JP2587849B2 - 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 producing a surfaced decorative board in which a decorative aggregate made of a body is adhered and fixed, in which the finished state of the board 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 uniform surface properties such as mixing a plurality of types of decorative aggregates with different colors, shapes, sizes, textures, etc., or irregularly appearing patterns in a fixed state. . As a conventional technique for obtaining such irregularities, there is a technique in which a patchy uneven surface is formed by embossing the surface of a substrate and a decorative aggregate such as sand is bonded and fixed thereto (Japanese Patent Publication No. 61-7346). And JP-B-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 on 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,
And because of the reason that spraying is performed by supplying quantitatively enough cosmetic aggregates, the distribution of the cosmetic aggregates after spraying becomes uniform and too homogenous, resulting in a monotonous surface state that cannot be obtained. There was a problem in that it was difficult to obtain a feeling.

By the way, when a plurality of types of decorative aggregates having different particle diameters are mixed and sprayed as described above, a certain degree of irregularity is obtained. However, small-grained decorative aggregates tend to penetrate between large-grained decorative aggregates and hardly appear on the outermost surface, and the obtained irregularities are limited and are far from the natural feeling. There was only.

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, the decorative aggregate is non-uniformly dispersed, and the amount of the decorative aggregate adhering to the substrate and the attached pattern are continuously changed, so that the visual texture is not 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 spray amount of the decorative aggregate (6) is continuously changed by the baffle plate (14) interposed in the falling path. The baffle plate (14) includes a shielding part (17) and a passage part (16), and is formed in, for example, a comb shape. This baffle board (14)
Is driven, for example, back and forth along the plate surface, so that the decorative aggregate (6) is spread unevenly.

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 part of the surface 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 only to the convex portion.

(Operation) According to the present invention, the cosmetic aggregate (6) dropped from the hopper (11) is once received by the scatter roll (13), and falls toward the substrate (2) with the rotation. I do. However, since the baffle plate (14) is provided in the fall path, the decorative aggregate (6) falls as it is at the opening (16), but the fall is blocked at the blocking part (17). In other words, when the entirety of the decorative aggregate (6) that has started falling at the same time is viewed, a difference occurs between the drop timing and the drop position in the width direction. In addition, since the baffle plate (14) is driven along the plate surface, the timing and position deviation at the time of dropping change every moment, and the amount of application on the substrate (2) changes vertically and horizontally.

By this non-uniform distribution, the decorative aggregate (6) is partially or excessively dispersed on the adhesive layer (5) of the substrate (2), or partially insufficiently dispersed, so that the whole is large or small. This produces an irregular pattern. After removal of the excess decorative aggregate (6) that has not adhered to the contact layer (5), the coarse-to-fine pattern still remains, which causes irregularities in the visual texture. Further, in the rough pattern portion, the distribution of the granular material according to the mixing state is observed almost independently of the size of the particle size, and a different texture is generated in other places. 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 6 show an embodiment of the present invention. The surface decorative board (1) is manufactured through a manufacturing line shown in FIG. In FIG. 3, 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 cosmetic 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. Blank states corresponding to the respective steps are shown in FIGS. 4 (A) to (E).

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 method of applying the sealer and primer is roll coating,
Any coating method such as flow coater coating or spray coating may be used. Examples of the sealer and the primer include acrylic, urethane, epoxy, vinyl, fluorine, polyester, phenyl, and amino-based organic coating materials, and inorganic sodium silicate-based materials. They 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. The application method does not need to be specified as in the case of the primer, but it is preferable that the application be in a roll relationship with the relationship with the 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 sprinkling roll (13) which is disposed immediately below the roll (13) and driven to rotate in a certain direction, and a baffle plate (14) and a wire net (15) which are sequentially arranged below the roll (13). The widths of the supply port (12), the scatter roll (13), the baffle plate (14), and the wire mesh (15) are each set to be larger than the width of the substrate (2). The baffle plate (14) is provided for dispersing the decorative aggregate (6) non-uniformly, and alternates between the opening (16) and the shielding part (17) as shown in FIG. And are formed in a comb shape as a whole. This baffle plate (14) is arranged in a substantially horizontal position on the falling path of the decorative aggregate (6) falling from the spreading roll (13), and reciprocates in the width direction of the plate surface as shown by the arrow in FIG. It is to be driven.

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 kinds of the above-mentioned granules, or by mixing a plurality of kinds of granules colored with a paint, a dye, or the like, further by mixing a plurality of kinds of granules adjusted to a constant particle diameter, 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), and falls from the roll peripheral surface as shown in FIG. Reach the board (14). In this case, the decorative aggregate (6) passes through the opening (16) as it is, and the falling of the decorative aggregate (6) is blocked at the closing portion (17). And the shielding part (17)
The decorative aggregate (6) that has fallen on the surface bounces off the plate surface or is shaken off, and is delayed by the decorative aggregate (6) that has passed through the opening (16), and furthermore, in the feed direction of the substrate (2). Fall to the better side. Therefore, on the substrate (2), a part dropped from the shielding part (17), a part dropped from the opening part (17), and a part dropped and deposited from both (16) and (17). Are irregularly formed. Moreover, since the baffle plate (14) is reciprocatingly driven, the dispersion of the spray amount also occurs irregularly in the width direction of the substrate (2).

