JP3742063B2 - Inorganic board having wood grain pattern and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an inorganic board used for a building board such as a wall board and a method for manufacturing the same, and in particular, has a fine unevenness part expressing a road pipe and surface fiber of wood, and faithfully expresses a wood texture. The present invention relates to an inorganic board having a natural wood-like grain pattern having a high-class feeling and a method for producing the same.
[0002]
[Prior art]
Conventionally, as this type of decorative plate, a trapezoidal portion having a plurality of deep concave grooves formed at intervals and small undulating irregularities formed randomly on the surface formed between the concave grooves. An undercoat coating layer of opaque coloring paint having a substantially uniform thickness so that the unevenness remains is provided on the entire surface of the substrate, and the concave groove extends from the groove upper side to the middle on the undercoat coating layer. As the thickness gradually increases only on the slope of the surface, the thin relief surface of the small undulation or the undercoating surface is exposed, and the coating surface gradually thickens on the concave surface of the small undulation, There is a decorative board having a concavo-convex portion, characterized in that a coating layer of an opaque coloring paint different from the color of the undercoat coating layer is provided, and a printed pattern layer is provided as an uppermost layer on the small undulating concave portion (for example, See Patent Document 1).
[0003]
Further, there is a decorative material in which a concealed solid print layer, a pattern print layer, a transparent synthetic resin layer, and a gloss adjustment layer are sequentially laminated on a base material and embossed (see, for example, Patent Document 2). This decorative material is further characterized in that a second pattern printing layer and a second transparent synthetic resin layer are provided between the transparent synthetic resin layer and the gloss adjusting layer. In this decorative material, the transparent synthetic resin layer protects the picture print layer, prevents the picture print layer from being contaminated, worn, and peeled off due to scratches, and improves the surface properties as a whole.
[0004]
[Patent Document 1]
JP-A-51-101102 (Claims, Fig. 1)
[Patent Document 2]
JP-A-2-128843 (Claims, FIG. 1)
[0005]
[Problems to be solved by the invention]
By the way, in the former decorative plate, the concave groove has a depth of about 2 to 5 mm, and there are many small undulating irregularities having a depth of 1 to 2 mm or less on the convex surface having a substantially trapezoidal cross section existing through the concave groove. It is formed intensively so as to be complicated, and these grooves and irregularities are previously formed in the wood fiber board. The unevenness formed here is continuous in the longitudinal direction of the substrate and does not have a non-uniform length, and the concave groove does not have a groove end. For this reason, it is impossible to express a natural wood tone having a high-class feeling because it is impossible to express the pipes and surface fibers peculiar to wood.
[0006]
In addition, the latter decorative material uses a base material on which unevenness is formed by embossing, and when applying a concealed solid print layer and a pattern print layer on this base material, printing is not performed if the unevenness is too deep. The printing rolls do not reach the recesses and the printing characteristics are deteriorated. Even if the unevenness is shallow, if uneven thickness or uneven thickness of the substrate occurs due to uneven pressing when the substrate is spring-backed or pressed after molding, it is necessary to adhere to the roll substrate during printing. Because of the different pressures, color and gloss differences occur on the printed paint surface. Furthermore, when a decorative base material is molded with a template, there is a possibility that fine cracks may occur at the boundary between the irregularities. Especially, when such a problem occurs during continuous production, that part is easily noticeable. As a result, the appearance of the product is impaired.
[0007]
The present invention has been made in view of such problems, and the object of the present invention is to provide a natural wood tone with a high-class feeling, having fine irregularities that are close to the road pipes and surface fibers unique to wood. An object of the present invention is to provide an inorganic board having a grain pattern. Another object of the present invention is to provide a method for producing an inorganic board having a wood grain pattern, which can easily form fine irregularities similar to the above-mentioned road pipes and surface fibers, and can produce a high-quality natural wood-like inorganic board. .
[0008]
[Means for Solving the Problems]
To achieve the above object, inorganic board having a grain pattern according to the present invention comprises a substrate, sharp numerous fine groove ends have a non-uniform length along its longitudinal direction in the needle A fine uneven portion is formed by engraving, and a wood grain pattern is added to the upper surface of the fine uneven portion. In particular, the fine groove portion is preferably fine so that several pieces are included in 1 mm formed by grinding or the like, and has a non-uniform length and a shape having an end portion. The end of the fine groove is pointed like a needle, and the planar shape of the fine groove is needle-like.
