Lattice-shaped exterior material

Abstract

To provide a lattice-shaped external facing material, in which there is no distinction between front and rear and appearance is improved while construction is facilitated, by using a wood-tone composite material.SOLUTION: This lattice-shaped external facing material is assembled with a first sash bar material 3 and a second sash bar material 4 arranged in the direction of crossing with the first sash bar material mutually arranged in parallel at a predetermined interval. Each of the first crosspiece members has a first core material made of metal and having a rectangular cylindrical shape, a first covering layer covering an outer peripheral surface of the first core material and containing a synthetic resin and wood flour, and a through hole penetrating in a direction intersecting a longitudinal direction, and each of the second crosspiece members has a through member penetrating the through hole of the first crosspiece member and disposed over two or more of the first crosspiece members, and a cylindrical member including a second core material made of metal and having a cylindrical shape, and a second covering layer covering an outer peripheral surface of the second core material and containing a synthetic resin and wood flour, the cylindrical member is located between the first sash bar materials, is fitted so as to cover the outer periphery of the through member, and is held and fixed by the first sash bar materials in the lattice-shaped external facing material 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an exterior material formed by combining wood-like composite materials into a lattice shape. [Background technology]

[0002] Fences are known that are constructed by arranging wooden timbers in parallel at intervals as crosspieces, and then assembling them with second crosspieces perpendicular to the first crosspieces to form a lattice structure. This type of fence is described, for example, in Patent Document 1. Meanwhile, wood-look composite materials are known that have a core made of a metal such as aluminum and a coating layer containing synthetic resin and wood powder on the outer surface of the core material, resulting in a high-quality wood-like texture (see, for example, Patent Document 2). Such wood-look composite materials are also assembled into a lattice structure.

[0003] The fence described in Patent Document 1 is constructed in a grid pattern by placing horizontal bars on the sides of vertical bars so as to straddle vertical bars that are arranged in parallel, and fixing the intersections of the two. As a result, the horizontal bars are arranged on one side of the vertical bars, and the fence has a front and back. This distinction between a front and back of the fence can cause inconvenience, such as limiting its uses depending on the location where it is used, and so there has been a demand for a fence that does not have a front or back in terms of its construction.

[0004] Generally, when combining orthogonal crosspieces to create a planar lattice structure, a known technique is to make interlocking cuts at the intersections of the crosspieces and fit these cuts together, or to divide the crosspieces in advance in the thickness direction and assemble them by sandwiching one crosspiece between the other crosspieces, thereby arranging the surfaces of the vertical and horizontal crosspieces on the same plane.When this configuration is used in a fence with two crosspieces intersecting, it is possible to eliminate the distinction between the front and back.

[0005] Patent Document 3 describes a fence made of a wood-grain composite material, in which a first crosspiece is divided along its length, and cutouts are provided on the divided surfaces of the divided first crosspieces into which a second crosspiece is fitted, and the first crosspieces are sandwiched together to form a lattice structure. The pair of divided first crosspieces are each provided with connecting pieces at opposing positions on their inner surfaces, and are connected with the second crosspiece sandwiched between them using a connecting member with a generally H-shaped cross section, which is made up of arc-shaped leaf springs protruding outward and has engaging parts that fit into the openings of the pair of connecting pieces to engage with the connecting pieces, and a connecting part that connects the opposing engaging parts together. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-074219 [Patent Document 2] Japanese Patent Application Laid-Open No. 2012-066403 [Patent Document 3] Japanese Patent Application Publication No. 2018-028227 Summary of the Invention [Problem to be solved by the invention]

[0007] The fence described in Patent Document 3 has no distinction between the front and back and has an excellent appearance. However, the fence described in Patent Document 3 has problems in that it requires separate connecting members for assembly, and its structure is complex, requiring skill to assemble.

[0008] The present invention has been made in consideration of the above, and aims to provide a lattice-shaped exterior material that uses a wood-like composite material, has no distinction between the front and back, has a good appearance, and is easy to assemble. [Means for solving the problem]

[0009] The lattice-shaped exterior material of the present invention is an assembled lattice-shaped exterior material consisting of first crosspieces arranged parallel to each other at a predetermined interval and second crosspieces arranged in a direction intersecting the first crosspieces. The first crosspieces include a first core material made of metal and having a rectangular cylindrical shape, a first coating layer containing synthetic resin and wood flour that coats the outer surface of the first core material, and a through-hole that penetrates the first core material in a direction intersecting the longitudinal direction. The second crosspieces include a through-member that passes through the through-hole of the first crosspieces and extends between two or more first crosspieces, a second core material made of metal and having a cylindrical shape, and a tubular member that coats the outer surface of the second core material and has a second coating layer containing synthetic resin and wood flour. The tubular member is fitted between the first crosspieces so as to cover the outer periphery of the through-member and is clamped and fixed between the first crosspieces.

