Multi-layer exterior cladding

Abstract

By using at least two types of multi-layered exterior materials, we can combine the required design with the necessary strength and other performance characteristics, thereby reducing the amount of expensive materials used and minimizing price increases. [Solution] The multi-layer exterior material 1 of the present invention is characterized by integrating a core material 2, which is a metal plate-like material having molded parts 22 and 23 on the side edges of the face plate portion 21 that can engage with each other, and a plurality of openings 210 provided in the face plate portion 21, and a surface material 3, which is a metal plate-like material having a planar portion 31 having substantially the same cross-section as the face plate portion 21 of the core material 2, and whose side edges extend to the molded parts 22 and 23 of the core material 2, and which is sandwiched when the core materials 2, 2 are engaged with each other.

Description

Technical Field

[0001] The present invention relates to a multi-layer exterior material that combines required design and performance such as strength by using at least two types of multi-layer exterior materials, thereby reducing the usage amount of expensive materials and minimizing price increases.

Background Art

[0002] Conventionally, various exterior materials used for roofs and the like are assumed to have various materials and plate thicknesses, and are variously selected and appropriately used depending on performance and designability in the usage environment. For example, as metal plates, various materials such as steel-based materials such as stainless steel and non-ferrous metal-based materials such as aluminum are known, and similarly, various materials are known for ceramic plates and resin plates. Generally, those having high performance characteristics have correspondingly high prices.

Summary of the Invention

Problems to be Solved by the Invention

[0003] However, the desired conditions and their prices do not necessarily match, and it is often seen that they cannot be adopted as desired. In addition, when laminating a plurality of plates (materials), it is necessary to cure them in a crimped state (pressurized state), so an increase in manufacturing cost was inevitable.

[0004] Therefore, an object of the present invention is to propose a multi-layer exterior material that combines required design and performance such as strength by using at least two types of multi-layer exterior materials, thereby reducing the usage amount of expensive materials and minimizing price increases.

Means for Solving the Problems

[0005] The present invention, proposed in view of the above, relates to a multi-layer exterior material characterized by integrating a core material which is a metal plate-like material having molded portions on the side edges of the face plate portion that can engage with each other and having a plurality of openings in the face plate portion, and a surface material which is a metal plate-like material having a surface portion having substantially the same cross-section as the face plate portion of the core material, with its side edges extending to the molded portions of the core material and being sandwiched between the core materials in an engaged state.

[0006] Furthermore, the present invention also proposes a multi-layer exterior material characterized in that a non-metallic sheet material is disposed on the back surface of the core material as a backing material. [Effects of the Invention]

[0007] The multi-layer exterior material of the present invention is formed by integrating a core material, which has molded portions formed on the side edges of a panel portion having multiple openings, with a surface material that is a metal plate. For example, the openings can be used as parts for fixing fasteners such as screws and bolts, and the molded portions can be used to sandwich adjacent multi-layer exterior materials in an engaged state, making it applicable as an exterior material for various walls, roofs, etc. Moreover, since the surface material is sandwiched in an engaged state with the core materials, a sense of unity is maintained without delamination from the core material. Furthermore, even if the bonding means such as adhesive deteriorates or becomes defective over time, delamination of the surface material from the core material can be minimized. Furthermore, the openings also serve as air vents when the surface material and core material are bonded together, making it possible to mold the material without curing.

[0008] Furthermore, if a non-metallic sheet material is provided as a backing material on the back of the core material, the aforementioned effect (the openings contributing to curing) also applies when integrating this backing material and the core material by adhesive, etc., and since the openings also act as air vents, molding becomes possible without curing. Moreover, the sheet material prevents adhesive from adhering to the molding machine, etc., even if it seeps through the openings to the back, thus enabling molding without curing. [Brief explanation of the drawing]

[0009] [Figure 1] (a) A cross-sectional view showing one embodiment of the connection structure for multi-layer exterior materials of the present invention, and (b) A cross-sectional view showing a part thereof in an enlarged view. [Figure 2] (a) A rear view showing the multi-layer exterior material of the present invention before molding, and (b) A perspective view showing each layer separated. [Best Mode for Carrying Out the Invention]

[0010] The multi-layer exterior material of the present invention is characterized by integrating a core material, which is a metal plate-like material having molded portions on the side edges of the face plate portion that can engage with each other, and having a plurality of openings in the face plate portion, and a surface material, which is a metal plate-like material having a surface portion having substantially the same cross-section as the face plate portion of the core material, with its side edges extending to the molded portions of the core material, and being sandwiched between the core materials in an engaged state. Furthermore, this multi-layered exterior material can be used for various types of walls and roofs, and when used as a roofing material, for example, it can be any type that is commonly used, such as horizontal or vertical roofing.

