Construction board material having flexibility, pliability and flame retardancy, method for improving the durability of construction board material, and method for forming and fixing a pattern on the surface of construction board material

Abstract

PURPOSE: To provide a construction plate material having both plasticity and flexibility and a method of manufacturing the construction plate material, a method of semipermanently enhancing durability of the construction plate material, and a method of semipermanently forming and fixing a pattern, characters or a figure on a surface of the construction plate material.CONSTITUTION: There are provided: a manufacturing method of mixing 79-89 wt.% of paste-like synthetic resin having viscosity, 2.5-11.5 wt.% of cement, 1-3 wt.% of a cement accelerator, 2-8 wt.% of aggregate, and 0.7-3 wt.% of fire-resistant inorganic fiber, and shaping and then drying the mixture; and the manufactured construction plate material. Further, there are provided: a method of heating and carbonizing the whole or a part of a surface of the construction plate material to semipermanently improve durability of the plate material; a method of semipermanently forming and fixing a predetermined pattern, characters, or a figure on the surface of the plate material; and the plate material.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] The present invention relates to a building board material that can be used for the exterior and interior walls of buildings such as houses, or for flower beds in gardens, and that has the form of a member called, for example, a tile, panel, board, or plate, and a method for manufacturing the same. [Background technology]

[0002] Conventionally, various building board materials such as tiles, panels, boards, or plates for exterior walls with improved performance such as light weight, flame retardancy, heat insulation, and durability have been developed, proposed, and sold. For example, Patent Document 1 proposes the production of a building board material that is lightweight, low cost, and has excellent flame retardancy and heat insulation properties by mixing a synthetic resin and granular aggregate, adding quicklime (in Patent Document 1, the "quicklime" is added for the purpose of removing the moisture in the process of reacting with the moisture released from the synthetic resin and transforming it into slaked lime), molding, and drying. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-204492 Summary of the Invention [Problem to be solved by the invention]

[0004] However, while conventional building board materials, such as those described in Patent Document 1, may have the properties of being lightweight, low cost, flame retardant, or insulating, they are not flexible (for example, flexibility that allows them to be easily bent (without causing cracks on the surface, etc.) so that when bent at the center of the longitudinal direction, the bending angle between the planes on both sides of the center is 90 degrees or less, even when formed into a plate with a thickness of at least 10 mm) and flexible (for example, flexibility that allows them to be cut with ordinary scissors, etc., even when formed into a plate with a thickness of at least 10 mm).

[0005] Furthermore, although it was possible to temporarily improve the durability of conventional building boards (for a certain period until the paint applied to the exterior wall surface deteriorates and peels off) by applying paint to the surface, it was not possible to improve the durability of building boards semi-permanently. Furthermore, it was possible to temporarily attach specific patterns, letters or figures to the surface of conventional building boards (for a certain period until the paint applied to the exterior wall surface deteriorates and peels off) by applying paint to the surface, but it was not possible to semi-permanently fix specific patterns, letters or figures to the surface of building boards.

[0006] The present invention addresses these problems of the prior art and aims to provide a building board that is flexible enough to be easily bent (without causing surface cracks) at the longitudinal center of a board at least 10 mm thick so that the bending angle between the planes on both sides of the center is 90 degrees or less, even when the board is formed into a board at least 10 mm thick, and that is both flexible enough to be cut with ordinary scissors, even when formed into a board at least 10 mm thick, and flame-retardant, as well as a method for manufacturing the same. Another object of the present invention is to provide a method for semi-permanently improving the durability of building boards and to provide building boards with semi-permanently improved durability. Another object of the present invention is to provide a method for forming a pattern on the surface of a building board and semi-permanently fixing the pattern, and to provide building boards with the pattern formed and semi-permanently fixed on the surface. [Means for solving the problem]

[0007] In order to solve the above problems, the present invention provides a method for manufacturing a building board that is flexible, pliable, and flame-retardant, which is characterized by mixing 79 to 89 weight percent of a viscous paste-like synthetic resin, 2.5 to 11.5 weight percent of cement, 1 to 3 weight percent of a cement quick-setting admixture, 2 to 8 weight percent of aggregate, and 0.7 to 3 weight percent of inorganic fiber, placing the mixture in a predetermined mold, shaping it, and drying it. The method for producing a building board according to the present invention involves mixing 79 to 89% by weight of a viscous paste-like synthetic resin, 2.5 to 11.5% by weight of cement, 1 to 3% by weight of a cement quick-setting admixture, 2 to 8% by weight of aggregate, and 0.7 to 3% by weight of inorganic fiber, and then molding and drying the mixture in a predetermined mold. This method can provide a building board that is flexible (highly flexible; it does not have the ability to return to its original shape) so that when the board is formed into a board with a thickness of at least 10 mm, it can be bent or twisted so that the bending angle between the flat surfaces on both sides of the central portion in the longitudinal direction (more precisely, the angle (acute angle) between the flat surfaces imaginarily extended from each of the flat surfaces) is 90 degrees or less, even when formed into a board with a thickness of at least 10 mm; it is also flexible enough to be cut with ordinary scissors or the like, even when formed into a board with a thickness of at least 10 mm; and is flame-retardant.

[0008] In addition, the building board material of the present invention, which has both flexibility and fire retardancy, is characterized by being composed of a mixture of 82 to 90 weight % flexible synthetic resin formed by drying a viscous paste-like synthetic resin, 2.5 to 11.5 weight % cement, 2 to 8 weight % aggregate, and 0.7 to 3 weight % inorganic fiber. Furthermore, the building board material according to the present invention is a mixture of 82 to 90% by weight of flexible synthetic resin formed by drying a viscous paste-like synthetic resin, 2.5 to 11.5% by weight of cement, 2 to 8% by weight of aggregate, and 0.7 to 3% by weight of inorganic fibers, and is flexible enough (highly flexible; it does not have the ability to return to its original shape) that when formed into a board with a thickness of at least 10 mm, it can be bent or twisted so that the bending angle between the flat surfaces on both sides of the central part in the longitudinal direction (more precisely, the angle (acute angle) between the flat surfaces formed by imaginary extensions of each of the flat surfaces) is 90 degrees or less, even when formed into a board with a thickness of at least 10 mm, and is also flame-retardant.

[0009] Furthermore, the method for improving the durability of building boards according to the present invention involves heating and carbonizing the entire surface of a building board (particularly a building board that contains a flexible synthetic resin formed by drying a viscous paste-like synthetic resin, as described above, and that has both flexibility and fire resistance), thereby semi-permanently improving the durability of the building board.

[0010] Furthermore, the construction board material with enhanced durability according to the present invention is a construction board material whose durability has been semi-permanently improved by heating and carbonizing the entire surface of the construction board material (particularly, construction board material that contains a flexible synthetic resin formed by drying a viscous paste-like synthetic resin as described above and has flexibility, pliability, and flame retardancy).

[0011] Furthermore, the method of forming and fixing a pattern on a building board according to the present invention involves heating and carbonizing the surface of a building board (particularly a building board that contains a flexible synthetic resin formed by drying a viscous paste-like synthetic resin, as described above, and that has both flexibility and fire resistance), in a manner that corresponds to a predetermined pattern, thereby forming and semi-permanently fixing the predetermined pattern on the surface of the board.

[0012] Furthermore, the building board material on which a pattern has been formed and fixed according to the present invention is a building board material in which the surface of the building board material (particularly, a building board material which contains a flexible synthetic resin formed by drying a viscous paste-like synthetic resin as described above and which has both flexibility and pliability and flame retardancy) is heated and carbonized in a manner that corresponds to (follows) the specified pattern, thereby forming the specified pattern on the surface and semi-permanently fixing it. [Effects of the Invention]

[0013] As described above, in the manufacturing method of the building board according to the present invention, a viscous paste-like synthetic resin is mixed in the proportions of 79 to 89% by weight, cement in the proportions of 2.5 to 11.5% by weight, cement quick-setting admixture in the proportions of 1 to 3% by weight, aggregate in the proportion of 2 to 8% by weight, and inorganic fiber in the proportion of 0.7 to 3% by weight, and the mixture is poured into a predetermined mold, shaped, and dried. This results in a new building board that has not existed before, that is, when formed into a board shape having a thickness of at least 10 mm (for the exterior walls of buildings, etc., board materials such as tiles are required to have a thickness of at least 10 mm in order to have sufficient strength for easy handling by workers during construction and long-term durability after construction). It will now be possible to manufacture building boards that have the flexibility (great bendability; they do not have the ability to return to their original shape) to be bent or twisted so that when folded at the center in the longitudinal direction, the bending angle between the flat surfaces on either side of the center (more precisely, the angle (acute angle) between the flat surfaces when each of the flat surfaces is virtually extended) is 90 degrees or less, even if the board is at least 10 mm thick), and that have the flexibility (including the elasticity and flexibility of the surface) to be cut with ordinary scissors, etc., even when formed into a board with a thickness of at least 10 mm, and are flame retardant.

