JP2021161655A - Building material and manufacturing method of building - Google Patents

Abstract

To provide a building material suitable for manufacturing with high productivity as a building material in which a texture with microbumps is expressed, and a manufacturing method thereof.SOLUTION: A building material X1 of the present invention includes: a base material S; a coating film 20 located on a decorative surface Sa side of the base material S; and a dot printing film 40 and granules 32 located on the opposite side of the base material S in the coating film 20. The coating film 20 contains a film-forming material 21 and a granular material 22, and has a convex surface 23 that projects to the opposite side of the base material S at a position where the film-forming material 21 covers the granular material 22. The dot printing film 40 has a curved surface that follows the convex surface 23 of the coating film 20. The granule 32 is positioned differently from the convex surface 23 of the coating film 20 in a spreading direction of the base material S. A method of manufacturing building materials of the present invention includes: a first step of forming the coating film 20 on the decorative surface Sa side of the base material S; a second step of forming the dot printing film 40 on the opposite side of the base material S in the coating film 20; and a third step of distributing the granules 32 on the opposite side of the base material S in the coating film 20.SELECTED DRAWING: Figure 1

Description

The present invention relates to a building material having a design surface and a method for producing the same.

As the base material of the building material for forming the outer wall and the inner wall of the building, for example, an inorganic board such as a ceramic siding board or a ceramic board, a fiber board such as a particle board, and a resin board are used. Then, in order to express, for example, a sandstone-like texture with fine irregularities on the design surface of the base material, a paint obtained by blending fine particles such as fine colored beads and colored sand with the clear paint (granular matter-containing clear). Paint) may be sprayed onto the surface of the substrate. Such spray painting is performed, for example, using a spraying device including a nozzle for spraying paint. A technique relating to spray coating of building materials is described in, for example, Patent Document 1 below.

Japanese Unexamined Patent Publication No. 2019-188343

However, in the spray coating of the granular material-containing clear paint, the nozzle of the spraying device is conventionally liable to be clogged. The more likely the nozzles of the sprayer are to be clogged, the more nozzle cleaning work is required to prevent and eliminate the clogging, and the lower the productivity of building materials.

The present invention has been conceived under such circumstances, and provides a building material suitable for producing with high productivity as a building material expressing a texture with fine irregularities, and a method for producing the same. That is the purpose.

According to the first aspect of the present invention, a building material is provided. This building material includes a base material having a design surface, a first coating film containing a first film forming material and a first grain, and located on the design surface side of the base material, and the base material in the first coating film. It includes a dot printing film located on the opposite side and a second particle located on the opposite side of the base material in the first coating film. The first coating film has a first convex surface that protrudes to the side opposite to the base material at a portion where the first film forming material covers the first granules. The dot printing film has a curved surface along the first convex surface. The position of the second granular material is different from that of the first convex surface in the spreading direction of the base material.

The building material having such a configuration includes the size and shape of the dot printing film having a curved surface, the color exhibited by the dot printing film having a curved surface, the size and shape of the second grain, and the material color of the second grain. It is suitable for expressing textures such as sandstone with fine irregularities by the complex combination of. The above-mentioned configuration in which the dot printing film has a curved surface along the first convex surface of the first coating film and the position of the second grain is different from that of the first convex surface in the substrate spreading direction is an expression of a predetermined texture. In this case, while expressing a color that is more suitable for expression in print color than expression in grain material color with a dot printing film with a curved surface, a color that is more suitable for expression in grain material color than expression in print color is used. Suitable for expressing by the second grain.

Further, in the present building material, as described above, a first convex surface (protruding to the opposite side of the base material) is formed at a portion of the first coating film where the first film forming material covers the first granules. Moreover, the dot printing film is located on the side opposite to the base material in the first coating film and has a curved surface along the first convex surface of the first coating film. The dot printing film is printed on, for example, a first film forming material that covers the surface of the first grain body.

Such a configuration is suitable for reducing the diameter of the first grain used, and therefore, when the first coating film is formed by spray coating the first grain-containing paint in the manufacturing process of the present building material, the spray is applied. Suitable for suppressing clogging of paint spray nozzles used for painting. Such suppression of clogging helps to reduce the cleaning work of the nozzles used and increase the productivity of building materials.

As described above, the building material according to the first aspect of the present invention is suitable for producing with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities.

Preferably, the first granule is smaller than the second granule. Such a configuration is suitable for reducing the diameter of the first particle to be used, and therefore, when the first coating film is formed by spray coating of the first particle-containing paint, clogging of the nozzle used is suppressed. Suitable for.

Preferably, the second granule is white. Such a configuration is preferable in order to easily express white color in a predetermined texture. Specifically, when a dot printing film is formed by, for example, inkjet printing, in which four colors of cyan, magenta, yellow, and black are often used, the second white grain is used without using a separate device for white printing. It is preferable because the white color in a predetermined texture can be easily expressed by the body.

The present building material is preferably located on the opposite side of the base material in the first coating film, contains a transparent film forming material and the above-mentioned second granules, and has a second convex surface along the first convex surface of the first coating film. A clear coating film having a third convex surface protruding to the opposite side of the base material at a portion where the transparent film forming material covers the second granules is further provided.

Such a configuration is suitable for fixing the dot printing film on the design surface when the dot printing film is located on the opposite side of the base material in the clear coating film, and the dot printing film is the first coating film. When it is located between the clear coating film and the clear coating film, it is suitable for protecting the dot printing film.

The building material may further include a second coating film located between the first coating film and the clear coating film and having a fourth convex surface along the first convex surface of the first coating film.

Such a configuration is suitable for reducing the diameter of the first particle to be used, and therefore, when the first coating film is formed by spray coating of the first particle-containing paint, clogging of the nozzle used is suppressed. Suitable for. When the dot printing film is located between the second coating film and the clear coating film, such a dot printing film is formed along the first convex surface of the first coating film via the second coating film and is the same first. It may have a curved surface having a larger radius of curvature than the case where it is in direct contact with the convex surface and along the first convex surface. When the dot printing film is located on the opposite side of the clear coating film from the substrate, such a dot printing film is formed on the first convex surface of the first coating film via the clear coating film in addition to the second coating film. Along, it may have a curved surface with a larger radius of curvature.

