JP2002096020A - Interior and exterior panel and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide mortar or ceramic interior and exterior panels which reproduce the surface form and tone of used brick, natural crushed stone or the like. SOLUTION: A panel substrate 1 having a surface formed with a complicated rugged pattern is obtained by using a die molded from used brick, natural crushed stone or the like. Then a sealer layer 2, a base coating layer 3 and a base such as sand, beads or the like adhered to the base coating layer 3 are applied on the substrate, and then coating ink is applied thereon through a masking material 10 by spraying several times for each color so as to spread the coating ink over the formed surface of the complicated rugged pattern as well as to form coating layers 5a to 5d with delicate tones by the combination of the ink. Then a clear layer 7 is formed on the surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior / exterior panel used for the exterior or interior of a building or building such as a building or a fence, and a method of manufacturing the same.

[0002]

2. Description of the Related Art As an exterior panel of this kind, for example, a metal-based siding or mortar in which a foamed synthetic resin is arranged on the back side of a colored steel sheet is formed, and bricks, tiles, natural stones and the like are formed on the surface. Mortars, ceramic sidings, curtain walls, etc. with painted colors are known, but metal siding has a monotonous color and cannot wipe off the metallic appearance, and mortar and ceramic sidings are also common. The color tone of the actual thing is not always faithfully reproduced. Even if the color tone can be faithfully reproduced, the color tone of a new brick, a tile, a natural stone, or the like is generally used, and the personality tends to be poor.

The present invention has been made in view of such circumstances, and a problem to be solved is to provide a complex uneven surface such as a weathered used brick or a natural crushed stone having a damaged surface. Another object of the present invention is to provide an exterior panel which is unique, has high quality, and is suitable for mass production, and a method of manufacturing the same, by applying a suitable coating to the complex uneven surface.

[0004]

SUMMARY OF THE INVENTION In accordance with the above objects, the present invention provides a method for forming a complex uneven surface by molding, and by applying a masking coating of a coating ink to form a complicated uneven surface by forming an ink color or overlapping the ink. The invention is characterized in that a subtle color tone can be expressed, that is, the invention according to claim 1 forms a coating layer by masking coating using a coating ink on a complicated uneven surface formed on a panel substrate surface. By doing so, the exterior surface panel is characterized in that the molding surface of the complex unevenness has a color tone of a coating ink color or a composite color thereof.

[0005] In addition to the above, the invention according to claim 2 provides:
The molded body of the above-mentioned complex unevenness on the panel surface is replaced with a used brick so that the panel base has a preferred form that reproduces the weathered or damaged complicated unevenness shape such as used brick, natural crushed stone, surface peeling mortar, etc. The exterior panel according to claim 1, wherein the exterior panel is formed as a molding surface that reproduces the uneven surface state of weathering or damage due to crushed stone, surface peeling mortar, or the like.

The invention according to a third aspect of the present invention also provides, in addition to the above, a preferable color tone for a molding surface having complicated irregularities so that the coating with the coating ink is made as natural as possible, for example. In this case, the coating layer formed by the masking coating is formed by coating a plurality of times with a multicolor coating ink using a plurality of masking materials having different through-hole shapes to form a complex uneven surface. The exterior panel according to claim 1 or 2, wherein a color tone of a composite color of the coating ink is obtained as a whole.

[0007] In addition to the above, the present invention according to claim 4 further provides a coating method using the above-mentioned coating ink so as to express fine and subtle color tones such as streaks and spots. A brush pattern is applied to a surface layer, an intermediate layer, or a lower layer of the coating ink, so that a faint pattern having a different color tone of the coating ink due to partial peeling of the coating ink is exposed on a molding surface. An interior / exterior panel according to claim 1, 2 or 3.

