JP3044232B2 - Ceramic veneer to which sand particles are fixed and a method of applying the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative panel for a ceramic industry applied to a wall of a building and a method of applying the decorative panel.

[0002]

2. Description of the Related Art At present, decorative panels made of various types of decorative materials are applied to factory-produced ceramic plates from the viewpoints of shortening the construction period, reducing manufacturing costs, and contaminating the environment. It is generally used. In particular, large buildings such as high-rise buildings require concrete panels or metal plates whose primary purpose is durability, while small buildings, apartments, private houses, etc. have delicate decorative surfaces such as ricin and stucco. Etc. are the mainstream. In addition, there are many types of decorative boards such as those imitating a brickwork pattern or those imitating a tile tone. In recent years, decorative boards expressing fine irregularities such as a fractured surface of natural stone have been favorably used.

[0003] Among these makeup methods, there are lysine in which an aggregate is mixed in a paint and spray-painted, or a method of mixing a metal powder in the paint to obtain a painted surface having a metallic feeling. Further, there is a so-called stucco-like decorative plate in which a paint is sprayed in large particles and the surface thereof is appropriately pressed to form a convex flat portion. Further, a method of embodying a fractured surface of natural stone by spraying two or three times using a larger aggregate than the above-mentioned lysine so that two or three colors of paint are applied appropriately is also used. In addition, as a deformation of lysine, there is a so-called sanding lysine, which is a method of spraying sand on the entire surface of a plate material on which a paint is sprayed on the entire surface by using a sanding machine and then hardening the paint to fix the sand.

[0004]

However, the above-mentioned conventional makeup method is a method of applying makeup to the entire surface of the plate material, and when applied to the wall of a building, the decorative plate is continuously bonded. At this time, a defect occurred at the butted portion of the decorative board due to variations in processing of the decorative surface, and the impression that the board had been applied was strongly given to the viewer, so that the sense of quality was significantly impaired. SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned drawbacks and to provide a high-quality ceramic decorative panel and a decorative method thereof, in which a bonded surface looks very natural when the decorative panels are bonded.

[0005]

SUMMARY OF THE INVENTION The present invention relates to a ceramic plate made of a concavo-convex design pattern, wherein a concave portion is formed in an joint portion, and a convex which is coated with a paint as a fixing means. One or more colored sand particles are fixed only on the upper surface of the part, and the transparent particles are further formed thereon to form a clear layer.
A visible resin coating is applied and a part of the
It was formed so as to be exposed from the rear layer . As a result, the natural feeling of brick or stone is realized, the variation of the processed surface is compensated for, and even if the decorative boards are attached, they do not receive the feeling of being attached, giving a very natural impression and a sense of quality.

In the case where the ridge portion between the upper surface of the convex portion and the rising surface of the joint portion has a rounded shape, a part of the sand-grained material including the ridge portion is exposed and fixed, so that the brick tile is formed. The appearance of the tone is more deep and the ceramic decorative panel has a good texture.

[0007] Particulates of the sandy particles uniformly distributed over the entire surface of the plate material remain on the upper surface of the projections, with part of the sandy particles being exposed, and almost all of them are removed at the joints. As a result, the appearance becomes clearer, and the contrast between the concave and convex portions is clear, and the ceramic decorative panel has a more real feeling.

In the makeup method, the means for fixing the sand particles to the plate is a paint, and after applying a predetermined amount of intermediate coating on the convex surface, the sand particles are uniformly spread on the entire plate surface. After spraying and applying appropriate vibration to the plate material to fix it on the intermediate coating layer of the sandy particles, after drying with far infrared rays etc., remove residual sandy particles remaining at the joints by wiping means such as a jet dryer. Remove, and finally apply a transparent resin paint on the top surface ,
A clear layer is formed such that a part of the sandy particles is exposed from the clear layer . This makes it possible to efficiently and efficiently produce a ceramic decorative board in which sand particles are fixed only to the independent convex portions of the decorative board without inverting the board.

[0009]

FIG. 1 is a perspective view showing an embodiment of a ceramic decorative panel according to the present invention, and FIG. 4 is a view showing a step of fixing sandy particles in the manufacturing process.

