present invention, as described above, 1) the specific surface area of the siliceous material exceeds 5,000 cm ² / g and exceeds 800 cm ² / g.
Less than 0 cm ² / g and the content of SiO ₂ is 90% by weight
Using the silica powder described above, CaO / SiO ₂ in the composition
2) a natural mineral fiber having a water absorbing property other than asbestos and / or an inorganic synthetic fiber having a water absorbing property of at least 5% by weight of 50 Only one of the technical means may be employed, or both of the technical means 1) and 2) may be employed simultaneously. The use of both of the methods 1) and 2) is preferable for improving the rate of change in length. In the present invention, a fibrous material other than the above-described water-absorbing inorganic fibers can be used as long as the effects of the present invention are not impaired.

As the fibrous material other than the inorganic fiber having water absorption, a cellulosic fiber material is preferably used.
The material and properties of the cellulosic fiber are not limited, but used newspaper, pulp fiber and the like are preferably used. In addition to the cellulosic fiber material, glass fiber, carbon fiber, iron wire, slag wool, inorganic fiber such as potassium titanate, polypropylene fiber, vinylon fiber, acrylic fiber, polyethylene terephthalate (PE
T) It is also possible to add synthetic fibers such as fibers. Cellulosic fibers may be used alone, or a mixture of cellulosic fibers and inorganic fibers, or a mixture of cellulosic fibers and organic fibers may be used.

Cellulose-based fibers are suitably added because they have a reinforcing effect and a water-retaining effect when present in the material, and contribute to the shape-retaining and lightening effects of the molded article. However, synthetic fibers, when used alone, have a reduced reinforcing effect, which is considered to be due to a decrease in fiber strength during curing at high temperatures, and when inorganic fibers other than inorganic fibers having water absorbency are used alone, the specific gravity is reduced. Is not preferable because the specific gravity of the molded article is increased because of its large size, contrary to the reinforcing effect.
These fiber materials may be used alone or as a mixture of two or more.

The fibrous material as described above can be added in an amount which does not impair the effect of the present invention. However, when the solid content is 100% by weight, it is preferably 1% by weight or more and 60% by weight or less. Is added in the range of 1.5% by weight or more and 40% by weight or less, and by setting the proportion of the fibrous material in the composition in such a range, a good molded product can be obtained.

As the expanded thermoplastic resin particles used as the lightweight aggregate in the inorganic hydraulic composition, those having an expansion ratio of 10 times or more and 100 times or less are preferably used. If the expansion ratio is less than 10 times, the effect of reducing the weight cannot be sufficiently exhibited, and if it is more than 100 times, the strength of the molded article tends to decrease, which is not preferable.

As the expanded thermoplastic resin particles, those having an average particle diameter of 10 μm or more and 1300 μm or less are preferably used. The average particle size of the expanded thermoplastic resin particles is 10μ.
If it is smaller than m, it tends to increase the specific gravity of the molded body by filling the gaps between the materials at the time of producing the molded body, and if it is larger than 1300 μm,
Due to the springback phenomenon that occurs when the molding pressure is removed, minute cracks are easily generated inside the molded body, causing a decrease in the strength of the molded body, and also tending to cause unevenness on the molded body surface after molding Having.

The foamed thermoplastic resin particles used in the present invention are not particularly limited as long as they have the above-mentioned properties. Even if one kind of foamed thermoplastic resin particles is added, two or more kinds of foamed thermoplastic resin particles may be used. Although there is no problem even if the thermoplastic resin foam particles are used in combination, especially acrylonitrile-based resin foam particles,
Expanded vinylidene chloride-based resin particles and expanded polystyrene-based resin particles are preferably used.

The foamed acrylonitrile resin particles and the foamed vinylidene chloride resin particles are preferable because foamed particles having a high expansion ratio and a small particle size can be easily produced, and springback upon release of pressure is small. Further, the foamed acrylonitrile resin particles have a softening point of the cell wall of 140.
° C, which is higher than 80 ° C of vinylidene chloride-based resin, so that when the formed molded body is cured by steam curing, the resin is hardly softened, and the inside of the molded body due to the deformation of the foamed particles is reduced. This is more preferable because the generation of fine cracks can be suppressed. These expanded acrylonitrile resin particles and expanded vinylidene chloride resin particles preferably have an expansion ratio of 15 to 80 times, more preferably 20 to 70 times, and a particle size of 10 μm to 10
0 μm or less, more preferably 20 μm or more and 80 μm or less.

