Manufacturing methods for building materials

Abstract

To provide a building material and a method for manufacturing the same that can reduce the feeling of heat when in contact with the human body, while also possessing high hardness and wear resistance. [Solution] A method for manufacturing a building material having a three-layer structure comprising a base layer, a porous layer formed on the surface of the base layer and having voids and resin, and a surface layer formed on the surface of the porous layer and having at least resin and being more resin-rich than the porous layer, wherein the porous layer is interposed between the base layer and the surface layer, and the building material and a method for manufacturing the same are provided, wherein the three layers are manufactured by co-extrusion molding. Furthermore, the surface layer may have an embossed surface.

Description

[Technical Field]

[0001] This invention relates to building materials and methods for manufacturing the same. [Background technology]

[0002] Building materials that make up living spaces become hot on the surface when exposed to sunlight for long periods in the summer, or cold when exposed to cold air in the winter. In such cases, it becomes inconvenient when the building materials are too hot to touch directly with the skin, such as when people need to wear some kind of clothing to touch them.

[0003] Patent Document 1 discloses a building material that improves the feel of heat upon contact by providing a porous insulating layer on the surface of the base material. However, such building materials have the problem that while increasing the void ratio in the porous structure improves the heat insulation performance, it also decreases the hardness of the building material. However, the range of void ratios that satisfies both useful heat insulation performance and hardness for a building material has not been clearly defined.

[0004] Patent Document 2 discloses a technique for constructing a porous structure using a chemical blowing agent. Patent Document 2 describes how specifying the blowing ratio of the chemical blowing agent enables the realization of a material and void ratio that achieves both desirable thermal conductivity and hardness. Furthermore, Patent Document 2 discloses a structure in which a skin layer with a higher density than the porous layer is located on the surface of the porous structure layer. It is described that this skin layer increases hardness and makes the material more resistant to wear. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2009-133074 [Patent Document 2] Japanese Patent Publication No. 2014-129511 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] The present invention has been made in view of the above, and aims to provide a building material that can reduce the feeling of heat when in contact with the human body, and has high hardness and wear resistance, as well as a method for manufacturing the same. [Means for solving the problem]

[0007] (1) The present invention provides a method for manufacturing a building material (for example, building material 1, described below) having a three-layer structure comprising a base layer (for example, base layer 2, described below), a porous layer (for example, porous layer 3, described below) formed on the surface of the base layer and having voids and resin, and a surface layer (for example, surface layer 4, described below) formed on the surface of the porous layer and having at least resin and being more resin-rich than the porous layer, wherein the porous layer is interposed between the base layer and the surface layer, and the method for manufacturing the building material is to manufacture the three layers by co-extrusion molding.

[0008] (2) The present invention also provides a method for manufacturing a building material having a three-layer structure comprising a base layer, a porous layer formed on the surface of the base layer and composed of a hollow filler and a resin, and a surface layer formed on the surface of the porous layer and composed of at least a resin and composed of a resin-richer layer than the porous layer, wherein the porous layer is interposed between the base layer and the surface layer, wherein the building material is manufactured as a three-layer structure by co-extruding two layers, the base layer and a mixed layer of the hollow filler and the resin (for example, the mixed layer 34 described later), and simultaneously separating the mixed layer into the porous layer and the surface layer using a flow straightening plate (for example, the flow straightening plate 5 described later) provided in a mold (for example, the mold 6 described later).

[0009] (3) The present invention also provides a method for manufacturing a building material having a three-layer structure comprising a base layer, a porous layer formed on the surface of the base layer and composed of a hollow filler and a resin, and a surface layer formed on the surface of the porous layer and composed of at least a resin and composed of a resin-richer layer than the porous layer, wherein the porous layer is interposed between the base layer and the surface layer, and the building material is manufactured by co-extrusion molding so that the two layers of the mixed layer of the hollow filler and the resin and the base layer are stacked from the bottom in this order.

[0010] (4) The present invention also provides a building material having a three-layer structure comprising a base layer, a porous layer formed on the surface of the base layer and having voids and resin, and a surface layer formed on the surface of the porous layer and having at least resin and being more resin-rich than the porous layer, wherein the porous layer is interposed between the base layer and the surface layer, and the three layers are manufactured by co-extrusion molding.