When the building material includes a second coating film, the second coating film preferably contains a second film-forming material and a third particle, and the second film-forming material covers the third particle. It has a fifth convex surface that protrudes to the opposite side of the base material at the location where it is formed. At the same time, the clear coating film has a sixth convex surface along the fifth convex surface of the second coating film. At the same time, the position of the second granular material is different from that of the fifth convex surface in the spreading direction of the base material. At the same time, the present building material further includes a dot printing film located on the side opposite to the base material in the second coating film and having a curved surface along the fifth convex surface.

Such a configuration includes the size and shape of the dot printing film having a curved surface along the first convex surface, the color exhibited by the dot printing film having a curved surface along the first convex surface, and the size and shape of the second grain. , The material color of the second grain, the size and shape of the dot printing film having a curved surface along the fifth convex surface, and the color exhibited by the dot printing film having a curved surface along the fifth convex surface are combined. , Suitable for expressing textures such as sand rocks with fine irregularities.

When the building material includes the above-mentioned clear coating film, in one preferred embodiment of the building material, the dot printing film is located on the opposite side of the base material in the clear coating film. Such a configuration is suitable for fixing the dot printing film on the design surface.

When the building material comprises the above-mentioned clear coating film, in another preferred embodiment of the building material, the dot printing film is located between the first coating film and the clear coating film. Such a configuration is suitable for protecting the dot printing film.

When the building material includes the above-mentioned second coating film in addition to the above-mentioned clear coating film, in one preferred embodiment of the present building material, the dot printing film is located between the second coating film and the clear coating film. Such a configuration is suitable for protecting the dot printing film.

According to the second aspect of the present invention, a method for manufacturing a building material is provided. This building material manufacturing method includes the following first step, second step, and third step.

In the first step, the first coating material containing the first film-forming material and the first granules is applied to the design surface side of the base material having the design surface, and the first film-forming material forms the first granules. A first coating film having a first convex surface protruding to the opposite side of the base material is formed at the coated portion.

In the second step, a dot printing film having a curved surface along the first convex surface is formed on the side of the first coating film opposite to the base material.

In the third step, the second granules are arranged on the side opposite to the base material in the first coating film at a position different from the first convex surface in the spreading direction of the base material.

In a preferred embodiment of the present building material manufacturing method, the above-mentioned third step is carried out after the above-mentioned second step. In another preferred embodiment of the present building material manufacturing method, the above-mentioned third step is carried out before the above-mentioned second step.

According to such a building material manufacturing method, the above-mentioned building material according to the first aspect of the present invention can be manufactured. Therefore, according to the present building material manufacturing method, the same technical effect as described above can be enjoyed in the manufactured building material with respect to the first aspect of the present invention.

It is a partial cross-sectional view of the building material which concerns on 1st Embodiment of this invention. The manufacturing method of the building material shown in FIG. 1 is shown. It is a partial cross-sectional view of the building material which concerns on the 2nd Embodiment of this invention. It is a partial cross-sectional view of the building material which concerns on 3rd Embodiment of this invention. The manufacturing method of the building material shown in FIG. 4 is shown. It is a partial cross-sectional view of the building material which concerns on 4th Embodiment of this invention. It is a partial cross-sectional view of the building material which concerns on 5th Embodiment of this invention. The manufacturing method of the building material shown in FIG. 7 is shown. It is a partial cross-sectional view of the building material which concerns on 6th Embodiment of this invention.

FIG. 1 is a partial cross-sectional view of the building material X1 according to the first embodiment of the present invention. The building material X1 has a laminated structure including a base material S, a coating film 10, a coating film 20, and a coating film 30, and includes a plurality of dot printing films 40 in the laminated structure.

The base material S has a design surface Sa on which the design is applied. The base material S includes, for example, a wood fiber reinforced cement board, a fiber reinforced cement board, a ceramic siding board such as a fiber reinforced cement / calcium silicate board, a slag gypsum board, a metal siding board, and a fiber board such as a particle board. , And a resin plate.

The coating film 10 is an undercoat coating film located on the design surface Sa of the base material S, and for example, various elements such as a coating film formed by laminating the base material of the design surface Sa on the design surface Sa. It has a function to ensure the adhesion and fixation of.

The coating film 10 includes a film forming material 11. Examples of the film forming material 11 include a resin. Examples of the resin include an acrylic resin, an acrylic urethane resin, a urethane resin, a fluororesin, and an acrylic silicone resin, and an acrylic resin is preferably used. Such a coating film 10 is, for example, a cured product of a composition (paint) containing a resin as the film forming material 11. The thickness of the coating film 10 is, for example, 5 to 30 μm, preferably 10 to 20 μm.

The coating film 20 is an intermediate coating film located between the coating film 10 and the coating film 30. The coating film 20 in the present embodiment corresponds to the first coating film in the present invention, is located on the design surface Sa side of the base material S, and has the film forming material 21 (first film forming material) and the granules 22 (first film forming material). 1 grain) is included. The coating film 20 has a convex surface 23 (first convex surface) protruding to the side opposite to the base material S at a position where the film forming material 21 covers the granular material 22. The thickness T1 of the coating film 20 other than the portion where the coating film 20 has the convex surface 23 is, for example, 10 to 50 μm, preferably 20 to 30 μm.

Examples of the film forming material 21 include resin. Examples of the resin include an acrylic resin, an acrylic urethane resin, a urethane resin, a fluororesin, and an acrylic silicone resin, and an acrylic resin is preferably used.

Examples of the constituent material of the granular material 22 include resin, glass, sand, and metal. Examples of the resin as a constituent material of the granule 22 include polyacrylonitrile resin, polymethacrylonitrile resin, polyvinylidene chloride resin, polyacrylic acid ester resin, and polystyrene resin, and polyacrylonitrile resin is preferably used.

