JP4413601B2 - Building board manufacturing method - Google Patents

Description

  The present invention relates to a building board to be constructed as an outer wall or the like of a building, and more particularly to a method of manufacturing a building board by painting a design surface on which an uneven pattern is formed.

In building boards that are mass-produced for construction as building outer walls, etc., in order to avoid a monotonous finish, the design surface unevenness pattern of the building board, the way of painting this design surface, etc. are made .
For example, Patent Document 1 manufactures a decorative board rich in three-dimensionality by extracting abundant shade differences and color tone changes. In Patent Document 1, first, an undercoat paint layer is provided on the entire surface of a substrate that is formed between a plurality of concave grooves and has a trapezoidal portion having a large number of irregularities on the surface. Then, the surface of the undercoat paint layer is rubbed onto the surface of the undercoat paint layer with a roller or the like to apply a different color to the undercoat paint layer, and a thin topcoat paint layer is formed on the uneven surface of the trapezoidal surface. Alternatively, the undercoat paint layer is exposed, while the concave surface is formed with an overcoat paint layer that gradually increases in thickness toward the bottom.

Moreover, in patent document 2, it has on the design surface of a building board the flat part and the pattern recessed part which depressed and formed from this flat part, By making the color tone of the said flat convex part and the said pattern recessed part differ from each other The design surface forms a building board with a natural appearance.
Moreover, in patent document 3, the uneven | corrugated pattern which exhibits a woodgrain tone is formed in the design surface of a building board, and the design surface exhibits a three-dimensional external appearance by making the color of the convex part and the recessed part in this uneven pattern differ. Forms a building board.

However, in the said patent documents 1-3, the device which manufactures the multiple types of decorative board or building board from which the color appearance in the design surface differs mutually is not made | formed. That is, in patent documents 1-3, it will paint on the same conditions with respect to any decorative board or building board, and the same kind of decorative board or architectural board will be mass-produced.
In general, in order to manufacture a plurality of types of building boards, a method of changing the uneven pattern on the design surface of the original plate or applying a different paint on the design surface of the original plate is used. However, if such a method is used, the manufacturing method of a building board will become complicated.

Japanese Patent Publication No.58-34186 Japanese Patent No. 3413719 Japanese Patent Laid-Open No. 10-317631

  The present invention has been made in view of such conventional problems, and is applied to a plurality of original plates having the same uneven pattern on the design surface by a simple method, while applying the same upper paint on the design surface. An object of the present invention is to provide a method capable of producing a plurality of types of building boards having different color appearances.

1st invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer on the original plate, and a removing step for adhering and removing the upper paint on the plurality of convex portions is performed, and A method of manufacturing a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer,
In the removal step, a plurality of types of the removal rolls having different roll surface hardnesses are prepared, and when the upper coating material is adhered and removed, the upper coating layer on the original plate is out of the plurality of removal rolls. In the method of manufacturing a building board, the above-mentioned upper paint on the design surface of each original board is adhered and removed as much as the original board in contact with the removal roll having a low hardness on the roll surface by contacting at least one ( Claim 1).

In the method for producing a building board of the present invention, in the preparation step, a plurality of convex portions are formed on the design surface of the original plate, and then the lower coating layer is formed in the lower coating layer forming step, and then the upper side is formed. In the paint layer forming step, the upper paint layer is formed.
Next, in the removal step, a plurality of types of removal rolls having different roll surface hardnesses are used, and the removal rolls brought into contact with the upper coating layer before drying on the design surface of each original plate are appropriately changed.

  That is, in this removal step, a removal roll that carries an original plate is selected from a plurality of removal rolls according to the color appearance to be formed on the design surface, and each original plate has a roll surface with various hardnesses. It is carried into the roll. And when the roll surface of a removal roll leaves | separates from the design surface of a negative | original plate, compared with a removal roll whose hardness of a roll surface is high, an upper coating tends to adhere to a removal roll whose hardness of a roll surface is lower than this. Become.

For this reason, a larger amount of the upper coating material on the design surface is adhered and removed from the original plate in contact with the removal roll having a lower roll surface hardness than that of the removal roll compared to the original plate in contact with the removal roll having a higher roll surface hardness.
In this way, the upper side coating on the design surface of each original plate is more adhered and removed as the original plate is in contact with the removal roll whose hardness on the roll surface is lower, and the original design surface of the original plate is as the original plate in contact with the removal roll whose hardness on the roll surface is lower The overall average thickness of the upper paint layer is reduced.

And when the upper paint layer on the design surface of the original plate is dried to produce a building board, a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer formed on the design surface are produced. Can do.
Therefore, according to the method for manufacturing a building board of the present invention, a plurality of concavo-convex patterns by a plurality of convex portions on the design surface are the same by a simple method using a plurality of types of removal rolls having different hardnesses on the roll surface. A plurality of types of building boards having different color appearances on the design surface can be produced while applying the same upper paint to the original plate.

2nd invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer on the original plate, and a removing step for adhering and removing the upper paint on the plurality of convex portions is performed, and A method of manufacturing a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer,
In the removing step, when the original plate is carried into the removing roll, a gap amount formed between the removing roll and a backup roll disposed so as to face the original roll is formed on the original plate. In the method for manufacturing a building board, the upper coating material on the design surface of each original plate is adhered and removed as the gap amount in the removal roll is reduced by making the difference depending on the appearance. ).

