JP4612220B2 - Decorative plate manufacturing method - Google Patents

Description

【００４９】
【発明の効果】
以上説明したように、この発明によれば、はじき剤を添加した塗料であっても、安定した塗料カーテンを形成してカーテン切れがなく且つ塗装不良もなく、塗料を均一に塗装することが可能となる。さらに、塗装不良もなく、柄および模様の再現性に優れた製品の製造が可能で、意匠性、特に光揮感、立体感、陰影感、深み感に優れた化粧板を製造することが可能となる。
【図面の簡単な説明】
【図１】この発明の実施の形態に係る塗料供給ヘッドを示す一部破断斜視図である。
【図２】図1の塗料供給ヘッドを示す一部破断正面図である。
【図３】図1の塗料供給ヘッドを示す側面断面図である。
【図４】変形例に係る塗料供給ヘッドを示す側面断面図である。
【図５】変形例に係る塗料供給ヘッドを示す側面断面図である。
【図６】変形例に係る塗料供給ヘッドを示す側面断面図である。
【図７】フローコーターの全体構成を示す図である。
【符号の説明】
１ タンク、２ 塗料、３ ポンプ、４，１６，１７ 導入管、５ 塗料供給ヘッド、６，１２ スリット、７ 塗料カーテン、８，９ コンベア、１０ 塗料回収桶、１１ 容器、１３，２８ 斜面部、１４ 塗料溜まり部、１５ 供給管、１８ 供給孔（下向き開口）、１９，２３，２７，３０ 樋、２０ 上向き開口部、２１ 外側面、２２ 液面、２４ 鉛直部分、２５ 斜板、２６ 底板、２９ 内壁面、Ａ被塗装物。[0001]
BACKGROUND OF THE INVENTION
  This inventionA paint with a repellent agent mainly composed of silicone oil is added.Form a paint curtain with slitsApply so-called flow coaterFor objects such as plate-shaped building materialsThe present invention relates to a method for producing a decorative board that has been painted and has excellent design properties, in particular, luminosity, three-dimensionality, shading, and depth..In addition,This inventionObtained by the manufacturing methodThe decorative panel is suitable for interior materials such as the inner wall of the bath unit, toilet booth, and kitchen front panel.
[0002]
[Prior art]
  In a typical flow coater, the liquid paint to be applied is passed through a slit to make a thin curtain or film paint curtain of a certain width using the viscosity of the liquid paint.FormingThis is a method of continuously supplying from above and coating the object to be coated. Specifically, the paint stored in the tank is supplied to the paint supply head by the paint pump, and the slit formed in the paint supply headFromA thin curtain or film paint curtain of a certain widthFormingWhile continuously supplying from above, the object to be coated is moved by a conveyor and submerged under the paint curtain to perform painting. Adhere to the object to be paintedShiThe paint that was not collected is recovered by the paint recovery tank and put into the tank.ReturnedIt is automatically circulated again by the paint pump.
[0003]
  Regarding paint supply head of flow coaterIs, To form a stable paint curtain for uniform paintingofVarious proposals have been made. For example, in Japanese Utility Model Publication No. 2-3829, a plurality of intervals are set such that paint is discharged from one end of a paint supply head into the interior, the discharge side is sparse in the paint supply head, and the opposite side is dense. An apparatus is disclosed in which a filter having a hole is provided, and a paint is allowed to flow down in a curtain shape by a slit formed in the paint supply head. Japanese Patent Application Laid-Open No. 10-323603 is provided with blades that alternately protrude from the flow path wall facing the flow down path in the paint supply head into the flow path.Paint supplyA head is disclosed. Furthermore, Japanese Patent Laid-Open No. 11-128803 discloses that a paint slit is connected to a flow-down slit in a paint supply head.ShiA taper surface having a V-shaped ridge and a slit formed at the bottom corner of the ridge is disclosed.
[0004]
  On the other hand, for the purpose of imparting high designability by painting, paints that are added or mixed with pigments that are difficult to disperse in paints, liquid additives that are difficult to dissolve in paints, surfactants, and the like have come to be used. TheHave. For example, Japanese Patent Laid-Open No. 10-291274 discloses design properties, particularly,A method for producing a decorative building material with enhanced glitter, three-dimensional, shadow, and depth is disclosed. This makeup building material,A decorative building material provided with a decorative layer on the surface of a smooth base material and a surface coating layer in which silicon oil is dispersed thereon,thisThe manufacturing method for decorative building materials is made of decorative paper or thermal transfer resin sheet printed with a pattern as a decorative layer, on which silicone oil is applied.TheDispersive mixingLetPaint using a roll coater or a conventional paint supply headByPaint and use the repelling effect of silicone oil to make the coating surface uneven.,It is intended to give a sense of depth. Also,thisIt is said that aluminum powder can be introduced into the paint as a pigment.
[0005]
[Problems to be solved by the invention]
  However, silicone oilA repellant mainly composed ofDispersive mixingShiConventional paint supply headPreparedWhen applying onto a substrate with a flow coater, the paint supply head may differ depending on the composition and properties (compatibility, surface tension, etc.) between the silicone oil and the paint.ofIn the paint flow slit at the bottomByThe conventional paint supply head with a structure that is usually on the market is used in order to cause a “curtain break” that the paint curtain that is formed breaks or breaks.PreparedPainting with a flow coaterIs difficultOr, coating defects (coating defects) due to “out of curtain” occur frequently and stable coating (manufacturing)IsThere was a problem that it was not possible.