[0010] In the above lattice-shaped exterior material, the first core material of the first crosspiece preferably has a partition wall that is parallel to the penetration direction of the through hole, extends in the longitudinal direction of the first core material, and divides the internal space of the first core material.

[0011] In any of the above lattice-shaped exterior materials, the through members are preferably made of metal.

[0012] In any of the above-described lattice-shaped exterior materials, the first crosspiece preferably has a first adhesive layer between the first core material and the first covering layer, i.e., the first crosspiece is an integrated member in which the first core material and the first covering layer are integrated via the first adhesive layer.

[0013] In the lattice-shaped exterior material having the above-mentioned first adhesive layer, the first crosspiece material is more preferably an integrally extruded member in which the first adhesive layer and the first covering layer are integrated with the first core material at the same time as the first adhesive layer and the first covering layer are extruded. [Effects of the Invention]

[0014] The grid-shaped exterior material of the present invention has no distinction between the front and back, has a good appearance, and is easy to assemble. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a diagram showing a fence using a lattice-shaped exterior material according to an embodiment. [Figure 2] FIG. 2 is a partially enlarged view of FIG. [Figure 3] 1A and 1B are diagrams showing the structure of the vertical bars. A: Side view, B: XX cross section of A, C: Bottom view. [Figure 4] 1A and 1B are diagrams showing the structure of a horizontal crosspiece, in which A is a side view of a through member, B is a YY cross-sectional view of A, C is a side view of a tubular member, and D is a ZZ cross-sectional view of C. [Figure 5] FIG. 2 is a vertical cross-sectional view showing the state in which the vertical and horizontal bars are joined together. [Figure 6] A to E: Diagrams showing how to assemble vertical and horizontal bars. [Figure 7] 10A and 10B are diagrams for explaining a method of attaching the fence body to a post. DETAILED DESCRIPTION OF THE INVENTION

[0016] 1 and 2, fence 1 comprises a fence body 2, which is one embodiment of the lattice exterior material of the present invention, and posts 5 that support both the left and right sides of fence body 2 and are installed on the ground. Vertical crosspieces (first crosspieces) 3, horizontal crosspieces (second crosspieces) 4, and posts 5 that make up fence body 2 are made of a composite material with a wood-like appearance. End caps 3a, 5a are fitted into the upper openings of vertical crosspieces 3 and posts 5.

[0017] The fence body 2 has vertical bars 3 arranged parallel to one another at a predetermined interval, and horizontal bars 4 passing through the vertical bars 3 and arranged perpendicular to the vertical bars 3. As a result, the fence body 2 has a structure in which the horizontal bars 4 are not fixed to the surface of either one of the vertical bars 3, and there is no distinction between a front and a back.

[0018] 3, vertical crosspiece 3 is a hollow, elongated body with a rectangular cross section perpendicular to the longitudinal direction. Vertical crosspiece 3 has a rectangular, cylindrical metal core material 31, an adhesive layer 34 that covers the outer surface of the core material, and a coating layer 33 that covers the outer surface of the adhesive layer and contains synthetic resin and wood powder. In the following, to distinguish it from the parts that make up the tubular member (42 in FIG. 4) described below, the core material of vertical crosspiece 3 will be referred to as the first core material, the adhesive layer as the first adhesive layer, and the coating layer as the first coating layer, while the core material of the tubular member will be referred to as the second core material, the adhesive layer as the second adhesive layer, and the coating layer as the second coating layer.

[0019] The vertical beam 3 has openings 36a, 36b on opposing side surfaces 35a, 35b, and a through-hole 37 is formed penetrating the vertical beam 3 in a direction perpendicular to the longitudinal direction. A through-hole 37 of the horizontal beam 4, which will be described later, is inserted through the through-hole 37.

