Metal exterior material with stone chip and method manufacturing the same

Abstract

A metal exterior material with attached stone chips according to one embodiment of the present invention comprises a metal part; a stone chip part attached to the front of the metal part; an insulating part provided at the rear of the metal part; and a rear part attached to the rear of the insulating part, wherein the metal part may include a main cover part; an upper protrusion protruding upward from the top of the main cover part; an upper concave part provided at the rear of the upper protrusion and formed concavely downward; a wall fixing part extending upward from the rear of the upper concave part; a pair of lower protrusions protruding downward from the bottom of the main cover part and spaced apart from each other in the front-rear direction; and a lower concave part formed concavely upward between the pair of lower protrusions.

Description

Technology Field

[0001] The present invention relates to a metal building exterior material and a method for manufacturing the same, and more specifically, to a metal exterior material with attached stone chips and a method for manufacturing the same, which can increase the durability of the metal, further enhance aesthetics, and reduce noise caused by external impacts such as rain by attaching stone chips to the metal surface. Background Technology

[0003] Metals are relatively lightweight and easy to process, so they are widely used as building exterior materials; among metals, galvanized steel sheets are the most widely used.

[0004] However, galvanized steel sheets have limitations in that rust can occur due to moisture, and the color of the surface coating may fade if exposed to strong ultraviolet rays for a long time.

[0005] In addition, it has the limitation that deformation or damage caused by external impact or scratches is easily visible to the naked eye, and it has the limitation of loud noise during rain. The problem to be solved

[0007] The present invention was devised to overcome the above limitations and aims to provide an architectural exterior material that is easy to install and has increased durability by coating stone chips on the metal surface. means of solving the problem

[0009] A metal exterior material with attached stone chips according to one embodiment of the present invention comprises a metal part; a stone chip part attached to the front of the metal part; an insulating part provided at the rear of the metal part; and a rear part attached to the rear of the insulating part, wherein the metal part may include a main cover part; an upper protrusion protruding upward from the top of the main cover part; an upper concave part provided at the rear of the upper protrusion and formed concavely downward; a wall fixing part extending upward from the rear of the upper concave part; a pair of lower protrusions protruding downward from the bottom of the main cover part and spaced apart from each other in the front-rear direction; and a lower concave part formed concavely upward between the pair of lower protrusions.

[0010] The stone chip portion may include a base coating portion applied to the front surface of the metal portion; a plurality of stone chips partially embedded and fixed in the base coating portion; and a top coating portion applied to the front surface of the stone chips.

[0011] The above stone chip portion can be provided in front of the above upper protrusion to increase bonding strength.

[0012] The stone chip portion above is provided in front of the wall fixing portion to facilitate the fixing of the fastener.

[0013] The above insulation may include polyurethane.

[0014] A method for manufacturing a metal exterior material with attached stone chips according to one embodiment of the present invention comprises the steps of: spraying an adhesive onto the metal surface of a metal exterior material including an insulating portion; dropping a plurality of stone chips onto the adhesive; removing excess stone chips that do not come into contact with the adhesive; spraying a top coating agent onto the stone chips; and drying, wherein in the maximum temperature range of the drying step, the metal exterior material with attached stone chips is allowed to remain at a temperature of 80°C or higher for less than 1 hour. Effects of the invention

[0016] According to the present invention, it is possible to provide a metal exterior material that is easy to install and has excellent durability.

[0017] In particular, the metal surface is coated with stone chips, which prevents rust from forming and increases the product's lifespan.

[0018] In addition, it prevents the paint color on the metal surface from deteriorating due to ultraviolet rays, allowing the aesthetics to be maintained for a long period.

[0019] In addition, it becomes possible to reduce noise caused by rain or external impact.

[0020] In addition, it is possible to prevent iron powder generated during cutting from scattering onto the metal surface due to stone chips on the metal surface, thereby preventing it from becoming a cause of rust.

[0021] In addition, heat transfer is reduced by the stone coating layer, thereby lowering the temperature of the interface of the urethane in contact with the metal, which prevents deformation caused by heat. Brief explanation of the drawing

[0023] FIG. 1 is a cross-sectional view of a metal exterior material with stone chips attached according to one embodiment of the present invention. Figure 2 is an enlarged view of a part of Figure 1. FIG. 3 is a drawing illustrating the construction of a metal exterior material with stone chips attached according to one embodiment of the present invention. Specific details for implementing the invention

[0024] Hereinafter, the composition of a metal exterior material with attached stone chips according to one embodiment of the present invention will be described with reference to the attached drawings.