The expanded styrene resin particles used as a lightweight aggregate in the inorganic hydraulic composition preferably have an expansion ratio of 20 to 50 times and an average particle size of 30 to 30 times.
Those having a size of 0 μm or more and 1300 μm or less are preferably used,
More preferably, those having an expansion ratio of 20 to 50 times and an average particle size of 300 to 700 μm are used. Such styrene-based resin foamed particles are lower in production cost than acrylonitrile-based resin foamed particles and vinylidene chloride-based resin foamed particles, and are particularly preferable as a lightweight material used in the present invention.

If the average particle size of the expanded styrene resin particles is 300 μm or more and 700 μm or less, the expanded styrene resin particles are not recognized on the surface of the molded product, and the molded article has extremely good surface properties. In contrast, the average particle size was 7
When foamed styrene-based resin particles larger than 00 μm are used, the surface properties of the molded article are slightly reduced, but the other properties are not particularly problematic, and the production cost is lower than that of a small particle size. It can be offered to the market at low cost. However, when the average particle diameter of the expanded styrene resin particles is larger than 1300 μm, fine cracks and defects are easily generated inside the molded body due to a springback phenomenon that occurs when the molding pressure is removed. However, it is not preferable because the surface property of the molded article after molding tends to be deteriorated.

Such a method for producing expanded styrene resin particles can be carried out, for example, in a reactor equipped with a stirrer charged with a continuous phase (eg, water) in which the monomer and the resulting polymer are substantially insoluble. Is dispersed as small droplets and then continuously stirred to polymerize under predetermined conditions.
An example of a specific manufacturing method is as follows. A styrene monomer represented by styrene, water, calcium phosphate, in a pressure-resistant reactor equipped with a stirrer and a temperature detection tube,
A polymerization initiator such as sodium dodecylbenzenesulfonate, benzoyl peroxide and tert-dibutyl perbenzoate was charged, and nitrogen was introduced with stirring until the pressure in the reactor reached a predetermined pressure. The polymerization is carried out for a time. Next, a foaming agent such as butane, pentane, hexane or the like is added and the temperature is raised to a predetermined temperature, and then the foaming agent is impregnated for a predetermined time. This is cooled to room temperature to obtain true spherical expandable styrene resin particles. Moisture is removed from the resin particles using a dryer and dried.
The resin particles are sieved to obtain particles having a predetermined particle size, and the obtained expandable styrene resin particles are then expanded with a heat medium such as steam to expand the styrene resin particles having a predetermined expansion ratio and particle size. Get the particles. The method for producing the expanded styrene resin particles used in the present invention is not limited at all, and it goes without saying that methods other than those described above are suitably used.

The styrene-based resin for producing the styrene-based resin expanded particles may be a homopolymer of a styrene-based monomer or a copolymer of a styrene-based monomer and another copolymerizable monomer. However, a homopolymer and a copolymer of a styrene monomer are preferably used, and a homopolymer of a styrene monomer and a polystyrene resin are more preferably used. As the styrene monomer, styrene,
Vinyl naphthalene, alkyl-substituted styrene, halo-substituted styrene, divinylbenzene, divinyltoluene, divinylxylene, divinylnaphthalene, trivinylbenzene, and the like, as the copolymerizable monomer, an alpha olefin having 2 to 12 carbon atoms, It is selected from cyclic olefins such as cyclopentene and norbornene, dienes such as 1,4-hexadiene and methyl-1,4-hexadiene, and vinyl monomers such as vinyl chloride, vinylidene chloride, acrylonitrile, vinyl acetate, acrylic acid, and methacrylic acid. One or more kinds may be mentioned.

