JP2005163284A - Manufacturing method of building plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a building plate having a design surface, presenting more natural design appearance. <P>SOLUTION: In this manufacturing method of the building plate 1, as a preparation process, an original plate 2 having the design surface 201 where a plurality of linear projected parts 21 are formed to be different in direction of forming the linear projected parts 21 is prepared. Subsequently, as a lower coating layer forming process, a lower coating layer 4 is formed, and as an upper coating layer forming process, an upper coating layer 5 is formed. After that, as a removal process, before the upper coating material 50 is dried, a removing roll 71 is brought into contact with the upper coating layer 5, thereby removing the upper coating material 50 in a front slant 212A positioned on the front side in the direction D of carrying in the original plate 2 to the removing roll 71 out of the paired slant faces 212 in the respective linear projected parts 21 much more than the upper coating material 50 in the rear side slant 212B, so that the thickness of the upper coating layer 5 on the front side slant 212A is made smaller than that of the upper coating layer 5 on the rear side slant 212B. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a building board to be constructed as an outer wall of a building, and more particularly to a method of manufacturing a building board by coating a design surface on which an uneven pattern is formed.

In a building board mass-produced for construction as an outer wall of a building, in order to avoid a monotonous finish, a design such as a concavo-convex pattern on the design surface of the building board, a method of painting the design surface, and the like are made.
For example, Patent Document 1 manufactures a decorative board rich in three-dimensionality by extracting abundant shade differences and color tone changes. In Patent Document 1, first, an undercoat paint layer is provided on the entire surface of a substrate that is formed between a plurality of concave grooves and has a trapezoidal portion having a large number of irregularities on the surface. Then, the surface of the undercoat paint layer is rubbed onto the surface of the undercoat paint layer with a roller or the like to apply a different color to the undercoat paint layer, and a thin topcoat paint layer is formed on the uneven surface of the trapezoidal surface. Alternatively, the undercoat paint layer is exposed, while the concave surface is formed with an overcoat paint layer that gradually increases in thickness toward the bottom.

Moreover, in patent document 2, it has on the design surface of a building board the flat part and the pattern recessed part which depressed and formed from this flat part, By making the color tone of the said flat convex part and the said pattern recessed part differ from each other The design surface forms a building board with a natural appearance.
Moreover, in patent document 3, the uneven | corrugated pattern which exhibits a woodgrain tone is formed in the design surface of a building board, and the design surface exhibits a three-dimensional external appearance by making the color of the convex part and the recessed part in this uneven pattern differ. Forms a building board.

  However, in Patent Document 1, the change in thickness formed in the top coat layer is formed corresponding to the fact that the convex surface of the plurality of irregularities protrudes from the concave surface. . Therefore, although a change in thickness is formed in the top coat layer on each convex surface, the degree of change in thickness formed for each convex surface is substantially the same. Therefore, in order to form a more natural design appearance on the surface of the decorative board, further ingenuity is required.

  Moreover, in the building board of the said patent document 2, the difference in the color tone expressed on the said design surface is formed because the design surface protrusion height of the said pattern recessed part is lower than the said flat part. Moreover, in the building board of the said patent document 3, the difference in the color expressed on the said design surface is formed because the design surface protrusion height of the said convex part is higher than the said recessed part. For this reason, as in the case of Patent Document 1, further ingenuity is required to form a more natural design appearance on the design surface of the building board.

Japanese Patent Publication No.58-34186 Japanese Patent No. 3413719 Japanese Patent Laid-Open No. 10-317631

  This invention is made | formed in view of this conventional problem, and intends to provide the manufacturing method of the building board which has the design surface which can exhibit a more natural design external appearance.

A first invention has a design surface formed by forming a plurality of line-shaped convex portions having a line-shaped apex portion and a pair of slopes on both sides thereof, and the forming directions of the plurality of line-shaped convex portions are different from each other. A preparation step of preparing the original plate,
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper coating material dries, when the removal roll for adhering and removing the upper coating material is brought into contact with the upper coating layer to remove a part of the upper coating material from the plurality of line-shaped protrusions, The upper coating material on the front side slope located on the front side in the direction of carrying the original plate to the removal roll is larger than the upper paint on the rear side slope located on the side opposite to the front side slope. There is a method of manufacturing a building board, comprising removing and adhering, and performing a removing step of making the thickness of the upper paint layer on the front slope smaller than the thickness of the upper paint layer on the rear slope. Item 1).

  In the building board manufacturing method of the present invention, in the preparation step, a plurality of line-shaped convex portions having different formation directions are formed on the design surface of the original plate, and then the lower coating layer is formed in the lower coating layer forming step. After forming, the upper paint layer is formed in the upper paint layer forming step.

And in the said removal process, before the upper side coating material in an upper side coating layer dries, a removal roll is made to contact an upper side coating layer. At this time, the upper side paint on the front side slope located on the front side in the loading direction of the original plate to the removal roll among the pair of slopes on each line-shaped convex part is located on the rear side opposite to the front side slope. More adhesion and removal than the upper paint on the slope. And the thickness of the upper side coating layer in a front side slope is formed thinner than the thickness of the upper side coating layer in a back side slope.
Then, the upper paint layer in the design surface of the original plate after performing the said removal process is dried, and a building board is manufactured.

  Thus, on the design surface of the building board, the portion where the upper paint layer is thin can exhibit an intermediate color that is neither the color of the upper paint layer nor the color of the lower paint layer. And as for the design surface of this building board, as the thickness of the upper paint layer is thinner, the color of the lower paint layer is more visible through the surface of the upper paint layer, and the intermediate color is more visible. The thinner the part is, the more visually recognizable as the color of the lower paint layer.

  Therefore, in each line-shaped convex part on the design surface of the building board, the front side slope where the thickness of the upper paint layer is thin is lower than the rear side slope where the thickness of the upper paint layer is thicker than this. The color is easily seen through the surface of the upper paint layer, and the intermediate color on the front slope is visually recognized as a color closer to the color on the lower paint layer than the intermediate color on the rear slope.

  In addition, due to the difference in the formation direction of each line-shaped convex portion, as the formation direction of the line-shaped convex portion is closer to the direction orthogonal to the carrying-in direction of the building board, one inclined surface in the line-shaped convex portion becomes the front-side inclined surface. It becomes easy to face the said removal roll from the front. Therefore, the closer the formation direction of the line-shaped convex part is to the direction orthogonal to the carrying-in direction of the building board, the more upper paint is adhered and removed on the front side slope of the line-shaped convex part. Thereby, the intermediate colors expressed in each line-shaped convex part can be made different from each other.

Therefore, the color appearance on the front side slope of each line-shaped convex part and the color appearance on the rear side slope can be made different, and the color appearance expressed in each line-like convex part can be made different from each other.
Therefore, according to the method for producing a building board of the present invention, it is possible to produce a building board having a design surface capable of presenting a more natural design appearance.

According to a second aspect of the present invention, there is provided a convex block formed by a plurality of line-shaped convex portions having a line-shaped apex portion and a pair of slopes on both sides thereof, which are partitioned by a vertical joint groove and a horizontal joint groove substantially orthogonal thereto. A preparation step of preparing a master plate having a design surface formed by arranging a plurality of the plurality of line-shaped convex portions, and preparing original plates made different from each other;
A base paint layer forming step of forming a base paint layer by applying a base paint to the entire design surface of the original plate and drying it,
A lower paint layer forming step of forming a lower paint layer by applying and drying a lower paint having a color different from that of the base paint on the surface of the base paint layer in each convex block;
An upper paint layer forming step of forming an upper paint layer by applying an upper paint different in color from the base paint and the lower paint on the surface of the lower paint layer in each convex block;
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer in the convex block, and a part of the upper paint on the plurality of line-shaped convex parts is adhered and removed. At the time, of the pair of slopes, the upper paint on the front side slope located on the front side in the loading direction of the original plate to the removal roll, the upper side on the rear side slope located on the opposite side of the front side slope A method for producing a building board, comprising: removing a larger amount of paint than adhering, and performing a removing step of making the thickness of the upper paint layer on the front slope smaller than the thickness of the upper paint layer on the rear slope. (Claim 2).

