JP4567997B2 - Manufacturing method of inorganic decorative board - Google Patents

Description

  The present invention is a method for producing an inorganic decorative board having an embossed uneven pattern on the surface, such as a stone pattern tone, ceramic tile pattern tone, brick pattern tone, etc., and is particularly suitable as an outer wall material. The present invention relates to a production method for producing an inorganic decorative board which is formed in different colors and textures and has excellent decoration and durability with high productivity.

  Conventionally, an inorganic decorative board that has been formed by applying an uneven pattern such as stone pattern, ceramic tile pattern, brick pattern, etc. to the surface of an inorganic substrate, and applying colored coating, colored spot coating, pattern printing, etc. to this surface is often used Are known.

  Further, in this type of decorative plate, there is also known a decorative plate that expresses a tiled appearance by painting a decorative surface such as a tile pattern and a joint-like concave portion by painting (see, for example, Patent Document 1). ).

On the other hand, in addition to painting and printing, methods such as those described in Patent Literature 2 and Patent Literature 3 are known as methods for distinguishing the concave portion and the convex portion using a decorative granular material.
Microfilm of actual application No.58-138556 JP-A-5-194059 JP-A-6-155424

  However, since the conventional decorative board shown in Patent Document 1 is decorated by colored painting or pattern printing, there is a limit to revealing the natural feeling and texture of stones, ceramic tiles, or bricks. was there. In addition, if the joint-like recesses are not painted separately from the makeup surface, the entire color becomes the same color and unnatural, and even if they are separated, the uniform coating feeling of the joint-like recesses becomes noticeable and unnatural. This reduces the natural feeling and texture of the entire board, and also requires troublesome painting such as masking, which has the disadvantage of very poor productivity.

  In addition, in the case of painting or printing, the adhesion between the substrate and the coating film may decrease due to use, and the coating film may be damaged, such as cracking and peeling, and may be discolored. I could not say.

  On the other hand, as shown in Patent Document 2 or Patent Document 3, in the method using the decorative granular material, it is possible to improve decorativeness such as natural feeling and texture, and weather resistance.

  However, in the former method shown in Patent Document 2, curing is performed after uniformly spreading colored sand on the surface of the inorganic substrate-like body, and then a concave pattern is formed by cutting. In addition, only an inorganic decorative board in which the substrate color without colored sand sticking is exposed in the recesses can be obtained.

  On the other hand, the latter method shown in the above Patent Document 3 is a method in which a granular material is sprayed on a template, an inorganic material is sprayed thereon to form a mat, and this mat is pressed and pressed. Is formed with the decorative surface of the inorganic substrate facing down, so it must be turned upside down when painting the surface, and since the template surface is facing up, the dispersed particles are uneven As a result, it was easy to collect in the recesses of the template, and as in the former case, only the inorganic decorative board with almost no powder particles adhered could be obtained in the recesses of the inorganic substrate, and the productivity was not good.

  The main object of the present invention is to decorate not only the decorative surface convex portion but also the concave portion such as the joint-like concave portion by the decorative powder granular material, so that the decorative surface convex portion and the joint-like concave portion are colored and textured. In order to achieve this main purpose, the present applicant has already made self-hardening uncured. We propose a method for manufacturing an inorganic decorative board in which a decorative granule is adhered to a molding surface of an emboss plate for forming a self-hardening uncured inorganic substrate to be an inorganic decorative board by pressing and pressing an inorganic mat. (See Japanese Patent Application No. 2003-334785).

  An object of the present invention is to further improve the above-described proposed inventive technique so that the decorative granular material can be more reliably and efficiently attached to the convex surface of the emboss plate. .

In order to achieve the above object, in the method for manufacturing an inorganic decorative board according to the invention of claim 1, a release agent application step of applying a release agent to the surface of the embossed plate having a molding uneven portion on the surface; The surface of the embossing plate and the surface on which the release agent is applied abuts on the surface of the surface of the decorative powder particles on the flat surface. The embossing plate placing step for placing the embossing plate on the surface of the embossing plate and pressing the back surface of the embossing plate with a rotating roll body to attach the decorative particles on the flat surface to the convex surface of the embossing plate. A step, an emboss plate transfer step of transferring the emboss plate on which the decorative powder particles adhere to the surface of the convex portion to the surface of the self-hardening uncured inorganic mat, and a state in which the emboss plate is transferred By pressurizing pressure tightening the self-hardening uncured mineral mat, self-hardening non of the decorative powder granules in a concave portion of the concavo-convex portion of the embossing plate is Utatekoku an uneven pattern on the surface and the unevenness pattern is attached An inorganic substrate forming step for forming a cured inorganic substrate; a curing step for curing the uncured inorganic substrate by curing; and a painting step for coating the surface of the cured inorganic substrate after curing. Features.

