JP2001001482A - Production of surface decorative material and surface decorative material having archtectural-concrete-like finish feeling - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an archtectural-concrete-like finish surface by a surface decorative material in a building and a structure. SOLUTION: In a surface decorative material, a decorative material part 12 having fine unevenness and vesicles 9 similar to the grain on its surface is formed from flexible mortar having a concrete color or a finish coating material due to aggregate coloration. Recessed parts similar to wood marks are provided according to circumstances. The surface decorative material is produced by coating a base material 11 wound in a roll form with a decorative material 12 and immediately covering the coated base material with release paper having fine unevenness similar to the grain and cutting the whole into a desired size through a drying process. By using this surface decorative material, an archtectural-concrete-like finish surface can be obtained in an ALC structure other than an RC structure, a wooden building or repair construction.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel surface covering material which can be applied to the inner and outer wall surfaces of buildings, floor surfaces, etc. or the surface of structures.

[0002]

2. Description of the Related Art Hitherto, an invention concerning a flexible covering material applicable to the outdoors has been disclosed in Japanese Patent Application Laid-Open No. 4-85447. In the case of conventional surface covering materials, as a decorative material on the surface, a molded product made of natural stone or colored aggregate and synthetic resin, or a coating film composed of a paint made of these compositions has been used. Further, in another conventional technology, a portion using a water-based elastic paint film is applied to a portion corresponding to a decorative material,
The invention of Japanese Patent Application Laid-Open No. Hei 4-47064 also exists. Furthermore,
In the invention of JP-A-2-210147, which is another invention, the decorative material is a waterproof layer and a decorative pattern layer formed by screen printing. The decorative pattern in JP-A-2-210147 was a rock-like colorful pattern or a joint pattern such as brick tone or tile tone. JP-A-4-85
In the examples of the decorative material disclosed in Japanese Patent No. 447 or JP-A-4-76151, natural stone, colored aggregate, and ceramic are used as aggregates, resin is used as a binder, and these are sprayed to obtain an appearance similar to natural stone. is there.

[0003]

SUMMARY OF THE INVENTION An object of the present invention is to provide a surface covering material having a surface similar to a bare concrete surface, which has not been disclosed in the conventional inventions. This is due to the fact that the appearance of a natural stone or a natural stone-like finish is required for finishing the surface of a building or structure, and the appearance similar to a bare concrete surface is required regardless of new construction or renovation.

[0004]

Means for Achieving the Object In the surface covering material of the present invention,
In order to obtain an appearance with a bare appearance, a flexible mortar or a finish coating material with aggregate coloring is used for the decorative material of the facing material.
Further, in order to prevent the finished surface from becoming monotonous, the decorative material is made to contain air bubbles, have fine irregularities similar to a grain of wood on its surface, or have a concave portion similar to a trace of a wooden cone.

[0005] As an example of a method of manufacturing such a surface covering material, a method in which a roll is wound around a base material for reinforcing the back surface of the surface mounting material or improving the adhesion of the back surface is used, and this is used on a conveyor. The coating material is applied by a knife coater with a flexible mortar or aggregate coloring, which is a cosmetic material, while being transported by a knife coater. Immediately thereafter, the cosmetic material is covered with a release paper having fine irregularities similar to a grain of wood, followed by a drying process. Is dried, cut into a desired size after the drying, and at the same time, a trace of a wooden cone is formed by a router or the like.

The components of the present invention will be described below. First, the composition that is used as a decorative material for a facing material will be described. One of the compositions used as a cosmetic material is a flexible mortar. As the flexible mortar, a mixture of a cement component, a polymer component, and sand as an aggregate component, which is generally called a polymer cement mortar, is suitable. Examples of compositions blended to obtain flexibility include JP-B-63-56185, JP-B-1-53228, JP-B1-53229, and JP-B-1-5429.
There is a composition disclosed in US Pat.

In the technology disclosed in Japanese Patent Publication No. 63-56185, Portland cement, alumina cement 1.5 to 7 times by weight of Portland cement, and 0.3 to 3 times by weight of Portland cement are used. As a polymer component to the sum of water gypsum and Portland cement, alumina cement, and hemihydrate gypsum,
There is a composition in which 0.15 to 1.5 times by weight of a polymer dispersion and an appropriate aggregate are blended.