[0009]
Since the inorganic plate having the wood grain pattern of the present invention configured as described above has an end portion with a non-uniform length of the fine groove portion constituting the fine concavo-convex portion, Compared to the conventional structure in which the concave and convex portions on the surface of the substrate are continuously formed over the entire length in the longitudinal direction, the surface approximates to the wood surface more accurately. It is possible to express a natural wood tone with a high-class feeling due to the fine irregularities and the grain pattern.
[0010]
As a preferable specific aspect of the inorganic board having a wood grain pattern according to the present invention, the fine groove portion is set to have a width and a depth of about 0.1 to 1 mm, and is substantially parallel to the longitudinal direction of the substrate. Several are formed between 1 mm. With this configuration, since the surface pipes and surface fibers peculiar to wood can be faithfully represented by the fine irregularities, it is possible to form an inorganic board having a wood grain pattern that expresses a high-quality natural wood tone.
[0011]
Further, as another preferred specific aspect of the inorganic board having a wood grain pattern according to the present invention, the fine concavo-convex portion is formed on the surface of the substrate by sanding with a sander device in which the circumferential grinding surface contacts. It is characterized by. Sanding is a process in which a sander belt or sand roll having a file surface is brought into contact with the surface of the substrate, and the surface is ground by moving the sander belt and the substrate relative to each other, and fine grooves are engraved. This is a processing method for forming fine irregularities. In addition, when two sander rolls having different surface roughness are used in the sanding process, it is possible to more faithfully represent a wood pipe and surface fibers.
[0012]
Furthermore, as another preferable specific embodiment of the inorganic board having a wood grain pattern according to the present invention, the fine uneven portion is formed on the surface that was on the lower surface side of the mat when the substrate was molded. Here, the mat is a raw material that has been distributed or molded before press molding, and the substrate is an uncured inorganic plate obtained by press molding the mat. The inorganic plate can be either a wet manufacturing method or a dry manufacturing method. It can also be molded by this manufacturing method.
[0013]
According to this configuration, when the substrate is molded by papermaking or the like, the upper surface side of the substrate has a relatively low specific gravity because of a large amount of fiber material, but the smoothness is poor, but the lower surface that is in contact with the mat surface is relatively powdered. Since there are many, specific gravity is large and smooth, and a fine uneven part can be formed beautifully in a short time. In addition, in the case of the press-pressing method after spraying dry raw material on a surface plate, the raw material mat has poor smoothness on the lower surface side of the mat due to spreading unevenness of the raw material, but the lower surface contacting the mat surface is smooth. Similarly, fine irregularities can be formed beautifully in a short time.
[0014]
The method for producing an inorganic board having a wood grain pattern according to the present invention includes a step of sanding a surface of a substrate with a sander device in contact with a circumferential grinding surface to form fine irregularities, and a base coating on the sanded surface. And a step of adding a wood grain pattern to the surface on which the base coating is applied by printing or the like. The wood grain pattern can be added using printing, painting, an inkjet method or the like. According to this manufacturing method, the surface of the substrate is sanded with a sander device, and the fine irregularities can be easily formed by the fine grooves with the ends sharpened like needles. Can be expressed in
[0015]
Another aspect of the method for producing an inorganic board having a grain pattern according to the present invention includes a step of press molding a mat, and a sander in which a circumferential ground surface is in contact with the surface that was on the lower surface side of the mat when the substrate was pressed. It comprises a step of sanding with an apparatus, a step of applying a base coat to the sanded surface, and a step of adding a grain pattern to the surface of the base coat by printing or the like. Also in this case, the inorganic plate can be molded by either a wet manufacturing method or a dry manufacturing method. When sanding the substrate, it is preferable that the press-molded substrate is turned upside down and processed with the lower surface side as the upper surface. In the manufacturing method of the present invention configured as described above, the surface that was on the lower surface side of the mat at the time of molding is relatively smooth with a lot of powder material. It can be formed beautifully.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of an inorganic board having a wood grain pattern according to the present invention will be described in detail with reference to the drawings. 1A and 1B show an inorganic board having a wood grain pattern according to the present embodiment, wherein FIG. 1A is a plan view of the grain part, FIG. 1B is a plan view of the part of the mesh part, and FIG. The top view which shows an uneven | corrugated | grooved part, (b) is the AA expanded sectional view of (a), (c) is the partial expanded perspective view of a fine uneven | corrugated part, FIG. 3 shows the grain pattern of FIG. It is a top view. In addition, the fine groove part of FIG. 1, FIG. 2 (a) is expressed in the thinned state for description. 1-3, the inorganic board 1 used for the wall board etc. of a building is the rectangular shape whose length of a vertical direction is about 3 m and the width of a horizontal direction is about 45 cm, for example, and thickness is 10--10. It is formed from the board | substrate 2 set to about 25 mm.
