JP2013036279A - Wall material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wall material which has an uneven pattern, hardly causes a defect in a processed part, and is excellent in design.SOLUTION: A wall material A is formed by disconnecting or cutting a base material 1 and has an uneven pattern 2 on its surface. A low recess-projection area 5, in which a recess-projection height of the uneven pattern 2 is low, is formed including a processing region 3 which is disconnected or cut. In one of preferable forms, the low recess-projection area 5 has: a low-level area 6 which is formed including the processing region 3 disconnected or cut; and a medium area 7 in which the recess-projection height of the uneven pattern 2 is higher than the low-level area 6. A processing burr generated when processing the base material and a missing pattern generated during construction can be reduced without damaging its design.

Description

  The present invention relates to a wall material having an uneven pattern on the surface.

  2. Description of the Related Art Conventionally, a wall material such as a housing outer wall material having a concavo-convex pattern formed on the surface is known. For example, Patent Document 1 discloses forming a concavo-convex pattern by embossing a coating layer with heat and pressure. Moreover, what forms an uneven | corrugated pattern by pressing an uneven | corrugated type | mold on the base material of the soft state after extrusion molding is also known. By providing an uneven pattern on the surface of the wall material in this way, it is possible to give a design to the wall surface, or to give a natural impression design to the wall surface when constructing, and to enhance the beauty of the wall Can be improved.

  FIG. 10 shows an example of a conventional method for producing a wall material A having an uneven pattern 2. As for this wall material A, the uneven | corrugated pattern 2 is formed of the several convex part 8 which protrudes on the surface.

  The overall shape of the wall material A is a shape as shown in FIG. 9 (a), and at one end of the wall material A, a rear side protrusion that protrudes outward in parallel with the substrate surface on the back surface side. A portion 11 is formed, and a front side protruding portion 12 that protrudes outward in parallel with the surface of the base material on the surface side is formed on the other end portion. Moreover, in this example, the low step part 10 which became low stepwise is formed in the edge part of the side by which the back side protrusion part 11 of the base material 1 is formed. As shown in FIG. 9 (b), during construction, the plurality of wall materials A are overlapped with the front side protruding portion 12 of the other wall material A on the surface side of the back side protruding portion 11 of one wall material A. And attached to the wall substrate, thereby forming a wall. In FIG. 10, the edge part by the side of the back side protrusion part 11 of the wall material A is shown in figure. In FIG. 9, the concave / convex pattern 2 is omitted.

  In producing the wall material A, first, the plate-like substrate 1 is produced by a method such as extrusion molding of a ceramic material. Next, as shown in FIG. 10A, the uneven pattern 2 is formed on the surface of the substrate 1 by pressing the mold material having the unevenness on the surface of the substrate to transfer the unevenness. When the base material 1 is not completely cured yet and is soft, the uneven pattern 2 can be formed by deforming the base material 1 made of a ceramic material. Or after forming a coating-film layer on the surface like patent document 1, an uneven | corrugated type | mold can be pressed against this coating-film layer, a coating-film layer can be deformed, and the uneven | corrugated pattern 2 can also be formed.

  And as shown in FIG.10 (b), the edge part of the base material 1 is made into a desired shape by cutting or cutting the unnecessary part of an edge part along the process line 9 shown to Fig.10 (a). Process. In this example, the front end of the end portion is cut into a step shape, and the back side protruding portion 11 having a lower height than the low step portion 10 is formed. Similarly, the other end of the wall material A is cut or cut to form the front protrusion 12 as shown in FIG. Thereby, the wall material A having a desired shape is formed.

JP 2009-137028 A

  When the substrate 1 is cut or cut, if it can be cut or cut at the portion where the height of the concavo-convex pattern 2 is lowered as shown by the processing line 9 in FIG. 10A, FIG. As shown by, the low part of the uneven pattern 2 appears as the surface shape of the processed part. In this case, the concavo-convex pattern 2 which is not broken and does not break and is hard to break can be formed.

  However, when cutting or cutting, it is difficult to set the machining line 9 with high accuracy, and the machining line 9 may deviate from the set position. This not only occurs due to a shift in the setting position of the processing machine itself, but can also occur due to a shift in the relative position of the processing machine due to the uneven pattern 2 being formed in a shifted manner. Even if cutting or cutting is performed along the processing line 9, the cutting or cutting may be performed by shifting from the position of the processing line 9 due to a cutting error or a cutting error of the processing machine. In this way, a range that can be cut or cut by the processing machine can be referred to as a processing region 3.

