JP4227747B2 - Interior board and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a board for interior that has been subjected to exposed concrete design and a method for producing the board.
[0002]
[Prior art]
In recent years, exposed concrete designs have been adopted for the frame surfaces of many buildings because they enhance the natural beauty of the materials and the design of heavy buildings. The cast-in concrete design is a design formed on the concrete surface in a state where concrete is placed in a mold and demolded after drying, but when concrete is actually placed on site, There is a disadvantage that the construction period is prolonged due to the relationship of securing the drying time and the cost is increased. In particular, when a concrete design is applied to the interior of a building, there is a problem that the drying process is further prolonged and the interior is soiled with concrete.
[0003]
Therefore, conventionally, a construction method has been proposed in which a concrete design is applied to the surface of an interior board in advance, transported to the site, and fixedly installed at a predetermined installation position. As the previously proposed method, for example, the one disclosed in Japanese Patent Laid-Open No. 2000-128665 can be cited.
[0004]
According to the publication, a permeable water absorption preventive material is applied to the entire surface of the interior board in which a recess resembling a tree root hole is formed, and a cement-based synthetic resin emulsion is applied thereon, and further from above The formwork pattern was created with the formwork pattern creation tool. Such a cement-based synthetic resin emulsion is obtained by mixing cement and pigment with a synthetic resin emulsion such as an acrylic copolymer resin and spraying the obtained concrete-colored coating agent on the interior board surface. It was.
[0005]
[Problems to be solved by the invention]
However, in the conventional method for manufacturing an interior board, there are many steps in the manufacturing process such as application of a permeable water absorption preventing material, application of a cement-based synthetic resin emulsion, and formation of a formwork pattern using a formwork pattern forming tool. There was a problem that the cost increased. In addition, since the coating material containing cement is applied to the interior board surface, there is a possibility that some white phenomenon may occur although it is not as much as that used for the exterior.
[0006]
This invention is made | formed in view of such a situation, and while being able to reduce the manufacturing cost by reducing the process in a manufacture process, it is providing the board for interiors which does not use cement, and its manufacturing method.
[0007]
[Means for Solving the Problems]
The invention according to claim 1 is a method for manufacturing an interior board in which a concrete design is applied to the surface of the interior board before installation and fixing at the installation location, and the surface of the interior board made of calcium silicate. A recess forming step for forming a recess for a tree root hole, and a waterproof property in which a pigment of a predetermined color is mixed into a substantially concrete color to the entire interior board surface in which the recess is formed in the recess forming step . And a coating step of coating a non- synthetic resin emulsion.
[0008]
According to such a configuration, when the synthetic resin emulsion is applied to the interior board surface made of calcium silicate in the coating process, the synthetic resin emulsion has a significant water absorption effect at a predetermined site, and does not generate a great water absorption effect at other sites. Color unevenness based on such non-uniformity occurs, and the coating unevenness is released and approximates to a concrete design.
[0009]
In the invention according to claim 2, after the coating step, a mask plate provided with a through hole having substantially the same diameter as the concave portion at a position corresponding to the concave portion for the tree root hole is matched with the surface of the interior board. The synthetic resin emulsion is applied to the bottom and side surfaces of the recess by applying a synthetic resin emulsion mixed with a pigment of a concrete color darker than the color of the coating film formed in the coating step from the upper surface. To do.
[0010]
The invention described in claim 3 is characterized in that, in the final step, a top coat is applied to the entire surface of the interior board.
[0011]
According to a fourth aspect of the present invention , a non-waterproof synthetic resin emulsion synthesized with a substantially concrete color by applying a predetermined color pigment is applied to the entire interior board surface where the recesses are formed in the recess forming step. immediately after the coating step of, characterized by repeated pressing of the surface of the board for the interior at the mold pattern Construction equipment.
[0012]
A fifth aspect of the present invention is an interior board manufactured by the manufacturing method according to the first to fourth aspects.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
The interior board according to the present embodiment is provided with a concave portion approximated to a tree root hole and an exposed concrete design on the surface of the calcium silicate plate, and is pre-manufactured in a factory or the like before being installed and fixed at an installation location of a building. Is. Hereinafter, the manufacturing process of such an interior board will be described.
[0014]
First, a calcium silicate compression-molded into a rectangular plate shape as shown in FIG. 1 is prepared. While positioning and fixing the calcium silicate plate 1, a cutting tool such as a router is used for FIG. A recess 1b for a tree root hole as shown in FIG. The concave portion 1b is formed of a bottomed cylindrical hole having a bottom surface 1ba and a side surface 1bb, and a plurality of (two in the present embodiment) are formed at a predetermined distance.
[0015]
The concave portion 1b is approximated to a tree root hole formed on the actual exposed concrete surface, and constitutes a part of the exposed concrete design. In this embodiment, the concave portion 1b is formed by a cutting tool such as a router. However, other methods (for example, when a calcium silicate plate is compression-molded, a convex shape is formed on one of the compression molds. In addition, a method of transferring the convex shape to form a concave portion may be used.