Also in the manufacturing method of the building board of the present invention, in the preparation step, a plurality of convex portions are formed on the design surface of the original plate, and then the lower coating layer is formed in the lower coating layer forming step, and then the upper side is formed. In the paint layer forming step, the upper paint layer is formed.
Next, in the removal step, a removal roll capable of changing the gap amount between the backup rolls or a plurality of types of removal rolls having different gap amounts between the backup rolls and the design surface of the original plate is used. The upper paint before drying applied to the plurality of convex portions is adhered and removed.

  That is, in this removal step, when the original plate is carried into the removal roll, the gap amount in the removal roll is made different from that when another original plate is carried in. And the said removal roll becomes easy to contact with respect to the upper side coating layer in the design surface of an original plate, when the said gap | interval amount is smaller than this compared with the case where the said gap | interval amount is large.

Therefore, compared to the original plate that contacts the removal roll in a state where the gap amount is large, the upper surface coating on the design surface adheres more from the original plate that comes into contact with the removal roll in the state where the gap amount is smaller than the removal roll in this state. Removed.
In this way, the upper coating material on the design surface of each original plate is more adhered and removed as the gap amount is reduced, and the upper plate layer on the entire design surface of the original plate is closer to the original plate in contact with the removal roll in a state where the gap amount is smaller. Is formed with a small average thickness.

And when the upper paint layer on the design surface of the original plate is dried to produce a building board, a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer formed on the design surface are produced. Can do.
Therefore, also by the manufacturing method of the building board of the present invention, the uneven pattern by the plurality of convex portions on the design surface is the same by a simple method of varying the gap amount between the removal roll and the backup roll. A plurality of types of building boards with different color appearances on the design surface can be produced while applying the same upper paint to a plurality of original plates.

3rd invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer on the original plate, and a removing step for adhering and removing the upper paint on the plurality of convex portions is performed, and A method of manufacturing a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer,
In the removal step, the design of each original plate is made by varying the degree of drying of the upper paint on the design surface of the original plate when contacting the removal roll according to the color appearance to be formed on the original plate. In the method for manufacturing a building board, the upper coating material on the surface is adhered and removed more as the original plate having a lower degree of dryness (claim 3).

Also in the manufacturing method of the building board of the present invention, in the preparation step, a plurality of convex portions are formed on the design surface of the original plate, and then the lower coating layer is formed in the lower coating layer forming step, and then the upper side is formed. In the paint layer forming step, the upper paint layer is formed.
Next, in the removing step, the removing roll is brought into contact with the upper paint layer before the upper paint in the upper paint layer is dried. At this time, in the present invention, the degree of drying of the upper coating material on the design surface of each original plate is varied according to the color appearance to be formed on each original plate.

Then, when the roll surface of the removal roll is separated from the design surface of the original plate, the removal roll has an upper side from the original plate having a lower degree of drying of the upper coating than the original plate having a higher degree of drying of the upper coating. It becomes easy for paint to adhere. For this reason, a larger amount of the upper paint on the design surface is attached and removed from the original plate having a lower degree of drying than the original plate, compared to the original plate having a higher degree of drying of the upper paint in the upper paint layer.
In this way, the upper paint on the design surface of each original plate is more adhered and removed as the original plate having a lower degree of drying of the upper paint, and the original plate having a lower degree of dryness of the upper paint has an average of the upper paint layer on the entire design surface of the original plate. The thickness is small.

Then, when the building board is manufactured by almost completely drying the upper paint layer on the design surface of the original plate, a plurality of types of building boards having different color appearances by the lower paint layer and the upper paint layer formed on the design surface are used. Can be manufactured.
Therefore, even by the method for manufacturing a building board of the present invention, the uneven pattern formed by a plurality of convex portions on the design surface can be obtained by a simple method of varying the degree of drying of the upper paint in the upper paint layer formed on the design surface of the original plate. A plurality of types of building boards having different color appearances on the design surface can be produced while applying the same upper paint to a plurality of original plates having the same.

  The degree of dryness refers to the degree of volatilization of the solvent in the upper paint, and the low degree of dryness refers to a state in which the solvent in the upper paint is not so volatilized, and the degree of dryness is large. Means that most of the solvent in the upper coating is volatilized.

4th invention prepares the original plate which has the design surface formed by forming a plurality of convex parts, and,
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer on the original plate, and a removing step for adhering and removing the upper paint on the plurality of convex portions is performed, and A method of manufacturing a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer,
In the removing step, the speed difference between the peripheral speed of the removing roll and the speed at which the original plate is carried into the removing roll is made different depending on the color appearance to be formed on the original plate, whereby the speed is increased. In the method for manufacturing a building board, the larger the difference, the greater the degree of bleeding of the upper paint layer.

Also in the manufacturing method of the building board of the present invention, in the preparation step, a plurality of convex portions are formed on the design surface of the original plate, and then the lower coating layer is formed in the lower coating layer forming step, and then the upper side is formed. In the paint layer forming step, the upper paint layer is formed.
Subsequently, in the said removal process, the upper coating material before drying apply | coated to the some convex part in the design surface of a negative | original plate is adhered and removed using a removal roll.

  That is, in this removal process, when the original plate is carried into the removal roll, the speed difference is made different from that when another original plate is carried. And when the said speed difference is larger than this, the said removal roll comes to slide a lot on the design surface of an original plate compared with the case where the said speed difference is small.