  With this configuration, it is possible to reversely attach the decorative powder particles to the convex portions of the emboss plate using a release agent applied to the emboss plate, and the concave and convex portions of the concave and convex patterns have a different color tone from the convex portions. The inorganic decorative board formed in the above can be produced with high productivity.

  Then, the back surface of the emboss plate is pressed by a rotating roll body so that the decorative powder particles on the flat surface are attached to the convex surface of the emboss plate. Therefore, the inorganic decorative board can be manufactured with very high productivity.

  In the invention of claim 2, the plane on which the decorative particulate matter is dispersed in the above-described particulate matter dispersing step is the belt surface of the belt conveyor. Thereby, the dispersion | distribution of the granular material for decoration and the movement mounting of the embossing plate to the distribution surface of this granular material for decoration can be performed in synchronization. In addition, it becomes possible to easily collect and reuse the surplus sprinkled particulates that have been dispersed, and in addition to the effect of the invention of claim 1, the inorganic decorative board is manufactured with higher productivity. be able to.

  In the invention of claim 3, the rotary roll body is a self-propelled rotary roll body that travels while pressing the back surface of the emboss plate. Thereby, it can press in the state which fixed the embossed plate mounted, for example, compared with the case where it presses with a fixed (non-self-propelled) rotary roll body, moving the embossing plate with a belt conveyor, In addition to the effects of the invention of claim 1 or 2, the inorganic decorative board can be manufactured with higher productivity and the production workability can be improved.

  According to a fourth aspect of the present invention, embossing is performed by depositing a plurality of emboss plates coated with a release agent with the release agent application surface facing downward between the release agent application step and the emboss plate placement step. A plate deposition alignment process is provided. In this way, the applied release agent does not accumulate excessively in the recesses of the embossing plate, and the embossing plate is adsorbed by its flat back surface, so that it can easily be placed on a flat surface on which decorative powder particles are scattered. Can be placed. Therefore, in addition to the effect of any one of claims 1 to 3, the productivity of the inorganic decorative board can be further improved.

  According to a fifth aspect of the present invention, the surface layer of the self-hardening uncured inorganic mat is formed as a colored surface layer having a different color from the decorative granular material, and the coating in the coating process is performed by applying a transparent paint. Paint with. As a result, the effect of any one of claims 1 to 4 can be obtained, and the colored surface layer and the concave pattern portion different in color from this layer appear on the surface. It is possible to produce an inorganic decorative board excellent in decorativeness and weather resistance with good productivity.

  In invention of Claim 6, the convex-part part decoration granular material is partially spread | dispersed on the surface of the self-hardening unhardened inorganic mat before mounting an embossing plate. In this way, in addition to the effect of any one of the first to fifth aspects, the colored surface layer of the convex pattern portion is provided with a non-uniform feeling or a blurry pattern feeling of stone, ceramic tile, brick, etc. It is possible to improve the natural feeling and texture of the inorganic decorative board. Moreover, the non-natural convex pattern portion decorative powder particles dispersed at the concave pattern portion forming position of the inorganic decorative plate are well concealed by the decorative powder particles fixed to the concave pattern portion, and the inorganic decorative plate Can enhance the decoration. Therefore, such an inorganic decorative board can be manufactured with high productivity.

According to the method for producing an inorganic decorative board according to the first aspect of the present invention, the mold release agent is applied to the surface of the embossed plate having the concave and convex portions for molding, and the decorative powder particles are sprayed on a predetermined plane. After placing the embossing plate on the application surface of the decorative powder and granular material so that the surface to which the release agent is applied comes into contact, the back surface of the embossing plate is pressed by the rotating roll body to the convex surface. A decorative powder granule on a flat surface is attached, and the emboss plate on which the decorative powder granule adheres to the surface of the convex portion is transferred to the surface of the self-hardening uncured inorganic mat, and the transferred state is not self-hardening. curing inorganic mat was applied pressure clamping, to form a self-hardening uncured mineral substrate decorative powder granules in a concave portion of the concavo-convex portion of the embossing plate is Utatekoku the uneven pattern and uneven pattern is attached to the surface, the non For curing cured inorganic substrates By coating the surface of the hardened inorganic substrate, it is possible to reversely adhere the decorative particulates to the convex part of the embossing plate using a release agent, and press the surface of the embossing plate with a rotating roll body. Then, the decorative powder particles on the flat surface are adhered to the convex surface of the emboss plate, and the decorative powder particles are reliably and quickly adhered to the convex surface of the emboss plate so as not to cause debris. Thus, an inorganic decorative board in which the concave and convex portions of the concavo-convex pattern are formed in a color tone different from that of the convex pattern portion can be produced with high productivity.

  According to the invention of claim 2, the spraying plane of the decorative granular material is the belt surface of the belt conveyor, so that the decorative powder granular material is distributed and the embossing plate is applied to the decorative powder granular material. In addition to being able to synchronize with the movement, it is possible to easily collect and reuse surplus decorative particulates, and to produce an inorganic decorative board with higher productivity.

