JP2005177577A - Method for manufacturing construction plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a construction plate having a design surface capable of exhibiting more natural design appearance. <P>SOLUTION: In the method for manufacturing the construction plate 1, an original plate 2 having the design surface 201 formed with a plurality of projections 21 is prepared as a preparation step. Nextly, a lower coating layer 4 is formed as a lower coating layer formation step and an upper coating layer 5 is formed as an upper coating layer formation step. Thereafter, before the upper coating 50 is dried, a removal roll 7 having a roll surface 701 having a low hardness part 711 and a high hardness part 712 is brought contact with the upper coating layer 5 as a removal step. A larger amount of the upper coating 50 at the projection 21 contacted with the low hardness part 711 is deposited/removed as compared with the upper coating 50 at the projection 21 contacted with the high hardness part 712. <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.

1st invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
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 paint is dried, a removal roll for attaching and removing the upper paint is brought into contact with the upper paint layer, and a removal process for attaching and removing the upper paint on the plurality of convex portions is performed to manufacture a building board. A way to
In the removal step, the removal roll has a low hardness part and a high hardness part whose hardness is higher than the low hardness part, and the removal roll is brought into contact with the upper coating layer. In some cases, the building material manufacturing method is characterized in that the upper coating material on the convex portion in contact with the low hardness portion is adhered and removed more than the upper coating material on the convex portion in contact with the high hardness portion. Item 1).

In the method for producing a building board of the present invention, in the preparation step, a plurality of convex portions 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, and then the upper side is formed. In the paint layer forming step, the upper paint layer is formed.
Next, in the removing step, a removing roll whose roll surface has a low hardness part and a high hardness part is used, and the roll surface of this removing roll is brought into contact with the upper paint layer before the upper paint in the upper paint layer is dried. Let

And when the roll surface of a removal roll leaves | separates from the design surface of an original plate, it becomes easy to adhere an upper coating material to the low-hardness part in a roll surface compared with a high-hardness part. Therefore, a larger amount of the upper coating material on the convex portion in contact with the low hardness portion is adhered and removed than the upper coating material on the convex portion in contact with the high hardness portion. Thereby, the upper paint layer in the convex part in contact with the low hardness part is formed thinner than the upper paint layer in the convex part in contact with the high hardness part. Moreover, in each convex part, an upper coating layer is formed so that 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.

  Therefore, in each convex part of the design surface of the building board, the convex part with a thin upper paint layer has a lower paint layer color than the convex part with a thicker upper paint layer. It becomes easier to see through the surface of the layer, and the intermediate color at the convex part where the upper paint layer is thin is more colored by the lower paint layer than the intermediate color at the convex part where the upper paint layer is thick. It is visually recognized as a color close to. Moreover, in each convex part, the said intermediate | middle color is visually recognized as a color near the color by a lower side paint layer, so that it approaches each vertex part.

Therefore, 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 of the lower paint layer nor the color appearance of the upper paint layer. In addition, the color appearance of the convex portion where the upper paint layer is thin and the color appearance of the convex portion where the upper paint layer is thick can be made different.
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.

The second invention has a design surface formed by forming a plurality of convex blocks, and in each convex block, a preparation step of preparing an original plate formed with a plurality of convex portions,
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 removing step for adhering and removing the upper paint on the plurality of convex portions is performed. A method of manufacturing a building board,
In the removal step, the removal roll has a low hardness part and a high hardness part whose hardness is higher than the low hardness part, and the removal roll is brought into contact with the upper coating layer. In some cases, the building material manufacturing method is characterized in that the upper coating material on the convex portion in contact with the low hardness portion is adhered and removed more than the upper coating material on the convex portion in contact with the high hardness portion. Item 2).

  In the method for producing a building board of the present invention, in the preparation step, a plurality of convex portions are formed on a plurality of convex blocks on the design surface of the original plate, and then in the base coating layer forming step, the entire design surface of the original plate After forming the base coating layer, the lower coating layer and the upper coating layer are formed on the respective convex blocks 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 coating layer is dried and a building board is manufactured, a lower coating layer is provided in each convex part in the convex block of the design surface of a building board similarly to the said 1st invention. It can be expressed by gradually changing the color appearance by the intermediate color between the two colors, which is not the color appearance by the color of the upper paint layer, and the color of the upper paint layer, and the thickness of the upper paint layer is thin. It is possible to make the color appearance different from the color appearance of the convex portion having a thick upper paint layer.

Moreover, in this invention, the color external appearance by the color of the said foundation coating layer can also be expressed in groove parts other than the convex block 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.

3rd invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
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 paint is dried, a removal roll for attaching and removing the upper paint is brought into contact with the upper paint layer, and a removal process for attaching and removing the upper paint on the plurality of convex portions is performed to manufacture a building board. A way to
In the removal step, the removal roll has a long surface portion and a short diameter portion whose radius is smaller than the long diameter portion, and when the removal roll is brought into contact with the upper paint layer, In the manufacturing method of a building board, the upper coating material in the convex part which contacted the said major axis part adheres and removes more than the said upper coating material in the convex part which contacted the said minor axis part (Claim 4). .