  FIG. 10 (c) shows the state of the wall material A that is cut or cut at a portion having a high concavo-convex height of the concavo-convex pattern 2 with the cutting or cutting position shifted from the processing line 9. When the cutting or cutting position is deviated from the original processing line 9 in this way, as shown in FIG. 10C, a high portion of the concavo-convex pattern 2 appears as a surface shape of the processing portion, so that burrs or the like are likely to occur, There is a risk of deteriorating the appearance. Further, since the convex portion 8a of the processed portion is formed in an incomplete shape as the convex portion 8, the convex portion 8a of the processed portion is missing and easily broken, and as a result, the convex portion 8a is missing. Good products may occur. Moreover, even if the convex part 8a of a process part remains, there exists a possibility that the convex part 8a of a process part may lack at the time of construction, and may obstruct construction work or worsen an external appearance. Moreover, even if it constructs without destroying the convex part 8a of a process part, since this convex part 8a is easy to be missing with slight force, there exists a possibility that it may become impossible to maintain the wall surface with a good design property.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a wall material that has an uneven pattern, hardly causes defects in a processed portion, and has excellent design properties.

  The wall material according to the present invention is a wall material formed by cutting or cutting a base material and having a concavo-convex pattern on a surface thereof, and a low concavo-convex region having a low concavo-convex height of the concavo-convex pattern is cut or cut. It is formed including a processing region.

  A further invention of the wall material is characterized in that the low unevenness region includes a low region formed including a processed region to be cut or cut, and a middle region in which the unevenness height of the uneven pattern is higher than the low region. It is characterized by having.

  ADVANTAGE OF THE INVENTION According to this invention, it has an uneven | corrugated pattern, it is hard to generate | occur | produce a defect in a process part, and the wall material excellent in the design property can be obtained.

It is sectional drawing which shows an example of embodiment of the wall material which concerns on this invention, (a) is before a process, (b) and (c) show the state after a process. (A) And (b) shows the expanded sectional view of the process part of wall material A. FIG. It is sectional drawing which shows another example of embodiment of the wall material which concerns on this invention, (a) is before a process, (b) and (c) show the state after a process. It is sectional drawing which shows another example of embodiment of the wall material which concerns on this invention, (a) is before a process, (b) and (c) show the state after a process. (A) And (b) shows the expanded sectional view of the process part of wall material A. FIG. (A) (b) And (c) is sectional drawing which shows an example of a convex part. It is sectional drawing which shows another example of embodiment of the wall material which concerns on this invention, (a) is before a process, (b) and (c) show the state after a process. It is a top view which shows an example of a wall material. (A) is sectional drawing which shows an example of a wall material, (b) is sectional drawing which shows an example of construction of a wall material. It is sectional drawing which shows an example of the conventional wall material, (a) is before a process, (b) and (c) show the state after a process.

  FIG. 1 shows an example in which the wall material A is formed. The wall material A is an outer wall material formed of a ceramic material (cement material).

  The overall shape of the wall material A is a shape as shown in FIG. 9 (a), and at one end of the wall material A, a rear side protrusion that protrudes outward in parallel with the substrate surface on the back surface side. Part 11 is formed. Further, the other end portion of the wall material A is formed with a front side protruding portion 12 that is notched on the back surface side and protrudes outward in parallel with the substrate surface on the front surface side. As shown in FIG. 9 (b), during construction, the plurality of wall materials A are overlapped with the front side protruding portion 12 of the other wall material A on the surface side of the back side protruding portion 11 of one wall material A. And attached to the wall substrate, thereby forming a wall. In FIG. 1, the edge part by the side of the back side protrusion part 11 of the wall material A is shown in figure.

  The wall material A has an uneven pattern on the surface. As the concavo-convex pattern of the wall material A, there are a large pattern divided by joint grooves and the like, and a small pattern for expressing the texture formed on the surface of the large pattern and the joint groove surface. Among these, the uneven | corrugated pattern 2 demonstrated by this form means the thing for expressing the small pattern finely formed in the surface. The uneven pattern 2 may constitute a pattern such as a grain or a grain. For example, it is possible to form a pattern like an annual ring of wood with the uneven pattern 2. In addition, the surface pattern formed by the uneven pattern 2 may be a general pattern such as satin or embossing as long as it is a wood tone. In FIG. 9, the description of the concavo-convex pattern 2 is omitted, but since the concavo-convex dimension of the concavo-convex pattern 2 is actually sufficiently smaller than the overall dimension of the wall material A, it is represented in this way.