[0020] The first core material 31 can be made of metals such as aluminum or aluminum alloy, stainless steel, galvanized steel, or copper. In this embodiment, however, aluminum or an aluminum alloy is used from the viewpoint of ease of processing. Hereinafter, aluminum and aluminum alloys will be collectively referred to as aluminum. The thickness of the first core material 31 is preferably 0.8 to 5.0 mm, particularly 1.1 to 3.0 mm, from the viewpoint of the rigidity and extrusion processability of aluminum. In addition, forming fine irregularities on the outer surface of the first core material can improve adhesion to the first coating layer 33.

[0021] The first core material 31 preferably also includes partition walls 32 that divide the internal space. The partition walls 32 are planar and parallel to the penetration direction of the through holes 37, and extend in the longitudinal direction of the vertical bars 3. Naturally, the portions of the partition walls 32 through which the through holes pass are removed.

[0022] At least the outermost surface of the first coating layer 33 is made of a material in which a base synthetic resin contains wood flour. The base synthetic resin is preferably a polyolefin resin in terms of water resistance, etc., and examples thereof include homopolymers or copolymers of α-olefins having 2 to 8 carbon atoms, preferably 2 to 6 carbon atoms, such as ethylene, propylene, isobutylene, and hexene. In this embodiment, polypropylene resin is used.

[0023] The wood flour contained in the first coating layer 33 is often made from wood such as cedar, cypress, and western hemlock, as well as crushed scraps and waste wood of such wood, sawdust, etc., and the particle size can be 10 to 500 mesh, but is more preferably about 60 to 100 mesh. The wood flour content is 5 to 50 parts by weight, preferably 10 to 40 parts by weight, per 100 parts by weight of polyolefin resin. The surface of the first coating layer can be roughly scraped, for example by sanding, to give it a wood-like appearance and feel.

[0024] The first covering layer 33 is preferably laminated to the first core material 31 via a first adhesive layer 34 made of an adhesive at the interface where it contacts the first core material 31. The adhesive strength between the first core material and the first covering layer can be improved by providing the first adhesive layer 34. The adhesive that constitutes the adhesive layer can be a polyester resin, an ionomer resin, or a copolymer resin obtained by polymerizing an α-olefin and an epoxy group-containing unsaturated monomer.

[0025] The thickness of the first covering layer 33 is not particularly limited, but is preferably about 0.5 to 7 mm from the viewpoints of adhesion, appearance, and productivity. When laminated to the first core material via a first adhesive layer, the thickness of the adhesive layer is preferably about 0.05 to 0.5 mm. From the viewpoints of further improving the wood texture when touched and the adhesion of the covering layer, the thickness of the first covering layer is preferably 1.0 to 5.0 mm, and particularly 1.1 to 3.5 mm.

[0026] The vertical crosspiece 3 can be manufactured by various known methods. For example, as described in Patent Document 2, the vertical crosspiece 3 can be manufactured as an integrally extruded body by manufacturing a first core material 31 by extrusion molding, and then sequentially laminating and covering the first core material with a first adhesive layer 34 and a first covering layer 33 in a die using a co-extrusion molding machine.

[0027] Referring to FIG. 4, horizontal beam 4 is composed of a through member 41 (FIGS. 4A and 4B) and a cylindrical member 42 (FIGS. 4C and 4D).

[0028] The through member 41 is inserted into the through-hole 37 of the vertical bars 3 to connect two or more vertical bars. The through member 41 is a long, rectangular tubular body made of metal. Metals that can be used for the through member include aluminum or aluminum alloy, stainless steel, galvanized steel, and copper, but aluminum is used in this embodiment.

[0029] The tubular member 42 is fitted onto the outer periphery of the through-hole member 41. The tubular member 42 comprises a second core member 43 made of metal and having a rectangular cylindrical shape, a second adhesive layer 45 covering the outer periphery of the second core member, and a second coating layer 44 containing synthetic resin and wood flour and covering the outer periphery of the second adhesive layer. The tubular member 42 has a structure similar to that of the vertical crosspiece 3, and the preferred materials and thicknesses of the second core member and the second coating layer are also similar to those of the first core member and the first coating layer of the vertical crosspiece 3. Furthermore, the second coating layer 44 is also preferably laminated on the surface of the second core member 43 via the second adhesive layer 45. However, the tubular member 42 differs from the vertical crosspiece 3 in that the second core member 43 does not have a partition wall. The tubular member 42 can be manufactured by cutting an integrally extruded body similar to that of the vertical crosspiece 3 to the required length. Furthermore, in order to improve the appearance of the contact area between the side surface and the end surface of the vertical crosspiece 3, the thickness of the second coating layer 44 is preferably 1.1 mm or more, and more preferably 1.2 mm to 3.0 mm when combined with the thickness of the second coating layer 44 and the second adhesive layer 45. Note that it is preferable to provide drainage holes on the underside of the horizontal crosspiece 4 near both ends in order to drain water that has infiltrated inside the horizontal crosspiece 4. In other words, it is preferable to provide holes with a diameter of about 3 to 8 mm that penetrate through the through member 41 and the tubular member 42.

