JP4107483B2 - Method for manufacturing ceramic decorative veneer - Google Patents

Description

【００４４】
表中、◎は極めて良好、○は熟練した技術者の目視観察により極く僅かな欠点が認められるものの商品としては問題なし、△は熟練した技術者の目視観察により欠点が確認され商品化不可、×は明らかな欠点が認められた、をそれぞれ示す。また、塗膜硬度は、ＪＩＳ Ｋ ５６００鉛筆引っかき値（機械式法）により測定した結果である。
【００４５】
【発明の効果】
本発明によれば、予め凸部から凹部までの深さが８０μｍ〜３００μｍの範囲の凹凸模様を付与した窯業系化粧基板の表面に、下塗り層を形成し、該下塗り層上に、パターンロールを用いてはじき剤を塗布して乾燥させることにより所定のパターンのはじき剤層を形成し、その表面温度を４０〜８０℃に調整した後、はじき剤層が形成された下塗り層の全面に化粧層形成用塗料を塗布し、はじき剤層上の化粧層形成用塗料をはじかせることによって所定の柄および模様を形成させ、硬化させることにより化粧層を形成するので、化粧層は、所定の柄および模様の再現性に優れ、自在に柄付けすることができる。また、化粧層は、窯業系化粧基板の凹凸に沿って不均一な層として形成され、そのレベリング性が阻害されて、塗膜の表面に凹凸模様が形成されるので、塗膜厚が変化して塗膜中の顔料の配 向方向または分散密度が変化し、意匠性、特に、光輝感、立体感、陰影感、深み感に優れた窯業系化粧板の製造方法を提供することができる。[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a method for producing a ceramic decorative board excellent in design properties, in particular, brilliant feeling, three-dimensional feeling, shadow feeling, depth feeling,Such a ceramic decorative veneerUsed for interior materials such as building materials, especially bathroom unit inner walls, toilet booths, kitchen front panels, etc.Be doneIs.
[0002]
[Prior art]
  Conventionally, it was designed to give a sense of design, especially radiance, three-dimensionality, shadow, and depth.Ceramic industryVeneerTo getFor example,A method for producing a decorative board, wherein a base coat layer is formed on a surface of a substrate, and a transfer sheet is pressure-bonded on the base coat layer by a desired means to form a transfer pattern layer. , Printing ink pattern layer and resin layer with pearl pigment dispersedButA method for producing a decorative board characterized by being appliedKnown(For example, refer to Patent Document 1). However, it is obtained by this manufacturing method.RuAlthough the decorative board has glitter, the sheet is adhered by the transfer method.InI couldn't deny the imitation of sticking a sticker, and couldn't give it a natural product.
[0003]
  Patent Document 2 and Patent Document 3soHas proposed a decorative board in which a specific treatment is applied to a sheet in which a pearl pigment is dispersed, and the dispersion density and / or orientation direction of the pearl pigment is changed depending on the portion to give a design. This gives a three-dimensional effectObtainedCame to manufacture the sheetForTakes time and effort,High costStickHas the disadvantageWas. Furthermore, generally, when the sheet is hardened, the workability when the sheet is attached to the substrate is deteriorated, so that the hardness of the sheet surface cannot be increased and the surface is easily damaged.Was.
[0004]
  Furthermore, in Patent Document 4, a decorative layer is provided on the surface of a smooth substrate.Makeup layerSilicone oil on topTheA cosmetic building material provided with a dispersed surface coating layer is disclosed. This decorative building material uses decorative printed paper or thermal transfer resin sheet.UseMakeup layerFormationAnd silicon oil on itTheRoll coater or flow coater with dispersed paintByPaint and use the repelling effect of silicone oil to make the coating surface uneven.,Give a sense of depthTheIs. In addition, it is said that aluminum powder can be introduced into the paint as a pigment. However,like thisObtained by applying paint on the decorative layer with a roll coater or flow coaterRuThe product has a nonuniform pattern size, especially,The size of the pattern was different between the center and the edge of the substrate, and a product with pattern reproducibility could not be produced. In order to improve designTrying to increase the unevenness of the coating surface,Increase the amount of silicone oil addedin case ofProvided on itRuThere was also a problem that a repelling effect was produced even on the coating film, which not only deteriorated the design but also caused poor coating.
