JP6413295B2 - Building materials - Google Patents

Description

  Aspects of the invention generally relate to building materials.

  By providing a painted pattern on the bathroom wall or bathroom floor, the interior of the bathroom can be made beautiful and a high-class atmosphere can be achieved. For example, as a method for decorating building materials such as bathroom walls and bathroom floors, a method is known in which a surface pattern material provided with a predetermined pattern in advance and an FRP molding material are laminated and pressure-heat-molded (patent) Reference 1). However, in the method disclosed in Patent Document 1, since the surface pattern material is prepared in advance, there is a problem that the cost increases in consideration of the management cost of the surface pattern material.

  On the other hand, there is a surface coating method for an exterior material in which a substrate having an uneven surface is coated with a flexo roll to form a pattern on a convex surface (Patent Document 2). However, when the surface of the building material is uneven and there is a flat surface portion that is thinner than the thickness of the convex portion at the end of the building material, a step is generated between the convex portion and the flat surface portion. Therefore, the flexo roll floats from the flat surface portion due to the step between the convex portion and the flat portion, and the region in the vicinity of the convex portion in the flat portion is not painted. Therefore, the boundary part between the area | region (painting area | region) to be painted and the area | region (non-coating area | region) which is not painted arises on the surface of a plane part.

  Furthermore, if there is unevenness on the surface of the convex part, or if there is unevenness as a whole of the plurality of convex parts by providing a plurality of convex parts apart, the flexo roll is Because of rolling, the degree to which the flexoroll is compressed changes. Therefore, the edge part of a non-painting area | region (boundary part between a painting area | region and a non-coating area | region) may be distorted, and the designability of building materials may be impaired.

JP 2004-160828 A JP 2004-330161 A

  This invention is made | formed based on recognition of this subject, and it aims at providing the building material which can suppress that the edge part of a non-coating area | region is distorted.

1st invention is the plate-shaped building material with which at least one part of the uneven part or the uneven | corrugated | grooved part and at least one part of the plane part were painted by the roll coat coating apparatus, Comprising: It is provided in the center part of the surface. The uneven portion or the concavo-convex portion and the uneven portion or the concavo-convex portion are provided in a portion on the peripheral side when viewed from the uneven portion or the concavo-convex portion, and are formed thinner than the thickness of the uneven portion or the concavo-convex portion. An end of a non-painted area that is provided at a predetermined interval from the upper surface of the convex portion and the flat portion that generates a step, and from the uneven portion or the uneven portion, and is generated on the flat portion based on the step. A distortion eliminating portion formed integrally with the planar portion for suppressing the distortion of the portion, and the distortion eliminating portion is provided at a portion including the end portion and protrudes upward from the surface of the planar portion to protrude the convex portion. The protrusion should be lower than the height of the Is a building material which is characterized in.

According to this building material, the building material includes the distortion eliminating portion that suppresses the distortion of the end portion of the unpainted region that is not painted that occurs in the flat portion. Therefore, distortion at the end of the non-painting area can be suppressed. Therefore, the end of the non-coating region can be expressed linearly without distortion using a roll coating method. Moreover, the building material excellent in aesthetics can be provided, without raising manufacturing cost. Moreover, according to this building material, the site | part of the edge part side of building material is protruded slightly from the surface of a plane part rather than the position where the edge part of a non-coating area | region is formed. Therefore, the coating roll comes into contact with the surface of the protrusion and the surface of the flat surface so as to become familiar with a slight step between the protrusion and the flat surface. For this reason, the end portion of the non-coating region is represented by the edge of the protruding portion on the projecting portion side. Thereby, the edge part of a non-coating area | region can be expressed substantially linearly, and the building material excellent in aesthetics can be obtained.

The second invention is a plate-like building material in which at least a part of the uneven part or the uneven part and at least a part of the flat part are coated by a roll coat coating apparatus, and are provided in the center part of the surface. The uneven portion or the concavo-convex portion and the uneven portion or the concavo-convex portion are provided in a portion on the peripheral side when viewed from the uneven portion or the concavo-convex portion, and are formed thinner than the thickness of the uneven portion or the concavo-convex portion. An end of a non-painted area that is provided at a predetermined interval from the upper surface of the convex portion and the flat portion that generates a step, and from the uneven portion or the uneven portion, and is generated on the flat portion based on the step. A distortion eliminating portion formed integrally with the flat surface portion to prevent the portion from being distorted, and the distortion eliminating portion is provided at a portion including the end portion and from the convex portion side to the peripheral edge side. Having a surface inclined downward toward the end A building material, characterized in that a tapered section connected portion and stepless of said flat portion on the side of the peripheral edge than location.

