JP7051557B2 - Manufacturing method of decorative building materials - Google Patents

Description

The present disclosure relates to a method for manufacturing a decorative building material in general, and more particularly to a method for manufacturing a decorative building material used for an exterior material or the like.

Patent Document 1 discloses a method for forming a pattern printing layer formed on a building material board. The method for forming the pattern print layer includes a step of forming an aqueous base layer, a step of forming a granular aqueous fixing agent film, a step of fixing a granular printed pattern, and a step of forming an aqueous clear layer. ..

JP-A-2010-005836 (Claim 4)

In the method for forming the pattern printing layer of Patent Document 1, a stencil printing system is used in the step of fixing the granular printed pattern. Specifically, in the step of fixing the granular printed pattern, the granular printing material is dropped onto the granular aqueous fixing agent film in a wet state by using a stencil printing system. I'm printing.

However, when the stencil printing system is used, when changing the pattern, it is necessary to prepare a stencil for each pattern, which is troublesome.

An object of the present disclosure is to provide a method for producing a decorative building material, which can produce a decorative building material having a natural texture without any trouble.

In the method for producing a decorative building material according to one aspect of the present disclosure, a granular material-containing clear paint obtained by blending a granular material with a clear paint is spray-coated on an arbitrary region on the surface of a base material to obtain a granular material-containing clear layer. Including the step of forming . The viscosity of the granular material-containing clear paint is in the range of 0.60 Pa · s or more and 1.0 Pa · s or less.

According to the present disclosure, it is possible to manufacture a decorative building material having a natural texture without any hassle.

FIG. 1A is an enlarged schematic cross-sectional view of a decorative building material according to an embodiment of the present disclosure, including a portion including a certain recess. FIG. 1B is an enlarged schematic cross-sectional view of a decorative building material according to an embodiment of the present disclosure, including a portion including a recess different from that of FIG. 1A. FIG. 2 is a schematic cross-sectional view of a decorative building material according to an embodiment of the present disclosure.

1. 1. Outline The method for producing the decorative building material 1 according to the present embodiment includes a step of spray-coating the surface of the base material 2 with the granular material-containing clear paint obtained by blending the granular material 4 with the clear paint. At least when this step is completed, the base material 2 becomes the decorative building material 1. The decorative building material 1 has a first surface 1a and a second surface 1b forming the front and back surfaces (see FIG. 2). After the above steps, the granular material-containing clear layer 31 is formed on the first surface 1a side of the decorative building material 1. The decorative building material 1 has a natural texture by providing the granular material-containing clear layer 31. Further, in the above process, only spray painting is performed, which does not require the trouble of stencil printing. As described above, according to the present embodiment, it is possible to manufacture the decorative building material 1 having a natural texture without any trouble.

2. 2. Details 2.1 Manufacturing method of decorative building material In the manufacturing method of the decorative building material 1 according to the present embodiment, the granular material-containing clear paint obtained by blending the granular material 4 with the clear paint is spray-coated on the surface of the base material 2. Including the process. Hereinafter, the step of spray-coating the surface of the base material 2 with the granular material-containing clear paint may be simply referred to as a “painting step”.

Preferably, the method for producing the decorative building material 1 includes a sealer coating step, a base coating step, a decoration step, a coating step, and a clear coating step in this order. All or part of the steps other than the painting step may not be included. Hereinafter, each step will be described. A functional coating film such as a photocatalyst layer may be further formed on the outermost surface of the decorative building material 1 obtained at least through the coating step.

2.1.1 Sealer coating process In the sealer coating process, the sealer is applied to the surface of the base material 2 and dried. After the sealer coating step, the sealer layer 5 is formed on the surface of the base material 2.

Here, the sealer is not particularly limited, and a conventionally known sealer can be used.