[0005]
  In order to solve such a problem, the present applicant has disclosed in Patent Document 5As disclosed, Ceramic-type decorative substrate,thisIn a ceramics decorative board having a base adjustment layer on a ceramics decorative board, a decorative layer on the base adjustment layer, and a transparent or translucent cured resin layer on the decorative layer, the ceramics decorative board is,The depth from the convex part to the concave part is 80 μm to 300 μmHave irregularities on the surface,And,The decorative layerInProduces a non-uniform phase in the makeup layerLetContains repellentCoughedCeramics type decorative board characterized by that,And,Adjust the surface temperature of the ceramics decorative substrate to 60-90 ° CThatA base adjustment layer is provided on the surface.ThisCeramic-based decorative boardBase adjustment layerAfter adjusting the surface temperature of the film to 50 to 80 ° C., a paint for forming a decorative layer to which a repellent is added is applied onto the base adjustment layer by a roll coater or a flow coater.,Hardened to provide a decorative layer,,A transparent or translucent cured resin layer coating is applied on the decorative layer by a roll coater or a flow coater.,A method for producing a ceramic decorative board characterized by curing and providing a transparent or translucent cured resin layer was proposed.
[0006]
  Further, Patent Document 6 discloses an undercoat film directly or on the surface of a target substrate.ofDryrearScratch any pattern with silicon resin on it, thenInTop coatTheApply to the entire surface, presence of silicon resinYouA pattern coating method is disclosed in which a pattern is revealed only by removing the top coating material.
[0007]
  Furthermore, in Patent Document 7, a repelling paint containing a silicon resin is applied to the base material,thisRepellent paintButScattered into an arbitrary pattern in the wet state to give a difference in film thickness to the coated film, and then a pattern due to the repelling effect appears.LetAfter,A three-dimensional cosmetic material characterized by solidifying a coating film is disclosed.
[0008]
  Moreover, in patent document 8, the uneven | corrugated pattern which consists of a recessed part and a convex part is formed in the decorative metal plate which gave the makeup | decoration foundation | substrate by undercoat,thisDifferent from the makeup base only in the recesses of the uneven patternBecomeIn addition to forming a top coat layer with a color top coat,A decorative metal plate with a concavo-convex pattern, wherein the overcoat layer is formed so that the coating thickness gradually increases from the upper part to the lower part of the inner side surface of the recess.,And,Undercoat paintsoAfter forming a concavo-convex pattern consisting of convex portions and concave portions on the surface of the decorative metal plate provided with a makeup base using an embossing machine, a coating liquid having a repellent effect is applied only to the convex upper surface of the convex portions, and then,The surface of the decorative metal plate is different from the makeup base.BecomecolorofA method for producing a decorative metal plate with a concavo-convex pattern, characterized by applying a paint and baking and drying is disclosed.
[0009]
  Further, in Patent Document 9, a tile joint pattern is formed on a base sheet using a liquid-emitting ink, and then a transparent paint having a property of being repelled by the joint pattern is applied to the entire surface.InApply,Manufacture of tile-like decorative material characterized by forming a surface layerDirectionThe law is disclosed.
[0010]
  Furthermore, in Patent Document 10, a three-dimensional pattern is formed on the surface of the base plate.RuA decorative plate manufacturing method, in which a three-dimensional pattern is formed by applying a release agent to the surface portion of the base plate corresponding to the end of the pattern, and then applying the pattern forming agent over the entire surface. The manufacturing method of the decorative board characterized by being performed by this is disclosed.
[0011]
  Patent Document 11 discloses that (A) a photocurable (meth) acrylate compound (a1) and / or a photopolymerizable unsaturated polyester (a2), (b) photopolymerization is started on the surface of a flat substrate (A). Coating a photocurable coating composition capable of embossed design finish coating, which contains an agent, and (c) a silicon polymer that is incompatible with the component (a). (C) a step of forming an uneven embossed pattern coated surface by the separation and repelling phenomenon of component (a); A substrate coated with an embossed design finish is disclosed, characterized in that it is obtained through a process of forming.