[0008] In addition to the above, the present invention according to claim 5 further improves the texture of the coating with the coating ink so that the coating state of the panel is improved so as to obtain a preferable state of coating. The molding surface is roughened by arranging fine particles or fine powders such as sand, resin beads, metal flakes between the molding surface having complex irregularities and the coating layer of the coating ink. 1,2,3
Or the exterior panel described in 4.

According to a sixth aspect of the present invention, in addition to the above, the coating with the coating ink is made to have excellent weather resistance, the color tone of the coating is secured for a long time, and the coating is protected from external force. 6. The exterior panel according to claim 1, wherein the coating layer of the coating ink is covered with a clear coating layer. It is.

[0010] The invention according to claim 7 reproduces the weathered or damaged complex surface shape and color tone as faithfully as possible, such as the above-mentioned used brick, natural crushed stone, surface peeling mortar, and has excellent texture and durability. In order to provide a method for manufacturing interior and exterior panels that are excellent and suitable for mass production, they are used to form complex uneven surfaces that reproduce the surface condition of weathering or damage caused by used brick, natural crushed stone, surface mortar, etc. A panel substrate forming step, an undercoating step of applying an undercoat to the molding surface, and a fine object dispersing step of dispersing and arranging fine particles or fine powders such as sand, resin beads, and metal flakes in the undercoating step. A masking coating process of a coating ink for applying a plurality of coatings with a multicolor coating ink a plurality of times using a plurality of masking materials having different through-hole shapes; Brushing the coating layer of the coating ink during or after the end of the coating process reveals a faint pattern on the convex surface of the molding surface that causes the color tone of the coating ink to differ due to partial peeling of the coating ink. And a clear coating step of applying a clear coating for coating the coating layer of the coating ink.

In the present invention, each of these is a gist of the invention and is a means for solving the above problems.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below in more detail with reference to the drawings, in which A is an interior / exterior panel made of, for example, a metal, mortar or ceramic. By forming the coating layers 5a to 5d by masking coating using a coating ink on the complex uneven surface disposed on the surface of the panel substrate 1, the complex uneven surface can be coated with the color of the coating ink color or its composite color. There is a thing.

In the present embodiment, the interior / exterior panel A reproduces the surface of the panel base 1 having a complex uneven surface by weathering or damage caused by a used brick, natural crushed stone, surface peeling mortar, or the like. In this case, the coating layers 5a to 5
d is a plurality of coatings with a plurality of coating inks of multiple colors using a plurality of masking materials 10 having different through-hole shapes, and the complex uneven surface is formed as a composite color tone of the coating ink over the entirety. At the same time, fine particles such as sand, resin beads, and metal flakes are arranged between the molding surface of the complex unevenness of the panel and the coating layer 5a of the coating ink to form a base of the coating ink on the molding surface. In addition, by brushing the surface, middle, or lower coating layers 5d to 5a of the coating ink, the surface of the molding surface has a different color tone due to partial peeling of the coating ink. And the coating layers 5a to 5d of the coating ink are covered with a coating layer 7 of clear coating, whereby the weathering or breakage is caused. Distressed brick, natural crushed stone,
The surface peeling mortar and the like, for example, natural crushed stones are extremely faithfully reproduced in both shape and color tone, and have high durability.

That is, the interior / exterior panel A of this embodiment is, for example, a mortar system, a ceramic system, a metal system or the like. 1, the sealer layer 2, the undercoat layer 3, the fine particle layer such as sand, resin beads, metal flakes, etc., which are sprayed and adhered to the undercoat layer 3, and the above-mentioned fine substance layer 4, and a plurality of times of masking In the coating, in this example, for example, the coating layers 5a to 5d made of the above-mentioned coating ink which form a maximum of four layers and, if necessary, show a faint pattern 6 with a different color tone of the coating ink due to the partial peeling. And the clear layer 7 on the outermost surface.