[0017]
The substrate 2 is formed by papermaking by mixing cement and a fibrous material such as pulp or fiber, and mixing a curing agent or the like as necessary. That is, in the wet manufacturing method, a slurry-like raw material mixture to which a fibrous material, a hydraulic inorganic material such as cement, an extender such as aggregate, and appropriate water are added is poured into a mold on a papermaking belt, and the slurry is poured. The substrate mat is prepared by suction dehydration, press molding while suction dehydration, and the molded product is cured and cured. In the dry process, a dry mat is formed by spraying a raw material mixture mainly composed of wood reinforcing materials such as wood fragments and wood fibers, hydraulic inorganic materials such as cement, and fillers such as aggregates on a template, The mat is pressed and cured after curing.
[0018]
In the inorganic plate 1, fine uneven portions 5 are formed on the surface 2 a of the substrate 2. The fine concavo-convex portion 5 is formed by a large number of fine groove portions 6 having a non-uniform length that are randomly engraved along the longitudinal direction of the substrate 2 and the surface 2a of the substrate 2. The fine groove part 6 of the book is formed by arbitrary length. Therefore, for example, the fine groove portion 6 having a thickness and depth of about 0.1 to 1 mm is several mm to several cm or continuously several tens cm long, and several lines are formed substantially in parallel within 1 mm. . For this reason, the end portions 6a are formed at both ends of each fine groove portion 6 and these end portions are pointed like needles, so that the fine groove portion 6 has a needle-like shape with both ends sharpened.
[0019]
When the substrate 2 is formed by papermaking, it is preferable that the fine concavo-convex portion 5 is formed on the substrate surface on the mat lower surface side that contacts the mat surface. When the substrate 2 is made, since the cement portion is precipitated on the lower mat surface side and the specific gravity is increased and the smoothness is improved, the fine irregularities 5 can be easily formed by sanding in a short time. In addition, the fiber portion such as pulp mixed inside is prevented from being exposed from the surface by the sanding process, and can be finished beautifully.
[0020]
For example, a skin-colored undercoat is applied to the substrate 2 on which the fine uneven portions 5 are formed, and a brown or dark brown wood grain pattern 7 is added to the upper surface by printing or the like. When the wood grain pattern 7 is added by, for example, offset printing, since the fine groove portion 6 has a depth of about 0.1 to 1 mm, the printing ink reaches the bottom of the fine groove portion 6 and the wood grain pattern 7 is not interrupted. . A clear coating is applied to the upper surface of the substrate 2 to which the wood grain pattern 7 is added to protect the undercoating and the wood grain pattern 7. The undercoat and clear coating are not shown. Further, intermediate coating may be performed after the undercoating.
[0021]
The inorganic board 1 of the present embodiment manufactured in this way is a fine plate in which a needle-like fine groove portion 6 having a groove end portion and a non-uniform length representing a path tube and surface fibers peculiar to wood is engraved. Since the concavo-convex portion 5 and the wood grain pattern 7 made of annual rings such as natural wood effectively match, a high-quality natural wood-like finish can be obtained. That is, the design attached to the non-uniform length needle-shaped fine groove portion 6 having the groove end portion 6a and the wood grain pattern 7 such as an annual ring can express a genuine natural wood-like design, Unlike a flat printed pattern such as a printed decorative board, if the direction of light is different, a shadow is generated and a three-dimensional and dynamic design can be expressed. In addition, it is possible to express a high-quality wood texture that has depth and a road pipe part, which is different from a monotonous texture that is large and monotonous continuously in the longitudinal direction of the substrate as in the past, and a monotonous wood texture due to a printed wood pattern. it can.
[0022]
In addition, the inorganic plate 1 of this embodiment is not printed on a substrate having shallow irregularities formed by a template or the like, but is formed by forming a large number of fine groove portions 6 by sanding, and the fine groove portions 6 and the surface 2a. Since the grain pattern 7 is added on the fine irregularities 5 made of the above, the thickness accuracy of the inorganic board 1 is good, and the uniformity in the thickness direction is ensured, so that a good finish feeling excellent in printing characteristics can be obtained. . Accordingly, color and gloss unevenness does not occur, and the quality can be improved without impairing the appearance of the product.
[0023]
A method for manufacturing the inorganic board having the wood grain pattern of the present embodiment configured as described above will be described below with reference to the process diagram of FIG. In the carrying-in process of step S1, the board | substrate 2 which is the material of the inorganic board 1 is carried in, and it installs on the belt conveyor of a manufacturing line with the surface which was the mat | matte lower surface side at the time of papermaking shaping | molding up. In the sanding process of step S2, the fine uneven portion 5 is formed on the surface 2a (surface on the mat lower surface side) 2a of the substrate 2 by sanding.