[0011] The core material is a plate-like material whose material, thickness, etc., are selected after the exterior structure has been constructed, depending on the required strength and various resistances. For example, known metal materials such as surface-decorated steel sheets, laminated steel sheets, plated steel sheets, stainless steel sheets, aluminum alloy sheets, titanium alloy sheets, copper sheets, brass sheets, and lead sheets can be used as appropriate. Furthermore, in the illustrated embodiment described later, a perforated plate is used for the panel portion of this core material that has multiple openings. However, the shape, number, size, and arrangement of the openings are not restricted as long as performance such as strength is ensured. These openings serve as air vents when the surface material and core material are integrated by adhesive or other means, making it possible to mold without curing. These openings can also be used as parts for fixing fasteners such as screws and bolts.

[0012] Furthermore, this core material has a configuration in which molded portions are formed on the side edges of the faceplate portion, which is provided with multiple openings, and these molded portions are not particularly limited as long as they can be engaged with each other. The illustrated embodiment described later shows an example of mutually engageable molded parts, in which one molded part has an engagement groove that is open on the side, and the other molded part has an insertion piece that is inserted into the engagement groove, but this is not particularly limited.

[0013] The surface material is a plate-like material whose color, material, etc., are selected after the exterior structure is constructed, according to the required design (decoration) and waterproofing performance (non-permeable performance), and has a planar portion having substantially the same cross-section as the face plate portion of the core material, with its side edges extending to the molded portion of the core material, and being sandwiched between the core materials in an engaged state. Since the planar portion of this surface material will be the exterior surface, various metal sheet materials or non-permeable sheet materials with decorative properties are used as appropriate, and it is desirable that they be able to be integrally superimposed and connected with adjacent surface materials by various bonding means including adhesive bonding, fusion bonding, welding, etc., or by well-known mechanical fixing, etc. When metal sheet materials are used, both the core material and this surface material are metal sheet materials, but as the core material, a general-purpose, inexpensive, high-strength sheet material of 0.5 mm or more is used, and as the surface material, a thin sheet material of about 0.35 to 0.5 mm is used, which has been treated with a special surface treatment or is expensive, such as titanium. As the non-permeable sheet material, PVC-based, olefin-based plastic sheet materials or other known waterproof sheet materials can be used, or a composite waterproof sheet with a resin layer such as PVC laminated with a core or reinforcing body such as polycloth, felt layer, or glass fiber base fabric may be used, and a composite waterproof sheet with excellent fire resistance (fire prevention) performance is particularly desirable.

[0014] Furthermore, the side edges (side edges, clamping portions) of the planar part of this surface material extend to the molded portion of the core material and are the parts that are clamped when the core materials are engaged with each other. In other words, by clamping, a sense of unity is maintained that prevents delamination from occurring with the core material. In addition, even if the bonding means such as adhesive deteriorates or becomes defective over time, delamination of the surface material from the core material can be minimized. The illustrated embodiment described later shows an example of molded parts that can engage with each other as described above. The clamping portion extends to these molded parts and is clamped within the engagement groove when engaged, so that peeling of the surface material is minimized. Any shape that forms a clamping shape is acceptable, and the ends may engage with the core material (by folding, etc.).

[0015] The core material and the surface material are integrated by bonding, fusion, welding, etc., but bonding using adhesives, etc., may be done by bonding the entire surface or only partially. The core material has multiple openings, and by using a thin metal plate or a non-permeable sheet material as the surface material to be integrated on the surface side, the openings are sealed and rainwater does not penetrate into the interior.

[0016] The core material and the surface material may be bonded substantially to each other by various bonding means, including adhesive bonding, fusion bonding, and welding (however, it is preferable that at least one side is not bonded), i.e., substantially bonded to each other, or they may be partially bonded, for example, in a dot pattern or stripe pattern. However, in order to maintain the integrated state, especially in the case of partial bonding with a small bonding area, it is necessary that the bonding is strong and does not peel off, but this does not limit the specific bonding means. They may also be bonded by heat bonding, heat fusion, etc., but it is desirable that the bonding or fusion is performed with a heat amount greater than that which occurs in nature.

[0017] The illustrated embodiment described later includes molded parts that allow adjacent exterior materials to engage with each other, as well as fixing parts for attaching to the substrate; however, neither the fixing parts nor the molded parts are particularly limited.

[0018] The aforementioned substrate can be used for both new and existing structures, and even in the case of new structures, it is not limited to RC, wood, steel frames, etc., and in the case of existing roofs, it can be used for various types of existing roofs, such as waterproof roofs, metal roofs, and tile roofs. Furthermore, it may also consist of foamed insulation material (such as polystyrene) placed on the surface of the substrate.