  FIG. 8 is a plan view of an example of the wall material A, and shows a state in which the concavo-convex pattern 2 having a wood grain pattern is applied to the surface. Thus, the wall material A can enhance the design of the wall surface by the uneven pattern 2.

  As shown in FIG. 9A, the wall material A has a base portion 13 that constitutes the outer surface of the wall at the center of the base material. In addition, a low step portion 10 that is lower than the base portion 13 in a step shape is formed at the end of the wall material A on the back side protruding portion 11 side. And the back side protrusion part 11 becomes the height lower than the low step part 10, and protrudes outward from this low step part 10.

  As shown in FIG. 9B, when the wall material A is attached by construction, the low step portion 10 can function as a joint groove. The joint groove is a portion that is stepped lower than the outer surface of the wall and exposed to the outside, and can be constituted by a concave portion that extends linearly. The joint groove is constituted by a low step portion 10 and two groove side portions 14 and 15. And in this form, the design property can be improved because the uneven | corrugated pattern 2 is formed also in the low step part 10 used as the surface of a joint groove.

  The wall material A is obtained by processing the base material 1. The base material 1 is formed by a method such as extrusion molding of ceramic materials. A rough shape (basic shape) of the substrate 1 is formed by extrusion. Then, as shown in FIG. 1 (a), the base material 1 having the concavo-convex pattern 2 formed on the surface thereof is formed by a method of pressing the mold material having the concavo-convex pattern on the surface of the base material 1 to transfer the concavo-convex pattern. The Furthermore, the base material 1 provided with the uneven pattern 2 is then cut or cut along the processing line 9. Thereby, the wall material A as shown in FIG.1 (b) or FIG.1 (c) is formed. Note that the concave / convex pattern 2 may not be provided in the portion of the base material 1 to be cut off. In FIG. 1 (a), the concave / convex pattern 2 is not formed at the tip of the end portion of the substrate 1 to be cut off.

  As shown in FIG. 1A, the concave / convex pattern 2 is composed of a plurality of convex portions 8. In this embodiment, the convex / concave pattern 2 is formed by continuously arranging the plurality of convex portions 8, but the plurality of convex portions 8 may be arranged apart from each other.

  The uneven pattern 2 may be formed on almost the entire surface exposed after the construction. Or the uneven | corrugated pattern 2 may be provided in the edge part with which the other wall material A is piled up. The concavo-convex pattern 2 is provided so that the concavo-convex pattern is continuous when a wall is formed with a plurality of wall materials A. The concavo-convex pattern 2 is provided so that the pattern continues to 10. In addition, between the base part 13 and the low step part 10, the groove | channel side part 14 used as the side surface of a joint groove is formed as an inclined surface. Since the surface of the groove side portion 14 becomes a surface perpendicular to the wall surface when the wall is formed, it becomes a portion that hardly constitutes the appearance of the concave / convex pattern 2 on the wall surface. Therefore, even if the uneven pattern 2 is not provided in this portion, the uneven pattern is continuously formed. Of course, the concave / convex pattern 2 may be provided on the groove side portion 14. Further, the surface of the groove side portion 14 may not be an inclined surface, and may be a surface substantially perpendicular to the surface of the substrate 1.

  The height of the unevenness of the uneven pattern 2 formed on the surface of the base portion 13 is substantially constant throughout the base portion 13. In addition, a region where the concave / convex pattern 2 having the same concave / convex height as the concave / convex pattern 2 in the base portion 13 is also formed on the base 13 side of the low step portion 10. A region where the uneven pattern 2 having a substantially uniform height is formed as a basic uneven region 4. The basic concavo-convex region 4 is formed across the base portion 13 and the low step portion 10, and a small concavo-convex pattern on the surface of the wall material A is mainly formed by the concavo-convex pattern 2 in the basic concavo-convex region 4.

  The uneven height of the basic uneven area 4, that is, the protruding height of the protrusion 8 in the basic uneven area 4 can be set to 0.5 to 1.0 mm, for example. If the irregularity height of the basic irregularity region 4 is too low, the design may be deteriorated, and if the irregularity height of the basic irregularity region 4 is too high, the convex portion 8 on the surface may be lost or broken.