Therefore, compared to the original plate that contacts the removal roll in a state where the speed difference is small, the original plate that contacts the removal roll in a state where the speed difference is larger than the removal roll in this state is the upper side of the upper paint layer on the design surface. A large amount of paint is stretched on the surface of the lower paint layer, and the degree of bleeding of the upper paint layer increases.
As described above, the upper paint on the design surface of each original plate is stretched more on the surface of the lower paint layer as the speed difference is increased, and the higher the speed difference is, the more the upper paint layer blurs on the design surface of the original plate. The degree increases.

And when the upper paint layer on the design surface of the original plate is dried to produce a building board, a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer formed on the design surface are produced. Can do.
Therefore, even with the method for manufacturing a building board of the present invention, the same upper coating material is applied to a plurality of original plates having the same concavo-convex pattern due to a plurality of convex portions on the design surface by a simple method of differentiating the speed difference. It is possible to manufacture a plurality of types of building boards having different color appearances on the design surface.

  The blur in the present invention refers to a state in which the upper paint in the upper paint layer is stretched and applied in the surface direction of the design surface of the original plate, and the degree of blur is the degree to which the upper paint is stretched. That means. And a low degree of bleeding means a state where the upper coating is not stretched so much, and a large degree of bleeding means a state where most of the upper coating is stretched.

A preferred embodiment of the above-described method for manufacturing a building board of the present invention will be described.
In the first to fourth inventions, the color difference of the upper paint can be formed by varying at least one of hue, lightness, and saturation, which are so-called three attributes of color.
Further, at least two of the first to fourth inventions can be applied in combination. In this case, it is possible to easily manufacture more types of building boards having different color appearances on the design surface.

In the first to fourth aspects of the invention, the removing roll is preferably formed by coating a surface of a sponge core layer made of a sponge material with a rubber surface layer made of a rubber material.
In this case, in the removing step, by elastically deforming the sponge core layer, the removing roll can be more flexibly brought into contact with the upper paint layer formed on the design surface of the original plate, and the rubber surface layer Thus, the upper paint can be more easily attached and removed.

The sponge material refers to a material obtained by blending a foam material with various rubbers, synthetic resins, and the like and foam-molded. The material has lower hardness and lower resilience than the rubber material. The rubber material refers to those molded from various rubbers.
The rubber hardness of the rubber material is preferably 30 to 70 degrees. When the rubber hardness is less than 30 degrees, the roll surface of the removal roll is too soft, and the wear deterioration of the removal roll is accelerated, and the amount of the upper paint on the design surface of the building board is adhered and removed. (Proportion) becomes too large, and it becomes difficult to form a color change on the design surface of the building board. On the other hand, when the rubber hardness exceeds 70 degrees, the roll surface of the removal roll is too hard to make it difficult to adhere and remove the upper paint.

Below, the Example concerning the manufacturing method of the building board of this invention is described using drawing.
Example 1
The manufacturing method of the building board 1 of this example repeats the following preparatory processes, a lower coating layer formation process, an upper coating layer formation process, and a removal process with respect to the some original plate 2, as shown in FIGS. Thus, a plurality of types of building boards 1 having different color appearances on the design surface 101 are manufactured.
That is, as shown in FIG. 1, in the preparation step, an original plate 2 having a design surface 201 in which a concavo-convex pattern 203 is formed by a plurality of convex portions 21 is prepared.

  Next, as shown in FIG. 2, in the lower coating layer forming step, the lower coating layer 4 is formed by applying the lower coating 40 to the design surface 201 of the original plate 2 and drying it. Next, in the upper paint layer forming step, the upper paint layer 5 is formed by applying an upper paint 50 having a color different from that of the lower paint 40 to the surface of the lower paint layer 4.

  Thereafter, as shown in FIG. 3 to FIG. 8, in the removing step, before the upper paint 50 is dried, the removal roll 7 for adhering and removing the upper paint 50 is brought into contact with the upper paint layer 5, so The upper coating material 50 on the convex portion 21 is adhered and removed. And the several types of building board 1 from which the color appearance by the lower side paint layer 4 and the upper side paint layer 5 in the design surface 101 mutually differs is manufactured.

Moreover, in a removal process, as shown in FIG.3, FIG.4, the multiple types (three types in this example) removal roll 7 from which the hardness of the roll surface 701 mutually differs is prepared. And in adhering and removing the said upper coating material 50, the upper coating material in the design surface 201 of each original plate 2 is brought into contact with the upper coating layer 5 in the original plate 2 by contacting at least one of the plurality of removal rolls 7. 50 is adhered and removed as the original plate 2 comes into contact with the removing roll 7 having a low hardness on the roll surface 701.
This will be described in detail below.

  As shown in FIG. 1 and FIG. 2, the manufacturing method of the building board 1 according to the present example forms a plurality of original plates 2 having the same shape in the preparation step, and in the lower coating layer forming step and the upper coating layer forming step, The lower coating layer 4 and the upper coating layer 5 are once formed on the original plate 2 under the same conditions. And in the said removal process, as shown in FIG. 3, by changing suitably the removal roll 7 which adheres and removes the upper side coating 50 in the upper side coating layer 5, the multiple types of building board 1 from which the color appearance in the design surface 101 differs is shown. To manufacture.