  In the building board manufacturing method of the present invention, in the preparation step, a plurality of line-shaped convex portions having different forming directions are formed on each convex block on the design surface of the original plate, and then the original plate is formed in the base paint layer forming step. After the base coating layer is formed on the entire design surface, the lower coating layer and the upper coating layer are formed on each convex block on the design surface of the original plate in the lower coating layer forming step and the upper coating layer forming step.

  And when the said removal process is performed and an upper paint layer is dried and a building board is manufactured, in the convex block of the design surface of a building board, the front side of each line-shaped convex part similarly to the said 1st invention. The color appearance on the slope and the color appearance on the rear-side slope can be made different, and the color appearance expressed in the respective line-shaped convex portions can be made different from each other.

Moreover, in this invention, the color external appearance by the color of the said foundation coating layer can also be expressed in the vertical joint groove and the horizontal joint groove in the design surface of a building board.
Therefore, the building board which has the design surface which can exhibit a more natural design external appearance can be manufactured also by the manufacturing method of the building board of this invention.

The third invention comprises a preparation step of preparing an original plate,
A lower paint containing a plurality of granules is applied to the design surface of the original plate and dried to form a lower paint layer, and a plurality of protrusions are formed on the surface of the lower paint layer by the plurality of granules. A lower paint layer forming step for forming a part;
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper coating material dries, a removal roll for adhering and removing the upper coating material is brought into contact with the upper coating layer, and the upper coating material in each concave portion formed between the respective convex portions is placed on the convex portion. A method for manufacturing a building board is characterized in that a part having a lower formation density is attached and removed, and a removal step for changing the thickness of the upper paint layer is performed.

  In the method for producing a building board of the present invention, in the lower paint layer forming step, a lower side formed by forming a plurality of convex portions on the design surface of the original plate with a lower paint containing a plurality of granules. A paint layer is formed, and then the upper paint layer is formed in the upper paint layer forming step.

  And in the said removal process, before the upper side coating material in an upper side coating layer dries, a removal roll is made to contact an upper side coating layer. At this time, in the design surface of the original plate, in the portion where the formation density of the protrusions is high, the removal roll is unlikely to come into contact with the upper coating applied to the recesses between the protrusions. In the portion where the formation density is low, the removal roll easily comes into contact with the upper coating material applied to the concave portions between the convex portions.

Therefore, on the design surface of the original plate, the upper coating material is more adhered and removed as the concave portion has a lower formation density of the convex portions, and the upper coating layer having a changed thickness is formed in each concave portion. That is, on the design surface of the original plate, an upper paint layer having a thinner thickness is formed in a concave portion where a large amount of the upper paint is adhered and removed by the removal roll.
Then, the upper paint layer in the design surface of the original plate after performing the said removal process is dried, and a building board is manufactured.

  Thus, on the design surface of the building board, the portion where the upper paint layer is thin can exhibit an intermediate color that is neither the color of the upper paint layer nor the color of the lower paint layer. And as for the design surface of this building board, as the thickness of the upper paint layer is thinner, the color of the lower paint layer is more visible through the surface of the upper paint layer, and the intermediate color is more visible. The thinner the part is, the more visually recognizable as the color of the lower paint layer.

Therefore, each concave portion on the design surface of the building board can express a color appearance by an intermediate color that is neither a color appearance by the color of the lower paint layer nor a color appearance by the color of the upper paint layer. In addition, the color appearance of the intermediate colors different from each other can be expressed in each recess.
Therefore, according to the method for producing a building board of the present invention, it is possible to produce a building board having a design surface capable of presenting a more natural design appearance.

4th invention prepares the original plate which has the design surface formed by arranging a plurality of convex blocks divided by the vertical joint groove and the horizontal joint groove substantially orthogonal to this,
A base paint layer forming step of forming a base paint layer by applying a base paint to the entire design surface of the original plate and drying it,
The lower coating layer is formed by applying and drying a lower coating containing a plurality of particles and having a color different from that of the underlying coating on the surface of the base coating layer in each convex block. On the surface of the side coating layer, a lower coating layer forming step for forming a plurality of convex portions by the plurality of granules, and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint different in color from the base paint and the lower paint on the surface of the lower paint layer in each convex block;
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer in the convex block, and the upper paint in each concave portion formed between the convex parts, A method for manufacturing a building board is characterized in that a part having a lower formation density of the convex portions is attached and removed, and a removal step of changing the thickness of the upper paint layer is performed.

  In the building board manufacturing method of the present invention, in the preparation step, a plurality of convex blocks are formed on the design surface of the original plate, and then the base coating layer is formed on the entire design surface of the original plate in the base coating layer forming step. Then, in the lower paint layer forming step, a lower paint layer is formed by forming a plurality of convex portions on the surface of the base paint layer in each convex block with a lower paint containing a plurality of granular materials. To do. Next, in the upper paint layer forming step, an upper paint layer is formed on the surface of the lower paint layer in each convex block.

  And when the said removal process is performed and an upper coating layer is dried and a building board is manufactured, it is the color by the color of a lower coating layer in each recessed part in the design surface of a building board similarly to the said 3rd invention. It is possible to express a color appearance based on an intermediate color that is neither the appearance nor the color appearance of the upper paint layer, and to express the color appearance based on the above-mentioned intermediate colors different from each other in each recess. Can do.

Moreover, in this invention, the color external appearance by the color of the said base coating layer can also be expressed to the vertical joint groove and the horizontal joint groove in the design surface of a building board.
Therefore, according to the method for producing a building board of the present invention, it is possible to produce a building board having a design surface capable of presenting a more natural design appearance.

5th invention, the preparatory process which prepares an original plate,
The lower coating layer is formed by applying and drying a lower coating containing a plurality of types of granular materials having different shapes on the design surface of the original plate, and the lower coating layer has a plurality of types of the coating on the surface of the lower coating layer. A lower coating layer forming step of forming a plurality of types of protrusions having different protruding surfaces from each other by a granular material;
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer, and the upper paint on the plurality of convex portions adheres more as the protruding surface of each convex portion becomes closer to flatness. There is a method for producing a building board characterized by performing a removing step of removing and making the thickness of the upper paint layer different from each other between the convex portions (Claim 5).

  In the method for producing a building board of the present invention, in the lower paint layer forming step, a plurality of different protruding surfaces are formed by lower paints containing a plurality of types of granular materials having different shapes on the design surface of the original plate. A lower paint layer formed by forming various types of convex portions is formed, and then an upper paint layer is formed in the upper paint layer forming step.

And in the said removal process, before the upper side coating material in an upper side coating layer dries, a removal roll is made to contact an upper side coating layer. At this time, the contact area where the upper coating material in each of the convex portions comes into contact with the removing roll becomes wider as the convex surface of each convex portion has a nearly flat surface.
Therefore, in each convex part, the above-mentioned upper coating material adheres and removes more as the projecting surface is more flat, and an upper paint layer having a different thickness is formed on each convex part. That is, in the plurality of convex portions, an upper paint layer having a thinner thickness is formed as the convex portion is adhered and removed by the removal roll. Moreover, in each convex part, the upper coating layer is formed so that the thickness is so thin that it approaches the vertex part of each convex part.
Then, the upper paint layer in the design surface of the original plate after performing the said removal process is dried, and a building board is manufactured.

  Thus, on the design surface of the building board, the portion where the upper paint layer is thin can exhibit an intermediate color that is neither the color of the upper paint layer nor the color of the lower paint layer. And as for the design surface of this building board, as the thickness of the upper paint layer is thinner, the color of the lower paint layer is more visible through the surface of the upper paint layer, and the intermediate color is more visible. The thinner the part is, the more visually recognizable as the color of the lower paint layer.