  According to the invention of claim 3, the rotating roll body is a self-propelled rotating roll body that travels while pressing the back surface of the emboss plate, so that the mounted emboss plate is pressed in a fixed state, It is possible to press with good workability with a compact facility, and it is possible to manufacture an inorganic decorative board with high productivity and to improve the production workability.

  According to the invention of claim 4, the embossing for depositing a plurality of embossing plates coated with the release agent with the release agent application surface facing downward between the release agent application step and the emboss plate mounting step. By providing the plate deposition matching process, the mold release agent is prevented from being excessively accumulated in the recesses of the embossing plate, and the embossing plate is adsorbed on the flat back surface, and the decorative powder particles are dispersed. It can be easily placed on a flat surface, and the productivity of the inorganic decorative board can be further improved.

  According to the invention of claim 5, the surface layer of the self-hardening uncured inorganic mat is formed in a colored surface layer having a different color from the decorative granular material, and the coating in the coating process is performed by applying a transparent paint. In addition, it is possible to produce an inorganic decorative board excellent in decoration and weather resistance such as a natural feeling and a material feeling, in which a colored surface layer and a concave pattern portion different in color from this layer appear on the surface. .

  According to the invention of claim 6, the natural feeling and material of the inorganic decorative board can be obtained by partially spraying the convex-patterned decorative particles on the surface of the self-hardening uncured inorganic mat before placing the emboss plate. The texture can be further improved, and the unnatural convex pattern decorative powder particles scattered on the concave pattern portion forming position of the inorganic decorative board are well concealed by the decorative powder particles fixed to the concave pattern portions. Thus, the decorativeness of the inorganic decorative board can be improved, and such an inorganic decorative board can be manufactured with high productivity.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.

(Inorganic decorative board)
7 and 8 show an inorganic decorative board P manufactured by the method for manufacturing an inorganic decorative board according to the embodiment of the present invention. The inorganic decorative board P includes, for example, a three-layered inorganic substrate 1 having a light beige colored surface layer 1a formed on the surface layer and having a core layer 1b and a back layer 1c. A concavo-convex pattern 4 is formed which is composed of a concave pattern portion 2 and a convex pattern portion 3 serving as a decorative surface.

  On the surface of the decorative pattern 3 on the decorative surface, an arbitrary small concavo-convex portion 3a such as a stone surface is formed, and a convex pattern portion made of colored sand having a particle diameter of less than 3 mm made of, for example, white, black, or brown. The decorative granular material 7 is non-uniformly and semi-embeddedly fixed so as to cover a part of the colored surface layer 1a.

  On the other hand, on the bottom surface of the joint-shaped concave pattern portion 2, the concave-pattern-portion decorative powder 8 is fixed. This concave-pattern-part decoration granular material 8 is composed of, for example, fine decorative granular particles of gray color.

  And by the fixed concave pattern part decorative powder 8, the colored surface layer 1 a on the bottom surface of the concave pattern part 2, and the convex pattern part decorative powder particles scattered on the bottom surface together with the decorative pattern convex part 3 surface. The object 7 is concealed.

  For this reason, the decorative decorative board P has a natural appearance of tiles, bricks, or stone-finished finishes, with the decorative pattern convex part 3 and the jointed concave pattern part 2 divided into color and texture. ing. The decorative surface convex pattern portion 3 is a natural color that cannot be obtained by coloring or printing due to the colored surface layer 1a, the small uneven portion 3a, and the convex pattern portion decorative powder 7 that is unevenly dispersed. Appearance rich in feeling and texture. On the other hand, the joint-shaped concave pattern portion 2 also has a natural and textured appearance that cannot be obtained by coloring, and the decorative face convex pattern portion 3 and the joint-shaped concave pattern portion as the entire inorganic decorative board P. 2 is formed so as to reveal an uncomfortable appearance.

  And in order to protect the surface of this inorganic decorative board P, transparent resin coatings, such as sealer coating, intermediate coating, and top coating, are given to this surface.

  Next, the manufacturing method of the said inorganic decorative board P based on embodiment of this invention is demonstrated with reference to FIGS. The inorganic decorative board P includes (1) a mold release agent application process, (2) an emboss plate deposition alignment process, (3) a powder particle dispersion process, (4) an emboss plate placement process, and (5) a powder particle adhesion process. (6) Emboss plate transfer process, (7) Inorganic substrate forming process, (8) Curing process, and (9) Coating process.

(1) Release agent application process FIG. 1 shows a release agent application process. In this step, a release agent L is applied to the surface of the emboss plate 11 (embossing mold material). The emboss plate 11 has a concave portion 11a and a convex portion 11b for molding on the surface, and the convex portion 11b of the emboss plate 11 has the shape of the joint-shaped concave pattern portion 2 to be formed on the surface of the inorganic substrate 1, and the concave portion 11a The surface of the inorganic substrate 1 is formed so as to correspond to the shape of the decorative pattern convex portion 3 such as a stone pattern, ceramic tile pattern, or brick pattern, and the inorganic substrate is formed by the concave portions 11a and the convex portions 11b. An uneven pattern 4 is formed on the surface of 1.