According to this building material, the building material includes the distortion eliminating portion that suppresses the distortion of the end portion of the unpainted region that is not painted that occurs in the flat portion. Therefore, distortion at the end of the non-painting area can be suppressed. Therefore, the end of the non-coating region can be expressed linearly without distortion using a roll coating method. Moreover, the building material excellent in aesthetics can be provided, without raising manufacturing cost. Further, according to the building material in the vicinity of a position where the end portion of the uncoated region is formed, a tapered portion which is steplessly connected to a part of the flat portion projects from the surface of the flat portion upward. Therefore, the surface of the coating roll is almost completely in contact with the surface of the tapered portion, and is continuously applied from the surface of the tapered portion to a part of the surface of the flat portion. For this reason, the end portion of the non-coating region is represented by the edge on the convex portion side of the tapered portion. Thereby, the edge part of a non-coating area | region can be expressed substantially linearly, and the building material excellent in aesthetics can be obtained.

According to a third invention, in the second invention, the tapered portion is a surface provided on the non-landing portion or the uneven portion side, and is steeper than a vertical surface or an inclination of an upper surface of the tapered portion. It is a building material characterized by having an inclined surface.

  According to this building material, at the time of roll coat coating, the coating roll may come into contact with the side surface of the taper portion on the non-land portion or the uneven portion side. That is, the end portion of the non-coating region may occur on the side surface of the tapered portion. At this time, if the amount of compressive deformation of the coating roll during roll coating is changed by the uneven portion or the uneven portion, the amount of the coating roll contacting the side surface of the tapered portion is changed. On the other hand, the side surface of the taper portion has a vertical surface or a surface that is steeper than the inclination of the upper surface of the taper portion. For this reason, even when viewed from the surface side of the building material, the distortion at the end of the non-coating region due to the change in the contact amount can hardly be recognized. Therefore, the edge part of a non-coating area | region can be expressed linearly and the building material excellent in aesthetics can be obtained.

A fourth invention is a plate-shaped building material in which at least a part of the uneven part or the uneven part and at least a part of the flat part are coated by a roll coat coating apparatus, and are provided in the center part of the surface. The uneven portion or the concavo-convex portion and the uneven portion or the concavo-convex portion are provided in a portion on the peripheral side when viewed from the uneven portion or the concavo-convex portion, and are formed thinner than the thickness of the uneven portion or the concavo-convex portion. An end of a non-painted area that is provided at a predetermined interval from the upper surface of the convex portion and the flat portion that generates a step, and from the uneven portion or the uneven portion, and is generated on the flat portion based on the step. A distortion eliminating portion formed integrally with the planar portion that suppresses distortion of the portion, and the distortion eliminating portion is provided in a portion including the end portion, and is a recess recessed backward from the surface of the planar portion. It is a building material characterized by

According to this building material, the building material includes the distortion eliminating portion that suppresses the distortion of the end portion of the unpainted region that is not painted that occurs in the flat portion. Therefore, distortion at the end of the non-painting area can be suppressed. Therefore, the end of the non-coating region can be expressed linearly without distortion using a roll coating method. Moreover, the building material excellent in aesthetics can be provided, without raising manufacturing cost. Moreover, according to this building material, the area | region including the position in which the edge part of a non-coating area | region is formed is dented below from the surface of a plane part. Therefore, the coating roll does not paint the recessed part. Therefore, the end portion of the non-painting region is not represented on the plane, but is represented at the edge between the plane portion and the recessed portion. Thereby, the edge part of a non-coating area | region can be expressed substantially linearly, and the building material excellent in aesthetics can be obtained.

  According to the aspect of the present invention, there is provided a building material capable of suppressing the end portion of the non-coating region from being distorted.

It is a schematic plan view which illustrates the roll coat coating apparatus which roll coat-coats the building material concerning this embodiment. FIG. 2 is a schematic plan view when the roll coat coating apparatus shown in FIG. 1 is viewed in the direction of arrow A. FIG. 3 is a schematic enlarged view of a region A11 illustrated in FIG. It is a schematic diagram explaining the non-coating area | region between a convex part and a plane part. It is a typical enlarged view which illustrates the state which roll-coat-coats the building material concerning a comparative example. It is a schematic diagram explaining the non-coating area | region between a convex part and a plane part in a comparative example. It is a typical enlarged view which illustrates the example of the distortion elimination part of the building material concerning this embodiment. It is a flowchart figure showing the roll coat coating method of the building material concerning this embodiment. It is a schematic plan view which illustrates a part of manufacture of the building material concerning this embodiment. It is typical sectional drawing which illustrates the specific example of the unevenness of this embodiment. It is a typical perspective view which illustrates the example of the building material concerning this embodiment. It is a schematic plan view which illustrates the other specific example of the building material concerning this embodiment.