For this reason, each convex part on the design surface of the building board is gradually changed in color appearance by the intermediate color between the two, which is neither the color appearance by the color of the lower paint layer nor the color appearance of the upper paint layer. Can be expressed. Further, when the color of the upper paint is made different from the colors of the plurality of granular materials, each convex portion on the design surface of the building board is not the color appearance due to the color of the granular material but the color of the upper paint layer. It is also possible to express the color appearance by gradually changing the color appearance that is not the color appearance. Furthermore, each convex part can express the color appearance by the intermediate colors different from each other.
Therefore, the building board which has the design surface which can exhibit a more natural design external appearance can be manufactured also by the manufacturing method of the building board of this invention.

6th invention prepares the original plate which has the design surface which arranges two or more convex blocks defined by the vertical joint groove and the horizontal joint groove substantially orthogonal to this,
A base paint layer forming step of forming a base paint layer by applying a base paint to the entire design surface of the original plate and drying it,
A lower coating layer is formed by applying and drying a lower coating having a plurality of types of granular materials having different shapes on the surface of the underlying coating layer in each convex block and having a color different from that of the underlying coating. In addition, on the surface of the lower coating layer, a lower coating layer forming step of forming a plurality of types of protrusions having different protruding surfaces from each other with the plurality of types of granules, and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint different in color from the base paint and the lower paint on the surface of the lower paint layer in each convex block;
Before the upper paint is dried, a removing roll for adhering and removing the upper paint is brought into contact with the upper paint layer in the convex block, and the upper paint in the plurality of convex parts is flattened on the protruding surface of each convex part. A building board manufacturing method is characterized in that a closer removal is performed and the removal step of making the thickness of the upper paint layer different from each other is performed between the convex portions (claim 6).

  In the building board manufacturing method of the present invention, in the preparation step, a plurality of convex blocks are formed on the design surface of the original plate, and then the base coating layer is formed on the entire design surface of the original plate in the base coating layer forming step. After that, in the lower coating layer forming step, the surface of the base coating layer in each of the convex blocks has a plurality of types of convexes having different protruding surfaces due to the lower coating containing a plurality of types of granular materials having different shapes. A lower paint layer formed by forming a portion is formed. Next, in the upper paint layer forming step, an upper paint layer is formed on the surface of the lower paint layer in each convex block.

  And when the said removal process is performed and an upper paint layer is dried and a building board is manufactured, each convex part in the design surface of a building board depends on the color of a lower paint layer similarly to the said 5th invention. It can be expressed by gradually changing the color appearance of the intermediate color between the two, which is neither the color appearance nor the color appearance of the upper paint layer. In addition, when the color of the upper paint is made different from the colors of the plurality of granular materials, the upper paint layer is not the color appearance due to the color of the granular material on each convex portion of the convex block on the design surface of the building board. It is also possible to express by gradually changing the color appearance by the intermediate color between the two, which is not the color appearance by the colors. Furthermore, each convex part can express the color appearance by the intermediate colors different from each other.

Moreover, in this invention, the color external appearance by the color of the said foundation coating layer can also be expressed in the vertical joint groove and the horizontal joint groove in the design surface of a building board.
Therefore, according to the method for producing a building board of the present invention, it is possible to produce a building board having a design surface capable of presenting a more natural design appearance.

A preferred embodiment of the above-described method for manufacturing a building board of the present invention will be described.
In the first to sixth inventions, the color difference of the upper paint can be formed by changing at least one of hue, lightness, and saturation, which are so-called three attributes of color.
In the first and second inventions, in the plurality of line-shaped protrusions formed on the design surface of the original plate, the formation directions of all the line-shaped protrusions are not necessarily different from each other. The formation direction of some line-shaped convex parts among the line-shaped convex parts may be the same.

Further, the shape of the plurality of line-shaped convex portions is not necessarily constant, and can be formed in various shapes. For example, the line-shaped convex portion can be formed in a linear shape, a curved shape, a bent shape, a curved shape, a wave shape, or the like. Further, the line-shaped convex portions are not necessarily formed continuously, and can be formed by being divided into a plurality of pieces, for example.
In addition to forming a plurality of line-shaped convex portions on the design surface of the original plate, a plurality of point-shaped convex portions having a point-like apex portion can be formed in a mixed manner.

In addition, at least two of the first invention, the third invention, and the fifth invention can be combined and applied to one building board. In this case, the design surface of the manufactured building board can exhibit a more complex and natural design appearance.
In addition, at least two of the second invention, the fourth invention, and the sixth invention can be combined and applied to one building board. Also in this case, the design surface of the manufactured building board can exhibit a more complex and natural design appearance.

In the second, fourth, and sixth inventions, it is preferable that the concavo-convex patterns formed on the convex blocks by the plurality of convex portions are different from each other in the convex blocks. ).
In this case, the color appearance exhibited by the entire convex blocks can be made different from each other, and a more natural design appearance can be formed on the design surface of the building board.

In the first to sixth inventions, it is preferable that the removing roll is formed by disposing a rubber surface layer made of a rubber material on a surface of a sponge core layer made of a sponge material.
In this case, in the removing step, by elastically deforming the sponge core layer, the removing roll can be more flexibly brought into contact with the upper paint layer formed on the design surface of the original plate, and the rubber surface layer By this, a part of the upper paint can be more easily attached and removed.

The sponge material refers to a material obtained by blending a foam material with various rubbers, synthetic resins, and the like and foam-molded. The material has lower hardness and lower resilience than the rubber material. The rubber material refers to those molded from various rubbers.
The rubber hardness of the rubber material is preferably 30 to 70 degrees. When the rubber hardness is less than 30 degrees, the roll surface of the removal roll is too soft, and the wear deterioration of the removal roll is accelerated, and the amount of the upper paint on the design surface of the building board is adhered and removed. (Proportion) becomes too large, and it becomes difficult to form a color change on the design surface of the building board. On the other hand, when the rubber hardness exceeds 70 degrees, the roll surface of the removal roll is too hard to make it difficult to adhere and remove a part of the upper paint.

Below, the Example concerning the manufacturing method of the building board of this invention is described using drawing.
(Example 1)
The manufacturing method of the building board 1 of this example performs the following preparation processes, a lower coating layer formation process, an upper coating layer formation process, and a removal process, as shown in FIGS. 1-6, and a more natural design external appearance. A building board 1 that can be presented is manufactured.
That is, as shown in FIG. 2, the preparation step has a design surface 201 formed by forming a plurality of line-shaped convex portions 21 having a line-shaped apex portion 211 and a pair of inclined surfaces 212 on both sides thereof, An original plate 2 is prepared in which the formation directions of the plurality of line-shaped convex portions 21 are different from each other.

Next, as shown in FIG. 3, in the lower coating layer forming step, the lower coating layer 4 is formed by applying and drying the lower coating 40 on the design surface 201 of the original plate 2.
Next, as shown in FIG. 4, in the upper paint layer forming step, an upper paint 50 having a color different from that of the lower paint 40 is applied to the surface of the lower paint layer 4, and the upper paint layer 5 is applied. Form.

Thereafter, as shown in FIG. 4 and FIG. 1, in the removing step, before the upper paint 50 is dried, a removal roll 71 for adhering and removing the upper paint 50 is brought into contact with the upper paint layer 5, so A part of the upper coating material 50 on the line-shaped convex portion 21 is adhered and removed.
At this time, as shown in FIG. 1, the upper coating material 50 on the front side slope 212 </ b> A located on the front side in the loading direction D of the original plate 2 to the removal roll 71 among the pair of slopes 212 in each of the line-shaped convex portions 21. The adhesion is removed more than the upper coating 50 on the rear side slope 212B located on the opposite side to the front side slope 212A. Thereby, the thickness of the upper paint layer 5 on the front side slope 212A is made thinner than the thickness of the upper paint layer 5 on the rear side slope 212B.
This will be described in detail below.