[0012]
[Patent Document 1]
          Japanese Patent Laid-Open No. 08-281897
[Patent Document 2]
          Japanese Patent Laid-Open No. 5-220916
[Patent Document 3]
          JP-A-5-278052
[Patent Document 4]
          JP-A-10-291274
[Patent Document 5]
          JP 2002-11830 A
[Patent Document 6]
          Japanese Patent Publication No.49-46135
[Patent Document 7]
          JP 54-52146 A
[Patent Document 8]
          JP-A-56-15353
[Patent Document 9]
          JP 58-72449 A
[Patent Document 10]
          JP 58-155950 A
[Patent Document 11]
          JP 2000-53889 A
[0013]
[Problems to be solved by the invention]
  However, the ceramics decorative board described in Patent Document 5 is a repellent.ButAdd to makeup layer coatingIsBecausePredeterminedPatternInThere was a problem that it could not be freely controlled. Moreover, what is described in patent document 6, patent document 9, and patent document 10 isDoes not have an uneven patternSince the flat base material is patterned with repellent, the pattern can be adjusted freely, but because the base material is flat, the pattern on the center and edge of the base material is subtle. There are problems such as misalignment, Lack of stability of the handle. Furthermore, the technique described in Patent Document 7 is to form irregularities on a decorative metal plate that has been subjected to a makeup undercoat with an undercoat paint.The repelling paint is scraped into an arbitrary pattern while it is undried,It can be applied to metal plates, and not applicable to ceramic substrates. Patent Document 11Listed inThen, a repellent is added to the paint,PredeterminedPatternInThere is a problem that it cannot be freely controlled.
[0014]
  Therefore, the object of the present invention is to freely handle patterns.TheCan handleofAn object of the present invention is to provide a method for producing a ceramic decorative panel having good stability.
[0015]
[Means for Solving the Problems]
  That is, the method for producing a ceramics decorative board according to the present invention has been previously embossed on the surface.The depth from the convex part to the concave part is 80 μm to 300 μmApply a primer to the surface of the ceramics decorative substrate with the uneven pattern within the range.TheAn undercoat layer is formed by curing, and a repellent agent is applied onto the undercoat layer using a pattern roll.TheDryLetBy predetermined patternofForming a repellent layer,After adjusting the surface temperature to 40-80 ° C,Undercoat layer with repellant layerofApply the paint for forming the makeup layer on the entire surface, and repel the paint for forming the makeup layer on the repellent layer.ByPredeterminedPatterns and patternsFormingLet, CureLetIt is characterized by forming a decorative layer.
[0016]
  In addition, the method for producing a ceramics decorative board according to the present invention comprises a repellent layer andOn the makeup layer orA transparent or translucent paint is applied on the decorative layer, applied onto the decorative layer or the repellent layer and the decorative layer, and then cured to form a transparent or translucent top clear layer.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
  The present inventionUsed in the methodAlthough it does not restrict | limit especially as a ceramics type | system | group decorative board | substrate, A cement board, a calcium silicate board, a gypsum board, a slag gypsum board, a lightweight concrete board, those fiber reinforced boards, a wood piece cement board, etc. are mentioned. The ceramic decorative board is on the surface.The depth from the convex part to the concave part is 80 μm to 300 μmIt is essential to have an uneven portion within the range.In additionPreferably, it is in the range of 80 to 200 μm. If the depth is less than 80 μm, there is no effect of providing an uneven portion,PredeterminedPatternAndThe product with reproducibility of the pattern cannot be manufactured, and the three-dimensional impression of the product is poor.TheThis is not preferable. On the other hand, when the thickness exceeds 300 μm, the coating for forming the decorative layer accumulates in the recess when forming the decorative layer, and there is no sense of depth.MayApply a paint with higher viscosity with a flow coaterDoCaseIn, On uneven partsSoBecause there is a place that can not be applied in layers (or film)InIt is not preferable. The depth from the convex part to the concave part is in the range of 80 μm to 300 μm.InsidesoIf there is, apply a repellent using a pattern roll and dry to form a repellent layer of a predetermined pattern,Due to its repelling effect, the resin and pigment that are the main components of the paint for forming the decorative layer are removed.Let me go,Ceramic veneer with a predetermined pattern or patternCan be manufactured. In addition, ceramic-based decorative substrateofThe method for providing the concavo-convex portion on the surface is not particularly limited, and for example, known methods such as press working and embossing roll processing can be used.
[0018]
  Next, the ceramics type decorative board of the present inventionManufacturing methodIn order to reinforce the surface part of the ceramic decorative substrate (improvement of strength and hardness), the undercoat layer reduces the influence of the ceramic decorative substrate on the decorative layer (for example, reduces the penetration of alkali components into the decorative layer). Therefore, it aims to improve and maintain the adhesion between the ceramic-type decorative substrate and the decorative layerForTo conceal the color of the ceramic-based decorative board itself until it has no effect when finished as a decorative board, etc.For the purpose of. For example,It refers to sealer treatment, surfacer treatment, undercoating (base coating), etc. The undercoat layer has various purposes as described above.AchieveTherefore, these processes may be performed in combination. Also, multicolor coating, printing pattern, etc.ofYou may give a design.