In the method for producing a building board according to the present invention, in the removing step, the roll surface has a long diameter part and a short diameter part, and the roll surface of the removal roll is dried before the upper paint in the upper paint layer is dried. In contact with the upper paint layer. At this time, the long diameter portion on the roll surface is more likely to come into contact with the upper paint on the convex portion on the design surface than the short diameter portion.
Therefore, a larger amount of the upper coating material on the convex portion in contact with the long diameter portion is adhered and removed than the upper coating material on the convex portion in contact with the short diameter portion. Thereby, the upper paint layer in the convex part in contact with the long diameter part is formed thinner than the upper paint layer in the convex part in contact with the short diameter part. Moreover, in each convex part, an upper coating layer is formed so that thickness is so thin that it approaches the vertex part of each convex part.

Thereafter, when the building board is manufactured by drying the upper paint layer, the upper paint is not formed on each convex portion on the design surface of the building board, not the color appearance by the color of the lower paint layer, as in the first invention. The color appearance that is not the color appearance due to the color of the layer but the color appearance due to the intermediate color between the two can be expressed gradually, and the color appearance at the convex portion where the thickness of the upper paint layer is thin, and the thickness of the upper paint layer The color appearance of the thick convex portion can be made different.
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 fourth invention has a design surface formed by forming a plurality of convex blocks, and in each of the convex blocks, a preparation step of preparing an original plate formed with a plurality of convex portions,
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 removing step for adhering and removing the upper paint on the plurality of convex portions is performed. A method of manufacturing a building board,
In the removing step, the removing roll has a long diameter portion and a short diameter portion whose radius is smaller than the long diameter portion, and the removing roll is in contact with the upper paint layer in the convex block. When it is made to do, it exists in the manufacturing method of the building board characterized by adhering and removing more of the said upper side coating materials in the convex part which contacted the said long diameter part than the said upper side coating material in the convex part which contacted the said short diameter part ( Claim 5).

  In the method for producing a building board of the present invention, in the preparation step, a plurality of convex portions are formed on a plurality of convex blocks on the design surface of the original plate, and then in the base coating layer forming step, the entire design surface of the original plate After forming the base coating layer, the lower coating layer and the upper coating layer are formed on the respective convex blocks 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 coating layer is dried and a building board is manufactured, a lower coating layer is provided in each convex part in the convex block of the design surface of a building board similarly to the said 3rd invention. It can be expressed by gradually changing the color appearance by the intermediate color between the two colors, which is not the color appearance by the color of the upper paint layer, and the color of the upper paint layer, and the thickness of the upper paint layer is thin. It is possible to make the color appearance different from the color appearance of the convex portion having a thick upper paint layer.

Moreover, in this invention, the color external appearance by the color of the said foundation coating layer can also be expressed in groove parts other than the convex block 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.

5th invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
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 paint is dried, a removal roll for attaching and removing the upper paint is brought into contact with the upper paint layer, and a removal process for attaching and removing the upper paint on the plurality of convex portions is performed to manufacture a building board. A way to
In the removing step, the removing roll has a smooth surface portion and a rough surface portion rougher than the smooth surface portion, and when the removing roll is brought into contact with the upper paint layer, the smooth surface portion In the method for manufacturing a building board, the upper coating material on the convex portion in contact with the surface is adhered and removed more than the upper coating material on the convex portion in contact with the rough surface portion (Claim 7).

In the method for producing a building board of the present invention, in the removing step, the roll surface uses a removing roll having a smooth surface portion and a rough surface portion, and before the upper coating material on the upper coating layer dries the roll surface of the removing roll. Contact the upper paint layer.
And when the roll surface of a removal roll leaves | separates from the design surface of a negative | original plate, an upper side coating becomes easy to adhere to the smooth surface part in a roll surface compared with a rough surface part. Therefore, a larger amount of the upper coating material on the convex portion in contact with the smooth surface portion is adhered and removed than the upper coating material on the convex portion in contact with the rough surface portion. Thereby, the upper paint layer in the convex part in contact with the smooth surface part is formed thinner than the upper paint layer in the convex part in contact with the rough surface part. Moreover, in each convex part, an upper coating layer is formed so that thickness is so thin that it approaches the vertex part of each convex part.

Thereafter, when the building board is manufactured by drying the upper paint layer, the upper paint is not formed on each convex portion on the design surface of the building board, not the color appearance by the color of the lower paint layer, as in the first invention. The color appearance that is not the color appearance due to the color of the layer but the color appearance due to the intermediate color between the two can be expressed gradually, and the color appearance at the convex portion where the thickness of the upper paint layer is thin, and the thickness of the upper paint layer The color appearance of the thick convex portion can be made different.
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 sixth invention has a design surface formed by forming a plurality of convex blocks, and in each convex block, a preparation step of preparing an original plate formed with a plurality of convex portions;
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 removing step for adhering and removing the upper paint on the plurality of convex portions is performed. A method of manufacturing a building board,
In the removing step, the removing roll has a smooth surface portion and a rough surface portion rougher than the smooth surface portion, and when the removing roll is brought into contact with the upper paint layer in the convex block. In the method of manufacturing a building board, the upper coating material on the convex portion in contact with the smooth surface portion is adhered and removed more than the upper coating material on the convex portion in contact with the rough surface portion (Claim 8). .