  And in this form, the low uneven | corrugated area | region 5 with low uneven | corrugated height of the uneven | corrugated pattern 2 is formed in the base material 1 including the process area | region 3 cut or cut. The processing region 3 is a range in which cutting or cutting may be performed when cutting or cutting is performed with the processing line 9 as a mark (center). The low concavo-convex area 5 is formed adjacent to the basic concavo-convex area 4 so that the pattern of the concavo-convex pattern 2 is continuous, and the concavo-convex height is formed lower than the concavo-convex height of the basic concavo-convex area 4. Thus, when the low unevenness | corrugation area | region 5 with the low unevenness | corrugation height of the uneven | corrugated pattern 2 is formed in the base material 1, the uneven | corrugated pattern 2 of the process part cut | disconnected or cut can be made hard to collapse. In this embodiment, the end of the low uneven area 5 on the base 13 side, that is, the boundary between the low uneven area 5 and the basic uneven area 4 is substantially the same position as the end of the processed area 3 on the base 13 side. In this case, since the low asperity region 5 does not become too wide, it is possible to prevent the design pattern from being deteriorated due to the range of the asperity pattern 2 having a low asperity height becoming too wide, and it can be efficiently reduced in a narrow range. Uneven region 5 can be provided.

  FIG. 1B shows the state of the wall material A when it is cut or cut along nine machining lines. FIG. 2A shows an enlarged view of the processed portion in the case of FIG. In this case, since the processed line 9 is set at a position where the uneven height of the uneven pattern 2 is low, the convex portion 8a in the processed portion is not the convex portion 8 having an incomplete shape (a chipped shape). . Therefore, burrs are not generated and incomplete convex portions 8 are hardly lost. In addition, the processed part is square and easily impacted by collision during construction or transportation, but the uneven height of the uneven pattern 2 in the vicinity of the processed part is lower than the uneven height of the normal uneven pattern 2; Compared to the case where the height of the handle 2 is not low, the uneven pattern 2 is less likely to collapse even when subjected to an impact.

  FIG. 1 (c) shows the state of the wall material A when it is cut or cut out of the processing line 9. FIG. 2B shows an enlarged view of the processed portion in the case of FIG. The processing line 9 is normally set so that the position where the uneven height of the uneven pattern 2 is small becomes the processing center position. However, when cutting or cutting, it is difficult to set the machining line 9 with high accuracy, and the machining line 9 may deviate from the set position. For example, when the set position of the processing machine is shifted, the position of the processing line 9 is shifted. Moreover, the relative position of the mold material to which the unevenness is transferred and the base material 1 may be shifted, and the uneven pattern 2 may be formed on the base material 1 in a shifted manner. In this case, even if the setting position of the processing machine is correct As a result, the machining line 9 deviates from the set position. Even if cutting or cutting is performed along the processing line 9, the cutting or cutting may be performed by shifting from the position of the processing line 9 due to a cutting error or a cutting error of the processing machine. In this way, the range that may be cut or cut out of the processing line 9 is the processing region 3. This processing region 3 may be referred to as a processing tolerance range. Usually, the machining line 9 is at the machining center position that is the center of the machining area 3.

  Here, as shown in the example of FIG. 10C, when cut or cut out of the processing line 9, it is cut or cut at a position with a high unevenness, and the processed portion has an incomplete shape. The convex part 8a may be formed. However, in this embodiment, as shown in FIG. 1C and FIG. 2B, the unevenness height of the uneven pattern 2 in the processed region 3 is low, so that the convex portion 8a of the processed portion has an uneven height. Even if it becomes low and it becomes incomplete shape, since it is closely_contact | adhered to the base material 1, it can suppress that a burr | flash generate | occur | produces. Further, even when burrs are generated, the height of the convex portions 8a is low, so that the burrs are not conspicuous, and it is possible to suppress the appearance from being damaged. Further, since the height of the convex portion 8 is low and the adhesiveness is high, the convex portion 8a of the processed portion is not easily broken even when an impact is given during construction or conveyance, and the uneven pattern 2 is missing in the processed portion. Can be suppressed. Moreover, even if the convex part 8a in the processed part is missing, the uneven height in the vicinity is low, so that it can be made inconspicuous in appearance.

  By the way, considering the deviation from the processing line 9, it is conceivable that the uneven pattern 2 is not provided at all in the processing region 3. However, in that case, since the uneven pattern 2 disappears at the end portion and is interrupted, there is a possibility that the design is not interesting and the design property is deteriorated. On the other hand, in this embodiment, by providing the concave / convex pattern 2 to the end portion, it is possible to give a continuous concave / convex pattern, and the design can be improved.