[0019]
  Here, the sealer treatment is carried out for the purpose of impregnating the ceramics decorative substrate surface part to improve the strength and hardness of the surface part and the adhesion between the ceramic decorative substrate and the coating film of the undercoat layer. The surfacer treatment fills the holes on the surface of the ceramics-type decorative substrate, and further, when the ceramic-type decorative substrate to be used contains an alkali component, the alkaline component suppresses the penetration into the coating layer such as the decorative layer. It is done for the purpose. In addition, the undercoat (base coating) is concealed so that the color of the ceramics-type decorative substrate does not affect the decorative layer and plays a role of firmly adhering to the ceramic-type decorative substrate.
[0020]
  The undercoating paint used for the undercoating layer is not particularly limited as long as it has a composition that does not impair the adhesion with the decorative layer described below, and commonly used urethane resins, acrylic urethane resins, Synthetic resin coatings such as unsaturated polyester resins, polyester acrylate resins, acrylic epoxy resins, acrylic resins, polyurethane resins, and acrylic polyurethane resins can be applied. In addition, the method for applying the undercoat paint is not particularly limited. For example, a method suitable for a material to be used from a known method used in normal coating such as a spray method, a roll coater method, a flow coater method, etc. The undercoat layer can be composed of a plurality of colors by a method such as silk screen printing.
[0021]
  In addition, the ceramics decorative board of the present inventionManufacturing methodThe repellent layer is a substance that acts to determine the pattern of the decorative layerLayer ofMeans. In other words, a repellant is applied in a predetermined pattern on the undercoat layer of the ceramics-type decorative substrate, and then dried.LetBy forming the repellent layer, even if the decorative layer forming paint described later is applied,For decorative layer formationPaint repelsAgentThe specific pattern you want without riding on topThat is, the predetermined patternCan be obtained.
[0022]
  Here, the type of the repellent that forms the repellent layer may be appropriately determined in consideration of other materials that constitute the decorative layer. For example, a silicon water repellent may be used. Silicone water repellents include oil-based solvent types, silane-based solvent types, varnish-based solvent types, and oil-based emulsion types.AgentLayer applicationAnd itsFrom the viewpoint of stability, it is preferable to use an emulsion type having a silicon oil concentration of 0.5 to 40% by mass, preferably 15 to 30% by mass. The predetermined patternFormationFor the formation of the repellent layer,For application,For example, flexographic printing techniques using pattern rolls can be used.
[0023]
  Ceramic ceramic decorative board of the present inventionManufacturing methodIn this case, a synthetic resin-based paint mainly composed of a resin or a pigment is suitable as the decorative layer forming paint, and this is applied to the undercoat layer.TheCureLetThus, a decorative layer is formed. When the paint for forming the decorative layer is applied to the entire exposed surface of the undercoat layer of the ceramic-based decorative substrate and the surface of the repellent layer, the decorative layer is not formed on the repellent layer of the predetermined pattern.,That is, a decorative layer is formed only on the exposed surface of the undercoat layer, andThe makeup layer isNon-uniform layer along the uneven surface of ceramic-based decorative substrateAsTo be formedNaLeveling of the makeup layer is hinderedTheAn uneven pattern is formed on the surface of the coating film.. Therefore,The coating thickness changesTheThe orientation direction or dispersion density of the pigment in the coating film is changed, and a ceramic decorative board excellent in design properties, in particular, light feeling, three-dimensional feeling, shadow feeling, and depth feeling can be provided.
[0024]
  The coating for forming the decorative layer is curedOf different,A thermosetting, ultraviolet curable, or electron beam curable coating can be used. A thermosetting paint is a paint composed of components such as pigments, resins, additives, solvents, etc., which are polymerized by the action of a catalyst / curing agent after crosslinking by evaporation after solvent volatilization. . The UV curable paint refers to a photopolymerizable compound that undergoes a chain polymerization reaction by generating radicals from a photopolymerization initiator upon irradiation with UV light. Specifically, a photopolymerizable resin, oligomer, It is a paint composed of components such as a reactive diluent solvent and a photopolymerization initiator (photosensitizer). Examples of the resin used for the paint include unsaturated polyester resins, polyester acrylate resins, acrylic epoxy resins, acrylic resins, acrylic polyurethane resins, and the like. Electron beam curable paints are those that are polymerized by irradiating the electron beam, which is mainly high energy, directly acting on the unsaturated group of the polymerizable compound, specifically unsaturated polyester resin, epoxy acrylate resin , Urethane acrylate resins, polyester acrylate resins, polyether acrylate resins, unsaturated acrylic resins, and the like.