  In the method for producing a building board of the present invention, in the preparation step, a plurality of convex portions are formed on a plurality of convex blocks on the design surface of the original plate, and then in the base coating layer forming step, the entire design surface of the original plate After forming the base coating layer, the lower coating layer and the upper coating layer are formed on the respective convex blocks 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 coating layer is dried and a building board is manufactured, it is the lower coating layer in each convex part in the convex block of the design surface of a building board 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 of the color nor the color appearance of the upper paint layer, and the thickness of the upper paint layer is thin. It is possible to make the color appearance different from the color appearance of the convex portion having a thick upper paint layer.

Moreover, in this invention, the color external appearance by the color of the said foundation coating layer can also be expressed in groove parts other than the convex block 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.

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, the removal roll is formed by forming the entire roll surface as a low hardness portion, and forming a high hardness portion at a plurality of locations partially with respect to the roll surface comprising the low hardness portion. Can be configured. On the contrary, the removal roll is formed by forming the entire roll surface as a high hardness portion and partially forming low hardness portions at a plurality of locations with respect to the roll surface composed of the high hardness portion. You can also
Moreover, the low hardness part and the high hardness part do not need to be regularly formed on the roll surface of the removal roll, and can be irregularly formed.

Moreover, the roll surface of the removal roll does not necessarily have to be different in hardness in two stages as a low hardness part and a high hardness part. For example, even if the hardness continuously changes from a low hardness part to a high part, Good. In this case, a portion of the roll surface having a hardness less than the specified hardness can be a low hardness portion, and a portion having a specified hardness or more can be a high hardness portion.
Further, the roll surface of the removal roll may have different hardness in three or more stages. In this case as well, a portion of the roll surface that is less than the specified hardness can be a low hardness portion, and a portion that is not less than the specified hardness can be a high hardness portion.

In the third and fourth inventions, the radii of the long diameter part and the short diameter part are partial radii in the circumferential direction of the removal roll, from the roll center of the removal roll to the roll surface. It means the length of.
Moreover, the said removal roll can form the whole roll surface as a short diameter part, and may form a long diameter part partially in multiple places with respect to the roll surface which consists of this short diameter part. In this case, the long diameter portion can be formed by partially protruding from the roll surface composed of the short diameter portion. In this case, the long diameter portion does not need to be regularly formed on the roll surface of the removing roll, and can be irregularly formed. Further, for example, the long diameter part and the short diameter part can be formed from a rubber material having a substantially smooth surface.
The removal roll can also be configured by forming the entire roll surface as a long diameter portion and partially forming short diameter portions at a plurality of locations with respect to the roll surface comprising the long diameter portion.

Further, the roll surface of the removal roll does not necessarily have different radii in two stages as the short diameter part and the long diameter part. For example, the radius is continuously changed from the short diameter part to the long diameter part having a larger radius than this. May be different. In this case, a portion having a radius smaller than a prescribed radius on the roll surface can be a short diameter portion, and a portion having a radius equal to or larger than the prescribed radius can be a long diameter portion.
Further, the roll surface of the removal roll may have different radii in three or more stages. Also in this case, a portion having a radius smaller than a prescribed radius on the roll surface can be a short diameter portion, and a portion having a radius equal to or larger than the prescribed radius can be a long diameter portion.

Further, in the fifth and sixth inventions, the removing roll is formed by forming the entire roll surface as a smooth surface portion having a substantially smooth surface, and partially roughing the roll surface including the smooth surface portion at a plurality of locations. A surface portion can be formed and configured. In this case, the rough surface portion does not need to be regularly formed on the roll surface of the removal roll, and can be formed irregularly.
Further, for example, the smooth surface portion can be formed from a rubber material having a substantially smooth surface, and the rough surface portion can be formed from a sand-like material having a surface having a large number of fine irregularities. The rough surface portion can also be formed from a mesh-like material whose surface has a large number of fine holes.
The removal roll can also be formed by forming the entire roll surface as a rough surface portion and partially forming smooth surface portions at a plurality of locations with respect to the roll surface comprising the rough surface portion.

Further, the roll surface of the removal roll does not necessarily need to have two different surface roughnesses as a smooth surface portion and a rough surface portion. For example, the surface roughness varies continuously from a smooth surface portion to a rough portion. It may be. In this case, a portion finer than the specified surface roughness on the roll surface can be defined as a smooth surface portion, and a portion greater than the specified surface roughness can be defined as a rough surface portion.
Further, the roll surface of the removal roll may have a different surface roughness in three or more stages. Also in this case, a portion finer than the specified surface roughness on the roll surface can be defined as a smooth surface portion, and a portion greater than the specified surface roughness can be defined as a rough surface portion.

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 first to sixth aspects of the invention, the entire length of the original plate in the carry-in direction is made longer than the circumferential length of the removal roll, and the removal roll rotates and contacts repeatedly with respect to the full length of the original plate in the carry-in direction. Can be made. In this case, the removal roll repeatedly rotates and contacts the entire length in the carry-in direction of the original plate by making the size and arrangement pattern of the plurality of convex portions on the design surface of the original plate different from each other in a complicated manner. In addition, the state in which the upper coating material is attached and removed from the design surface of the original plate when the removal roll makes one rotation contact can be made different for each rotation contact.
Thereby, the pattern of the color appearance by the lower coating layer and the upper coating layer formed when the removing roll makes one rotation contact with the original plate can be made inconspicuous, and the design surface of the manufactured building board Can exhibit a more complex and natural design appearance.