As shown in FIG. 1, the original plate 2 to be molded in the preparation step is a cement-based original plate 2 containing a cementitious material. And this cement-type original board 2 mixes woody raw material (wood fiber, wood chip, etc.), an additive, water, etc. with cementitious raw material (cement, silicic acid raw material, etc.), makes a mixed raw material, and this mixed raw material Is sprayed on the molding surface of the mold and dried and cured.
Further, the molding surface of the mold is formed in an uneven shape in order to mold the design surface 201 of the original plate 2. And the some convex part 21 can be formed in the design surface 201 of the original plate 2 shape | molded by the said shaping | molding die.
Moreover, the protrusion height H of each convex part 21, ie, the thickness from the back surface 202 of the original plate 2, to the design surface 201 is substantially the same.

As shown in FIG. 2, the lower coating 40 used in the lower coating layer forming step and the upper coating 50 used in the upper coating layer forming step all contain a resin, a pigment, various additives, water as a solvent, and the like. This is a water-based paint. In this example, the lower paint 40 and the upper paint 50 are different in lightness (lightness) as colors. In addition to this, for example, the lower paint 40 and the upper paint 50 may be paints having different saturations as colors.
And after performing the said lower side coating layer formation process and the upper side coating layer formation process, the whole design surface 201 of the original plate 2, ie, all the convex parts 21, and all formed between the convex parts 21 mutually. The lower paint layer 4 and the upper paint layer 5 are formed in the recess 22.

  As shown in FIGS. 3 and 4, three types of removal rolls 7 having different hardness on the roll surface 701 are used in the removal step. These removing rolls 7 come into contact with the upper coating layer 5 before drying on the design surface 201 of the original plate 2 to adhere and remove the upper coating 50. Each removal roll 7 is provided with a backup roll 75 that faces the back surface 202 of the original plate 2 and conveys the original plate 2 with the removal roll 7 sandwiched therebetween.

As shown in FIG. 4, each removing roll 7 is brought into contact with the upper paint layer 5 formed on the design surface 201 of the original plate 2 more flexibly and more easily attaches and removes the upper paint 50 in the upper paint layer 5. The surface of the sponge core layer 72 made of a sponge material is covered with a rubber surface layer 71 made of a rubber material.
The rubber material constituting the rubber surface layer 71 in each removal roll 7 is made of EPDM (ethylene propylene rubber), and the sponge material constituting the sponge core layer 72 in each removal roll 7 is made of butyl sponge rubber. Each removal roll 7 has an iron core 73 made of a metal material at the center of the sponge core layer 72.

  Further, as shown in FIG. 3, the three types (three) of the removal rolls 7 in this example have different hardnesses of the roll surface 701 by making the hardness of the rubber material used for the rubber surface layer 71 different. . Specifically, the first removal roll 7A has a rubber surface layer 71 with a rubber hardness of about 70 °, and the second removal roll 7B has a rubber surface layer 71 with a hardness of about 60 °, The third removal roll 7C has a rubber surface layer 71 having a hardness of about 50 °.

And in the said removal process as shown in FIGS. 3-5, before the upper coating material 50 in the upper side coating layer 5 of the said original plate 2 dries, the said original plate 2 is made between the removal roll 7 and the backup roll 75. FIG. To the gap 79.
At this time, among the three types of removal rolls 7, the removal roll 7 that carries the original plate 2 is selected according to the color appearance to be formed on the design surface 101, and the original plate 2 is carried into the selected removal roll 7. Is done. And when the roll surface 701 of the removal roll 7 leaves | separates from the design surface 201 of the original plate 2, compared with the removal roll 7 whose hardness of the roll surface 701 is high, it is the removal roll 7 whose hardness of the roll surface 701 is lower than this. The upper paint 50 tends to adhere.

Specifically, compared to the first removal roll 7A having the rubber surface layer 71 having a rubber hardness of 70 °, the second removal roll 7B having the rubber surface layer 71 having a rubber hardness of 60 ° includes: The upper paint 50 is likely to adhere, and the upper paint 50 is more likely to adhere to the third removal roll 7C having the rubber surface layer 71 having a rubber hardness of 50 ° as compared to the second removal roll 7B. .
Therefore, compared with the original plate 2 in contact with the removal roll 7 having a high hardness on the roll surface 701, the original plate 2 in contact with the removal roll 7 having a lower hardness on the roll surface 701 than the removal roll 7 has an upper side on the design surface 201. A lot of paint 50 is adhered and removed.

As described above, the upper coating 50 on the design surface 201 of each original plate 2 is more adhered and removed as the original plate 2 comes into contact with the removal roll 7 having a low hardness on the roll surface 701, and comes into contact with the removal roll 7 having a low hardness on the roll surface 701. The average thickness of the upper coating layer 5 on the entire design surface 201 of the original plate 2 is formed smaller as the original plate 2 is processed.
Thereafter, when the upper paint layer 5 on the design surface 201 of the original plate 2 is dried to produce the building board 1, a plurality of types in which the color appearances of the lower paint layer 4 and the upper paint layer 5 formed on the design surface 101 are different. The building board 1 can be manufactured.

  In the design surface 101 of the building board 1, the portion where the thickness of the upper paint layer 5 is small can exhibit an intermediate color that is neither the color of the upper paint layer 5 nor the color of the lower paint layer 4. . Therefore, the design surface 101 of the building board 1 is more easily visible through the surface of the upper paint layer 5 as the average thickness of the upper paint layer 5 on the entire design surface 101 is smaller. And the said intermediate color is visually recognized as the color close | similar to the color by the lower side paint layer 4 so that the design surface 101 of the building board 1 which has the upper side paint layer 5 with small thickness.