[0025] FIG. 1 is a cross-sectional view of a metal exterior material with stone chips attached according to one embodiment of the present invention, and FIG. 2 is an enlarged view of a part of FIG. 1.

[0026] A metal exterior material with stone chip attachment according to one embodiment of the present invention comprises a metal part (100) formed in a structure that is easy to fix directly or indirectly to a wall part, a stone chip part (200) provided on the front surface of the metal part, an insulating part (300) provided on the rear of the stone chip part, and a rear part (400) provided on the rear of the insulating part.

[0028] The metal part (100) includes a main cover part (110) that occupies most of the front area, an upper protrusion (120) provided at the top of the main cover part and protruding upward, a wall fixing part (130) located at a distance from the upper protrusion and rearward, an upper concave part (140) that is concave downward between the upper protrusion (120) and the wall fixing part (130), a pair of lower protrusions (151, 152) located at the bottom of the main cover part (110) and protruding downward, and a lower concave part (160) provided between the pair of lower protrusions (150) and having a shape that is concave upward.

[0029] At this time, the upper and lower parts of the metal part (100) have a structure that corresponds to each other so as to be combined.

[0030] To explain this in more detail, since the upper protrusion (120) must be inserted into the lower concave portion (160), the front-rear width of the upper protrusion (120) must be approximately equal to or smaller than the front-rear width of the lower concave portion (160). For reference, in FIGS. 1 to 3, the right side of the drawing is the front, and the left side of the drawing is the rear. The front refers to the outer side of the building, and the rear refers to the side of the building.

[0031] The lower protrusions (151, 152) include a front lower protrusion (151) located at the front and a rear lower protrusion (152) located at the rear, and the rear lower protrusion (152) must be insertable into the upper concave portion (140). Accordingly, the front-rear width of the rear lower protrusion (152) must be equal to or smaller than the front-rear width of the upper concave portion (140).

[0032] The metal part (100) may be made of an aluminum-zinc alloy plated steel sheet, but is not limited thereto.

[0034] The stone chip portion (200) is provided in front of the metal portion (100). The stone chip portion (200) includes a stone chip (210), a base coating portion (220), and a top coating portion (230).

[0035] The stone chip (210) is made by crushing rock, and may be colored by applying a dye to the surface of the crushed rock. The stone chip (210) may be made of porous basalt which is advantageous for coloring by applying a dye. The stone chip (210) may include crushed pieces with a diameter of 1 mm or more and less than 3 mm.

[0036] The base coating portion (220) is sprayed onto the surface of the metal portion (100) and hardened, and may have a viscosity of at least 3000 cps or more so that stone chips can fall and be embedded. The base coating portion (200) may be an acrylic water-soluble adhesive.

[0037] The top coating portion (230) is applied and cured in front of the base coating portion (220) after the stone chip (210) is applied thereto, and may be an acrylic water-soluble adhesive with a transparent color.

[0038] Therefore, some of the stone chips may come into contact with the base coating (220), and others may come into contact with the top coating (230).

[0039] Meanwhile, if the stone chip portion (200) is provided in front of the upper protrusion (120), the bonding strength between one exterior material and another exterior material adjacent vertically can be increased. If molded with only metal without stone chips, it is inevitable that some gap will be formed to account for errors in the manufacturing process. However, if the stone chip portion (200) is provided in front of it, the excess stone chips slide out during the bonding process, filling the gap and allowing for a tight fit, thereby enabling a more robust bond. When a robust bond is achieved, it is possible to prevent noise caused by clicking in strong winds due to the gap.

[0040] Meanwhile, if the stone chip portion (200) is fixed to the front of the wall fixing portion (130), construction can be made easier. When fasteners such as screw bolts are fixed on a smooth metal surface, the fasteners may slip, but if the front of the wall fixing portion becomes rough due to the stone chip portion (200), the fasteners such as screw bolts will not slip, making construction easier.