  Further, by providing a small uneven portion on the surface of the concave portion 11a of the emboss plate 11 that can reprint small uneven portions such as stone, ceramic tile, or brick, the decorative pattern convex portion 3 has, for example, a stone. The surface small uneven part 3a can be easily revealed.

  In addition, each shape of the recessed part 11a and the convex part 11b of the embossing plate 11 can use a various thing corresponding to the uneven | corrugated pattern 4 of the inorganic decorative board P desired.

  The mold release agent L has adhesiveness, for example, mineral oil such as kerosene, light oil, spindle oil, machine oil, turbine oil, vegetable oil, fatty acids, metal soap, carboxyl compound, synthetic resin, wax emulsion, or these A release agent solution prepared by mixing a commercially available release agent or a release material such as a mixture of the above and an additive such as a surfactant can be used. As a specific example, for example, 99% by weight of kerosene, 0.9% by weight of a fatty acid and 0.1% by weight of an antioxidant can be mentioned. In addition, powders such as silica powder and thickeners can be added to such a release agent L for the purpose of imparting an appropriate viscosity.

  Then, as shown in FIG. 1, the emboss plate 11 is arranged so that the surface with the concave portion 1a and the convex portion 1b faces downward, and the surface (lower surface) facing downward is directed upward as a coating means. The release agent L is applied by the spray gun device 14.

  In this way, when the release agent L is applied by the spray gun device 14 from below with the surface of the emboss plate 11 facing downward, the surface of the emboss plate 11 is directed upward and separated by the spray gun device facing downward from above. The excess release agent L does not accumulate in the recess 11 a of the emboss plate 11 as in the case of applying the mold agent L, and the release agent L can be uniformly applied to the surface of the emboss plate 11. Of course, the surface of the embossing plate 11 is not limited to the downward direction, and the release agent L can be applied, for example, in the horizontal direction, the diagonal direction, or the upward direction. However, it is preferable to face downward for the above reasons.

  The release agent L is preferably applied to the entire surface of the emboss plate 11 in order to easily remove the mold after molding.

  As a means for applying the release agent L, in addition to the spray gun device 14, for example, a roll coater or a flow coater using a sponge roll that deforms following the concave portions 11a and convex portions 11b on the surface of the emboss plate 11 Can be used.

  Further, after such a release agent L is applied, a viscous liquid such as a synthetic resin coating material can be adhered only to the convex portion 11b by a roll or the like.

(2) Emboss plate deposition alignment process After the release agent coating process, the process proceeds to an emboss plate deposition alignment process. In this step, as shown in the left part of FIG. 2, the emboss plates 11, 11,... Having the release agent L applied on the surface are placed with the application surface (front surface) of the release agent L facing downward. It deposits on the mounting table 17 that can be moved up and down of the deposition aligning device 16 by adjusting the position. The stacking alignment device 16 is provided with an elevating mechanism (not shown) that moves the mounting table 17 up and down, and an alignment mechanism 18 that adjusts the front, rear, left and right positions of the emboss plate 11 deposited on the mounting table 17. The position of the emboss plate 11 is automatically adjusted by the deposition matching device 16.

  In this way, a plurality of emboss plates 11, 11,... Are deposited on the mounting table 17 of the deposition aligning device 16 with the application surface (surface) of the release agent L facing downward, so that the release agent L on the application surface is obtained. Excessive accumulation in the recess 11a of the emboss plate 11 will not occur. Moreover, since the flat back surface of the embossing plate 11 becomes the top surface, the embossing plate 11 is sucked by the back surface by suction portions 45 of suction transfer devices 43 and 44, which will be described later, and the concave portion decorative powder 8 is scattered. It can be easily placed on the belt surface 25.

  As shown in FIG. 2, a powder particle adhering and adhering device 21 is disposed on the side of the deposit aligning device 16, and a mat is conveyed on the opposite side of the adhering and aligning device 16 on the side of the particle aligning and adhering device 21. Each device 36 is installed. And the ceiling frame 42 is constructed over each of the said stacking alignment apparatus 16, the granular material dispersion | distribution adhesion apparatus 21, and the mat | matte conveyance apparatus 36, and the deposition alignment apparatus 16 and the granular material distribution adhesion are attached to this ceiling frame 42. A first adsorption transfer device 43 composed of a self-propelled lift that can move between the devices 21, and a similar second adsorption transfer device 44 that can move between the particulate matter spreading and attachment device 21 and the mat conveyance device 36. Suspended and supported. Each of the suction transfer devices 43 and 44 has a suction portion 45 that can lift each emboss plate 11 by suction on the back surface, and the first suction transfer device 43 has an emboss in the deposition matching device 16. The plate 11 is adsorbed by the adsorbing unit 45 and lifted up to the powder particle adhering and adhering device 21. In the second adsorbing and transferring apparatus 44, the emboss plate 11 in the adhering material and adhering device 21 is adsorbed by the adsorbing unit 45. They are sucked and lifted and transferred to the mat conveying device 36 respectively.