Embodiments of the present invention will be described below with reference to the drawings. In addition, in each drawing, the same code | symbol is attached | subjected to the same component and detailed description is abbreviate | omitted suitably.
FIG. 1 is a schematic plan view illustrating a roll coat coating apparatus that roll coats a building material according to this embodiment.
FIG. 2 is a schematic plan view when the roll coat coating apparatus shown in FIG. 1 is viewed in the direction of arrow A. FIG.

  A roll coat coating apparatus 100 illustrated in FIG. 1 includes a coating roll 110, a backup roll 120, and a pickup roll 130. A member having elasticity such as rubber is provided on the outer periphery of the coating roll 110. The coating roll 110 can rotate around the shaft 110c. The backup roll 120 is provided at a position facing the coating roll 110 and can rotate about the shaft 120c. The pick-up roll 130 is provided at a position facing the coating roll 110 and is rotatable about a shaft 130c.

  The coating roll 110 rotates in the direction of the arrow A1 shown in FIG. 1 and can apply the coating 140 on the surface 201 of the object (base material or building material) 200 to be coated. The coating material 140 is supplied to the surface 201 of the object 200 by the coating roll 110 rotating in the direction of the arrow A1 shown in FIG. 1 and the pickup roll 130 rotating in the direction of the arrow A3 shown in FIG. The The object to be coated 200 passes between the coating roll 110 and the backup roll 120 by, for example, a conveyor, and is sent out in the direction of the arrow A4 shown in FIG. At this time, the backup roll 120 applies pressure to the object to be coated 200 and suppresses the object 200 from being bent.

  Examples of the article to be coated 200 include floor materials and wall materials. The wall material includes, for example, an exterior material used outdoors. The object to be coated 200 is used as a building material, for example.

  As shown in FIG. 2, the article to be coated 200 has a convex portion 210 and a flat portion 220 and has a plate shape. The convex part 210 is provided in the center part on the surface 201 side in the article to be coated 200. The flat portion 220 is provided in the portion on the surface 201 side of the article to be coated 200 and on the peripheral side when viewed from the convex portion 210. The flat portion 220 has a step difference from the surface (upper surface) 211 (see FIG. 3) of the convex portion 210, and is formed lower (or thinner) than the convex portion 210.

  The plane part 220 includes a tapered part (distortion eliminating part) 221 and a horizontal part 223. The horizontal portion 223 has a surface substantially parallel to the axis 110c of the coating roll 110. The taper part 221 is provided in the vicinity of the convex part 210 in the flat part 220 and has a surface inclined downward from the convex part 210 side toward the end part side (periphery side) of the article 200 to be coated. The tapered portion 221 is connected to the horizontal portion 223 without a step.

  Here, “downward” in the specification of the present application refers to a direction from the surface 201 (painted surface: the surface on which the paint 140 is applied) of the article 200 to the surface opposite to the painted surface (back surface 203). On the other hand, “upward” in the specification of the present application refers to a direction from the back surface 203 of the article 200 to the front surface 201.

  The article to be coated 200 may have one convex portion 210 or a plurality of convex portions 210. A workpiece 200 shown in FIG. 2 has a plurality of convex portions 210. When the object to be coated 200 has a plurality of convex portions 210, unevenness exists on the surface 201 side of the object to be coated 200 due to the entirety of the plurality of convex portions 210. On the other hand, when the article 200 has one convex portion 210, unevenness exists on the surface (upper surface) 211 of one convex portion 210. Thus, in the specification of the present application, “non-land” means that a plurality of convex portions 210 are provided and the surface of one convex portion 210 is formed by forming unevenness and unevenness on the entire surface 201. And the land that exists in 211. Details of the unevenness of the object 200 will be described later.

