JP2587848B2 - Manufacturing method of surface decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to an architectural plate applied to the inner and outer walls of a building, ceiling, floor, fence, etc. The present invention relates to a method for manufacturing a decorative surface plate on which a decorative aggregate made of a body is bonded and fixed, in which the finished state of the plate surface is improved.

(Prior art) To obtain a more natural feel by improving the finished state of the board surface, especially the visual texture such as depth and profound feeling, in the surface decorative board with decorative aggregate applied to the board surface It is effective to avoid uniformity of surface properties, for example, by mixing a plurality of types of decorative aggregates having different colors, shapes, sizes, textures, and the like, or by making the appearance pattern in a fixed state regular. As a conventional technique for obtaining such irregularities, for example, there is a technique in which a mottled uneven surface is formed on a surface of a substrate by embossing and a decorative aggregate such as sand is bonded and fixed thereto (Japanese Patent Publication No. 61-1986).
7346, JP-A-53-103619).

(Problems to be Solved by the Invention) As described above, in the one in which the decorative aggregate is adhered and fixed in accordance with the previously formed irregular pattern, the irregular pattern can be obtained only within the range of the peripheral length of the embossing roll, for example. , The degree of pattern change is small. For this reason, in many cases, when the surface decorative boards are arranged adjacent to each other, the same pattern appears at the same location, and it is difficult to obtain a natural feeling as an impression of the entire wall surface.

In addition, the production of such a surface decorative board is usually performed by applying an adhesive paint on the surface of the substrate and spraying decorative aggregate such as sand on the upper surface thereof. However, in the conventional production method, that the particle size of the decorative aggregate is aligned in a certain range,
Because of the fact that the cosmetic aggregate is supplied in a fixed quantity without excess or shortage, the distribution of the cosmetic aggregate after spraying becomes uniform and too homogenous, and only a monotonous surface state can be obtained. There was a problem in that it was difficult to obtain a feeling.

The present invention solves the above-mentioned problems, and improves the supply method of the decorative aggregate such as sand, thereby continuously changing the amount and the pattern of the decorative aggregate attached to the substrate. The purpose is to obtain a surface veneer with a natural feel.

(Means for Solving the Problems) According to the present invention, by distributing the decorative aggregate unevenly and continuously changing the amount and the pattern of the decorative aggregate adhering to the substrate, the visual texture is reduced. Make sure you get the rules.

Specifically, as shown in FIG. 1, a waterproof layer (3), a base layer (4) and an adhesive layer (5) are sequentially formed on the surface of the substrate (2), and then a decorative layer is formed on the adhesive layer (5). In the step of spraying the aggregate (6), the decorative aggregate (6) is put into the hopper (11).
And the spraying roll (13) interposed in the falling path continuously changes the spraying amount of the decorative aggregate (6). That is, a number of depressions (15) are formed irregularly on the peripheral surface of the spraying roll (13),
Sprinkle decorative aggregates (6) while rotating.

Here, the formation of the spraying layer of the decorative aggregate (6), that is, the process of forming the waterproof layer (3), the base layer (4), and the adhesive layer (5) sequentially to spray the decorative aggregate (6). May be applied to only a part of the substrate (2) in addition to the entire surface. For example, when the surface of the substrate (2) is an uneven surface, it may be applied to the convex portion.

(Operation) According to the present invention, the decorative aggregate (6) dropped from the hopper (11) is once received by the scatter roll (13), and falls onto the substrate (2) with its rotation. go.
At this time, since the roll surface is provided with the depression (15), the portion of the depression (15) is made up of extra decorative aggregate (6).
Is accepted. Then, depending on the position and shape of the depression (15), the timing at which the decorative aggregate (6) slides down therefrom is shifted, and the amount of fall varies in the width and circumferential direction of the spreading roll (13). .

Due to the uneven distribution, as shown in FIG. 5, the decorative aggregate (6) is partially or excessively spread on the adhesive layer (5) of the substrate (2), or is partially insufficient. Scattered, producing irregularly dense and dense patterns as a whole. After removal of the excess decorative aggregate (6) that has not adhered to the adhesive layer (5), the coarse-to-fine pattern still remains, which causes irregularities in the visual texture. In addition, in the rough pattern portion, the distribution of the granular material according to the mixed state is observed almost independently of the size of the particle size, and a texture different from other portions is generated. Accordingly, a surface decorative board having a natural feeling rich in depth and solid feeling can be obtained as a whole.

(Embodiment) FIGS. 1 to 5 show an embodiment of the present invention. The decorative surface plate (1) is manufactured through a manufacturing line shown in FIG. In FIG. 2, the production line includes a step (A) of continuously supplying a substrate (2) and a base treatment for sequentially forming a waterproof layer (3) and a base layer (4) on the surface of the substrate (2). Step (B), an adhesive paint is applied to the outer surface of the base layer (4) to form an adhesive layer (5), and the adhesive layer (5)
A step (C) of spraying a decorative aggregate (6) made of a granular material thereon and a step (D) of removing excess cosmetic aggregate (6).
And a step (E) of forming an overcoat layer (7) on the outer surface of the decorative aggregate (6), wherein each step is continuously arranged in alphabetical order. FIGS. 3A to 3E show blank states corresponding to the respective steps.