[0014] The flexibility and pliability of the building boards produced by the manufacturing method of the present invention are imparted primarily by the inclusion of the synthetic resin in the above-mentioned blending ratio (note that the flexibility is also contributed by the inorganic fibers). The flame retardancy of the building boards produced by the manufacturing method of the present invention is imparted primarily by the inclusion of the cement in the above-mentioned blending ratio. The "shape retention that prevents excessive flexibility and pliability (which would make the building boards difficult to handle on-site)" of the building boards produced by the manufacturing method of the present invention is also imparted primarily by the inclusion of the cement in the above-mentioned blending ratio. Furthermore, the aggregate contained in the building boards produced by the manufacturing method of the present invention in the above-mentioned blending ratio is primarily responsible for the lightweight nature of the building boards, and the inorganic fibers contained in the building boards produced by the manufacturing method of the present invention in the above-mentioned blending ratio are primarily responsible for the building boards' resistance to cracking (shattering) even when bent. Furthermore, the inclusion of the cement quick-setting admixture in the above-mentioned blending ratio contributes to improving the efficiency (time reduction, etc.) of the manufacturing process according to the manufacturing method of the present invention.

[0015] Furthermore, in the building board material according to the present invention, a flexible synthetic resin obtained by drying a viscous paste-like synthetic resin is contained and mixed in a ratio of 82 to 90% by weight, cement in a ratio of 2.5 to 11.5% by weight, aggregate in a ratio of 2 to 8% by weight, and inorganic fiber in a ratio of 0.7 to 3% by weight. Therefore, when formed into a board having a thickness of at least 10 mm (for the outer walls of buildings, etc., it is common for board materials such as tiles to have a thickness of at least 10 mm or more in order to have strength that allows workers to handle them easily during construction and long-term durability after construction, etc., and a board thickness of less than 10 mm is not suitable for individual applications. It will be possible to provide a building board that has flexibility (great bendability; it does not have the ability to return to its original shape) that allows it to be bent or twisted so that when bent at the center in the longitudinal direction, the bending angle between each plane on either side of the center (more precisely, the angle (acute angle) between each plane obtained by imaginarily extending each of the above planes) is 90 degrees or less, even if the board is made into a board with a thickness of at least 10 mm (including the elasticity and flexibility of the surface), and is flame-retardant.

[0016] The flexibility and pliability of the building board of the present invention are imparted primarily by the inclusion of the synthetic resin in the above-mentioned blending ratio (note that the flexibility is also contributed by the inorganic fibers). The flame retardancy of the building board of the present invention is imparted primarily by the inclusion of the cement in the above-mentioned blending ratio. The "shape retention that prevents the building board from becoming excessively flexible and pliable (becoming floppy) and making it difficult to handle on-site" of the building board of the present invention is also imparted primarily by the inclusion of the cement in the above-mentioned blending ratio. Furthermore, the aggregate contained in the building board of the present invention in the above-mentioned blending ratio is primarily responsible for the lightweight nature of the building board, and the inorganic fibers contained in the building board of the present invention in the above-mentioned blending ratio are primarily responsible for the building board's resistance to cracking (breaking) even when bent.

[0017] As mentioned above, even when a building board manufactured by the manufacturing method of the present invention or a building board according to the present invention is formed into a plate shape with a thickness of at least 10 mm, when it is bent at the center in the longitudinal direction, it has the flexibility (great bendability; it does not have the property of returning to its original shape) to be bent or twisted so that the bending angle between the planes on either side of the center (more precisely, the angle (acute angle) between the planes obtained by imaginarily extending each of the planes) is 90 degrees or less, making it possible to easily and stably attach it to, for example, a curved exterior wall surface or the corner of an exterior wall. It is possible that a "thin building board merely about 5 mm thick" (containing synthetic resins, etc.) with the above-described "flexibility to bend or twist so that the planes on either side of the central portion are 90 degrees or less" may have existed in the past (although it is unclear at this time whether such a board existed). However, such a "thin building board merely about 5 mm thick" would not be strong enough for workers to easily handle it during construction, such as for the exterior walls of buildings, or provide long-term durability after construction, making it virtually unpractical and unmarketable. Thus, a building board with a "thickness of at least 10 mm" that meets the requirements for strength to be easily handled during construction and long-term durability after construction, and the above-described "flexibility to bend or twist so that the planes on either side of the central portion are 90 degrees or less," as described in the present invention, and a manufacturing method thereof, have not previously existed.

[0018] Furthermore, as mentioned above, even when the building board material manufactured by the manufacturing method of the present invention or the building board material of the present invention is formed into a plate shape with a thickness of at least 10 mm (for the exterior walls of buildings, etc., tiles and other board materials generally require a thickness of at least 10 mm in order to be strong enough to be easily handled during construction and to have long-term durability after construction), it has flexibility (including the elasticity and flexibility of the surface) that allows it to be cut with ordinary scissors or the like, and therefore, for example, at a construction site, workers can easily cut it with scissors or the like to the size and shape appropriate for the area to be constructed, which is very convenient, and even if it is accidentally dropped from above during construction work on a house or the like, the impact on the human body is minimal (since the surface is elastic and flexible, there is less impact and damage when it hits the human body or the like compared to conventional building board materials with hard surfaces). It is possible that, for example, thin building boards merely about 5 mm thick (containing synthetic resins, etc.) with the above-mentioned flexibility to be cut with ordinary scissors, etc., have existed in the past (although it is unclear at this time whether such boards existed). However, such thin building boards simply about 5 mm thick would not be strong enough for workers to easily handle them during construction, or durable enough for long periods after construction, making them virtually useless and unmarketable. Thus, there have been no building boards or manufacturing methods for the present invention that are "at least 10 mm thick" and capable of meeting the requirements for strength to be easily handled during construction and durability for long periods after construction, and that have the above-mentioned flexibility to be cut with ordinary scissors, etc. (including surface elasticity and flexibility).

[0019] Furthermore, as described above, the building boards manufactured by the manufacturing method of the present invention or the building boards of the present invention contain a predetermined proportion or more of cement, and therefore have flame retardant properties, and can be used safely on the exterior walls of buildings, etc.

[0020] Furthermore, in the method for increasing the durability of building boards according to the present invention, the entire surface of the building board (particularly, the building board, which contains a soft synthetic resin formed by drying a viscous paste-like synthetic resin and has flexibility, pliability, and flame retardancy, as described above, is preferable) is heated and carbonized, thereby making it possible to improve the durability of the building boards semi-permanently.

[0021] Furthermore, in the construction board material with enhanced durability according to the present invention, the entire surface of the construction board material (particularly, construction board material that contains a soft synthetic resin formed by drying a viscous paste-like synthetic resin as described above and has flexibility, pliability and flame retardancy) is heated and carbonized, making it possible to provide construction board material with significantly improved durability on a semi-permanent basis.

[0022] Furthermore, in the method of forming and fixing a pattern on a building board according to the present invention, the surface of the building board (particularly, a building board that contains a soft synthetic resin formed by drying a viscous paste-like synthetic resin and has flexibility, pliability, and flame retardancy, as described above, is preferably heated and carbonized in accordance with the desired pattern, thereby making it possible to form the desired pattern on the surface of the building board and fix it semi-permanently.