[0006]
  In addition, silicone oil is used to enhance the design of cosmetic building materials.Repellants mainly composed ofSince the number of occurrences of “curtain breaks” tends to increase as the amount of addition increases, there is also a problem that an increase in defective coating is caused when the intended designability is obtained. Furthermore, silicon oilA repellant mainly composed ofdispersion,MixedSetPaint without "curtain break"Form a curtainEven if it can, the paint curtain becomes unstable andRepellentDistribution of,Since the mixed state is not necessarily uniform, the size of the applied pattern is not uniform, especially,At the center and end of the substrateofProducts with different pattern sizes and pattern reproducibilityTheThere was also a problem that it could not be manufactured.
[0007]
  Furthermore, in the apparatus disclosed in Japanese Patent Application Laid-Open No. 11-128803, a V-shaped wrinkle having a slit at the bottom corner inside a paint supply head is connected to a paint flow slit located at the bottom of the paint supply head. It is characterized by being attached to a tapered surface, forming a stable paint curtain even with paint with low viscosity and coarse aggregateNaIt is possible to paintShiing.thisThe device has a low viscosity and is suitable for paint containing coarse aggregate.forIs effective, but in paints for the purpose of improving design properties, for example,A conventional paint supply head can be used to mix paint with additives different from the composition and properties of paint such as silicone oil.PreparedWhen painting with a flow coaterFromDischarge into paint supply headIsWhen the paint falls to the V-shaped cross-section, air is entrained, which causes the paint curtain to become unstable and cause a "curtain break".,The resulting paint curtain is unstable and the pattern is reproducibleButIt cannot be manufactured.
[0008]
  So, this invention is,It was made to solve the above problems and dissolves in pigments and paints that are difficult to disperse.,dispersionLiquid additivesRepellentA stable paint curtain is continuously formed using a paint with added or mixed,High design and excellent physical propertiesCoatingPaint supply head that can perform paintingA method of manufacturing a decorative board with a flow coater equippedThe purpose is to provide.
[0009]
  IeThis inventionWith the manufacturing method of the decorative boardApply paint with repellent added with a flow coaterIf you wantIt is possible to stably produce products with reproducibility of patterns and patterns without causing painting defects such as “out of curtains”, and design characteristics, especially luminous feeling, three-dimensional feeling, shadow feeling, depth To provide a method for producing a decorative board with excellent feelingCan. In addition,thisDescribed in the description”Pattern”Is a design formed by the action of a repellent added to the paint for forming the decorative layer,”pattern”And each refers to a design as a macroscopic ceramic veneer.
[0010]
[Means for Solving the Problems]
  Of this inventionThe manufacturing method of the decorative boardA paint supply head in the form of a container through an introduction pipe with paint added with a repellentTo supply continuously,further,Paint curtain from slit formed in this paint supply headIn the method for manufacturing a decorative board, in which a coating material is attached to the surface of a substrate that is supplied downward and moved by a conveyor, the supply head isA long box-like container having a slit at the bottom, a supply means connected to the introduction pipe and having a downward opening for supplying the paint into the container, and once receiving the paint from the supply means And a mixing / dispersing means for flowing out in layers from the upward opening, and a paint reservoir for storing the paint flowing out from the mixing / dispersing means, which is defined between the slope and the side connected to the slit. The supply means and the mixing / dispersing means are arranged so that the uppermost position of the opening of the supplying means is located below the lowermost position of the opening of the mixing / dispersing means, and from the supply means The paint is supplied so that the liquid level of the paint reservoir is in the range from the upward opening of the mixing and dispersing means to the lowest part of the mixing and dispersing means.
[0011]
  The mixing / dispersing means can be composed of ridges arranged substantially parallel to the slits, and the cross-sectional shape of the ridge can be U-shaped, V-shaped, U-shaped or L-shaped.AlsoThe supply means may be constituted by a tube disposed substantially parallel to the slit and having an opening in the outer peripheral portion. The opening may be a plurality of holes formed along the length direction of the tube, or a tube Elongated linear slit formed along the length directionFormed downward as. In the case of using a plurality of holes, it is preferable to form them at intervals such that the upstream side is sparse and the downstream side is dense with respect to the flow direction of the paint in the pipe. Moreover, when using a linear slit, it is preferable to form so that a slit width may be narrow on the upstream side and wide on the downstream side with respect to the flow direction of the paint in the pipe.
[0012]
  IeIn the decorative plate manufacturing method according to the present invention, the coating material supply head is used on the surface of the substrate, and the coating material from the supplying means is applied.Apply the paint while supplying so that the liquid level in the paint reservoir is in the range from the upward opening of the mixing and dispersing means to the bottom of the mixing and dispersing means.Cured to form a decorative layerthingIt is. Preferably, the substrate is any one of a metal plate, an inorganic plate, a wood plate, a paper plate, a resin plate, and a film (thin plate), and a substrate adjustment layer can be provided on the substrate in advance. further,On the makeup layerA transparent or translucent top clear layer may be formed. In the paint supply headOf paint reservoirThe liquid level of the paint is maintained in the range from the opening of the mixing and dispersing means to the lowest part of the mixing and dispersing means.Is a thing.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
  Embodiments of the present invention will be described below with reference to the accompanying drawings.