[0008] In the technique disclosed in Japanese Patent Publication No. 1-53228, Portland cement, alumina cement 1.5 to 7 times the weight of Portland cement,
In addition, there is a composition obtained by mixing a polymer dispersion of 0.15 to 1.5 times by weight and an appropriate aggregate as a polymer component with respect to the sum of Portland cement and alumina cement.

In the technique disclosed in Japanese Patent Publication No. 53229/1990, 0.1 to 1 times by weight of portland cement, 0.1% to 1% by weight of portland cement, 0.1% by weight of polymer, and 0.1% by weight of polymer as a polymer component.
1 to 0.8 weight times polymer dispersion and appropriate aggregate and Portland cement, 0.35 including water in polymer dispersion with respect to sum of gypsum
There is a composition containing 1 weight of water.

In the technique disclosed in Japanese Patent Publication No. 1-54295, 0.05 to 1.2 times by weight of portland cement, alumina cement and 0.05 to 1.
As a polymer component with respect to the sum of gypsum and Portland cement, alumina cement and gypsum at 2 times the weight,
There is a composition in which 0.1 to 0.8 times by weight of a polymer dispersion, an appropriate aggregate, and an appropriate amount of water are blended.

Another one of the compositions to be used as a cosmetic material is a finish coating material obtained by coloring aggregate. In a finish coating material using aggregate coloring, the color of the entire coating material is expressed by a unique color of the aggregate itself. The main components are aggregates and binders. Aggregates include natural stone grains, silica sand, cold water sand, aggregates colored with glass beads, colored glass grains, and colored plastic grains. Alternatively, there is a synthetic resin emulsion. The particle size of the aggregate is 0.02
It is preferable that 90% by weight or more is contained between の 間 に 5.0 mm. Here, it is 0.02 m
This is because fine powder of less than m may enter.

The color tone of the aggregate used is, of course, a cement color. If it is selected from the standard color sample book for paint of the Japan Paint Manufacturers Association, the S version issued in 1993 will be S1-1.
032, S1-1002, S1-1003, S1-10
04, S1-1005, S2-1006, S4-38
3, S5-462, S6-851, etc., and intermediate colors and mixed colors of these colors are also candidates for the color of the aggregate. This natural or colored aggregate is not used in a single color, but it is preferable to use a mixture of a plurality of colors. This is because the real mortar itself is an aggregate of multiple colors of silica sand or cement.

In the decorative material part of the present invention, the surface of the decorative material has a fine uneven pattern resembling a grain of wood. This is due to the fact that when concrete is actually poured using a wooden concrete panel, the wood grain of the wooden panel is transferred to the concrete surface and has a wood grain pattern. The grain of the decorative material is formed by pouring the slurry of the decorative material into a mold having fine irregularities similar to the grain, or by using a release paper having the fine irregularities similar to the grain as mentioned in the invention of the manufacturing method. This is made possible by covering the cosmetic material applied thereon while it is not yet cured. Examples of paper with fine irregularities include:
There is wrinkled paper such as crepe, which is called sandpaper or widow paper, and those subjected to a release agent treatment are used.
Screen printing, letterpress printing, and gravure printing using a wood pattern as a plate are used for printing the wood pattern. In particular, screen printing is preferable in terms of forming an uneven pattern and having an allowable width of particles in a coating material to be subjected to printing.

On the surface of the decorative material portion, it is necessary to have fine irregularities resembling a grain of wood and another one having a bubble hole 9. This is also due to the existence of air holes inside and on the surface of the concrete to some extent even when the concrete is compacted when the concrete is actually poured. The pores are formed by a flexible mortar or a finish coating material serving as a cosmetic material.
ol% of bubbles and the viscosity is 80 ps to 200 ps.
Immediately after applying a ps material to a uniform thickness with a knife coater, cover the surface with release paper and heat and dry to collect bubbles inside the coating material. Will have. In the case where heating and drying are not performed, similar vibration holes can be formed by applying a slight vibration before drying and curing. When the content ratio of the bubbles is less than 5 vol%, almost no bubble pores are generated, and when the content ratio is more than 20 vol%, the bubbles become too large and do not have a good hitting surface. In addition, the viscosity is 80
If it is lower than ps, the pore size is too large or too large. When the pressure is higher than 200 ps, almost no bubbles are generated.

