Building material and method for manufacturing the same

Abstract

To provide a building material thin and high in weather resistance, and a method for manufacturing the same.SOLUTION: A building material 1 comprises: a hollow aluminum alloy base material 2; a resin layer 4 that covers the hollow aluminum alloy base material; and an adhesive layer 3 provided between the aluminum alloy base material and the resin layer to bond the aluminum alloy base material and the resin layer. The resin layer and the adhesive layer do not contain wood flours. The thickness of the adhesive layer is 0.1-0.3 mm, preferably 0.2 mm. The thickness of the resin layer is 0.1-1 mm, preferably 0.7 mm. The method for manufacturing the building material comprises the steps of: forming the adhesive layer on the hollow aluminum alloy base material; and forming the resin layer on the adhesive layer. The resin layer and the adhesive layer are formed on the basis of the specification.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a building material and a method for producing a building material. [Background technology]

[0002] In general, not only in houses but also in interior and exterior construction, plate-shaped members are often used as the main members. Generally, plate-shaped members are made of wood powder, but wood powder is prone to corrosion and has issues with weather resistance, and its weight also increases depending on the size of the plate-shaped member used.

[0003] In response to this, Patent Document 1 below describes a technology that uses hollow members and applies a resin layer around the hollow members to reduce the weight of plate-shaped building materials. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2023-79099 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, the above-mentioned Patent Document 1 contains wood powder, which still leaves issues regarding the weather resistance of the wood powder.In addition, since it contains wood powder, there is also the problem that it is difficult to adjust the thickness, for example, to be thin.

[0006] In view of the above problems, an object of the present invention is to provide a thinner building material with excellent weather resistance and a method for manufacturing the same. [Means for solving the problem]

[0007] A building material according to one aspect of the present invention that solves the above problems is a building material having a hollow aluminum alloy substrate, a resin layer covering the hollow aluminum alloy substrate, and an adhesive layer provided between the aluminum alloy substrate and the resin layer to bond the aluminum alloy substrate and the resin layer, wherein the resin layer and the adhesive layer do not contain wood powder, the adhesive layer has a thickness of 0.1 mm or more and 0.3 mm or less, preferably 0.2 mm, and the resin layer has a thickness of 0.1 mm or more and 1 mm or less, preferably 0.7 mm.

[0008] Also, in this respect, although not limited thereto, it is preferable that the adhesive layer contains at least one of POE (polyolefin elastomer), LLDPE (linear low density polyethylene), EAA (ethylene-acrylic acid copolymer), and the like.

[0009] In addition, from this viewpoint, it is preferable that the resin layer contains at least one of a Surlyn resin, polypropylene, and a maleic anhydride compatibilizer.

[0010] In addition, in this respect, although not limited thereto, it is preferable that the thickness of each aluminum portion of the hollow aluminum alloy substrate is 0.1 cm to 0.5 cm, the plate width is 5 cm to 22 cm, the thickness is 0.9 cm to 5 cm, and the length is 200 cm or more.

[0011] In addition, in this respect, although not limited thereto, when the elongation percentage in the longitudinal direction of the hollow aluminum alloy substrate layer is taken as 1, it is preferable that the elongation percentage of the material of the resin layer and the adhesive layer is in the range of 300% or more and 700% or less.

[0012] In addition, in this respect, although not limited thereto, it is preferable that the hollow aluminum alloy substrate has a pair of flat surfaces, and side wall portions and a center column portion for supporting the pair of flat surfaces with a gap therebetween.