  In the first to sixth inventions, the protrusion heights (thicknesses from the back surface of the original plate to the design surface) of the plurality of convex portions formed on the design surface of the original plate can be made substantially the same. On the other hand, the protrusion heights of the plurality of convex portions can be varied in a complicated manner. In this case, in the removal step, the upper coating is more easily attached and removed by the removal roll as the protrusion height is higher, and the design surface of the manufactured building board may exhibit a more complex and natural design appearance. it can.

In the first to sixth inventions, the plurality of convex portions on the design surface of the original plate can be formed in various shapes.
In the second, fourth, and sixth inventions, the convex block can be formed in various shapes. Each convex block can be defined by, for example, a vertical joint groove as a groove other than the convex block and a horizontal joint groove substantially orthogonal to the groove, and is defined by a joint groove extending from one side of the building board to the other. You can also

In the first and second inventions, the removal roll is formed by covering a surface of a sponge core layer made of a sponge material with a rubber surface layer made of a rubber material, and the rubber surface layer is made of the low hardness portion. And it is preferable to form the said high hardness part (Claim 3).
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 Thus, the upper paint can be more easily attached and removed.

  Moreover, the low hardness part and the high hardness part in the roll surface of the said removal roll can be formed by varying the hardness of the rubber material in the said rubber surface layer. For example, the low hardness part can be formed from a rubber material having a hardness of 30 degrees or more and less than 50 degrees, and the high hardness part can be formed from a rubber material having a hardness of 50 degrees or more and less than 70 degrees.

In the third and fourth inventions, the removal roll is formed by covering a surface of a sponge core layer made of a sponge material with a rubber surface layer made of a rubber material, and the rubber surface layer is made of the major axis portion and Preferably, the short diameter portion is formed (claim 6).
Also 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 Thus, the upper paint can be more easily attached and removed.

In the fifth and sixth inventions, the removal roll is formed by covering a surface of a sponge core layer made of a sponge material with a rubber surface layer made of a rubber material, and the rubber surface layer is made of the smooth surface portion and The rough surface portion is preferably formed (claim 9).
Also 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 Thus, 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 the upper paint.

In the second, fourth, and sixth inventions, it is preferable that the formation state of the upper paint layer in the plurality of convex portions is different from each other in the plurality of 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.

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, in the preparation step, an original plate 2 having a design surface 201 formed with a plurality of convex portions 21 is prepared.

  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, 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.

  Thereafter, as shown in FIGS. 4 and 1, in the removing step, before the upper paint 50 is dried, the removing roll 7 for adhering and removing the upper paint 50 is brought into contact with the upper paint layer 5, and the plural The upper coating material 50 on the convex portion 21 is adhered and removed. The removing roll 7 used in this removing step has a low hardness part 711 whose roll surface 701 has a low hardness and a high hardness part 712 whose hardness is higher than that of the low hardness part 711.

As shown in FIGS. 4 and 1, when the roll surface 701 of the removal roll 7 is brought into contact with the upper paint layer 5, the upper paint 50 in the convex portion 21 in contact with the low hardness part 711 is transferred to the high hardness part 712. More adhesion and removal than the upper coating 50 in the convex part 21 which contacted is carried out. Thereby, the thickness of the upper paint layer 5 in the convex part 21 in contact with the low hardness part 711 is made thinner than the thickness of the upper paint layer 5 in the convex part 21 in contact with the high hardness part 712.
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.
Further, the molding surface of the molding die is formed in a concavo-convex shape in order to form a concavo-convex pattern formed by the plurality of convex portions 21 formed on the design surface 201 of the original plate 2. And the some convex part 21 can be formed in the design surface 201 of the original plate 2 shape | molded by the said shaping | molding die.
Moreover, the protrusion height H of each 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.

As shown in FIG. 3, 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 all contain a resin, a pigment, various additives, water as a solvent, and the like. This is a water-based paint. 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, all the convex parts 21, and all formed between the convex parts 21 mutually. The lower paint layer 4 and the upper paint layer 5 are formed in the recess 22.

  As shown in FIG. 5, in the removal step, the removal roll 7 that contacts the design surface 201 of the original plate 2 to adhere and remove the upper coating 50 is disposed opposite to the removal roll 7 and the back surface of the original plate 2. A paint removing device 70 having a backup roll 75 in contact with 202 is used. The removal roll 7 is made of a sponge material made of a sponge material in order to 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 the upper paint 50 in the upper paint layer 5. A rubber surface layer 71 made of a rubber material is coated on the surface of the core layer 72.

The roll surface 701 in the removal roll 7 is the surface of the rubber surface layer 71, and the low hardness portion 711 and the high hardness portion 712 are formed on the surface of the rubber surface layer 71.
Further, the removal roll 7 has an iron core 73 made of a metal material at the center portion of the sponge core layer 72. The sponge material constituting the sponge core layer 72 of this example is made of butyl sponge rubber.