[0015] In addition, a concave portion expressing the wooden concrete trace 10 may be formed on the surface of the decorative material portion. In actual reinforced concrete construction, binding material is used to fix the position of the formwork and prevent deformation, but one of the binding materials is wooden concrete,
One of the members on the concrete surface side that supports the concrete panel at both ends of the separator that regulates the thickness of the concrete. When removing this form,
It is removed at the same time, but its use remains as a dent and remains on the concrete surface. Actual wooden concrete trace is 5mm
Although it appears as a depression of a degree, in the decorative material portion of the facing material, if the concave is increased, it is necessary to increase the thickness of the decorative material portion. In addition, the diameter of the surface side of the wooden cone trace of the truncated cone is usually about 25 m.
m, and the diameter of the concave portion similar to the trace of a wooden cone provided in the decorative material portion is also set to about 25 mm. The formation of a concave part similar to the wood-container mark in the decorative material part can be achieved by providing an inverted-type convex part on the mold when pouring into the mold, or by applying the wood-grain and wood conical when applying on the base material. This can be achieved by pressing with a mold having a similar convex portion or providing a concave portion by means such as a router after hardening flexible mortar or the like constituting the decorative material portion.

The surface material includes a portion for forming a surface design by the above-described decorative material, a portion for reinforcing the surface design, and a base portion. An example thereof is disclosed in Japanese Patent Application Laid-Open No. 4-854.
In the invention of No. 47, a base material serving as a base sheet is used on the back surface side of the decorative material. Here, the base member is made of a material selected from a woven fabric, a nonwoven fabric, a glass cloth, a synthetic resin, or the like, or a material obtained by subjecting them to a filling process. This base material portion, besides for reinforcing the decorative material portion, is conveniently present also in the production of a facing material, and, in addition, when attaching the facing material to a surface such as a wall surface,
It will also help to obtain more adhesive strength. The woven, non-woven or knitted material used for the base material is appropriately selected from natural fibers, synthetic fibers, mineral fibers, metal fibers and the like.

Further, in the invention described in Japanese Patent Application Laid-Open No. 4-76151, an example of a structure in which a core material made of a synthetic fiber woven fabric is sandwiched in the middle of a decorative material, and a synthetic resin woven fabric is further fixed to one surface of the surface. There is. Further, JP-A-4-6466
In the invention described in No. 0, there is also an example in which a fiber-reinforced synthetic resin layer is formed on the back surface side.

FIG. 1 or FIG. 2 and FIG. 4 show examples of the covering material of the present invention with reference to the drawings. FIG. 1 shows a surface-mounting material having no wood-contained traces, FIG. 2 shows a wooden-contained trace formed thereon, and FIG. It has become. In addition, the facing material shown in FIGS. 1 and 2 includes a base material portion 11 and a decorative material portion 12. The facing material shown in FIG. 4 has an overlapping portion 13 in addition to the base material portion and the decorative material portion.

Next, a description will be given of an invention of a method for manufacturing a surface covering material having the above-described structure. The manufacturing means is schematically shown in the drawings. FIG. 3 shows a manufacturing flow from the right to the left. In the figure, a roll-wound base sheet 1 serving as a base material part prepared in advance is supplied, and a knife coater 2 is placed thereon.
The mortar or the coating material which becomes the decorative material part is applied by the. Immediately after the application of the decorative material 3, the release paper 4 having fine irregularities similar to a grain of wood is covered from above the decorative material without applying much load. Subsequently, when the decorative material is a finish coating material, the decorative material is passed through the drying furnace 5 together with the base material to dry and harden the decorative material. When the cosmetic material is mortar, it does not cure in the drying line, so a curing period is required. After the drying step, only the release paper is peeled off, and further dried by a heat roll 6 as necessary, the transport speed is adjusted, and the outer cover material is cooled, and then cut by a cutting machine 7 at a desired fixed length. In this figure, when the release paper is covered and pressed from above the decorative material, the press roll 8 is a roll having a projection so as not to press with a uniform force on the entire surface.

Although not shown in FIG. 3, the finish coating material supplied to the knife coater by flexible mortar or aggregate coloring is made into a plurality of colors, these are made into a plurality of vertical stripes, and a number of colors are alternately applied to the knife coater. It is also possible to obtain a decorative material part which is supplied and whose color tone changes gradually.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In a practical example, a manufacturing method and a product obtained will be described with reference to a schematic diagram of a manufacturing process in FIG.