[0023] Furthermore, in the building board material on which a pattern is formed and fixed according to the present invention, the surface of the building board material (particularly, a building board material that contains a soft synthetic resin formed by drying a viscous paste-like synthetic resin as described above and has flexibility, pliability, and flame retardancy is preferable) is heated and carbonized in a manner that corresponds to (follows) the specified pattern, making it possible to provide a building board material on whose surface the specified pattern is formed and fixed semi-permanently. [Brief explanation of the drawings]

[0024] [Figure 1A]FIG. 2 is a diagram for explaining (a part of) the method for manufacturing a building board according to the first embodiment of the present invention. [Figure 1B] 1 is a diagram for explaining (a part of) the manufacturing method of the building board according to the present Example 1. FIG. [Figure 1C] FIG. 2 is a diagram illustrating the building board according to the first embodiment (in a bent state). [Figure 2] FIG. 10 is a diagram illustrating a building board (in a bent state) according to a second embodiment of the present invention. [Figure 3] FIG. 10 is a diagram illustrating a building board according to a third embodiment of the present invention (in a state of being cut with scissors). [Figure 4A] FIG. 10 is a diagram illustrating a building board (in a bent state) according to a fourth embodiment of the present invention. [Figure 4B] FIG. 10 is a diagram for explaining a building board according to the fourth embodiment (in a state of being cut with scissors). [Figure 4C] FIG. 10 is a diagram illustrating a building board according to Example 4 (with a lighter flame applied to the surface). [Figure 5A] FIG. 10 is a diagram illustrating a building board (in a bent state) according to a fifth embodiment of the present invention. [Figure 5B] FIG. 10 is a diagram for explaining a building board according to the fifth embodiment (in a state of being cut with scissors). [Figure 5C] FIG. 10 is a diagram for explaining the building board according to Example 5 (in a state where the flame of a lighter is applied to the surface). [Figure 6] FIG. 10 is a diagram showing an example of a method for forming and fixing a pattern, letter or figure on the surface of a building board in Example 7 of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0025] Example 1 Hereinafter, a first embodiment of the present invention will be described with reference to the drawings. Figures 1A and 1B are diagrams illustrating a manufacturing method for a building board according to the first embodiment of the present invention. In the manufacturing method of this first embodiment, as shown in Figure 1A, first, 79 to 89 wt%, for example, about 80 wt%, of a viscous paste-like synthetic resin, 2.5 to 11.5 wt%, for example, about 7 wt%, of cement, 0.7 to 3 wt%, for example, about 3 wt%, of flame-retardant inorganic fiber, 2 to 8 wt%, for example, about 8 wt%, of granular aggregate (e.g., artificial aggregate such as perlite) having a particle size of about 0.3 to 5 mm (more preferably, about 0.5 to 2 mm), and 1 to 3 wt%, for example, about 2 wt%, of a cement quick-setting admixture are mixed (and, if necessary, a desired pigment is added) in a mixing vessel and stirred and mixed by an electric mixer or the like. Thereafter, as shown in FIG. 1B, the mixed material is poured into a mold for molding into a size and shape suitable for use as a tile or other board material for the exterior walls of a house (for example, a rectangular parallelepiped shape with a length of about 60 mm, a width of about 200 mm, and a thickness of at least about 10 mm), molded, dried, and then removed from the mold.

[0026] Among the materials to be mixed, the viscous paste-like synthetic resin is the main material that provides flexibility (the ability to bend or twist) and the flexibility to be cut with ordinary scissors to the building board material of this Example 1. The degree of flexibility and flexibility can be adjusted mainly by changing the mixing and blending ratio of the viscous paste-like synthetic resin and cement within the overall material.

[0027] The viscous paste-like synthetic resin may be, for example, a known synthetic resin such as acrylic resin or epoxy resin, or a material based (main ingredient) on such a synthetic resin. Examples of such commercially available paints, exterior finishing materials, or primers include the paint "Aqueous Urethane Varnish" (trademark) manufactured by Asahipen Co., Ltd. (4-1-12 Tsurumi, Tsurumi-ku, Osaka), the primer "Nippe Aqueous Cationic Sealer" (trademark) manufactured by Nippon Paint Co., Ltd. (4-7-16 Minamishinagawa, Shinagawa-ku, Tokyo), the exterior elastic finishing material "DAN Fresh" (trademark) made primarily from acrylic resin and manufactured by Nippon Paint Co., Ltd. (4-7-16 Minamishinagawa, Shinagawa-ku, Tokyo), the exterior elastic finishing material "New Top Screen" (trademark) manufactured by S.T. Kaken Co., Ltd. (3-5-25 Nakahozumi, Ibaraki-shi, Osaka), and the exterior wall elastic coating material "EC-5000PCM" (trademark) manufactured by Astec Paint Co., Ltd. (4-2-8 Beppukita, Shime-machi, Kasuya-gun, Fukuoka). In order to ensure flame retardancy in building boards, it is necessary or desirable to use water-based paints, exterior finishing materials, primers, etc. rather than oil-based paints.

[0028] Among the materials to be mixed, cement is a powder material that provides the resulting building board with shape retention, hardness, and strength (according to the inventor's experiments, without adding cement, the manufactured building board was unable to maintain its shape and ended up collapsing). The shape retention, hardness, and strength can be adjusted by varying the mixing and blending ratio of the cement within the overall material. This cement can be any of a variety of commercially available cements, such as those manufactured by Mitsubishi Materials Corporation (3-2-3 Marunouchi, Chiyoda-ku, Tokyo).

[0029] The flame-retardant inorganic fibers in the mixed materials are used to impart flexibility, high bending strength, and pliability to the building board (such as the rectangular parallelepiped tile) manufactured in Example 1, so that it will not break (sever) or crack even when bent at least at an angle of approximately 90 degrees or less between the planes on both sides of the center. The degree of flexibility, high bending strength, and pliability can be adjusted by varying the mixing ratio of the flame-retardant inorganic fibers in the overall material. Examples of such flame-retardant inorganic fibers include commercially available flame-retardant inorganic fibers, such as glass fiber (or carbon fiber) manufactured by Nitto Boseki Co., Ltd. (2-4-1 Kojimachi, Chiyoda-ku, Tokyo). The length of each of these inorganic fibers is preferably approximately 1 to 10 mm, and more preferably 2 to 4 mm.

[0030] Among the materials mixed, the granular aggregate, more preferably the granular artificial aggregate, is used to impart lightweight, heat-insulating, and flame-retardant properties to the resulting building board of Example 1. The degree of the weight-saving effect can be adjusted by varying the mixing ratio of the artificial aggregate within the overall material. Examples of such artificial aggregate include various commercially available artificial aggregates (made from artificial minerals, etc.), such as "Mitsui Perlite" (trademark) manufactured by Mitsui Mining & Smelting Co., Ltd. (1-11-1 Osaki, Shinagawa-ku, Tokyo). While artificial aggregate is preferred, natural materials such as sand may also be used.

[0031] Furthermore, among the materials to be mixed, the cement quick-setting admixture is used in the process of producing the building board of Example 1 to improve work efficiency during production (e.g., shorten the time of the production process) by allowing the mixed materials to dry relatively quickly after being placed in a mold (in the inventor's experiments, without using this cement quick-setting admixture, the time required to dry and harden the mixed materials to a certain extent after being placed in a mold was extremely long, taking several days or more, resulting in extremely poor work efficiency). As this cement quick-setting admixture, various cement quick-setting admixtures already widely available on the market (e.g., admixtures mainly composed of calcium chloride, sodium silicate, etc.), such as those manufactured by Toyo Materan Co., Ltd. (1512 Akechi-cho, Kasugai City, Aichi Prefecture), can be used.

[0032] As shown in Figure 1B, in this Example 1, the materials mixed in the above proportions are placed in molds having the size and shape of building boards such as tiles, or in large-area flat molds, and then dried naturally or in a drying device. Once dried, the materials are removed from the molds if they were placed in the molds. If they were placed in flat molds, they are removed from the flat molds and cut to the specified size. The boards removed from the molds (and further cut in the case of flat molds) are then subjected to finishing operations such as deburring, necessary surface decoration, coloring, and drawing to produce building boards.