(3) Particulate matter sprinkling step The particulate matter sprinkling and adhering device 21 installed on the side of the deposition matching device 16 comprises a belt conveyor 22, a sprinkling device 28, and a sticking device 31, as shown in FIG. . The belt conveyor 22 includes a conveyor belt 24 that is a hard rubber flat belt that is wound between the conveyor rollers 23 and 23 and has a belt width larger than the width of the inorganic decorative plate P (the width of the emboss plate 11). The upper surface of the upper span of the belt 24 is a flat surface and forms a belt surface 25. The upper span of the belt 24 is supported by a support roller (not shown) so as not to bend downward even when a pressing force of a rotating roll body 34 described later is received.

  Further, the spraying device 28 is disposed above the start end side of the belt conveyor 22, and is disposed on the lower side of the hopper 28a for storing the decorative granular material 8 (concave pattern portion decorative granular material). The decorative particulate matter 8 that has been passed through the roller 28b is provided with a roller 28b that receives the ornamental particulate matter 8 supplied from the hopper 28a at its outer peripheral surface and adjusts its size (particle size) and amount. It is dropped and supplied onto the belt surface 25 of the conveyor belt 24.

  As the decorative granular material 8, a natural color or a colored granular material can be used. For example, silica sand having a particle size of less than 3 mm, artificially colored sand, mica, resin particles, pulverized materials such as stone, glass, brick, ceramics, and inorganic pigments such as bengara, titanium oxide, chromium oxide, and carbon black can be used. A particle size of 3 mm or more is not preferable because it becomes too large and the decorative properties deteriorate. The decorative granular material 8 may be a mixture of a plurality of colors, particle sizes, and materials.

  The adhering device 31 further includes a pair of guide rails 32 and 32 erected on the left and right sides of the belt conveyor 22 so as to extend parallel to each other along the length direction of the conveyor belt 24. The slider 33 is supported so as to be able to travel (slidably moveable), and both sliders 33 and 33 are configured to travel in synchronization with each other along the guide rail 32 by a travel drive mechanism (not shown). A rotary roll body 34 is stretched between the upper portions of the sliders 33 and 33 so as to be positioned above the belt surface 25 of the conveyor belt 24, and the rotary roll body 34 can be moved up and down with respect to the sliders 33 and 33. Supported as possible. Further, a pressing drive mechanism (not shown) such as a cylinder for driving the rotary roll body 34 downward is provided. A predetermined gap is provided between the outer peripheral lower surface of the rotating roll body 34 and the belt surface 25 of the conveyor belt 24 in a non-operating state of the pressing drive mechanism.

  In FIG. 2, reference numeral 39 denotes a powder and particulate matter collecting device provided on the side of the end of the belt conveyor 22. The powder and particulate matter collecting device 39 allows the upper belt surface 25 of the conveyor belt 24 to be the end-side conveyor roller 23. Then, the excess decorative powder 8 that does not adhere to the surface of the emboss plate 11 on the belt surface 25 is received and collected.

  Then, in the powder particle dispersion step, the conveyor belt 24 of the belt conveyor 22 is moved from the position of the conveyor roller 23 on the upper end surface (left side in FIG. 3) to the end side (right side in FIG. 3) While traveling only the distance to the position, the decorative granular material 8 is dropped from the spraying device 28 onto the belt surface 25 (predetermined plane) on the start end side of the belt conveyor 22 and sprayed. Thus, the decorative granular material 8 is dispersed on the entire belt surface 25 (the entire upper surface) of the conveyor belt 24.

  It should be noted that the surface on which the decorative powder particles 8 are dispersed is not limited to the belt surface 25 as long as the surface can supply the decorative powder particles 8 in a flat shape. For example, a plate such as a metal plate, a plastic plate, or a wooden plate, or a bat-shaped container made of the above-described material having a flat bottom surface can be used. However, when the belt surface 25 of the conveyor belt 24 is used, the decorative granular material 8 is continuously supplied to the embossing plate 11 in the subsequent process as the conveyor belt 24 rotates, and the surplus Since the decorative granular material 8 can be continuously collected, there is an advantage that the productivity can be further improved.