  When the workpiece 200 is viewed in the direction of arrow A shown in FIG. 1, the entire workpiece 200 passes between the coating roll 110 and the backup roll 120. Therefore, the convex portion 210 of the object to be coated 200 and the flat surface portion 220 of the object to be coated 200 are coated substantially simultaneously by the roll coat coating apparatus 100. At this time, the surface of the coating roll 110 (outer peripheral surface: the surface on which the coating material 140 is applied to the object to be coated 200) cannot completely follow the step between the surface 211 of the convex portion 210 and the flat portion 220. Therefore, a non-painting area where the paint 140 is not applied and a paint area where the paint 140 is applied are generated in the flat portion 220.

Here, as described above, since unevenness exists on the surface 201 side of the object 200, the surface of the coating roll 110 fluctuates up and down when rolling on the unevenness of the object 200. There is. Alternatively, when the surface of the coating roll 110 rolls on the uneven surface of the object 200, the degree to which the coating roll 110 is compressed may change. Then, when the taper part 221 is not provided in the plane part 220, the edge part of the non-painting area | region which arose in the plane part 220 (The coating area to which the coating material 140 is applied, the non-coating area to which the coating material 140 is not applied, May be distorted.
This will be further described with reference to the drawings.

FIG. 3 is a schematic enlarged view of a region A11 shown in FIG.
FIG. 4 is a schematic diagram for explaining a non-coating region between the convex portion and the flat portion.
FIG. 5 is a schematic enlarged view illustrating a state in which the building material according to the comparative example is roll-coated.
FIG. 6 is a schematic diagram illustrating a non-coating region between the convex portion and the flat portion in the comparative example.

  FIG. 4A is a schematic plan view showing the surface of an object to be coated after painting. FIG. 4B is a schematic perspective view showing the surface of the object to be coated after painting. FIG. 5 corresponds to a schematic enlarged view of the region A11 illustrated in FIG. FIG. 6A is a schematic plan view showing the surface of an object to be coated according to a comparative example after coating. FIG.6 (b) is a typical perspective view showing the surface of the to-be-coated object concerning the comparative example after coating.

  As shown in FIG. 3, a portion where the convex portion 210 is provided (a central portion on the surface 201 side of the object to be coated 200) is referred to as a “pattern portion”, a “non-land portion”, or an “uneven portion”. . The boundary line 241 between the pattern unit 230 and the plane unit 220 is as shown in FIG. That is, the boundary line 241 between the pattern unit 230 and the plane unit 220 exists between the projection unit 210 closest to the plane unit 220 among the plurality of projection units 210 and the plane unit 220. By providing the convex portion 210, a pattern portion (non-land portion, uneven portion) 230 is formed.

  Here, the comparative example shown in FIG. 5 will be described. An object to be coated 200a shown in FIG. 5 has a convex portion 210 and a flat portion 220. The convex portion 210 of the workpiece 200a is the same as the convex portion 210 described above with reference to FIG. The planar portion 220 of the object to be coated 200a has a horizontal portion 223, but does not have the tapered portion 221 like the object to be coated 200 shown in FIGS.

  The surface 111 of the coating roll 110 cannot completely follow the step between the surface 211 of the convex portion 210 and the flat portion 220. More specifically, the surface 111 of the coating roll 110 floats from a part of the flat portion 220 due to a step between the surface 211 of the convex portion 210 and the flat portion 220. Therefore, as illustrated in FIG. 5, a non-painting region 223 a where the paint 140 is not applied and a paint region 223 b where the paint 140 is applied are generated in the flat portion 220.

  Since unevenness exists on the surface 201 side of the object to be coated 200, when the surface 111 of the coating roll 110 rolls on the unevenness of the object to be coated 200, it may fluctuate up and down. Alternatively, when the surface of the coating roll 110 rolls on the uneven surface of the object 200, the degree to which the coating roll 110 is compressed may change. Then, as shown in FIGS. 6A and 6B, the end portion of the non-coating region 223a (the boundary portion between the non-coating region 223a and the coating region 223b) 223c may be distorted. If the end 223c of the non-coating region 223a is distorted, the design of the article 200 is impaired.

  On the other hand, the to-be-coated object 200 according to the present embodiment has a distortion eliminating portion provided at a predetermined interval from the pattern portion 230. The distortion eliminating portion suppresses distortion of the end portion 223c of the non-coating region 223a. In the example illustrated in FIG. 3, the distortion eliminating portion is a tapered portion 221 provided at a portion including the end portion 223 c of the non-painting region 223 a.