[0025]
  Examples of the pigment that can be used in the paint as described above constituting the decorative layer include scale-like pigments such as metal powders such as pearl, mica, and aluminum powder. Such scaly pigments can give a glittering feeling, a three-dimensional feeling, a shading feeling, and a feeling of depth by changing the orientation direction or dispersion density in the decorative layer due to the repelling effect of the repellent layer. The content of the pigment is preferably 1 to 8% by mass, more preferably 2 to 5% by mass, based on the total solid content of the synthetic resin paint for forming the decorative layer. If the content is less than 1% by mass, the effect of depth cannot be expected, and if the content exceeds 8% by mass, it does not contribute to the improvement of the feeling of depth. Cause poor dispersion and precipitation, and,When the paint for forming the decorative layer is an ultraviolet curable paint,IrradiationSometimes ultraviolet rays are shielded by pigments, which may cause poor curing. When using scaly pigmentsInThe average particle size is preferably 20 μm to 150 μm. More preferably, it is 50 micrometers-100 micrometers. If it is less than 20 μm, the finished decorative board will not have a sense of depth or three-dimensionality, and if it exceeds 150 μm, it will precipitate inside the coating device or paint circulation, in the route, and inside the coating device or paint circulation. Clogged in the route partREtc.TheOccurs and stable production becomes impossible.
[0026]
  The thickness of the decorative layer is not particularly limited and is, for example, 10 to 100 μm although it depends on the unevenness of the ceramics-type decorative substrate. In addition,In order to obtain the effect of the repellent layer as a method of applying the paint for forming the decorative layer,Paint for forming a decorative layer immediately after applicationButIt is essential to have fluidity, flow coater or roll coaterApplication byIs preferable, and a flow coater is more preferable. This is because when the paint for forming a decorative layer is applied with a flow coater, the pattern and pattern obtained are larger than with a roll coater.outstandingBrilliant, three-dimensional, shaded and deepcan getBecause. The coating amount is 10 to 60 g / m with a roll coater.²In a flow coater, 50-150 g / m²Is preferred. In addition, it describes in this specificationIsThe applied amount is applied to the ceramic-based decorative substrateIsIt means the mass (including solvent) of the paint applied per unit area immediately after (uncured state).
[0027]
  Furthermore, in the ceramics type decorative board of the present invention, a transparent or translucent top clear layer can be formed on the decorative layer or the repellent layer and the decorative layer. Here, the transparent or translucent top clear layer means a cured resin layer having a total light transmittance of 40% or more, more preferably 50% or more. The total light transmittance can be measured by a conventionally known method using a haze meter or the like. Further, the transparent or translucent top clear layer serves as a protective layer for the decorative layer and imparts further depth and stereoscopic effect.
[0028]
  The transparent or translucent paint for forming the transparent or translucent top clear layer is not particularly limited, and examples thereof include urethane-based, acrylic-based, acrylic-urethane-based, unsaturated polyester-based, urethane acrylate-based, etc. A colorless transparent resin paint made of a thermosetting resin, an ultraviolet curable resin, an electron beam curable resin, or the like, or a translucent resin paint in which a coloring pigment is added thereto can be used. In the case of adding a color pigment, the ratio of the color pigment to the paint component excluding the solvent is 0.3 to 4% by mass, preferably 0.8 to 2% by mass.
[0029]
  The coating method of transparent or translucent paint for forming a transparent or translucent top clear layer is particularly preferably a roll coater method or a flow coater method, but other existing spray methods, transfer methods, sheet adhesion methods, etc. The method may be used. The thickness of the transparent or translucent top clear layer is not particularly limited,,It is in the range of 15-100 μm, preferably 20-50 μm. Here, even if the top clear layer is formed on the entire surface using a paint that is compatible with the repellent layer in consideration of the application of the ceramics decorative board, the top clear layer uses a paint that is repelled by the repellent layer. It may be formed only on the top.
