Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Reexamination Certificate
1999-05-13
2001-10-23
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
Foam
C052S309170, C052S342000, C052S612000, C052S590100
Reexamination Certificate
active
06305135
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a composite building material manufactured by combining, for instance, a foamed synthetic resin material with a concrete material or with a reinforcing material and also to a method for manufacturing the composite building material, the composite building material ensuring that floor materials, framework walls and the like in, for instance, various buildings, e.g., general houses and residences, can be formed firmly in a simple and speedy manner.
2. Description of the Related Art
In customary production of this type of composite building material, for instance, when a cement mortar material is bonded with, for example, a flat plate-like foamed polystyrene board which is a heat-insulating material made of a foamed synthetic resin material, both materials are bonded with each other either by the adhesion of the cement mortar material itself or by using an adhesive thereby integrating the foamed polystyrene board with the cement mortar material. The adhesive include resin-soluble types and resin-insoluble types in which a synthetic rubber powder is compounded.
However, in the prior art, when the foamed synthetic resin plate layer is bonded with the cement mortar material only by the adhesion of the cement mortar material itself, both materials are easily separated from each other to produce cracks on account of very week adhesion, bringing about defects in strength for building materials. On the other hand, when the adhesive is used, the adhesive durability is reduced due to the deterioration of the adhesive itself caused by, for instance, a variation in the elastic modulus with time and denaturing of the composition and hence there is a possibility of exfoliations. Also, when the aforementioned resin-soluble adhesive is used, it solves part of the foamed synthetic resin plate layer, whereby clearances are produced between the foamed synthetic resin plate layer and the cement mortar layer and nonuniformity in the thickness of the foamed synthetic resin plate layer is caused. This is the cause of cracks and exfoliations. The aforementioned resin-insoluble adhesive formulated with a synthetic rubber powder is very expensive and hence the use of the resin for composite building materials is not very practical. Moreover, because the conventional composite building material using a foamed synthetic resin material is not provided with any reinforcing treatment for preventing buckling against bending stress, it has inferior strength particularly when it is used as a floor material and is not used very widely as framework wall materials for composite building materials.
SUMMARY OF THE INVENTION
The present invention has been made in view of such a situation as stated above and has an object of providing a composite building material which is produced without using an adhesive like the conventional processes, can prevent the occurrences of exfoliations and cracks by improving the adhesion of a cement mortar material itself to a foamed synthetic resin plate layer, has high strength, forms floor materials, framework walls and the like firmly, simply and speedily and has a resistance to buckling caused by bending stress to the composite building materials whereby it is improved in the strength, for instance when it is used for floor materials, framework walls or the like. The present invention also has an object of providing a method for the production of the composite building material.
In order to attain the above object, a composite building material according to the present invention comprises a foamed synthetic resin plate layer
2
formed with plural concave grooves
6
(
9
) on at least one of the surface and the backface thereof, a net-like groove lathing material
3
which is disposed in each inside of the grooves
6
, a net-like surface lathing material
4
stretched on all of one surface such that it covers an opening of each groove
6
(
9
) and a cement mortar layer
5
laminated so as to bury both of the lathing materials
3
and
4
.
The plural grooves
6
and
9
of the foamed synthetic resin plate layer
2
may be formed concavely on both surfaces of the foamed synthetic resign plate layer such that the groove
6
formed on one of the surfaces and the groove
9
formed on another of the surfaces have openings with widths different from each other and are arranged alternately in parallel such that they
6
,
9
do not oppose to each other.
The grooves
6
and
10
of the foamed synthetic resinplate layer
2
may be arranged so as to cross lengthwise and breadth wise.
The grooves
6
and
9
of the foamed synthetic resin plate layer
2
may be made concavely in the form of almost a dovetail groove type, almost an inverse T-shaped type or almost an inverse V-shaped type and the groove lathing material
3
is arranged in each back section of the grooves
6
and
9
. Alternatively, the grooves
6
and
9
of the foamed synthetic resin plate layer
2
may be made concavely in almost a sectionally circular form and the groove lathing material
3
is arranged almost cylindrically along the circumferential wall of the grooves
6
and
9
.
In the surface opposite to the one surface provided with the grooves
6
, plural reinforcing materials
8
made of wood, concrete panel materials, rigid materials, iron materials, corrugated board materials or the like may be buried in opposition to each groove
6
such that each of these reinforcing materials is included or one of its surfaces is exposed.
In the foamed synthetic resin plate layer
2
constituting the composite building material
1
, plural lengthy and narrow plate reinforcing materials
28
made of wood, concrete panel materials, rigid materials, iron materials, corrugated board materials or the like may be buried such that the reinforcing material is included or at least one of its surfaces is exposed.
At least one of the surfaces of the foamed synthetic resin plate layer
2
may be provided with a plywood layer
21
made of wood, concrete panel materials, rigid materials, iron materials, corrugated board materials or the like.
In a method for manufacturing a composite material according to the present invention,plural concave grooves
6
(
9
) are formed in parallel on at least one of the surface and the backface of a foamed synthetic resin plate layer
2
constituting a composite building material
1
. After a net-like groove lathing material
3
corresponding to the size of each groove is arranged in each groove
6
(
9
) and a cement mortar material is then filled so as to bury the groove lathing material
3
, a net-like surface lathing material
4
is stretched over all of one surface such that it covers an opening of each groove
6
(
9
) and a cement mortar material is also laminated. Alternatively, after a net-like groove lathing material
3
is arranged in each groove
6
(
9
) and a net - like surface lathing material
4
is stretched over all of one surface such that it covers an opening of each groove
6
, a cement mortar material is filled such that both of the lathing materials
3
and
4
are buried and a concrete material layer
11
is laminated,thereby integrating the foamed synthetic resin plate layer with the cement mortar material.
Plural reinforcing materials
28
which are made in the form of a lengthy and narrow plate and made of wood, concrete panel materials, rigid materials, iron materials, corrugated board materials or the like and a lengthy and rectangular prismatic foamed synthetic resin material are applied alternately and integrated to form a plate.
Plural reinforcing materials
28
which are made in the form of a lengthy and narrow plate and made of wood, concrete panel materials, rigid materials, iron materials, corrugated board materials or the like may be buried in a foamed synthetic resign plate layer such that the reinforcing materials are included or one of the surfaces of each reinforcing material is exposed.
A plywood layer
21
made of wood, concrete panel materials, rigid materials, iron materials, corru
A Phi Dieu Tran
Schwegan, Lundberg, Woessner & Kluth, P.A.
Stephan Beth A.
Yoshiki Kimura
LandOfFree
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