  As described above, the surface 111 of the coating roll 110 cannot completely follow the step between the surface 211 of the convex portion 210 and the flat portion 220. Therefore, as illustrated in FIG. 3, a non-painting region 223 a where the coating material 140 is not applied and a coating region 223 b where the coating material 140 is applied are generated in the planar portion 220. The connecting portion 225 in which the tapered portion 221 is connected to the horizontal portion 223 without a step is located on the end portion side of the object 200 to be coated with respect to the end portion 223c of the non-coating region 223a. The side surface of the tapered portion 221 on the convex portion 210 side has a vertical surface or a surface with an inclination (angle) steeper than the inclination (angle) of the upper surface of the tapered portion 221.

  According to this, since the article to be coated 200 has the distortion eliminating portion, the distortion of the end portion 223c of the non-coating region 223a can be suppressed. More specifically, even if unevenness exists on the surface 201 side of the article 200, the surface 111 of the coating roll 110 is in stable contact with the surface of the tapered portion 221. Therefore, it can suppress that the position of the edge part 223c of the non-coating area | region 223a fluctuates. As a result, as shown in FIGS. 4A and 4B, the end portion 223c of the non-painting region 223a generated based on the step between the surface 211 of the convex portion 210 and the flat portion 220 is not distorted. It can be expressed linearly. Moreover, the building material excellent in aesthetics can be provided, without raising manufacturing cost.

  Further, in the vicinity of the position where the end portion 223c of the non-coating region 223a is formed, a tapered portion 221 connected to the flat portion 220 without a step protrudes upward from the surface of the flat portion 220. Therefore, the surface 111 of the coating roll 110 is almost completely in contact with the surface of the tapered portion 221 and is continuously applied from the surface of the tapered portion 221 to the surface of the flat portion 220. Therefore, the end portion 223c of the non-coating region 223a is expressed at the edge of the tapered portion 221 on the convex portion 210 side. Thereby, the edge part 223c of the non-coating area | region 223a can be expressed substantially linearly, and the building material excellent in aesthetics can be obtained.

  Moreover, the coating roll 110 may contact the side surface of the taper part 221 on the convex part 210 side at the time of roll coating. That is, the end portion 223c of the non-painting region 223a may be generated on the side surface of the tapered portion 221. At this time, when the amount of compressive deformation of the coating roll 110 during roll coating changes due to the uneven portion or the uneven portion, the amount of the coating roll 110 that contacts the side surface of the tapered portion 221 changes. On the other hand, the side surface of the taper portion 221 has a vertical surface or a surface that is steeper than the inclination of the upper surface of the taper portion 221. Therefore, even when viewed from the surface 201 side of the object to be coated 200, the distortion of the end 223c of the non-coating region 223a due to the change in the contact amount can hardly be recognized. Therefore, the edge part 223c of the non-coating area | region 223a can be expressed linearly, and the building material excellent in aesthetics can be obtained.

FIG. 7 is a schematic enlarged view illustrating a specific example of the distortion eliminating portion of the building material according to the present embodiment.
FIG. 7 corresponds to a schematic enlarged view of the region A11 illustrated in FIG.

  FIG. 7A shows the object 200a described above with reference to FIG. FIG. 7B shows the article 200 described above with reference to FIGS. A range 223d illustrated in FIG. 7 represents a range in which the end portion 223c of the non-coating region 223a is distorted (variable range) in the workpiece 200a illustrated in FIG.

  An object to be coated 200b according to the specific example shown in FIG. 7C has a first recess 221b. The 1st recessed part 221b is provided in the site | part containing the edge part 223c of the non-coating area | region 223a. The first recess 221b has a shape that is recessed downward from the surface of the flat portion 220. That is, the first recess 221 b is recessed downward from the surface of the flat portion 220. An end portion 223c of the non-coating region 223a is represented at an edge between the flat portion 220 and the first recess 221b.

  An object to be coated 200c according to the specific example shown in FIG. 7D has a second recess 221c. The 2nd recessed part 221c is provided in the site | part containing the edge part 223c of the non-coating area | region 223a. The second recess 221c has a shape that is recessed downward from the surface of the flat portion 220. That is, the second recess 221 c is recessed downward from the surface of the flat portion 220. The bottom of the second recess 221c has a surface inclined downward from the convex portion 210 side toward the flat portion 220 side. An end portion 223c of the non-coating region 223a is represented at an edge between the flat portion 220 and the second recess 221c.