[0033] FIG. 1C(a) is a perspective view showing the building board according to Example 1 manufactured as described above. The building board manufactured by molding and drying the materials mixed in the above proportions contains, for example, about 81% by weight of viscous paste-like synthetic resin, about 7.5% by weight of cement, about 3% by weight of inorganic fiber, and about 8.5% by weight of aggregate (the cement quick-setting admixture disappears due to a chemical reaction during the manufacturing process shown in FIGS. 1A and 1B). Even when this building board was bent around the central portion 1a of the planar rectangular building board 1 so that the angle between the two planes approaches approximately 90 degrees or less (from the initial angle of approximately 180 degrees to approximately 90 degrees or less), as shown in FIGS. 1C(b) and 1C(c), it did not break, and no cracks or other defects were observed on the surface of the central portion 1a or the like.

[0034] Example 2 Next, Example 2 of the present invention will be described with reference to FIG. 2. FIG. 2(a) is a perspective view showing a building board according to Example 2 of the present invention, which was manufactured by mixing, molding, drying, and other processes using substantially the same materials as those used in Example 1. However, Example 2 used a different known paste-like synthetic resin as the main material, and added a different known pigment than that used in Example 1. Similarly to Example 1, the building board according to Example 2 manufactured in this manner did not break when folded around the longitudinal center portion 2a of the flat rectangular building board 2 as shown in FIG. 2(b), and even when folded so that the angle between the planes on both sides of the center portion 2a changed from 180 degrees to less than 90 degrees as shown in FIG. 2(c). Furthermore, no cracks or other defects were observed on the surface of the center portion 2a or the like.

[0035] Example 3 Next, Example 3 of the present invention will be described with reference to FIG. 3. FIG. 3(a) is a perspective view showing a building board according to Example 3 of the present invention, which was manufactured by mixing, molding, drying, and other processes using substantially the same materials as those in Example 1 described above in the same proportions. However, Example 3 was manufactured using a known paste-like synthetic resin different from those used in Examples 1 and 2 as the main material, and a known pigment different from those used in Examples 1 and 2 was added. The inventors conducted experiments on Example 3 to determine whether it had flexibility that allowed it to be cut with ordinary scissors. Specifically, FIGS. 3(b) and 3(c) are perspective views showing the building board 3 of Example 3 in the middle of being cut with scissors 4, and FIG. 3(d) is a perspective view showing the building board 3 after being cut with scissors. In FIG. 4(d), reference symbol 3a indicates the cut surface of the building board 3 after cutting. As described above, the building board 3 according to this Example 3 is mainly composed of the viscous paste-like synthetic resin, and therefore has great flexibility overall, so that workers can easily cut and process it into any size and shape with scissors 4 or the like at the work site during construction of a building, etc. Note that when cutting the building board according to this Example 3 with scissors or the like, there is no need to use special scissors or other tools, and it can be easily cut and processed simply by using cutting means such as ordinary scissors (relatively large scissors are preferable) found in ordinary stationery, etc.

[0036] Example 4 Next, Example 4 of the present invention (an example in which the blending ratio of cement to synthetic resin is relatively small) will be described with reference to Figures 4A to 4C. As Example 4 of the present invention, the inventors manufactured a building board according to Example 4 of the present invention by a manufacturing method in which a mixture of approximately 89% by weight of viscous paste-like synthetic resin, approximately 2.5% by weight of cement, approximately 1% by weight of cement quick-setting admixture, approximately 6% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fiber was mixed, and then molded and dried (see Figures 1A and 1B).

[0037] In this Example 4, the viscous paste-like synthetic resin used was "EC-5000PCM" (trademark), an elastic exterior wall coating material made primarily of acrylic resin and manufactured by Astec Paint Co., Ltd. (4-2-8 Beppukita, Shime-machi, Kasuya-gun, Fukuoka Prefecture, Japan) (however, the present invention is not limited to this). In addition, in this Example 4, the cement, cement quick-setting admixture, aggregate, and flame-retardant inorganic fiber used were the same as those used in Example 1.

[0038] The building board material of Example 4 manufactured as described above is composed of approximately 90% by weight of flexible synthetic resin formed by drying a viscous paste-like synthetic resin, approximately 2.5% by weight of cement, approximately 6% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fiber.

[0039] Next, the flexibility (bendability) of the building board according to Example 4 manufactured as described above was confirmed as follows. First, it was confirmed that the building board 14 according to Example 4 had a thickness of at least 10 mm, as shown by the ruler 21 in Figures 4A(a) and 4A(b). (Typically, exterior wall materials such as tiles used on the exterior walls of buildings are required to have a thickness of 10 mm or more for ease of handling during construction and long-term durability after construction, except in cases where "products in which multiple panels are pre-attached to a single sheet" are attached to the exterior wall. Therefore, in reality, there is almost no demand for building boards with a thickness of less than about 10 mm as exterior wall materials such as independent tiles used individually in the construction of building exterior walls.)

[0040] As shown in Figures 4A(a) and 4A(b), despite the thickness of the building board 14 of Example 4 being at least 10 mm, the building board 14 of Example 4 was confirmed to have sufficient flexibility to be easily bent with very little force, even by an ordinary person, so that the planes on both sides of the bent portion (central portion 14a) of the building board 14 changed from the initial 180-degree angle to a nearly parallel state (approximately 0 degrees) with only a very small force. (Note that Example 4 does not have the elasticity to immediately return to its original shape after the bent portion is released.) Furthermore, even when the building board 14 of Example 4 was bent to a nearly parallel state (approximately 0 degrees) with only a very small force, as described above, no cracks or other damage occurred on the surface of the longitudinal central portion 14a of the building board 14, which was the center of the bending, as shown in Figure 4A(c). Thus, in the building board material of Example 4, the flexible synthetic resin formed by drying a viscous paste-like synthetic resin is approximately 90% by weight, and the cement is approximately 2.5% by weight, so the synthetic resin to cement ratio is relatively high, which gives the material great flexibility (bendability).

[0041] Next, the flexibility of the building board according to Example 4 manufactured as described above was confirmed as follows. First, it was confirmed that the building board 14 according to Example 4 had a thickness of at least 10 mm, as shown by the ruler 21 in Fig. 4B(a). (Typically, exterior wall materials such as tiles used on the exterior walls of buildings are required to have a thickness of about 10 mm or more for ease of handling during construction and durability after construction, except in cases where "products in which multiple panels are pre-attached to a single sheet" are attached to the exterior wall. Therefore, in reality, there is almost no demand for building boards with a thickness less than about 10 mm as exterior wall materials such as independent tiles that are installed individually one by one in the construction of building exterior walls.)

[0042] Thus, although the building board 14 according to Example 4 is thick, at least 10 mm, when an attempt is made to cut the longitudinal center portion of the board with scissors 22 commonly used by an ordinary person, it can be cut extremely easily with a relatively small force, as shown in Figure 4B(b). As described above, the building board according to Example 4 has a relatively high blend ratio of synthetic resin to cement, with a flexible synthetic resin formed by drying a viscous paste-like synthetic resin at about 90% by weight and cement at about 2.5% by weight, which gives the board great flexibility.

[0043] Furthermore, the flame retardancy of the building board according to Example 4 manufactured as described above was confirmed as follows. That is, even when the surface of the building board 14 according to Example 4 was exposed to a flame 23a from a commercially available lighter 23 commonly used by ordinary people in their daily lives, as shown in FIGS. 4C(a)-(c), the surface did not burn, and no burning odor was emitted from the surface. This confirmed that the building board 14 according to Example 4 has the flame retardancy required for tiles, etc., to be used in the construction of building exterior walls, etc. As described above, the building board according to Example 4 contains a certain blend ratio of cement to synthetic resin, i.e., about 90 wt % of flexible synthetic resin formed by drying a viscous paste-like synthetic resin, and about 2.5 wt % of cement, thereby imparting good flame retardancy.

[0044] As described above, in Example 4, a manufacturing method was carried out in which a mixture of approximately 89% by weight of viscous paste-like synthetic resin, approximately 2.5% by weight of cement, approximately 1% by weight of cement quick-setting admixture, approximately 6% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fibers was mixed, and the mixture was then molded and dried. This resulted in the production of a building board material consisting of approximately 90% by weight of soft synthetic resin, which was formed by drying the viscous paste-like synthetic resin, approximately 2.5% by weight of cement, approximately 6% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fibers, which can achieve the following effects.