The base material 2 is not particularly limited, and examples thereof include building materials. More specifically, ceramic siding and metal siding can be mentioned. As shown in FIG. 2, the base material 2 has a first surface 2a and a second surface 2b forming the front and back surfaces. The surface of the base material 2 (first surface 2a in this embodiment) has at least one recess 21. The recess 21 is specifically a joint. In FIG. 2, the recess 21 is provided so as to extend in a direction perpendicular to the paper surface. There are non-recesses 22 on both sides of the recess 21. The non-recessed portion 22 is a portion that is not a recessed portion 21 (that is, a joint). The surface of the non-recessed portion 22 is a flat surface. As shown in FIG. 2, when the base material 2 has two or more recesses 21, the pitch P between the adjacent recesses 21 and 21 is not particularly limited. The surface of the non-recessed portion 22 may have a dent or a groove smaller than that of the recessed portion 21.

The recess 21 has two facing inner side surfaces 210 and a bottom surface 211. As shown in FIG. 1A, the inclination angle θ (θa, θb) of the inner side surface 210 (210a, 210b) of the recess 21 is preferably in the range of 50 ° or more and 70 ° or less. The inclination angle θ (θa, θb) is an angle formed by the plane including the bottom surface 211 and the inner side surface 210 (210a, 210b). When the inclination angle θ (θa, θb) of the inner side surface 210 (210a, 210b) of the recess 21 is 50 ° or more, the inclination is not too loose. As a result, when the first surface 1a of the decorative building material 1 is viewed, the boundary between the concave portion 21 and the non-recessed portion 22 can be clarified. In other words, the presence of joints can be emphasized on the first surface 1a of the decorative building material 1. On the other hand, since the inclination angle θ (θa, θb) of the inner side surface 210 (210a, 210b) of the recess 21 is 70 ° or less, the inclination does not become too steep. As a result, it is possible to prevent the granules 4 from accumulating on the bottom surface 211 of the recess 21 in the painting process. The width W of the bottom surface 211 is not particularly limited.

The method for coating the base material 2 of the sealer is not particularly limited, and examples thereof include a spray gun, a roll coater, a flow coater, and a curtain coater.

2.1.2 Base coating process In the base coating process, the base paint is applied to the surface of the base material 2 (the surface of the sealer layer 5 in this embodiment) and dried. After the base coating step, the base layer 6 is formed on the surface of the sealer layer 5. Here, the base paint is not particularly limited, and conventionally known base paints can be used. The method for applying the base paint to the sealer layer 5 is not particularly limited, and examples thereof include a spray gun, a roll coater, a flow coater, and a curtain coater.

2.1.3 Decoration step In the decoration step, decoration is added to the surface of the base material 2 (the surface of the base layer 6 in this embodiment). After the decoration step, the colored layer 7 is formed on the surface of the base layer 6. Examples of adding decoration include flexographic printing, gravure offset printing, and painting with a roll coater. For decoration, for example, water-based ink or water-based paint is used.

2.1.4 Painting step In the painting step, the granular material-containing clear paint is spray-coated on the surface of the base material 2 (a part of the surface of the colored layer 7 in this embodiment) and dried. A spray gun is preferably used for spray painting. After the coating step, the granular material-containing clear layer 31 is formed on the entire surface or a part (part in the present embodiment) of the surface of the colored layer 7. The granular material-containing clear layer 31 is transparent except for the granular material 4. Hereinafter, the granular material-containing clear layer 31 may be referred to as a “first clear layer 31”. The thickness of the first clear layer 31 is not particularly limited, but is, for example, in the range of 20 μm or more and 150 μm or less.

Here, the granular material-containing clear paint is obtained by blending the granular material 4 with the clear paint.

The clear paint is not particularly limited, but is preferably a water-based paint from the viewpoint of reducing the environmental load. Specific examples of the clear paint include acrylic resin paint, silicon resin paint (acrylic silicon paint), urethane resin paint and fluororesin paint.

Granule 4 is an aggregate of particles. The granular material 4 is not particularly limited, and examples thereof include sand, silica sand (silica sand, silica sand), color sand, beads, color chips, mineral chips, glass chips, wood chips, pigments, and color beads.