(4) Emboss plate placing step In this emboss plate placing step, the operation of the spreading device 28 and the running of the belt conveyor 22 in the powder and dust material spreading and attaching device 21 are stopped, and in that state, the emboss plate deposition matching The uppermost embossed plate 11 of the plurality of embossed plates 11 deposited on the mounting table 17 of the deposition alignment device 16 in the process is sucked and picked up by the suction portion 45 of the first suction transfer device 43, The embossing plate 11 is placed so that the surface to which the release agent L is applied contacts the belt surface 25 of the belt conveyor 22 in a stopped state, that is, the spraying surface of the decorative granular material 8 on the belt surface 25. Put. When the uppermost embossing plate 11 is taken up from the mounting table 17 and the height of the accumulated embossing plate 11 is lowered, the mounting table 17 rises.

(5) Particulate matter adhering step In this particulate matter adhering step, as shown by the phantom line in FIG. The rotary roll body 34 that travels from the side to the end side and is supported by the slider 33 also travels in the same direction. As the rotating roll body 34 travels, the emboss plate 11 placed on the belt surface 25 is inserted between the outer peripheral lower surface of the rotating roll body 34 and the belt surface 25 of the conveyor belt 24 in the stopped state. The At the same time, the pressing drive mechanism pushes the rotating roll body 34 downward, and the rotating roll body 34 presses the back surface (upper surface) of the emboss plate 11. That is, the rotary roll body 34 is a self-propelled rotary roll body that travels while pressing the back surface of the emboss plate 11. The rotary roll body 34 presses the emboss plate 11 with the back surface of the emboss plate 11. By running while rotating from one end to the other end, the decorative granular material 8 dispersed on the belt surface 25 is attached to the surface of the convex portion 11 b of the surface (lower surface) of the emboss plate 11. The rotating roll body 34 is pressed against the back surface of the emboss plate 11 so that the convex portion 11b on the surface of the emboss plate 11 has a pressing force of about 200000 Pa to 1000000 Pa on the decorative granular material 8 on the belt surface 25.

  As a result, the convex portion 11b on the surface of the emboss plate 11 is pressed against the decorative granular material 8 on the belt surface 25 with a sufficient pressing force, and the decorative granular material 8 is applied to the surface of the convex portion 11b. It adheres satisfactorily without causing blurring or unevenness due to the applied release agent L.

(6) Embossing plate transfer process As shown in FIG. 2, the mat conveying device 36 includes a conveying conveyor 37 formed of a belt conveyor, and the self-hardening uncured inorganic mat 1 ″ is placed on the conveying conveyor 37. The embossing plate 11 having the decorative particulates 8 adhered to the surface of the convex portions 11b in the embossing plate transfer step is backside in the embossing plate transfer step. Is lifted from the belt surface 25 of the belt conveyor 22 in the powder and dust material dispersing and adhering device 21 by being adsorbed by the adsorbing unit 45 of the second adsorbing and transferring device 44, and the conveying conveyor in the mat conveying device 36 on the side of the belt conveyor 22 37 is transferred to the surface (upper surface) of the self-hardening uncured inorganic mat 1 ″ on the surface 37. Thus, as shown in FIG. 4, the emboss plate 11 is placed on the colored surface layer 1 a of the self-hardening uncured inorganic mat 1 ″ with the surface of the convex portion 11 b in contact with the surface of the mat 8. .

  After the embossing plate 11 has been transferred, the decorative powder and particulate matter spreading and adhering device 21 starts running the belt conveyor 22 from which the embossing plate 11 has disappeared from the belt surface 25, and on the belt surface 25. The excess decorative powder 8 that has not adhered to the surface of the emboss plate 11 is dropped from the belt surface 25 to the powder collection device 39 and collected.

  This completes the attachment of the decorative granular material 8 to the surface of one emboss plate 11 and the transfer of the emboss plate 11 to the self-hardening uncured inorganic mat 1 ″. Thereafter, one emboss plate 11, the above-mentioned (3) powder and particulate matter dispersion step, (4) emboss plate placement step, (5) powder and particulate matter adhesion step, and (6) emboss plate transfer step are repeated in this order. .. Are spread on the entire belt surface 25, and a plurality of emboss plates 11, 11,... Deposited on the mounting table 17 of the deposition alignment device 16 are spread on the belt surface 25 from the upper side. Then, the decorative powder particles 8 on the belt surface 25 are adhered to the surface (lower surface), and then the emboss plate 11 is transferred to the self-hardening uncured inorganic mat 1 ″. In this way, the emboss plate deposition alignment process is finished, and the plurality of emboss plates 11, 11,... Deposited on the mounting table 17 are sequentially applied from (3) the powder and particulate matter spraying process to (4) the emboss plate mounting. The embossing plate 11 in which the decorative granular material 8 is adhered to the surface of the convex portion 11b is semi-continuously self-hardening by repeating the placing step and (5) the granular material adhesion step and (6) the embossing plate transfer step. It can be placed on the surface of the uncured inorganic mat 1 ″, and the production efficiency can be improved with a compact apparatus configuration.