As shown in FIG. 2, the original plate 2 to be molded in the preparation step is a cement-based original plate 2 containing a cementitious material. And this cement-type original board 2 mixes woody raw material (wood fiber, wood chip, etc.), an additive, water, etc. with cementitious raw material (cement, silicic acid raw material, etc.), makes a mixed raw material, Is sprayed on the molding surface of the mold and dried and cured.
In addition, the molding surface of the mold is formed in a concavo-convex shape in order to form a concavo-convex pattern formed by a plurality of line-shaped convex portions 21 formed on the design surface 201 of the original plate 2. A plurality of line-shaped convex portions 21 having different forming directions can be formed on the design surface 201 of the original plate 2 molded by the molding die.

The formation direction of each said line-shaped convex part 21 means the direction where each line-shaped convex part 21 is extended. Each of the line-shaped convex portions 21 in this example is formed as a curved convex portion whose formation direction changes in a curved shape. Moreover, the shape of each line-shaped convex part 21 of this example is not constant, and is formed in various shapes. Moreover, the protrusion height H of each line-shaped convex part 21, ie, the thickness from the back surface 202 of the original plate 2, to the design surface 201 is substantially the same.
It should be noted that the plurality of line-shaped convex portions 21 formed on the design surface 201 of the original plate 2 are not necessarily different from each other in shape and forming direction. Some have substantially the same shape and direction of formation.

As shown in FIGS. 3 and 4, the lower coating 40 used in the lower coating layer forming step and the upper coating 50 used in the upper coating layer forming step are all resins, pigments, various additives, water as a solvent, and the like. Is a water-based paint comprising In this example, the lower paint 40 and the upper paint 50 are different in lightness (lightness) as colors. In addition to this, for example, the lower paint 40 and the upper paint 50 may be paints having different saturations as colors.
And after performing the said lower side coating layer formation process and the upper side coating layer formation process, the whole design surface 201 of the original plate 2, ie, between all the line-shaped convex parts 21, and the line-shaped convex parts 21 mutually. The lower paint layer 4 and the upper paint layer 5 are formed in all the formed recesses 22.

  As shown in FIG. 5, in the removing step, a removing roll 71 that comes in contact with the design surface 201 of the original plate 2 to adhere and remove a part of the upper paint 50 is disposed opposite to the removing roll 71, and the original plate A paint removing device 7 having a backup roll 72 in contact with the second back surface 202 is used. In order to make the removal roll 71 more flexibly contact the upper paint layer 5 formed on the design surface 201 of the original plate 2 and more easily attach and remove a part of the upper paint 50 in the upper paint layer 5, a sponge material is used. A rubber surface layer 712 made of a rubber material is disposed on the surface of the sponge core layer 711 made of. The removal roll 71 has an iron core 713 made of a metal material at the center of the sponge core layer 711. The sponge material constituting the sponge core layer 711 of this example is made of butyl sponge rubber, and the rubber material constituting the rubber surface layer 712 is made of EPDM (ethylene propylene rubber) having a rubber hardness of about 50 degrees.

As shown in FIGS. 4 and 5, in the removing step, before the upper paint 50 in the upper paint layer 5 of the original plate 2 is dried, the original plate 2 is placed between the removal roll 71 and the backup roll 72. To the gap 75. At this time, the upper coating layer 5 formed on the design surface 201 of the original plate 2 is in contact with the roll surface 710 of the removal roll 71, and the back surface 202 of the original plate 2 is in contact with the roll surface 720 of the backup roll 72.
Further, in this example, the upper paint layer 5 on the entire design surface 201 of the original plate 2, that is, the upper paint layer 5 formed on almost all the line-shaped convex portions 21 and the concave portions 22 is formed on the roll surface 710 of the removing roll 71. Touch.

  At the time of the contact, the front side slope 212A located on the front side in the loading direction D of the original plate 2 to the removal roll 71 among the pair of slopes 212 in each line-shaped convex portion 21 is opposite to the front side slope 212A. This makes it easier to come into contact with the removing roll 71 more strongly than the rear side slope 212B located at the position.

Therefore, as shown in FIGS. 1 and 6, when the original plate 2 passes through the gap 75 between the removal roll 71 and the backup roll 72, the upper paint 50 on each front side slope 212 </ b> A becomes on each rear side slope 212 </ b> B. More than the upper paint 50 is adhered and removed, and the thickness of the upper paint layer 5 on the front slope 212A is thinner than the thickness of the upper paint layer 5 on the rear slope 212B. In addition, on the front side slope 212 </ b> A and the rear side slope 212 </ b> B of each line-shaped convex portion 21, the upper paint layer 5 is formed to be thinner as it approaches the vertex 211 of each line-shaped convex portion 21.
Thereafter, the upper paint layer 5 on the design surface 201 of the original plate 2 after the above removal process is dried to manufacture the building board 1.

  Thus, as shown in FIGS. 1 and 6, in the design surface 101 of the building board 1, the portion where the thickness of the upper paint layer 5 is thin is neither the color due to the upper paint layer 5 nor the color due to the lower paint layer 4. An intermediate color can be exhibited. And as for the design surface 101 of this building board 1, as the thickness of the upper paint layer 5 is thinner, the color of the lower paint layer 4 is more easily seen through the surface of the upper paint layer 5, and the intermediate color described above. However, the thinner the thickness of the upper paint layer 5 is, the more visually recognizable as the color closer to that of the lower paint layer 4.

  Therefore, in each line-shaped convex part 21 of the design surface 101 of the building board 1, the front side slope 212 </ b> A in which the upper paint layer 5 is thinner than the rear side slope 212 </ b> B in which the upper paint layer 5 is thicker than this. However, the color of the lower paint layer 4 can be easily seen through the surface of the upper paint layer 5, and the intermediate color on the front side slope 212A is lower than the intermediate color on the rear side slope 212B. It is visually recognized as a color close to the color by the layer 4.

  Moreover, as shown in FIGS. 1 and 6, due to the difference in the formation direction of each line-shaped convex portion 21, the formation direction of the line-shaped convex portion 21 is close to the direction orthogonal to the carrying-in direction D of the building board 1. The one inclined surface 212 in the line-shaped convex portion 21 is likely to face the removal roll 71 from the front as the front-side inclined surface 212A. Therefore, the closer the forming direction of the line-shaped convex part 21 is to the direction orthogonal to the carrying-in direction D of the building board 1, the more the upper coating material 50 on the front side slope 212A of the line-shaped convex part 21 is attached and removed. Thereby, the intermediate colors expressed in each line-shaped convex part 21 can be made different from each other.

Therefore, the color appearance on the front side slope 212A of each line-shaped convex portion 21 and the color appearance on the rear side slope 212B can be made different, and the color appearance expressed in each line-like convex portion 21 can be made different from each other. be able to.
Moreover, in each recessed part 22 formed between each line-shaped convex part 21, the color appearance by the color of the upper side coating layer 5 is expressed substantially. Also, most of the upper paint 50 is adhered and removed from the apex portions 211 of the respective line-shaped convex portions 21 and the portions near the apex portion 211 of the front-side inclined surface 212A of each of the line-shaped convex portions 21, so that the lower paint layer is substantially removed. In some cases, the color appearance of four colors is expressed.

  Therefore, according to the manufacturing method of the building board 1 of this example, the building board 1 having the design surface 101 capable of exhibiting a more natural and delicate design appearance as represented by the design appearance of natural stone is produced. be able to.

In the removing step, after the upper paint layer 5 is formed on the surface of the lower paint layer 4 on the design surface 201 of the original plate 2, a part of the upper paint 50 in the upper paint layer 5 is removed from the removal roll 71. It is removed by adhesion. Therefore, the upper paint layer 5 is not formed so as to rub the paint adhered to the roll onto the surface of the original plate 2.
Therefore, the upper paint 50 hardly accumulates excessively in the concave portions 22 between the convex portions 21, and cracks or the like due to excessive paint hardly occur in the concave portions 22. Therefore, according to the manufacturing method of the building board 1 of this example, the building board 1 excellent in quality can be manufactured.