In this example, as shown in FIG. 6, the first building board 1 </ b> A from which a part of the upper coating material 50 is adhered and removed by the first removal roll 7 </ b> A has the smallest amount of adhesion removal of the upper coating material 50. The upper coating layer 5 on the entire design surface 201 is formed with the largest average thickness. Further, as shown in FIG. 8, the third building board 1C from which a part of the upper paint 50 is adhered and removed by the third removal roll 7C has the largest amount of adhesion removal of the upper paint 50, and the design of the original board 2 The upper paint layer 5 on the entire surface 201 is formed with the smallest average thickness.
Further, as shown in FIG. 7, the second building board 1B from which part of the upper paint 50 is adhered and removed by the second removal roll 7B is the average of the upper paint layer 5 on the entire design surface 201 of the original board 2. The thickness is smaller than the first building board 1A and larger than the third building board 1C.

  Therefore, according to the manufacturing method of the building board 1 of the present example, the uneven pattern formed by the plurality of convex portions 21 on the design surface 201 by a simple method using a plurality of types of removal rolls 7 having different hardnesses on the roll surface 701. A plurality of types of building boards 1 having different color appearances on the design surface 101 can be produced while applying the same upper coating 50 to a plurality of original plates 2 having the same 203.

Moreover, in this example, the removal roll 7 which carries in each original plate 2 was either one of the three types of removal rolls 7. On the other hand, the removal roll 7 which carries in each original plate 2 can also be made into any two or more of the multiple types of removal roll 7, for example.
Further, in this example, a plurality of types of removal rolls 7 are arranged in parallel with the carrying-in direction of the original plate 2, and the removal is carried into the original plate 2 according to the color appearance to be formed on the design surface 201 of the original plate 2. Roll 7 was selected. On the other hand, a plurality of types of removal rolls 7 are arranged in series with respect to the loading direction of the original plate 2, and the original plate out of the plurality of removal rolls 7 according to the color appearance to be formed on the design surface 201 of the original plate 2. The removal roll 7 to be brought into contact with the second design surface 201 can be selected, and the remaining removal roll 7 can be retracted so as not to contact the design surface 201 of the original plate 2. And by carrying in the original plate 2 in this state, the multiple types of building board 1 can be manufactured similarly to the above.

  As shown in FIGS. 9 and 10, the original plate 2 prepared in the preparation step may have a plurality of convex blocks 25 partitioned by vertical joint grooves 251 and lateral joint grooves 252 on the design surface 201. it can. Then, as the base paint layer forming step, the base paint 30 is applied to the entire design surface 201 of the original plate 2 and dried to form the base paint layer 3, and the lower paint layer forming step and the upper paint layer forming step are performed. The lower coating layer 4 and the upper coating layer 5 are formed on each of the convex blocks 25 except the vertical joint grooves 251 and the horizontal joint grooves 252, and then the upper coating 50 is removed using the removing roll 7 in the removing step. It is also possible to remove a part of the film. In this case, the color appearances of the convex blocks 25 having the color appearance of the lower paint layer 4 and the upper paint layer 5 and the joint grooves 251 and 252 can be made different.

(Example 2)
In this example, as shown in FIGS. 11 to 14, the color appearance on the design surface 101 is different while applying the same upper paint 50 to a plurality of original plates 2 having the same uneven pattern 203 on the design surface 201. When manufacturing a plurality of types of building board 1, in the removal step, a gap amount D formed between the removal roll 7 and the backup roll 75 disposed opposite thereto is formed on the design surface 201 of the original plate 2. This is an example that varies depending on the color appearance to be attempted.

In the manufacturing method of the building board 1 of this example, the preparation process, the lower paint layer forming process, and the upper paint layer forming process are performed in the same manner as in the first embodiment. The paint layer 4 and the upper paint layer 5 are formed.
In the removal process of this example, three types of removal rolls 7 having different gap amounts D with the backup roll 75 are prepared.

As shown in FIG. 11, the three types (three) of the removal rolls 7 in this example include a first removal roll 7A having the largest gap amount D and a third removal roll 7C having the smallest gap amount D. The gap amount D is composed of a second removal roll 7B having an amount between the first removal roll 7A and the third removal roll 7C.
In this removal step, the original plate 2 is carried into the gap 79 between the removal roll 7 and the backup roll 75 before the upper paint 50 in the upper paint layer 5 of the original plate 2 is dried.

  Of the three types of removal rolls 7, the removal roll 7 that carries the original plate 2 is selected according to the color appearance to be formed on the design surface 101, and the original plate 2 is carried into the selected removal roll 7. The At this time, in each original plate 2, the original plate 2 carried into the removal roll 7 having a smaller gap amount D than the removal roll 7 having a larger gap amount D is placed on the roll surface 701 of the removal roll 7. On the other hand, it becomes easy to contact with stronger pressure. Therefore, when the roll surface 701 of the removal roll 7 is separated from the design surface 201 of the original plate 2, the removal roll 7 having a smaller gap amount D than the removal roll 7 having a larger gap amount D has The upper paint 50 is likely to adhere.