By performing such non-uniform spraying, the densely spread area where the decorative aggregate (6) is partially excessively spread as shown in FIG. 5 on the adhesive layer (5) of the substrate (2). (F),
A coarse scatter area (G) in which the decorative aggregate (6) is partially scattered in a slightly insufficient manner and an intermediate scatter area (H) in which an intermediate amount thereof is scattered are irregularly formed in a spotted 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 coarse-dense pattern formed in the spraying step (C) remains 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 skeleton (6) from peeling off and improves the weather resistance of the decorative surface plate (1).
In addition, gloss and luster are given to the entire surface of the surface decorative plate (1), and complicated light reflection is caused particularly at a place where the cosmetic bone agent (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. Further, the visual texture differs between the rough pattern portion and the dense pattern portion, and the boundary of each pattern portion becomes unclear. Therefore, on the entire plate surface, the decorative aggregate (6) has irregularities in the individual colors, shapes, sizes, etc. and irregularities in the appearance pattern, and the background of the base layer (4), the adhesive layer, etc. in the rough pattern portion. Color and decorative aggregate (6)
Interaction, and furthermore, complicated light reflection on the overcoat layer (7) can enhance the visual texture such as a sense of depth and solidness, and provide a natural-looking surface decorative plate (1)
Becomes

Also, when a plurality of granules having different particle diameters are mixed and the decorative aggregate (6) is sprayed, most of the decorative aggregate (6) that falls through the shielding part (17) has a particle size. Irrespective of the fact that the particles adhere to the adhesive layer (5) earlier than others, it is possible to suppress the appearance of the granular material having the same particle size on the outermost surface. That is, as shown in FIG. 6, when a group of small particles (6a) adheres to the adhesive layer (5) in advance, the large particles (6b) hardly adhere to the outer surface thereafter. Become. On the other hand, the granular material (6a) having a small particle size enters between the granular materials (6b) having a large particle size, or soaks up even on the outer surface of the granular material (6b) having a large particle size. It is adhered by a small amount of adhesive application material, and hardly peels off. Therefore, as compared with the conventional manufacturing method, the decorative aggregate (6) having a large or small particle size appears on the outermost surface, and a natural feeling can be easily obtained.

(Modification) In the above embodiment, the substrate (2) is formed of a water-curable raw material containing an inorganic or organic substance. However, this is not always necessary, and the substrate (2) may 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 following can be considered as means for changing the scatter pattern of the decorative aggregate (6). The width and shape of the entrance (16) and the shielding (17) are changed irregularly. Change the drive speed of the baffle plate (14). The baffle (14) is supported so as to be tiltable, and its tilt angle is changed. The baffle plate (14) is composed of a pair of upper and lower comb-toothed plates, and the width of the opening (16) or the shielding portion (17) is continuously changed.

The baffle plate (14) may be formed in a disk shape. In this case, the shielding part (17) and the entrance (16) are located near the periphery of the plate surface.
Are arranged irregularly, and spraying is performed while rotating the entire baffle plate (14) along the plate surface. The baffle plate (1
4) may be provided anywhere below the spraying roll (13) as long as the decorative aggregate (6) falls.

(Effects of the Invention) As described above, in the present invention, the decorative aggregate (6) is unevenly scattered with the baffle plate (14) to form irregular and dense patterns vertically and horizontally and large and small. Since it is formed on the top, it is possible to make the visual texture of each of the coarse and dense pattern portions different, and due to the irregularity and the irregularity of the decorative aggregate (6), etc., the overall feeling of depth and solidity is increased. It is possible to obtain a surface decorative board (1) rich in natural texture. 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. Point, the width of the pattern change is large,
This is advantageous in that the pattern can be easily changed by replacing the baffle plate (14) or changing the driving speed.

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]

Drawings show an embodiment of the present invention, FIG. 1 is a longitudinal side view of a spraying device, FIG. 2 is a partial plan view of a baffle plate, and FIG. 3 is an explanatory diagram showing an outline of a production line for a decorative surface plate. 4 (A) to 4 (E) are cross-sectional views showing a blank state of a decorative surface plate corresponding to each manufacturing process, FIG. 5 is a plan view showing a scatter pattern, and FIG. 6 is a surface of the decorative surface plate. FIG. (1) Surface decorative board, (2) substrate, (3) waterproof layer, (4) base layer, (5) adhesive layer, (6)
…… Cosmetic aggregate, (10)… Spray device, (11)… Hopper, (14)… Baffle plate, (16)… Vent, (17)…
Blocking part.

Claims (4)

(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
Drops are supplied continuously from 1).
A baffle plate (14) having a 7) and an opening (16) is interposed, and the baffle plate (14) is displaced along the plate surface with the closing portion (17) and the opening (16). A decorative aggregate (6) is sprayed while driving, and the amount of the decorative aggregate (6) sprayed onto the adhesive layer (5) is continuously changed. 2. The surface of the substrate (2) is formed with an uneven surface, and a waterproof layer (3) and a base layer (4) are sequentially formed on the substrate (2). Adhesive layer (5)
The method for producing a decorative surface plate according to claim 1, wherein the decorative aggregate is formed and sprayed. 3. The baffle plate (14) is formed in a comb shape by alternately arranging shielding portions (17) and opening portions (16), and blocking the baffle plate (14). The method for producing a decorative surface plate according to claim (1) or (2), wherein the decorative aggregate (16) is sprayed while being reciprocated in the arrangement direction of the portion (17) and the opening portion (16). 4. A baffle plate (14) is formed in a disk shape, and a number of blocking portions (17) and passage portions (16) are irregularly arranged near the periphery of the plate surface. The method for producing a decorative surface plate according to claim 1 or 2, wherein the decorative aggregate (6) is sprayed while the roller is rotationally driven along the plate surface.