  According to the specific example shown in FIG. 7C and the specific example shown in FIG. 7D, the region including the position where the end portion 223c of the non-coating region 223a is formed is lower than the surface of the flat portion 220. Recessed. Therefore, the coating roll 110 does not paint the recessed part (the 1st recessed part 221b and the 2nd recessed part 221c). Therefore, the end portion 223c of the non-painting region 223a is not represented on the plane, but is represented at the edge between the plane portion 220 and the recessed portion. Thereby, the edge part 223c of the non-coating area | region 223a can be expressed substantially linearly, and the building material excellent in aesthetics can be obtained.

  An object to be coated 200d according to the specific example shown in FIG. 7E has a protrusion 221d. The protrusion 221d is provided at a portion including the end 223c of the non-painting region 223a. The protrusion 221d protrudes upward from the surface of the flat portion 220. When viewed from the surface of the flat portion 220, the height of the protrusion 221d is lower than the height of the convex portion 210. The height of the protruding portion 221d is such that the surface 111 of the coating roll 110 can follow the step between the convex portion 210 and the protruding portion 221d and the step between the flat portion 220 and the protruding portion 221d. It is height.

  According to the specific example shown in FIG. 7 (e), the part of the object to be coated 200 d on the side closer to the end part 223 c of the non-coating region 223 a is made lower than the convex part 210. It protrudes slightly from the surface of the flat part 220. Therefore, the coating roll 110 comes into contact with the surface of the protrusion 221 d and the surface of the flat surface 220 so as to become familiar with a slight step between the protrusion 221 d and the flat surface 220. Therefore, the end portion 223c of the non-painting region 223a is represented on the edge of the protruding portion 221d on the convex portion 210 side. Thereby, the edge part 223c of the non-coating area | region 223a can be expressed substantially linearly, and the building material excellent in aesthetics can be obtained.

FIG. 8 is a flowchart showing a building material roll coat coating method according to this embodiment.
FIG. 9 is a schematic plan view illustrating a part of the manufacturing of the building material according to the embodiment.
In the flowchart shown in FIG. 8, a case where any one of the shapes of the objects 200, 200b, 200c, and 200d shown in FIGS. 7B to 7E is formed is taken as an example.
FIG. 9A is a schematic plan view illustrating a calendar forming apparatus used for heat lamination molding. FIG. 9B is a schematic plan view illustrating the shape transfer device.

  In the roll coat coating method shown in FIG. 8, before coating the object 200, the uneven portion (the convex portion 210 in the present embodiment) and the uneven portion, and FIGS. 7B to 7E. Any one of the shapes of the objects 200, 200b, 200c, and 200d shown in (5) is formed by thermal lamination molding (step S101: base material molding). The molding method is not limited to heat lamination molding, and may be other molding methods such as press molding.

  Subsequently, the object 200 is applied by roll coating (step S103: printing of color and pattern). Subsequently, a surface protective layer is formed by roll coating (step S105: guard coating). In step S105, spray coating or the like may be used instead of roll coating.

With reference to FIG. 9 (a) and FIG. 9 (b), the roll coating method for building materials according to this embodiment will be further described.
The calendar forming apparatus 400 illustrated in FIG. 9A includes a delivery unit 410, a heating unit 420, and a pressurizing unit 430. Further, a shape transfer device 440 and a cutting device 450 are provided at the subsequent stage of the calendar forming device 400.

  For example, each of the plurality of sheet materials included in the article to be coated 200 is wound in a roll shape and set in the delivery unit 410. Each roll-shaped sheet material set in the delivery unit 410 is sent from the delivery unit 410 to the heating unit 420 while being stacked in a direction perpendicular to the sheet surface.

  The heating unit 420 is provided with a heater (not shown). Each sheet material passing through the heating unit 420 is heated to a predetermined temperature by the heat of the heater.

  Each sheet material heated by the heating unit 420 is pressed in the pressurizing unit 430. The pressure unit 430 includes a first pressure roller 431 and a second pressure roller 432. Each sheet material is fed between the first pressure roller 431 and the second pressure roller 432 while being stacked in a direction perpendicular to the sheet surface, and the first pressure roller 431 and the second pressure roller 432 are fed. By being sandwiched between the pressure rollers 432, they are pressed against each other. Since each sheet material is heated by the heating unit 420, the sheet materials are welded to each other by the pressure between the first pressure roller 431 and the second pressure roller 432. As a result, the sheet materials are stacked in close contact with each other.

  Next, on the surface of the heat-laminated laminate (intermediate structure), uneven portions and uneven portions, and the objects 200, 200b, 200c, and 200d to be coated shown in FIGS. 7B to 7E. Transfer one of the shapes. A shape transfer device 440 is disposed following the pressure unit 430. The shape transfer device 440 transfers a predetermined shape (such as an uneven portion or a non-land portion) to the intermediate structure when the intermediate structure is in a soft state before being cooled and hardened.