[0016]
After the recess forming step, the surface 1a is placed on the processing table with the surface 1a facing upward, and the coating material synthesized in a substantially concrete color is sprayed and applied to the entire surface 1a (application step). At this time, the coating material is also applied to the concave portion 1b obtained in the concave portion forming step, and the coating film a is formed on the entire surface 1a of the calcium silicate plate 1 as shown in FIG.
[0017]
Such a coating material is composed of a synthetic resin emulsion of an acrylic copolymer resin or acrylic / styrene copolymer resin mixed with a predetermined color pigment and synthesized into a substantially concrete color. In general, synthetic resin emulsions are roughly classified into waterproof ones and non-waterproof ones (adhesive ones). In this embodiment , synthetic resin emulsions that are not waterproof are used.
[0018]
Further, pigments to be mixed with the synthetic resin emulsion to be applied in the coating step, concrete and it is preferred to use inorganic pigments or organic pigments tinged substantially the same color, coloring material tinged concrete and substantially the same color (Gray amorphous material such as silica fume) may be used.
[0019]
When the coating material is applied onto the calcium silicate plate 1, color unevenness based on non-uniformity occurs such that the coating material has a significant water absorption effect at a predetermined site and a little water absorption effect at other sites. Since this color unevenness approximates the exposed concrete design, it is not necessary to perform a separate concrete design.
[0020]
That is, in general, a permeable water absorption preventive material is applied to the surface of a plate material in advance, and after the permeable water absorption preventive material is dried, a coating material of a desired color is applied so as not to cause color unevenness. On the other hand, in the present invention, the coating material is applied without applying such a permeable water absorption preventing material, and color unevenness is positively generated.
[0021]
In particular, the calcium silicate plate 1 has a property that the water absorption is remarkably non-uniform, and by spraying the coating material, the dark portion and the thin portion are mixed together in a mottled manner and approximated to the concrete surface. A design is obtained. In the present embodiment, the coating material is sprayed and applied in consideration of productivity, but the coating material may be applied by a brush or a roller.
[0022]
It is preferable that correction work is appropriately performed at a portion where the exposed concrete design cannot be satisfactorily obtained (such as around the recess 1b where it is difficult to obtain desired color unevenness). This correction work is performed by repeatedly pressing the surface of the calcium silicate plate 1 with a formwork pattern forming tool, and may not be performed if not necessary.
[0023]
The formwork pattern forming tool used here is made of a felt that can be impregnated with a coating material while having elasticity, and the formwork pattern forming tool is repeatedly pressed against a portion of the calcium silicate plate 1 to be corrected. you. Thereby, the said correction | amendment site | part can be blurred and a natural finish can be obtained.
[0024]
After the coating material is dried, as shown in FIG. 5, the mask plate 2 provided with through holes 2 a having substantially the same diameter as the concave portions 1 b is formed on the calcium silicate plate 1. Match to surface 1a. Thereafter, as shown in FIG. 6, a synthetic resin emulsion mixed with a pigment of a predetermined color is sprayed and applied from the upper surface of the mask plate 2.
[0025]
As such a synthetic resin emulsion, an acrylic copolymer resin-based mixture of an inorganic pigment mainly composed of Fe3O4 is used. As an example of this synthetic resin emulsion, NY-7000 (trade name of Nichie Yoshida Co., Ltd.) is used. Examples of pigments include Biferox (trade name of Bayer Co., Ltd.). The color to be colored here is preferably a concrete color that is darker than the color of the coating film a formed in the coating step.
[0026]
By such spray coating, as shown in FIG. 7, the coating film b is formed on the bottom surface 1ba and the side surface 1bb of the recess 1b, and the exposed concrete design is made more realistic, while the coating film b is surrounded by can be prevented from being scattered, it is possible to obtain a reliable good Uchihanashi concrete design looking. Note that the color of the coating film b may be substantially the same as the color of concrete as described above, or may be another color (such as a primary color of red or yellow).
[0027]
After the mask plate 2 is removed from the surface 1a of the calcium silicate plate 1 and the coating film b is dried, a top coat is applied to the entire upper surface to form a top coat film c (see FIG. 8). Such a top coat is composed of a silicone resin-based transparent synthetic resin emulsion having excellent antifouling properties. One example is NY-7090 (trade name of Nichie Yoshida Co., Ltd.). Thus, since the top coat film c by the top coat having excellent antifouling properties is formed so as to cover the paint film a and the paint film b, the concrete design may be soiled even if a person or an object touches the interior board. Peeling can be avoided, the durability of the interior board can be improved, and the life can be extended.
[0028]
As described above, the interior board with the exposed concrete design is manufactured. The interior board manufactured through the above steps is transported to the building site, and is installed and fixed to an installation location such as a wall surface using an adhesive or a hidden screw. At that time, if the shape of the installation location is different from the shape of the calcium silicate plate 1, it is cut into a shape corresponding to the installation location with a saw or the like and then fixed.