At this time, the sealer layer 2 and the undercoat layer 3
The coating layers 5a to 5d are formed by spray coating, and the coating layers 5a to 5d by the coating ink are formed by spray coating or roll coating in the masking state. The paint or coating ink is spread evenly over the complex concave surface and the complex convex surface of the molding surface to make the coating of the molding surface free of paint leakage, and the complex ink is spray-coated with the above-mentioned coating ink. The composite color of the coating ink color can be expressed as freely as possible on the molding surface of the surface, and by using roll coating, for example, the coating ink can be applied to the complex convex surface of the molding surface excluding the complex concave surface. Coating shall be performed, and spray coating or roll coating of the coating ink shall be performed by masking. There as that performed the coating by supplying a paint ink to expose the predetermined color respectively predetermined positions of the molding surface by masking coating.

The fine material layer 4 is formed by using a non-glossy material such as sand to form a base of a coating ink for giving an impression of a rough and rough background, and for example, a resin bead or metal flake. The use of a light diffuse reflective material is used as a base for a coating ink which gives an impression that glassy materials in used bricks, natural crushed stones and the like are diffusely reflected.

The blurred pattern 6 is made of a brushing material 11 such as a roll of felt, urethane rubber or the like, a cloth of a multi-fiber such as a cloth or a plant, or a woven or non-woven fabric.
By applying high-speed rotation or high-speed movement or manual rubbing to the outermost surface or the intermediate coating layer 5d to 5a of the above-mentioned coating ink in a contact state, thereby coating one or more surface layers. The ink is partially removed so as to scrape off the ink, and the underlying coating ink is partially exposed so that, for example, a streak pattern or a speckled pattern is exposed.

The interior / exterior panel A of the present embodiment will be described in further detail with reference to the method of manufacturing the interior / exterior panel A. The irregular interior / external panel A of the present embodiment reproduces the uneven surface state of weathering or damage caused by used brick, natural crushed stone, surface peeling mortar, or the like. A base substrate forming step of forming a forming surface of the above, a base coating step of applying a base coat to the forming surface, and spraying fine particles 4 of fine particles or fine powder such as sand, resin beads, metal flakes in the base coating step. A step of dispersing fine objects to be arranged, a step of masking a coating ink for coating a plurality of times with a multicolor coating ink using a plurality of masking materials having different through-hole shapes; and After the completion, brushing is performed on the coating layers 5d to 5a of the coating ink to partially peel off the coating ink on the convex surface of the molding surface. It is provided with a brushing process for displaying a faint pattern 6 having a different color tone of the mounting ink and a clear coating process for applying a clear coating for coating the coating layers 5a to 5d of the coating ink. In this embodiment, a sealer coating process is added before the undercoating process.

That is, in the panel substrate forming step, for example, a molding material such as mortar is cast from a used brick, a natural crushed stone, a flaked mortar or the like by molding the surface condition of the weathered or damaged irregularities from the mortar or the like. Drying and demolding, and pressing and molding the ceramic material and then sintering it. Alternatively, after vacuum suctioning the resin sheet into the sand mold, the casting metal material is poured and molded, and the mold is released. This is a step of forming the panel base 1 which reproduces the above-mentioned uneven surface state on the surface by, for example, press-molding a pressed metal material using a mold having the above-mentioned uneven surface state precisely processed.

In the sealer coating step, a resin coating such as acryl, polyisocyanate, urethane or the like is applied by, for example, spray coating. In the undercoating step, after drying and curing, the base color is changed to acryl, acrylic silicon or the like. As described above, for example, a white resin paint is applied by spray coating, and the fine substance spraying step is performed by using, for example, a sieve on the surface of the paint before drying and curing so that the paint in the undercoating step is used as a binder. The application is performed by uniformly supplying fine substances.