Further, as shown in FIG. 6, in the removing roll 7 of this example, the entire rubber surface layer 71 is formed as a low hardness portion 711, which is partially with respect to the rubber surface layer 71 composed of the low hardness portion 711. And the high hardness part 712 is formed in multiple places irregularly.
In this example, the rubber material constituting the low hardness portion 711 in the rubber surface layer 71 is made of EPDM (ethylene propylene rubber) having a rubber hardness of about 50 degrees, and the rubber material constituting the high hardness portion 712 in the rubber surface layer 71. Is made of EPDM (ethylene propylene rubber) having a rubber hardness of about 60 degrees.

4 and 5, in the removing step, before the upper paint 50 in the upper paint layer 5 of the original 2 is dried, the original 2 is placed between the removal roll 7 and the backup roll 75. To the gap 79. 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 701 of the removal roll 7, and the back surface 202 of the original plate 2 is in contact with the roll surface 751 of the backup roll 75.
Further, in this example, the upper coating layer 5 formed on almost all the convex portions 21 on the design surface 201 of the original plate 2 is in contact with the roll surface 701 of the removal roll 7.

And when the roll surface 701 of the removal roll 7 leaves | separates from the design surface 201 of the original plate 2, the upper coating material 50 becomes easy to adhere to the low hardness part 711 in the roll surface 701 compared with the high hardness part 712.
Therefore, as shown in FIG. 1, when the original plate 2 passes through the gap 79 between the removal roll 7 and the backup roll 75, the upper paint 50 in the convex portion 21 that is in contact with the low hardness portion 711 is the high hardness portion 712. More than the upper coating material 50 on the convex portion 21 that is in contact with the surface. Thereby, the upper paint layer 5 in the convex part 21 in contact with the low hardness part 711 is formed thinner than the upper paint layer 5 in the convex part 21 in contact with the high hardness part 712. Moreover, in each convex part 21, the upper coating layer 5 is formed so that 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. 1, 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, in each convex part 21 of the design surface 101 of the said building board 1, the convex part 21 in which the thickness of the upper coating layer 5 is thin is lower than the convex part 21 in which the thickness of the upper coating layer 5 is thicker than this. The color of the paint layer 4 is easily visible through the surface of the upper paint layer 5, and the intermediate color in the convex portion 21 with the thin upper paint layer 5 is in the convex portion 21 with the thick upper paint layer 5. It is visually recognized as a color closer to the color of the lower paint layer 4 than the intermediate color. Moreover, in each convex part 21, the said intermediate | middle color is visually recognized as a color near the color by the lower side paint layer 4, so that it approaches each vertex part 211. FIG.

  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 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 the two. Can be expressed by gradually changing the color appearance of the convex portion 21 where the upper paint layer 5 is thin and the color appearance of the convex portion 21 where the upper paint layer 5 is thick. it can.

As described above, in this example, although the original plate 2 in which the projecting height H of each convex portion 21 on the design surface 201 is substantially the same, the low hardness portion 711 and the high hardness are provided on the roll surface 701 of the removal roll 7. A plurality of types of convex portions 21 having different thicknesses of the upper coating layer 5 can be formed by the device that forms the portion 712.
Moreover, in each recessed part 22 formed between each convex part 21, the color appearance by the color of the upper side coating layer 5 is expressed substantially. Further, most of the upper paint 50 is adhered and removed from the apex portion 211 of each convex part 21 so that the color appearance of the color of the lower paint layer 4 is generally 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 forming the upper paint layer 5 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 7. 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.

(Example 2)
In this example, as shown in FIGS. 7 and 8, 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. 7, 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. A plurality of convex portions 21 are formed on each convex block 25 on the design surface 201 of the original plate 2.

  Next, in the base coating layer forming step, the base coating layer 30 is applied to the entire design surface 201 of the original plate 2 and dried to form the base coating layer 3. Further, 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 except for the vertical joint grooves 251 and the horizontal joint grooves 252. The lower coating layer 4 is formed by applying and drying.

Next, in the upper paint layer forming step, the surface of the lower paint layer 4 in each convex block 25 excluding the vertical joint groove 251 and the horizontal joint groove 252 is different in color from the base paint 30 and the lower paint 40. The upper paint layer 5 is formed by applying the upper paint 50.
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.

  Then, as shown in FIG. 8, in the removing step, the removing roll 7 having a roll surface 701 having a low hardness portion 711 and a high hardness portion 712 is used as in the first embodiment. Then, the roll surface 701 of the removal roll 7 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, a larger amount of the upper paint 50 on the convex portion 21 in contact with the low hardness portion 711 is attached and removed than the upper paint 50 on the convex portion 21 in contact with the high hardness portion 712. The upper paint layer 5 in the convex portion 21 in contact with the low hardness portion 711 is formed to be thinner than the upper paint layer 5 in the convex portion 21 in contact with the high hardness portion 712.
Then, when the upper paint layer 5 is dried and the building board 1 is manufactured, each convex portion 21 in each convex block 25 on the design surface 101 of the building board 1 does not have a color appearance due to the color of the lower paint layer 4. The color appearance of the convex portion 21 having a thin thickness of the upper paint layer 5 that can be expressed 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; The color appearance of the convex portion 21 with the thick upper paint layer 5 can be made different.