[0030]
  Ceramic ceramic decorative board of the present inventionManufacturing methodIsThe surface was previously provided with a concavo-convex pattern with a depth of 80 μm to 300 μm from the convex part to the concave part by embossing.Adjust the surface temperature of the ceramic-based decorative substrate to 60-90 ° C,thisUndercoat layer on the surface of ceramicsFormingThen, after adjusting the surface temperature of the undercoat layer to 50 to 80 ° C.,On the undercoat layerIt is applied using a pattern roll and dried to form a repellent layer. Next, after adjusting the surface temperature of the ceramic-type decorative substrate on which the repellent layer is formed to 40 to 80 ° C., the decorative layer-forming paint is applied to the entire surface of the undercoat layer on which the repellent layer is formed by a roll coater or a flow coater. Repel the decorative layer-forming paint applied on the repellent layer.NoAfter forming a predetermined pattern, it is cured to provide a decorative layer, and,Transparent or translucent paint is applied by roll coater or flow coaterAs appropriateApply, apply on the decorative layer or on the repellent layer and the decorative layer, and then cure to provide a transparent or translucent top clear layerIs made up of.
[0031]
  As mentioned above, the surface temperature of the ceramics-type decorative substrate by preheating before forming the undercoat layer is 60 to 90 ° C, preferably 70 to 85 ° C. When the surface temperature by preheating is less than 60 ° C., the undercoat paint is hard to be cured, and when the next repellent is applied in a state of insufficient curing, the undercoat layer and the repellent layerButEach other at the interfaceInMixing is not preferable. If the surface temperature by preheating is less than 60 ° CInIn particular, a flow coater having a large coating amount is not preferable because the undercoat paint may be leveled without being cured and fill the recesses of the ceramic-type decorative substrate. Further, when an ultraviolet curable coating is used as a decorative layer forming coating on an undercoat layer formed at a surface temperature of less than 60 ° C. by preheating, it occurs in the decorative layer when the decorative layer forming coating is cured by ultraviolet irradiation. This is not preferred because there is a risk of shrinkage of the undercoat layer due to internal stress, or poor adhesion between the undercoat layer and the decorative layer. In addition, it is not preferable that the surface temperature exceeds 90 ° C., because the undercoat layer may have a coating film abnormality such as foaming, blistering, or flaming.
[0032]
  Moreover, the surface temperature by the preheating of the ceramics type | system | group decorative board | substrate before apply | coating the repellent which gave the undercoat layer is 50-80 degreeC, Preferably it is 55-70 degreeC. When the surface temperature is less than 50 ° C., the repellent layer becomes insufficiently dried, and when the decorative layer-forming paint is applied,Patterns and patternsIs not preferable because it may not be formed. Moreover, when the surface temperature by preheating exceeds 80 degreeC, for applying a repellent layerpatternRoll surface temperature risespatternThe repellant dries on the roll surface, and the repellant cannot be applied as set on the undercoat layer.Patterns and patternsIs not preferable because it may not be formed.
[0033]
  Moreover, the surface temperature by the preheating of the ceramics type | system | group decorative substrate before formation of the decorative layer which gave the undercoat layer and the repellent layer is 40-80 degreeC, Preferably it is 55-70 degreeC. When the surface temperature is less than 40 ° C., for example, when a decorative layer is formed using a thermosetting synthetic resin coating as a coating for forming a decorative layer, the resin of the decorative layer is hard to be cured and the synthetic resin based coating is fluid. Until you lose (fix)ofThe time is long and the reproducibility of the pattern and the pattern may not be obtained. In addition, if the surface temperature by preheating exceeds 80 ° C., the time until the synthetic resin paint loses fluidity is too short to obtain pattern and pattern reproducibility, and the decorative layer is foamed, blistered, etc. This is not preferable because it may cause an abnormal coating film.
[0034]
  In addition, as a preheating method, a heating device such as an infrared lamp dryer, a far infrared lamp dryer, a direct hot air dryer, an indirect hot air dryer or the like can be used to form an undercoat layer. It is possible to promote leveling and curing of the synthetic resin-based paint, the repellant, and the synthetic resin-based paint for forming the decorative layer.
[0035]
  Just pre-heated and dried and curedWhen applying paint,As the temperature changes, the repelling effect also changes, and the pattern and pattern also change.AlsoChange and stableOf patterned and patterned productsIt is not preferable because it cannot be produced.
[0036]
【Example】
  The ceramics decorative board of the present invention according to the following examples and comparative examplesManufacturing methodWill be further described.
  Example 1
  The surface of an uncured fiber reinforced cement board (910 mm × 1820 mm × thickness 5 mm) manufactured by the paper making method is pressed against the uneven surface of the FRP template having unevenness, and then pressed at 80 ° C. for 8 hours. It was cured by reaction by performing steam curing for a period of time, and after removing the template, it was dried to prepare a ceramics-type decorative substrate having a concavo-convex portion having a depth of 120 μm from the convex portion to the concave portion.