[0045] That is, even when the building board 14 manufactured by the manufacturing method of this Example 4 (or the building board 14 according to this Example 4) is formed into a plate having a thickness of at least 10 mm (for the exterior walls of buildings, etc., plates such as tiles as independent products generally require a thickness of at least 10 mm because of the need for strength sufficient for easy handling during installation and durability after installation, and plates less than 10 mm thick as independent tiles that are installed one by one have almost no marketability), when an attempt is made to bend it at the longitudinal center portion 14a, it has flexibility (great bendability; it does not have the ability to return to its original shape) that allows it to be easily bent or twisted so that the planes on both sides of the center portion 14a are approximately parallel to each other (approximately 0 degrees) with only an extremely weak force for an ordinary person, and it has flexibility (including surface elasticity and flexibility) that allows it to be cut with ordinary scissors, etc., even when formed into a plate having a thickness of at least 10 mm, and it is flame retardant.

[0046] The flexibility and pliability of the building board 14 according to Example 4 are primarily imparted by the inclusion of the synthetic resin in the above-mentioned blending ratio (note that the flexibility is also contributed by the inorganic fibers). The flame retardancy of the building board 14 according to Example 4 is primarily imparted by the inclusion of the cement in the above-mentioned blending ratio. The "shape retention that prevents the building board 14 according to Example 4 from becoming excessively flexible and pliable (becoming floppy) and making it difficult to handle on-site" is also primarily imparted by the inclusion of the cement in the above-mentioned blending ratio. Furthermore, the aggregate contained in the building board 14 according to Example 4 in the above-mentioned blending ratio primarily contributes to the lightweight nature of the building board, and the inorganic fibers contained in the building board 14 according to Example 4 in the above-mentioned blending ratio primarily contribute to the building board's resistance to cracking (shattering) even when bent. Furthermore, in the manufacturing method of this Example 4, the fact that the cement quick-setting admixture is contained in the above-mentioned blending ratio contributes to making the manufacturing process of the manufacturing method more efficient (time reduction, etc.).

[0047] Therefore, as mentioned above, even when the building board 14 manufactured by the manufacturing method of this Example 4 (building board 14 of this Example 4) is formed into a plate with a thickness of at least 10 mm, when an attempt is made to bend it at the central part 14a in the longitudinal direction, it has flexibility (great bendability; it does not have the ability to return to its original shape) that allows an ordinary person to easily bend it via the bending part (central part 14a) of the building board 14 until the planes on both sides become almost parallel to each other (the angle between them is about 0 degrees) with only a very weak force. Therefore, it can be attached very easily and stably to, for example, a curved exterior wall surface or a corner part of an exterior wall surface. For example, a "thin building board with a thickness of merely about 5 mm" (mixed with synthetic resin, etc.) with the above-described "flexibility that allows the flat surfaces on both sides to be bent through the bending portion (central portion 14a) until they are nearly parallel to each other (at an angle of approximately 0 degrees)" may have existed in the past (although it is unclear at this time whether such a board existed). However, such a "thin building board with a thickness of merely about 5 mm" does not meet the requirements for strength that allows workers to easily handle it during construction, such as in the construction of building exterior walls, or for long-term durability after construction, and therefore its practicality and marketability are extremely limited. Thus, a building board with a thickness of at least 10 mm or more that meets the requirements for strength that allows easy handling during construction and long-term durability after construction, such as in Example 4, and a manufacturing method thereof, which have the above-described "flexibility that allows the flat surfaces on both sides to be bent through the bending portion (central portion 14a) until they are nearly parallel to each other (at an angle of approximately 0 degrees)" have not previously existed.

[0048] Furthermore, as mentioned above, the building board 14 manufactured by the manufacturing method of this Example 4 (building board 14 of this Example 4) has flexibility (including elasticity and flexibility of the surface) that allows it to be cut with ordinary scissors or the like, even when formed into a plate shape with a thickness of at least 10 mm (for the exterior walls of buildings, etc., tiles and other board materials generally require a thickness of at least about 10 mm in order to be strong enough to be easily handled during construction and to be durable after construction), and therefore, for example, at a construction site, workers can easily cut it with scissors or the like to the size and shape appropriate for the area to be constructed, which is very convenient, and there are effects such as less impact on humans, etc., even if it accidentally falls from above during construction work on a house, etc. (because the surface is elastic and flexible, there is less impact and damage when it hits a human body, etc., compared to conventional building boards with hard surfaces). For example, if a "thin building board material with a thickness of merely about 5 mm" (mixed with synthetic resin, etc.) has the flexibility (including surface elasticity and flexibility) that can be cut with ordinary scissors, etc., as described above, it may have existed in the past (it is currently unknown whether such a material existed). However, such a "thin building board material with a thickness of merely about 5 mm" cannot meet the needs for strength that can be easily handled by workers during construction, such as in the construction of building exterior walls, and long-term durability after construction, and therefore its practicality and marketability are extremely limited. Thus, as in Example 4, a building board material with a thickness of at least 10 mm or more that can meet the needs for strength that can be easily handled during construction and long-term durability after construction, and the above-mentioned "flexibility (including surface elasticity and flexibility) that can be cut with ordinary scissors, etc.", and a manufacturing method thereof, have not existed in the past. Furthermore, as mentioned above, the building board 14 manufactured by the manufacturing method of this Example 4 (or the building board 14 according to this Example 4) contains a predetermined proportion or more of cement, and therefore has flame retardant properties, and can be used safely on the exterior walls of buildings, etc.

[0049] Example 5 Next, Example 5 of the present invention (an example in which the blending ratio of cement to synthetic resin is relatively high) will be described with reference to Figures 5A to 5C. As Example 5 of the present invention, the inventors manufactured a building board according to Example 5 of the present invention by a manufacturing method in which a mixture of approximately 79% by weight of viscous paste-like synthetic resin, approximately 11.5% by weight of cement, approximately 3% by weight of cement quick-setting admixture, approximately 5% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fiber was mixed, and then molded and dried (see Figures 1A and 1B).

[0050] In this Example 5, the viscous paste-like synthetic resin used was "EC-5000PCM" (trademark), an elastic exterior wall coating material made primarily of acrylic resin and manufactured by Astec Paint Co., Ltd. (4-2-8 Beppukita, Shime-machi, Kasuya-gun, Fukuoka Prefecture, Japan) (however, the present invention is not limited to this). Furthermore, in this Example 5, the cement, cement quick-setting admixture, aggregate, and flame-retardant inorganic fiber used were the same as those used in Examples 1 and 4.

[0051] The building board material of Example 5 manufactured as described above was composed of approximately 82% by weight of flexible synthetic resin formed by drying a viscous paste-like synthetic resin, approximately 11.5% by weight of cement, approximately 5% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fiber.

[0052] Next, the flexibility (bendability) of the building board according to Example 5 manufactured as described above was confirmed as follows. First, it was confirmed that the building board 15 according to Example 5 had a thickness of at least 10 mm, as shown by the ruler 21 in Figures 5A(a) and (b). (Tile materials and other exterior wall materials generally used on the exterior walls of buildings are required to have a thickness of 10 mm or more due to requirements such as ease of handling during construction and durability after construction, except in cases where multiple panels are attached to a single sheet and then installed on the exterior wall. Therefore, in reality, there is almost no demand for building boards that do not have a thickness of 10 mm or more as exterior wall materials such as independent tiles that are installed one by one on the exterior walls of buildings.)