[0011] (5) The present invention also provides a building material having a three-layer structure comprising a base layer, a porous layer formed on the surface of the base layer and comprising a hollow filler and a resin, and a surface layer formed on the surface of the porous layer and comprising at least a resin and being more resin-rich than the porous layer, wherein the porous layer is interposed between the base layer and the surface layer, and is manufactured by co-extruding two layers, the base layer and the mixed layer of the hollow filler and the resin, and simultaneously separating the mixed layer into the porous layer and the surface layer by a flow straightening plate provided in the mold, thereby creating a three-layer structure.

[0012] (6) The present invention also provides a building material comprising a base material layer, a porous layer formed on the surface of the base material layer and composed of a hollow filler and a resin, and a surface layer formed on the surface of the porous layer and having at least a resin and being richer in resin than the porous layer. The porous layer is interposed between the base material layer and the surface layer, and the building material has a three-layer structure. The building material is manufactured by coextrusion molding such that two layers, namely, a mixed layer of the hollow filler and the resin and the base material layer, are laminated in this order from the bottom.

[0013] (7) In the invention according to (1) to (6), it is preferable that the surface layer is embossed on the surface from the viewpoints of contact warm feeling and anti-slip property.

Advantages of the Invention

[0014] According to the present invention, it is possible to provide a building material and a method for manufacturing the same, which can reduce the warm feeling upon contact with the human body and have high hardness and wear resistance.

Brief Description of the Drawings

[0015] [Figure 1] It is a perspective view showing a building material according to an embodiment of the present invention. [Figure 2] It is a view showing the layer structure of a cross-section of a building material according to a first embodiment of the present invention. [Figure 3] It is a view showing the extrusion molding process of a building material according to a second manufacturing method of the present invention. [Figure 4] It is a view showing the manufacturing process of a building material according to a third manufacturing method of the present invention. [Figure 5] It is a view showing the layer structure of a cross-section of a building material according to a second embodiment of the present invention.

Modes for Carrying Out the Invention

[0016] Hereinafter, embodiments of the present invention will be described, but the present invention is not limited to the following embodiments.

[0017] (First Embodiment) Figures 1 and 2 are diagrams showing the configuration of building material 1 according to the first embodiment of the present invention. The building material 1 of this embodiment is composed of three layers: a base layer 2 having a rectangular tubular hollow portion; a porous layer 3 formed on the surface of the base layer 2 and having voids and resin; and a surface layer 4 having at least resin and formed on the surface of the porous layer 3, and being more resin-rich than the porous layer 3. The building material 1 also has a three-layer structure in which the porous layer 3 is interposed between the base layer 2 and the surface layer 4.

[0018] The base layer 2 is a layer that ensures the bending strength required for the building material 1. The porous layer 3 provides the building material 1 with thermal insulation properties, reducing the feeling of heat when it comes into contact with the human body. The surface layer 4 provides the building material 1 with high surface hardness and abrasion resistance. Note that the shape of the base layer 2 is not limited to a rectangular tubular hollow shape; it can be molded according to the location where the building material 1 will be used and the required strength.

[0019] The material constituting the base layer 2 is not particularly limited; for example, polystyrene, polyethylene, polypropylene, ASA resin, etc., can be used, and it is preferable to select the material such that the building material 1 has appropriate bending strength according to its application. The base layer 2 can also be made lighter and cost-reduced by including a chemical blowing agent or hollow filler.

[0020] The porous layer 3 is composed of a layer having a porous structure. Materials that can be used to constitute the porous layer 3 include, for example, polystyrene, polyethylene, polypropylene, and ASA (acrylonitrile-styrene-acrylic rubber) resin, but polystyrene is particularly preferred. Polystyrene has low thermal conductivity and specific heat, making it particularly excellent at reducing the feeling of heat on contact (see below).

[0021] The pores in the porous layer 3 may be formed using a chemical blowing agent, or by incorporating a hollow filler into the layer. The chemical blowing agent is not particularly limited, and those used in conventional foamed resin molding can be used. For example, inorganic blowing agents such as sodium bicarbonate or ammonium carbonate, or organic blowing agents such as nitroso compounds or azide compounds may be used. Similarly, the hollow filler is not particularly limited, and for example, ceramic balloons or silica balloons can be used.