Reference numeral 1 denotes a plate material, which is a special cement-based extruded material (thickness: 16 mm, width: 455 mm, length: 273)
0 mm). Normally, since the dimensional error of the thickness of this type of plate material is ± 0.7 mm, the back surface is ground on the basis of the front surface to adjust the thickness tolerance to ± 0.4 mm. Next, a recess with a width of 7 mm and a depth of 3 mm from the surface was formed with a multi-axis router.
The plate material is cut into five joints in the width direction and 16 joints in the length direction at equal intervals to form joints 2. (Hereinafter, the concave portions will be described as joints.) Here, the cutting powder after cutting is completely removed using a brush, pressurized air, or the like to form a brick-stacked form. In addition, the ridge part of the board | substrate surface and the rising surface of a joint was rounded about 1.5R.

It is necessary to completely seal the front and back and the joints of the plate material 1 on which the joints 2 have been processed in order to maintain a constant water content, and apply a urethane resin-based sealer using an airless spray to naturally seal the joints. After drying, a gray color was applied over the entire surface to emphasize the joints and to provide weather resistance.

Next, an intermediate coating layer 5 is provided to fix the sandy particles 6 on the upper surface 4 of the convex portion of the plate material 1 on which the joint color layer 3 formed as described above is formed. When fixing the sand-like material 6 to the layer 5, the size of the particle size is naturally limited. Furthermore, sandy particles 6 due to design problems
Must be determined. When the joint 2 is processed as described above, the width × length of the plate material is 455.
× 2730, the upper area of the convex part is approximately 69mm × 1
It is 54 mm, and there are 102 convex portions. The surface of the ceramic plate is not flat at all, and in addition to the fine irregularities, when measuring the thickness of these 102 pieces, although the back side of the thickness regulation was first performed, it was usually ± 0.
It has a variation of 5 mm. Under these circumstances,
A test was conducted to prevent the paint from flowing into the joint portion 2 and to apply as much as possible the amount of coating on the upper surface of the convex portion.

In general, a roll coater is used to paint the surface of a plate material, but the type of the material and the surface material of the roll vary greatly depending on the purpose of painting. In this example, a test was conducted to determine the surface material of the roll, empirically using a natural roll coater.

The paint used was 100 V-Seran # 100 (Dainippon Paint) whose main ingredient was acrylic urethane resin paint.
And 20 parts of the same curing agent and 20 parts of thinner, and the viscosity was 70 seconds (Iwata cup). The test plate was cut by a joint processing plate so that the total area on the convex portions became 522 cm ² . The test results are shown in Tables 1 and 2.

(1) In the case of a rubber roll (hardness 40)

[Table 1]

(2) In the case of a sponge roll (hardness 40)

[Table 2]

Judging from Tables 1 and 2, it can be seen that the sponge roll is much more advantageous even if the hardness of the roll surface is the same. Here, when the thickness of the paint is calculated in a wet state at 8 g per 30.3 cm square, the specific gravity becomes 1.2 as 0.073 mm.

The hardness of the sponge roll is 35
And a hardness of 50 were tested in the same manner. When the hardness was 35, the proportion of coating to the bottom of the joint increased, and when the hardness reached 50, unpainted portions were likely to be formed on the convex surface. Also, as shown in FIG. 2, only the upper surface of the convex surface 4 can be painted with the rubber roll, but the sponge roll can be painted up to the rounded portion of the end surface of the convex as shown in FIG. Can be obtained.

Next, a description will be given of a situation in which the sandy particles are fixed at the coating portion on the upper surface of the above-mentioned convex portion. When the sand granules are natural materials or inorganic crushed pieces, the shape of the sand granules is never spherical, but the number of meshes of the sieve is selected to indicate the average particle size. Many of the commercially available sand particles are indicated by the number, but in this example, silica sand was used as the sand particles, and hence the sand particles are hereinafter referred to as silica sand.
In order to know the optimum value of the particle size, commercially available silica sand No. 4 and No. 5 are appropriately sprayed on the above-mentioned paint layer of 8 g / 30.3 cm square wet middle coat and observed. If the silica sand is not properly buried in the paint, it can be easily removed by light friction when the paint dries.