Specifically, compared with the first removal roll 7A having the largest gap amount D, the upper paint 50 is applied to the second removal roll 7B having the gap amount D smaller than that of the first removal roll 7A. The upper coating material 50 is most likely to adhere to the third removal roll 7C having the smallest gap amount D.
Therefore, compared with the original plate 2 that has contacted the removal roll 7 having a large gap amount D, the upper coating material 50 on the design surface 201 has a larger distance from the original plate 2 that has contacted the removal roll 7 having a smaller gap amount D than the removal roll 7. A lot of adhesion is removed.

In this way, the upper coating 50 on the design surface 201 of each original plate 2 is adhered and removed more as the original plate 2 is in contact with the removal roll 7 with the smaller gap amount D, and the original plate is in contact with the removal roll 7 with the smaller gap amount D. As much as 2, the average thickness of the upper coating layer 5 on the entire design surface 201 of the original plate 2 is formed smaller.
When the upper paint layer 5 on the design surface 201 of the original plate 2 is dried to produce the building board 1, a plurality of types in which the color appearances of the lower paint layer 4 and the upper paint layer 5 formed on the design surface 101 are different. The building board 1 can be manufactured.

In this example, as shown in FIG. 12, the first building board 1A from which a part of the upper paint 50 is adhered and removed by the first removal roll 7A has the smallest amount of adhesion removal of the upper paint 50, and the original board 2 The upper coating layer 5 on the entire design surface 201 is formed with the largest average thickness. Further, as shown in FIG. 14, the third building board 1 </ b> C in which a part of the upper paint 50 is adhered and removed by the third removal roll 7 </ b> C has the largest amount of adhesion removal of the upper paint 50, and the design of the original board 2. The upper paint layer 5 on the entire surface 201 is formed with the smallest average thickness.
Further, as shown in FIG. 13, the second building board 1B from which a part of the upper paint 50 is adhered and removed by the second removal roll 7B is the average of the upper paint layer 5 on the entire design surface 201 of the original board 2. The thickness is smaller than the first building board 1A and larger than the third building board 1C.

  Therefore, also by the manufacturing method of the building board 1 of this example, the uneven pattern 203 on the design surface 201 is formed by a simple method using a plurality of types of removal rolls 7 having different gap amounts D from the backup roll 75. A plurality of types of building boards 1 having different color appearances on the design surface 101 can be manufactured while applying the same upper paint 50 to a plurality of original plates 2 that are the same.

(Example 3)
In this example, a plurality of types of building boards 1 having different color appearances on the design surface 101 are manufactured while applying the same upper paint 50 to a plurality of original plates 2 having the same uneven pattern 203 on the design surface 201. In the removal step, the degree of drying of the upper coating material 50 on the design surface 201 of the original plate 2 when the removal roll 7 is brought into contact is varied according to the color appearance to be formed on the design surface 201 of the original plate 2. It is an example.

In the manufacturing method of the building board 1 of this example, the preparation process, the lower paint layer forming process, and the upper paint layer forming process are performed in the same manner as in the first embodiment. The paint layer 4 and the upper paint layer 5 are formed.
In the removal step of this example, the removal roll 7 is brought into contact with the upper paint layer 5 before the upper paint 50 in the upper paint layer 5 is dried. In this removal step, the time from when the upper coating layer 5 is formed on the design surface 201 of the original plate 2 to when the original plate 2 is carried into the removal roll 7 is appropriately changed.

  That is, if the time until the upper coating layer 5 is carried into the removal roll 7 after the formation is short, the upper coating 50 in the upper coating layer 5 is not so dry (the solvent in the upper coating 50 is hardly volatilized). ) And the degree of drying becomes small. On the other hand, when the time until it is carried into the removal roll 7 after the formation of the upper paint layer 5 becomes long, the upper paint 50 in the upper paint layer 5 is dried (a lot of the solvent in the upper paint 50 is volatilized). ), The degree of drying increases.

  And when the roll surface 701 of the removal roll 7 leaves | separates from the design surface 201 of the original plate 2, compared with the original plate 2 with a large dry degree of the said upper coating material 50, the removal roll 7 of this upper coating material 50 is more than this. The upper paint 50 is likely to adhere from the original plate 2 having a low degree of drying. Therefore, the upper coating material 50 on the design surface 201 is more adhered and removed from the original plate 2 having a lower degree of drying than the original plate 2 as compared to the original plate 2 having a higher degree of drying of the upper coating material 50 in the upper coating layer 5.

In this way, the upper coating 50 on the design surface 201 of each original plate 2 is more adhered and removed as the original plate 2 having a lower degree of drying of the upper coating 50, and the original plate 2 having a lower degree of drying of the upper coating 50 is applied to the design surface of the original plate 2. The average thickness of the upper coating layer 5 in the whole 201 is formed small.
When the building board 1 is manufactured by almost completely drying the upper paint layer 5 on the design surface 201 of the original plate 2, the color appearance of the lower paint layer 4 and the upper paint layer 5 formed on the design surface 101 is increased. Different types of building boards 1 can be manufactured.

  The degree of drying means the degree of volatilization of the solvent in the upper paint 50, and the degree of drying is small means that the solvent in the upper paint 50 is not so volatilized. “Large” means a state in which most of the solvent in the upper coating 50 is volatilized. Further, the upper paint 50 in this example is a water-based paint, and the solvent is water. Then, on the design surface 101 of the building board 1, moisture is volatilized from the upper paint 50, and the upper paint layer 5 is formed by fixing resin, pigment, and various additives as paint solids. Become.