First, a base sheet serving as a base material was prepared by applying a dark gray synthetic resin emulsion paint to both sides of a non-woven fabric made of polyester (basis weight: 100 g) with a knife coater and performing a sealing treatment. . The width of the base sheet was 1 m.

As the finish coating material used as a cosmetic material, the compositions shown in the following formulations 1 and 2 are used. The coating material of the formulation 1 is supplied to both sides of the knife coater, and the coating material of the formulation 2 is provided in the center of the knife coater. Was supplied. The amount of application on the base sheet was 3 kg / m2 in the total amount of finishing coating materials A and B when wet. Finishing Coating Materials A and B contained air bubbles of 15 vol% and 18 vol%.

Formulation 1 (Finishing material A) Colored aggregate a (S1-1003 color, particle size 0.1 to 0.5 mm) 40.0 parts by weight Colored aggregate b (S1-1005 color, particle size 0.1 to 0.5 mm) 1 to 0.5 mm) 20.0 parts by weight Colored aggregate c (S1-1006 color, particle size 0.5 to 0.8 mm) 10.0 parts by weight Synthetic resin emulsion 20.0 parts by weight Film-forming aid 1. 0 parts by weight Defoamer 0.5 parts by weight Thickener 1.0 parts by weight Other additives (preservative, fungicide, etc.) 0.5 parts by weight

Formulation 2 (Finishing material B) Colored aggregate d (S1-1005 color, particle size 0.1 to 0.5 mm) 40.0 parts by weight Colored aggregate e (S1-1006 color, particle size 0.1 to 0.5 mm) 1 to 0.5 mm) 20.0 parts by weight Colored aggregate f (S1-1032 color, particle size 0.5 to 0.8 mm) 10.0 parts by weight Synthetic resin emulsion 20.0 parts by weight Film-forming aid 1. 0 parts by weight Defoamer 0.5 parts by weight Thickener 1.0 parts by weight Other additives (preservative, fungicide, etc.) 0.5 parts by weight

Immediately after the application of the cosmetic material, a wrinkle-like wrinkle paper like crepe similar to a grain of wood, and a release paper having fine irregularities with a size of irregularities of 0.2 mm or less are pressed lightly on the decorative material. Roll press. As for the degree of lightness, the weight of the roll should not be applied to the release paper and the decorative material. As for the degree of thickness regulation, the clearance between the knife coater and the conveyor was 3 mm. The clearance between the conveyor and the conveyor was 2.5 mm. The roll surface used at this time was not flat but 1.5 cm
Every other was a roll having a convex portion having a shape similar to a mirror cake having a diameter of 1 cm and a height of 1 mm. In addition, the projections are provided with irregularities in the foamed rubber, so that the pressing force is not directly transferred to the minute irregularities.

In the drying step, the mixture was passed through a furnace using gas steam as a heat source for 30 minutes. The temperature in the furnace was set at 60 ° C. at the inlet and 80 ° C. from the middle part to the end point of the furnace. After leaving the drying oven, peel off only the release paper,
The base material and the decorative material were further passed through the surface of a heat roll (surface temperature: 150 ° C.) to assist in drying. After that, the outer cover material is cooled and the conveying speed is adjusted, and then the outer cover material is cut into desired sizes. In Example 1, the cut material was cut into 60 cm × 30 cm, and a tape of the same quality as that of the substantially L-shaped base part having a width of 6 cm, which forms the overlap margin, was attached to the back of the surface material, and the overlap margin was 3 cm.
And made it into a product.

In the process shown in FIG. 3, the formation of the concave portion similar to the wooden concrete trace is not included in the process. For example, the formation of the wooden concrete trace 9 shown in FIG. A concave portion having a depth of 2 mm can be formed by utilizing the above. In addition, it is also possible to form the traces of the wooden cone by arranging a mold having a shape similar to that of a wooden cone having a releasable property at predetermined intervals after applying the decorative material, and then covering the release paper continuously. .

The facing material obtained by the above-described method was such that the finishing coating material B was applied at the center and the finishing coating material A was applied to both sides in the flow direction of the production line. And
Fine irregularities resembling the grain of wood transferred from release paper were formed on the surface, and in some places the traces of bubbles contained in the coating material became holes as they were.