(Paint supply head)
  FIG. 7 shows the overall configuration of the flow coater type coating apparatus. The paint 2 stored in the tank 1 with the mixing and stirring device is supplied to the paint supply head 5 via the introduction pipe 4 by the pump 3.ContinuouslyBy supplying the paint 2 through the slit 6 formed in the paint supply head 5,A thin curtain or film paint curtain 7 with a certain widthFormingFrom aboveDownContinuouslySupply,MovingObject A to be coated A by conveyors 8 and 9Ie substrateThe paint curtain 7inIs caused to adhere to the surface of the object A to be coated.In addition,Adhering to workpiece AShiThe paint 2 that was missing,Recovered by paint recovery bowl (paint receiver) 10 to tank 1ReturnedThe pump 3 automatically circulates again.
[0014]
  Embodiment 1Used inThe paint supply head is shown in FIGS. The paint supply head is a long box-shaped container 11Consist ofAt the bottom of this container 11IsThe slit 12 for the paint flow is formed,At the top of the slit 12To the slitLinkingShiA slope portion 13 is formed,The slope 13 and the side of the container 11Thus, the paint reservoir portion 14 is defined.Also,In the container 11, a supply pipe 15 (supply means) is disposed above and in parallel with the slit 12, and both ends of the supply pipe 15 are attached to the left and right outer surfaces of the container 11, respectively.TheConnected to inlet pipes 16 and 17Shiing. Supply pipe 15 opens downwardDoA plurality of supply holes 18Ie downward openingIs formed. The paint is parallel to the slit 12 so as to accommodate the supply pipe 15.TheMixed dispersionTo make樋 19ButMixing and dispersing meansAsIt is arranged. As shown in FIG.TheThus, the collar 19 has a U-shaped cross-sectional shape and has an upward opening 20.
[0015]
  Next, a method of forming a paint curtain made of a paint containing a component that is difficult to disperse and dissolve using the paint supply head will be described. First, paint 2 mixed and dispersed in a tank 1 with a stirring and mixing device as shown in FIG.TheThe introduction pipe 4 (introduction pipes 16, 17 in FIGS. 1 and 2) is pumped by the pump 3.ThroughAnd quantitativeAnd continuousIntroduced into paint supply head like laminar flowTheThe
[0016]
  As shown in FIGS. 1 and 2, the paint introduced through the introduction pipes 16 and 17 enters the supply pipe 15,Is a downward openingIt is supplied into the basket 19 from the plurality of supply holes 18. At this time, paintTheIt flows out like a turbulent flow in the ridge 19 by the flow velocity.Let meInsoluble ingredientsTheAgain dispersed evenly in the paintSetAndSuppliedpaintEntrains air,BubblesNever produce.IeThe position of the supply hole 18 of the supply pipe 15 is located below the upward opening 20 provided in the mixing / dispersing ridge 19.Therefore, the paint supplied from the supply hole 18 that is the downward opening is supplied into the paint in the basket 19.
[0017]
  In this way, the paint supplied from the supply pipe 15 into the basket 19 is,UpperUpwardOpening 20 to slit 12With the front and both sides of the container at the top of theIt flows out to the paint reservoir part 14 defined by the slope part 13. At this time, disperse and dissolvehardPaint with re-dispersed ingredientsFrom upward opening 20Paint reservoir 14WhatMake it flow like a laminar flow uniformlyBy,In the transport routeEntrainment in paintMaretaairConsist ofHas the effect of removing bubbles. In addition,Side wallThe outer surface 21 isUpwardOutflow from opening 20 like laminar flowDoThe paint is uniformly supplied to the paint reservoir 14To doAt the same time againIn paintHas the effect of removing bubbles. In addition,The supply of paintLiquid level 22 of the paint accumulated in the paint reservoir 14ButIt is between the lower end and the upper end of 樋 19Adjusted asIt is necessary. When the liquid level 22 falls below the lower end of the ridge 19Side wallThe paint drops from the outer surface 21airIt becomes easy to entrain,Of the opening 20As you go up from the top, paint is removed from opening 20Side wallIt becomes impossible to flow out like a laminar flow along the outer side surface 21, and the mixing and dispersing function of the ridge 19 is exhibited, and the coating material is conveyedoccuredThe ability to remove bubblesDifficultBecause it becomes.
[0018]
  In this way,19Side wallPaint is applied to the paint reservoir 14 along the outer surface 21.Like laminar flowBy flowing out, evenly mixed in the paint reservoir 14,DecentralizedThe paint is also free of bubblesThe thin curtain-like or film-like paint curtain 7 having a constant width is continuously supplied by the slits 6 and 12.