  The shape transfer device 440 includes a first transfer roller 441 and a second transfer roller 442. The first transfer roller 441 and the second transfer roller 442 are provided close to each other. On one of the surfaces of the first transfer roller 441 and the second transfer roller 442, for example, a protruding portion 441a having a reverse shape of the convex portion 210 is provided. In the shape transfer device 440 shown in FIG. 9B, a protrusion 441 a is provided on the surface of the first transfer roller 441.

  The intermediate structure welded by the pressure unit 430 is sent between the first transfer roller 441 and the second transfer roller 442 while still warm. When the intermediate structure passes between the first transfer roller 441 and the second transfer roller 442, the protrusion 441a provided on the surface of the first transfer roller 441 is pushed into the surface of the intermediate structure. It is.

  Thereby, a groove is formed on the surface of the intermediate structure. A portion where the groove is not formed, that is, a region partitioned by the groove becomes a relatively convex portion 210.

  After the irregularities including the grooves are transferred by the shape transfer device 440, the surface of the article 200 is painted by roll coating. After the painting is performed, the intermediate structure is sent to a cutting device 450 provided at the subsequent stage of the shape transfer device 440 and cut into a required size.

  Next, a resin-based hydrophilic coating agent is sprayed and applied to the surface of the painted base material using, for example, a spray. Thereafter, the coating agent is cured by, for example, irradiating ultraviolet rays. As a result, a surface protective layer is formed on the surface to which the paint 140 is applied.

FIG. 10 is a schematic cross-sectional view illustrating a specific example of unevenness according to the present embodiment.
In the specific example shown in FIG. 10A, a plurality of convex portions 210a are provided. The surface 211 of the convex part 210a is a horizontal surface. The horizontal surface is substantially parallel to the axis 110c of the coating roll 110, for example. In the specific example shown in FIG. 10A, unevenness exists as a whole of the surface 201 of the article 200 by providing a plurality of convex portions 210 a.

  In the specific example shown in FIG. 10B, a plurality of convex portions 210b are provided. At least one surface 211 of the plurality of convex portions 210b is an inclined surface. The inclined surface is non-parallel to the axis 110c of the coating roll 110, for example. In the specific example shown in FIG. 10B, unevenness exists as a whole of the surface 201 of the article 200 by providing the plurality of convex portions 210b.

  In the specific example shown in FIG. 10C, a plurality of convex portions 210c are provided. On the surface of each of the plurality of convex portions 210c, unevenness finer than the unevenness formed by the convex portions 210c is formed. In the specific example shown in FIG. 10C, unevenness exists as a whole of the surface 201 of the article 200 by providing a plurality of convex portions 210c, and in each surface 211 of the plurality of convex portions 210c. There is unevenness.

  In the specific example shown in FIG. 10D, one convex portion 210d is provided. On the surface of the convex portion 210d, irregularities finer than the irregularities formed by the convex portion 210d are formed. In the specific example shown in FIG. 10D, unevenness exists on the surface 211 of one convex portion 210d.

FIG. 11 is a schematic perspective view illustrating a specific example of the building material according to the present embodiment.
An object to be coated 200 shown in FIG. 11 is a flooring material used in, for example, a bathroom. A workpiece 200 shown in FIG. 11 has a washing place 251. A plurality of convex portions 210 (see FIG. 2) are formed in the washing area 251. The plurality of convex portions 210 in this specific example function as, for example, a slip stopper. Portions between the plurality of adjacent convex portions 210 function as drainage grooves. A drain outlet 253 is provided in a part of the washing area 251. In the to-be-coated object 200 shown in FIG. 11, the plurality of convex portions 210 are provided in the washing place 251, so that the entire washing place 251 has unevenness.

FIG. 12 is a schematic plan view illustrating another specific example of the building material according to this embodiment.
Fig.12 (a) is the typical top view which looked at the unevenness of the building material of this example from the side. 12B is a schematic plan view when the building material shown in FIG. 12A is viewed in the direction of arrow B. FIG.

  A workpiece 200 shown in FIGS. 12A and 12B is a wall material used in, for example, a bathroom. Or the to-be-coated object 200 represented to Fig.12 (a) and FIG.12 (b) is the wall material (exterior material) used in the outdoors etc., for example. In the workpiece 200 shown in FIGS. 12A and 12B, unevenness exists on the surface 255. As described above with reference to FIG. 10 (d), the unevenness formed on the surface 255 of the workpiece 200 shown in FIGS. 12 (a) and 12 (b) is, for example, on the surface 211 of one convex portion 210. Exists.