Examples of the shape of the granular material 22 include a spherical shape and an ellipsoidal shape. The granular material 22 may be either colorless or colored. The particle size of the particle 22 is, for example, 10 to 100 μm, preferably 20 to 50 μm, as long as it is larger than the above-mentioned thickness T1 of the coating film 20. The above-mentioned convex surface 23 is formed by the coating film 20 containing such particles 22.

The arrangement density of the granules 22 in the coating film 20 (that is, the arrangement density of the granules 22 in the spreading direction of the base material S) is, for example, 10 to 100 pieces / mm ² , preferably 30 to 50 pieces / mm. It is ^2.

Such a coating film 20 is, for example, a cured product of a composition (paint) containing a resin as a film forming material 21 and particles 22. The coating film 20 may be colored by containing a coloring material such as a pigment or a dye. When the coating film 20 is colored, a coloring material is blended in the composition for forming the coating film 20.

The coating film 30 contains the transparent film forming material 31 and the granules 32 (second granules), and is located on the side opposite to the base material S in the coating film 20 (thus, the granules 32 in the coating film 30). Is located on the opposite side of the coating film 20 from the base material S). The coating film 30 has a convex surface 33 (second convex surface) along the convex surface 23 of the coating film 20 via the dot printing film 40 described later, and the transparent film forming material 31 covers the granules 32. It has a convex surface 34 (third convex surface) protruding to the opposite side of the base material S at the present location. Such a coating film 30 corresponds to the clear coating film in the present invention. The thickness T2 of the coating film 30 other than the portion where the coating film 30 has the convex surfaces 33 and 34 is, for example, 10 to 50 μm, preferably 20 to 30 μm.

Examples of the transparent film forming material 31 include a transparent resin. Examples of the transparent resin include acrylic silicone resin, epoxy resin, fluororesin, and urethane resin, and acrylic silicone resin is preferably used.

The position of the granular material 32 is different from that of the convex surface 23 of the coating film 20 in the spreading direction of the base material S. The fact that the positions of the elements (convex surface, granules, etc.) differ in the spreading direction of the base material S means that the positions of the base material S in the spreading direction are not completely the same, and the positions are located in the spreading direction of the base material S. It shall include that it is out of alignment. As the constituent material of the granular material 32, for example, the same material as described above can be mentioned as the constituent material of the granular material 22, and a polyacrylonitrile resin is preferably used. Examples of the shape of the granular material 32 include a spherical shape and an ellipsoidal shape. Further, the granular material 32 is colored, preferably white.

The particle size of the grain 32 is, for example, 50 to 300 μm, preferably 80 to 200 μm, as long as it is larger than the above-mentioned thickness T2 of the coating film 30. Further, the granular material 32 is preferably larger than the above-mentioned granular material 22. That is, the granular material 22 is preferably smaller than the granular material 32.

The arrangement density of the granules 32 in the coating film 30 (that is, the arrangement density of the granules 32 in the spreading direction of the base material S) is, for example, 2 to 50 pieces / mm ² , preferably 3 to 30 pieces / mm. It is ^2.

Such a coating film 30 is, for example, a cured product of a composition (paint) containing a resin as a transparent film forming material 31 and particles 32.

The dot printing film 40 is a dot-shaped printing film formed by a printing method, is located on the side opposite to the base material S in the coating film 20, and has a curved surface along the convex surface 23 of the coating film 20. The entire dot printing film 40 may have a curved surface along the convex surface 23, or a part of the dot printing film 40 may have a curved surface along the convex surface 23 (the entire dot printing film 40 may have a curved surface 23 along the convex surface 23). The case of having a curved surface along the line is illustrated as an example). In the present embodiment, the dot printing film 40 is located between the coating film 20 as the first coating film and the coating film 30 which is the clear coating film. Such a dot printing film 40 is preferably a printing film formed by full-color inkjet printing, and each exhibits a predetermined color.

The dot size of the dot printing film 40 is, for example, 1 to 200 μm, preferably 20 to 50 μm. The arrangement density (pointillism density) of the dot printing film 40 in the spreading direction of the base material S is, for example, 10 to 100 pieces / mm ² , preferably 30 to 50 pieces / mm ² . Such a dot printing film 40 may be formed of one dot or a plurality of dots. When the dot printing film 40 is formed of a plurality of small dots in the manufacturing process of the building material X1 as described later, after the color ink droplets for forming the dot printing film 40 land on the convex surface 23, the dot printing film 40 is formed on the convex surface 23. The movement of the ink droplets is suppressed, and it is easier to form the dot printing film 40 along the curved surface, which is preferable. Further, when the dot printing film 40 is formed of a plurality of dots having a small size, it is preferable because various color tones can be easily expressed by the combination of colors exhibited by each dot.

The building material X1 may be provided with a further clear coating film (not shown) on the side opposite to the base material S in the coating film 30 which is a clear coating film. Such a configuration is useful for protecting the design surface of the building material X1. The fact that such an additional clear coating film may be provided also applies to the building materials according to the other embodiments described later.

FIG. 2 shows a method for manufacturing the building material X1 shown in FIG. This manufacturing method is a method of manufacturing a building material while transporting a base material S in a building material manufacturing line, and includes the following undercoating step, intermediate coating step, printing step, and clear coating film forming step. In the building material production line, a spray coating device is installed for each coating film to be formed, and a printing device for forming a dot printing film is installed. Each spray coating device includes a plurality of nozzles for spraying paint. The printing apparatus is preferably a full-color inkjet printing apparatus.

First, in the undercoating step, as shown in FIG. 2A, the coating film 10 is formed on the design surface Sa of the base material S. In this step, for example, a paint containing a resin and a solvent as the film forming material 11 is spray-coated on the design surface Sa to form a coating film 10 having a predetermined thickness. Examples of the solvent include toluene, xylene, and butyl acetate (the same applies to the solvent of each coating material described later). The coating film 10 is dried.

Next, in the intermediate coating step, as shown in FIG. 2B, the coating film 20 as the first coating film is formed on the coating film 10 on the design surface Sa side of the base material S. In this step, for example, a paint (first paint) containing a resin as a film forming material 21 (first film forming material), particles 22 (first particles), and a solvent is sprayed onto the coating film 10. It is applied to form a coating film 20 having a predetermined thickness. The coating film 20 is dried.