The content of the expanded thermoplastic resin particles in the inorganic hydraulic composition is preferably 0.1% by weight or more and 3% by weight or less when the weight of the solid content is 100% by weight. 0.1
If the amount is less than 3% by weight, the effect of reducing the weight cannot be sufficiently exhibited. If the amount is more than 3% by weight, minute cracks and defects are easily generated inside the molded body due to a springback phenomenon that occurs when the molding pressure is removed, and the strength is reduced. May cause

In the present invention, in addition to the foamed thermoplastic resin particles, an average particle diameter of 50 μm or more and 300 μm or less, a bulk specific gravity of 0.1 or more and 0.7 or less, a pressure resistance of 8 MPa or more and 20% by weight or more and 50% by weight or less. It is more preferable to use an inorganic lightweight aggregate containing the above aluminum oxide component.

The addition of pearlite and shirasu balloon having a small pressure resistance, which has been conventionally used as a lightweight aggregate of an inorganic molded article, is likely to cause the lightweight aggregate to be broken by an external force received during mixing, kneading and extrusion. It was difficult to achieve sufficient weight reduction. On the other hand, when the inorganic lightweight aggregate having the above-mentioned characteristics is used, it is hard to be broken by the external force received when performing mixing, kneading, and extrusion molding, and it is possible to obtain a lightweight effect by maintaining its shape. .

When the aluminum oxide component of the inorganic lightweight aggregate is out of the range of 20% by weight or more and 50% by weight or less, preferably 25% by weight or more and 50% by weight or when the compressive strength is less than 8 MPa, mixing is performed. And kneading,
Since the external force at the time of the extrusion molding causes the destruction of the inorganic lightweight aggregate, it is difficult to sufficiently exert the lightening effect.

The compressive strength of the inorganic lightweight aggregate means the pressure applied when 75% by weight of the inorganic lightweight aggregate remains without being destroyed under hydrostatic pressure.
Specifically, after the aggregate is immersed in water and left for 24 hours, the aggregate floating on the water surface is scooped, dried at 80 ° C. for about 24 hours to remove moisture, and is not destroyed. Obtain aggregate. Thereafter, a predetermined amount of the dried aggregate is put together with water in a tester (for example, a pressure vessel), and pressure is applied (for example, a gas such as nitrogen is added to the center of the pressure vessel).
Leave at the specified pressure for 5 minutes. Then, after taking out the aggregate and water from the tester and allowing it to stand, the aggregate floating on the water surface is filtered, dried at 80 ° C. for 24 hours, and weighed. The pressure when the weight of the suspended aggregate after the test is 75% by weight when the weight of the aggregate put in the container before the test is 100% by weight is defined as the pressure resistance. .

The inorganic lightweight aggregate used in the present invention is:
It is necessary to have a bulk specific gravity of 0.7 or less.
When the bulk specific gravity is larger than 0.7, the effect of reducing the weight cannot be sufficiently exerted, and it is necessary to add a large amount to reduce the weight.

There is no particular limitation on the shape and particle size of the inorganic lightweight aggregate. However, a) suppresses a decrease in pressure resistance, b) improves the flowability of a molding material obtained by adding water to the inorganic hydraulic composition, and c) each component of the composition at the time of producing a molded article The inorganic lightweight aggregate preferably has a spherical shape, and preferably has an average particle size of 50 μm or more and 300 μm or less, for the reason that the specific gravity of the compact is not increased by being filled in the gaps between them. Therefore, as the inorganic lightweight aggregate, alumina silicate balloon (Reball Co., Ltd.), Microcells (Chichibu Onoda Co., Ltd.) and the like are preferably used.

The content of the inorganic lightweight aggregate in the composition can be added in such an amount as not to impair the effect of the present invention, but when the solid content is 100% by weight, it is 1% by weight or more. 50% by weight or less, preferably 3% by weight or more and 30%
It is added in the range of not more than% by weight.

Further, an inorganic lightweight aggregate other than the specific inorganic lightweight aggregate may be added to the inorganic hydraulic composition as long as the effect of the present invention is not impaired.

The inorganic hydraulic composition used in the present invention may further contain, if necessary, a commonly added admixture such as blast furnace slag, crushed inorganic board waste, or wood-based chips such as wood chips and wood powder. A material derived from the material can be added.

