JP2000054593A - Manufacture of decorative material for finishing surface of outside angle section - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative material for finishing the surface of an outside angle section, in which a manufacturing process can be omitted and is simplified, productive efficiency is improved, the waste of a raw material for the decorative material is also decreased, manufacturing cost is reduced, the durability of a joining section is enhanced, the color tone of the joining section can be adjusted without a sense of incompatibility and the execution of works is also facilitated. SOLUTION: A linear slit is formed to the decorative material layer 2 of a laminated sheet 5, in which the decorative material layer 2 is formed onto a bendable base material sheet 1, the laminated sheet 5 is folded double while the base material sheet is directed inwards along the slit, and a plurality of the laminated sheets 5 are brought into contact while the mutual surfaces of the decorative material layers 2 are faced oppositely and arranged so that the cut surfaces of the decorative material layers are formed in approximately the same plane. The cut surfaces of the decorative material layers are coated with a raw material 3 for the decorative material, and placed on a patch form 11 having a bent surface at an angle α the same as or slightly smaller than the angle of the outside-angle section cross section, the coated raw material 10 for the decorative material is dried, and a section 10 in the vicinity of the raw-material coating section for the decorative material is polished and a corner is exposed, thus obtaining the decorative material for finishing the surface of the outside angle section.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative material for finishing a surface at an outside corner.

[0002]

2. Description of the Related Art Sheet-shaped decorative materials have been widely used in recent years as decorative materials for finishing the interior and exterior surfaces of buildings or other structures or floor surfaces.

[0003] When a decorative sheet for surface finishing is attached to the interior and exterior of a building such as a building, the protruding corner of the building is used as a finishing method as described in, for example, JP-A-6-264593. The outline is shown in FIG.
With reference to (d) (all are sectional views),
Two decorative sheets for surface finishing 100a, 100b to be attached to the two surfaces constituting the corner 120 of the building 110
Each of the base material sheet 101 and the decorative material layer 102 is tapered at an angle (45 ° in this case) which is half the angle (90 ° in this case) of the corner 120. Decorative sheets for surface finishing 100a, 10
For example, the end of the decorative sheet for surface finishing is a few mm in the thickness direction of the decorative sheet for surface finishing by shaving the end of the decorative sheet for surface finishing by shaving the end with a sander 105 or the like so that the two sheets abut each other (see FIG. 3A). A method is shown in which the sheet is shifted and attached to the protruding corner 120 (see (b) and (c) in FIG. 3), and the protruding portion is scraped off with, for example, a sander 105 (see (d) in FIG. 3).

[0004]

However, in such a method, the sheet is cut or sanded on site to form a sharp tapered edge required for finishing the protruding corner, so that the shaving is performed. Including the problem that the angle must be adjusted at the site so that the angle is also adjusted to the predetermined angle, it also requires relatively skill, it takes a considerable amount of time, and the work efficiency is low, temporarily cutting or sanding in advance at the factory It can be transported to the work site after forming the taper part and constructing it.However, even if it is cut or sanded at the factory to form the taper part, if it is not polished to the tapered shape as designed, it is constructed Since the tapered surface does not match well and the appearance is poor, it needs to be carefully polished in the same way as above Is still bad, and in any case, the adhesive where the tapered part is overlapped after application is only relatively thin, so the adhesive strength of this part is relatively weak, There are problems such as repeated thermal expansion and contraction due to repeated sunshine, peeling from that part when exposed to wind and rain for many years, and easy entry of water etc. When the adhesive is protruded, the adhesive generally does not contain aggregates and the like contained in the decorative material layer, so that the color tone cannot be adjusted to the same level as that of the decorative material layer, and there is a problem that the appearance is slightly lowered.