As described above, the coating film 20 formed by the spray coating of the granular material 22-containing paint protrudes to the side opposite to the base material S at the portion where the film forming material 21 covers the granular material 22. It has a convex surface 23. This step of forming the coating film 20 as the first coating film corresponds to the first step in the present invention.

The content ratio of the granular material 22 in the coating material used in this step is, for example, 5 to 180% by volume, preferably 10 to 80% by volume. Such a configuration is suitable for achieving the above-mentioned arrangement density of the granular material 22. Further, the above-mentioned thickness T1 of the coating film 20 to be formed can be adjusted by, for example, adjusting the viscosity of the paint used in this step.

Next, in the printing step, as shown in FIG. 2C, a plurality of dot printing films 40 are formed on the coating film 20. In this step, specifically, using the above-mentioned printing apparatus, various hues of cyan, magenta, yellow and black on the surface of the coating film 20 (first coating film) opposite to the base material S are formed. Land the color ink drops. As a result, the dot printing film 40 having a curved surface along the convex surface 23 (first convex surface) of the coating film 20 is formed. The dot printing film 40 is dried as needed. This step of forming the dot printing film 40 corresponds to the second step in the present invention. In this step, the dot printing film 40 may be formed by one dot, or the dot printing film 40 may be formed by a plurality of dots. When the dot printing film 40 is formed of a plurality of dots having a small size, after the above-mentioned color ink droplets land on the convex surface 23, the movement of the ink droplets on the convex surface 23 is suppressed, and the dots along the curved surface are suppressed. The printing film 40 is easily formed, which is preferable. Further, when the dot printing film 40 is formed of a plurality of dots having a small size, it is preferable because various color tones can be easily expressed by the combination of colors exhibited by each dot.

As described above, the dot size of the dot printing film 40 formed in this step is, for example, 1 to 200 μm, preferably 20 to 50 μm. As described above, the arrangement density (pointillism density) of the dot printing film 40 in the spreading direction of the base material S is, for example, 10 to 100 pieces / mm ² , preferably 30 to 50 pieces / mm ² . These configurations are suitable for forming the dot printing film 40 having a curved surface along the convex surface 23 of the coating film 20 including the granules 22 at the above-mentioned arrangement density.

Next, in the clear coating film forming step, as shown in FIG. 2D, the coating film 30 which is a clear coating film 30 is placed on the coating film 20 on the design surface Sa side of the base material S and on the dot printing film 40. To form. In this step, for example, a paint containing a resin as a transparent film forming material 31, particles 32 (second particles), and a solvent is spray-coated on the coating film 20 and the dot printing film 40 to obtain a predetermined thickness. The solvent coating film 30 is formed. The coating film 30 is dried. As described above, the coating film 30 to be formed has a convex surface 34 protruding to the side opposite to the base material S at the position where the transparent film forming material 31 covers the granules 32.

In the present embodiment, due to the formation of the coating film 30, the granules 32 are arranged on the side opposite to the base material S in the coating film 20 and at a position different from the convex surface 23 of the coating film 20 in the spreading direction of the base material S. Will be done. Such this step corresponds to the third step in the present invention.

The content ratio of the granular material 32 in the coating material used in this step is, for example, 5 to 150% by volume, preferably 10 to 80% by volume. Such a configuration is suitable for achieving the above-mentioned arrangement density of the granular material 32. Further, the above-mentioned thickness T2 of the coating film 30 to be formed can be adjusted by, for example, adjusting the viscosity of the paint used in this step.

As described above, the building material X1 can be manufactured.

As described above, the building material X1 includes the base material S having the design surface Sa, the film forming material 21 (first film forming material) and the granules 22 (first granules), and the design surface of the base material S. The coating film 20 located on the Sa side, the dot printing film 40 located on the side opposite to the base material S in the coating film 20, and the granular material 32 (second) located on the side opposite to the base material S in the coating film 20. (Granular material). As described above, the coating film 20 has a convex surface 23 (first convex surface) protruding to the side opposite to the base material S at the portion where the film forming material 21 covers the granular material 22. As described above, the dot printing film 40 has a curved surface along the convex surface 23 of the coating film 20. As described above, the granular material 32 is different from the convex surface 23 of the coating film 20 in the spreading direction of the base material S.

The building material X1 having such a configuration includes the size and shape of the dot printing film 40 having a curved surface, the color exhibited by the dot printing film 40 having a curved surface, the size and shape of the grain 32, and the material color of the grain 32. It is suitable for expressing textures such as sandstone with fine irregularities by combining with. The configuration in which the dot printing film 40 has a curved surface along the convex surface 23 of the coating film 20 and the grain 32 is different in position from the convex surface 23 of the coating film 20 in the spreading direction of the base material S has a predetermined texture. In terms of expression, while expressing a color that is more suitable for expression in print color than expression in grain material color by the dot printing film 40 with a curved surface, it is more suitable for expression in grain material color than expression in print color. It is suitable for expressing the color by the grain 32.

Further, in the building material X1, as described above, a convex surface 23 (protruding to the opposite side of the base material S) is formed at a portion of the coating film 20 where the film forming material 21 covers the particles 22, and the coating material X1 is coated. On the side of the film 20 opposite to the base material S, the dot printing film 40 has a curved surface along the convex surface 23 of the coating film 20.

Such a configuration is suitable for reducing the diameter of the particles 22 to be used, and therefore, in the manufacturing process of the building material X1, by spray coating the particles 22-containing paint as described above with reference to FIG. 2 (b). When forming the coating film 20, it is suitable for suppressing clogging of the paint spraying nozzle used for the spray coating. Such suppression of clogging is useful for reducing the cleaning work of the nozzles used and increasing the productivity of the building material X1.

As described above, the building material X1 is suitable for producing with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities.

As described above, the granular material 22 is preferably smaller than the granular material 32. Such a configuration is suitable for reducing the diameter of the granular material 22 to be used, and therefore, when the coating film 20 is formed by spray coating the granular material 22-containing paint as described above with reference to FIG. 2 (b). It is suitable for suppressing clogging of the nozzle used in the above. Such a technical effect due to the particle 22 being smaller than the particle 32 can also be enjoyed in the building materials according to other embodiments described later.