  The plurality of line-shaped convex portions 21 can also be formed in a straight line shape. For example, as shown in FIGS. 7 and 8, the design surface 201 of the original plate 2 has a plurality of first line-shaped convex portions 21 </ b> A having a formation direction directed in a direction substantially orthogonal to the carry-in direction D of the original plate 2. And a plurality of second line-shaped convex portions 21 </ b> B having a forming direction toward the carrying-in direction D of the original plate 2 can be formed.

  In this case, as shown in FIGS. 7 and 8, the removal roll 71 causes the upper paint 50 on the front side inclined surface 212A of each first linear convex portion 21A to be applied to each first linear convex portion 21A. By attaching and removing more than the upper paint 50 on the rear slope 212B, the thickness of the upper paint layer 5 on the front slope 212A and the rear slope 212B can be made different. Further, in this case, the upper roll 50 is adhered and removed from the pair of inclined surfaces 212 in each second line-shaped convex portion 21 </ b> B almost evenly by the removing roll 71, and each pair of inclined surfaces 212 is apex from the concave portion 22. The upper coating layer 5 whose thickness decreases toward the portion 211 can be formed.

(Example 2)
In this example, as shown in FIGS. 9 to 11, when manufacturing the building board 1 having the design surface 101 that can exhibit a more natural and delicate design appearance, the vertical joint groove 251 is formed on the design surface 201 of the original plate 2. In this example, a plurality of convex blocks 25 defined by the horizontal joint grooves 252 are formed, and the color appearances of the convex blocks 25 and the joint grooves 251 and 252 are also different.
That is, in the manufacturing method of the building board 1 of this example, the following preparation process, base coating layer forming process, lower coating layer forming process, upper coating layer forming process, and removal process are performed to manufacture the building board 1. .

  As shown in FIG. 9, in the preparation step, the original plate 2 having the design surface 201 formed by forming a plurality of convex blocks 25 defined by the vertical joint grooves 251 and the horizontal joint grooves 252 substantially orthogonal thereto is prepared. The original plate 2 is a cement-based original plate 2 formed by spraying the mixed raw material on the forming surface of the forming die in the same manner as in the first embodiment. Further, each convex block 25 on the design surface 201 of the original plate 2 is formed with a plurality of line-shaped convex portions 21 having a line-shaped apex portion 211 and a pair of inclined surfaces 212 on both sides thereof, and each line-shaped convex portion. 21 are formed in different directions.

  Next, as shown in FIG. 10, in the base paint layer forming step, the base paint 30 is applied to the entire design surface 201 of the original plate 2 and dried to form the base paint layer 3. Next, in the lower paint layer forming step, the lower paint 40 having a color different from that of the base paint 30 is applied to the surface of the base paint layer 3 in each convex block 25 excluding the vertical joint grooves 251 and the horizontal joint grooves 252. The lower coating layer 4 is formed by applying and drying.

Next, as shown in FIG. 10, in the upper paint layer forming step, the base paint 30 and the lower paint are applied to the surface of the lower paint layer 4 in each convex block 25 except for the vertical joint grooves 251 and the horizontal joint grooves 252. The upper coating layer 50 having a color different from that of the upper coating layer 40 is applied to form the upper coating layer 5.
Thus, after performing the lower paint layer forming step and the upper paint layer forming step, only the base paint layer 3 is formed in the vertical joint grooves 251 and the horizontal joint grooves 252.

  As shown in FIGS. 10 and 11, in the removal step, the removal roll 71 is brought into contact with the upper paint layer 5 in each convex block 25 before the upper paint 50 in the upper paint layer 5 is dried. At this time, the upper coating material 50 on the front side slope 212A located on the front side in the loading direction D of the original plate 2 to the removal roll 71 among the pair of slopes 212 in each line-like convex portion 21 of each convex block 25 is the front More adhesion and removal than the upper coating material 50 on the rear side slope 212B located on the opposite side to the side slope 212A. And the thickness of the upper side coating layer 5 in the front side slope 212A is formed thinner than the thickness of the upper side coating layer 5 in the back side slope 212B.

  Thereafter, when the building board 1 is manufactured by drying the upper paint layer 5, the color appearance and the rear side of the front side inclined surface 212 </ b> A of each line-like convex portion 21 in each convex block 25 of the design surface 101 of the building board 1. The color appearance on the slope 212B can be made different, and the color appearance expressed in the line-shaped convex portions 21 can be made different from each other.

Moreover, in this example, the color appearance by the color of the said foundation coating layer 3 can also be expressed in the vertical joint groove 251 and the horizontal joint groove 252 in the design surface 101 of the building board 1.
Therefore, also by the manufacturing method of the building board 1 of this example, the building board 1 which has the design surface 101 which can exhibit a more natural and delicate design external appearance can be manufactured.
Also in this example, the other parts are the same as those in the first embodiment, and the same effects as those in the first embodiment can be obtained.

(Example 3)
In this example, as shown in FIGS. 12 to 14, when the building board 1 having the design surface 101 that can exhibit a more natural and delicate design appearance is produced, the formation density is reduced in each part of the design surface 201 of the original plate 2. In this example, a plurality of different convex portions 21 are formed using a plurality of granular bodies 6.
That is, in the manufacturing method of the building board 1 of this example, the building board 1 is manufactured by performing the following preparation process, lower paint layer forming process, upper paint layer forming process, and removal process.

As shown in FIG. 12, in the preparation step, the original plate 2 having almost no irregularities on the design surface is prepared. The original plate 2 is a cement-based original plate 2 formed by spraying the mixed raw material on the forming surface of the forming die in the same manner as in the first embodiment.
Next, in the lower coating layer forming step, the lower coating layer 40 containing the plurality of granular bodies 6 is applied to the design surface 201 of the original plate 2 and dried to form the lower coating layer 4. At this time, a plurality of convex portions 21 are formed on the surface of the lower coating layer 4 by the plurality of granular bodies 6. The plurality of convex portions 21 are formed when the thickness of the lower coating layer 4 formed on the design surface 201 of the original plate 2 is smaller than the particle size of the plurality of granular bodies 6.

Further, as shown in FIG. 12, the lower coating material 40 includes a plurality of particles 6 nonuniformly, and the particles 6 are unevenly distributed on the design surface 201 of the original plate 2, On the surface of the coating layer 4, a plurality of convex portions 21 are formed in an uneven distribution. In this way, the formation density of the convex portions 21 is formed differently in each part of the design surface 201 of the original plate 2 due to the difference in the density of the granular bodies 6 in each part of the design surface 201 of the original plate 2.
Here, the formation density of the convex portions 21 (the degree of density of the granular materials 6) refers to an amount represented by the number of convex portions 21 per unit area (the number of granular materials 6).
In order to form the lower coating layer 4 in which the granular materials 6 are unevenly distributed on the design surface 201 of the original plate 2, a plurality of types of lower coating materials 40 having different contents of the granular materials 6 are prepared. It is also possible to apply the lower coating 40 of the type to the design surface 201 of the original plate 2 as appropriate.

In this example, the plurality of granular bodies 6 are substantially spherical, but besides this, the plurality of granular bodies 6 can be of a plurality of types having different shapes. . For example, the shape of the granule 6 can be various shapes such as a substantially cube, a rectangular parallelepiped, and a polyhedron having eight or more faces.
The granular material 6 does not necessarily have a chromatic color, and may be a transparent color, for example.

Next, as shown in FIG. 13, in the upper paint layer forming step, an upper paint layer 5 having a color different from that of the lower paint 40 is applied to the surface of the lower paint layer 4 to form the upper paint layer 5. To do.
Next, as shown in FIGS. 13 and 14, in the removal step, the removal roll 71 is brought into contact with the upper paint layer 5 on the design surface 201 of the original plate 2 before the upper paint 50 in the upper paint layer 5 is dried. At this time, in the design surface 201 of the original plate 2, the removal roll 71 is unlikely to contact the upper coating 50 applied to the concave portions 22 between the convex portions 21 in the portion where the formation density of the convex portions 21 is high. On the other hand, in the part where the formation density of the convex part 21 is low, the said removal roll 71 becomes easy to contact the upper coating material 50 apply | coated to the recessed part 22 between each convex part 21. FIG.