[0013] In addition, a manufacturing method for a building material according to another aspect of the present invention is a manufacturing method for a building material having a step of forming an adhesive layer on a hollow aluminum alloy substrate and a step of forming a resin layer on the adhesive layer, wherein the resin layer and the adhesive layer do not contain wood powder, the adhesive layer is formed to a thickness of 0.1 mm or more and 0.3 mm or less, preferably 0.2 mm, and the resin layer is formed to a thickness of 0.1 mm or more and 1 mm or less, preferably 0.7 mm. Effect of the Invention

[0014] As described above, the present invention can provide a thinner building material with excellent weather resistance and a method for producing the same. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic diagram of a building material according to an embodiment. [Diagram 2] FIG. 2 is a diagram showing an example of cross-sectional dimensions, etc. of a building material according to an embodiment. [Diagram 3] 1 is a schematic diagram showing an example of a hollow aluminum alloy substrate according to an embodiment. FIG. [Figure 4] FIG. 2 is a diagram showing an example of cross-sectional dimensions of a hollow aluminum alloy substrate according to an embodiment. [Diagram 5] FIG. 1 is a diagram showing an outline of a manufacturing process for a building material according to an embodiment. BEST MODE FOR CARRYING OUT THEINVENTION

[0016] Hereinafter, the embodiments of the present invention will be described in detail with reference to the drawings. However, the present invention can be embodied in many different forms, and the specific examples described in the following embodiments and examples can be appropriately modified and adjusted, and the present invention is not limited thereto.

[0017] Fig. 1 is a schematic diagram of a building material according to this embodiment (hereinafter referred to as "this building material") 1. As shown in this figure, this building material 1 is a building material having a hollow aluminum alloy substrate 2, a resin layer 4 covering the hollow aluminum alloy substrate 2, and an adhesive layer 3 provided between the hollow aluminum alloy substrate 2 and the resin layer 4 to bond the hollow aluminum alloy substrate 2 and the resin layer 4, and the resin layer 4 and the adhesive layer 3 do not contain wood powder, the adhesive layer 3 has a thickness of 0.1 mm to 0.3 mm, preferably 0.2 mm, and the resin layer 4 has a thickness of 0.1 mm to 1 mm, preferably 0.7 mm.

[0018] According to the present building material 1, by ensuring the thickness of the adhesive layer 3 and the resin layer 4, the building material 1 becomes thinner and has excellent weather resistance.

[0019] In addition, in the present building material 1, the hollow aluminum alloy substrate 2 is a so-called core material, and is a main member for ensuring the strength of the present building material 1. By using an aluminum alloy, it is possible to achieve weight reduction while maintaining strength.

[0020] In addition, in the present building material 1, although not limited thereto, it is preferable that the hollow aluminum alloy substrate 2 has a pair of flat surfaces, and a side wall and a center column for supporting the pair of flat surfaces with a gap therebetween. In other words, such a configuration allows a hollow portion to be provided, which makes it possible to reduce the weight.

[0021] In addition, in the present building material 1, although not limited thereto, the hollow aluminum alloy substrate 2 preferably has a thickness of 0.1 cm to 0.5 cm at each aluminum portion, i.e., each flat portion of the plate, a plate width of 5 cm to 22 cm, a total thickness of 0.9 cm to 5 cm, and a length of 200 cm or more. By setting the dimensions in this range, it is possible to achieve both strength and weight reduction as described above.

[0022] In addition, it is preferable that fine grooves are formed on the surface of the hollow aluminum alloy substrate 2. By forming fine grooves, it is possible to increase the adhesive's adhesion. The height of the grooves is preferably in the range of 0.15 mm to 0.5 mm. An outline of this hollow aluminum substrate is shown in Fig. 3 and Fig. 4.

[0023] In addition, in this building material 1, the adhesive layer 3 is provided around the hollow aluminum alloy substrate 2 to bond the hollow aluminum alloy substrate 2 and the resin layer 4, and is provided between the hollow aluminum alloy substrate 2 and the resin layer 4 in the completed form of this building material 1.

[0024] In addition, in the present building material 1, the adhesive layer 3 preferably contains at least one of POE (polyolefin elastomer), LLDPE (linear low density polyethylene), EAA (ethylene-acrylic acid copolymer), etc. By providing the adhesive layer 3 with these materials, the thin adhesive layer 3, in combination with the resin layer 4 described below, can have the advantage of being extremely thin and highly fusible.