[0042] The insulation part (300) may be polyurethane. Polyurethane (PU) is a polymer having urethane bonds (-NH-COO-) within the polymer chain, and is a polymer compound formed by the reaction of a divalent or higher isocyanate (-N=C=O) and a polyol (-OH). Such polyurethane is deformed by thermal stimulation. To explain in more detail, polyurethane is a material that is relatively weak against heat, and generally begins to decompose due to heat at about 80 to 100°C. Therefore, if polyurethane used in exterior materials is exposed to high temperatures for a long time, performance degradation or deformation may occur. However, in Korea and Japan, the surface temperature of metal exterior materials in the summer approaches 80°C and sometimes exceeds 80°C. Therefore, by blocking heat conduction and slightly lowering the temperature of the interface of the urethane in contact with the metal, the onset of deformation due to heat can be prevented, thereby extending the lifespan of the exterior material.

[0043]

[0044] [Graph 1]

[0045] Graph 1 above shows temperature measurement data of the lower space separated from the roofing material, conducted by a specialized distributor of building materials in Japan. It can be seen that a temperature difference of 6 to 7°C or more occurs between building materials with a surface made entirely of metal and roofing materials coated with stone chips around 14:00. Therefore, when the surface temperature of general metal exterior materials exceeds 80°C in the summer, the polyurethane in contact with the general metal exterior materials may be damaged, whereas the polyurethane of the stone chip-attached exterior material according to the present invention may not be damaged.

[0046] That is, according to the present invention, the external heat transferred to the insulation part (300) by the stone chip part (200) can be blocked, thereby increasing the lifespan of the polyurethane and exterior material.

[0047] Meanwhile, in this embodiment, polyurethane was described as an example of the insulating part (300), but the composition of the insulating part (300) is not limited to polyurethane.

[0049] The rear portion (400) preferably has a waterproof function and may be a heat-reflective film. The insulation portion (300) and the rear portion (400) may have a shape in which a portion of the lower part is recessed toward the front, and this recessed portion forms a wall fixing portion receiving portion (410). When a plurality of stone chip-attached metal exterior materials are connected vertically and installed, the wall fixing portion (130) of the exterior material located at the bottom is located in the wall fixing portion receiving portion (410) of the exterior material located at the top.

[0051] Hereinafter, with reference to FIG. 3, a method for constructing a metal exterior material with attached stone chips according to an embodiment of the present invention will be briefly described. FIG. 3 is a drawing illustrating the construction of a metal exterior material with attached stone chips according to an embodiment of the present invention.

[0052] Referring to FIG. 3, if the flatness of the outer wall of a building is poor, a supporting structure (500) is installed. The supporting structure (500) is installed to extend long in the vertical direction.

[0053] After positioning one stone chip-attached metal exterior material in front of the lower structure, a fastener is fixed to the lower structure (500) by penetrating the wall fixing part (130). One stone chip-attached metal exterior material is fixed to multiple lower structures through multiple fasteners.

[0054] Once a row of stone chip-attached metal exterior materials is fixed in the horizontal direction, another row of stone chip-attached metal exterior materials is fixed on top of it. At this time, the upper protrusion (120) of the exterior material located at the bottom is inserted into the lower concave portion (160) of the exterior material located at the top, and the upper part of the upper protrusion (120) and the upper part of the lower concave portion (160) may come into contact with each other.

[0055] In addition, the wall fixing part (130) of the exterior material located at the bottom is positioned in the space formed by the wall fixing part receiving part (410) of the exterior material located at the front and top of the lower structure (600).

[0056] In this way, multiple exterior materials can be fixed to the exterior walls of a building, etc.

[0057] Meanwhile, if the flatness of the exterior wall of a building is good, the stone chip attachment exterior material according to the present invention may be fixed directly to the exterior wall without a supporting structure.

[0059] Below, the method for manufacturing a metal exterior material with attached stone chips as described above will be explained, focusing on the stone chip attachment process.

[0060] The method for manufacturing a metal exterior material with attached stone chips according to the present embodiment comprises the steps of: preparing a metal exterior material including an insulating material such as urethane; applying an adhesive to the surface of the metal exterior material including the insulating material; dropping stone chips onto the surface where the adhesive is applied; removing excess stone chips that are not in contact with the contact agent; applying an upper coating agent to the top of the stone chips; and drying.