Therefore, as shown in FIG. 14, on the design surface 201 of the original plate 2, the upper coating 50 is attached and removed more as the concave portions 22 in the portions where the formation density of the convex portions 21 is lower, and the thickness of each concave portion 22 is changed. The upper paint layer 5 is formed. That is, on the design surface 201 of the original plate 2, the upper coating layer 5 is formed such that the thickness of the concave portion 22 from which a large amount of the upper coating 50 is adhered and removed by the removing roll 71. Moreover, in each convex part 21, the upper coating layer 5 is formed so that the thickness is so thin that it approaches the vertex part 211 of each convex part 21. FIG.
Thereafter, the upper paint layer 5 on the design surface 201 of the original plate 2 after the above removal process is dried to manufacture the building board 1.

  Thus, as shown in FIG. 14, in the design surface 101 of the building board 1, the portion where the upper paint layer 5 is thin is intermediate between the colors that are neither the color of the upper paint layer 5 nor the color of the lower paint layer 4. Can exhibit a variety of colors. And as for the design surface 101 of this building board 1, as the thickness of the upper paint layer 5 is thinner, the color of the lower paint layer 4 is more easily seen through the surface of the upper paint layer 5, and the intermediate color described above. However, the thinner the thickness of the upper paint layer 5 is, the more visually recognizable as the color closer to that of the lower paint layer 4.

Therefore, each concave portion 22 in the design surface 101 of the building board 1 has a color appearance that is neither a color appearance due to the color of the lower paint layer 4 nor a color appearance due to the color of the upper paint layer 5, and an intermediate color between them. It is possible to express the color appearance by the intermediate colors different from each other.
Further, in this example, most of the upper paint 50 is adhered and removed from the apex portion 211 of the convex portion 21 formed by the granular material 6, and the color appearance by the color of the granular material 6 or the lower paint layer 4 is approximately. Expressed.

Therefore, also by the manufacturing method of the building board 1 of this example, the building board 1 which has the design surface 101 which can exhibit a more natural and delicate design external appearance can be manufactured.
Also in this example, the other parts are the same as those in the first embodiment, and the same effects as those in the first embodiment can be obtained.

Example 4
In this example, as shown in FIGS. 15 and 16, when manufacturing the building board 1 having the design surface 101 that can exhibit a more natural and delicate design appearance, the vertical joint groove 251 is formed on the design surface 201 of the original plate 2. And a plurality of convex blocks 25 defined by the horizontal joint grooves 252 are formed so that the color appearances of the convex blocks 25 and the joint grooves 251 and 252 are different from each other, and the formation density is formed in each part of the design surface 201 of the original plate 2. This is an example in which a plurality of convex portions 21 having different sizes are formed using a plurality of granular bodies 6.
That is, in the manufacturing method of the building board 1 of this example, the following preparation process, base coating layer forming process, lower coating layer forming process, upper coating layer forming process, and removal process are performed to manufacture the building board 1. .

  As shown in FIG. 15, in the preparation step, the original plate 2 having the design surface 201 formed by forming a plurality of convex blocks 25 defined by the vertical joint grooves 251 and the horizontal joint grooves 252 substantially orthogonal thereto is prepared. The original plate 2 is a cement-based original plate 2 formed by spraying the mixed raw material on the forming surface of the forming die in the same manner as in the first embodiment.

  Next, as shown in FIG. 15, in the base paint layer forming step, the base paint 30 is applied to the entire design surface 201 of the original plate 2 and dried to form the base paint layer 3. Next, in the lower coating layer forming step, the surface of the base coating layer 3 in each convex block 25 excluding the vertical joint groove 251 and the horizontal joint groove 252 contains a plurality of granules 6 and the base coating 30 The lower coating layer 40 having different colors is applied and dried to form the lower coating layer 4. At this time, a plurality of convex portions 21 are formed on the surface of the lower paint layer 4 by the plurality of granular bodies 6.

Next, as shown in FIG. 15, in the upper paint layer forming step, the base paint 30 and the lower paint are formed on the surface of the lower paint layer 4 in each convex block 25 excluding the vertical joint grooves 251 and the horizontal joint grooves 252. The upper coating layer 50 having a color different from that of the upper coating layer 40 is applied to form the upper coating layer 5.
Thus, after performing the lower paint layer forming step and the upper paint layer forming step, only the base paint layer 3 is formed in the vertical joint grooves 251 and the horizontal joint grooves 252.

  Next, as shown in FIG. 15 and FIG. 16, the upper coating 50 in the upper coating layer 5 formed on each convex block 25 of the design surface 201 of the original plate 2 is dried in the removal step as in the third embodiment. Before, the removal roll 71 is brought into contact with the upper paint layer 5 formed on each convex block 25. Then, more of the upper coating 50 in the recesses 22 formed between the projections 21 is adhered and removed at a portion where the formation density of the projections 21 is lower, and the thickness of the upper coating layer 5 is changed.

  Thereafter, as shown in FIG. 16, when the upper paint layer 5 is dried and the building board 1 is manufactured, each concave block 22 in each convex block 25 of the design surface 101 of the building board 1 is formed in the same manner as in the third embodiment. It is possible to express a color appearance based on an intermediate color that is neither the color appearance of the lower paint layer 4 nor the color of the upper paint layer 5, and the recesses 22 are different from each other. The color appearance by the intermediate color can be expressed.

Moreover, in this example, the color appearance by the color of the said foundation coating layer 3 can also be expressed in the vertical joint groove 251 and the horizontal joint groove 252 in the design surface 101 of the building board 1.
Therefore, also by the manufacturing method of the building board 1 of this example, the building board 1 which has the design surface 101 which can exhibit a more natural and delicate design external appearance can be manufactured.
Also in this example, the other parts are the same as those in the third embodiment, and the same effects as those in the third embodiment can be obtained.

(Example 5)
In this example, as shown in FIGS. 17 to 19, when manufacturing the building board 1 having the design surface 101 capable of presenting a more natural and delicate design appearance, a plurality of types of convex portions 21 having different projecting surfaces are provided. This is an example in which a plurality of types of granular materials 6 are used.
That is, in the manufacturing method of the building board 1 of this example, the building board 1 is manufactured by performing the following preparation process, lower paint layer forming process, upper paint layer forming process, and removal process.

As shown in FIG. 17, in the preparation step, the original plate 2 having almost no irregularities on the design surface 201 is prepared. The original plate 2 is a cement-based original plate 2 formed by spraying the mixed raw material on the forming surface of the forming die in the same manner as in the first embodiment.
Next, in the lower coating layer forming step, the lower coating layer 40 containing a plurality of types of granular materials 6 is applied to the design surface 201 of the original plate 2 and dried to form the lower coating layer 4. At this time, on the surface of the lower coating layer 4, a plurality of types of protrusions 21 having different protruding surfaces are formed by the plurality of types of granules 6.
In this example, the lower coating layer 4 is formed on the surfaces of the plurality of granular bodies 6.

  As shown in FIG. 17, the plurality of types of convex portions 21 are formed when the thickness of the lower coating layer 4 formed on the design surface 201 of the original plate 2 is smaller than the particle size of the plurality of granules 6. And the protrusion surface of the convex part 21 is formed when a part of granular material 6 protrudes rather than the lower side coating layer 4. FIG.