[0005] Apart from this, the inventor further studied a method as shown in FIG. FIG. 4 is a schematic process cross-sectional view for explaining a method of manufacturing a decorative material for finishing a protruding corner portion studied by the present inventors. As shown in FIG. 4A, a decorative sheet for surface finishing comprising a base material sheet 101 and a decorative material layer 102 (hereinafter sometimes referred to as a laminated sheet).
From the position of the arrow 130 by using a cutter such as a cutter knife to leave the base material sheet 101 and leave the decorative material layer 102
A substantially straight cut is made in the base sheet 10 as shown in FIG. 4 (b).
4 is folded inward so that the base material 1 has a surface bent at substantially the same angle α as the cross-sectional shape of the target projected corner portion, as shown in FIG. The decorative material 3 having the same composition and the same color as the decorative material layer 102 is sprayed over the open cut 107 so that the sheet 101 is placed in contact with the backing mold 11 by spraying, for example, from a spray gun 4. It is also difficult to spray the application area by the spray gun in a concentrated manner only on the portion of the open cut 107 alone, because the cosmetic material material 3 blown out with the compressed air from the spray gun nozzle spreads radially and is ejected. Therefore, the cosmetic material material 3 is applied to the surface 109 of the decorative material layer 102 so as to protrude onto the surface 109 of the decorative material layer 102 so that the surface 109 of the decorative material layer 102 is not stained. Previously cured tapes Toka curing sheet referred back to the adhesive material or the like on the surface of 9 paste every time the sheet 108 for sealing pointed coated keep covering the surface of the surface 109 of the facing layers 102. In this manner, the raw material for cosmetic material 3 is sprayed from the spray gun 4 to form a portion 102b which is protruded from the joint portion 102a and is applied (see FIG. 4 (d)). Peeling off, for example, the portion 102b which is shown as being obliquely below the dotted line 90 and applied is removed together with the sealing sheet 108, and although not shown, the angle of this portion is reduced in a state where the joint portion 102a is dried. The surface of the joining portion 102a is polished by sanding or the like so as to form a desired angle α of the protruding corner portion.

However, according to this method, the sealing sheet 108 is stuck to each other, or within a specific time (ie, one time).
02b is in a semi-dry state), it is very troublesome and costs increase, and if the raw material 3 for the protruding and applied portion 102b is wasted. There's the problem I said.

In this case, a common method is the same process up to FIG. 4A and FIG. 4B, and thereafter, as shown in FIG. Cut 10
In the portion 7, apply a raw material for a cosmetic material with a spatula or a trowel so that the joint portion 102 c is almost flat so as not to protrude or flow down onto the surface 109 of the cosmetic material layer 102 so as not to rise, and then dried. A method of forming a protruding corner is often adopted.

However, this method also has a problem that the strength of this portion is weak because the protruding corner has a chamfered shape as shown in the figure. In addition, the decorative material layer 102 is not a one-color blown one, but a two-color or three-color blown (two or three kinds of raw materials for cosmetics adjusted to different colors are separately sprayed with a plurality of spray guns or two heads). Spraying with a gun or a three-head gun, etc. to form the decorative material layer 102), the problem is that when applied with a spatula or trowel, it is difficult to finish the same pattern as the multicolor simultaneous spraying described above. There is also.

The present invention solves the above-mentioned problems of the method for producing a decorative material for finishing a surface at a protruding corner, simplifies the production process, improves the production efficiency, and reduces waste of the raw materials for the cosmetic material to be used. Less, the manufacturing cost can be kept low, there is no problem as described with reference to FIGS. 3, 4 and 5, and the amount of the raw material for the cosmetic material applied to the joint can be relatively large, and The strength and durability of the joints are high, and the color tone of the raw material for the cosmetic material applied to the joints can be easily adjusted to a harmonious one without discomfort. It is an object of the present invention to provide a method for manufacturing a decorative material for finishing a surface at a protruding corner.

[0010]

Means for Solving the Problems In order to solve the above-mentioned problems, a method of manufacturing a decorative material for finishing a surface at an outer corner according to the present invention is as follows.

(1) (a) a step of forming a substantially linear cut in the thickness direction of the decorative material layer of a laminated sheet having a decorative material layer formed on a foldable base material sheet; (b)
A step of folding the laminated sheet along the cuts of the decorative material layer so that the base sheet is on the inside, and substantially folds the laminated sheet.
(C) By arranging the plural folded sheets in contact with each other so that the surfaces of the decorative material layers face each other in a state where each of the laminated sheets is folded in two, almost two
(D) arranging the cut surfaces of the decorative material layer appearing by folding so that the cut surfaces of the decorative material layer become substantially the same plane; and (d) applying a cosmetic material to the cut surface of the decorative material layer appearing in that state. (E) Coating material is applied to the cut surface such that the base material sheet is in contact with the backing die on a backing die having a surface bent at an angle substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner. Placing each of the obtained laminated sheets while widening the bending angle thereof, and drying the applied raw material for a decorative material, (f) after drying, polishing the vicinity of the applied portion of the decorative material obtained for the decorative material for the obtained decorative material. A method for producing a decorative material for surface finishing at a protruding corner portion, comprising a step of squaring.