Further, when the extrusion molding method is selected as the method for producing a molded article, the inorganic hydraulic composition used in the present invention is given extrusion fluidity to the composition, and the molded article after extrusion is kept in shape. Molding aids such as methylcellulose and polyethylene oxide for maintaining the properties can also be added. Further, additives such as pigments, dyes, flame retardants, curing accelerators, curing retarders and the like may be used.

Water is added to the above-mentioned inorganic hydraulic composition, mixed, molded and cured to obtain an inorganic lightweight molded article having a water content of 10 to 5% by weight. The rate of change in length between them can be 0.01% or less and the specific gravity can be 1.1 or less. The specific gravity of the molded body is a true specific gravity of the molded body itself, and in a case of a molded body having a hollow portion, a value ignoring the hollow portion. As described above, when a molded plate made of an inorganic hydraulic composition is applied as an outer wall material, the moisture content of the molded plate increases due to moisture absorption due to humidity in the air, water absorption due to ingress of rainwater, and the like. Expand, and the moisture content is reduced by the subsequent drying, and the molded plate shrinks. Generally, when a molded plate is used as an outer wall material, the water content increases or decreases between about 5% by weight and 10% by weight, and the water content hardly falls outside this range. Therefore, it is important to grasp the length change rate when the water content is between 10% by weight and 5% by weight, and the length change rate during that time is 0.01% or less, preferably 0.005% or less. If so, even the most commonly used molded plate with a length of 3030 mm has a shrinkage of about 0.3 mm or less, or 0.3 mm.
It is as small as 15 mm or less, and the joint width does not increase after the formed plate is applied to the outer wall. Further, a molded article having a small dimensional change rate is a good molded article with little occurrence of warpage or undulation in a molded plate.

Casting, press molding, and extrusion molding methods are known as methods for producing a molded article from the inorganic hydraulic composition. The inorganic hydraulic composition of the present invention has a hollow cross-sectional shape. Despite being able to manufacture molded articles, and having excellent continuous productivity and being commercially advantageous, a sufficient weight-reducing effect has not been conventionally obtained due to the destruction of weight-reducing materials such as inorganic lightweight aggregates. The effect is particularly exhibited by the extrusion molding method.

In producing an inorganic lightweight molded article from the inorganic hydraulic composition, water is blended with the inorganic hydraulic composition, uniformly mixed and kneaded. The mixing amount of water is preferably 15 parts by weight or more and 100 parts by weight or less based on the total amount of solids (100 parts by weight). When the amount is less than 15 parts by weight, the flowability of the kneaded material is deteriorated, and not only does the load on the extruder increase, but also uniform extrusion cannot be performed with an increase in the molding pressure, so that a product having a good shape can be produced. When the amount is more than 100 parts by weight, the inorganic hydraulic composition and the excess moisture tend to be separated inside the extruder, and the extrusion itself tends to be difficult. This is not preferable because it exceeds the limit of the shape retention required for maintaining the shape of the formed molded article.

The method of mixing the inorganic hydraulic composition with water is not particularly limited as long as it can be uniformly mixed and kneaded. The molding material thus obtained is extruded by an extruder having a vacuum deaeration tank, and then cured and cured to produce an inorganic lightweight molded body.

The method of curing and curing is not particularly limited, and ordinary curing methods such as underwater curing, natural curing, steam curing, and autoclave curing under high temperature and high pressure can be applied, but good dimensional stability is obtained. Autoclave curing is most effective for obtaining a molded product having high bending strength.

The method for curing the autoclave is not particularly limited. Autoclave curing is curing with saturated steam at a high temperature and a high pressure exceeding 100 ° C.
The reaction is performed at a temperature of 0 ° C. or more, more preferably 150 ° C. or more, and further preferably 160 ° C. or more. The curing time can be changed as appropriate depending on the composition of the composition, the curing temperature, and the desired physical properties of the molded body.

Prior to autoclave curing, ordinary curing such as underwater curing, natural curing, and steam curing may be performed. In addition, when autoclaving is performed immediately after molding, the molded article is rapidly heated, and significant expansion of bubbles and moisture in the molded article occurs, which tends to cause cracks in the molded article or on the molded article surface.
In order to develop an initial strength that can withstand the inflation pressure, it is preferable to perform these pre-curing.