  In this example, the plurality of types of granular bodies 6 are configured by mixing a plurality of substantially spherical granular bodies 6A, granular bodies 6B having a substantially cubic shape, and granular bodies 6C having a rectangular parallelepiped shape. The protruding surface of the convex portion 21 formed by the substantially spherical granular body 6A is formed into a curved surface, and some of the protruding surfaces of the convex portion 21 formed by the approximately cubic-shaped granular body 6B are substantially cubic. It is sharpened by the corners. Further, most of the protruding surface of the convex portion 21 formed by the rectangular parallelepiped-shaped granular body 6C is formed in a substantially flat shape by a substantially rectangular parallelepiped surface. The granular material 6 does not necessarily have a chromatic color, and may be a transparent color, for example.

Next, as shown in FIG. 18, in the upper paint layer forming step, the upper paint layer 5 is formed by applying an upper paint 50 having a color different from that of the lower paint 40 to the surface of the lower paint layer 4. To do.
In the removing step, the removing roll 71 is brought into contact with the upper paint layer 5 before the upper paint 50 in the upper paint layer 5 is dried. At this time, the contact area where the upper coating material 50 contacts the removal roll 71 in each convex portion 21 becomes wider as the convex portion 21 of each convex portion 21 whose projection surface is nearly flat.

  Therefore, as shown in FIG. 19, in each convex portion 21, the upper coating 50 is adhered and removed more in the convex portion 21 whose protruding surface is almost flat, and the upper paint layer having different thicknesses is provided in each convex portion 21. 5 is formed. In other words, in the plurality of convex portions 21, the upper paint layer 5 having a thinner thickness is formed in the convex portion 21 from which a large amount of the upper paint 50 is adhered and removed by the removing roll 71. Moreover, in each convex part 21, the upper coating layer 5 is formed so that the thickness is so thin that it approaches the vertex part 211 of each convex part 21. FIG.

Specifically, in this example, most of the upper coating material 50 is adhered and removed from the convex portion 21 having a substantially flat protruding surface formed by the above-mentioned rectangular parallelepiped-shaped granular body 6C, so that the upper coating layer is thin. 5 is formed. Further, from the convex portion 21 having a curved protruding surface formed by the substantially spherical granular body 6A, the upper coating material 50 is more adhered and removed as it approaches the apex portion 211, and the thickness approaches the apex portion 211. The upper paint layer 5 is formed to be thin. Further, the upper paint 50 is not so much adhered and removed from the convex portion 21 having the sharp projecting surface formed by the substantially cubic granular body 6B, and the upper paint layer 5 having a relatively large thickness is formed. .
Thereafter, the upper paint layer 5 on the design surface 201 of the original plate 2 after the above removal process is dried to manufacture the building board 1.

  Thus, as shown in FIG. 19, in the design surface 101 of the building board 1, the portion where the upper paint layer 5 is thin is intermediate between the colors that are neither the color of the upper paint layer 5 nor the color of the lower paint layer 4. Can exhibit a variety of colors. And as for the design surface 101 of this building board 1, as the thickness of the upper paint layer 5 is thinner, the color of the lower paint layer 4 is more easily seen through the surface of the upper paint layer 5, and the intermediate color described above. However, the thinner the thickness of the upper paint layer 5 is, the more visually recognizable as the color closer to that of the lower paint layer 4.

Therefore, each convex portion 21 on the design surface 101 of the building board 1 has a color appearance that is not a color appearance by the color of the lower paint layer 4 nor a color appearance by the color of the upper paint layer 5, and an intermediate color between the two. It can be expressed by gradually changing.
Further, when the color of the upper paint 50 is made different from the colors of the plurality of granular bodies 6, the convex portions 21 on the design surface 101 of the building board 1 have no color appearance due to the colors of the granular bodies 6. It is also possible to express by gradually changing the color appearance by the intermediate color between the two, which is not the color appearance by the color of the upper paint layer 5.
Furthermore, each convex part 21 can express the color appearance by the intermediate colors different from each other.

Therefore, also by the manufacturing method of the building board 1 of this example, the building board 1 having the design surface 101 that can exhibit a more natural design appearance can be manufactured.
Also in this example, the other parts are the same as those in the first embodiment, and the same effects as those in the first embodiment can be obtained.

(Example 6)
In this example, as shown in FIGS. 20 and 21, when manufacturing the building board 1 having the design surface 101 capable of exhibiting a more natural and delicate design appearance, the vertical joint groove 251 is formed on the design surface 201 of the original plate 2. The plurality of convex blocks 25 defined by the horizontal joint grooves 252 are formed so that the color appearances of the convex blocks 25 and the joint grooves 251 and 252 are different, and the plurality of types of convex parts 21 having different projecting surfaces are used. Is an example in which a plurality of types of granular materials 6 are used.
That is, in the manufacturing method of the building board 1 of this example, the following preparation process, base coating layer forming process, lower coating layer forming process, upper coating layer forming process, and removal process are performed to manufacture the building board 1. .

  As shown in FIG. 20, in the preparation step, the original plate 2 having the design surface 201 formed by forming a plurality of convex blocks 25 partitioned by the vertical joint grooves 251 and the horizontal joint grooves 252 substantially orthogonal thereto is prepared. The original plate 2 is a cement-based original plate 2 formed by spraying the mixed raw material on the forming surface of the forming die in the same manner as in the first embodiment.

Next, as shown in FIG. 20, in the base paint layer forming step, the base paint 30 is applied to the entire design surface 201 of the original plate 2 and dried to form the base paint layer 3. Next, in the lower coating layer forming step, the surface of the base coating layer 3 in each convex block 25 excluding the vertical joint groove 251 and the horizontal joint groove 252 contains a plurality of types of granular materials 6 having different shapes from each other and the above. A lower paint layer 40 having a color different from that of the base paint 30 is applied and dried to form the lower paint layer 4. At this time, on the surface of the lower coating layer 4, a plurality of types of convex portions 21 having different protruding surfaces are formed by the plurality of types of granular materials 6.
In this example, the lower coating layer 4 is formed on the surfaces of the plurality of granular bodies 6.

Next, as shown in FIG. 20, in the upper paint layer forming step, the upper paint 50 having a color different from that of the base paint 30 and the lower paint 40 is applied to the surface of the lower paint layer 4 in each convex block 25. The upper coating layer 5 is formed by coating.
Next, as shown in FIGS. 20 and 21, the upper coating 50 in the upper coating layer 5 formed on each convex block 25 of the design surface 201 of the original plate 2 is dried in the removal step, as in the fifth embodiment. Before, the removal roll 71 is brought into contact with the upper paint layer 5 formed on each convex block 25. And the upper coating 50 in the plurality of convex portions 21 is adhered and removed as the protruding surface of each convex portion 21 becomes flat, and the thickness of the upper coating layer 5 is made different between the convex portions 21.

Then, as shown in FIG. 21, when the upper paint layer 5 was dried and the building board 1 was manufactured, like the said Example 5, to each convex part 21 in each convex block 25 of the design surface 101 of the building board 1, as shown in FIG. Can be expressed by gradually changing the color appearance by the intermediate color between the colors of the lower paint layer 4 and the color appearance of the upper paint layer 5.
Further, when the color of the upper paint 50 is made different from the colors of the plurality of granular bodies 6, each convex portion 21 in the convex block 25 of the design surface 101 of the building board 1 depends on the color of the granular body 6. It is also possible to express the color appearance by gradually changing the color appearance that is neither the color appearance nor the color appearance by the color of the upper paint layer 5.
Furthermore, each convex part 21 can express the color appearance by the intermediate colors different from each other.

Moreover, in this example, the color appearance by the color of the said foundation coating layer 3 can also be expressed in the vertical joint groove 251 and the horizontal joint groove 252 in the design surface 101 of the building board 1.
Therefore, also by the manufacturing method of the building board 1 of this example, the building board 1 which has the design surface 101 which can exhibit a more natural and fine design external appearance can be manufactured.
Also in this example, the other parts are the same as those in the fifth embodiment, and the same effects as those in the fifth embodiment can be obtained.