(2) After the polishing in the step (f), the method further comprises a step (g) of applying an emulsion or solution of a synthetic resin, which becomes transparent when dried, on the surface, drying and applying a top coat layer. (1) The method for producing a decorative material for finishing a surface at a protruding corner according to the item (1).

(3) The abutting die is made of a paperboard bent substantially in an L-shape at an angle substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner portion. 3. The method for producing a decorative material for finishing a surface at an outside corner according to the above.

(4) The method for producing a decorative material for finishing a surface at an outer corner according to any one of the above (1) to (3), wherein the decorative material layer comprises a synthetic resin layer in which aggregate is dispersed. . (5) The decorative material for finishing a surface of a protruding corner according to any one of the above (1) to (4), wherein the raw material for the cosmetic material is a synthetic resin emulsion or an application material obtained by dispersing an aggregate in a solution. The method of manufacturing the material.

(6) The aggregate mainly has a particle size of 0.05 to
The method for producing a decorative material for finishing a surface at a protruding corner according to any one of the above (4) or (5), which is an aggregate having a size of 1.5 mm.

(7) The aggregate according to any one of (4) to (6), wherein the aggregate is at least one kind of aggregate selected from natural stone powder, silica sand, ceramic powder, plastic aggregate, and a coloring material thereof. A method for producing a decorative material for finishing a surface at a protruding corner as described in Crab.

(8) The method according to any one of the above (4) to (7), wherein the synthetic resin component of the synthetic resin layer is an acrylic resin. (9) The method for producing a decorative material for finishing a surface at a protruding corner according to any one of the above (5) to (8), wherein the synthetic resin emulsion or solution as a raw material for a cosmetic material is an acrylic resin solution or emulsion.

(10) The method according to any one of the above (1) to (9), wherein the base sheet is a cloth-like base sheet.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings for easy understanding of the present invention. However, the present invention is specifically described in the embodiments. However, it is not limited to only those given.

FIGS. 1 and 2 are process perspective views showing a preferred embodiment of a method for producing a decorative material for finishing a surface at an outside corner according to the present invention, and process perspective showing a production-construction process also showing the construction process. FIG. (A), (b), (c) of FIG.
And (d), (e), (f), and (g) in FIG. 2 are a series of steps subsequent to FIG. 1, but are not fit in one figure, and thus are drawn separately in FIG. 1 and FIG. Things.

As shown in FIG. 1A, for example, a raw material 3 for a decorative material layer 2 as a raw material for a decorative material layer 2 is placed on a nonwoven fabric, a woven fabric, or another foldable base sheet 1 as shown in FIG.
A laminated sheet 5 on which the decorative material layer 2 is formed is prepared by spraying and applying from a spray gun as indicated by 4 in (a).

Next, as shown in FIG. 1B, a substantially linear cut 7 is made in the decorative material layer 2 of the laminated sheet 5 in the thickness direction. In FIG. 1B, reference numeral 6 denotes a cutter knife. The means for forming the cut 7 is not limited to the cutter knife, as long as the purpose is achieved.

Next, as shown in FIG. 1 (c), the laminated sheet 5 is folded into two substantially along the cuts 7 of the decorative material layer 2 with the base sheet 1 inside. Note that, here, the cut surface of the decorative material layer appearing by being substantially folded into two is the surface indicated by reference numeral 8, and the surface of the decorative material layer is the surface indicated by reference numeral 9.

Next, as shown in FIG.
A plurality of folded laminated sheets 5 are arranged in such a manner that the surfaces 9 of the decorative material layer 2 are brought into contact with each other in a state where each of the laminated sheets 5 is folded in two, so that the cosmetics appearing by being substantially folded into two. The layers are arranged such that the cut surfaces 8 of the material layers are substantially the same plane.

Then, on the cut surface 8 of the decorative material layer 2 of the laminated sheet 5 which is folded in two and arranged in plural, a decorative material material 3 having the same composition and the same color tone as shown in FIG.
The coating is performed by spraying from a spray gun as shown by (1) (coating layer 10). In this case, the surfaces 9 of the decorative material layer 2 are arranged so as to be in contact with each other so as to face each other, and the raw material for decorative material 3 is sprayed and applied only to the cut surface 8. Raw material 3 for cosmetic material on surface 9 of 2
Is not stained on the surface 9 of the decorative material layer 2. Suppose that the raw material for cosmetic material 3 is applied to the surface 9 of the outermost decorative material layer 2 located on the left and right sides of the laminated sheet 5 folded in two and arranged in plurals, and the surface 9 of the decorative material layer 2 may be stained. In some cases, it is sufficient to seal only the surface 9 of the decorative material layer 2 on both sides with the above-mentioned curing sheet or curing tape, and if the number of the laminated sheets 5 folded in two can be considerably increased, for example, If one building, or the number of batches used for the building or a number thereof is listed at a time, the production is extremely efficient because only two seals are required on each side. In addition, if the spraying method is good, as described above, the raw material for cosmetic material sprayed from the nozzle of the spray gun is radially fired,
Even without a seal, the surface 9 of the decorative material layer 2 on both sides can be applied without soiling. On the other hand, when the method as shown in FIG. 4 is adopted, the surface 109 of the decorative material layer 120 must be sealed one by one and two on the left and right sides, which is extremely inefficient.