In this example, the first building board 1A in which the upper paint 50 is dried for the longest time and then adhered and removed by the removal roll 7 has the smallest amount of adhesion removal of the upper paint 50, and the entire design surface 201 of the original board 2 The upper coating layer 5 is formed with the largest average thickness (similar to FIG. 12). Further, the third building board 1 </ b> C in which the upper paint 50 is dried for the shortest time and then adhered and removed by the removal roll 7 has the largest amount of adhesion removal of the upper paint 50, and the upper side of the entire design surface 201 of the original board 2. The paint layer 5 is formed with the smallest average thickness (similar to FIG. 14).
Moreover, the 2nd building board 1B which made the time for drying the upper side coating material 50 the time between the case of the 1st building board 1A and the case of the 3rd building board 1C is the upper side in the design surface 201 whole of the original board 2 The coating layer 5 is formed to have an average thickness smaller than that of the first building board 1A and larger than that of the third building board 1C (similar to FIG. 13).

  Further, the longer the drying time of the upper coating material 50 applied to the design surface 201 of the original plate 2 or the higher the drying temperature, the higher the solid content concentration (solid content concentration) in the upper coating material 50. In this example, the solid content concentration of the upper coating 50 before being applied to the design surface 201 of the original plate 2 is 35 to 50 wt%.

  And 1 A of said 1st construction boards dries the upper side coating 50 in the upper side coating layer 5 of the original plate 2 for 30 to 60 seconds in a 60 degreeC dryer, and the solid content density | concentration is 50 to 80 wt%. Then, the original plate 2 was carried into a removing roll 7 and manufactured. Moreover, the said 2nd building board 1B dries the upper side coating 50 in the upper side coating layer 5 of the original board 2 in a dryer whose temperature is 60 degreeC for 10 to 30 seconds, and the solid content density | concentration is 40 to 70 wt%. Then, the original plate 2 was carried into a removing roll 7 and manufactured.

The third building board 1C is obtained by drying the upper paint 50 in the upper paint layer 5 of the original board 2 in a dryer having a temperature of 60 ° C. for 0 to 10 seconds (with almost no drying). The original plate 2 was carried into the removing roll 7 and manufactured while the partial concentration was 35 to 50 wt%.
Thus, when the solid content concentration in the upper coating 50 increases, the amount of adhesion removal by the removal roll 7 decreases, and the upper coating layer 5 having a larger thickness is formed.

  Therefore, even in the manufacturing method of the building board 1 of this example, a plurality of the design surfaces 201 on the design surface 201 can be obtained by a simple method of varying the drying degree of the upper paint 50 in the upper paint layer 5 formed on the design surface 201 of the original plate 2. A plurality of types of building boards 1 having different color appearances on the design surface 101 can be manufactured while applying the same upper coating 50 to a plurality of original plates 2 having the same uneven pattern 203 by the convex portions 21 of the same. .

Example 4
In this example, as shown in FIG. 15, a plurality of types of different color appearances on the design surface 101 are applied to the plurality of original plates 2 having the same concavo-convex pattern 203 on the design surface 201 while applying the same upper paint 50. In manufacturing the building board 1, in the above removal step, the difference between the circumferential speed (moving speed of the roll surface 701) W of the removing roll 7 and the speed V of bringing the original board 2 into the removing roll 7 is determined as the original board 2. It is an example made different according to the color appearance to be formed on the design surface 201.

In the manufacturing method of the building board 1 of this example, the preparation process, the lower paint layer forming process, and the upper paint layer forming process are performed in the same manner as in the first embodiment. The paint layer 4 and the upper paint layer 5 are formed.
In the removal step of this example, the removal roll 7 is brought into contact with the upper paint layer 5 before the upper paint 50 in the upper paint layer 5 is dried.

In this removal process, as shown in FIG. 15, the carry-in speed V of the original plate 2 is made substantially constant, and plural types (three types in this example) of removal rolls 7 having different peripheral speeds W with respect to the carry-in speed V of the original plate 2. Prepare. Specifically, the first removal roll 7A has a circumferential speed W substantially the same as the carry-in speed V of the original plate 2, and the second removal roll 7B has a circumferential speed W of the original plate 2 carrying-in speed. The third removal roll 7C has a peripheral speed W higher than the carry-in speed V of the original plate 2 as compared with the second removal roll 7B.
Of the three types of removal rolls 7, the removal roll 7 that carries the original plate 2 is selected according to the color appearance to be formed on the design surface 101, and the original plate 2 is carried into the selected removal roll 7. The

At this time, in the original plate 2 carried into the first removal roll 7A, the upper coating material 50 is removed from the design surface 201 of the original plate 2 with almost no slippage of the roll surface 701 of the first removal roll 7A. Done. The upper paint 50 in the upper paint layer 5 formed on the design surface 201 of the original plate 2 is hardly stretched. Therefore, the degree of bleeding of the upper paint layer 5 formed on the design surface 201 of the original plate 2 is the smallest.
On the other hand, in the original plate 2 carried into the second removal roll 7B, the upper coating 50 is removed while the roll surface 701 of the second removal roll 7B slides on the design surface 201 of the original plate 2. . Then, the upper paint 50 in the upper paint layer 5 formed on the design surface 201 of the original plate 2 is stretched. Therefore, the degree of bleeding in the upper paint layer 5 formed on the design surface 201 of the original plate 2 is larger than that in the case of the first removal roll 7A.