[0019]
  The supply pipe 15Is a downward openingSupply hole 18 is a paintIs thatMix using flow rate,DisperseIsFrom,樋 19AgainstEach supply hole 18InIt is preferable to form so that the flow rate or flow rate of the paint is uniform. Therefore, it is preferable to form the plurality of supply holes 18 at intervals such that the upstream side is sparse and the downstream side is dense with respect to the flow direction of the paint in the pipe. Further, instead of the plurality of supply holes 18, a slit that opens downward along the length direction of the supply pipe 15 is provided.As a downward openingWhen forming, along the length of the tubeIs an openingIn order to make the flow rate or flow rate of the paint flowing out from each part of the slit uniform,Open the slitShape that the upstream side is narrower and the downstream side is wider than the flow direction of the paint in the pipeInIt is preferable to form.
[0020]
  In the first embodiment, the shape of the heel 19 iscross sectionIt is U-shaped, but it is not limited to this, for example,As shown in FIG.cross sectionU-shapedWas樋 23 can also be used. Other,cross sectionV-shaped or L-shaped ridges may be used. However, the paint should be allowed to flow out uniformly and laminarly to the paint reservoir 14.Opening 20Form.AndThe soot positioned above the liquid surface 22 of the paint reservoir 1419ofSide wallOutsideHorizontalIt is preferably formed so as to form a right angle or an obtuse angle with respect to the liquid surface 22. When it comes to an acute angle,Paint sidewalls forming openingsTop of orOf the outer surface of the side wallDripping from the middle, there is a bias in flow rate and flow rateairIt is because it becomes easy to involve. Therefore, as shown in FIG.cross sectionIn the U-shaped ridge 23, the ridge 23Side wallThe liquid level 22 is formed on the upper vertical portion 24 of the outer surface.ThepositionAdjust the paint supply to letIt is preferable.
[0021]
  Further, as shown in FIG. 5, a swash plate 25 having a lower end in contact with the surface of the slope portion 13 is provided, and the slope portion 13 and the swash plate 25 are provided.BothA bottom plate 26 to be connected may be provided, and a flange 27 for accommodating the supply pipe 15 may be formed by the slope portion 13, the swash plate 25, and the bottom plate 26. Further, as shown in FIG. 6, a planar slope portion 28 is formed to be connected to the upper portion of the slit 12, and the inner wall surface 29 of the container 11 is cross-sectioned.Reverse LThe collar 30 may be formed by bending it in the shape of a letter and connecting it to the back of the slope portion 28.
[0022]
  This inventionAccording to the manufacturing method of the decorative board,UsedThis paint means a paint containing a repellent mainly composed of silicone oil and the like. When these paints are used, there is a remarkable effect in forming a particularly good paint curtain, Can be formed.
[0023]
(Manufacturing method of decorative board)
  The method for producing a decorative board according to the present invention comprises a paint to which a repellent containing silicon oil or the like as a main component is added,On the surface of the boardAboveUsing paint supply headTheIt is characterized in that it is applied with a flow coater and cured to form a decorative layer. The substrate in the present invention is not particularly limited in terms of material and shape (not limited to a plate shape), and may be any material. For example, a substantially flat metal plate, an inorganic plate, a wooden plate, a paper plate, a resin Inorganic boards, especially ceramic boards, such as cement boards, calcium silicate boards, gypsum boards, slag gypsum boards, lightweight concrete boards, and their fiber reinforced boards, and wood chip cement boards, etc. The following is an example of a method for producing a ceramic board with excellent design using a ceramic substrate as a substrate and a paint for forming a decorative layer to which a repellent is added as a paint containing components that are difficult to disperse and dissolve. explain.
[0024]
  The surface shape of the ceramic substrate in this invention is not particularly limited, and the intended use of the ceramic decorative plate obtained as a product such as a flat (substantially flat plate) shape, an embossed shape (having irregularities on the surface), etc. And a shape more suitable for design and the like can be selected. The flat surface of the ceramic substrate described in the present specification means a state in which the uneven surface is not intentionally provided on the substrate surface, and the presence or absence of the polishing treatment on the substrate is particularly limited. Is not to be done. The surface of the ceramic substrate is embossed when the substrate surface is intentionally provided with irregularities by a known method such as press working or embossing roll processing.
[0025]
  Although it does not specifically limit with the foundation | substrate adjustment layer in this invention, For example, the layer for reinforcement (strength and hardness improvement) of a ceramics system substrate surface part, reduction of the influence which a ceramics system board has on a decorative layer (for example, Layer for reducing the intrusion of alkaline components into the decorative layer), the layer for processing for the purpose of improving and maintaining the adhesion between the ceramic substrate and the decorative layer, and the color of the ceramic substrate itself is makeup A layer intended to be concealed until there is no effect when finished as a plate. For example, it refers to sealer treatment, surfacer treatment, sanding treatment, undercoating treatment (base coating) and the like. In addition, since the base adjustment layer is provided in order to obtain layers for various purposes as described above, these treatments may be performed in combination. Sealer treatment is performed for the purpose of impregnating the ceramic substrate surface part to improve the strength and hardness of the surface portion and the adhesion between the ceramic substrate and the coating film of the base adjustment layer. When the ceramic substrate to be used is filled with a hole on the surface of the system substrate and further contains an alkali component, the alkali component is used for the purpose of suppressing penetration of the coating layer such as a decorative layer. Sanding is performed for the purpose of improving the smoothness of the ceramic substrate surface and removing fuzz remaining on the substrate surface, and polishing on the substrate surface.ofThe entire surface of the substrate is uniformly polished after the layer is formed and the sanding layer to be polished is cured. The type of the polishing machine used in the polishing step is not particularly limited, and a known apparatus such as a platen type belt sander or a drum type belt sander can be selected and used. Undercoating (base coating) is performed so as to conceal the color of the ceramic substrate so that it does not affect the decorative layer and firmly adhere to the ceramic substrate.