[0022] The porous layer 3 has a thickness of 1 mm or more and a thermal conductivity of 286 J / (m²). 2 ·s 1 / 2 The structure is configured such that the temperature is below 43°C. This ensures that, for example, even if building materials reach temperatures close to 70°C due to summer sunlight, the skin temperature will not exceed 43°C, allowing contact with the building materials without feeling pain or other discomfort from the heat. Note that, according to the contact thermal sensation test described later, human skin feels pain when its temperature exceeds 43°C.

[0023] Here, thermal osmosis is (thermal conductivity × density × specific heat). 1 / 2 Thermal osmosis is a material property represented by the coefficient of thermal permeability, and the higher the coefficient of thermal permeability, the faster heat transfer occurs upon contact. In other words, materials like metals have a high thermal permeability, so you feel the heat or cold instantly upon contact, but with materials that have a low thermal permeability, it takes time for the heat or cold to be transmitted after contact.

[0024] Therefore, by increasing the foaming ratio of the porous layer 3 to reduce its density, or by using a material with low thermal conductivity and specific heat, such as polystyrene, the thermal permeability can be reduced, thereby reducing the feeling of heat when in contact with the building material 1.

[0025] Furthermore, the foaming ratio of the porous layer 3 is preferably 1.3 to 2.2 times. If the foaming ratio is large, 1.3 times or more, the thermal permeability will decrease, and the feeling of heat on contact can be reduced. If it exceeds 2.2 times, the porous layer 3 will become brittle, and there is a risk that sufficient surface hardness as a building material cannot be obtained. Note that the foaming ratio of the molded body in this invention is equal to the reciprocal of the volume filling rate. Therefore, when the porous layer 3 is formed by containing a hollow filler in the layer, the corresponding foaming ratio can be calculated from the correspondence between foaming ratio [times] = 1 / (volume filling rate [times]).

[0026] The surface layer 4 is composed of at least a resin and is formed to be more resin-rich than the porous layer 3. In the first manufacturing method of the present invention, which will be described later, the material constituting the surface layer 4 can be the same as that of the base layer 2 and the porous layer 3, or a different material can be used. In the latter case, for example, the porous layer 3 may be made of polystyrene and the surface layer 4 may be made of ASA. This makes it possible to achieve both the excellent effect of reducing the contact heat sensation of polystyrene and the solvent resistance of the surface of the ASA resin. Furthermore, since polystyrene and ASA exhibit good adhesion, they are less likely to peel off and the solvent resistance is maintained over a long period of time. In addition, if a resin with excellent abrasion resistance is used for the surface layer 4, the abrasion resistance of the building material 1 can be further improved.

[0027] Furthermore, in the second and third manufacturing methods of the present invention, which will be described later, the same material is used as the main component for the porous layer 3 and the surface layer 4. When polystyrene is used for the porous layer 3 and the surface layer 4, it is preferable to further add a rubber-based filler such as butadiene rubber, acrylic rubber, or silicone-acrylic composite rubber. Polystyrene has low solvent resistance, and cracks tend to occur and propagate on the surface due to solvent adhesion, but the propagation of cracks can be prevented by using a rubber-based filler in combination.

[0028] When a high-density surface layer 4 is formed on the porous layer 3, the thermal permeability of the surface of the building material 1 increases, and the effect of reducing the feeling of heat on contact decreases. Therefore, it is preferable that the surface layer 4 be formed thinly enough so as not to impair the effect of reducing the feeling of heat on contact of the porous layer 3. For example, it is sufficient if a surface layer 4 with a thickness of 0.25 mm is formed on the surface of a porous layer 3 with a thickness of 1 mm.

[0029] Because the surface layer 4 is located on the outermost layer, the voids 31 in the porous layer 3 are not exposed to the surface even when the surface of the building material is polished, preventing the accumulation of dirt in the exposed voids 31 and preventing clothing from getting caught.

[0030] In addition to the above-mentioned substances, additives may be included in any of the base layer 2, porous layer 3, and surface layer 4. For example, they can be composed of wood powder or inorganic fillers.

[0031] <First manufacturing method> Next, the first method for manufacturing the building material 1 of this embodiment will be described. The building material 1 of this embodiment is manufactured by co-extrusion molding.