[0025] In the present building material 1 , the resin layer 4 is for covering the hollow aluminum alloy substrate 2 , and more specifically, covers the hollow aluminum alloy substrate 2 via the adhesive layer 3 .

[0026] In addition, in the present building material 1, the resin layer 4 preferably contains at least one of Surlyn resin, polypropylene, and maleic anhydride compatible solvent. In addition, it is also possible to create a wood grain pattern by mixing pigment masterbatches of multiple colors into the resin layer 4 and utilizing the difference in melting points between the colors.

[0027] It is also important that in this building material 1, not only the adhesive layer 3 but also the resin layer 4 does not contain wood flour. Wood flour is added from the viewpoint of forming a wood tone, but the inclusion of wood flour causes water absorption, which can lead to deterioration of the resin layer 4 due to expansion and contraction. However, by not including wood flour, it is possible to achieve an extremely low water absorption rate and prevent performance deterioration due to expansion and contraction caused by heat.

[0028] In addition, in this building material 1, when the elongation rate in the length direction of the hollow aluminum alloy substrate layer is taken as 1, the elongation rate of the material of the resin layer 4 and the adhesive layer 3 is preferably in the range of 300% to 700%, although this is not limited thereto. Here, "elongation rate" refers to the ratio of the length that expands when heated from room temperature to 50°C. Building materials are often placed not only indoors but also outdoors, and the expansion rate differs due to the temperature difference between day and night, which varies greatly depending on the season. Therefore, there is an advantage in that the weather resistance can be improved by keeping the elongation rate between the core material, adhesive layer, and resin layer within the above range. In addition, the thermal expansion coefficient of aluminum alloys, which is generally said to be about 22 x 10 ―6 / ℃, if the length of this building material is 2m, even if the thermal environment is assumed to be 50℃, the expansion length can be estimated to be 0.019mm. Therefore, when considering that it will be used under both of these conditions, it is believed that the resin layer and adhesive layer can adequately handle the expansion of the aluminum alloy and problems such as peeling will not occur.

[0029] (Manufacturing method) Here, we will explain the manufacturing method of this building material (hereinafter referred to as "this manufacturing method"). This manufacturing method is a manufacturing method of a building material having a step of (S1) forming an adhesive layer on a hollow aluminum alloy substrate, and a step of (S2) forming a resin layer on the adhesive layer, and the resin layer and adhesive layer do not contain wood powder, the adhesive layer is formed to a thickness of 0.1 mm to 0.3 mm, preferably 0.2 mm, and the resin layer is formed to a thickness of 0.1 mm to 1 mm, preferably 0.7 mm. Figure 5 shows an image of the steps in this manufacturing method.

[0030] In this figure, first, the hollow aluminum alloy substrate is placed on a moving mechanism such as a conveyor, and while moving, it passes above an adhesive filling hopper and below a resin filling hopper, and adhesive and resin are extruded in sequence to cover the periphery of the hollow aluminum alloy substrate. Then, the resin surface is pressed with decoration such as bumps and recesses to complete the product. Also, as mentioned above, a wood grain pattern can be created by mixing multiple color pigment masterbatches into the resin and utilizing the difference in the melting points of the pigments.

[0031] As described above, this embodiment can provide a thinner building material with excellent weather resistance and a manufacturing method thereof. EXAMPLES

[0032] Here, the building material according to the above embodiment was actually manufactured and its effects were confirmed. A specific description will be given below.

[0033] First, a hollow aluminum alloy substrate with a width of 11.72 cm, a height of 0.92 cm, a length of 200 cm, and a thickness of 1 mm was prepared. Three center pillars were provided at equal intervals in the hollow portion. That is, the hollow aluminum alloy substrate had a pair of flat portions, and side walls and a center pillar for supporting the pair of flat portions with a gap therebetween. In addition, grooves were made in the extrusion die to increase the adhesive's bite, and fine grooves were made on the surface of the extruded hollow aluminum alloy substrate. See Figures 3 and 4.