[0026]
  The material used for the base adjustment layer is not particularly limited as long as it has a composition that does not impair the adhesion to the decorative layer, and is generally used urethane resin, acrylic urethane resin, unsaturated Polyester resins, polyester acrylate resins, acrylic epoxy resins, acrylic resins, polyurethane resins, acrylic polyurethane resins, and the like can be applied. The method for applying the base adjustment layer is not particularly limited, and a method suitable for the material to be used can be selected from known methods used in ordinary coating, such as a spray method, a roll coater method, and a flow coater method. . The decorative layer in the present invention is a layer formed by adding and applying a repellent to a paint for forming a decorative layer mainly composed of a resin or a pigment.
[0027]
  Moreover, the manufacturing method of the ceramics type decorative board in the present invention is mixed,A repellent is used as a component that is difficult to disperse, and the amount of this repellent addedTheFor example,The range is 0.1 to 1.2% by mass with respect to the total solid content of the paint for forming the decorative layer. The repellent in the present invention means a substance that causes a non-uniform phase in the decorative layer. The non-uniform phase here means, for example, that the density of the resin in the decorative layer is non-uniform; the density of the contained pigment is non-uniform; therefore, the light reflectance or light diffusivity also changes; Point to. The heterogeneous phase is formed by the repellent effect of the repellent (the effect of repelling the repellent and other substances). The leveling property of the paint for forming a decorative layer to which a repellent is added is inhibited, an uneven pattern is formed on the surface of the coating film, the coating film thickness is changed, and the orientation direction or dispersion density of the pigment in the coating film is changed. Thereby, the ceramics-type decorative board excellent in design property, especially a luminous feeling, a three-dimensional feeling, a shadow feeling, and a deep feeling can be manufactured.
[0028]
  The type of repellent may be appropriately determined in consideration of other materials that make up the decorative layer.,Silicone oil etc.As the main componentUse. If the selected silicone oil has a high viscosity and is difficult to disperse in the paint for forming the decorative layer, use it after diluting with a solvent for dilution that does not adversely affect the paint for forming the decorative layer. Also good. Further, the amount of the repellent added varies depending on the surface temperature of the ceramic substrate to which the base layer is applied when applying the decorative layer, the viscosity of the paint for forming the decorative layer to which the repellent is added, For example,Up to 3% by mass can be added to the total solid content of the paint for forming the decorative layer. In addition, when a transparent or translucent top clear layer is formed on the decorative layer, the transparent or translucent top clear layer that has been applied or adhered by the action of the repellent agent present on the surface of the decorative layer is also partially applied. RepelSometimesSince there may be a coating film defect, it can be selected and used as appropriate.
[0029]
  The paint for forming a decorative layer used in the present invention may contain a pigment. As the pigment, scaly pigments such as metal powders such as pearl, mica and aluminum powder are preferable. Such scale-like pigments can give a glittering feeling, a three-dimensional feeling, a shading feeling, and a feeling of depth by changing the orientation direction or dispersion density in the decorative layer due to the repelling effect of the repellent. The pigment content is, for example,,Although it can be added up to 10% by mass with respect to the total solid content of the paint for forming the decorative layer, it contributes to the depth of the design, causes coating equipment or paint circulation, causes poor dispersion and precipitation in the path, and If the decorative layer forming paint is an ultraviolet curable paint, the ultraviolet light may be shielded by the pigment during UV curing, resulting in poor curing.To do.
[0030]
  Although the specific curing method of the paint for forming a decorative layer varies depending on the type of resin used as the binder, a thermosetting type, an ultraviolet curable type, or an electron beam curable type is preferable. A thermosetting paint is a paint composed of components such as pigments, resins, additives, solvents, etc., which are polymerized by the action of a catalyst or a curing agent after heating and after solvent volatilization. . The UV curable paint refers to those in which a photopolymerizable compound undergoes a chain polymerization reaction by generating radicals from a photopolymerization initiator by irradiation with UV light. Specifically, a photopolymerizable resin, oligomer, It is a paint composed of components such as a reactive diluent solvent and a photopolymerization initiator (photosensitizer). Examples of the resin used for the paint include unsaturated polyester resins, polyester acrylate resins, acrylic epoxy resins, acrylic resins, acrylic polyurethane resins, and the like. Electron beam curable paints are those that are polymerized by irradiating mainly with high energy electron beams and acting directly on unsaturated groups of polymerizable compounds, specifically unsaturated polyester resins, epoxy acrylate resins. , Urethane acrylate resins, polyester acrylate resins, polyether acrylate resins, unsaturated acrylic resins, and the like. The thickness of the decorative layer is not particularly limited and is, for example, 10 to 100 μm although it depends on the surface shape of the ceramic substrate.