  Next, the surface temperature of the substrate is adjusted in advance to 60 ° C., and an acrylic urethane-based paint (220 Conitan undercoat manufactured by DIC Color Coaching Co., Ltd.) is used as an undercoat on the roll coater.², 160g / m with flow coater²(80 g / m²× 2 times coating), 200 g / m in total²It was applied and then dried and cured at 80 ° C. for 5 minutes to form an undercoat layer.
  Subsequently, a silicon oil emulsion [pattern forming agent WO manufactured by DIC Color Coaching Co., Ltd.] is used as a repellent on the undercoat layer whose surface temperature is adjusted to 60 ° C., Using pattern rollIt was applied by a flexographic printing method and dried at a preheating temperature to form a repellent layer.
  Subsequently, the surface temperature was adjusted to 60 ° C.,Acrylic urethane-based paint containing 220% by weight of scaly pearl pigment having an average particle size of 50 μm as a decorative layer-forming paint over the entire surface of the undercoat layer on which the repellent layer is formed [220 Konitan, manufactured by DIC Color Coaching Co., Ltd. Topcoat Brighton Silver] with a roll coater 50g / m²After applying and repelling the paint for forming the decorative layer on the repellent layer, the coating layer is dried at 80 ° C. for 20 minutes and cured to form a decorative layer.andA ceramic decorative board of the present invention having a pattern was obtained.
  About the obtained ceramics decorative board, in visual appearance observationMasturbationEvaluation of the unevenness and the stability of the handle and the measurement of the coating film hardness were performed.
[0037]
  Example 2
  On the surface of the ceramic decorative board obtained in Example 1 (with the decorative layer formed by drying at 80 ° C. for 20 minutes), an ultraviolet curable resin paint having a total light transmittance of 89% as a transparent paint [D Icy Color Coaching Co., Ltd. 700 Violet Clear 509H] with a flow coater at 100 g / m²Apply and set for 5 minutes in a 40 ° C atmosphere, then move at 6 m / min, and cure by irradiating with UV rays under the condition of 80 W / cm x 2 lamps and transparent top clear on the repellent layer and makeup layer A layer was formed.
  About the obtained ceramics decorative board, by visual observationPatternEvaluation of the unevenness and the stability of the handle and measurement of coating film hardness were performed.
[0038]
  Example 3
  As a paint for decorative layer formationInstead of pearl pigmentAn acrylic urethane paint containing 5% by weight of a color pigment is applied with a roll coater at 50 g / m.²Example 1 except that it was applied to form a decorative layerSimilar operationWas repeated.
  About the obtained ceramics decorative board, in visual appearance observationMasturbationEvaluation of the unevenness and the stability of the handle and the measurement of the coating film hardness were performed.
[0039]
  Example 4
  The surface of an uncured fiber reinforced cement board (910 mm × 1820 mm × thickness 5 mm) manufactured by the paper making method is pressed against the uneven surface of the FRP template having unevenness, and then pressed at 80 ° C. for 8 hours. By performing steam curing for a period of time, it was cured by reaction, and after removing the template, it was dried to prepare a ceramics-type decorative substrate having an uneven part with a depth of 80 μm from the convex part to the concave part.
  Next, the surface temperature of the substrate is adjusted in advance to 60 ° C., and an acrylic urethane-based paint (220 Conitan undercoat manufactured by DIC Color Coaching Co., Ltd.) is used as an undercoat on the roll coater.², 160g / m with flow coater²(80 g / m²× 2 times coating), 200 g / m in total²It was applied and then dried and cured at 80 ° C. for 5 minutes to form an undercoat layer.
  Subsequently, a silicon oil emulsion [pattern forming agent WO manufactured by DIC Color Coaching Co., Ltd.] is used as a repellent on the undercoat layer whose surface temperature is adjusted to 60 ° C., Using pattern rollIt was applied by a flexographic printing method and dried at a preheating temperature to form a repellent layer.
  Subsequently, an acrylic urethane ultraviolet ray containing 4% by mass of a scale-like pearl pigment having an average particle diameter of 100 μm as a decorative layer-forming coating material on the entire surface of the undercoat layer on which the repellent layer having a surface temperature adjusted to 60 ° C. is formed. 50 g / m of curable paint [700 Bioren Brighton Silver manufactured by DIC Color Coaching Co., Ltd.] with a roll coater²After applying and repelling the paint for forming the decorative layer on the repellent layer, it is irradiated with ultraviolet rays under the conditions of 120 W x 2 lights and a line speed of 6 m / min, cured, and a decorative layer is formed to form a predetermined pattern.andI got a pattern.