The granular material 32 is colored, preferably white, as described above. Such a configuration is preferable in order to easily express white color in a predetermined texture. Specifically, when the dot printing film 40 is formed by full-color inkjet printing, it is preferable because the white particles 32 can easily express the white color in a predetermined texture without using a separate device for white printing. Such a technical effect due to the white color of the granular material 32 can also be enjoyed in the building materials according to the other embodiments described later.

As described above, the dot printing film 40 in the building material X1 is located between the coating film 20 and the coating film 30 which is a clear coating film. Such a configuration is suitable for protecting the dot printing film 40.

FIG. 3 is a partial cross-sectional view of the building material X2 according to the second embodiment of the present invention. The building material X2 has a laminated structure including a base material S, a coating film 10, a coating film 20, and a coating film 30, and includes a plurality of dot printing films 40. The building material X2 is described above in that the dot printing film 40 is provided on the side opposite to the base material S in the coating film 30 instead of the configuration in which the dot printing film 40 is located between the coating films 20 and 30. It is different from the building material X1. Except for this point, the building material X2 has the same configuration as the building material X1.

For such a building material X2, instead of carrying out the above-mentioned clear coating film forming step with reference to FIG. 2 (d) after the above-mentioned printing step with reference to FIG. 2 (c), the clear coating is performed. It can be manufactured by the same manufacturing method as the manufacturing method of the building material X1 except that the printing step is carried out after the film forming step. The formation of the dot printing film 40 on the coating film 30 which is a clear coating film is suitable for fixing the dot printing film 40 on the design surface.

The building material X2 is suitable for being manufactured with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above for the building material X1.

FIG. 4 is a partial cross-sectional view of the building material X3 according to the third embodiment of the present invention. The building material X3 has a laminated structure including a base material S, a coating film 10A, a coating film 20A, and a coating film 30, and includes a dot printing film 40 in the laminated structure. The building material X3 is different from the above-mentioned building material X1 in that the coating films 10A and 20A are provided instead of the coating films 10 and 20. Except for this point, the building material X3 has the same configuration as the building material X1.

The coating film 10A is an undercoat coating film similar to the above-mentioned coating film 10, and for example, various elements such as a coating film laminated and fixed on the design surface Sa by sealing the base material of the design surface Sa are adhered and fixed. It has a function to ensure sex.

The coating film 10A corresponds to the first coating film in the present invention, is located on the design surface Sa side of the base material S, and has the film forming material 11 (first film forming material) and the granules 12 (first particles). including. The coating film 10A has a convex surface 13 (first convex surface) protruding to the side opposite to the base material S at a position where the film forming material 11 covers the granular material 12. The thickness T3 of the coating film 10A other than the portion where the coating film 10A has the convex surface 13 is, for example, 5 to 30 μm, preferably 10 to 20 μm.

The coating film 10A is different from the above-mentioned coating film 10 in that it contains particles 12 in addition to the film forming material 11 in terms of constituent components. Such a coating film 10A is, for example, a cured product of a composition (paint) containing a resin as a film forming material 11 and particles 12.

Examples of the constituent material of the granular material 12 include resin, glass, and metal. Examples of the resin as a constituent material of the granule 12 include polyacrylonitrile resin, polymethacrylonitrile resin, polyvinylidene chloride resin, polyacrylic acid ester resin, and polystyrene resin, and polyacrylonitrile resin is preferably used.

Examples of the shape of the granular material 12 include a spherical shape and an ellipsoidal shape. The granular material 12 may be either colorless or colored. The particle size of the particle body 12 is, for example, 5 to 50 μm, preferably 5 to 40 μm, as long as it is larger than the above-mentioned thickness T3 of the coating film 10A. The above-mentioned convex surface 13 is formed by the coating film 10A containing such particles 12.

The arrangement density of the granules 12 in the coating film 10A (that is, the arrangement density of the granules 12 in the spreading direction of the base material S) is, for example, 10 to 100 pieces / mm ² , preferably 30 to 50 pieces / mm. It is ^2.

The coating film 20A is an intermediate coating film like the above-mentioned coating film 20. The coating film 20A in the present embodiment corresponds to the second coating film in the present invention, is located between the coating film 10A (first coating film) and the coating film 30 (clear coating film), and is a convex surface of the coating film 10A. It has a convex surface 24 (fourth convex surface) along 13 (first convex surface).

The coating film 20A is different from the above-mentioned coating film 20 in that it contains the film forming material 21 but does not contain the particles 22 in terms of constituent components. Such a coating film 20A is, for example, a cured product of a composition (paint) containing a resin as a film forming material 21. The thickness of the coating film 20A is, for example, 10 to 50 μm, preferably 20 to 30 μm.

In the present embodiment, the dot printing film 40 is located between the coating film 20A and the coating film 30, and the curved surface of each dot printing film 40 is formed on the coating film 10A (first coating film) via the coating film 20A. Along the convex surface 13 (first convex surface).

In the present embodiment, the coating film 30 is located on the opposite side of the coating film 20A from the base material S, and each convex surface 33 of the coating film 30 passes through the coating film 20A and the dot printing film 40, and the coating film 10A ( Along the convex surface 13 (first convex surface) of the first coating film).

FIG. 5 shows a method for manufacturing the building material X3 shown in FIG. This manufacturing method is a method of manufacturing a building material while transporting a base material S in a building material manufacturing line, and includes the following undercoating step, intermediate coating step, printing step, and clear coating film forming step. In the building material production line, a spray coating device is installed for each coating film to be formed, and a printing device for forming a dot printing film is installed. Each spray coating device includes a plurality of nozzles for spraying paint. The printing apparatus is preferably a full-color inkjet printing apparatus.

First, in the undercoating step, as shown in FIG. 5A, the coating film 10A is formed on the design surface Sa of the base material S. In this step, for example, a paint (first paint) containing a resin as a film forming material 11 (first film forming material), granules 12 (first granules), and a solvent is sprayed on the design surface Sa. It is applied to form a coating film 10A having a predetermined thickness. The coating film 10A is dried.