[0019] In addition, when a non-metallic sheet material such as a non-woven fabric sheet, a foamed sheet having heat insulation performance, or a glass fiber sheet is disposed on the back surface of the core material as the back surface material, the above-described action (the opening contributes to curing) is also applied when integrating the back surface material and the core material by adhesion or the like. Since the opening also serves as a vent for air, it becomes possible to perform molding without curing. Moreover, since the sheet material can prevent the adhesive from adhering to the molding machine or the like even if it turns from the opening to the back surface, molding without curing becomes possible. As this back surface material (non-metallic sheet material), a non-woven fabric sheet, a foamed sheet having heat insulation performance, a glass fiber sheet, or the like is used.

[0020] Furthermore, the manufacturing method of the multilayer exterior material of the present invention includes a step of integrating the surface material, the core material, and the back surface material into a composite board, and a step of forming a molding portion on at least the core material side edge of the integrated composite board that can engage with other exterior materials. Therefore, various multilayer exterior materials can be manufactured more simply.

Example 1

[0021] As shown in FIG. 1, the multilayer exterior material 1 of Example 1 of the present invention includes a core material 2 provided with engaging portions 22 and 23 that can engage with each other on the side edges of the face plate portion 21, and a plurality of opening portions 210 provided in the face plate portion 21. A surface material 3 is provided with a planar portion 31 having substantially the same cross section as the face plate portion 21 of the core material 2, and its side edges (side edge portions 32 and 33) extend to the engaging portions 22 and 23 of the core material 2 and are sandwiched in the engaged state of the core materials 2 and 2. It is a structure integrated with.

[0022] The core material 2 is a plate-like material whose material, plate thickness, etc. are selected according to the required strength, various resistances, etc. after the exterior structure is constructed, and is a perforated plate made of various metal plate materials having opening portions 210 formed therein. Before its molding, this core material 2 is joined to a surface material (3) in a polymerized state with an adhesive (not shown) as shown in FIG. In addition, FIG. 2 shows a state in which not only the surface material (3) but also the back surface material (4) is polymerized on the core material (2). The state excluding this back surface material (4) is the multilayer exterior material 1 before molding used in FIG. 1.

[0023] On the side edges of the panel portion 21 provided with the plurality of apertures 210 of the core material 2, forming portions 22 and 23 that can be engaged with each other are formed. In the panel portion 21 in this Example 1, by providing slight steps 211 and 211 at the boundary between the side edge portion and the central portion, the central portion is slightly recessed on the back side compared to the side edge portion and is formed in a substantially flat shape.

[0024] The forming portion 22 formed on one side (the right side in FIG. 1) of the panel portion 21 has a configuration including an engaging groove 222 and a concave portion 224, and the forming portion 23 formed on the other side (the left side in FIG. 1) is an insertion piece that is engaged in an inserted manner with the engaging groove 222. This one forming portion 22 is formed by continuously performing folding processing on the side edge of the panel portion 21, and a polymerized protruding portion 221, an extending portion 223 extending laterally, and an engaging groove 222 are formed therebetween. Further, a concave portion 224 that is recessed toward the back side is formed at the tip of the extending portion 223. Note that the aperture 210 shown in FIG. 2 is formed so as to be located substantially at the center of the concave portion 224. In other words, when forming the forming portion 22, the concave portion 224 is formed so that the aperture 210 is located at the center thereof.

[0025] The surface material 3 is a plate-like material whose color, material, etc. are selected according to the required design (decoration), waterproof performance (non-permeable performance), etc. after the exterior structure is constructed. Various thin metal plate materials are used. As shown in FIG. 2, it is formed narrower in width than the core material 2, and a material having elasticity in the thickness direction is used. This surface material 3 has a planar portion 31 having substantially the same cross-section as the panel portion 21 of the core material 2, and its side edges (side edge portions 32 and 33) extend to the forming portions 22 and 23 of the core material 2 and are sandwiched in the engaged state of the core materials 2 and 2.

[0026] These core material 2 and surface material 3 are bonded together almost entirely with an adhesive (not shown) to polymerize and integrate. During molding, the surface material 3 follows the shape-retaining core material 2, with the surface portion 31 following (attaching) to the faceplate portion 21 of the core material 2, and the side edge portions 32 and 33 following (attaching) to the molded portions 22 and 23. However, as mentioned above, the surface material 3 is formed to be narrower than the core material 2, so the side edge portion 32 does not reach the tip of the molded portion 22. Note that the reference numeral 32a in the figure refers to the portion folded back to the back side (clamping portion). Therefore, although the right end of Figure 1(a) shows the molded portion 22 and the side edge portion 32 before connection, the side edge portion 32 is attached to the protruding portion 221 of the molded portion 22, but the side edge portion 32 is not attached (present) to the extended portion 223 or the concave portion 224 beyond that point.