[0053] As shown in Figures 5A(a) and 5A(b), the building board 15 according to Example 5, despite its large thickness of at least 10 mm, was found to be flexible enough to bend at its longitudinal center portion 15a with normal human force, such that the bending angle (acute angle) between the planes on both sides of the bending portion (center portion 15a) (more precisely, the planes formed by imaginary extensions of the planes) was approximately 90 degrees or less. (Note that Example 5 does not have the elasticity to immediately return to its original shape after the bending state is released.) Furthermore, even when the building board 15 according to Example 5 was bent so that the bending angle (acute angle) between the planes on both sides of the bending portion (center portion 15a) was approximately 90 degrees or less, no cracks or other defects were observed on the surface of the longitudinal center portion 15a of the building board 15, which was the center of the bending, as shown in Figure 5A(c). As described above, in the building board material of Example 5, the flexible synthetic resin formed by drying a viscous paste-like synthetic resin is approximately 82% by weight, and the cement is approximately 11.5% by weight, so the synthetic resin to cement ratio is relatively high, and therefore a certain degree of good flexibility (good bendability) is imparted to the board material.

[0054] Next, the flexibility of the building board according to this Example 5 manufactured as described above was confirmed as follows. First, the building board 15 according to this Example 5 has a thickness of at least 10 mm, as shown by the ruler 21 in Figures 5B(a) and (b). (Typically, exterior wall materials such as tiles used on the exterior walls of buildings are required to have a thickness of 10 mm or more due to requirements such as ease of handling during installation and long-term durability after installation, except when "products in which multiple panels are pre-attached to a single sheet" are attached to the exterior wall. Therefore, in reality, there is almost no demand for building boards that do not have a thickness of 10 mm or more as exterior wall materials such as independent tiles that are installed one by one on the exterior walls of buildings.)

[0055] Thus, although the building board 15 according to Example 5 has a large thickness of at least 10 mm, when an attempt is made to cut the building board 15 according to Example 5 at approximately the center in its longitudinal direction with scissors 22 that an ordinary person would use in their daily lives, it was confirmed that the building board 15 according to Example 5 can be easily cut with a relatively small force by an ordinary person, as shown in Figures 5B(b) and (c). As described above, the building board according to Example 5 has a fairly high blend ratio of synthetic resin to cement, with the flexible synthetic resin formed by drying a viscous paste-like synthetic resin being about 82% by weight and the cement being about 11.5% by weight, so that the building board has good flexibility.

[0056] Furthermore, the flame retardancy of the building board 15 according to Example 5 manufactured as described above was confirmed as follows. That is, even when the surface of the building board 15 according to Example 5 was exposed to a flame 23a from a commercially available lighter 23 commonly used by ordinary people in their daily lives, as shown in FIGS. 5C(a)-(c), the surface did not burn, and no burning odor was emitted from the surface. This confirmed that the building board 15 according to Example 5 meets the flame retardancy required for building exterior walls, etc. As described above, the building board 15 according to Example 5 contains a fairly large proportion of cement relative to the synthetic resin, i.e., approximately 82% by weight of soft synthetic resin formed by drying a viscous paste-like synthetic resin, and approximately 11.5% by weight of cement, thereby imparting good flame retardancy.

[0057] As described above, in Example 5, a manufacturing method was carried out in which a mixture of approximately 79% by weight of viscous paste-like synthetic resin, approximately 11.5% by weight of cement, approximately 3% by weight of cement quick-setting admixture, approximately 5% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fibers was mixed, and then the mixture was molded and dried. This resulted in the production of a building board material consisting of approximately 82% by weight of soft synthetic resin, which was formed by drying the viscous paste-like synthetic resin, approximately 11.5% by weight of cement, approximately 5% by weight of aggregate, and approximately 1.5% by weight of flame-retardant inorganic fibers, which can achieve the following effects.

[0058] In other words, the building board 15 according to this embodiment 5, manufactured by the manufacturing method of this embodiment 5, even when formed into a plate with a thickness of at least 10 mm (for the exterior walls of buildings, tiles and other plate materials generally require a thickness of 10 mm or more because of the need for strength that allows easy handling during construction and long-term durability after construction), has the flexibility (great bendability; it does not have the ability to return to its original shape) that allows it to be easily bent when an attempt is made to be made to bend it at the central part 15a in the longitudinal direction using normal human force, so that the angle between the planes on both sides of the bending part (central part 15a) (more precisely, the angle at the intersection of the planes obtained by virtually extending each of the planes; acute angle) changes from the initial value of approximately 180 degrees to approximately 90 degrees or less, even when formed into a plate with a thickness of at least 10 mm (including surface elasticity and flexibility), and is flame retardant.

[0059] The flexibility and pliability of the building board 15 according to Example 5 are imparted primarily by the inclusion of the synthetic resin in the above-mentioned blending ratio (note that the flexibility is also contributed by the inorganic fibers). The flame retardancy of the building board 15 according to Example 5 is imparted primarily by the inclusion of the cement in the above-mentioned blending ratio. The "shape retention that prevents the building board 15 according to Example 5 from becoming excessively flexible and pliable (becoming floppy) and making it difficult to handle on-site" is also imparted primarily by the inclusion of the cement in the above-mentioned blending ratio. Furthermore, the aggregate contained in the building board 15 according to Example 5 in the above-mentioned blending ratio primarily contributes to the lightweight nature of the building board, and the inorganic fibers contained in the building board 15 according to Example 5 in the above-mentioned blending ratio primarily contribute to the building board's resistance to cracking (shattering) even when bent. Furthermore, in the manufacturing method of this Example 5, the fact that the cement quick-setting admixture is contained in the above-mentioned blending ratio contributes to making the manufacturing method more efficient (reducing the time, etc.).

[0060] Therefore, as mentioned above, even when the building board 15 manufactured by the manufacturing method of this Example 5 (building board 15 of this Example 5) is formed into a plate with a thickness of at least 10 mm, when an attempt is made to bend it around the central part 15a in the longitudinal direction using normal human force, it has flexibility (bendability; it does not have the ability to return to its original shape) that allows it to be easily bent so that the angle between the planes on both sides of the bent part (central part 15a) (more precisely, the angle at the point where the planes obtained by virtually extending each of the above planes intersect; acute angle) changes from the initial value of approximately 180 degrees to approximately 90 degrees or less, making it possible to easily and stably attach it to, for example, a curved exterior wall surface. For example, a "thin building board with a thickness of merely about 5 mm" (mixed with synthetic resin, etc.) may have existed in the past that has the flexibility to bend so that the angle between the planes on both sides of the bent portion changes from the initial angle of approximately 180 degrees to approximately 90 degrees or less (although it is unclear at this point whether this is possible). However, such a "thin building board with a thickness of merely about 5 mm" would not be able to meet the needs for strength that allows workers to easily handle it during construction on the exterior walls of buildings, or for long-term durability after construction, and therefore its practicality and marketability are extremely limited. Thus, a building board with a thickness of at least 10 mm or more that can meet the needs for strength that allows easy handling during construction and long-term durability after construction, as in Example 5, and that has the flexibility to bend so that the angle between the planes on both sides of the bent portion changes from the initial angle of approximately 180 degrees to approximately 90 degrees or less, as described above, and a manufacturing method thereof, have not existed in the past.

[0061] Furthermore, as described above, the building board 15 manufactured by the manufacturing method of this Example 5 (building board 15 of this Example 5) has flexibility (including elasticity and flexibility of the surface) that allows it to be cut with ordinary scissors or the like, even when formed into a plate with a thickness of at least 10 mm (for the exterior walls of buildings, etc., tiles and other board materials are generally required to have a thickness of at least 10 mm because of the need for strength that allows them to be easily handled during construction and durability after construction), and therefore, for example, at a construction site, workers can easily cut it with scissors or the like to the size and shape appropriate for the area to be constructed, which is very convenient, and even if it accidentally falls from above during construction work on a house or the like, there is little impact on the human body, etc. (because the surface is elastic and flexible, there is less impact and damage when it hits the human body, etc., compared to conventional building boards with hard surfaces). For example, if a "thin building board material with a thickness of merely about 5 mm" (mixed with synthetic resins, etc.) has the above-mentioned "flexibility (including surface elasticity and flexibility) that can be cut with ordinary scissors, etc.", it may have existed in the past (although it is unclear at this point whether such a possibility exists). However, such a "thin building board material with a thickness of merely about 5 mm" cannot meet the needs of strength that can be easily handled by workers during construction on the exterior walls of buildings, etc., and long-term durability after construction, so its practicality and marketability are extremely limited. Thus, as in Example 5, a building board material with a "thickness of at least 10 mm" that can meet the needs of strength that can be easily handled during construction and long-term durability after construction, and the above-mentioned "flexibility (including surface elasticity and flexibility) that can be cut with ordinary scissors, etc.", and a manufacturing method thereof, have not existed in the past.