[0031]
  In the method for producing a decorative board according to the present invention, the surface temperature of the ceramic substrate is adjusted to 60 to 90 ° C., a base layer is provided on the surface of the ceramic substrate, and then the surface temperature of the ceramic substrate is 50 to 80 ° C. After adjusting to, paint for forming a decorative layer with a repellent added,AboveA paint supply head is applied and cured on the base adjustment layer to provide a decorative layer, and a transparent or translucent cured resin coating is applied and cured on the decorative layer to form a transparent or translucent top clear layer. It can be obtained by forming.
[0032]
  Moreover, the surface temperature by the preheating of the ceramics-type board | substrate before the decorative layer application | coating which gave the foundation | substrate adjustment layer has preferable 50-80 degreeC. When the surface temperature is less than 50 ° C., for example, when the decorative layer is applied with a thermosetting type cosmetic layer forming paint to which a repellent is added, the resin of the decorative layer is hard to be cured, and for the decorative layer to which a repellent is added It takes a long time until the paint loses fluidity (fixing), and the pattern and pattern reproducibility may not be obtained. In addition, the effect of the repellent added to the decorative layer-forming paint can initially produce a concavo-convex pattern on the surface of the decorative layer, but the decorative layer-forming paint added with the repellent maintains the fluidity, so that the leveling is reversed. As the pattern progresses, the pattern formed partially or entirely collapses or changes, and the pattern reproducibility cannot be obtained.Not, Lack of a sense of depth and depth. When the surface temperature by preheating exceeds 80 ° C,If the paint for forming the makeup layer with the addition of a repellent is a thermosetting type, the repellent will act and an uneven pattern will be obtained on the surface of the decorative layer. This is not preferable because the fluidity of the previously applied paint is drastically reduced. In addition, as a preheating method, a heating apparatus such as an infrared lamp dryer, a far infrared lamp dryer, a direct hot air dryer, an indirect hot air dryer, or the like can be used. Leveling and curing of the paint for forming a decorative layer to which a repellent is added can be promoted. In addition,LikeThe ceramic substrate is heated, but this is not done and it is dried and cured only after applying the paint.RuAlone,As the temperature changes, the repelling effect also fluctuates, the pattern and pattern also fluctuate, the unevenness on the surface of the decorative layer changes, and it is not preferable because stable production cannot be achieved.
[0033]
  In the present invention,,A ceramic substrate with an undercoat adjustment layer and a paint for forming a decorative layer with a repellent added to a paint supply head that does not have a commercially available paint supply means and mixing / dispersing meansThanTrying to paintDoIf the paint supply headOn both sidesOn the sideConnectedWhen paint falls from the introduction pipe 17 into the paint supply head,airOr entangledAirBubblesAsIt is in an included state.further,Commercially available paint supply heads,Due to its structure, the paint stays in the paint supply head for a short time, and the paint flows down with air bubbles in the paint and flows out from the slit 12 as a paint curtain. Frequently occurBecauseUsedDifficultIt is. on the other hand,AboveUsing paint supply headTry to paintIf in the paint supply headInIn paint for cosmetic layer formation with repellent addedAir toOnce and disperse once in tank 1 with mixing and stirring device,MixedThisIn addition, the paint for forming the decorative layer to which the repellent is added is mixed well again with the component for forming the decorative layer and the paint for forming the decorative layer in the paint supply head.,The paint flows down after being dispersed.do itAs a structure to delay the time from the slit 12 to fall as a paint curtainCagePaint flow in the paint supply headMovementIs preferable, and a uniform paint curtain can be obtained.
[0034]
  Also, in the paint supply head of the present inventionPaint reservoir 14The liquid level 22 of the paint is mixed and dispersedTop ofOpening20To the bottom of the mixing and dispersing meansAdjusted asThere is a need to.thisIn the paint supply headOf the paint reservoir 14The liquid level 22 of the paint,Mixing and dispersing means when below the bottom of the mixing and dispersing meansOpeningFromofThe paint falls on the liquid level 22 or the slope in the painting head.And thatWhen paintofFlowThisDisturbanceairThis may cause the paint curtain to become unstable and cause “curtain breakage”. Meanwhile, in the paint supply headPaint reservoir 14The coating liquid level 22 in,Of mixing and dispersing meansUpperWhen above the openingIn,Since the paint cannot flow out from the opening uniformly like a laminar flow,The effect of removing (defoaming) air bubbles mixed in the paint is obtained.hard.
[0035]
  In addition, the present inventionMethod for manufacturing decorative panelsInAndWhen using the paint supply head,The coating amount of the paint for forming the decorative layer to which the repellent is added depends on the coating conditions such as the addition amount of the repellent, the viscosity of the paint for forming the decorative layer to which the repellent is added, the slit width, the speed of the conveyor, and the discharge amount from the slit. Depending on, for example,Under the conditions of a viscosity of 30 seconds when measured with Iwata # 2 cup, a speed of the conveyor for substrate transfer of 80 m / min, and a slit width of 0.8 mm, 60 to 200 g / m², Preferably 70 to 150 g / m²It is. Application amount is 60g / m²In the following, since the liquid level of the paint in the paint supply head is located below the lowermost part of the mixing and dispersing means, the paint curtain becomes unstable and "curtain break" occurs.originalThis is not preferable because of the cause. Application amount is 200 g / m²If it is more, it is not preferred because the pattern obtained by the action of the repellent added to the paint for forming the decorative layer and the reproducibility of the pattern are difficult to obtain. Also, depending on the coating conditions, the liquid level of the paint in the paint supply head is located above the opening of the mixing and dispersing means.TransportRemoval of bubbles entrained in the pathofsexNohIs unfavorable because of lowering. In addition, the application amount described in this specification means the mass of the coating material applied per unit area immediately after application to the ceramic substrate (uncured state).