[0020] Silica sand No. 4 and No. 5 were sprayed on the middle 8g / 30.3cm square wet paint layer to the extent that the silica sand did not overlap, several test plates were prepared, and after far infrared ray drying was sufficiently performed. Silica sand was collected by gently stroking it by hand, and the particle size distribution was investigated. When 30 g of silica sand collected by superimposing the respective mesh counts of 28, 24, 20, and 16 was sieved, 9% of mesh # 16, 70% of mesh # 20, 20% of mesh # 24, and 20% of mesh # 28 had a 1% yield. The mesh opening is 0.71 mm for mesh # 24 and 0.84 for mesh # 20.
mm. From these experiments, it is determined that silica sand having a particle size distribution smaller than mesh # 20 is favorable for the intermediate coating layer.

Table 3 shows a typical commercial silica sand particle size distribution. The particle size is shown in μm.

[Table 3]

From the viewpoint of the adhesion of silica sand, it has been found that No. 5 silica sand or one having a smaller particle size is suitable. However, as a decorative plate, design elements are naturally emphasized. Since it is imagined as a fractured surface of natural stone, it is more advantageous to color silica sand and it is more preferable not to use only one color. Although it depends on the hue of the intermediate coating layer 5 (FIG. 1), it is basically preferable to knead each color such as black, red, blue, green, rust, yellow, and white.

In the case of silica sand having a grain size of No. 4 to No. 8, it is preferable to use a mesh roll to spray it. In the process, first put silica sand into the hopper, install a knurled mesh roll on the bottom, and rotate the mesh roll through a small gap between the bottom of the hopper and the mesh roll to spread the silica sand over a predetermined width. By sliding down a certain amount continuously and passing the plate material at a constant speed, it is possible to uniformly spread the plate material over the entire plate surface.

In determining the amount of application when using silica sand No. 5, consideration must be given to prevent the amount of silica sand that is not fixed to the surface of the plate material in the intermediate coating layer due to overlapping of individual silica sands. First, a plate material of the same quality that is not subjected to joint processing is cut into a 30.3 cm square to obtain a test piece. Using the sponge roll coater described above, white V-Selan # 100
Was adjusted to a viscosity of 70 seconds (Iwata cup), and 8 g / 30.3
Apply cm 2 wet paint and sprinkle sand within 10 seconds. A sample of 2 to 7 g / 30.3 cm square was prepared, and the design surface was evaluated. The amount and hue of the silica sand varies depending on the coloring of the intermediate coating layer, but when the intermediate coating color is brick color, 5 to 10 g / 30. When a 3 cm square sample was made and evaluated, 6-7 g / 30.3 cm flat
Is more appropriate.

In the sanding, silica sand is uniformly spread on the surface of the plate material, so that the silica sand is naturally sprayed on the joints 2 (FIG. 1). In this embodiment, the paint is applied only to the upper surface 4 of the convex portion of the plate material having the joint portion processed. Therefore, if the plate material 1 is inverted, the silica sand sprayed on the joint portion 2 is naturally dropped and removed. However, in practice, a considerable amount of silica sand remains. In addition, it is necessary to carry out the sheet material one by one in order to turn over the sheet material, which is not suitable for a step of performing continuous production and at the same time cannot sufficiently remove silica sand.

Therefore, it is necessary to devise a method of removing unnecessary silica sand at joints without inverting while transporting the plate material. As a cause of difficulty in removing, the sponge rolls up the sponge suddenly when painting the convex part with the sponge roll. If the joint is repelled and rolls on the joint, it is considered that some of the paint adheres to the joint. Therefore, the plate was placed on a vibrating conveyor immediately after the silica sand was sprayed, and a vibration of 200 to 300 per minute was given at a vibration of 5 to 10 mm. In this way, first, unnecessary silica sand is prevented from sticking, and the silica sand 6 on the intermediate coating layer 5 is promoted to be buried in the intermediate coating layer 5. The time required during this time may be about 10 seconds.

Next, far infrared drying is performed. The reason for this is that the silica sand is surely fixed by drying gently to the extent that fluidity is lost without foaming to the inside of the intermediate coating layer 5 having a thickness of 70 μm. The time required during this time may be about one minute.