  The uneven height of the low uneven area 5, that is, the protruding height of the protrusion 8 in the low uneven area 5 may be lower than the uneven height of the basic uneven area 4, but is preferably 1 mm or less. Thereby, even if a burr | flash generate | occur | produces or the convex part 8 is missing, it can make it inconspicuous further on an external appearance. The unevenness height of the low unevenness region 5 may be less than 0.5 mm or less than 0.3 mm. However, since the concavo-convex pattern 2 may be unrecognizable if the concavo-convex pattern 2 is small, in order not to impair the design of the concavo-convex pattern 2, the concavo-convex height of the low concavo-convex pattern 4 is 0.1 mm or more. Preferably there is.

  The convex portions 8 constituting the concavo-convex pattern 2 can be provided in a dot shape or a linear shape when the wall material A is viewed from the surface side. For example, when a plurality of small dot-like projections formed by the convex portions 8 are provided on the wall material A in the form of random dots, a grain pattern can be formed. Further, when the curved protrusions formed by the convex portions 8 are provided on the wall material A while forming a plurality of ellipses, it is possible to represent the annual rings of wood and to form a grain pattern.

  FIG. 8 shows a wall material A in which the concavo-convex pattern 2 having a grain pattern is formed by the convex portions 8. In such a wall material A, the low concavo-convex region 5 including the processing region 3 is provided as described above. Thus, a natural pattern can be formed on the wall surface. In particular, as shown in FIG. 8 and the like, in the case where the concavo-convex pattern extends over the other wall material A and the concavo-convex pattern 2 is formed by the linear convex portions 8, the processing region It is difficult to make 8 a range without the convex portion 8, and the convex portion 8 is included in the processing region 3. In this case, a portion where the convex portion 8 is cut or cut is generated in the processed portion, and if the uneven pattern 2 remains at the basic height, burrs and pattern defects are likely to occur. In this embodiment, even in such a case, by providing the low unevenness region 5, it is possible to suppress burrs and pattern defects and to improve the design.

  The distance between the convex parts 8 in the concavo-convex pattern 2 may be constant or different. For example, in order to improve the design of the concavo-convex pattern 2, the distance between the adjacent convex portions 8 can be set to 1 to 10 mm. Moreover, the width | variety (horizontal width) of the convex part 8 can be 0.5-5 mm.

  FIG. 3 shows another example of forming the wall material A. As shown in FIG. 3A, the low asperity region 5 includes the processed region 3. However, in this embodiment, the low asperity region 5 further includes an end portion (groove side portion 14) of the low step portion 10 on the substrate 13 side. To the boundary). Thus, as shown in FIGS. 3B and 3C, the low uneven region 5 is provided in the entire low step portion 10 of the wall material A after being cut or cut. Thus, if the low unevenness | corrugation area | region 5 is provided in the whole low step part 10 after cutting or cutting, the low unevenness | corrugation area | region 5 can be provided easily. For example, in the form of FIG. 1, when trying to reduce the area of the low unevenness region 5 as much as possible, the position of the end portion on the base 13 side of the low unevenness region 5 is located at the position of the base portion 13 side of the processing region 3. By positioning so as to be disposed, the low unevenness region 5 is formed. At this time, the position of the end of the processing region 3 on the base 13 side is difficult to confirm with the naked eye. On the other hand, in the form of FIG. 3, it is only necessary to make the entire low step portion 10 a low uneven region 5, and the end portion (boundary with the groove side portion 14) of the low step portion 10 can be easily confirmed with the naked eye. The low uneven area 5 can be easily formed. Even if the base material 1 is cut or cut by mistake beyond the processing region 3, the low uneven region 5 can be left on the wall material A because the range of the low uneven region 5 is wide. Further, since the low step portion 10 of the wall material A is a portion constituting the joint groove, the pattern is less conspicuous than the surface of the base portion 13, and the uneven height of this portion is slightly smaller than the uneven height of the basic uneven region 4. However, it can be less likely that the uneven pattern 2 is uncomfortable.

  Even in the form of FIG. 3, as in the form of FIG. 1, when cut or cut along the machining line 9, as shown in FIG. ing. For this reason, it is possible to make the concavo-convex pattern 2 in the angular portion difficult to collapse. Further, as shown in FIG. 3C, even when the cut portion is cut or cut out of the processing line 9 and the incompletely shaped convex portion 8a is formed in the processed portion, the convex portion 8a of the processed portion is formed. Has a low concavo-convex height and is in close contact with the substrate 1. Therefore, generation | occurrence | production of a burr | flash can be suppressed, the uneven | corrugated pattern 2 of a process part can be made hard to collapse, and also when the uneven | corrugated pattern 2 of a process part collapses, a pattern collapse can be made inconspicuous. .