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. 9 and 10, in manufacturing the building board 1 having the design surface 101 that can exhibit a more natural and delicate design appearance, the roll surface 701 has a large radius in the removal step. This is an example of using a removing roll 7 having a long diameter portion 713 and a short diameter portion 714 having a radius smaller than that of the long diameter portion 713.

Further, in the removing roll 7 of the present example, the entire rubber surface layer 71 is formed as a short diameter portion 714, and a plurality of portions are irregularly and partially arranged with respect to the rubber surface layer 71 including the short diameter portion 714. A long diameter portion 713 is formed by attaching a patch member 74 made of a rubber material (see FIG. 6).
In addition, the radius of the long diameter part 713 and the short diameter part 714 means the partial radius in the circumferential direction of the removal roll 7, and from the roll center O (refer FIG. 5) of the removal roll 7 to the roll surface 701. It means length.

In the manufacturing method of the building board 1 of this example, the following preparation process, base paint layer forming process, lower paint layer forming process, upper paint layer forming process, and removal process are performed to manufacture the building board 1.
That is, in the preparation step, the original plate 2 having the design surface 201 formed with the plurality of convex portions 21 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 is formed by applying the lower coating 40 to the design surface 201 of the original plate 2 and drying it. 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.

  Next, as shown in FIG. 9 and FIG. 10, in the removal step, the roll surface 701 uses a removal roll 7 having a long diameter portion 713 and a short diameter portion 714, and the roll surface 701 of the removal roll 7 is used as the upper coating layer. The upper paint layer 5 is brought into contact with the upper paint layer 5 before drying. At this time, the long diameter portion 713 on the roll surface 701 is more likely to come into contact with the upper paint 50 on the convex portion 21 on the design surface 201 than the short diameter portion 714.

  Therefore, the upper coating material 50 on the convex portion 21 in contact with the long diameter portion 713 is adhered and removed more than the upper coating material 50 on the convex portion 21 in contact with the short diameter portion 714. Thereby, the upper paint layer 5 in the convex portion 21 in contact with the long diameter portion 713 is formed thinner than the upper paint layer 5 in the convex portion 21 in contact with the short diameter portion 714. Moreover, in each convex part 21, the upper coating layer 5 is formed so that thickness is so thin that it approaches the vertex part 211 of each convex part 21. FIG.

  Then, when the upper paint layer 5 is dried and the building board 1 is manufactured, the color depending on the color of the lower paint layer 4 is formed on each convex portion 21 on the design surface 101 of the building board 1 as in the first embodiment. The color appearance of the convex portion 21 can be expressed by gradually changing the color appearance of the intermediate color between the two, which is neither the appearance nor the color appearance of the upper paint layer 5, and the upper paint layer 5 is thin. The appearance and the color appearance of the convex portion 21 where the upper paint layer 5 is thick can be made different.

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
As shown in FIG. 11, this example produces a building board 1 having a design surface 101 that can exhibit a more natural and delicate design appearance. Is an example of using a removing roll 7 having a major axis 713 and a minor axis 714. Further, in this example, a plurality of convex blocks 25 defined by the vertical joint grooves 251 and the horizontal joint grooves 252 are formed on the design surface 201 of the original plate 2, and the color appearance of each convex block 25 and each joint groove 251, 252. Is also an example of making them different.

  That is, in the manufacturing method of the building board 1 of this example, similarly to Example 2, the preparation process, the base paint layer forming process, the lower paint layer forming process, and the upper paint layer forming process are performed, The ground coating layer 3 is formed on the ground groove 251 and the horizontal joint ground groove 252, and the base coating layer 3, the lower coating layer 4, and the upper coating layer 5 are formed on the convex block 25.

Then, as shown in FIG. 11, in the removal step, the removal roll 7 in which the roll surface 701 has a major diameter part 713 and a minor diameter part 714 is used as in the third embodiment. Then, the roll surface 701 of the removal roll 7 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, a larger amount of the upper paint 50 on the convex portion 21 in contact with the long diameter portion 713 is attached and removed than the upper paint 50 on the convex portion 21 in contact with the short diameter portion 714. The upper paint layer 5 in the convex portion 21 in contact with the long diameter portion 713 is formed thinner than the upper paint layer 5 in the convex portion 21 in contact with the short diameter portion 714.

  Then, when the upper paint layer 5 is dried and the building board 1 is manufactured, each convex portion 21 in each convex block 25 on the design surface 101 of the building board 1 does not have a color appearance due to the color of the lower paint layer 4. The color appearance of the convex portion 21 having a thin thickness of the upper paint layer 5 that can be expressed 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; The color appearance of the convex portion 21 with the thick upper paint layer 5 can be made different.

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. 12 and 13, in manufacturing the building board 1 having the design surface 101 that can exhibit a more natural and delicate design appearance, the roll surface 701 is substantially smooth in the removal step. In this example, the removal roll 7 having a smooth surface portion 715 made of a smooth surface and a rough surface portion 716 rougher than the smooth surface portion 715 is used.
Further, in the removal roll 7 of this example, the entire rubber surface layer 71 is formed as a smooth surface portion 715, and the rubber surface layer 71 formed of the smooth surface portion 715 is partially and irregularly provided at a plurality of locations. A sandy rough surface portion 716 having a large number of fine irregularities on the surface is formed (see FIG. 6). Similar to the smooth surface portion 715, the rough surface portion 716 of this example is made of a rubber material.