Further, a jet drier of a type in which hot air is jetted was used for the purpose of removing silica sand accumulated in joints and drying the intermediate coating layer. Hot air is injected from pipes having an inner diameter of 20 to 30 mm, which are alternately arranged in a zigzag pattern at intervals of about 100 mm. Wind speeds in excess of 10 m / sec are required. Even under such strong wind pressure, the silica sand fixed to the middle coating layer on the upper surface of the convex part of the plate does not scatter because the far-infrared ray has already been dried, and the silica sand at the joints has some residue. Although almost completely removed. Further, even if it soars and falls again on the intermediate coating layer, it is not fixed and can be easily removed.
The far-infrared drying process is performed under conditions where silica sand is not blown off.
Any method may be used, and natural drying or room temperature drying may be used.

A transparent resin paint was uniformly applied on the entire surface of the plate material from which the silica sand had been fixed and unnecessary silica sand had been removed from the joints by an airless spray machine to form a clear layer 7. In this case, even if a part of the surface of the silica sand was exposed, the weather resistance was not affected.

[0030]

As described above, in the ceramic decorative panel of the present invention, one or more colored sand particles are coated only on the projections .
Since it is fixed so as to be exposed from the rear layer, it becomes a decorative plate that gives the impression that natural stone or brick has been stuck, and the coating on the thick convex surface gives a tile feeling, and the concave portion serves as the joint. The repetition of the design pattern due to this makes up for the unnaturalness at the abutting part when this decorative board is stuck, so even when mounted on a large wall, there is no feeling like using a decorative board and a more luxurious feeling It can be a decorative plate that can be brewed. Further, in the decorative method, the ceramic decorative panel can be manufactured more efficiently.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of a ceramic decorative panel according to the present invention.

FIG. 2 is a vertical cross-sectional view of a plate material showing a case where a top surface of a convex portion and a ridge portion of a rising surface of a concave portion are rounded, and an intermediate coating is not rounded.

FIG. 3 is a vertical cross-sectional view of the plate member of FIG. 2 showing a state in which a round portion is intermediately coated and a sand-like substance is fixed.

FIG. 4 is a schematic side view of an apparatus showing a manufacturing process for fixing a sandy granular material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Board material 2 Joint part 3 Joint color layer 4 Upper surface of convex part 5 Intermediate coating layer 6 Sandy-grained material 7 Clear layer

Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FI E04F 13/14 101 E04F 13/14 101 (56) References JP-A-1-285344 (JP, A) JP-A-2-59481 (JP, A) JP-A-1-2156 (JP, A) JP-A-54-34385 (JP, A) JP-A-55-140779 (JP, A) JP-A-3-112607 (JP, A)

Claims (4)

(57) [Claims] 1. A ceramic plate material formed with an uneven design pattern, wherein a concave portion is formed in an joint portion, and one or more colors of sand are formed only on the upper surface of the convex portion to which a paint as a fixing means is applied. Granules are fixed , and clear
-Apply a transparent resin paint to form a layer
Formed so that a part of the material is exposed from the clear layer.
A ceramic veneer. 2. The method according to claim 1, wherein the ridge portion between the upper surface of the convex portion and the rising surface of the joint portion has a round shape, and a part of the sand-like material including the ridge portion is exposed and fixed. The ceramic decorative panel according to claim 1. 3. A portion of the sandy particles uniformly distributed over the entire surface of the plate material is exposed and remains on the upper surface of the convex portion, and almost all of the sandy particles are removed at the joint portion. The ceramic decorative panel according to claim 1 or 2, which is formed. 4. A means for fixing the sandy particles to the plate material is a paint, and after applying a predetermined amount of intermediate coating on the convex surface, the sandy particles are evenly spread over the entire plate surface and a suitable vibration is applied. To the sheet material to fix it to the intermediate coating layer of the sandy particles, and then remove the residual sandy particles remaining at the joint after drying with far infrared rays using a wiping means such as a jet drier. A transparent resin paint is applied to the upper surface, and a part of the
4. The method of claim 1 , wherein the clear layer is formed so as to be exposed from the rear layer . 5.