As described above, the coating film 10A formed by the spray coating of the granular material 12-containing paint protrudes to the side opposite to the base material S at the portion where the film forming material 11 covers the granular material 12. It has a convex surface 13. This step of forming the coating film 10A as the first coating film corresponds to the first step in the present invention.

The content ratio of the granular material 12 in the paint used in this step is, for example, 0.02 to 160% by volume, preferably 0.2 to 100% by volume. Such a configuration is suitable for achieving the above-mentioned arrangement density of the granular material 12. Further, the above-mentioned thickness T3 of the coating film 10A to be formed can be adjusted by, for example, adjusting the viscosity of the coating material used in this step.

Next, in the intermediate coating step, as shown in FIG. 5B, the coating film 20A is formed on the coating film 10A. In this step, for example, a paint containing a resin and a solvent as the film forming material 21 is spray-coated on the coating film 10A to form a coating film 20A having a predetermined thickness. The coating film 20A is dried. As described above, the coating film 20A formed on the coating film 10A by such spray coating has a convex surface 24 protruding on the opposite side of the base material S on the convex surface 13 of the coating film 10A.

Next, in the printing step, as shown in FIG. 5C, a plurality of dot printing films 40 are formed on the coating film 20A. Specifically, in this step, using the above printing apparatus, color ink droplets having hues of cyan, magenta, yellow, and black are landed on various parts of the surface of the coating film 20A opposite to the base material S. .. As a result, the dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10A is formed through the convex surface 24 of the coating film 20A. The dot printing film 40 is dried as needed. The dot size and arrangement density (pointillism density) of the formed dot printing film 40 are the same as those described above for the printing process shown in FIG. 2 (c). This step of forming the dot printing film 40 corresponds to the second step in the present invention.

Next, in the clear coating film forming step, as shown in FIG. 5D, the coating film 30 as a clear coating film 30 is placed on the coating film 20A and the dot printing film 40 on the design surface Sa side of the base material S. To form. Specifically, this step can be carried out in the same manner as the above-mentioned clear coating film forming step with reference to FIG. 2D. Such this step corresponds to the third step in the present invention.

As described above, the building material X3 can be manufactured.

The building material X3 is suitable for being manufactured with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above for the building material X1.

Further, the building material X3 is a coating film 20A (second coating film) located between the coating film 10A (first coating film) and the coating film 30 (clear coating film) and having a convex surface 24 along the convex surface 13 of the coating film 10A. A coating film) is provided. Such a configuration is suitable for reducing the diameter of the granular material 12 (first granular material) to be used. The dot printing film 40 is formed on the convex surface 13 along the convex surface 13 (first convex surface) of the coating film 10A (first coating film) via the coating film 20A (second coating film) while being in direct contact with the same convex surface 13. This is because it is possible to have a curved surface having a larger radius of curvature than when it is along the line.

The diameter of the granules 12 used can be reduced by spray coating when the coating film 10A is formed by spray coating the particles 12-containing paint as described above with reference to FIG. 5A in the manufacturing process of the building material X3. Suitable for suppressing clogging of the paint spray nozzle used in the above. Such suppression of clogging is useful for reducing the cleaning work of the nozzles used and increasing the productivity of the building material X3.

FIG. 6 is a partial cross-sectional view of the building material X4 according to the fourth embodiment of the present invention. The building material X4 has a laminated structure including a base material S, a coating film 10A, a coating film 20A, and a coating film 30, and includes a plurality of dot printing films 40. The building material X4 is described above in that the dot printing film 40 is provided on the side opposite to the base material S in the coating film 30 instead of the configuration in which the dot printing film 40 is located between the coating films 20A and 30. It is different from the building material X3. Except for this point, the building material X4 has the same configuration as the building material X3.

In such a building material X4, instead of carrying out the above-mentioned clear coating film forming step with reference to FIG. 5 (d) after the above-mentioned printing step with reference to FIG. 5 (c), the clear coating is performed. It can be manufactured by the same manufacturing method as the manufacturing method of the building material X3 except that the printing step is carried out after the film forming step. The formation of the dot printing film 40 on the coating film 30 which is a clear coating film is suitable for fixing the dot printing film 40 on the design surface.

The building material X4 is suitable for being manufactured with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above for the building material X1.

Further, the building material X4 is a coating film 20A (second coating film) which is located between the coating film 10A (first coating film) and the coating film 30 (clear coating film) and has a convex surface 24 along the convex surface 13 of the coating film 10A. A coating film) is provided. Such a configuration is suitable for reducing the diameter of the granular material 12 (first granular material) to be used. The dot printing film 40 has the same convex surface along the convex surface 13 (first convex surface) of the coating film 10A (first coating film) via the coating film 20A (second coating film) and the coating film 30 (clear coating film). This is because it is possible to have a curved surface having a larger radius of curvature than when it is in direct contact with 13 and along the convex surface 13.

The reduction in the diameter of the particles 12 used suppresses clogging of the paint spray nozzle used for the spray coating when the coating film 10A is formed by spray coating the paint containing the particles 12 in the manufacturing process of the building material X4. Suitable for. Such suppression of clogging is useful for reducing the cleaning work of the nozzles used and increasing the productivity of the building material X4.

FIG. 7 is a partial cross-sectional view of the building material X5 according to the fifth embodiment of the present invention. The building material X5 has a laminated structure including a base material S, a coating film 10B, a coating film 20B, and a coating film 30, and includes a plurality of dot printing films 40 in the laminated structure. The building material X5 is a coating film 10 instead of the coating films 10 and 20.
It differs from the above-mentioned building material X1 in that it includes B and 20B. Except for this point, the building material X5 has the same configuration as the building material X1.

The coating film 10B is an undercoat coating film similar to the above-mentioned coating film 10, and for example, various elements such as a coating film laminated and fixed on the design surface Sa by sealing the base material of the design surface Sa are adhered and fixed. It has a function to ensure sex.