[0032] In co-extrusion molding, the thermoplastic materials constituting each layer—the base layer 2, the porous layer 3, and the surface layer 4—are melt-mixed in three separate extruders or co-extruders, and then molded bodies of each layer are extruded. The three mixed bodies merge during the extrusion process and are extruded in a stacked state. By cooling this, a three-layer molded body can be obtained. The porous layer 3 can be foamed and extruded by adding a chemical blowing agent during melt-mixing or by adding the chemical blowing agent beforehand when mixing the raw materials (resin, wood flour, etc.), thereby obtaining a molded body layer with a porous structure. Alternatively, the porous layer 3 can have voids by including a hollow filler in the layer.

[0033] The surface of the extruded building material 1 is preferably polished, which improves its aesthetic appeal and, for example, when used as flooring or wall material, is effective in improving the feel against the skin and preventing clothing from snagging. The surface of the surface layer 4 may also have an uneven structure 42. This improves the aesthetic appeal, reduces the number of contact points with the human body depending on the processing method, reduces the feeling of heat upon contact, and also improves slip resistance.

[0034] The building material 1 manufactured by the first manufacturing method is produced efficiently by three-layer co-extrusion molding, and since the thickness of each layer can be controlled by the design of the co-extrusion mold 6, it becomes easy to control the thickness of the surface layer with high precision. This makes it possible to more reliably achieve both a reduction in contact heat sensation and sufficient surface hardness.

[0035] <Second manufacturing method> The second manufacturing method of the present invention is applicable when the porous layer 3 is composed of a hollow filler and the surface layer 4 is composed of a resin.

[0036] Figure 3 is a schematic diagram illustrating the extrusion molding process of building materials according to the second manufacturing method of the present invention. The thermoplastic materials constituting the base layer 2 and the mixed layer 34 of hollow filler and resin are melt-kneaded in two extruders or co-extruders, respectively, and then the molded bodies of each layer are extruded along the extrusion direction 7. The two kneaded bodies merge during the extrusion process and are extruded in a laminated state.

[0037] At this time, a flow straightening plate 5, as shown in Figure 3, is provided in the flow path of the mixed body in the mixed layer 34 within the mold 6 for co-extrusion. The flow straightening plate 5 is a plate-shaped component having multiple slits (not shown) with a width approximately the same as the particle size of the hollow filler, and the hollow filler cannot pass through the slits and is pushed towards the base layer 2 by the flow straightening plate. On the other hand, only the resin passes through the slits, so the mixed layer 34 is separated into a porous layer 3 containing the hollow filler and a surface layer 4 with a higher density than the porous layer 3. By cooling this, a molded body with a three-layer structure can be obtained.

[0038] In Figure 3, all of the hollow filler is schematically contained within the porous layer 3. However, if the surface layer 4 is denser than the porous layer 3, some of the hollow filler may pass through the slits in the rectifier plate and be contained within the surface layer 4. This is because designing the slit width so that the hollow filler cannot pass through completely may cause clogging in the mold 6.

[0039] The building material 1 manufactured by the second manufacturing method is produced with high efficiency by two-layer co-extrusion molding, and the thickness of each layer can be easily controlled with high precision by designing the length of the co-extrusion mold 6 and the rectifier plate 5. This makes it possible to more reliably achieve both a reduction in contact heat sensation and sufficient surface hardness.

[0040] <Third manufacturing method> The third manufacturing method of the present invention is applicable when the porous layer 3 is composed of a hollow filler and the surface layer 4 is composed of a resin.

[0041] Figure 4 is a schematic diagram illustrating the manufacturing process of a building material according to the third manufacturing method of the present invention. The thermoplastic resin materials constituting the base layer 2 and the mixed layer 34 of hollow filler and resin are melt-mixed in two extruders or co-extruders, and then molded bodies of each layer are extruded. The two mixed bodies merge during the extrusion process and are extruded in a stacked state. At this time, the mixed body of the mixed layer 34 is stacked from the bottom, followed by the mixed body of the base layer 2.

[0042] Figure 4(a) shows a laminate of the compound immediately after extrusion. At this point, each compound is not yet solidified. In this state, the hollow filler with low density in the compound of the mixed layer 34 is buoyant and moves towards the upper base material layer. As a result, the compound of the mixed layer 34 separates into a porous layer 3 and a surface layer 4, as shown in Figure 4(b). By cooling and inverting this, a three-layer molded body can be obtained.

[0043] The building material 1 manufactured by the third manufacturing method is produced efficiently by two-layer co-extrusion molding, and since the thickness of each layer can be controlled by the design of the mold 6 for co-extrusion and the amount of hollow filler added, it becomes easy to control the thickness of the surface layer with high precision. This makes it possible to more reliably achieve both a reduction in contact heat sensation and sufficient surface hardness.