Next, as shown in FIG. 2E, an angle α substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner portion.
Each of the cut surfaces 8 is applied with the coating material 10 (coating layer 10) so that the base sheet 1 is in contact with the contact mold 11 on the contact mold 11 having a surface bent in the above manner. The laminated sheet 5 is placed with its angle widened so that the bending angle thereof matches the angle α of the contact mold 11, and the applied cosmetic material material 3 (application layer 10) is dried. The thus-obtained rough finished product is bent at a desired angle on the inner surface side where the base sheet is present, but the formed coating layer 10 is slightly thickened. The portion which is present is polished by a suitable means such as sanding, and is squared to a desired angle as shown in FIG. Then, if necessary, an emulsion or solution of a synthetic resin which becomes transparent after drying is thinly applied to the surface from the front side, dried, and a top coat layer is applied. The top coat layer may be applied as needed, and is not always necessary. In particular, when a matte decorative material layer is desired, the top coat layer may not be applied. In addition, by applying a top coat layer, it is possible to impart a surface gloss to the decorative material, to prevent the resin layer from being shaved after polishing and to make it look whitish due to irregular reflection, or to have properties such as weather resistance, water resistance, stain resistance, etc. Is further effective.

As shown in FIG. 2 (g), the decorative material for surface finishing at the corners of the present invention thus obtained is coated on the base sheet side with an appropriate adhesive to expose a building or a building. The adhesive is fixed to the corner 12.

The bendable base sheet used in the method for producing a decorative material for finishing a surface at an outer corner according to the present invention may be any bendable sheet that can reinforce the strength of the decorative material layer. A substrate sheet made of a cloth-like material is particularly preferable because it is light and has good adhesiveness.Specifically, for example, a woven fabric or nonwoven fabric made of synthetic fiber or inorganic fiber, for example, more specifically, a cold gauze made of acrylic fiber or polyester fiber or Fabrics such as nonwoven fabric, glass fiber woven fabric, glass wool nonwoven fabric, and synthetic paper are preferred. Non-absorbent or low-absorbent fabrics are preferred because those with high water absorption tend to expand due to moisture and tend to shrink during drying, and the product after drying may warp and deform. However, when a cloth material having no or low water absorption is used, such a problem does not occur, which is preferable.

Other base sheets include aluminum sheets, galvanized steel sheets and other metal sheets, metal wire mesh,
Expanded metal, rubber sheet, synthetic resin sheet and the like are also included.

In the present invention, as the decorative material layer, a material in which an aggregate is dispersed in a synthetic resin component is preferably used. However, the present invention is not particularly limited thereto. Any material that is used as a decorative material layer of a material and does not hinder the object of the present invention can be adopted.

As a raw material for a decorative material for forming the decorative material layer, a synthetic resin emulsion or a mixture of a synthetic resin solution and an aggregate (which may be abbreviated as a coating material or a spray material) is preferably used. As a raw material of the synthetic resin component, various synthetic resin emulsions and solutions conventionally used in the production of decorative materials having a natural stone pattern can be used. A synthetic resin emulsion is preferably used from the viewpoint that there is no need to consider the recovery of the organic solvent, environmental problems, and the like. Especially weather resistance,
Synthetic resin emulsions satisfying alkali resistance, water resistance, adhesion, flexibility, water absorption resistance and the like are preferable. Specific examples include acrylic resin emulsions (acryl-styrene resin emulsion, acryl-urethane resin). Emulsion, acrylic-silicone resin-based emulsion, acrylic-fluororesin-based emulsion),
Examples thereof include a vinyl acetate resin emulsion such as an ethylene-vinyl acetate resin, a vinyl chloride resin emulsion, and a urethane resin emulsion. The resin component after drying of any of these resins also has appropriate flexibility,
It is easy to work on the corner. Above all, acrylic resin emulsions are relatively inexpensive, but they are more durable in terms of weather resistance, so they have long-term durability, such as when used as a decorative material for surface finishing at the corners of buildings and structures. preferable.