The substrate (2) is made of an inorganic water-curable raw material mainly composed of cement, gypsum, gypsum slag, blast furnace slag, calcium silicate, lime, or the like, or a water-curable raw material containing an organic material, and is formed by extrusion molding, papermaking. It is molded by a molding method or a press dehydration molding method. Structurally, it may be solid or hollow, and the surface state is flat, parallel or lattice-shaped grooves are formed and uneven, pearskin or mottled ground pattern is formed Any of these may be used.

In the base treatment step (B), a sealer is applied to the entire surface of the substrate (2) to form a waterproof layer (3), and after drying, a primer is applied to the outer surface of the waterproof layer (3) to form a base layer. Form (4) and dry.

The application of the sealer and the primer may be any application method such as roll application, flow coater application or spray application. Acrylic, urethane, epoxy, vinyl,
There are organic coating materials such as fluorine-based, polyester-based, phenyl-based, and amino-based materials, and inorganic sodium silicate-based materials. The sealer and the primer may be different or the same.

In the spraying step (C), first, an adhesive paint is applied to the outer surface of the base layer (4) to form an adhesive layer (5).
And before the adhesive layer (5) loses its tackiness,
The substrate (2) is moved by the transfer device (9), and the spraying device (1) is moved.
By passing under 0), the decorative aggregate (6) is scattered and supplied on the adhesive layer (5), and dried. As the adhesive paint, the same paint as the primer is used by coloring it in the same color as the basic color of the decorative aggregate (6), but a different color may be used if necessary. It is not necessary to specify the coating method as in the case of the primer, but it is preferable to use a roll coating in view of viscosity.

In FIG. 1, a spraying device (10) is a decorative aggregate (6).
Hopper (11) for supplying oil and supply port (12) at the lower end
And a wire mesh (14) provided below the spraying roll (13) and rotated below the spraying roll (13). The widths of the supply port (12), the scatter roll (13), and the wire mesh (14) are set slightly larger than the width of the substrate (2). In order to spread the decorative aggregate (6) unevenly, a number of depressions (15) are irregularly formed on the peripheral surface of the spreading roll (13). As shown in FIG. 4, the depression (15) is formed so that the opening shape, the opening area, the cross-sectional shape, the degree of inclination near the opening edge, and the like are different from each other. Perform processing.

Cosmetic aggregate (6) is composed of silica sand, crushed rock, crushed ceramic,
Spherical, glass-like, scale-like, needle-like and other various shapes made of crushed glass, etc., having a maximum diameter of 5 mm or less, preferably 0.5 to
Use a 3mm one. Then, by mixing a plurality of types of the above-mentioned granules, or by mixing a plurality of types of granules colored with a paint, a dye, or the like, further by mixing a plurality of types of granules adjusted to a constant particle size, Mix to avoid uniform color, shape, size and texture.

The decorative aggregate (6) supplied from the supply port (12) of the hopper (11) is received by the scatter roll (13), moves with the rotation thereof, and falls along the roll peripheral surface. At this time, the interior of the depression (15) is filled with the decorative aggregate (6). Therefore, in the position where the depression (15) is formed, a larger amount of decorative aggregate (6) falls than in other places. Also,
The depression (15) has a generally shallow concave shape. Due to its cross-sectional shape, the depression (1) may be earlier or slightly later than the decorative aggregate (6) on the roll surface at the same phase position.
The decorative aggregate (6) in 5) falls. In other words, the depression (1
The falling timing of the decorative aggregate (6) is shifted depending on the formation position and the shape of (5). This shift slightly changes depending on the mixed composition of the decorative aggregate (6) in the depression (15). Therefore, the decorative aggregate (6) is spread non-uniformly not only in the width direction of the spreading roll (13) but also in the circumferential direction (with time), and the spreading state for each rotation of the roll changes subtly.

By performing such non-uniform spraying, depressions (1) are formed on the adhesive layer (5) of the substrate (2) as shown in FIG.
5) Spray area (F) dropped from the roll surface with no, densely spread area (G) with partially excessively applied decorative aggregate (6), and partial shortage of decorative aggregate (6) The coarsely scattered area (H) slightly scattered is irregularly formed in a spot pattern.

In the step (D) for removing the excess decorative aggregate (6), first, the entire substrate (2) is inverted or tilted by 90 degrees or more by a reversing machine (not shown) so that the decorative material that does not adhere to the adhesive layer (5). When a groove is formed in the aggregate (6) or the substrate (2), excess cosmetic aggregate (6) or the like that has fallen into the groove is dropped. Then, compressed air is blown onto the front surface of the substrate (2) to completely remove the decorative aggregate (6) that is easily peeled off and the excess decorative aggregate (6) in the groove. Even after passing through this step, the dense / dense pattern formed in the dispersing step (C) remains as dependent although the shading slightly decreases.