[0024]
Here, the sander apparatus which performs a sanding process is demonstrated with reference to FIG. FIG. 5 is a schematic perspective view of the sander device 10 installed between the belt conveyors of the production line. The belt conveyor B conveys the substrate 2 that is the material of the inorganic board 1, and the circumferential grinding surfaces of the first and second sander belts 11 and 12 arranged in parallel and the conveyance direction of the substrate 2. The sander device 10 is installed so that and are orthogonal to each other.
[0025]
This sander device is for forming fine irregularities 5 on the surface 2a of the substrate 2. The first sander belt 11 is a filed belt having a surface roughness of about 10 to 30, and the second The sander belt 12 is a filed belt having a finer surface roughness of about 40-80. The sander belt is stretched over the backup roller R between the rollers of the belt conveyors B and B, and the sander belts 11 and 12 and the substrate 2 are not in surface contact but in a state close to line contact. The rotation directions of the sander belts 11 and 12 are set so that the moving direction of the substrate and the rotating direction of the sander belt are opposite to each other at the contact portion between the sander belt and the substrate 2.
[0026]
The circumferentially ground surface having a relatively rough surface roughness of the sander belts 11 and 12 is brought into contact with the substrate 2 and subjected to sanding (grinding or sanding) processing, whereby the fine groove portions 6 can be formed by engraving. . When the circumferential grinding surface of the sander belt is pressed strongly against the substrate 2, all of the grinding projections come into contact with the substrate 2 and a large number of fine groove portions 6 are formed. When pressed weakly, only the high portion of the grinding projection is formed. Since a small number of fine groove portions 6 are formed in contact with the substrate 2, the interval between the fine uneven portions 5 can be adjusted within a range of, for example, about 0.3 to 1 mm by pressing force. Moreover, when a rough fine uneven part is formed with the first sander belt 11 and then a fine fine uneven part is formed with the second sander belt 12, the fine uneven part does not become monotonous, and a random passage having a different thickness is formed. It can be approximated and a more faithful natural wood-like surface can be expressed.
[0027]
In this sanding process, the substrate 2 is moved at a speed of, for example, 10 to 25 m / min, the sander belts 11 and 12 of the sander device 10 are rotated at 1500 to 2500 revolutions per minute, and many sander belts are formed on the surface 2a of the substrate 2. The projections of the two come into contact with each other and are ground to form the fine groove portions 6 parallel to the longitudinal direction of the substrate 2. Since many protrusions of the sander belts 11 and 12 are randomly arranged, the fine groove portions 6 are also randomly formed with an arbitrary length. Further, since the sander belt and the substrate 2 are in line contact, the fine groove portion 6 is formed with a sharp needle-like end portion 6a.
[0028]
Since the first sander belt 11 and the second sander belt 12 have file surfaces with different surface roughnesses, for example, after forming the fine uneven portions 5 having relatively rough intervals with the first sander belt 11, It is possible to form the fine uneven portions with fine intervals with the two sander belts 12 in an overlapping state, and to form a natural wood-like fine uneven portion having a sense of quality by wiping away the monotonous feeling. The first and second thunder belts are not limited to those rotated at the same rotational speed. When rotating at different rotational speeds, the relatively coarse intervals, the fine irregularities, and the fine irregularities with fine intervals are different in length, and the monotonous feeling can be further removed.
[0029]
The substrate 2 on which the fine uneven portion 5 is formed on the surface 2a is subjected to undercoating on the surface 2a of the substrate in the undercoating process in step S3. This undercoat coating process also serves as a seal for the base, and a light color that becomes a base such as light brown or skin color is attached thereto. Thereafter, in the dryer process of step S4, the undercoat of step S3 is dried. Next, if necessary, there is an intermediate coating process in step S5, and there is a dryer process in step S6 for drying it. Steps S5 and S6 may be omitted.
[0030]
The substrate 2 on which the fine concavo-convex portion 5 is formed and is undercoated and / or intermediately coated is provided with the wood grain pattern 7 in the first and second printing steps of steps S7 and S8. In this example, since there are two printing processes, for example, a dark brown wood pattern is added in the first printing process S7, and a brown fine wood pattern is added in the second printing process S8. Can be added. Of course, only one printing process is required. The printing process is preferably offset printing, but is not limited to this, and other printing methods may be used. In addition, it is preferable that the wood grain pattern added in the printing process is added when the coating film applied in the undercoating process is partially left, so that the wood grain pattern is deep.