[0036]
  Moreover, the viscosity of the paint for forming a decorative layer to which a repellent is added when applying with the paint supply head is adjusted to a range of 20 seconds to 50 seconds with Iwata # 2 cup. Also,The width of the slit is not particularly limited, and is preferably adjusted in the range of 0.5 mm to 0.8 mm in the same manner as a commercially available flow coater. Paint flowforThe distance from the lowermost part of the slit to the substrate transporting conveyor is preferably in the range of 100 mm to 200 mm, and the speed of the substrate transporting conveyor in the flow coater is not particularly limited.
[0037]
  In this inventionVeneerThe transparent or translucent top clear layer means a layer formed on the decorative layer and has a total light transmittance of 40% or more, more preferably 50% or more. The total light transmittance can be measured by a conventionally known method using a haze meter or the like. In addition, the transparent or translucent top clear layer serves as a protective layer for the decorative layer, and further imparts a sense of depth and stereoscopic effect. A transparent or translucent top clear layer is a method in which a paint that forms a transparent or translucent coating layer is applied on the decorative layer by curing after coating, or a transparent or translucent film is applied on the decorative layer. It is formed by a method such as bonding to the surface. The coating material for forming the top clear layer is not particularly limited. For example, urethane-based, acrylic-based, acrylic-urethane-based, unsaturated polyester-based, urethane acrylate-based thermosetting resin coating, and ultraviolet curable resin coating. A colorless transparent paint made of an electron beam curable resin paint or a translucent paint containing a coloring pigment can be used. When the colorant is added to the resin paint as the top clear layer-forming paint, for example, it is 0.3 to 4% by mass, preferably 0.8 to 2% by mass with respect to the resin paint. . Roll coater method and flow coater method can be used to apply the top clear layer coating.SpecialHowever, other existing methods such as a spray method and a transfer method may be used. The thickness of the top clear layer isSpecialAlthough it is not restrict | limited to, it is 15-100 micrometers.
[0038]
【Example】
  Examples of the present invention will be described below.
Example 1
  The surface of an uncured fiber-reinforced cement board manufactured by papermaking is pressed against the uneven surface of an FRP template with unevenness, and then subjected to steam curing at 80 ° C for 8 hours, followed by reaction hardening. Then, after removing the template, it was dried to produce a ceramic substrate having a concavo-convex part with a depth of 100 μm from the convex part to the concave part. next,thisThe surface temperature of the substrate is adjusted to 60 ° C. in advance, and an acrylic urethane-based paint (220 Conitan undercoat manufactured by Osaka Varnish Co., Ltd.) is applied as a base adjustment layer on the roll coater to 40 g / m.²160g / m with conventional flow coater²(80 g / m²× 2 times coating), 200 g / m in total²It was applied and then dried and cured at a surface temperature of 80 ° C. for 5 minutes.
[0039]
  Thereafter, the presence or absence of coating failure on the painted surface was evaluated. Subsequently, an acrylic urethane-based paint (produced by Osaka Varnish Co., Ltd.) containing 5% by mass of a scale-like pearl pigment having an average particle size of 50 μm on a ceramic substrate having a base layer adjusted to a surface temperature of 60 ° C. 220 Conitan topcoat Brighton Silver) is applied to the coating layer supply head of the present invention by adding 0.5% by mass of a repellent containing silicone oil as a main component to the total solid content of the coating layer forming coating. 80 g / m with the flow coater used²It was applied and then dried at 80 ° C. for 20 minutes. The coating conditions of the paint supply head in the flow coater are as follows. Supply of the paint for forming the decorative layer from the introduction pipe to the paint head is made from two places (16 and 17 positions) in the width direction, and the slit width is 0.8 mm. The distance from the slit to the substrate transfer conveyor was 100 mm, the substrate transfer conveyor speed was 80 m / min, and the viscosity of the paint for forming the decorative layer to which the repellent was added was 30 seconds (measured value with Iwata # 2 cup). . In addition, the amount of paint flowing into the paint supply head was 6.3 kg / min.
[0040]
  Apply the paint supply head to the paint for forming the decorative layer with the addition of repellent.PreparedThe paint curtain stability when coating with a flow coater is generally justified in a flow coater type coating device because the paint curtain tends to become unstable immediately after the flow coater and paint circulation pump device are started. Since it is difficult to evaluate, the flow coater and the paint circulation pump device are started under the condition of applying the paint for forming the decorative layer to which the repellent is added. After 10 minutes, the paint curtain is visually observed for 5 minutes. This was a method of measuring the number of “curtain breaks” within an observation time of 5 minutes. In addition, visual observation of the paint curtain was performed by five persons to prevent oversight and miscounting, and was expressed as an average of three values excluding the maximum value and the minimum value in the number of measurements of five persons. Moreover, the presence or absence of the coating defect generation | occurrence | production on the coating surface of the coating material for decorative layer formation was also evaluated.