As described above, when an aggregate is used by mixing it with a synthetic resin raw material, the aggregate to be mixed may be any of various types of materials that have been conventionally used in the production of decorative materials having a natural stone pattern. Known aggregates can be used, so-called colored aggregates such as marble powder, granite powder, silica sand and other natural stone powder, ceramic powder, plastic aggregate, or artificially colored such as, for example, colored calcined silica sand and colored ceramic powder. Aggregates such as those referred to as "Aggregates" are mentioned. Among them, aggregates made of inorganic materials are preferably used from the viewpoint of cost.

The size of the aggregate is mainly 0.05 to
It is preferable to use an aggregate having a size of 1.5 mm. Here, when the aggregate is not spherical, when the aggregate is not spherical, the particle of the observed aggregate is visible when observing with an appropriate instrument such as a microscope at the time of measurement. The diameter is used as the diameter of the aggregate particles.

It is to be noted that by appropriately using one or two or more of artificially colored aggregates, or aggregates of the same color as the material which is not artificially colored, it is possible to obtain desired aggregates. The color tone and hand can be adjusted.

The blending ratio of the aggregate and the synthetic resin component is slightly different depending on the purpose, such as what kind of texture the decorative material layer has, but the ratio of the synthetic resin emulsion or solution is a solid content and the aggregate is It is preferably about 5 to 20 parts by weight based on 100 parts by weight.

In a preferred embodiment of this range, the amount of the synthetic resin component is sufficient to also serve as a binder for the aggregate, and the amount of the synthetic resin component may be too large to cause shrinkage and cracks. Further, it is possible to easily produce a material having a texture such as natural stone tone and the like, and it is preferable because the decorative material layer has durability and appropriate strength.

In order to adjust the color tone of the decorative material layer, the amount of one or more kinds of various aggregates, so-called colored aggregates obtained by artificially coloring these aggregates, the type of aggregate to be added, the particle size, This can be achieved by appropriately selecting and blending colors, or adding a coloring agent as necessary.

The raw material for the cosmetic material thus adjusted is not particularly limited, but the color tone is different.
Spraying multicolored patterns using individual single-headed guns for each color tone, or spraying multicolored patterns using a multi-headed gun such as a two-headed gun or a three-headed gun, using more than one kind of cosmetic material raw materials It is also common to form the decorative material layer in a multicolored pattern, and it is preferable to obtain a high-quality natural stone-like texture or the like.

In addition, one or more colored flake-like synthetic resin flakes may be separately added to the raw material for the cosmetic material in order to give a unique feeling as required. As the colored flaky synthetic resin flake, various known flakes can be used. Among them, it is preferable to use amorphous and flexible colored flaky resin flakes (hereinafter, sometimes referred to as colored flaky amorphous flexible resin flakes),
The method for producing the colored flaky amorphous flexible resin flakes is not particularly limited, but the colored flaky amorphous flexible resin flakes obtained by the following manufacturing method newly developed and proposed by the present applicant are: It can be said that this is one of the preferable ones. That is, a mixture comprising an aggregate and a synthetic resin emulsion or a solution and, if necessary, a coloring material, a flat material having a smooth or somewhat uneven surface having releasability, such as a polypropylene film or a foam sheet, a silicone rubber sheet, Spray thinly onto a fluororesin film or sheet using a spray gun or the like and dry. When thinly sprayed, the thickness is usually uneven even if it is not intentionally unevenly sprayed, but in some cases, it may be unevenly thinly sprayed to such an extent that unevenly and partially non-sprayed portions are generated. This is dried, and a substantially continuous but flexible thin resin sheet obtained by peeling from the flat material having the peeling property is obtained. The sheet is mixed with the raw material for the decorative material and stirred. By doing so, the colored flaky amorphous flexible resin flakes that are divided into small pieces and become amorphous flaky amorphous flexible resin flakes have good production efficiency and are thin and flexible,
Even when flakes of somewhat large size are easily mixed through the spray gun nozzle and sprayed even when sprayed and applied using a spray gun after mixing into the raw materials for cosmetics, the flakes are flexible, so there are also problems such as the ends jumping up. Preferred. In particular, the flakes used for imparting a slightly larger spot pattern to the decorative material layer are preferably used.