  1 and 3 show the case where the unevenness height in the low unevenness region 5 is a constant height, the height of the low unevenness region 5 may not be constant. For example, the concavo-convex height of the low concavo-convex region 5 may gradually decrease as the processing region 3 is approached from the boundary with the basic concavo-convex region 4. At this time, the uneven height may be gradually decreased continuously, or the uneven height may be gradually decreased step by step. If the height of the unevenness is gradually lowered, the pattern height will change continuously, and the discomfort in the appearance between the area where the unevenness height is low and the area where the unevenness height is the basic height will be made smaller. be able to. Therefore, the uneven pattern 2 can be made a more natural pattern, and the design can be improved.

  FIG. 4 shows another example of forming the wall material A, and shows an example in which the unevenness height of the low unevenness region 5 gradually decreases. In this embodiment, as shown in FIG. 4A, the low uneven region 5 including the processed region 3 includes a low region 6 having a low uneven height, and a middle region having an uneven height higher than the low region 6. 7. The lower region 6 is formed including the processing region 3. The unevenness height of the lower region 6 can be the same as the unevenness height of the low unevenness region 5 in the form of FIG. 1, and can be, for example, 1 mm or less.

  The middle region 7 is formed adjacent to these regions between the lower region 5 and the basic uneven region 4. That is, each region is arranged in the order of the basic concavo-convex region 4, the middle region 7, and the low region 5 from the center side to the end portion of the base material 1, and the concavo-convex height of the concavo-convex pattern 2 gradually increases stepwise. It is getting smaller. Thereby, a sense of incongruity due to the difference in unevenness height can be relieved, a more natural pattern can be formed, and the design is improved.

  The boundary of the lower region 6 on the base 13 side, that is, the boundary between the lower region 6 and the middle region 7 is substantially the same position as the end of the processing region 3 on the base 13 side. Thereby, since the low region 6 does not become too wide, it is possible to suppress the design pattern from being lowered due to the wide range of the concave / convex pattern 2 having a low concave / convex height, and the low region can be efficiently efficiently in a narrow range. 6 can be provided. The lower region 6 only needs to include the processing region 3, and the end of the lower region 6 on the base 13 side may be located closer to the base 13 than the end of the processing region 3 on the base 13 side. .

  In the example shown in FIG. 4, the middle region 7 is formed by one convex portion 8, but the middle region 7 may be formed by a plurality of convex portions 8. Further, the position of the end portion on the base material 13 side of the middle region 7 may be set to the position of the boundary between the low step portion 10 and the groove side portion 14. Further, a plurality of middle regions 7 having different uneven heights may be formed. In that case, it is preferable to form the middle region 7 so that the height of the unevenness gradually decreases from the basic uneven region 4 toward the lower region 6.

  And the base material 1 of Fig.4 (a) is cut | disconnected or cut by the process line 9, and the wall material A as shown in FIG.4 (b) or FIG.4 (c) is formed. FIG. 5A is an enlarged view of the processed portion in the case of FIG. 4B, and FIG. 5B is an enlarged view of the processed portion in the case of FIG. 4C.

  4, as in the case of FIGS. 1 and 3, when cut or cut along the processing line 9, the vicinity of the processed portion is uneven as shown in FIG. 4B. Is low. Therefore, it is possible to make the uneven pattern 2 in the angular portion difficult to collapse. Furthermore, in this embodiment, as shown in the enlarged view of FIG. 5A, the uneven height of the uneven pattern 2 is gradually lowered by providing the middle region 7, so that the height of the uneven pattern 2 The change becomes smooth, the design can be improved, and the concave-convex pattern 2 can be further prevented from collapsing. Further, as shown in FIG. 4C and FIG. 5B, even when the projection 8a having an incomplete shape is formed in the processed part by being cut or cut out of the processing line 9, The convex part 8a of the processed part has a low uneven height and is in close contact with the base material 1. Therefore, generation | occurrence | production of a burr | flash can be suppressed, the uneven | corrugated pattern 2 of a process part can be made hard to collapse, and also when the uneven | corrugated pattern 2 of a process part collapses, a pattern collapse can be made inconspicuous. . Furthermore, in this embodiment, since the concave / convex height of the concave / convex pattern 2 is gradually lowered by providing the middle region 7, even when the convex portion 8 a of the processed portion may collapse, it is more conspicuous. Can be difficult.