In the final step (E), an overcoat layer (7) is formed by spray-coating a transparent acrylic, urethane, or fluorine-based paint on the entire surface of the substrate (2). The overcoat layer (7) prevents the decorative aggregate (6) from peeling off, improves the weather resistance of the decorative surface plate (1), and imparts gloss and gloss to the entire surface of the decorative surface plate (1). In particular, a complicated light reflection is caused at a portion where the decorative aggregate (6) is attached.

According to the surface decorative board (1) obtained as described above, irregularly dense and small patterns of large and small sizes are continuously irregularly arranged vertically and horizontally. In addition, the visual texture differs between the coarse pattern portion and the dense pattern portion, and the boundary of each pattern portion becomes unclear. Therefore, on the entire board surface, the decorative aggregate (6) has irregularities such as individual colors, shapes, sizes, etc. and irregularities of the appearance pattern, and the base layer (4) and the adhesive layer (5) in the rough pattern portion. By the interaction between the background color such as the above and the decorative aggregate (6), and the complicated light reflection on the overcoat layer (7), it is possible to improve the visual texture such as the feeling of depth and the pressure. It becomes a natural decorative surface veneer.

(Modification) In the above embodiment, the substrate (2) is formed of a water-curable raw material containing an inorganic or organic material. However, this is not always necessary, and the substrate (2) can be formed of a metal plate or a plastic plate. . Metal sheets include zinc-coated steel sheets, vinyl chloride coated steel sheets, surface-treated steel sheets such as painted steel sheets, aluminum sheets,
There is a stainless plate, etc. Further, as the plastic plate, there is a vinyl chloride plate or the like.

The spray roll (13) is connected to the supply port (12) of the hopper (11).
Between the adhesive layer (5) of the substrate (2) and the decorative aggregate (6)
It may be provided anywhere as long as it is a falling path. For example, a sprinkling roll having no depression (15) is provided directly below the supply port (12), and a spreading roll (13) having the depression (15) is provided below the wire mesh (14) to perform non-uniform distribution. You can also. In addition, the depression (15) may be formed by irregularly arranging a plurality of types of geometric patterns in addition to irregular shapes such as spots, craters, and erosion patterns. The number, distribution density, etc. are not limited at all.

(Effects of the Invention) As described above, according to the present invention, the decorative aggregate (6) is unevenly scattered by the scatter roll (13) provided with a large number of depressions (15) on the peripheral surface, and uneven scatter is caused. Since irregular coarse and dense patterns are formed vertically and horizontally and large and small, the visual texture of each of the coarse and dense pattern portions can be made different, and this irregularity and the irregularities of the decorative aggregate (6) As a result, it is possible to obtain a surface decorative board (1) having a natural feeling rich in a deep feeling and a solid feeling as a whole. In addition, since the amount of application of the decorative aggregate (6) is made uneven and an irregular pattern appears, even if the application is performed under the same conditions, the appearance pattern changes subtly, and a more natural coarse and dense pattern is obtained. This is advantageous in that the change width of the pattern is large.

Further, when the overcoat layer (7) is provided as in the above-described embodiment, the weather resistance can be improved, and the change in the pattern can be further emphasized by complicated light reflection and the like.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS The drawings show an embodiment of the present invention, FIG. 1 is a longitudinal side view of a spraying apparatus, FIG. 2 is an explanatory view showing an outline of a production line for a surface decorative plate, and FIGS. 3 (A) to (E). Is a cross-sectional view showing a blank state of the decorative surface plate corresponding to each manufacturing process, FIG. 4 is a perspective view of a spray roll, and FIG. 5 is a plan view showing a spray pattern. (1) Surface decorative board, (2) substrate, (3) waterproof layer, (4) base layer, (5) adhesive layer, (6)
…… Cosmetic aggregate, (10)… Spray device, (11)… Hopper, (13)… Spray roll, 15… Dent.

Claims (2)

(57) [Claims] An undercoating step of forming a waterproof layer (3) on the surface of a substrate (2) and then forming a base layer (4) on the outer surface of the waterproof layer (3); Applying a paint for adhesion to form an adhesive layer (5), and spraying a decorative aggregate (6) made of a granular material on the adhesive layer (5). Put the aggregate (6) in the hopper (1
The spraying roll (13), which is continuously dropped and supplied from 1) and has a number of depressions (15) formed irregularly on its peripheral surface, is interposed in the dropping path of the decorative aggregate (6). Surface makeup characterized in that the makeup aggregate (6) is sprayed while rotating the roll (13), and the amount of the makeup aggregate (6) sprayed on the adhesive layer (5) is continuously changed. Plate manufacturing method. 2. The surface of the substrate (2) is formed with an uneven surface. A waterproof layer and a base layer (4) are sequentially formed on the substrate (2), and then an adhesive layer ( The method according to claim 1, wherein the step (5) is formed and the decorative aggregate (6) is sprayed.