[0030] The shape of the through member 41 is not limited to a rectangular cylindrical shape, as long as the position of the through member is determined in a plane intersecting the through-hole direction when inserted into the through-hole 37 of the vertical crosspiece 3, and the position of the cylindrical member is determined in the longitudinal direction of the through member, i.e., in a plane intersecting the through-hole direction when the cylindrical member 42 is fitted around the outer periphery. The shape of the through member 41 may be, for example, a cylindrical shape with an elliptical cross section. Furthermore, the shape of the cylindrical member 42 is not limited to a rectangular shape, and may be, for example, a cylindrical shape with a circular or elliptical cross section.

[0031] 5 shows a vertical cross section of the assembled vertical and horizontal bars 3 and 4. At the end of the horizontal bar 4, a tubular member 42 is fixed to a through member 41 with a screw 9 or the like. The other tubular members 42 are clamped and fixed between the vertical bars 3. The outer shape of the end face of the tubular member 42 is larger than the opening of the through hole 37 (36a, 36b in FIG. 3), and as a result, the through hole 37 is hidden by the tubular member 42 and cannot be seen from the outside.

[0032] If the first core material 31 of the vertical bar 3 has a partition wall 32 parallel to the penetration direction, the partition wall 32 will resist the force that clamps the tubular member 42 between the vertical bar 3, thereby preventing the side surface of the vertical bar (35a, 35b in FIG. 3) from being dented. Having the partition wall 32 in the first core material 31 is preferable because it reduces the thickness of the first core material and makes the vertical bar 3 lighter.

[0033] At the portions (6) where the end faces of the tubular members 42 abut against the side faces 35a, 35b of the vertical bars 3, the second coating layer 44 of the tubular members that make up the horizontal bars is made of a synthetic resin layer with a certain thickness, effectively reducing the intrusion of rainwater into the vertical bars 3 without the need for solid or liquid sealant. If rainwater infiltrates the vertical bars 3, it will drip from the bottom ends of the vertical bars 3 over a long period of time, significantly damaging the appearance of the fence. To achieve sufficient waterproofing without sealant, it is preferable that the thickness of the second coating layer 44 of the tubular members that make up the horizontal bars be 1.1 mm or more.

[0034] Next, with reference to Figure 6, a method for assembling the fence main body 2 will be described. Please note that in Figure 6, the vertical bars 3 are drawn horizontally and the horizontal bars 4 are drawn vertically. The vertical bars with through holes, the through members for the horizontal bars, and the tubular members are prepared. A tubular member 42 is fixed to one end of the through member 41 with a screw or the like (Figure 6A). The vertical bar 3 is fitted so that the through member 41 passes through the through hole (Figure 6B). The tubular member 42 is fitted into the through member 41 protruding from the through hole (Figure 6C). The next vertical bar 3 is fitted, followed by the tubular member 42 (Figure 6D), and this process is repeated. The tubular member 42 is fitted into the other end of the through member 41 and fixed with a screw or the like (Figure 6E). This completes the assembly of the fence main body 2.

[0035] To secure the fence body 2 to the post 5, for example, referring to Figure 7, a U-shaped mounting bracket 7 is fixed to the side of the post, the mounting bracket 7 is inserted into the end opening of the cross rail 4 of the fence body 2, and the cross rail 4 is secured to the mounting bracket with screws 9 or the like. [Example]

[0036] The vertical bars 3 were fabricated as follows. A rectangular cylindrical first core material 31 was extruded from an aluminum alloy, measuring 900 mm in length, with cross-sectional dimensions of 48.5 mm x 28.5 mm and a partition wall 32 connecting the midpoints of the long sides. The wall thickness of each part of the first core material was 1.2 mm. A first adhesive layer 34 made of a copolymer resin of α-olefin and an epoxy-containing unsaturated monomer and a first coating layer 33 made of wood flour-containing polypropylene resin were sequentially laminated on the surface of the first core material and formed by integral extrusion molding. The thickness of the first adhesive layer 34 was 0.2 mm, and the thickness of the first coating layer 33 was 1.3 mm, for a total thickness of 1.5 mm. This resulted in the cross-sectional dimensions of the vertical bars being 51.5 mm x 31.5 mm. Two through holes measuring 43 mm long x 18 mm wide were formed by NC machining on the 51.5 mm-wide side of the integral extrusion molded body at positions where the horizontal bars would be located, penetrating the 31.5 mm thickness. The surface of the first coating layer was sanded to create a wood grain look.