The average particle size of the granular material 4 is preferably in the range of 0.08 mm or more and 0.4 mm or less. When the average particle size of the granular material 4 is 0.08 mm or more, a more natural texture can be imparted to the decorative building material 1. On the other hand, when the average particle size of the granular material 4 is 0.4 mm or less, clogging of a nozzle such as a spray gun can be suppressed during spray painting. The average particle size of the granular material 4 is a numerical value obtained by measuring the particle size of 100 randomly selected particles using a microscope and calculating the average value of these measured values. be.

The viscosity of the granular material-containing clear paint is preferably in the range of 0.60 Pa · s or more and 1.0 Pa · s or less. When the viscosity of the granular material-containing clear paint is 0.60 Pa · s or more, the viscosity is not too low, so that it is possible to prevent the granular material 4 from settling in the granular material-containing clear paint. In other words, it is possible to prevent the granular material 4 from settling in the granular material-containing clear layer 31 that is not completely dried. Further, the thickness of the granular material-containing clear layer 31 can be made uniform. That is, if the viscosity is too low, the granular material-containing clear paint tends to flow from the non-recessed portion 22 into the concave portion 21, and as shown in FIG. 1B, the thickness of the granular material-containing clear layer 31 may increase in the concave portion 21. There is a risk that it will become thinner on the non-recessed portion 22. On the other hand, when the viscosity of the granular material-containing clear paint is 1.0 Pa · s or less, the viscosity is not too high, so that the granular material 4 can be uniformly dispersed in the granular material-containing clear paint.

The viscosity of the granular material-containing clear paint can be measured by a Stormer viscometer method according to JIS K 5600-2-2 or ASTM D562-10. This measurement can be made using a Stormer viscometer. That is, a sample (clear paint containing granules according to the present embodiment) is placed in a certain container, and a wing of a specified size is rotated by the force of a weight that freely falls, and the viscosity (KU value, KU value) of the sample is determined from the rotation speed. Krebs value) is calculated. The unit of viscosity is appropriately converted into SI unit Pa · s (Pascal second).

The content of the granular material 4 is preferably in the range of 20% by mass or more and 30% by mass or less with respect to the total mass of the granular material-containing clear paint. When the content of the granular material 4 is 20% by mass or more, a more natural texture can be imparted to the decorative building material 1. On the other hand, when the content of the granular material 4 is 30% by mass or less, the amount of clear paint necessary for anchoring the granular material 4 to the granular material-containing clear layer 31 is secured, and the granular material-containing clear is secured. It is possible to suppress the dropping of the granular material 4 from the layer 31.

The spray coating of the clear paint containing granules may be applied to the entire surface of the base material 2 or a part thereof. That is, any region on the surface of the base material 2 can be spray-painted. When the surface of the base material 2 is divided into a plurality of regions, the amount of paint ejected by the spray may be changed for each region. By adjusting the amount of paint ejected in an arbitrary region on the surface of the base material 2, it is possible to cope with the production of the decorative building material 1 having a wide variety of designs. Compared to stencil printing, it is easier to select the coating area and change the amount of paint ejected in the case of spray coating.

2.1.5 Clear coating step In the clear coating step, the clear paint is applied to the surface of the base material 2 (in this embodiment, the surfaces of the first clear layer 31 and the colored layer 7) and dried. After the clear coating step, the second clear layer 32 is formed on the surface of the base material 2. The second clear layer 32 is transparent. The thickness of the second clear layer 32 is not particularly limited, but is, for example, in the range of 20 μm or more and 50 μm or less.