In the manufacturing method of the building board 1 of this example, the following preparation process, base paint layer forming process, lower paint layer forming process, upper paint layer forming process, and removal process are performed to manufacture the building board 1.
That is, in the preparation step, the original plate 2 having the design surface 201 formed with the plurality of convex portions 21 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 is formed by applying the lower coating 40 to the design surface 201 of the original plate 2 and drying it. 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.

Next, as shown in FIGS. 12 and 13, in the removing step, the roll surface 701 uses a removing roll 7 having a smooth surface portion 715 and a rough surface portion 716, and the roll surface 701 of the removing roll 7 is used as the upper coating layer 5. The upper paint layer 50 is brought into contact with the upper paint layer 5 before drying.
And when the roll surface 701 of the removal roll 7 leaves | separates from the design surface 201 of the original plate 2, the upper side coating | coated 50 becomes easy to adhere to the smooth surface part 715 in the roll surface 701 compared with the rough surface part 716.

  Therefore, the upper coating material 50 on the convex portion 21 in contact with the smooth surface portion 715 is adhered and removed more than the upper coating material 50 on the convex portion 21 in contact with the rough surface portion 716. Thereby, the upper paint layer 5 in the convex part 21 in contact with the smooth surface part 715 is formed thinner than the upper paint layer 5 in the convex part 21 in contact with the rough surface part 716. Moreover, in each convex part 21, the upper coating layer 5 is formed so that thickness is so thin that it approaches the vertex part 211 of each convex part 21. FIG.

  Then, when the upper paint layer 5 is dried and the building board 1 is manufactured, the color depending on the color of the lower paint layer 4 is formed on each convex portion 21 on the design surface 101 of the building board 1 as in the first embodiment. The color appearance of the convex portion 21 can be expressed by gradually changing the color appearance of the intermediate color between the two, which is neither the appearance nor the color appearance of the upper paint layer 5, and the upper paint layer 5 is thin. The appearance and the color appearance of the convex portion 21 where the upper paint layer 5 is thick can be made different.

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 6)
As shown in FIG. 14, this example produces a building board 1 having a design surface 101 that can exhibit a more natural and delicate design appearance. In the removal step, the roll surface 701 is the same as in Example 5 described above. Is an example in which the removing roll 7 having the smooth surface portion 715 and the rough surface portion 716 is used. Further, in this example, a plurality of convex blocks 25 defined by the vertical joint grooves 251 and the horizontal joint grooves 252 are formed on the design surface 201 of the original plate 2, and the color appearance of each convex block 25 and each joint groove 251, 252. Is also an example of making them different.

  That is, in the manufacturing method of the building board 1 of this example, as in Example 5, the preparation step, the base paint layer forming step, the lower paint layer forming step, and the upper paint layer forming step are performed. The ground coating layer 3 is formed on the ground groove 251 and the horizontal joint ground groove 252, and the base coating layer 3, the lower coating layer 4, and the upper coating layer 5 are formed on the convex block 25.

And as shown in FIG. 14, in the said removal process, similarly to the said Example 5, the removal roll 7 in which the roll surface 701 has the smooth surface part 715 and the rough surface part 716 is used. Then, the roll surface 701 of the removal roll 7 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, a larger amount of the upper paint 50 on the convex portion 21 in contact with the smooth surface portion 715 is attached and removed than the upper paint 50 on the convex portion 21 in contact with the rough surface portion 716. The upper paint layer 5 in the convex portion 21 in contact with the smooth surface portion 715 is formed to be thinner than the upper paint layer 5 in the convex portion 21 in contact with the rough surface portion 716.

  Then, when the upper paint layer 5 is dried and the building board 1 is manufactured, each convex portion 21 in each convex block 25 on the design surface 101 of the building board 1 does not have a color appearance due to the color of the lower paint layer 4. The color appearance of the convex portion 21 having a thin thickness of the upper paint layer 5 that can be expressed 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; The color appearance of the convex portion 21 with the thick upper paint layer 5 can be made different.

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 fifth embodiment, and the same effects as those in the fifth embodiment can be obtained.

Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the removal roll in Example 1, and manufactures a building board. Sectional explanatory drawing which expands and shows an original plate in Example 1. FIG. Sectional explanatory drawing which expands and shows the negative | original plate in the state in which the lower side coating layer and the upper side coating layer in Example 1 were formed. Cross-sectional explanatory drawing which expands and shows the state which made the removal roll contact the design surface of the original plate in Example 1. FIG. BRIEF DESCRIPTION OF THE DRAWINGS FIG. FIG. 3 is a perspective explanatory view showing a removal roll in the first embodiment. FIG. 9 is a perspective explanatory view showing an original plate in Example 2. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the removal roll in Example 2, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which made the removal roll contact the design surface of an original plate in Example 3. FIG. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the removal roll in Example 3, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of a negative | original plate with the removal roll in Example 4, and manufactures a building board. Sectional explanatory drawing which expands and shows the state which made the removal roll contact the design surface of an original plate in Example 5. FIG. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the removal roll in Example 5, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the removal roll in Example 6, and manufactures a building board.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Building board 101 Design surface 2 Original board 21 Convex part 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 7 Removal roll 701 Roll surface 71 Rubber surface layer 711 Low hardness portion 712 High hardness portion 713 Long diameter portion 714 Short diameter portion 715 Smooth surface portion 716 Rough surface portion 72 Sponge core layer 75 Backup roll