The embodiment of the present invention has been described above. However, the present invention is not limited to these descriptions. As long as the features of the present invention are provided, those skilled in the art appropriately modified the design of the above-described embodiments are also included in the scope of the present invention. For example, the shape, dimensions, material, arrangement, etc. of each element included in the roll coat coating apparatus 100 and the article (building material) 200 to be coated, and the installation form of the uneven part and the uneven part are limited to those illustrated. Instead, it can be changed as appropriate.
Moreover, each element with which each embodiment mentioned above is provided can be combined as long as technically possible, and the combination of these is also included in the scope of the present invention as long as it includes the features of the present invention.

  DESCRIPTION OF SYMBOLS 100 roll coat coating apparatus, 110 coating roll, 110c axis | shaft, 111 surface, 120 backup roll, 120c axis | shaft, 130 pick-up roll, 130c axis | shaft, 140 coating material, 200, 200a, 200b, 200c, 200d To-be-coated object, 201 surface, 203 Back surface, 210, 210a, 210b, 210c, 210d convex portion, 211 surface, 220 flat portion, 221 tapered portion, 221b first concave portion, 221c second concave portion, 221d protruding portion, 223 horizontal portion, 223a non-coating region, 223b coating region, 223c end, 223d range, 225 connection part, 230 pattern part, 241 boundary line, 251 washing place, 253 drainage port, 255 surface, 400 calendar molding device, 410 delivery part, 420 Heating unit, 430 pressure unit, 431 first pressure roller, 432 second pressure roller, 440 shape transfer device, 441 first transfer roller, 441a protrusion, 442 second transfer roller, 450 cutting device

Claims (4)

At least a part of the uneven part or the uneven part, and at least a part of the flat part are plate-like building materials coated by a roll coat coating device,
The uneven portion or the uneven portion provided in the center of the surface;
The uneven portion or the uneven portion is provided in a portion on the peripheral side, and is formed thinner than the uneven portion or the uneven portion, thereby forming a step with the upper surface of the convex portion of the uneven portion. A plane portion;
It is provided at a predetermined interval from the non-land portion or the uneven portion, and is formed integrally with the flat portion that suppresses distortion of the end portion of the non-painted area that is generated in the flat portion based on the step. The distortion elimination section,
Equipped with a,
The said distortion elimination part is a protrusion provided in the site | part containing the said edge part, protrudes upwards from the surface of the said plane part, and is lower than the height of the said convex part . At least a part of the uneven part or the uneven part, and at least a part of the flat part are plate-like building materials coated by a roll coat coating device,
The uneven portion or the uneven portion provided in the center of the surface;
The uneven portion or the uneven portion is provided in a portion on the peripheral side, and is formed thinner than the uneven portion or the uneven portion, thereby forming a step with the upper surface of the convex portion of the uneven portion. A plane portion;
It is provided at a predetermined interval from the non-land portion or the uneven portion, and is formed integrally with the flat portion that suppresses distortion of the end portion of the non-painted area that is generated in the flat portion based on the step. The distortion elimination section,
With
The distortion eliminating portion is provided in a portion including the end portion and has a surface inclined downward from the convex portion side toward the peripheral edge side, and the flat surface on the peripheral edge side rather than the position of the end portion. building materials you being a tapered section connected portion and stepless of parts. The tapered portion, the a surface provided on the side of the non land part or the concave-convex portion, wherein characterized in that it comprises a vertical plane or surface of the steep slope than the slope of the upper surface of the tapered portion The building material according to Item 2 . At least a part of the uneven part or the uneven part, and at least a part of the flat part are plate-like building materials coated by a roll coat coating device,
The uneven portion or the uneven portion provided in the center of the surface;
The uneven portion or the uneven portion is provided in a portion on the peripheral side, and is formed thinner than the uneven portion or the uneven portion, thereby forming a step with the upper surface of the convex portion of the uneven portion. A plane portion;
It is provided at a predetermined interval from the non-land portion or the uneven portion, and is formed integrally with the flat portion that suppresses distortion of the end portion of the non-painted area that is generated in the flat portion based on the step. The distortion elimination section,
With
The distortion canceller is building materials you characterized in that provided in the region including the end portion from the surface of the flat portion is a recess which is retracted downward.

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