  FIG. 6 shows an example of the shape of the convex portion 8 that forms the concave / convex pattern 2. FIG. 6A shows a convex portion 8 in the basic concave / convex region 4. As shown in the figure, the convex portion 8 may have a shape that rises and protrudes in an inverted U shape. And the surface of the convex part 8 is a curved surface.

  FIG. 6B is an example of the convex portion 8 provided in the low uneven region 5. The convex part 8 of FIG.6 (b) is the shape which compressed the convex part 8 of Fig.6 (a) to the up-down direction (height direction), and made height low. That is, the surface of the convex portion 8 in the low concavo-convex region 8 is a curved surface whose height is lower than the surface of the convex portion 8 in the basic concavo-convex region 4. Thus, when the convex part 8 becomes a shape compressed in the up-down direction, the difference in shape with the convex part 8 of the basic uneven | corrugated area | region 4 becomes small, and the discomfort on an external appearance can be relieve | moderated.

  FIG. 6C is another example of the convex portion 8 provided in the low uneven region 5. The convex part 8 in FIG. 6C has a shape in which the upper end part of the convex part 8 in the basic concavo-convex region 4 is removed by being removed in the horizontal direction. Therefore, the upper end of the convex portion 8 in FIG. 6C is a flat surface, and the curved surface of the original convex portion 8 is divided. As described above, when a flat surface is formed on the convex portion 8 of the low uneven region 5, the difference in shape from the convex portion 8 of the basic uneven region 4 becomes large, and there is a possibility that an uncomfortable appearance may occur. Therefore, as the convex portion 8 of the low unevenness region 5, the convex portion 8 constituted by the curved surface shown in FIG. 6B is more than the convex portion 8 having a flat surface shown in FIG. preferable. Note that even in the case of the convex portion 8 in FIG. 6C, if the surface of the convex portion 8 is made closer to a smooth curved surface by, for example, scraping a corner portion that is an edge of the flat surface, a sense of incongruity is felt. It is possible to mitigate.

  The formation method of the low unevenness region 5 is not particularly limited as long as the unevenness height of the uneven pattern 2 can be reduced, but the convex portion 8 as shown in FIG. 6B is formed. Therefore, it is preferable to form by compressing up and down. For example, by forming the basic shape of the base material 1 by extrusion molding, pressing the surface of the base material 1 with a concave / convex mold to form the concave / convex pattern 2, and then pressing the region where the low concave / convex region 5 is to be formed from above with a flat plate or the like The unevenness height of the uneven pattern 2 can be lowered to form the low unevenness region 5.

  As already explained, immediately after the extrusion molding, the base material 1 is not yet completely cured and is in a soft state, and by deforming the base material 1 made of the ceramic material with a concavo-convex-type press, The uneven pattern 2 can be formed. Furthermore, the base material 1 immediately after the uneven pattern 2 is formed is not yet completely cured and has a slight fluidity. In this state, the substrate 1 is pressed with a flat plate from above, so that FIG. The convex part 8 compressed in the up-down direction as shown in b) can be easily formed.

  Moreover, when forming the uneven | corrugated pattern 2 with a coating-film layer, after forming the coating-film layer for forming the uneven | corrugated pattern 2 on the surface of the base material 1, it presses and applies an uneven | corrugated type | mold to this coating-film layer. The convex / concave pattern 2 may be formed by deforming the film layer, and then the flat plate may be pressed and compressed to form the convex portion 8.

  In order to form the concavo-convex pattern 2 having a low concavo-convex height, it is possible to use a concavo-convex mold having a low concavo-convex height. However, it is difficult to work with a method in which a concavo-convex mold having different concavo-convex heights is produced and the concavo-convex mold is pressed against the substrate 1 with high positional accuracy. Therefore, it is preferable to press and compress the flat plate as described above, rather than reducing the height of the unevenness with the uneven shape, because the height of the unevenness can be reduced more easily.