[0037] The horizontal crosspiece 4 was fabricated as follows. The through-hole 41 was made of aluminum alloy and extruded into a rectangular tube approximately 1165 mm long, with cross-sectional dimensions of 41.4 mm x 16 mm and a wall thickness of 2.5 mm. The tubular member 42 was fabricated by integrally extruding the same wood-like composite material as the vertical crosspiece 3 and cutting it to a length of 32 mm. The second core member 43 of the tubular member 42 was made of aluminum alloy and had a rectangular tube shape with cross-sectional dimensions of 47 mm x 22 mm and no internal partitions. The wall thickness of the second core member was 1.2 mm, with a 2 mm thick portion protruding into the interior space at the center of each side. A second adhesive layer 45 made of a copolymer resin of α-olefin and an epoxy-containing unsaturated monomer, and a second coating layer 44 made of wood flour-containing polypropylene resin were sequentially laminated on the surface of the second core member 43 by integral extrusion molding. The thickness of the second adhesive layer 45 was 0.2 mm, and the thickness of the second coating layer 44 was 1.3 mm, for a total thickness of 1.5 mm. As a result, the outer dimensions of the cross section of the cylindrical member 42 were 50 mm x 25 mm. Although not shown in the drawings, drain holes with a diameter of 6 mm were provided on the undersides of the cross bars at both ends.

[0038] Eighteen vertical bars, two through members, and 38 tubular members were assembled using the method shown in Figure 7 to create a fence body 2 measuring 900 mm in length and approximately 1168 mm in width.

[0039] The assembled fence body 2 has no front or back because the through members 41 of the horizontal bars 4 pass through the vertical bars 3. Also, because it is made up of the vertical bars 3 and the horizontal bars 4, which are made up of through members and tubular members, the number of parts is small and assembly is easy.

[0040] The present invention is not limited to the above-described embodiment, and various modifications are possible within the scope of the technical concept thereof. [Explanation of symbols]

[0041] 1. Fence 2 Fence body (lattice exterior material) 3 Vertical crosspiece (first crosspiece) 3a End cap 4. Crosspiece (second crosspiece) 5 pillars 5a End cap 6. The part where the side of the vertical beam and the end face of the cylindrical member come into contact 7 Mounting bracket 9 screws 31 First core material 32 Bulkhead 33 First coating layer 34 1st adhesive layer 35a, 35b side 36a, 36b opening 37 Through hole 41 Through member 42 Cylindrical member 43 Second core material 44 Second coating layer 45 Second adhesive layer

Claims

1. A lattice-shaped exterior material in which first crosspieces are arranged parallel to each other at a predetermined interval and second crosspieces are arranged in a direction intersecting the first crosspieces, The first crosspiece is a first core material made of metal and having a rectangular cylindrical shape; a first coating layer that coats the outer peripheral surface of the first core material and contains a synthetic resin and wood powder; a through hole passing through in a direction intersecting the longitudinal direction, The second crosspiece is a through-member that passes through the through-hole of the first crosspiece and is disposed across two or more of the first crosspieces; a cylindrical second core material made of metal; and a cylindrical member having a second coating layer that coats the outer circumferential surface of the second core material and includes a synthetic resin and wood powder; the tubular member is positioned between the first crosspieces, fitted to cover the outer periphery of the through member, and clamped and fixed between the first crosspieces; Lattice exterior material.

2. the first core material of the first crosspiece includes a partition wall that is parallel to the penetration direction of the through hole, extends in the longitudinal direction of the first core material, and divides an internal space of the first core material; The grid-shaped exterior material according to claim 1.

3. The through member is made of metal. The grid-shaped exterior material according to claim 1.

4. The first crosspiece has a first adhesive layer between the first core material and the first coating layer. The grid-shaped exterior material according to claim 1.

5. the first crosspiece is an integrally extruded member obtained by integrating the first adhesive layer and the first covering layer with the first core material simultaneously with extrusion molding of the first adhesive layer and the first covering layer; The grid-shaped exterior material according to claim 4.

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