Claims (10)

A preparation step of preparing an original plate having a design surface formed with a plurality of convex portions;
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 paint is dried, a removal roll for attaching and removing the upper paint is brought into contact with the upper paint layer, and a removal process for attaching and removing the upper paint on the plurality of convex portions is performed to manufacture a building board. A way to
In the removal step, the removal roll has a low hardness part and a high hardness part whose hardness is higher than the low hardness part, and the removal roll is brought into contact with the upper coating layer. In some cases, the building board manufacturing method is characterized in that a larger amount of the upper paint on the convex portion in contact with the low hardness portion is adhered and removed than the upper paint on the convex portion in contact with the high hardness portion. A preparation step having a design surface formed by forming a plurality of convex blocks, and preparing a master plate formed by forming a plurality of convex portions on each convex block, and
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 removing step for adhering and removing the upper paint on the plurality of convex portions is performed. A method of manufacturing a building board,
In the removal step, the removal roll has a low hardness part and a high hardness part whose hardness is higher than the low hardness part, and the removal roll is brought into contact with the upper coating layer. In some cases, the building board manufacturing method is characterized in that a larger amount of the upper paint on the convex portion in contact with the low hardness portion is adhered and removed than the upper paint on the convex portion in contact with the high hardness portion.   3. The removal roll according to claim 1 or 2, wherein the surface of a sponge core layer made of a sponge material is coated with a rubber surface layer made of a rubber material, and the rubber surface layer comprises the low hardness portion and the high hardness portion. The manufacturing method of the building board characterized by forming. A preparation step of preparing an original plate having a design surface formed with a plurality of convex portions;
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 paint is dried, a removal roll for attaching and removing the upper paint is brought into contact with the upper paint layer, and a removal process for attaching and removing the upper paint on the plurality of convex portions is performed to manufacture a building board. A way to
In the removal step, the removal roll has a long surface portion and a short diameter portion whose radius is smaller than the long diameter portion, and when the removal roll is brought into contact with the upper paint layer, A method for producing a building board, comprising depositing and removing more of the upper paint on the convex part in contact with the major axis part than on the upper paint on the convex part in contact with the minor axis part. A preparation step having a design surface formed by forming a plurality of convex blocks, and preparing a master plate formed by forming a plurality of convex portions on each convex block, and
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 removing step for adhering and removing the upper paint on the plurality of convex portions is performed. A method of manufacturing a building board,
In the removing step, the removing roll has a long diameter portion and a short diameter portion whose radius is smaller than the long diameter portion, and the removing roll is in contact with the upper paint layer in the convex block. When it is made to do, the said upper coating material in the convex part which contacted the said long diameter part adheres and removes more than the said upper paint in the convex part which contacted the said short diameter part, The manufacturing method of the construction board characterized by the above-mentioned.   6. The removal roll according to claim 4 or 5, wherein the surface of a sponge core layer made of a sponge material is coated with a rubber surface layer made of a rubber material, and the rubber surface layer has the major axis part and the minor axis part. A method for manufacturing a building board, characterized in that it is formed. A preparation step of preparing an original plate having a design surface formed with a plurality of convex portions;
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 paint is dried, a removal roll for attaching and removing the upper paint is brought into contact with the upper paint layer, and a removal process for attaching and removing the upper paint on the plurality of convex portions is performed to manufacture a building board. A way to
In the removing step, the removing roll has a smooth surface portion and a rough surface portion rougher than the smooth surface portion, and when the removing roll is brought into contact with the upper paint layer, the smooth surface portion A method for manufacturing a building board, comprising adhering and removing more of the upper paint on the convex portion in contact with the upper part than on the upper paint on the convex portion in contact with the rough surface portion. A preparation step having a design surface formed by forming a plurality of convex blocks, and preparing a master plate formed by forming a plurality of convex portions on each convex block, and
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 removing step for adhering and removing the upper paint on the plurality of convex portions is performed. A method of manufacturing a building board,
In the removing step, the removing roll has a smooth surface portion and a rough surface portion rougher than the smooth surface portion, and when the removing roll is brought into contact with the upper paint layer in the convex block. A method of manufacturing a building board, wherein a larger amount of the upper paint on the convex part in contact with the smooth surface part is adhered and removed than on the upper paint on the convex part in contact with the rough surface part.   9. The removal roll according to claim 7 or 8, wherein the surface of a sponge core layer made of a sponge material is coated with a rubber surface layer made of a rubber material, and the rubber surface layer forms the smooth surface portion and the rough surface portion. The manufacturing method of the building board characterized by having performed.   The method for manufacturing a building board according to any one of claims 2, 5 and 8, wherein the formation state of the upper paint layer in the plurality of convex portions is different from each other in the plurality of convex blocks. .

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