[0027] Then, with the insulation material 5 interposed on the back side, the molded portion 22 of the multi-layer exterior material 1 located on the left and the molded portion 23 of the multi-layer exterior material 1 located on the right are connected so as to engage with each other. In this embodiment 1, first, the fastener 6A is positioned above the concave portion 224 of the multi-layer exterior material 1 located on the left, and is fixed in place with its head hidden in the concave portion 224 and with the waterproofing material 6B interposed. Furthermore, the insulation material 5 has a side end 51 that gradually thins towards the edge and the other side end 52 that butt together to form an insulation layer, and a concave mounting recess 511 is formed on the surface side of the side end 51, so the position of the concave portion 224 can be easily fixed when it is installed.

[0028] Subsequently, the multi-layer exterior material 1 located on the right side is brought forward so as to slide over the insulation material 5 from right to left, and the molded part 23, which is an insertion piece, is engaged with the engagement groove 222 of the fixed molded part 22 by inserting it. As described above, the engagement groove 222 has the side edge portion 32 (clamping portion 32a) of the surface material 3 interposed on the upper side. When the molded portion 23 is inserted therein, the adjacent multi-layer exterior material 1 covers the surface of the fastener 6A, and the side edge portion 33 and the clamping portion 32a are pressed against each other within the engagement groove 222, so that a stable mounting state can be maintained.

[0029] As described above, the multi-layer exterior material 1 of the present invention is formed by integrating a core material 2 and a surface material 3, with molded parts 22 and 23 formed on the side edges of a panel part 21 having a plurality of openings 210. Therefore, the openings 210 can be used as parts for fixing fasteners 6A such as screws and bolts, and the molded parts 22 can be used to sandwich adjacent multi-layer exterior materials 1,1 in an engaged state. This maintains integrity without peeling between the core material 2 and the surface material 3, and can be applied as an exterior material used for various walls, roofs, etc. Furthermore, the opening 210 also serves as an air vent when the surface material 3 and core material 2 are integrated with adhesive, making it possible to mold without curing.

[0030] Furthermore, since the side edges 32 and 33 follow (attach to) the mutually engageable molded parts 22 and 23, when the molded part 23, which is the insertion piece, is engaged with the engagement groove 222, it is held within the engagement groove 222 in the engaged state, thus minimizing peeling of the surface material 3. In particular, the surface material 3 used in this embodiment 1 has elasticity in the thickness direction, so the side edge 32 (clamping portion 32a) and the side edge 33 are attached in a pressure-contact manner, and are held more stably.

[0031] Furthermore, in this embodiment 1, the connection structure of the multi-layer exterior materials 1,1 is such that a fastener 6A is fixed to the recessed portion 224 with a water-stopping material 6B in between, and adjacent multi-layer exterior materials 1 are attached so as to cover the recessed portion 224, thus exhibiting high waterproof performance even against rainwater intrusion from the surface side. Furthermore, the side edges 32, 33 (clamping portions 32a) of the planar portion 31 of the surface material 3 extend to the molded portions 22, 23 of the core material 2, and are the portions that are clamped when the core materials 2, 2 are engaged with each other.

[0032] Figures 2(a) and 2(b) show the surface material (3), core material (2), and back material (4) before molding, but at this point the aforementioned multiple openings 210 have already been formed in the core material (2). Of these, the core material (2) is formed wider than the surface material (3) to form the molded parts (22) and (23), and the surface material (3) is formed wider than the back material (4) to form the side edges (32, 33). [Explanation of Symbols]

[0033] 1. Multi-layer exterior cladding 2 Core material 21 Face plate section 210 Opening part 211 steps 22 Molding section 221 Protrusion 222 Engagement groove 223 Extension 224 Concave part 23 Molding section (2) Core material before molding (22) Molded part before molding (23) Molded part before molding 3 Surface material 31 Planar part 32 Side edge 32a Clamping part 33 Side edge (3) Surface material before molding (32) Side edge before molding (4) Back material before molding 5. Insulation 6A Fasteners 6B Waterproofing material

Claims

1. A core material is a metal plate-like material having mutually interlocking molded parts on the side edges of the faceplate portion, and a plurality of openings provided in the faceplate portion, A multi-layer exterior material characterized by integrating a surface material, which is a metal plate material having a planar portion having substantially the same cross-section as the face plate portion of the core material, with its side edges extending to the molded portion of the core material and being sandwiched between the core materials in an engaged state.

2. The multi-layer exterior material according to claim 1, characterized in that a non-metallic sheet material is disposed on the back surface of the core material as a backing material.

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