  The structure of the self-hardening uncured inorganic mat 1 ″, its constituent material and molding method are not particularly limited, but the self-hardening uncured inorganic mat 1 ″ in this embodiment is as shown in FIG. For example, the above-mentioned three-layer structure composed of a surface layer 1a, a core layer 1b, and a back surface layer 1c formed by a semi-dry molding method using cement as a main raw material, and at least the surface layer 1a is mixed with a color pigment. The colored surface layer 1a is formed by coloring pigments so that the color tone of the colored surface layer 1a is different from the color tone of the decorative granular material 8.

  Moreover, the convex part decoration granular material 7 different from the said decorative granular material 8 is sprayed on the coloring surface layer 1a of the inorganic mat 1 ″ before the emboss plate 11 is transferred. As the decorative part granular material 7, a natural color or a colored granular material can be used similarly to the concave part decorative powder 8. The convex part decorative powder 7 May be the same as the concave-part decorative powder 8 or may be different in at least one of color, particle size, and material.

  When this convex pattern part decoration granular material 7 is sprayed, as a spraying device, for example, as shown in FIG. 5, a rotating drum body 51 having a large number of bottomed holes 51a, 51a,. And a hopper 52 for supplying the decorative granular material 7 from above the rotating drum body 51 to the hole 51a on the peripheral surface thereof. Is supplied to the hole 51a of the surface, and when the hole 51a moves downward with the rotation of the rotary drum body 51, the decorative granular material 7 in the hole 51a falls onto the inorganic mat 1 ″. I try to let them.

  In FIG. 5, 53 is a scraping means made of hard rubber or the like that scrapes off the decorative powder 7 excessively supplied to the peripheral surface of the rotating drum body 51, and 54 is arranged below the rotating drum body 5129 for decoration. A screen plate 55 for adjusting the falling flow of the granular material 7, 55 is a shielding plate that changes its spraying pattern by appearing and falling with respect to the falling flow of the decorative granular material 7 falling through the screen plate 54. .

  In addition, a decorative powder granule different from the convex pattern decorative powder 7 may be spot-added to the surface colored layer 1a of the inorganic mat 1 ″ and further dispersed. By spraying these convex pattern portion decorative powder particles 7 and additional decorative powder particles, the decorativeness of the manufactured inorganic decorative board P can be further enhanced.

(7) Inorganic substrate forming step In this step, the transporting conveyor 37 of the mat transporting device 36 is operated to transport the inorganic mat 1 ″ thereon together with the embossing plate 11 to a pressing and pressing device (not shown). In the fastening device, the self-hardening uncured inorganic mat 1 ″ with the embossed plate 11 transferred is pressure-pressed. Specifically, a laminate of a support plate 9, a self-hardening uncured inorganic mat 1 ″ formed thereon, and an emboss plate 11 placed thereon is taken as one set, and this set is divided into a plurality of stages. (Multiple sets of laminates are formed by repeating the steps (3) to (6) above), and the stacked laminates are pressed and pressed in the vertical direction. 6, the self-curing uncured inorganic mat 1 ″ is compressed to form an uncured inorganic substrate 1 ′. On the surface coloring layer 1a of the uncured inorganic substrate 1 ', there are formed a convex pattern portion 3 in which the concave portion 11a of the emboss plate 11 is rolled, and a concave pattern portion 2 in which the convex portion 11b is rolled. The In addition, the colored surface layer 1a includes a decorative powder 8 adhered to the surface of the convex portion 11b of the emboss plate 11 and the colored surface 1a of the inorganic mat 1 ″ before the emboss plate 11 is placed. The convex-patterned part decoration granular material 7 (including the case where it is sprayed in a spot manner) is fixed.

(8) Curing step After the inorganic substrate forming step, a temperature of 40 ° C. to 80 ° C. in a state of pressing and pressing a plurality of stacked layers of the support plate 9, the inorganic substrate 1 ′ and the emboss plate 11. It is carried in the primary curing room outside the figure kept in, and kept for about 10 hours for primary curing. In this primary curing, the hydration reaction is advanced to bring the inorganic substrate 1 'into a semi-cured state with moderate strength.

  When this primary curing is completed, the stacked product and the respective laminates are disassembled and the semi-cured inorganic substrate 1 ′ is taken out, and then a large number of semi-cured inorganic substrates 1 ′ are stacked and the temperature is lower than 180 ° C. Steam cure under temperature for about 10 hours to fully cure the cement. Further, the support plate 9 and the emboss plate 11 are collected for reuse.

  At this time, if the surface of the semi-cured inorganic substrate 1 ′ disassembled after the primary curing is applied with a sealer coating made of a penetrating resin such as acrylic, efflorescence is generated in the subsequent steam curing process. Since it can prevent, it is preferable. Such a sealer needs to have transparency when it is decorated with the colored surface layer 1a and the decorative granular materials 7, 8 as in the present embodiment.

(9) Coating process Next, the cured inorganic substrate 1 after the curing process is transferred to a coating apparatus outside the figure, and an acrylic resin system, an acrylic urethane resin system, a fluororesin system, an acrylic silicon resin system or the like is appropriately applied to the surface. The inorganic decorative board P is manufactured by performing undercoating and topcoating made of a transparent paint.