The coating film 10B corresponds to the first coating film in the present invention, is located on the design surface Sa side of the base material S, and has the film forming material 11 (first film forming material) and the granules 12 (first particles). including. The coating film 10B has a convex surface 13 (first convex surface) protruding to the side opposite to the base material S at a position where the film forming material 11 covers the granular material 12. The constituent material and thickness (thickness T3) of the coating film 10B are the same as those of the constituent material and thickness T3 described above with respect to the coating film 10A in the building material X3.

The coating film 10B is different from the coating film 10A in terms of the arrangement density of the particles 12 (that is, the arrangement density of the particles 12 in the spreading direction of the base material S). The arrangement density of the particles 12 in the coating film 10B is smaller than the arrangement density of the particles 12 in the coating film 10A, for example, 1 to 25 pieces / mm ² , preferably 2 to 15 pieces / mm ² .

The coating film 20B is an intermediate coating film like the above-mentioned coating film 20. The coating film 20B in the present embodiment corresponds to the second coating film in the present invention, is located between the coating film 10B (first coating film) and the coating film 30 (clear coating film), and is the film forming material 21. (Second film forming material) and grain 22 (third grain) are included. The coating film 20B has a convex surface 24 (fourth convex surface) along the convex surface 13 (first convex surface) of the coating film 10B, and is based on a portion where the film forming material 21 covers the granular material 22. It has a convex surface 23 (fifth convex surface) protruding to the opposite side of the material S. The constituent material and thickness (thickness T1) of the coating film 20B are the same as those of the constituent material and thickness T1 described above with respect to the coating film 20 in the building material X1.

The coating film 20B is different from the coating film 20 in terms of the arrangement density of the particles 22 (that is, the arrangement density of the particles 22 in the spreading direction of the base material S). The arrangement density of the particles 22 in the coating film 20B is smaller than the arrangement density of the particles 22 in the coating film 20, for example, 1 to 25 pieces / mm ² , preferably 2 to 15 pieces / mm ² .

In the present embodiment, the plurality of dot printing films 40 are located between the coating film 20B and the coating film 30. Among the plurality of dot printing films 40, some of the dot printing films 40 have a curved surface along the convex surface 13 (first convex surface) of the coating film 10B (first coating film) via the coating film 20B. The other part of the dot printing film 40 of the plurality of dot printing films 40 has a curved surface along the convex surface 23 (fifth convex surface) of the coating film 20B (second coating film).

In the present embodiment, the coating film 30 is located on the opposite side of the coating film 20B from the base material S. In addition to the above-mentioned convex surface 33 (second convex surface) and convex surface 34 (third convex surface), the coating film 30 has a convex surface 35 (fifth convex surface) along the convex surface 23 (fifth convex surface) of the coating film 20B via the dot printing film 40. It has a sixth convex surface).

FIG. 8 shows a method of manufacturing the building material X5 shown in FIG. This manufacturing method is a method of manufacturing a building material while transporting a base material S in a building material manufacturing line, and includes the following undercoating step, intermediate coating step, printing step, and clear coating film forming step. In the building material production line, a spray coating device is installed for each coating film to be formed, and a printing device for forming a dot printing film is installed. Each spray coating device includes a plurality of nozzles for spraying paint. The printing apparatus is preferably a full-color inkjet printing apparatus.

First, in the undercoating step, as shown in FIG. 8A, the coating film 10B is formed on the design surface Sa of the base material S. In this step, for example, a paint (first paint) containing a resin as a film forming material 11 (first film forming material), granules 12 (first granules), and a solvent is sprayed on the design surface Sa. It is applied to form a coating film 10B having a predetermined thickness. The coating film 10B is dried.

As described above, the coating film 10B formed by the spray coating of the granular material 12-containing paint protrudes to the side opposite to the base material S at the portion where the film forming material 11 covers the granular material 12. It has a convex surface 13. This step of forming the coating film 10B as the first coating film corresponds to the first step in the present invention.

The content ratio of the granular material 12 in the paint used in this step is, for example, 0.01 to 80% by volume.
It is preferably 0.1 to 50% by volume. Such a configuration is suitable for realizing the above-mentioned arrangement density of the granular material 12 in the coating film 10B.

Next, in the intermediate coating step, as shown in FIG. 8B, the coating film 20B is formed on the coating film 20B. In this step, for example, a paint containing a resin, particles 22 (third particles) and a solvent as the film forming material 21 (second film forming material) is spray-coated on the coating film 10B to have a predetermined thickness. 20B of the coating film is formed. The coating film 20B is dried.

Next, in the printing step, as shown in FIG. 8C, a plurality of dot printing films 40 are formed on the coating film 20B. Specifically, in this step, using the above printing apparatus, color ink droplets having hues of cyan, magenta, yellow, and black are landed on various parts of the surface of the coating film 20B opposite to the base material S. .. As a result, the dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10B and the dot printing film 40 having a curved surface along the convex surface 23 of the coating film 20B are formed via the coating film 20B. The dot printing film 40 is dried as needed. The dot size and arrangement density (pointillism density) of the formed dot printing film 40 are the same as those described above for the printing process shown in FIG. 2 (c). This step of forming the dot printing film 40 corresponds to the second step in the present invention.

Next, in the clear coating film forming step, as shown in FIG. 8D, the coating film 30 as a clear coating film 30 is placed on the coating film 20B and the dot printing film 40 on the design surface Sa side of the base material S. To form. Specifically, this step can be carried out in the same manner as the above-mentioned clear coating film forming step with reference to FIG. 2D. Such this step corresponds to the third step in the present invention.

As described above, the building material X5 can be manufactured.

Such a building material X5 is suitable for being manufactured with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above for the building material X1. In the building material X5, the size and shape of the dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10B, the color exhibited by the dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10B, and the coating film 20B. The size and shape of the dot printing film 40 having a curved surface along the convex surface 23 of the above, the color exhibited by the dot printing film 40 having a curved surface along the convex surface 23 of the coating film 20B, the size and shape of the grain 32, and the grains. It is possible to express a texture such as sand rock with fine irregularities by combining with the material color of the body 32.