In Example 2, the first layer of the decorative material portion was prepared using only the finishing coating material B, which was obtained by applying the finishing coating material A and the finishing coating material B in Example 1 so as to form a striped pattern. After applying and drying the first layer, using a screen having a wood pattern of a pine board as a plate, a finishing coating material A
Printing was performed with an application amount of g / m2. By this printing process, a wood grain pattern deeper than the irregularities formed by the sandalwood paper could be formed.

As Comparative Example 1, decorative material A and B were coated with a knife coater and then dried without using a release paper. It was created. Also in Comparative Example 2, after drying, a trace of wood cone was formed by a router.

Table 1 below shows the main structure of the decorative material portion or the corresponding portion of the facing material in Examples and Comparative Examples 1 and 2.

[0033]

[Table 1]

The sheet manufactured according to the present embodiment and the comparative examples 1 and 2 were attached to the outer wall surface of a real exposed finished building by about 10 m2 each, and the finished feeling was compared. There was a texture that was close to being exposed. On the other hand, the asbestos slate plate of Comparative Example 1 was uniform in color, had no pores, and was not seen in a blown air. In Comparative Example 2, although there was color unevenness close to the blown air, there was no bubble hole peculiar to the blown air, and there was no fine unevenness resembling a grain of wood.

[0035]

According to the covering material of the present invention, it has flexibility,
A surface having an appearance similar to that of a bare concrete finish is obtained. The obtained surface covering material can obtain a finish similar to a bare concrete surface in an ALC structure or a wooden building as well as in an RC structure, or in a renovation work. The exterior material obtained is not only similar in appearance to the genuine one, but also waterproof,
It is possible to protect the building for a long time in terms of pollution resistance.

[Brief description of the drawings]

FIG. 1 is an external perspective view of a facing material according to an embodiment.

FIG. 2 is an external perspective view of a facing material having a concave portion similar to a wooden concrete trace.

FIG. 3 is a diagram schematically showing a process of manufacturing the surface covering material of the present invention.

FIG. 4 is an external perspective view of a surface covering material having a woodgrain pattern similar to pine board making.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base sheet 2 Knife coater 3 Cosmetic material 4 Release paper 5 Drying furnace 6 Heat roll 7 Cutting machine 8 Pressing roll 9 Bubble hole 10 Wood cone mark 11 Base material part 12 Cosmetic material part 13 Overlapping part 14 Wood pattern

Claims (4)

[Claims] 1. A decorative material portion is formed by applying a finish coating material made of a flexible mortar or an aggregate by a knife coater onto a roll-wound base material portion for reinforcing or bonding to a substrate, and forming the decorative material portion. A method of manufacturing a surface covering material having fine irregularities and pores resembling a grain of wood on a surface of a decorative material portion, comprising a flexible mortar or a finish coating material by coloring an aggregate containing air bubbles of about 5 to 20 vol% and a viscosity of about 5 to 20 vol%. Is 8
Using a material of 0 ps to 200 ps, and immediately after the coating on the base material, the surface is covered with the release paper for forming the fine unevenness, and the air bubbles are collected and floated by heating and drying to form the air bubbles. A method of manufacturing a surface material, comprising: 2. A decorative material portion is formed by applying a finish coating material made of flexible mortar or aggregate by a knife coater onto a roll-wound base material portion for reinforcing or bonding to a base material, and forming the decorative material portion. A method of manufacturing a surface covering material having fine irregularities and pores resembling a grain of wood on a surface of a decorative material portion, comprising a flexible mortar or a finish coating material by coloring an aggregate containing air bubbles of about 5 to 20 vol% and a viscosity of about 5 to 20 vol%. Is 8
0 ps to 200 ps, and the surface is covered with the release paper for forming the fine irregularities immediately after the coating on the base portion, and the microbubbles are applied by applying a slight vibration before the coating layer is dried and hardened. A method for producing a surface covering material, characterized by forming: 3. A method in which the flexible mortar or an aggregate coloring finish coating material supplied to the knife coater has a plurality of colors, and a plurality of the finishing coating materials are supplied side by side or continuously so that the color changes. The method for producing a surface covering material according to claim 1, wherein the method is applied to the base member. 4. A surface covering material having a hit feeling finish, produced by the method for producing a surface covering material according to any one of claims 1 to 3.