[0031]
Thereafter, in the clear coating process of step S9, the clear coating film is applied on the wood grain pattern 7 added by printing or the like, and the clear coating film is dried in the dryer process of step S10, whereby the inorganic board 1 is completed. A clear paint film can be applied to protect the wood grain pattern 7. And the inorganic board 1 completed by the packing and carrying-out process of step S11 is packed by a predetermined quantity, and is carried out from a manufacturing line.
[0032]
According to the manufacturing method of the inorganic board of the present embodiment, the inorganic material is formed in a series of work processes such as the formation of the fine irregularities 5 by sanding, the undercoating, the printing process of the wood grain pattern 7, the clear coating process of the top coat, and the dryer process. The board 1 can be manufactured efficiently. If the fine uneven part 5 is formed by the sander device 10, a template for forming the fine uneven part becomes unnecessary, and the fixing cost can be reduced.
[0033]
Although one embodiment of the present invention has been described in detail above, the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention described in the claims. Design changes can be made. For example, an example in which the needle-like fine groove portion constituting the fine uneven portion is formed by sanding is shown. However, a fine protrusion for forming the fine groove portion is formed on the template so as to protrude, and the substrate is pressed against the template. The fine irregularities may be transferred and formed. Further, the file surface of the sander device is not limited to a belt shape, and may be a cylindrical shape.
[0034]
【The invention's effect】
As can be understood from the above description, the inorganic board having a wood grain pattern of the present invention has a road pipe peculiar to wood and fine irregularities similar to surface fibers, and has a natural wood tone with a sense of quality. Can be expressed. And since a fine uneven part is comprised by the fine groove part carved on the surface, if the direction where light hits differs, a shadow will arise and a dynamic three-dimensional design can be expressed.
[0035]
Moreover, according to the manufacturing method of the inorganic board which has the grain pattern of this invention, the fine uneven | corrugated | grooved part which approximates the channel | pipe and surface fiber peculiar to wood can be formed realistically. Furthermore, the fine irregularities can be formed beautifully in a short time. If the fine irregularities are formed by sanding, a template is not required, and fixing costs can be reduced.
[Brief description of the drawings]
FIG. 1 (a) is a plan view of an enlarged part of an essential part of an embodiment of an inorganic board having a wood grain pattern according to the present invention, and FIG.
2A is a plan view showing the fine uneven portion of FIG. 1, FIG. 2B is an enlarged cross-sectional view taken along the line AA of FIG. 1A, and FIG. 2C is a partially enlarged perspective view of the fine uneven portion;
FIG. 3 is a plan view showing the wood grain pattern of FIG.
FIG. 4 is a process chart showing a method for producing an inorganic plate according to the present invention.
FIG. 5 is a schematic perspective view of a sander device for forming fine uneven portions.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Inorganic board, 2 ... Board | substrate, 2a ... Surface of substrate (surface of mat | matte lower surface side), 5 ... Fine uneven part, 6 ... Fine groove part, 6a ... End part of fine groove part, 7 ... Wood grain pattern, 10 ... Thunder apparatus 11 ... 1st thunder belt, 12 ... 2nd thunder belt

Claims (6)

On the surface of the substrate, Yes to form a fine concavo-convex portion by longitudinally along and have a non-uniform length end of the substrate is engraved pointed numerous fine grooves in a needle shape, the fine An inorganic board having a wood grain pattern, characterized in that a wood grain pattern is added to the upper surface of the uneven part. The width and depth of the fine grooves are set to about 0.1 to 1 mm, and several fine grooves are formed between 1 mm and approximately parallel to the longitudinal direction of the substrate. An inorganic board having the wood grain pattern described. The inorganic plate having a wood grain pattern according to claim 1 or 2, wherein the fine uneven portion is formed by sanding on the surface of the substrate with a sander device in which a circumferential grinding surface contacts . The inorganic plate having a wood grain pattern according to any one of claims 1 to 3, wherein the fine uneven portion is formed on a surface that is on the lower surface side of the mat when the substrate is molded. Sanding is performed on the surface of the substrate with a sander device in contact with the circumferential grinding surface to form fine irregularities, a step of applying a ground coating to the sanded surface, and a grain pattern on the surface of the base coating The manufacturing method of the inorganic board which has a grain pattern provided with the process added by printing etc. A step of press-molding the mat, a step of sanding with a sander device in which a circumferential grinding surface is in contact with the surface that was on the lower surface side of the mat at the time of the press-molded substrate molding, and a step of applying a base coat to the sanded surface A method for producing an inorganic board having a wood grain pattern, comprising a step of adding a wood grain pattern to the surface of the base coating by printing or the like.

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