[0044] (Second Embodiment) Figure 5 is a diagram showing the layer structure of a cross-section of a building material according to the second embodiment of the present invention. In a second embodiment of the present invention, the building material 1 according to the first embodiment is provided with an embossed surface layer 4. This improves the aesthetic appeal, reduces contact points with the human body depending on the processing method, reduces the feeling of heat upon contact, and also improves slip resistance. Furthermore, similar to surface polishing, the presence of the surface layer 4 prevents the voids 31 in the porous layer 3 from being exposed on the surface, preventing the accumulation of dirt in the exposed voids 31 and preventing clothing from snagging.

[0045] Furthermore, decorative elements can be added to the surface of the building material 1 by attaching a decorative sheet. The presence of the surface layer 4 prevents the voids 31 in the porous layer 3 from being exposed on the surface, ensuring the adhesive strength of the decorative sheet to the building material 1. When attaching a decorative sheet to the surface, care should be taken to consider the effect that the material and physical properties of the sheet have on the thermal permeability of the building material 1.

[0046] The building material 1 of this embodiment is preferably used, for example, in a wooden deck. Since it is prone to becoming hot when exposed to sunlight for long periods of time, and there are many opportunities for contact with it when walking on the deck, reducing the feeling of heat upon contact so as not to hinder walking greatly improves the convenience of the wooden deck.

[0047] The configuration of the building material 1 according to each embodiment of the present invention has been described above. The building material of the present invention will be described in more detail below using examples and comparative examples. [Examples]

[0048] Test specimens of building materials relating to Examples 1-7 and Comparative Examples 1-5 were prepared using the first manufacturing method. Test specimens of building materials relating to Examples 8-10, 12 and Comparative Examples 6-8 were prepared using the second manufacturing method. Furthermore, a test specimen of building material relating to Example 11 was prepared using the third manufacturing method. Contact thermal sensation tests, abrasion tests, stocking snagging tests, and solvent resistance tests were performed on the prepared test specimens, and the foaming ratio, surface hardness, and thermal permeability were also measured. The compositions and evaluation test results for Examples 1-6 and Comparative Examples 1-6 are shown in Table 1 below, and the compositions and evaluation test results for Examples 7-9 and Comparative Examples 7-11 are shown in Table 2 below.

[0049] The contact thermal sensation test was conducted through sensory evaluation and measurement of skin surface temperature after contact. First, the palm of the right hand was placed in contact with the test specimen, which had been left in a 70°C incubator for more than 24 hours beforehand, for 10 seconds. After removing the palm from the test specimen, the palm was turned towards a thermograph and its temperature was measured, with the highest temperature of the palm being used as the measurement value. Subsequently, participants whose palm temperature was measured using thermography were given questionnaires based on the following legend to obtain the results of the sensory evaluation. Test subjects that met evaluation criteria 1-3 were deemed unsuitable because they were experiencing thermal stimulation. (Legend) 1. It's too hot to touch for more than 3 seconds. 2. It's too hot to touch for more than 10 seconds. 3. It can be touched for more than 10 seconds, but causes thermal stimulation (pain). 4. I don't feel any heat irritation, but it's slightly hot. 5. Warm 6. Slightly warm

[0050] The abrasion test was conducted in accordance with JIS K 7204. After 1000 rotations with the abrasion disc in contact with the test specimen, the condition of the decorated surface layer was visually observed, and the evaluation was based on whether the pattern applied to the surface of the building material by the decoration remained after abrasion. The test was conducted under the following conditions: disc rotation speed: 60 rpm, disc type: H22, load: 4.9 N x 2 locations (A: pattern remaining, B: pattern not remaining).

[0051] The snagging test using stockings was conducted by placing the test specimen on the floor, then having the subject walk for one minute while wearing stockings on bare feet, and checking for any tears in the stockings (A: No tears, B: Tears present).

[0052] The solvent resistance test was conducted by applying petroleum benzine to the test specimen, leaving it for one hour, then removing it with water, and visually observing the condition immediately after washing and 24 hours later (A: no deterioration, B: slight deterioration).

[0053] Surface hardness was measured using a Rockwell hardness tester (manufactured by Nakai Seiki Seisakusho Co., Ltd.), and samples with a Rockwell hardness of 100 or higher were considered acceptable. A 12.7mm diameter sphere indenter (R scale, hardness symbol: HRR) was used. A 3.3kg weight was used.