The thickness of the flaky amorphous flexible resin flakes is preferably 1 mm or less in average thickness, more preferably 0.2 to 2 mm.
When about 0.9 mm has flexibility, and is added to the raw material for cosmetic material (sometimes referred to as a spraying material or a coating material) and is applied to the base material sheet by a spray gun or the like, Since it easily passes through the nozzle of the spray gun and is extremely flexible, it is preferable that the flake ends do not jump from the surface of the decorative material layer even after being applied.

The material of the aggregate used to obtain a substantially continuous soft thin resin sheet for the flaky amorphous flexible resin flakes is selected from those of the aggregate mixed with the raw material for the decorative material. Aggregate of the same material as the material can be used. However, the particle size of the aggregate is preferably slightly smaller, specifically, the particle size is 0.5 mm or less, more preferably 0.01 mm or less.
Those having a size of about 0.5 mm to 0.5 mm are preferably used. As the synthetic resin emulsion or solution for forming the flexible thin resin sheet, the same synthetic resin emulsion or solution used as a component of the above-mentioned raw material for a cosmetic material can be used. In this case, the mixing ratio of the aggregate and the synthetic resin emulsion or the solution is preferably about 20 to 100 parts by weight, particularly 30 to 70 parts by weight, based on 100 parts by weight of the aggregate in terms of resin solids. It is preferably about parts by weight.

Further, in order to obtain a unique feeling as required, mica flakes such as mica and colored mica may be separately added to the raw material for the cosmetic material. The cosmetic material raw material composition (coating material) in which the aggregate is mixed with the synthetic resin emulsion or solution may further include a filler, a film forming aid, a thickener, a defoaming agent, a pH adjuster, if necessary. May be added, or water or an appropriate solvent may be added to adjust the viscosity.

The application of the raw material composition onto the base sheet is most commonly performed by a spraying method using a spray gun or the like. In addition, the application may be performed using a trowel or another application device. However, since the method using a spray gun is excellent in workability, a spray method using a spray gun is usually preferably used. The thickness of the coating varies depending on the material and the kind used, and is not particularly limited. Usually, about 2 to 10 mm is applied once or twice or more, and applied and dried.

The synthetic resin emulsion or solution used to form the top coat layer may be any as long as it can form a transparent coating layer when dried. Alternatively, a synthetic resin emulsion or solution similar to the solution can be used. Especially acrylic-silicone resin or acrylic-
Fluororesin-based emulsions or solutions are particularly excellent in weather resistance, water resistance and antifouling properties, and are preferred.

As the backing die, a backing die having a surface bent at an angle substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner portion is used, and is formed of a sheet-like material having a certain degree of rigidity. For example, those having a substantially L-shaped cross section or a triangular prism having the above-mentioned angle may be used.

In the case of a sheet-like material, a paperboard (for example, “Fiber Angle” manufactured by Saga Paperboard Co., Ltd.)
It is extremely convenient to use a thick paperboard already formed in an L-shape, and the cost is low. ), Plastic plate molding, wood plate, metal plate, ceramic plate molding, glass plate, gypsum plate molding, etc. In the case of triangular prisms, plastic molding, wood, metal molding, ceramic There is no particular limitation as long as the object of the present invention is not impaired, such as a molded product, a glass molded product, a gypsum molded product, and a cement molded product. Among them, paperboard is one of the preferable ones in that it can be manufactured at low cost.

As shown in FIG. 2E, the contact mold 11
Is a contact mold having a surface bent at an angle α substantially equal to or slightly smaller than the angle formed by the target corner cross section, but this angle α is substantially equal to the angle formed by the corner cross section. If the angle α is slightly smaller than the angle formed by the cross-section of the protruding corner, it is of course possible to easily adhere to the protruding corner using an adhesive if it is provided. In order to return to the original angle, a slight pressure is applied to the building surface at the protruding corner, which is preferable because the adhesion becomes better. Further, in some cases, it is usual to support the decorative material adhered until the adhesive is solidified so that the decorative material does not come off. However, such a support may not be required, which is preferable. There is no particular limitation on the angle slightly smaller than the angle formed by the protruding corner section, but it is preferable to make the angle smaller than the angle formed by the protruding corner section by about 7% or less.