[0086] In this way, the inorganic lightweight moldings produced by performing the autoclave curing is a specific gravity of 1.1 or less, and has a 6.5 N / mm ² or more flexural strength. In addition, the specific gravity of the molded body is a true specific gravity of the molded body itself, and in the case of a molded body having a hollow portion, a value ignoring the hollow portion.

The shape of the inorganic lightweight molded article used as the outer wall material of the wall structure according to the present invention may be either a solid shape or a hollow shape.

[0088]

Next, the present invention will be described based on examples and comparative examples in which a molded plate used as an outer wall material is obtained in a wall structure of a building, but the present invention is limited to only such examples. Not something. In the following Examples and Comparative Examples, the physical properties and the like of the molded body were measured or evaluated by the following methods.

<True Specific Gravity> The true specific gravity was calculated from the weight of the molded body and the volume obtained by the submersion method. Hollow portions were ignored, and the specific gravity of the molded body itself was described. <Bending strength> It was measured in accordance with JIS A1408. However, the size of the test piece is 50 mm wide x 140 m long
m and a span of 100 mm. <Non-flammability> Evaluated based on the base material test of Ministry of Construction Notification No. 1828. <Impact resistance> Measured according to JIS A1408. An iron ball of 530 g was dropped from a height of 110 cm, and one having no crack penetrating was judged to be acceptable. However, the test piece dimensions were 200 mm x 150 mm. <Length change rate> A measuring pin was attached to both ends of a test piece having a size of 40 mm and a length of 150 mm to obtain a test piece. The test piece is erected in water, and water is absorbed until the weight becomes constant while measuring the weight (W) and length (L). Thereafter, the sample is allowed to stand in a desiccator, and dried until a constant weight is obtained while measuring the weight (W) and the length (L). Then 105
℃ dryer at dried to a constant weight by weight of (W _0),
The length (L ₀ ) is measured and used as a reference, and the moisture content and the rate of change in length are calculated by the following equations. In addition, the length was measured to 1/1000 mm with a dial gauge. Water content (% by weight) = (W−W ₀ ) / W ₀ × 100 Length change rate (%) = (L−L ₀ ) / L ₀ × 100 The values of the water content and the length change rate are plotted on a graph. Then, the amount of change in the length change rate when the water content increases from 5% by weight to 10% by weight is calculated, and then the change in the length change rate when the water content decreases from 10% by weight to 5% by weight is calculated. Calculate the amount of change and record the average value. <Extrusion Moldability> The state of the molded product discharged from extrusion molding was visually observed and evaluated according to the following criteria. Good: A molded product according to the mold is discharged. Poor: Molded product is not discharged according to the mold. <Surface Properties> The surface of the molded article was visually observed and evaluated according to the following criteria. ：: The surface has no dog-tooth-like cracks, swelling, and wavy surface, and has extremely good surface properties. ：: The surface has good surface properties with no dog-tooth-shaped cracks, swelling, and surface undulations. ×: The surface has dog-tooth-shaped cracks, swelling, and surface undulations.

(Example 1) An inorganic hydraulic composition having the mixing ratio shown in Table 1 was mixed with a mixer (MHS-M manufactured by Miyazaki Tekko Co., Ltd.).
(Type 165), and wet mixing was performed by adding water in the amount shown in Table 1 after dry mixing. Next, this mixed material was put into an extrusion kneading machine (Miyazaki Iron Works screw diameter 100 φ kneader ruder) and kneaded to obtain a molding material. This molding material is 150 m in width having eight hollow portions.
The extruder was extruded from a vacuum extruder (Honda Tekko extruder) with a screw diameter of 75 mm to which a hollow plate-shaped die having a thickness of 20 mm and a thickness of 20 mm was attached. The discharged molded body was subjected to wet steam curing at 60 ° C. for 8 hours, and then autoclaved at 160 ° C. under a pressure of 0.6 MPa for 4 hours to obtain a plate-shaped inorganic lightweight molded body. Table 1 shows the evaluation results of the specific gravity, bending strength, incombustibility, length change rate, extrudability and surface properties of this molded product.