[0054] The thermal conductivity of the foam layer is (thermal conductivity × density × specific heat). 1 / 2 It is calculated by the following formula. Thermal conductivity, specific heat, and density were measured by cutting the foam layer from the molded test specimen and measuring them using the following methods.

[0055] The thermal conductivity λ was calculated using a steady-state method by cutting a foam sample to a diameter of Φ50 mm and a thickness of approximately 1 mm. Specifically, the sample was left to stand with the measured heat flow (q) flowing through it until a steady state was reached, and the temperature difference (ΔΘ) between both ends of the sample was measured. Then, q, ΔΘ, and the sample thickness (Δx) were applied to Fourier's law to calculate λ using the formula λ = (q / ΔΘ) × Δx.

[0056] The density ρ was calculated by measuring the weight W of the foam sample cut out above, then measuring the average thickness of the foam at five points to determine the volume V from Φ, and finally using the formula ρ = W / V.

[0057] Specific heat was measured using a differential scanning calorimeter (DSC, NETZSCH DSC3500 Sirius) under an argon gas atmosphere.

[0058] Furthermore, the foaming ratio of the porous layer was calculated using the following formula. Foaming ratio = (Density of porous layer in foamed state) / (Density of porous layer in non-foamed state)

[0059] [Table 1]

[0060] [Table 2]

[0061] <Examples and comparative examples relating to the first manufacturing method> The test specimens of the building materials in Examples 1 to 5 consist mainly of a porous layer made of PS (polystyrene), with an expansion ratio of 1.3 to 2.2 times. The porous layer of these building materials has a thermal permeability of 286 J / (m²). 2 ·s 1 / 2 The hardness was below 10°C. Furthermore, a surface layer made of PS (polystyrene) was present on its surface. These building materials showed a skin temperature of less than 43°C after 10 seconds of contact in a contact thermal sensation test, and could be touched without causing pain in sensory tests. Additionally, the Rockwell hardness of the building material surface was sufficiently high, indicating sufficient hardness for use as a building material.

[0062] The test specimen of the building material according to Example 6 has a porous layer mainly composed of PP (polypropylene). The thermal osmosis under conditions of a foaming ratio of 1.8 times is 259 J / (m²). 2 ·s 1 / 2 It was (K), and like Examples 1-5, it had a good effect in reducing contact heat sensation and sufficient hardness. Furthermore, the surface layer was mainly composed of PP (polypropylene), and showed high solvent resistance compared to Examples 1-3 and 5, which were composed of PS.

[0063] The test specimen of the building material in Example 7 had the same porous layer structure as in Example 1, but the surface layer was mainly composed of ASA, and showed higher solvent resistance compared to Examples 1-3 and 5, which were composed of PS. By using PS for the porous layer and ASA for the surface layer, it is possible to achieve both the high contact heat sensation reduction effect of PS and the solvent resistance of ASA.

[0064] The test specimens of the building materials according to Comparative Examples 1 and 2 have a foaming ratio of the porous layer of 1 times (not foamed) and 1.2 times. The porous layers of these building materials had a thermal transmittance of 334 J / (m 2 ·s 1 / 2 ·K) or higher. Also, a surface layer made of polystyrene existed on the surface thereof. In these building materials, the skin temperature after 10 seconds of contact in the contact warm feeling test exceeded 43°C, and as a result of the sensory test, pain was also felt.

[0065] The test specimen of the building material according to Comparative Example 3 has a foaming ratio of the porous layer of 2.5 times. This building material has a thermal transmittance of the porous layer of 160 J / (m 2 ·s 1 / 2 ·K), and although the result of the contact warm feeling test was good, the Rockwell hardness was low and it was insufficient as a building material.

[0066] The test specimen of the building material according to Comparative Example 4 has a foaming ratio of the porous layer of 1.5 times and does not have a surface layer. This building material has a thermal transmittance of the porous layer of 250 J / (m 2 ·s 1 / 2 ·K), which is small and the result of the contact warm feeling test was good, but it was weak against abrasion and snagging of stockings occurred.