Sectional explanatory drawing which expands and shows a part of manufactured board in Example 1. FIG. Sectional explanatory drawing which expands and shows a part of original plate in Example 1. FIG. Sectional explanatory drawing which expands and shows a part of original plate in the state in which the lower side paint layer in Example 1 was formed. Sectional explanatory drawing which expands and shows a part of original plate in the state which formed the lower side coating layer and the upper side coating layer in Example 1. FIG. BRIEF DESCRIPTION OF THE DRAWINGS FIG. The top view which expands and shows a part of manufactured building board in Example 1. FIG. The perspective view which shows the state which makes the removal roll contact the design surface of the other original plate in the state in which the upper coating layer was formed in Example 1. FIG. Sectional explanatory drawing which expands and shows a part of other manufactured building board in Example 1. FIG. FIG. 6 is a perspective view showing a part of an original plate in Example 2. Sectional explanatory drawing which expands and shows a part of original plate in the state in which the base coating layer in Example 2, the lower side coating layer, and the upper side coating layer were formed. Sectional explanatory drawing which expands and shows a part of manufactured building board in Example 2. FIG. Cross-sectional explanatory drawing which expands and shows a part of original plate in the state in which the lower side paint layer in Example 3 was formed. Sectional explanatory drawing which expands and shows a part of original plate in the state which formed the lower side coating layer and the upper side coating layer in Example 3. FIG. Sectional explanatory drawing which expands and shows a part of manufactured building board in Example 3. FIG. Sectional explanatory drawing which expands and shows a part of original plate in the state in which the base coating layer in Example 4, the lower side coating layer, and the upper side coating layer were formed. Sectional explanatory drawing which expands and shows a part of manufactured building board in Example 4. FIG. Sectional explanatory drawing which expands and shows a part of original plate in the state in which the lower side paint layer in Example 5 was formed. Sectional explanatory drawing which expands and shows a part of original plate in the state in which the lower side coating layer and the upper side coating layer in Example 5 were formed. Sectional explanatory drawing which expands and shows a part of manufactured building board in Example 5. FIG. Sectional explanatory drawing which expands and shows a part of original plate in the state in which the base coating layer, the lower side coating layer, and the upper side coating layer in Example 6 were formed. Sectional explanatory drawing which expands and shows a part of manufactured building board in Example 6. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Architectural board 101 Design surface 2 Original board 21 Protruding part 211 Apex part 212A Front side slope 212B Back side slope 22 Concave part 25 Convex block 251 Vertical joint groove 252 Horizontal joint groove 3 Base coating layer 30 Base coating 4 Lower coating layer 40 Lower coating 5 Upper coating layer 50 Upper coating 6 Granule 71 Removal roll 711 Sponge core layer 712 Rubber surface layer D Loading direction

Claims (8)

Prepare an original plate having a design surface formed by forming a plurality of line-shaped convex portions having a line-shaped apex portion and a pair of inclined surfaces on both sides thereof, and forming the plurality of line-shaped convex portions different from each other A preparation process to
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper coating material dries, when the removal roll for adhering and removing the upper coating material is brought into contact with the upper coating layer to remove a part of the upper coating material from the plurality of line-shaped protrusions, The upper coating material on the front side slope located on the front side in the direction of carrying the original plate to the removal roll is larger than the upper paint on the rear side slope located on the side opposite to the front side slope. A method of manufacturing a building board, comprising: removing and adhering, and performing a removing step of making the thickness of the upper paint layer on the front side slope thinner than the thickness of the upper paint layer on the rear side slope. A plurality of convex blocks formed by forming a plurality of line-shaped convex portions having a line-shaped apex portion and a pair of slopes on both sides thereof are partitioned by a vertical joint groove and a horizontal joint groove substantially orthogonal thereto. A preparatory step of preparing a master plate having a design surface and having the formation directions of the plurality of line-shaped convex portions different from each other;
A base paint layer forming step of forming a base paint layer by applying a base paint to the entire design surface of the original plate and drying it,
A lower paint layer forming step of forming a lower paint layer by applying and drying a lower paint having a color different from that of the base paint on the surface of the base paint layer in each convex block;
An upper paint layer forming step of forming an upper paint layer by applying an upper paint different in color from the base paint and the lower paint on the surface of the lower paint layer in each convex block;
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer in the convex block, and a part of the upper paint on the plurality of line-shaped convex parts is adhered and removed. At the time, of the pair of slopes, the upper paint on the front side slope located on the front side in the loading direction of the original plate to the removal roll, the upper side on the rear side slope located on the opposite side of the front side slope A method for producing a building board, comprising: removing a larger amount of paint than adhering, and performing a removing step of making the thickness of the upper paint layer on the front slope smaller than the thickness of the upper paint layer on the rear slope. . A preparation process for preparing the original plate;
A lower paint containing a plurality of granules is applied to the design surface of the original plate and dried to form a lower paint layer, and a plurality of protrusions are formed on the surface of the lower paint layer by the plurality of granules. A lower paint layer forming step for forming a part;
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper coating material dries, a removal roll for adhering and removing the upper coating material is brought into contact with the upper coating layer, and the upper coating material in each concave portion formed between the respective convex portions is placed on the convex portion. A method for producing a building board, comprising: removing and attaching a larger amount to a portion having a lower formation density and changing the thickness of the upper paint layer. A preparation step of preparing an original plate having a design surface in which a plurality of convex blocks partitioned by a vertical joint groove and a transverse joint groove substantially orthogonal to the longitudinal joint groove is provided;
A base paint layer forming step of forming a base paint layer by applying a base paint to the entire design surface of the original plate and drying it,
The lower coating layer is formed by applying and drying a lower coating containing a plurality of particles and having a color different from that of the underlying coating on the surface of the base coating layer in each convex block. On the surface of the side coating layer, a lower coating layer forming step for forming a plurality of convex portions by the plurality of granules, and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint different in color from the base paint and the lower paint on the surface of the lower paint layer in each convex block;
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer in the convex block, and the upper paint in each concave portion formed between the convex parts, A method of manufacturing a building board, wherein a removal step of attaching and removing more of a portion having a lower formation density of the convex portion to change the thickness of the upper paint layer is performed. A preparation process for preparing the original plate;
The lower coating layer is formed by applying and drying a lower coating containing a plurality of types of granular materials having different shapes on the design surface of the original plate, and the lower coating layer has a plurality of types of the coating on the surface of the lower coating layer. A lower coating layer forming step of forming a plurality of types of protrusions having different protruding surfaces from each other by a granular material;
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer, and the upper paint on the plurality of convex portions adheres more as the protruding surface of each convex portion becomes closer to flatness. A method for producing a building board, comprising: removing and making the thickness of the upper paint layer different from each other between the convex portions. A preparation step of preparing an original plate having a design surface in which a plurality of convex blocks partitioned by a vertical joint groove and a transverse joint groove substantially orthogonal to the longitudinal joint groove is provided;
A base paint layer forming step of forming a base paint layer by applying a base paint to the entire design surface of the original plate and drying it,
A lower coating layer is formed by applying and drying a lower coating having a plurality of types of granular materials having different shapes on the surface of the underlying coating layer in each convex block and having a color different from that of the underlying coating. In addition, on the surface of the lower coating layer, a lower coating layer forming step of forming a plurality of types of protrusions having different protruding surfaces from each other with the plurality of types of granules, and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint different in color from the base paint and the lower paint on the surface of the lower paint layer in each convex block;
Before the upper paint is dried, a removing roll for adhering and removing the upper paint is brought into contact with the upper paint layer in the convex block, and the upper paint in the plurality of convex parts is flattened on the protruding surface of each convex part. A method for manufacturing a building board, comprising: removing and adhering more and removing the closer the closer, and the thickness of the upper paint layer being different from each other between the convex portions.   7. The building board according to claim 2, wherein the concavo-convex pattern formed on each convex block by the plurality of convex portions is different from each other in each convex block. Production method.   8. The building board according to claim 1, wherein the removing roll is formed by disposing a rubber surface layer made of a rubber material on a surface of a sponge core layer made of a sponge material. Method.

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