[0062] Furthermore, as mentioned above, the building board 15 manufactured by the manufacturing method of this Example 5 (or the building board 15 according to this Example 5) contains a predetermined proportion or more of cement, and therefore has flame retardant properties, and can be used safely on the exterior walls of buildings, etc.

[0063] Comparative Example 1 Next, as a comparative example (Comparative Example 1) of Example 4 (an example in which the blending ratio of cement to synthetic resin was relatively low), a building board (Comparative Example 1) was produced by mixing approximately 90% by weight of viscous paste-like synthetic resin, approximately 2% by weight of cement, approximately 1% by weight of cement quick-setting admixture, approximately 5% by weight of aggregate, and approximately 2% by weight of flame-retardant inorganic fiber, followed by molding and drying (see FIGS. 1A and 1B). In this Comparative Example 1, the viscous paste-like synthetic resin, cement, cement quick-setting admixture, aggregate, and flame-retardant inorganic fiber were the same as those used in Example 4. The building board according to Comparative Example 1 produced in this manner had a blending ratio of approximately 91% by weight of flexible synthetic resin formed by drying the viscous paste-like synthetic resin, approximately 2% by weight of cement, approximately 5% by weight of aggregate, and approximately 2% by weight of flame-retardant inorganic fiber.

[0064] Next, the flexibility (bendability) of the building board according to Comparative Example 1 manufactured as described above was confirmed as follows. First, the building board 14 according to Comparative Example 1 had a thickness of approximately 10 mm. When attempting to bend the building board according to Comparative Example 1 with the fingers, the building board could be easily bent with extremely little force, even for an average person, so that the angle between the planes on both sides of the bent portion (the longitudinal center portion) was approximately 90 degrees or less. Furthermore, when bending the building board about the longitudinal center portion, no cracks occurred in the longitudinal center portion. Thus, the building board according to Comparative Example 1 had even greater flexibility (bendability) than that of Example 4. This is thought to be due to the fact that the building board according to Comparative Example 1 had a smaller cement content (approximately 91% by weight) of approximately 2% by weight relative to the synthetic resin, as described above, than that of Example 4.

[0065] Next, the flexibility of the building board according to Comparative Example 1 manufactured as described above was confirmed as follows. First, the building board according to Comparative Example 1 has a thickness of approximately 10 mm, but when an attempt was made to cut the building board at approximately the center in the longitudinal direction with scissors 22, which an average person would normally use in their daily lives, it could be easily cut with an extremely small force. Thus, the building board according to Comparative Example 1 had even greater flexibility than Example 4. This is thought to be because, as mentioned above, the building board according to Comparative Example 1 had a smaller cement to synthetic resin (approximately 91% by weight) ratio of approximately 2% by weight than Example 4.

[0066] In contrast to the flexibility and pliability described above, the flame retardancy of the building board of Comparative Example 1 manufactured as described above was confirmed as follows. That is, when the surface of the building board of Comparative Example 1 was exposed to the flame of a commercially available lighter used by ordinary people in their daily lives, the surface did not burn, but a burnt smell was emitted from the surface and the surface was slightly damaged, confirming that the building board of Comparative Example 1 does not necessarily meet the flame retardancy required for building exterior walls, etc. This is thought to be due to the fact that, as mentioned above, the building board of Comparative Example 1 had a smaller cement to synthetic resin (approximately 91% by weight) ratio of approximately 2% by weight than that of Example 4.

[0067] Comparative Example 2 Next, as a comparative example (Comparative Example 2) of Example 5 (an example in which the blending ratio of cement to synthetic resin was relatively high), a building board (Comparative Example 2) was produced by mixing approximately 77 wt% viscous paste-like synthetic resin, approximately 13 wt% cement, approximately 3 wt% cement quick-setting admixture, approximately 5 wt% aggregate, and approximately 2 wt% flame-retardant inorganic fiber, followed by molding and drying (see FIGS. 1A and 1B). In this Comparative Example 2, the viscous paste-like synthetic resin, cement, cement quick-setting admixture, aggregate, and flame-retardant inorganic fiber were the same as those used in Example 5. The building board according to Comparative Example 2 produced as described above had a blending ratio of approximately 79 wt% flexible synthetic resin formed by drying a viscous paste-like synthetic resin, approximately 14 wt% cement, approximately 5 wt% aggregate, and approximately 2 wt% flame-retardant inorganic fiber.

[0068] Next, the flexibility (bendability) of the building board according to Comparative Example 2 manufactured as described above was confirmed as follows. First, the building board 14 according to Comparative Example 2 had a thickness of approximately 10 mm. However, when attempting to bend the building board according to Comparative Example 2 with the fingers, it was difficult for an average person to easily bend it so that the angle between the planes on either side of the bend (the longitudinal center) was approximately 90 degrees or less without a significant force. Furthermore, when the building board was bent around the longitudinal center, some cracks occurred in the longitudinal center. Even if the building board according to Comparative Example 2 was bent to approximately 90 degrees or less and secured to a curved portion (such as a corner) of a building, the presence of the cracks and other factors meant that it could not be said to fully satisfy practical durability and decorativeness. Thus, it was difficult to say that the building board according to Comparative Example 2 had sufficient flexibility (good bendability) in the practical sense described above. This is thought to be because in the building board material of Comparative Example 2, the cement to synthetic resin (approximately 79% by weight) ratio is approximately 14% by weight, which is higher than that in Example 5, as mentioned above.

[0069] Next, the flexibility of the building board according to Comparative Example 2 manufactured as described above was confirmed as follows. First, the building board according to Comparative Example 2 had a thickness of approximately 10 mm, but when an attempt was made to cut the building board at approximately the center in the longitudinal direction using scissors 22, which are commonly used by ordinary people in their daily lives, it was difficult for an ordinary person to cut it easily without applying a great deal of force. Thus, it is difficult to say that the building board according to Comparative Example 2 has sufficient flexibility in a practical sense. This is thought to be due to the fact that the building board according to Comparative Example 2 had a higher cement to synthetic resin (approximately 79% by weight) ratio of approximately 14% by weight, as described above, than that of Example 5.

[0070] In contrast to the flexibility and pliability described above, the flame retardancy of the building board according to Comparative Example 2, manufactured as described above, was confirmed as follows. That is, even when the surface of the building board according to Comparative Example 2 was exposed to the flame of a commercially available lighter used by ordinary people in their daily lives, the surface did not burn and no burning odor was emitted from the surface, confirming that the building board according to Comparative Example 2 has high flame retardancy. This is thought to be because, as mentioned above, the building board according to Comparative Example 2 had a higher cement to synthetic resin (about 79 wt%) ratio of about 14 wt%, which was higher than that of Example 5.

[0071] Example 6 Next, a method for semi-permanently improving the durability of a building board according to Example 6 of the present invention, and a building board whose durability has been semi-permanently improved by said method, will be described.

[0072] In Example 6, as described in the section "7. Finishing" in FIG. 1B, the mixed materials are dried and removed from the mold, followed by quenching. This quenching is performed, for example, by heating (roasting) the surface of the building board with a flame from a burner for several seconds or longer, as shown in the section "7. Finishing" in FIG. 1B. In this case, the entire surface of the building board may be heated, or only a portion of the surface of the building board (for example, only the rectangular outer periphery or only the edge of the periphery) may be heated. In addition to the method of heating all or part of the surface of the building board using a burner, other methods are also possible, such as placing the building board in a furnace and heating all or part of its surface with a heater.

[0073] In this way, when all or part of the surface of a building board is heated with a burner, heater, etc., the surface is carbonized, and the carbonized surface is less susceptible to oxidation and other deterioration due to long-term sunlight, wind, rain, etc., thereby significantly improving the durability of the building board. As described above, in Example 6, all or part of the surface of a building board (such as shown in Examples 1-5 above, which contains a soft synthetic resin formed by drying a viscous paste-like synthetic resin and has flexibility that allows it to be cut with ordinary scissors, etc.) is heated and carbonized, thereby semi-permanently improving the durability of the building board.