[0062] First, prepare a metal exterior material including an insulating section and feed it into the stone chip coating line. At this time, the outer surface of the metal is positioned so that it faces upward.

[0063] When a metal exterior material including an insulating layer is fed into a stone chip coating line and moves, an adhesive is sprayed onto the surface of the metal part during the movement process. At this time, it is preferable that the adhesive has a viscosity of 3000 cps or higher. After undergoing a drying process, this adhesive hardens to form a base coating layer.

[0064] After the adhesive is applied, a number of stone chips are dropped onto it. When a number of stone chips are dropped, some of them come into contact with the adhesive and adhere, while the excess stone chips that do not come into contact with the adhesive are piled up on top.

[0065] The excess stone chips accumulated on top like this are removed by blowing air through a blower.

[0066] Once the excess stone chips are removed, a top coating agent is sprayed onto the stone chips attached to the surface. This coating agent hardens after undergoing a drying process to form a top coating layer.

[0067] Meanwhile, after the top coating agent is sprayed, the metal exterior material is moved to a drying oven to undergo a drying process.

[0068] During the drying process, the temperature should not be maintained at 80°C or higher for more than one hour. If the temperature is maintained at 80°C or higher for more than one hour, and the insulating part is made of urethane, the urethane may swell and ooze out to the sides, and a void may be formed between it and the metal part. Therefore, it is desirable to keep the residence time at the maximum temperature range of 80°C or higher during the drying process less than one hour.

[0070] The foregoing description is merely an illustrative explanation of the technical concept of the present invention, and those skilled in the art to which the present invention pertains will be able to make various modifications and variations within the scope of the essential characteristics of the present invention. Accordingly, the embodiments disclosed in the present invention are intended to explain, not limit, the technical concept of the present invention, and the scope of the technical concept of the present invention is not limited by these embodiments.

[0071] In describing the present invention, the thickness or size of some of the components shown in the drawings may be exaggerated, omitted, or schematically depicted for convenience and clarity of explanation. Additionally, the size of each component does not entirely reflect its actual size. Explanation of the symbols

[0073] 100: Metal part 110: Main cover 120: Top protrusion 130: Wall fixing part 140: Upper concave part 150: Bottom protrusion 160: Lower concave part 200: Stone Chip Part 210: Stone Chip 220: Base coating part 230: Top coating section 300: Insulation section 400: Rear 410: Wall fixing part receiving part 500: Lower limb structures 600: Fastener

Claims

Claim 1 A metal exterior material for stone chips, comprising: a metal part; a stone chip part attached to the front of the metal part; an insulating part provided at the rear of the metal part; and a rear part attached to the rear of the insulating part, wherein the metal part comprises: a main cover part; an upper protrusion protruding upward from the top of the main cover part; an upper concave part provided at the rear of the upper protrusion and formed concavely downward; a wall fixing part extending upward from the rear of the upper concave part; a pair of lower protrusions protruding downward from the bottom of the main cover part and spaced apart from each other in the front-rear direction; and a lower concave part formed concavely upward between the pair of lower protrusions. Claim 2 A metal exterior material with attached stone chips according to claim 1, wherein the stone chip portion comprises: a base coating portion applied to the front surface of the metal portion; a plurality of stone chips partially embedded and fixed in the base coating portion; and a top coating portion applied to the front surface of the stone chips. Claim 3 In claim 1, the stone chip portion is provided in front of the upper protrusion to increase bonding strength, forming a stone chip-attached metal exterior material. Claim 4 In claim 1, the stone chip portion is provided in front of the wall fixing portion to facilitate the fixing of the fastener, and is a stone chip-attached metal exterior material. Claim 5 In claim 1, the insulation portion is a stone chip-attached metal exterior material comprising polyurethane. Claim 6 A method for manufacturing a metal exterior material with attached stone chips according to claim 5, comprising the steps of: spraying an adhesive onto the metal surface of a metal exterior material including an insulating part; dropping a plurality of stone chips onto the adhesive; removing excess stone chips that do not come into contact with the adhesive; spraying a top coating agent onto the stone chips; and a drying step, wherein, in the maximum temperature range of the drying step, the metal exterior material with attached stone chips stays at a temperature of 80°C or higher for less than 1 hour.

Images