  Moreover, in the original plate 2 carried into the third removal roll 7C, the roll surface 701 of the third removal roll 7C is more on the design surface 201 of the original plate 2 than the case of the second removal roll 7B. The upper paint 50 is removed while sliding. Then, the upper paint 50 in the upper paint layer 5 formed on the design surface 201 of the original plate 2 is stretched more than in the case of the second removal roll 7B. Therefore, the degree of bleeding in the upper paint layer 5 formed on the design surface 201 of the original plate 2 is the largest.

Thus, the upper coating 50 on the design surface 201 of each original plate 2 is stretched more on the surface of the lower coating layer 4 as the speed difference is increased, and the design surface 201 of the original plate 2 is increased as the speed difference is increased. The degree of bleeding of the upper paint layer 5 becomes larger.
When the upper paint layer 5 on the design surface 201 of the original plate 2 is dried to produce the building board 1, a plurality of types in which the color appearances of the lower paint layer 4 and the upper paint layer 5 formed on the design surface 101 are different. The building board 1 can be manufactured.
Therefore, also by the manufacturing method of the building board 1 of this example, the uneven pattern 203 by the plurality of convex portions 21 on the design surface 201 is the same for the plurality of original plates 2 by the simple method of differentiating the speed difference. Thus, a plurality of types of building boards 1 with different color appearances on the design surface 101 can be manufactured while applying the same upper paint 50.

  The blur referred to in this example refers to a state in which the upper paint 50 in the upper paint layer 5 is stretched and applied in the surface direction of the design surface 201 of the original plate 2, and the blur degree refers to the upper paint 50. This refers to the degree of stretching. And a low degree of bleeding means a state where the upper coating material 50 is not stretched so much, and a high degree of bleeding means a state where most of the upper coating material 50 is stretched.

Further, the carry-in speed V of the original plate 2 is determined by the peripheral speed W of the backup roll 75 and the conveyance speed of a carry-in conveyor or the like for carrying the original plate 2 into the removal roll 7.
Further, the speed difference in each of the removal rolls 7 can be made different from the carry-in speed V of the original plate 2 by reducing the peripheral speed W of the removal roll 7. Moreover, if possible, the speed difference in each removal roll 7 can also be made different by rotating the removal roll 7 in the opposite direction to the loading direction of the original plate 2.

Sectional explanatory drawing which expands and shows an original plate in Example 1. FIG. Sectional explanatory drawing which expands and shows the negative | original plate in the state in which the lower side coating layer and the upper side coating layer in Example 1 were formed. FIG. 3 is an explanatory diagram showing three types of removal rolls in Example 1. Explanatory drawing which expands and shows one removal roll in Example 1. FIG. Cross-sectional explanatory drawing which expands and shows the state which made the removal roll contact the design surface of the original plate in Example 1. FIG. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the 1st removal roll in Example 1, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the 2nd removal roll in Example 1, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the 3rd removal roll in Example 1, and manufactures a building board. The perspective explanatory view which shows the original plate which has the design surface in which the some convex block was formed in Example 1. FIG. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of the original plate which has a some convex block with the removal roll in Example 1, and manufactures a building board. Explanatory drawing which shows three types of removal rolls in Example 2. FIG. Sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the 1st removal roll in Example 2, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the 2nd removal roll in Example 2, and manufactures a building board. Cross-sectional explanatory drawing which expands and shows the state which adheres and removes an upper side coating material from the design surface of an original plate with the 3rd removal roll in Example 2, and manufactures a building board. Explanatory drawing which shows three types of removal rolls in Example 4. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Architectural board 101 Design surface 2 Original board 203 Concavity and convexity pattern 21 Convex part 22 Concave part 4 Lower coating layer 40 Lower coating layer 5 Upper coating layer 50 Upper coating layer 7 Removal roll 75 Backup roll

Claims (2)

A preparation step of preparing an original plate having a design surface formed with a plurality of convex portions;
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer on the original plate, and a removing step for adhering and removing the upper paint on the plurality of convex portions is performed, and A method of manufacturing a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer,
In the removal step, the design of each original plate is made by varying the degree of drying of the upper paint on the design surface of the original plate when contacting the removal roll according to the color appearance to be formed on the original plate. A method for producing a building board, characterized in that a larger amount of the upper coating on the surface adheres to and removes as the original plate has a lower degree of drying. A preparation step of preparing an original plate having a design surface formed with a plurality of convex portions;
A lower coating layer forming step of forming a lower coating layer by applying and drying the lower coating on the design surface of the original plate; and
An upper paint layer forming step of forming an upper paint layer by applying an upper paint having a color different from that of the lower paint on the surface of the lower paint layer,
Before the upper paint is dried, a removal roll for adhering and removing the upper paint is brought into contact with the upper paint layer on the original plate, and a removing step for adhering and removing the upper paint on the plurality of convex portions is performed, and A method of manufacturing a plurality of types of building boards having different color appearances due to the lower paint layer and the upper paint layer,
In the removing step, the speed difference between the peripheral speed of the removing roll and the speed at which the original plate is carried into the removing roll is made different depending on the color appearance to be formed on the original plate, whereby the speed is increased. A method for producing a building board, characterized in that the degree of bleeding of the upper paint layer increases as the original plate has a larger difference.

Images