[0048]

According to the method for producing a decorative material for finishing a surface at an outside corner according to the present invention, a plurality of laminated sheets, each of which is folded in two along a cut of a decorative material layer, are each folded into two. The surfaces of the material layers are arranged in contact with each other so as to face each other, and the raw material for cosmetic material is applied to the cut surface of the decorative material layer that appears in that state, so the production process can be omitted, production is simple, and production efficiency is good. , Less waste of raw materials for cosmetics used, lower manufacturing cost, relatively large amount of raw materials for cosmetics applied to the joints, therefore the strength and durability of the joints are high, The color of the cosmetic material used in the joint can be easily adjusted to a harmonious one without discomfort, and it is easy to apply it to the corners of buildings and structures at the site. A method for producing a decorative material for finishing can be provided.

(2) As described in the above item (2), after polishing in the step (f), an emulsion or solution of a synthetic resin which becomes transparent when dried is further applied to the surface,
By providing a preferred embodiment of the present invention including a step (g) of drying and applying a top coat layer, the decorative material is imparted with surface gloss and further imparted with properties such as weather resistance, water resistance and stain resistance. The decorative material for finishing the surface at the protruding corner can be easily manufactured, which is preferable.

(3) As described in the above item (3), the contact mold is made of a paperboard bent into an approximately L-shape at an angle substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner. According to the preferred embodiment of the present invention, since the contact mold can be supplied with a low-cost material, the decorative material for finishing the surface at the corner can be easily manufactured at a low cost, which is preferable.

(4) Further, as described in the above item (4), by setting the decorative material layer to a preferred embodiment of the present invention comprising a synthetic resin layer in which aggregate is dispersed, natural stone tone can be easily obtained. A decorative material for finishing the surface of the corner having a texture can be produced, which is preferable.

(5) As described in the above item (5), a preferred embodiment of the present invention is that the raw material for the decorative material comprises a synthetic resin emulsion or a coating material in which an aggregate is dispersed in a solution. Thus, it is possible to easily apply with a spraying gun or the like, and it is possible to easily produce a decorative material for finishing the surface of a protruding corner having a natural stone-like texture, which is preferable.

(6) As described in the above item (6), in a preferred embodiment of the present invention, wherein the aggregate is mainly an aggregate having a particle size of 0.05 to 1.5 mm, It is possible to easily apply the raw material for the cosmetic material with a spray gun or the like, and it is also possible to easily produce a decorative material for finishing the surface at the corner of the corner having a feeling similar to that of natural stone, having a thick, deep and luxurious feeling. .

(7) As described in the above item (7), the aggregate is at least one selected from natural stone powder, silica sand, ceramic powder, plastic aggregate, and a colored material thereof.
By adopting the preferred embodiment of the present invention, which is a kind of aggregate, the texture is more similar to that of natural stone, the thickness can be easily manufactured, and the decorative material for finishing the surface at the corner of the corner having a rich and rich feeling can be easily manufactured. .

(8) As described in the above item (8), by setting the synthetic resin component of the synthetic resin layer to the preferred embodiment of the present invention in which the synthetic resin component is an acrylic resin, the acrylic resin is relatively inexpensive. Has weather resistance after drying, water resistance,
Since all properties such as adhesiveness and flexibility can be sufficiently satisfied, it is preferable because it has good durability, can withstand long-term use, can be easily processed and constructed, and can easily produce a decorative material for finishing a surface at a protruding corner.

(9) As described in the above item (9), in a preferred embodiment of the present invention in which the synthetic resin emulsion or solution as a raw material for a cosmetic material is an acrylic resin solution or emulsion, the acrylic resin Although the solution or emulsion is relatively inexpensive, all properties such as weather resistance, water resistance, adhesiveness, and flexibility of the cosmetic layer after drying can be sufficiently satisfied, so it has good durability and can withstand long-term use. It is preferable because it can be easily processed and constructed, and the decorative material for finishing the surface at the corner can be easily manufactured.

(10) As described in the above item (10), the decorative material can be lightened by adopting a preferred embodiment of the present invention in which the substrate sheet is a substrate sheet made of cloth. In addition, it has a sufficient reinforcing effect, the base material sheet has good adhesion to the decorative material layer, and also has good adhesion to the surface of buildings and structures. It can be easily manufactured and is preferable.

[Brief description of the drawings]

FIG. 1 is a process perspective view showing a part of a manufacturing process of an embodiment of a manufacturing method of a decorative material for finishing a surface at a comer portion according to the present invention.

FIG. 2 is a process perspective view showing a continuation of the manufacturing process shown in FIG. 1 and a construction process according to an embodiment of the method for manufacturing a decorative material for finishing a surface at an outside corner according to the present invention.

FIG. 3 is a process cross-sectional view showing an example of a case in which a conventional decorative sheet for surface finishing is pasted to form a decorative material for surface finishing at a protruding corner portion.