(Examples 2 to 18) Molding materials were obtained in the same manner as in Example 1 except that the blending amounts were changed as shown in Tables 1 to 3. From these molding materials, plate-like inorganic lightweight molded articles were obtained in the same manner as in Example 1. The specific gravity, bending strength, nonflammability, impact resistance, length change rate, extrudability and surface properties of these molded articles were evaluated. Tables 1, 2 and 3 show the results.
Are shown together.

[0092]

[Table 1]

[0093]

[Table 2]

[0094]

[Table 3]

(Comparative Examples 1 to 9) A molding material was obtained in the same manner as in Example 1 except that the compounding amounts were changed as shown in Tables 4 and 5. From these molding materials, plate-like inorganic lightweight molded articles were obtained in the same manner as in Example 1. The true specific gravity, bending strength, nonflammability, impact properties, rate of change in length, extrudability, and surface properties of this molded article were evaluated. The results are shown in Tables 4 and 5.

[0096]

[Table 4]

[0097]

[Table 5]

The materials shown as Note 1) to Note 7) in Table 1, Table 2, Table 3, Table 4, and Table 5 are as follows. Note 1) Organic fiber: Cellulosic fiber, PP fiber Note 2) Thermoplastic resin foam: Styrene resin foam particles (expansion ratio 30 times, average particle diameter 500 μm) Note 3) Thermoplastic resin foam: Styrene resin foam Particles (expansion ratio: 30 times, average particle size: 1100 μm) Note 4) Thermoplastic resin foam: acrylonitrile resin expanded particles (Matsumoto Microsphere 80E), expansion ratio: 50 to 60 times, particle size: 30 to 60 μm (Matsumoto Yushi Pharmaceutical Co., Ltd.) Note 5) Thermoplastic resin foam: expanded particles of vinylidene chloride-based resin (Matsumoto Microsphere 30E), expansion ratio 50-60 times, particle size 30-80 μm (Matsumoto Yushi Pharmaceutical Co., Ltd.) Note 6) Inorganic lightweight aggregate: ASB (alumina silicate balloon), particle size 150-300 μm, bulk specific gravity about 0.
4, pressure resistance 13MPa, aluminum oxide component about 30
% By weight (Reball Co., Ltd.). Note 7) Admixture: Aluminum oxide-based admixture

[0099]

As described above, according to the wall structure of a building according to the present invention, the rate of change in length between water content of 10% by weight and 5% by weight is 0.01% or less, and the specific gravity is By using an inorganic lightweight molded body having a thickness of 1.1 or less as a decorative finishing base material or an outer wall panel of a building outer wall, cracking of the decorative finishing material in the entire wall and joints, opening of the outer wall joint,
It can prevent breakage of coking, etc., has a good appearance, can prevent infiltration of rainwater etc. into the wall surface, and constructs the inorganic lightweight molded body on the outer wall of a wooden detached exterior insulation method, thereby providing an outer wall material Problems such as sagging, opening of outer wall joints, and breakage of coking can be solved. Therefore, according to the present invention, a wall structure that improves the durability of the building itself can be provided, and a beautiful wall surface can be maintained for a long time.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view of a wall structure using an inorganic lightweight molded body as a decorative finish base material.

FIG. 2 is a schematic perspective view of a wall structure of an external heat-insulating specification using an inorganic lightweight molded body as a decorative finish base material.

FIG. 3 is a schematic perspective view of an external heat-insulating wall structure using an inorganic lightweight molded body for an outer wall panel.

FIG. 4 is a schematic perspective view of a wall structure of a tile dry construction method of external heat insulation specification using an inorganic lightweight molded body as a finishing base material.

FIG. 5 is a schematic perspective view of a conventional wall structure using a mortar base as a decorative finish base material.

FIG. 6 is a schematic perspective view of a conventional wall structure of external insulation specification using a mortar base as a decorative finish base material.