In the masking coating step of the coating ink, for example, a through hole having a size equivalent to or partially covering the panel base 1 and having a shape corresponding to a desired coating portion on the molding surface of the panel base 1 is provided. Using a plurality of masking materials 10 made of a metal plate, a resin plate, a metal foil, a resin sheet, or the like, and partially covering the complex concave surface, the complex convex surface, or both, of the molding surface, each of which is placed on the panel base 1 Then, the above-mentioned spray coating or roll coating is applied a plurality of times or many times.
The ink color of the coating ink is made the same or changed for each arbitrary masking material 10 so that a composite color of the coating ink can be obtained as needed. This is performed by using four different masking materials 10 and different ink colors. At this time, the ink colors include various colors such as red system, yellow system, brown system, black system, blue system, and white system. Used appropriately, the monochromatic or composite tones are randomly arranged so as to cover complex concave surfaces, complex convex surfaces, or both, so that the weathered or damaged colors of used bricks, natural crushed stones, surface peeling mortar, etc. can be used. It is reproduced as faithfully as possible.

In the brushing step, the brushing material 11 such as a roll, a brush, a cloth, or the like is appropriately brought into contact with the coating ink by mechanical or manual work as an intermediate step or a subsequent step of the masking coating step. A partial ink peeling is performed on the intermediate coating ink coating layers 5a to 5c or the outermost coating layer 5d, and the underlying coating layer of one or more coating inks is exposed. Faint pattern 6
To express this.

In the clear coating step, a resin coating such as acrylic, acrylic silicon, fluorine or the like or an inorganic coating such as water glass is used as a final step of performing necessary coating.
For example, this is applied by spray coating so as to cover the entire molding surface of the complex unevenness, and drying is performed as necessary.

The interior / exterior panel A of this example is a state in which natural crushed stones of complex irregularities of, for example, granite of irregular size are piled up through joints made of clay or the like and the fence or outer wall constructed on site is weathered or damaged due to aging. The color tone of natural crushed stone is partially expressed in yellow, red, slightly black, etc., joints are expressed in white, and other natural crushed stones have different colors on the surface. Was mixed with the whole, and the natural crushed stones could have a shape and color tone with the appearance of old color as a result of aging.

Although the illustrated example is as described above, the appearance of a faint pattern by brushing the interior and exterior panels, the arrangement of fine objects between the molding surface having complex irregularities and the coating layer of the coating ink, and the manufacturing method Fine object spraying process,
In practicing the present invention, including omitting the brushing step as necessary, the panel base, the molding surface with complex irregularities, the coating ink, the coating layer by the masking coating, the masking material of the masking coating, if necessary, The summary of the above-mentioned invention includes the fine object used, the specific shape, structure, material, and size of the blurred pattern due to brushing, their relationship, addition to these, the specific use of the interior and exterior panels, and the specific steps of the manufacturing method. Various forms can be adopted as long as they do not violate the above.

[0026]

The present invention is configured as described above.
According to the first aspect of the present invention, a complicated uneven surface is exposed by molding, and a subtle color tone due to an ink color or a superposition thereof is exposed on the complex uneven surface by applying a masking coating of a coating ink. As a result, it is possible to provide a unique and high-quality exterior panel suitable for mass production and a method of manufacturing the same.

[0027] The invention according to claim 2 provides, in addition to the above,
The panel base can be of a preferred form that reproduces weathered or damaged complex irregularities, such as used bricks, natural crushed stones, and surface mortar.

The invention according to claim 3 is the same as the above, and furthermore, in order to make the coating with the coating ink as natural as possible, for example, a color having a preferable color tone on the molding surface having complicated irregularities. Things.

According to a fourth aspect of the present invention, in addition to the above, the coating with the coating ink can express minute and subtle color tones such as streak patterns and spots.

According to the fifth aspect of the present invention, in addition to the above, the texture in the coating with the coating ink can be further improved, and the coating state can be in a preferable form.

According to a sixth aspect of the present invention, in addition to the above, the coating with the coating ink is excellent in weather resistance, the color tone of the coating is secured for a long time, and the coating is protected from external force. You can do it.