Further, the building material X5 is a coating film 20B (second coating film) which is located between the coating film 10B (first coating film) and the coating film 30 (clear coating film) and has a convex surface 24 along the convex surface 13 of the coating film 10B. A coating film) is provided. Such a configuration is suitable for reducing the diameter of the granular material 12 (first granular material) to be used. The dot printing film 40 is formed on the convex surface 13 along the convex surface 13 (first convex surface) of the coating film 10B (first coating film) via the coating film 20B (second coating film) while being in direct contact with the same convex surface 13. This is because it is possible to have a curved surface having a larger radius of curvature than when it is along the line.

The diameter of the granules 12 used can be reduced by spray coating when the coating film 10B is formed by spray coating the particles 12-containing paint as described above with reference to FIG. 8A in the manufacturing process of the building material X5. Suitable for suppressing clogging of the paint spray nozzle used in the above. Such suppression of clogging is useful for reducing the cleaning work of the nozzles used and increasing the productivity of the building material X5.

Further, in the building material X5, the coating film 10B (first coating film) contains granules 12 (first granules) and the coating film 20B (second coating film) contains granules 22 (third particles). The configuration is suitable for reducing the granular content of each of the paints used in the spray coating described above with reference to FIGS. 8 (a) and 8 (b). Decreasing the particle content of the paint for spray painting is preferable in suppressing clogging of the nozzle for spraying the paint used for the spray painting, and the cleaning work of the nozzle used is reduced to increase the productivity of the building material X5. Useful for.

FIG. 9 is a partial cross-sectional view of the building material X6 according to the sixth embodiment of the present invention. The building material X6 has a laminated structure including a base material S, a coating film 10B, a coating film 20B, and a coating film 30, and includes a plurality of dot printing films 40. The building material X6 is described above in that the dot printing film 40 is provided on the side opposite to the base material S in the coating film 30 instead of the configuration in which the dot printing film 40 is located between the coating films 20B and 30. It is different from the building material X5. Except for this point, the building material X6 has the same configuration as the building material X5.

In such a building material X6, instead of carrying out the above-mentioned clear coating film forming step with reference to FIG. 8 (d) after the above-mentioned printing step with reference to FIG. 8 (c), the clear coating is performed. It can be manufactured by the same manufacturing method as the manufacturing method of the building material X5 except that the printing step is carried out after the film forming step. The formation of the dot printing film 40 on the coating film 30 which is a clear coating film is suitable for fixing the dot printing film 40 on the design surface.

The building material X6 is suitable for being manufactured with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above for the building materials X1 and X5.

Further, the building material X6 is located between the coating film 10B (first coating film) and the coating film 30 (clear coating film) and has a convex surface 24 along the convex surface 13 of the coating film 10B, similarly to the building material X5. A coating film 20B (second coating film) is provided. Such a configuration is suitable for reducing the diameter of the granular material 12 (first granular material) to be used, as described above for the building material X5, and by extension, the production of the building material X6 is performed by reducing the cleaning work of the nozzles used. Helps to improve sex.

Further, in the building material X6, similarly to the building material X5, the coating film 10B (first coating film) contains granules 12 (first granules) and the coating film 20B (second coating film) is granules 22 (third). It has a structure that includes (grains). Such a configuration is suitable for reducing the particle content of each paint used for spray coating, as described above for the building material X5, and thus reduces the cleaning work of the nozzles used to reduce the productivity of the building material X6. Helps to increase.

X1, X2, X3, X4, X5, X6 Building material S Base material Sa Design surface 10, 20, 30 Coating film 10A, 10B, 20A, 20B Coating film 11,21 Film forming material 12, 22, 32 Granules 13, 23 , 24, 33, 34, 35 Convex surface 31 Transparent film forming material 40 dot printing film

Claims (10)

A base material with a design surface and
The base material is located on the design surface side of the base material and contains the first film-forming material and the first granules, and the first film-forming material covers the first particles. A first coating film having a first convex surface protruding to the opposite side of the
A dot printing film located on the opposite side of the first coating film to the base material and having a curved surface along the first convex surface.
A building material comprising a second granular material located on the side opposite to the base material in the first coating film and different in position from the first convex surface in the spreading direction of the base material. The building material according to claim 1, wherein the first granular material is smaller than the second granular material. The building material according to claim 1 or 2, wherein the second granule is white. Located on the opposite side of the first coating film from the base material,
Contains the transparent film forming material and the second granules
A second convex surface along the first convex surface of the first coating film, and
Any of claims 1 to 3, further comprising a clear coating film having a third convex surface protruding to the opposite side of the base material at a portion where the transparent film forming material covers the second granules. The building materials listed in one. The fourth aspect of the present invention further comprises a second coating film located between the first coating film and the clear coating film and having a fourth convex surface along the first convex surface of the first coating film. Building materials. The second coating film contains a second film-forming material and a third particle, and is located on a side opposite to the base material at a position where the second film-forming material covers the third particle. Has a protruding fifth convex surface,
The clear coating film has a sixth convex surface along the fifth convex surface of the second coating film.
The position of the second granular material is different from that of the fifth convex surface in the spreading direction of the base material.
The building material according to claim 5, further comprising a dot printing film, which is located on the side opposite to the base material in the second coating film and has a curved surface along the fifth convex surface. The building material according to any one of claims 4 to 6, wherein the dot printing film is located on the opposite side of the clear coating film from the base material. The building material according to claim 4, wherein the dot printing film is located between the first coating film and the clear coating film. The building material according to claim 5 or 6, wherein the dot printing film is located between the second coating film and the clear coating film. A first paint containing the first film-forming material and the first granules is applied to the design surface side of the base material having the design surface, and the first film-forming material covers the first granules. The first step of forming the first coating film having the first convex surface protruding to the opposite side of the base material at the place where the base material is formed.
A second step of forming a dot printing film having a curved surface along the first convex surface on the side of the first coating film opposite to the base material,
A method for producing a building material, which comprises a third step of arranging the second granules at positions different from the first convex surface in the spreading direction of the base material on the side opposite to the base material in the first coating film.

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