[0041]
  Subsequently, an ultraviolet curable resin paint having a total light transmittance of 89% (700 Bioren Clear 509H manufactured by Osaka Varnish Co., Ltd.) as a transparent curable resin at a flow coater of 100 g / m.²After coating and setting in an atmosphere of 40 ° C. for 5 minutes, UV rays were applied and cured under the condition of 80 W / cm × 2 lamps while moving at 6 m / min. Thereafter, the evaluation of the radiance, stereoscopic effect, shadow, and depth of the appearance by visual observation was performed, and the presence or absence of poor coating on the painted surface was evaluated.
[0042]
(Example 2)
  It was carried out in the same manner as in Example 1 except that the surface shape was a flat ceramic substrate, and the surface temperature of the ceramic substrate provided with the base adjustment layer was 75 ° C.
[0043]
Example 3
  The same procedure as in Example 1 was performed except that the preheating temperature was 70 ° C., the average particle size of the pearl pigment was 110 μm, and no repellent was used.
  In Example 3, no repellent was used, so this example is a reference example.
[0044]
Example 4 Example except that the substrate is a fiber reinforced calcium silicate plate, the unevenness depth is 120 μm, the paint is a UV curable resin paint, the average particle size of the pearl pigment is 100 μm, and the addition amount of the pearl pigment is 4% by mass. 1 was performed.
[0045]
(Comparative Example 1)
  The decorative layer-forming paint to which the repellent was added was carried out in the same manner as in Example 1 except that a conventional paint supply head that is not provided with a commercially available supply means and mixing / dispersing means was used.
[0046]
(Comparative Example 2)
  A decorative layer-forming coating material to which a repellent was added was carried out in the same manner as in Example 1 except that the coating material supply head described in JP-A-11-128803 was used.
[0047]
  Evaluation results of Examples 1 to 4 and Comparative Examples 1 and 2tableShown in In Table 1, the “surface temperature” in the condition for forming the decorative layer means the surface temperature of the ceramic base substrate provided with the ceramic base preparation layer.
[0048]
[Table 1]

[0049]
【The invention's effect】
  As described above, according to the present invention, even a paint to which a repellent is added can form a stable paint curtain so that the paint can be applied uniformly without any curtain breakage and painting failure. It becomes. In addition, it is possible to produce products with excellent pattern and pattern reproducibility without painting defects, and it is possible to produce decorative panels with excellent design characteristics, especially luminous feeling, three-dimensional feeling, shadow feeling, and depth. It becomes.
[Brief description of the drawings]
FIG. 1 is a partially broken perspective view showing a paint supply head according to an embodiment of the present invention.
FIG. 2 is a partially cutaway front view showing the paint supply head of FIG.
FIG. 3 is a side sectional view showing the paint supply head of FIG. 1;
FIG. 4 is a side sectional view showing a paint supply head according to a modification.
FIG. 5 is a side sectional view showing a paint supply head according to a modification.
FIG. 6 is a side sectional view showing a paint supply head according to a modification.
FIG. 7 is a diagram showing an overall configuration of a flow coater.
[Explanation of symbols]
  1 tank, 2 paint, 3 pump, 4, 16, 17 introduction pipe, 5 paint supply head, 6, 12 slit, 7 paint curtain, 8, 9 conveyor, 10 paint collection tank, 11 container, 13, 28 slope part, 14 paint reservoir, 15 supply pipe, 18 supply hole(Downward opening)19, 23, 27, 30 樋, 20UpwardOpening, 21 outer surface, 22 liquid surface, 24 vertical portion, 25 swash plate, 26 bottom plate, 29 inner wall surface, A coating object.

Claims (4)

The paint to which the repellent is added is continuously supplied to the container-like paint supply head via the introduction pipe , and further supplied downward as a paint curtain from the slit formed in the paint supply head, and is moved by the conveyor. in the method for manufacturing decorative laminates to adhere the coating to the surface of the substrate, said feed head, a long box-like container in which a slit is formed in the bottom, in order to supply paint to the container, connected to the inlet tube with a supply means to form a downward opening, and mixing and dispersing means for flowing out the upward opening in layers with accept paint from the supply means temporarily, and the sides of the concatenated inclined surface portion and the container on the slit And a paint reservoir for storing paint that flows out in layers from the mixing / dispersing means, and the supply means and the mixing / dispersing means are connected to the supply means. The uppermost position of the mouth is disposed below the lowermost position of the opening of the mixing / dispersing means, and the paint from the supply means is disposed so that the liquid level of the paint reservoir portion is the upward opening of the mixing / dispersing means. To a bottom of the mixing / dispersing means is supplied so as to supply the decorative board . The said board | substrate is either a metal plate, an inorganic board, a wooden board, a paper board, a resin board, and a film, The manufacturing method of the decorative board of Claim 1 characterized by the above-mentioned. The method for producing a decorative board according to claim 1 or 2, wherein the substrate is provided with a base adjustment layer in advance . Above the top layer of the decorative plate has a transparent or decorative board manufacturing method according to any one of claims 1 to 3, characterized that you form a top clear layer of semi-transparent.

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