The invention according to claim 7 is to reproduce the weathered or damaged complex surface shape and color tone as faithfully as possible, such as the above used brick, natural crushed stone, surface peeling mortar, etc., and have excellent texture and durability. It is possible to provide a method of manufacturing an interior and exterior panel which is excellent and suitable for mass production.

[Brief description of the drawings]

FIG. 1 is a partially enlarged plan view showing a surface state of an interior / exterior panel.

FIG. 2 is a partially enlarged longitudinal sectional view showing a model of painting on a panel base.

FIG. 3 is a model process drawing of painting in a manufacturing method.

FIG. 4 is a partially enlarged photograph showing the surface state of the interior and exterior panels without coloring.

[Explanation of symbols]

 A Interior / exterior panel 1 Panel substrate 4 Fine material layer 5a to 5d Coating layer of coating ink 6 Blurred pattern 7 Clear layer 10 Masking material 11 Brushing material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04F 13/08 E04F 13/08 E (72) Inventor Akio Sakuma 2-1-1 Oshima, Koto-ku, Tokyo Within Tostem Co., Ltd. (72) Shuji Kitamura 4-7-28 Kitahama, Chuo-ku, Osaka City, Osaka Prefecture Inside Sumitomo Forestry Co., Ltd. (72) Norio Serizawa 145-1, Kuzawa, Fuji City, Fuji City, Shizuoka Prefecture F-term in Industrial Co., Ltd. (reference) 2E110 AA26 AA57 AB04 AB22 AB23 BA02 BA12 BB04 BB05 BB22 BB32 BB38 EA06 EA09 GA32W GA33X GA42W GA43W GB01W GB01X GB13W GB24X GB28X GB42W 4D075 AA02 AD02 EC02 CB02 EC02 CB02 EC02

Claims (7)

[Claims] 1. A molding layer formed by masking coating using a coating ink on a complex uneven surface disposed on a surface of a panel substrate, thereby forming the complex uneven surface on the surface of the complex ink. Interior / exterior panels characterized by a color tone. 2. The method according to claim 1, wherein the molding surface of the complex irregularities on the surface of the panel base is a molding surface reproducing the irregular surface condition of weathering or damage due to a used brick, natural crushed stone, surface mortar or the like. Panel for interior and exterior according to. 3. A coating layer formed by said masking coating is formed by coating a plurality of times with a multicolor coating ink using a plurality of masking materials having different through-hole shapes, and coating a complex uneven surface over the entire surface. The interior / exterior panel according to claim 1 or 2, wherein the panel has a color tone of a composite color of the ink for use. 4. A brush pattern is applied to a surface layer, an intermediate layer, or a lower layer of the coating ink, so that a faint pattern having a different color tone of the coating ink due to partial peeling of the coating ink is formed on the surface of the molding surface. The interior / exterior panel according to claim 1, 2 or 3, wherein 5. The molding surface is roughened by arranging fine particles or fine powders such as sand, resin beads, metal flakes between the molding surface of the complex unevenness of the panel and the coating layer of the coating ink. Claims 1, 2, and 3,
The interior / exterior panel according to 3 or 4. 6. The interior / exterior panel according to claim 1, wherein the coating layer of the coating ink is covered with a clear coating layer. 7. A panel substrate forming step of forming a complex uneven surface by reproducing a surface condition of weathered or damaged by a used brick, natural crushed stone, surface mortar or the like;
The undercoat coating step of applying an undercoat to the molding surface, the fine object spraying step in which fine particles or fine powders such as sand, resin beads, and metal flakes are scattered and arranged in the undercoat coating step are different in through-hole shape. A masking coating process of a coating ink for applying a plurality of coatings with a multicolor coating ink using a plurality of masking materials, and brushing the coating layer of the coating ink during or after the masking coating process; A brushing process to reveal a faint pattern that changes the color tone of the coating ink due to partial peeling of the coating ink on the convex surface of the molding surface, and a clear coating that covers the coating layer of the coating ink A method for producing an interior / exterior panel, comprising a clear coating step.