[0067] The test specimen of the building material according to Comparative Example 5 has a porous layer mainly composed of PE (polyethylene) and a foaming ratio of 1.5 times. This building material has a thermal transmittance of the porous layer of 616 J / (m 2 ·s 1 / 2 ·K), and as a result, a good contact warm feeling reduction effect could not be obtained. Since the porous layer of this building material using PE as the main component has a large thermal conductivity and specific heat, the thermal transmittance is larger than that in the case of using PS.

[0068] The test specimen of the building material according to Example 5 is constructed using a hollow filler instead of a chemical blowing agent in the porous layer. Compared with Examples 1, 4, and 7, which use a chemical blowing agent in the porous layer and have approximately the same foaming ratio and thermal permeability, no significant difference was observed in the results of the contact thermal sensation test. Therefore, the porous layer may be constructed using a hollow filler.

[0069] Furthermore, the test specimen of the building material in Example 4 has a rubber-based filler incorporated into the porous layer. In Examples 1-3, 5 and Comparative Examples 1-4, the porous layer constructed using PS has low thermal conductivity and specific heat, making it suitable for achieving low thermal permeability. However, when PS is exposed on the surface, deterioration is observed on the surface in solvent resistance tests. However, in Example 4, which incorporates a rubber-based filler, crack propagation is prevented, and the surface does not deteriorate easily even after solvent contact.

[0070] <Examples and comparative examples relating to the second and third manufacturing methods> Examples 8-10 and Comparative Examples 6-8 are examples produced by the second manufacturing method of the present invention. Each example consists of a porous layer with the same foaming ratio as Examples 1-3 and Comparative Examples 1-3, and comparable performance was obtained regardless of the manufacturing method when compared from the perspective of each evaluation test. Furthermore, Example 11 is an example produced by the third manufacturing method of the present invention, and although the porous layer consists of the same foaming ratio as Examples 1 and 8, comparable performance was obtained regardless of the manufacturing method.

[0071] Example 12 is an example in which the surface layer 4 was embossed after being manufactured by the second manufacturing method. The porous layer is composed of the same foaming ratio as in Examples 1, 8, and 11, but the embossing on the surface reduces contact with the human body, lowers the skin temperature after contact, and further improves the sensation of warmth upon contact in sensory evaluation.

[0072] The building materials and their manufacturing methods of the present invention have been described in detail above based on the examples and comparative examples. According to the present invention, it is possible to provide building materials that can reduce the feeling of heat when in contact with the human body and have high hardness and wear resistance, as well as a method for manufacturing the same.

[0073] Furthermore, the building material of the present invention can be used not only to reduce the feeling of heat upon contact when the temperature becomes high due to sunlight in the summer, but also to reduce the feeling of coldness upon contact when the temperature becomes low due to cold air in the winter.

[0074] The present invention is not limited to the embodiments described above, and modifications and improvements to the above embodiments are also included in the present invention. [Explanation of Symbols]

[0075] 1 Building materials 2 Base material layer 3. Porous layer 31 Holes 4 Surface layer 34 Mixed layer 5 Rectifier plate 6 molds 7. Extrusion direction

Claims

1. A base layer and A porous layer formed on the surface of the substrate layer, having voids and composed of polystyrene or polypropylene, It consists of a surface layer formed on the surface of the porous layer, having at least polystyrene, acrylonitrile styrene acrylic rubber, or polypropylene, and being more resin-rich than the porous layer. A method for manufacturing a building material having a three-layer structure in which the porous layer is interposed between the base material layer and the surface layer, The building material is manufactured as a three-layer structure by co-extruding the two layers, the base layer and the mixed layer of a chemical blowing agent or hollow filler and the resin, while simultaneously separating the mixed layer into the porous layer and the surface layer using a rectifier plate provided in the mold. A method for manufacturing building materials, wherein the foaming ratio of the porous layer is 1.3 to 2.2 times.

2. A base layer and A porous layer formed on the surface of the substrate layer, having voids and composed of polystyrene or polypropylene, It consists of a surface layer formed on the surface of the porous layer, having at least polystyrene, acrylonitrile styrene acrylic rubber, or polypropylene, and being more resin-rich than the porous layer. A method for manufacturing a building material having a three-layer structure in which the porous layer is interposed between the base material layer and the surface layer, The product is manufactured by co-extrusion molding, stacking two layers—a mixed layer of the hollow filler and the resin, and the base layer—in that order from bottom to top. A method for manufacturing building materials, wherein the foaming ratio of the porous layer is 1.3 to 2.2 times.

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