  Subsequently, an ultraviolet curable resin having a total light transmittance of 89% [700 Bioren Clear 509H manufactured by DIC Color Coaching Co., Ltd.] as a top clear layer at a flow coater of 100 g / m.²Apply and set for 5 minutes in an atmosphere of 40 ° C, then move at 6m / min, irradiate with UV light under the condition of 80W / cm x 2 lamps and cure to make a transparent top on the repellent layer and decorative layer A clear layer was formed to obtain the ceramics decorative board of the present invention.
  About the obtained ceramics decorative board, in visual appearance observationMasturbationEvaluation of the unevenness and the stability of the handle and the measurement of the coating film hardness were performed.
[0040]
  Comparative Example 1
  After pressurizing uncured fiber reinforced cement board (910mm x 1820mm x thickness 5mm) manufactured by papermaking method, reaction curing is performed by steam curing at 80 ° C for 8 hours to produce a flat ceramics decorative board did. Thereafter, a comparative ceramics decorative board was obtained by the same operation as in Example 1.
  About the obtained ceramics decorative board, by visual observationPatternEvaluation of the unevenness and the stability of the handle and measurement of coating film hardness were performed.
[0041]
  Comparative Example 2
  In Comparative Example 1, when applying the paint for forming the decorative layerThe repellent layer was formedThe surface temperature of the undercoat layer is 85 ° CAdjust toComparative Example 1 except thatSame operation asWas repeated.
  About the obtained ceramics decorative board, by visual observationPatternEvaluation of the unevenness and the stability of the handle and measurement of coating film hardness were performed.
[0042]
  Comparative Example 3
  In Comparative Example 1, when applying the paint for forming the decorative layerThe repellent layer was formedThe surface temperature of the undercoat layer is 30 ° CAdjust toComparative Example 1 except thatSame operation asWas repeated.
  About the obtained ceramics decorative board, by visual observationPatternEvaluation of the unevenness and the stability of the handle and measurement of coating film hardness were performed.
[0043]
[Table 1]

[0044]
  In the table, ◎ is very good, ○ is a slight defect as a result of visual observation by a skilled engineer, but there is no problem as a product. , X indicates that obvious defects were observed. The coating film hardness is a result of measurement according to JIS K 5600 pencil scratch value (mechanical method).
[0045]
【The invention's effect】
  According to the present invention,An undercoat layer is formed on the surface of a ceramic-type decorative substrate that has been previously provided with an uneven pattern with a depth from the convex part to the concave part in the range of 80 μm to 300 μm, and a repellent is applied on the undercoat layer using a pattern roll. After forming a repellent layer having a predetermined pattern by drying and adjusting the surface temperature to 40 to 80 ° C., a decorative layer forming paint is applied to the entire surface of the undercoat layer on which the repellent layer is formed. , By forming the predetermined pattern and pattern by repelling the paint for forming the decorative layer on the repellent layer, and forming the decorative layer by curing, the decorative layer has excellent reproducibility of the predetermined pattern and pattern It can be freely patterned. In addition, the decorative layer is formed as a non-uniform layer along the unevenness of the ceramics-type decorative substrate, and its leveling property is hindered, and an uneven pattern is formed on the surface of the coating film. The pigment distribution in the coating Change direction or dispersion density,It is possible to provide a method for producing a ceramic-based decorative board excellent in design properties, in particular, brilliant feeling, three-dimensional feeling, shadow feeling, and depth feeling.

Claims (2)

An undercoat layer is formed by applying an undercoat paint on the surface of a ceramic-type decorative substrate that has been previously provided with a concavo-convex pattern in the range of 80 μm to 300 μm in depth from the convex portion to the concave portion by embossing on the surface. Then, a repellent layer having a predetermined pattern is formed on the undercoat layer by applying a repellent using a pattern roll and drying, and after the surface temperature is adjusted to 40 to 80 ° C., the repellent layer is A decorative layer-forming paint is applied to the entire surface of the formed undercoat layer, and the decorative layer-forming paint on the repellent layer is repelled to form a predetermined pattern and pattern, followed by curing to form a decorative layer. The manufacturing method of the ceramics type decorative board characterized by the above-mentioned. 2. The ceramic industry according to claim 1, wherein a transparent or translucent paint is applied on the repellent layer and the decorative layer or on the decorative layer, and the paint is cured to form a transparent or translucent top clear layer. Of manufacturing decorative decorative board.