[0034] A layer of POE (polyolefin elastomer) was applied to the periphery of the hollow aluminum alloy substrate as an adhesive layer with a thickness of 0.2 mm, and a Surlyn resin layer was formed with a thickness of 0.95 mm on top of the layer to form a building material according to this embodiment (the material in question). The dimensions of the material in question that was actually produced are shown in Figure 2. The size of the material in question that is actually produced is not limited to the dimensions described in paragraph 0010.

[0035] On the other hand, as a comparative example, a POE (polyolefin elastomer) adhesive layer was formed to a thickness of 0.1 mm, and a resin layer containing polypropylene and wood powder was formed to a thickness of 1.3 mm to prepare a comparative material. It was confirmed that the comparative material already had issues such as poor abrasion resistance.

[0036] In response to this, the following tests were conducted on the subject product and an aluminum-coated sheet material made from resin containing wood powder (comparison material) from another company, and the results of the comparison with the other company's comparison material were as follows:

[0037] (1) Boiling test (tap water at 100°C for 60 hours) [Table 1]

[0038] As a result, the material in question had a low rate of change before and after the test, and was deemed to be excellent in terms of elongation, expansion, and water absorption / absorption. Furthermore, blisters were visible on the surface of the comparative material.

[0039] (2) Friction test (60 revolutions per minute, 500 revolutions per minute, 500g weights for friction tester x 2) [Table 2]

[0040] As a result of the above, it was confirmed that the wear rate of the comparative material was approximately 7 times that of the subject material for brown colors and approximately 20 times that of the subject material for dark gray colors, confirming that the subject material is superior in terms of both temperature and wear rate.

[0041] (3) Weather resistance test (exposure to natural light outdoors) Although there was no visible change in the subject material after just under two months, the other company's material, which contained wood powder, was found to have "sunburned" due to ultraviolet rays, and it was therefore confirmed that the subject material is superior from this perspective as well.

[0042] As described above, the present example confirmed the effects of the present building material. [Industrial Applicability]

[0043] The present invention has industrial applicability as a building material and a manufacturing method thereof. [Explanation of symbols]

[0044] 1…Building materials 2…Hollow aluminum alloy substrate 3...adhesive layer 4…Resin layer

Claims

1. A hollow aluminum alloy substrate; A resin layer covering the hollow aluminum alloy substrate; and an adhesive layer provided between the hollow aluminum alloy substrate and the resin layer for adhering the hollow aluminum alloy substrate and the resin layer. The resin layer and the adhesive layer do not contain wood flour, The adhesive layer has a thickness of 0.1 mm to 0.3 mm, preferably 0.2 mm. The resin layer of the building material has a thickness of 0.1 mm to 1 mm, preferably 0.7 mm.

2. 2. The building material according to claim 1, wherein the adhesive layer contains at least one of POE (polyolefin elastomer), LLDPE (linear low density polyethylene), and EAA (ethylene-acrylic acid copolymer).

3. 2. The building material according to claim 1, wherein the resin layer contains at least one of a Surlyn resin, polypropylene, and a maleic anhydride compatibilizer.

4. 2. The building material according to claim 1, wherein the hollow aluminum alloy substrate has an aluminum portion having a thickness of 0.1 cm to 0.5 cm at each location, a plate width of 5 cm to 22 cm, a plate thickness of 0.9 cm to 5 cm, and a length of 200 cm or more.

5. 2. The building material according to claim 1, wherein the hollow aluminum alloy substrate has a pair of flat surfaces, and side walls and a center column for supporting the pair of flat surfaces with a gap therebetween.

6. forming an adhesive layer on the hollow aluminum substrate; forming a resin layer on the adhesive layer, The resin layer and the adhesive layer do not contain wood flour, The adhesive layer is formed to a thickness of 0.1 mm or more and 0.3 mm or less, preferably 0.2 mm, The method for manufacturing a building material, wherein the resin layer is formed to a thickness of 0.1 mm or more and 1 mm or less, preferably 0.7 mm.

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