Composite building material and method for manufacturing the same

• US 6,305,135 B1
• Filed: 05/13/1999
• Issued: 10/23/2001
• Est. Priority Date: 05/14/1998
• Status: Expired due to Fees

• Current Assignee: Yoshiko Kimura
• Original Assignee: Yoshiki Kimura
• Inventors: Inaba, Hiroshi
• Primary Examiner(s): Stephan, Beth A.
• Assistant Examiner(s): A, PHI DIEU TRAN
• Application Number:
  US09/311,233
• Time in Patent Office: 894 Days
• Field of Search: 523/091.2, 523/091.7, 526/12, 525/901, 523/42, 523/43
• US Class Current: 52/309.12
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material

Abstract

Provided is a composite building material which is more improved in the bonding capability of a cement mortar material itself with a foamed synthetic resin plate layer, furthermore prevents the occurrences of exfoliations and cracks and has higher strength compared with conventional composite materials. Plural concave grooves are formed in parallel on at least one of the surface and backface of a foamed synthetic resin plate layer and a net-like groove lathing material corresponding to the size of each groove is arranged within each groove. A cement mortar material is filled in the groove so as to bury the groove lathing material, a net-like surface lathing material is then stretched over all of one surface and a cement mortar material is further laminated to form a composite building material in which the foamed synthetic resin plate layer and the cement mortar layer are integrated with each other. The groove is made concavely in almost a dovetail groove form and the composite building material is structured so as to dispose the groove lathing material in the back section of the groove.

Claims

1. A composite building material, comprising:

a foamed synthetic resin plate layer including a first surface, a second surface, and a plurality of concave grooves formed in at least one of the first surface and the second surface,

a net-like groove lathing material which is completely disposed in the plurality of grooves,

a net-like surface lathing material stretched on the at least one surface such that it covers an opening of the plurality of grooves, and

a mortar layer filling the plurality of grooves and covering the at least one surface so as to bury both the groove lathing material and the surface lathing material.

2. The composite building material according to claim 1, wherein the plurality of grooves are formed concavely on both the first surface and the second surface, the grooves formed on the first surface each have a first opening, the grooves formed on the second surface each have a second opening, and the first opening has a width different than the width of the second opening.

3. The composite building material according to claim 2, wherein the grooves formed on the first surface and the grooves formed on the second surface are arranged alternatively in parallel.

4. The composite building material according to claim 1, wherein the plurality of grooves in the foamed synthetic resin plate layer are arranged so as to cross lengthwise and breadth wise.

5. The composite building material according to claim 1, wherein the plurality of grooves include at least one groove in one of a dovetail groove type, an inverse T-shaped type and an inverse V-shaped type and the groove lathing material is arranged in each back section of the grooves.

6. The composite building material according to claim 1, wherein the plurality of grooves include a semi-circular form and the groove lathing material is arranged semi-cylindrically adjacent a circumferential wall of each semi-circular form groove.

7. The composite building material according to claim 1, wherein the plurality of concave grooves are formed in only the first surface, the second surface is opposite the first surface and includes a plurality of secondary grooves, and wherein a reinforcing structure made of at least one of wood, concrete panel material, rigid material, iron material, and corrugated board material is arranged in at least one of the secondary grooves.

8. The composite building material of claim 7, wherein the reinforcing structure has a surface exposed through an opening in the secondary groove.

9. The composite building material of claim 7, wherein the reinforcing structure includes a first material in the secondary grooves, a second material secured to the first material, and a third material secured to the second material.

10. A composite building material, comprising:

a foamed synthetic resin plate layer including a first surface, a second surface, and a plurality of concave grooves formed in at least one of the first surface and the second surface, wherein the grooves include an opening having an opening width;

a net-like groove lathing material which is completely disposed in the grooves and has a groove lathing width, the groove lathing width being greater than the opening width;

a net-like surface lathing material stretched on the at least one surface such that it covers the openings of the grooves, and

a filling layer in the at least one groove and covering the at least one surface so as to bury both the groove lathing material and the surface lathing material.

11. The composite building material according to claim 10, wherein the grooves include a base having a base width, the base width being greater than the opening width and a width of the groove lathing material.

12. A method of manufacturing a composite material, comprising:

forming a plurality of concave grooves in parallel on at least one of a first surface and a second surface of a foamed synthetic resin plate layer;

arranging a net-like groove lathing material corresponding to the size of each groove completely in each groove;

filling the groove with a cement mortar material so as to bury the groove lathing material;

stretching a net-like surface lathing material over the one surface such that it covers an opening of each groove; and

applying cement mortar material to encase the surface lathing material thereby integrating the foamed synthetic resin plate layer with the cement mortar material.

13. The method of claim 12, wherein forming the plurality of concave grooves includes forming the opening of each groove to an opening dimension, and wherein arranging the groove lathing material includes positioning a groove lathing material having a dimension extending generally aligned with the opening dimension which is an greater than the opening dimension in each groove.

14. The method of claim 12, wherein the steps are performed in the order recited.

15. The method for manufacturing a composite material according to claim 12, further comprising applying a further layer made of at least one of wood, concrete panel materials, rigid materials, iron materials, and corrugated board materials onto at least one of the first surface and the second surface of the foamed synthetic resin plate layer.

16. A method for manufacturing a composite material, comprising:

forming a plurality of concave grooves in parallel on at least one of a front surface and a back face of a foamed synthetic resin plate layer;

arranging a net-like groove lathing material in each groove such that the groove lathing material is completely within the groove;

stretching a net-like surface lathing material over all of the at least one surface such that it covers an opening of each groove; and

then filling the grooves with a cement mortar material so as to bury both the groove lathing material and the surface lathing material, thereby integrating the foamed synthetic resin plate layer with cement mortar material.

17. The method for manufacturing a composite material according to claim 16, further comprising alternately applying a plurality of reinforcing materials which are made in the form of a lengthy and narrow plate and made of at least one of wood, concrete panel materials, rigid materials, iron materials, and corrugated board materials and a lengthy and rectangular prismatic foamed synthetic resin material to form an integrated plate.

18. The method for manufacturing a composite material according to claim 16, further comprising burying a plurality of reinforcing materials, which are made in the form of a lengthy and narrow plate and made of at least one of wood, concrete panel materials, rigid materials, iron materials, and corrugated board materials, in the formed synthetic resin plate layer such that one of the surfaces of each reinforcing material is exposed.

19. A composite building material, comprising:

a foamed resin layer including a first surface, a second surface, and a plurality of elongate grooves formed in at least one of the first surface and the second surface, each of the grooves having an opening which has a length and a width;

a net-like groove lathing material completely disposed in the plurality of grooves, the groove lathing material including a segment in one of the plurality of grooves, the segment having a width which is greater than the width of the opening;

a surface lathing material stretched over the at least one surface such that it covers the openings of the plurality of grooves; and

a mortar layer filling the plurality of grooves and covering the at least one surface so as to encase both the groove lathing material and the surface lathing material.