  In addition, the convex part 8 as shown in FIG.6 (c) is obtained by the method of cutting out the part more than fixed height like what is called a head cut. The formation of such a convex portion 8 is likely to cause an uncomfortable appearance, but has an advantage that it can be formed even after the substrate 1 is completely cured. Even when the upper end portion of the convex portion 8 is removed by cutting, cutting, or polishing to reduce the height of the convex portion 8, the upper end portion of the convex portion 8 is formed so that a curved surface is formed. If removed, it is possible to approach the shape of FIG. 6B and reduce the appearance of discomfort.

  FIG. 7 shows an example of the formation of the end portion of the wall material A on the surface protruding portion 12 side. The appearance improvement of the concavo-convex pattern 2 by the low concavo-convex region 5 can also be applied to the end portion of the substrate 1 on the surface protruding portion 12 side.

  As shown in FIG. 7A, the low unevenness region 5 includes the processing region 3, and the end of the low unevenness region 5 on the base 13 side is substantially the same position as the end of the processing region 3 on the base 13 side. It has become. Thereby, since the low unevenness region 5 is not excessively widened, it is possible to suppress the design pattern from being lowered due to the wide range of the uneven pattern 2 having a low unevenness height, and the low unevenness can be efficiently reduced in a narrow range. Region 5 can be provided. The low uneven region 5 only needs to include the processed region 3, and the end of the low uneven region 5 on the base 13 side is located closer to the base 13 side than the end of the processed region 3 on the base 13 side. Also good.

  And in the form of FIG. 7, the base material 1 is cut | disconnected or cut in the diagonal direction, a corner | angular part is removed, and the groove | channel side part 15 which forms the side surface of a joint groove is formed. At this time, when the concavo-convex pattern 2 of the processed portion formed by cutting or cutting has the same concavo-convex height as that of the basic concavo-convex region 4, there is a possibility that burrs may occur or the convex portion 8 may be lost.

  However, in the form of FIG. 7, the low unevenness region 5 is formed at the end of the substrate 1. Therefore, as in the case of FIG. 1, as shown in FIG. 7B, when cut or cut along the machining line 9, since the unevenness height is low in the vicinity of the machining portion, the angular portion The uneven pattern 2 can be made difficult to collapse. Further, as shown in FIG. 7C, even when the cut part 8 is cut or cut out of the processing line 9 and the convex part 8a having an incomplete shape is formed in the processed part, the convex part 8a of the processed part is formed. Has a low concavo-convex height and is in close contact with the substrate 1. Therefore, generation | occurrence | production of a burr | flash can be suppressed, the uneven | corrugated pattern 2 of a process part can be made hard to collapse, and also when the uneven | corrugated pattern 2 of a process part collapses, a pattern collapse can be made inconspicuous. .

  In the above, although the form which forms the low unevenness | corrugation area | region 5 in the edge part of the base material 1 was demonstrated, this invention is not limited to this. For example, the present invention can be applied to the case where the groove portion is formed by cutting or cutting as a large pattern in the central portion of the substrate 1. In this case, if the low concavo-convex region 5 is provided including the processed region 3 when forming the groove portion, the concavo-convex height of the concavo-convex pattern 2 in the processed portion of the groove portion can be lowered. Therefore, generation | occurrence | production of the burr | flash in this part can be suppressed, it can suppress that the uneven | corrugated pattern 2 is missing, and even if it lacks, it can become inconspicuous.

  Further, in the above-described wall material A, the concave / convex pattern 2 formed by the convex portions 8 has been described, but the present invention can be applied not only to the convex portions 8 but also to the concave / convex pattern 2 formed by concave portions such as grooves. In this case, by forming the low unevenness region 5 having a low unevenness height, that is, a depth of the recessed portion including the processed region 3, it is possible to make the uneven pattern 2 in the processed portion less likely to be collapsed. Can be increased.

  As described above, in the wall material A of the above-described embodiment, it is possible to reduce processing burrs that occur during base material processing and pattern omission during construction without impairing the design.

A Wall material 1 Base material 2 Uneven pattern 3 Processing region 4 Basic uneven region 5 Low uneven region 6 Low region 7 Middle region 8 Convex portion 9 Processing line 10 Low step portion 11 Back side protruding portion 12 Front side protruding portion 13 Base portions 14 and 15 Groove side

Claims (2)

  A base material is formed by cutting or cutting, and is a wall material having a concavo-convex pattern on its surface, and a low concavo-convex area having a low concavo-convex height of the concavo-convex pattern is formed including a processing area to be cut or cut. A wall material characterized by   The low uneven region has a low region formed including a processing region to be cut or cut, and a middle region in which the unevenness of the uneven pattern is higher than the low region. The wall material according to 1.

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