FIG. 4 is a schematic process cross-sectional view for explaining a method of manufacturing a decorative material for finishing a surface at a protruding corner other than the present invention studied by the present inventors.

FIG. 5 is a schematic cross-sectional view of a process in the case of manufacturing a decorative material for finishing a surface at an outside corner by using a spatula or a trowel.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Base sheet 2 Decorative material layer 3 Decorative material raw material 4 Spray gun 5 Laminated sheet 6 Cutter knife 7 Cut 8 Cut face of decorative material layer 9 Surface of decorative material layer 10 Coating layer 11 Applying mold 12 Building or building Corners 100a, 100b Decorative sheet for surface finishing 101 Base sheet 102 Cosmetic material layer 102a Coated material 102b applied and dried with the material 3 for cosmetic material Part where the material 3 for cosmetic material protrudes and is applied 102c Material 3 for cosmetic material Joint 105 formed with a spatula 105 Thunder 107 Open cut 108 Curing sheet 109 Surface of decorative material layer 102 110 Building 120 Outer corner 130 Arrow indicating the position of the cut

Continued on the front page F-term (reference) 2E110 AA26 AA47 AA57 AA70 AB22 AB23 AB27 BA02 BA12 BA24 EA09 GA23W GA33W GA42X GA43W GB02X GB06X GB13W GB14W GB28W GB32X GB42X GB43W GB44W GB44X GB45W GB46W GB52X GB55F02CB63FA10 GB63FAB AC02H AC06B AC06H AD00B AD00H AK01B AK01H AK25B AR00B AT00A BA02 CA24B DA20 DE01B DE01H DG11A EH462 EJ263 EJ322 GB07 HB00B JK01 JL00 JL02 JL10B JL10H JM01B YY00B YY00H

Claims (10)

[Claims] 1. A step of making a substantially linear cut in a thickness direction of a decorative material layer of a laminated sheet having a decorative material layer formed on a foldable base material sheet, and (b) the decorative material A step of folding the laminated sheet along the cut of the layer so that the base sheet is on the inner side and substantially folding the laminated sheet into two pieces; (D) a step of arranging the decorative material layers such that the cut surfaces of the decorative material layers appearing by being substantially folded into two substantially equal planes by contacting and arranging the surfaces of the decorative material layers so as to face each other; Applying cosmetic material to the cut surface of the cosmetic material layer appearing in
(E) Coating material is applied to the cut surface such that the base material sheet is in contact with the backing die on a backing die having a surface bent at an angle substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner. Placing each of the obtained laminated sheets while widening the bending angle thereof, and drying the applied raw material for a decorative material, (f) after drying, polishing the vicinity of the applied portion of the decorative material obtained for the decorative material for the obtained decorative material. A method for producing a decorative material for surface finishing at a protruding corner portion, comprising a step of squaring. 2. A step (g) of applying an emulsion or solution of a synthetic resin, which becomes transparent when dried after polishing in the step (f), on the surface and drying to apply a top coat layer.
The method for producing a decorative material for surface finishing of a protruding corner portion according to claim 1, comprising: 3. The protruding corner according to claim 1, wherein the abutment is formed of a paperboard bent substantially in an L-shape at an angle substantially equal to or slightly smaller than the angle formed by the cross section of the protruding corner. Production method of decorative material for surface finishing of part. 4. The method according to claim 1, wherein the decorative material layer comprises a synthetic resin layer in which aggregates are dispersed. 5. The decorative material for finishing a surface at an outer corner according to any one of claims 1 to 4, wherein the raw material for a cosmetic material comprises a synthetic resin emulsion or a coating material in which an aggregate is dispersed in a solution. Production method. 6. The aggregate mainly has a particle size of 0.05 to 1.5 m.
The method for producing a decorative material for finishing a surface at a protruding corner according to any one of claims 4 and 5, wherein the aggregate is an aggregate having a size of m. 7. The corner according to claim 4, wherein the aggregate is at least one kind of aggregate selected from natural stone powder, silica sand, porcelain powder, plastic aggregate, and a colored material thereof. Production method of decorative material for surface finishing of part. 8. The method according to claim 4, wherein the synthetic resin component of the synthetic resin layer is an acrylic resin. 9. The method for producing a decorative material for finishing a surface at a protruding corner according to claim 5, wherein the synthetic resin emulsion or solution as a raw material for a cosmetic material is an acrylic resin solution or emulsion. 10. The method according to claim 1, wherein the base sheet is a cloth-like base sheet.