[Explanation of symbols]

1: pillar, 2: stud, 3: plywood, 4: waterproof paper, 5: lath wire mesh, 6: mortar base, 7: decorative finish, 8: heat insulating board, 9: trunk, 10: decorative finish base, 11: outer wall panel, 12: vertical joint caulking part, 13: horizontal joint caulking part, 14: base, 15: tile.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C04B 14:38 C04B 14:46 14:46 16:04 16:04 22:06) Z 22:06) B28B 11/00 A (72) Inventor Naoaki Yamada 2-3-2 Yoshinori Sawa, Ibaraki-shi, Osaka 2-3-2 Higashi Tabata Heights 307 F-term (reference) 2E110 AA02 AA13 AB04 AB22 BA02 GB17Y GB23Y GB42Y 4G012 MA00 PA04 PA18 PA24 PB03 4G055 AA03 AB03 AC01 BA02

Claims (14)

[Claims] 1. An inorganic lightweight molded article having a length change rate of 0.01% or less and a specific gravity of 1.1 or less between 10% by weight and 5% by weight is used as an outer wall material. And the wall structure of the building. 2. The wall structure of a building according to claim 1, wherein the inorganic lightweight molded body is used as a decorative base material for a building outer wall. 3. The wall structure of a building according to claim 1, wherein the inorganic lightweight molded body is used as an exterior material of a building outer wall. 4. The wall structure of a building according to any one of claims 1 to 3, wherein the outer wall material made of the inorganic lightweight molded body is used on the outdoor side of a heat insulating material in a detached outdoor heat insulation method. 5. The composition as claimed in claim 1, wherein the inorganic lightweight molded article comprises an inorganic hydraulic material, a siliceous material, a fibrous material and a lightweight aggregate, and satisfies at least one of the following 1) and 2): The wall structure of a building according to any one of claims 1 to 4, which is obtained by adding water to the inorganic hydraulic composition, forming the composition, and then curing the composition. 1) exceeds the specific surface area 5000 cm ² / g as siliceous materials, of less than 8000 cm ² / g, and the content of SiO ₂ is used silica powder is 90 wt% or more, Ca in the composition
The molar ratio of O / SiO ₂ is in the range of 0.5 to 1.2. 2) The fiber material contains water-absorbing natural mineral fibers other than asbestos and / or water-absorbing inorganic artificial fibers in a total amount of 5% by weight or more and 50% by weight or less. 6. The water-absorbing natural mineral fiber is at least one fiber selected from the group consisting of wollastonite, sepiolite and attapulgite, and the water-absorbing inorganic artificial fiber is rock wool.
The wall structure of the described building. 7. The lightweight aggregate has an expansion ratio of 10 to 100 times.
7. The thermoplastic resin foamed particles having a particle size of not more than doubled.
The wall structure of the described building. 8. The thermoplastic resin expanded particles having an average particle size of 10
8. The wall structure of a building according to claim 7, which is not less than 1 μm and not more than 1300 μm. 9. The foamed thermoplastic resin particles are at least one foamed particle selected from the group consisting of foamed acrylonitrile-based resin particles, foamed vinylidene chloride-based resin particles, and foamed styrene-based resin particles. Building wall structure. 10. The building wall structure according to claim 9, wherein the expanded thermoplastic resin particles are expanded styrene resin particles. 11. The wall structure of a building according to claim 10, wherein the expansion ratio of the expanded styrene resin particles is 20 times or more and 50 times or less, and the average particle diameter is 300 μm or more and 1300 μm or less. 12. The wall structure of a building according to claim 10, wherein the expansion ratio of the expanded styrene resin particles is 20 times or more and 50 times or less, and the average particle size is 300 μm or more and 700 μm or less. 13. As a lightweight aggregate, in addition to foamed thermoplastic resin particles, an average particle diameter of 50 μm or more and 300 μm or less, a bulk specific gravity of 0.1 or more and 0.7 or less, and a compressive strength of 8 MPa
The wall structure of a building according to any one of claims 7 to 12, further comprising an inorganic lightweight aggregate containing 20% to 50% by weight of an aluminum oxide component. 14. The inorganic lightweight molded article is obtained by adding water to the inorganic hydraulic composition, mixing and molding the same,
14. An autoclave cured product.
The wall structure of a building according to any one of the above.