[0074] Example 7 Next, we will explain a method for forming a pattern, letter or figure on the surface of a building board according to Example 7 of the present invention and semi-permanently fixing it, and the building board on whose surface a pattern, letter or figure has been formed and semi-permanently fixed by this method.

[0075] In this Example 7, a building board manufactured through processes such as mixing, stirring, drying, and removal from a mold as shown in Figures 1A and 1B is subjected to flame heating (searing) of a portion of the surface of the building board with a burner, thereby forming and fixing a pattern, letter, or figure on the surface of the building board.

[0076] Fig. 6 shows an example of a method for forming and fixing a pattern, letter, or figure on the surface of the above-mentioned building board. In Fig. 6(a), 11 is a building board manufactured by the process shown in Fig. 1A and Fig. 1B, 12 is a heat shield plate made of aluminum or ceramic material and having a heat shielding function, which is placed in contact with the surface side of the building board 11 or in close proximity thereto with a short gap of, for example, several centimeters, several millimeters, or less, and 12a is a cavity (opening) formed in the heat shield plate 12 and formed to have a predetermined shape, such as a predetermined letter, figure, or pattern.

[0077] When such a heat shield plate 12 is placed in contact with or close to the surface of the building board 11 and the building board 11 and heat shield plate 12 are hardened using the burner shown in the "7. Finishing" section of Figure 1B, the heat of the flame that passes through the hollow portion 12a of the heat shield plate 12 is applied to the surface of the building board 11, and as a result, only the portion 11a (see Figure 6(b)) on the surface of the building board 11 that follows the shape of the hollow portion 12a (shape of letters, figures or patterns) takes on a carbonized color (a color different from the other parts of the surface).

[0078] Furthermore, since the carbonized portion 11a of the carbonized letters, figures or patterns on the surface of the building board 11 is carbonized, it is possible to reduce the degree of deterioration such as oxidation due to long-term sunlight, wind and rain, etc., and therefore the carbonized portion 11a of the letters, figures or patterns is semi-permanently fixed and remains on the surface of the building board 11. In this Example 7, in addition to the method of heating a part of the surface of the building board 11 using the burner, as in the above Example 7, it is also possible to, for example, place the building board 11 in a furnace and heat its outer surface with a heater via the heat shield 12.

[0079] As described above, in Example 7, a portion of the surface of a building board (a flexible and pliable building board containing a soft synthetic resin formed by drying a viscous paste-like synthetic resin, as shown in Examples 1-5) is heated using a burner or the like through the heat shield plate 12 in which the cavity 12a is formed. This heats and carbonizes only the portion 11a of the surface of the building board that corresponds to the cavity 12a, allowing a pattern, letter, or figure corresponding to the cavity 12a to be formed and fixed semi-permanently on the surface of the building board. The pattern, letter, or figure formed on the surface of the building board by the method of Example 7 can be in a variety of shapes and forms. It is also possible to form and fix a grid-like pattern on the entire surface of the building board, as well as letters or figures as shown in FIG. 6(b).

[0080] Although the present invention has been described above with reference to various embodiments, it is not limited to the above-described embodiments and various modifications and variations are possible. For example, in Examples 6 and 7, various methods are possible for heating all or part of the surface of the building board, such as heating the outer surface of the building board in a furnace using a heater, in addition to using a burner. Furthermore, the methods described in Examples 6 and 7 do not necessarily require the building boards described in the examples (building boards containing a flexible synthetic resin formed by drying a viscous paste-like synthetic resin and having both flexibility and flexibility that allows cutting with ordinary scissors). They can also be applied to conventional, commercially available building boards (conventionally known building boards other than the building boards described in the examples) and to building boards containing a flexible synthetic resin formed by drying a viscous paste-like synthetic resin as part of their material. [Explanation of symbols]

[0081] 1,2,3,11,14,15 Architectural board materials 1a, 2a, 14a, 15a: longitudinal center portion of building board 3a Cut surface 4,22 Scissors 11a Letters or figures fixed to the surface of building boards 12 Heat shield 12a Cavity (opening) 21 Ruler 23 writer 23a Lighter flame

Claims

1. A building board material containing and mixed in the following proportions: 82 to 90% by weight of a flexible synthetic resin obtained by drying a viscous paste-like synthetic resin; 2.5 to 11.5% by weight of cement; 2 to 8% by weight of aggregate having a particle size of approximately 0.3 to 5 mm; and 0.7 to 3% by weight of inorganic fibers; The building board contains and mixes the soft synthetic resin formed by drying the viscous paste-like synthetic resin, cement, aggregate with a particle size of approximately 0.3 to 5 mm, and inorganic fibers in the above-mentioned mixing ratio, so that even if it has a thickness of at least 10 mm, which is necessary for practical use as a general building board from the viewpoints of strength that allows workers to easily handle it during construction and long-term durability after construction, when the board having a thickness of at least 10 mm is bent at the center in the longitudinal direction, it can be bent or twisted until the bending angle between the flat surfaces on both sides of the center is 90 degrees or less, and even when bent until the bending angle between the flat surfaces on both sides of the center is 90 degrees or less, it has a flexible configuration such that no cracks occur on the surface of the center, and The construction board is a flame-retardant construction board characterized in that it is made by mixing a flexible synthetic resin formed by drying the viscous paste-like synthetic resin, cement, aggregate with a particle size of approximately 0.3 to 5 mm, and inorganic fibers in the above-mentioned mixing ratio, and therefore has a thickness of at least 10 mm, which is required for practical use as a general construction board from the standpoints of strength that allows workers to easily handle it during construction and long-term durability after construction, but is also flexible enough that workers at the construction site can cut the board of at least 10 mm thick using ordinary scissors, etc.

2. A building board material containing and mixed in a blending ratio of 90% by weight of a flexible synthetic resin obtained by drying a viscous paste-like synthetic resin, 2.5% by weight of cement, 6% by weight of aggregate having a particle size of approximately 0.3 to 5 mm, and 1.5% by weight of inorganic fibers, The building board is a mixture of a flexible synthetic resin formed by drying the viscous paste-like synthetic resin, cement, aggregate with a particle size of approximately 0.3 to 5 mm, and inorganic fibers in the above-mentioned mixing ratio, and therefore has a thickness of at least 10 mm, which is necessary for practical use as a general building board from the standpoints of strength that allows workers to easily handle it during construction and long-term durability after construction, and is flexible enough that when a board of at least 10 mm in thickness is bent at the center in the longitudinal direction, it can be bent until the flat surfaces on both sides of the center are parallel to each other without causing cracks on the surface of the center, and The construction board is a flame-retardant construction board characterized in that it contains and mixes a flexible synthetic resin formed by drying the viscous paste-like synthetic resin, cement, aggregate with a particle size of approximately 0.3 to 5 mm, and inorganic fibers in the above-mentioned mixing ratio, and therefore has a thickness of at least 10 mm, which is required for practical use as a general construction board from the standpoints of strength that allows workers to easily handle it during construction and long-term durability after construction, but is also flexible enough that workers at the construction site can cut the board of at least 10 mm thick using ordinary scissors, etc.

3. A building board material having flexibility, softness and flame retardancy, characterized in that the entire surface of the building board material according to claim 1 or 2 is heated and carbonized, thereby semi-permanently improving the durability of the building board material.

4. A method for semi-permanently improving the durability of a building board material that has flexibility, pliability, and flame retardancy, characterized by heating and carbonizing the entire surface of the building board material described in claim 1 or 2, thereby semi-permanently improving the durability of the board material.

5. A building board material having flexibility, softness and flame retardancy, characterized in that the surface of the building board material described in claim 1 or 2 is heated and carbonized along a predetermined pattern, thereby forming the predetermined pattern on the surface and semi-permanently fixing it.

6. A method for forming and fixing a pattern on the surface of a building board that is flexible, pliable, and flame-retardant, characterized in that the surface of the building board described in claim 1 or 2 is heated and carbonized in a manner that corresponds to a predetermined pattern, thereby forming and semi-permanently fixing the predetermined pattern on the surface.

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