  The inorganic decorative board P thus obtained has a concave groove pattern in which the colored surface layer 1a of the convex pattern portion 3 in the substrate 1 and the decorative powder particles 8 having a different color tone from the colored surface layer 1a are fixed. The natural feeling and texture of stones, ceramic tiles, bricks, etc. are provided by the portion 2 and the decorative powder 7 fixed on the colored surface layer 1a of the convex pattern portion 3 nonuniformly or in a blurred pattern. It appears on the surface through the transparent resin layer and exhibits a highly decorative appearance.

  According to the present invention, an inorganic decorative board that is suitable as an outer wall material and has excellent decorativeness and durability in which the concave and convex portions of the embossed concavo-convex pattern are formed in different colors and textures is obtained. The inorganic decorative board can be manufactured with a compact apparatus configuration and extremely high productivity, and the industrial applicability of the present invention is high.

It is explanatory drawing which shows a mold release agent application | coating process. It is a side view which shows the apparatus structure which performs from an emboss plate deposition alignment process to an emboss plate transfer process. It is explanatory drawing which shows a granular material dispersion | spreading process, an embossing plate mounting process, and a granular material adhesion process. It is explanatory drawing which shows the state by which the embossing plate was mounted on the colored surface layer of a self-hardening unhardened inorganic mat | matte in an embossing plate transfer process. It is explanatory drawing which shows the state which disperse | distributes the granular material for convex pattern part decoration to the coloring surface layer of the inorganic mat before transferring an emboss plate. It is explanatory drawing which shows the state which compresses a self-hardening uncured inorganic mat | matte in an inorganic substrate formation process, and forms an uncured inorganic substrate. It is the VII-VII sectional view taken on the line of FIG. It is a top view of the inorganic decorative board manufactured by the method concerning the embodiment of the present invention.

Explanation of symbols

P Inorganic decorative board 1 Inorganic substrate 1 'Uncured inorganic substrate 1 "Self-hardening uncured inorganic mat 1a Colored surface layer 7 Convex pattern part decorative powder (second)
DESCRIPTION OF SYMBOLS 8 Powder and granular material for decoration of a concave pattern part 11 Embossing plate 11b Convex part 21 Powder and granular material spreading | attachment adhesion apparatus 22 Belt conveyor 25 Belt surface 34 Rotary roll body L Mold release agent

Claims (6)

A mold release agent application step for applying a mold release agent to the surface of the embossed plate having the uneven portions on the surface;
A powder and dust dispersion process for spraying decorative powder and granules on a predetermined plane;
An embossing plate placement step of placing the embossing plate on the surface of the decorative powder particles on the flat surface so that the surface to which the release agent is applied is in contact;
By pressing the back surface of the emboss plate with a rotating roll body, the powder and particulate matter attaching step for attaching the decorative powder and particulate matter on the flat surface to the convex surface of the emboss plate,
An emboss plate transfer step of transferring the emboss plate on which the decorative powder particles adhere to the surface of the convex portion to the surface of the self-hardening uncured inorganic mat;
By the embossing plate is applied pressure tightening the self-hardening uncured mineral mats while being transferred, uneven portions of the embossing plate is Utatekoku an uneven pattern on the surface and the decor in a concave portion of the uneven pattern An inorganic substrate forming step of forming a self-hardening uncured inorganic substrate to which the powdered granular material is attached;
Curing process for curing and curing the uncured inorganic substrate,
A method for producing an inorganic decorative board, comprising: a coating step of coating the surface of the cured inorganic substrate after curing. In the manufacturing method of the inorganic decorative board of Claim 1,
The method for producing an inorganic decorative board, wherein the flat surface on which the decorative granular material is scattered in the powder particle scattering step is a belt surface of a belt conveyor. In the manufacturing method of the inorganic decorative board of Claim 1 or 2,
The rotary roll body is a self-propelled rotary roll body that travels while pressing the back surface of the emboss plate. In the manufacturing method of the inorganic decorative board of any one of Claims 1-3,
There is an emboss plate deposition matching step for depositing a plurality of emboss plates coated with a release agent with the release agent application surface facing downward between the release agent application step and the emboss plate placement step. The manufacturing method of the inorganic decorative board characterized by the above-mentioned. In the manufacturing method of the inorganic decorative board of any one of Claims 1-4,
The surface layer of the self-hardening uncured inorganic mat is formed in a colored surface layer that is different from the decorative granular material,
A method for producing an inorganic decorative board, wherein the painting in the painting process is painting by applying a transparent paint. In the manufacturing method of the inorganic decorative board of any one of Claims 1-5,
A method for producing an inorganic decorative board, comprising: partially spraying a convex-patterned decorative powder on the surface of a self-hardening uncured inorganic mat before placing an emboss plate.

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