[0029]
According to the above-described embodiment, the surface of the interior board that has been installed and fixed has already been exposed to the concrete design, so that the work of applying the design at the site is unnecessary. That is, since the concrete design can be applied in advance at a factory or the like, it is excellent in productivity, can be mass-produced, and the manufacturing cost can be reduced.
[0030]
Further, since the coating material is sprayed and applied in the coating process, it can be quickly applied to the surface to be coated, and a desired pattern can be easily formed by spraying. Moreover, since the exposed concrete design is naturally formed due to the properties of the calcium silicate plate, the step of applying the design is not required, and the manufacturing cost can be reduced.
[0031]
Although the present embodiment has been described above, the present invention is not limited to this. For example, the top board may not be applied and only the coating films a and b may be formed on the surface. Here, the term “for interior use” generally refers to what is installed and fixed in the interior of a building, but in this specification, it also includes exteriors such as eaves that are not exposed to rain.
[0032]
【The invention's effect】
According to the first aspect of the present invention, if the synthetic resin emulsion is applied to the interior board surface made of calcium silicate, the color unevenness that is naturally released and approximates the concrete design is generated, so the permeable water absorption inhibitor is applied in advance. There is no need, and the manufacturing cost can be reduced by reducing the steps in the manufacturing process of the interior board. Furthermore, since a coating material containing cement is not used, it is possible to avoid the occurrence of white flower phenomenon.
[0033]
According to the invention of claim 2, by making the mask plate coincide with the interior board surface, only the concave portion for the tree hole in the interior board is faced upward, and the synthetic resin emulsion is applied to the bottom and side surfaces thereof. Therefore, it is possible to prevent the synthetic resin emulsion from scattering and adhering to other surfaces, and it is possible to produce an interior board with a concrete design that is surely and beautifully released.
[0034]
According to the invention of claim 3, since the top coat is applied to the entire surface of the interior board that has undergone the coating process, even if a person or an object touches the interior board, the concrete design is soiled or peeled off. The durability of the interior board can be improved, and the life can be extended.
[0035]
According to the invention of claim 4, immediately after the coating step, the surface of the interior board is repeatedly pressed by the formwork pattern forming tool, so that even if the desired exposed concrete design is not obtained in the coating step, it is ensured. The design can be applied.
[0036]
According to the invention of claim 5, it is possible to obtain an interior board that is very close to the design of the actual exposed concrete surface.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a calcium silicate plate as a material plate applied to an interior board according to an embodiment of the present invention. FIG. 2 is a state in which a recess is formed in the interior board according to the embodiment of the present invention. FIG. 3 is a perspective view showing the same. FIG. 4 is a perspective view showing the state in which a coating film a is formed on the surface of the interior board according to the embodiment of the present invention. FIG. 6 is a perspective view showing a state in which the mask board is matched with the interior board according to the embodiment of the present invention. FIG. 7 is a perspective view according to the embodiment of the present invention. FIG. 8 is a schematic cross-sectional view showing a state in which coating films a and b are formed on the surface of the interior board. FIG. 8 shows coating films a and b and a top coat film c formed on the surface of the interior board according to the embodiment of the present invention. Schematic cross-sectional view showing the state
1 ... Calcium silicate board (board for interior)
DESCRIPTION OF SYMBOLS 1a ... Surface 1b (of a calcium silicate board) ... Recessed part 1ba (for tree root hole) ... Bottom face 1bb ... Side face 2 ... Mask plate 2a ... Through-hole a ... Coating film b formed in the application process ... (Formed) coating film c ... top coat film

Claims (5)

It is a manufacturing method of an interior board that is exposed to the surface of the interior board before being installed and fixed at the installation location, and is given a concrete design,
A recess forming step for forming a recess for a tree root hole on the surface of the interior board made of calcium silicate;
An application step of applying a non-waterproof synthetic resin emulsion mixed with a predetermined color pigment to the whole interior board surface in which the recesses are formed in the recess formation step;
A method for manufacturing an interior board, comprising:   After the coating step, a mask plate provided with a through-hole having substantially the same diameter as the concave portion at a position corresponding to the concave portion for the tree root hole is matched with the surface of the interior board, and formed from the upper surface in the coating step. 2. The interior resin composition according to claim 1, wherein the synthetic resin emulsion is applied to the bottom and side surfaces of the recess by applying a synthetic resin emulsion mixed with a pigment of a concrete color darker than the color of the coated film. Board manufacturing method.   The method for manufacturing an interior board according to claim 1 or 2, wherein a top coat is applied to the entire surface of the interior board in the final step. Immediately after the application step of applying a non-waterproof synthetic resin emulsion mixed with a predetermined color pigment to the entire interior board surface where the recesses are formed in the recess formation step , The method for manufacturing an interior board according to any one of claims 1 to 3, wherein the surface of the interior board is repeatedly pressed by a formwork pattern forming tool.   An interior board manufactured by the manufacturing method according to claim 1.

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