As described above, it is preferable that the method for producing the decorative building material 1 further includes a step of applying a clear paint on the surface of the base material 2. By further including the clear coating step, the first clear layer 31 can be covered with the second clear layer 32, and the falling off of the granular material 4 from the first clear layer 31 can be suppressed. More specifically, for example, in FIGS. 1A and 1B, the second clear layer 32 is formed, but when focusing on the thickness of the first clear layer 31 on the non-recessed portion 22, the thickness is increased in FIG. 1A. , Thin in FIG. 1B. That is, in FIG. 1A, the granular material 4 on the non-recessed portion 22 is confined in the first clear layer 31, but in FIG. 1B, the granular material 4 on the non-recessed portion 22 is partially from the inside of the first clear layer 31. Is protruding. In such a state, if the second clear layer 32 is not formed, the protruding granules 4 are exposed and easily fall off. In the present embodiment, since the second clear layer 32 is formed so as to cover the first clear layer 31, even if the granules 4 protrude from the first clear layer 31, such granules 4 fall off. Can be further suppressed.

Here, as the clear paint, the same clear paint as above (see 2.1.4) can be used.

After the clear coating step, the decorative building material 1 as shown in FIG. 2 is obtained. When the first surface 1a of the decorative building material 1 is viewed, the granular material 4 and the colored layer 7 under it can be seen through the second clear layer 32 and the first clear layer 31. In combination with the granular material 4 and the colored layer 7, the decorative building material 1 has a natural texture (for example, masonry tone). In forming the first clear layer 31, only spray painting is performed, and it is not necessary to prepare a plurality of stencil plates and replace the stencil plates for each pattern as in the case of stencil printing.

From the above, according to the present embodiment, it is possible to manufacture the decorative building material 1 having a natural texture without any trouble.

2.2 Decorative building material The decorative building material 1 according to the present embodiment includes a base material 2 and a granular material-containing clear layer 31 existing on the base material 2. The granular material-containing clear layer 31 contains the granular material 4.

Preferably, as shown in FIG. 2, the decorative building material 1 includes a base material 2, a sealer layer 5, a base layer 6, a colored layer 7, and a granular material-containing clear layer 31 (first clear layer 31). The second clear layer 32 and the second clear layer 32 are provided in this order. Hereinafter, the description overlapping with 2.1 will be omitted as appropriate.

The content of the granular material 4 is preferably in the range of 20% by mass or more and 30% by mass or less with respect to the total mass of the granular material-containing clear layer 31. When the content of the granular material 4 is 20% by mass or more, a more natural texture can be imparted to the decorative building material 1. On the other hand, when the content of the granular material 4 is 30% by mass or less, the amount of clear paint necessary for anchoring the granular material 4 to the granular material-containing clear layer 31 is secured, and the granular material-containing clear is secured. It is possible to suppress the dropping of the granular material 4 from the layer 31.

It is preferable that the decorative building material 1 further includes a second clear layer 32 on the granular material-containing clear layer 31, which is the first clear layer 31. By further providing the second clear layer 32, the first clear layer 31 can be covered with the second clear layer 32, and the falling off of the granular material 4 from the first clear layer 31 can be suppressed (FIG. 1A). And FIG. 1B).

The decorative building material 1 is used as an exterior material or the like. Specific examples of the exterior material include an outer wall material. When the first surface 1a of the decorative building material 1 is viewed, the granular material 4 and the colored layer 7 under it can be seen through the second clear layer 32 and the first clear layer 31. In combination with the granular material 4 and the colored layer 7, the decorative building material 1 has a natural texture (for example, masonry tone).

From the above, according to the present embodiment, it is possible to obtain a decorative building material 1 having a natural texture.

3. 3. Modification Example In the above embodiment, the case where the surface of the base material 2 has the recess 21 has been described, but the recess 221 may not be provided.

In the above embodiment, the case where the recess 21 is a joint has been described, but it does not have to be a joint.

In the above embodiment, the case where the surface of the non-recessed portion 22 is a flat surface has been described, but an upwardly convex curved surface or a downwardly convex curved surface may be used.

In the above embodiment, the case where the inclination angle θa of the inner side surface 210a and the inclination angle θb of the inner side surface 210b are the same angle has been described, but different angles may be used.

In the above embodiment, the sealer layer 5, the base layer 6, the colored layer 7, the first clear layer 31 (granular substance-containing clear layer 31) and the second clear layer 32 are all formed on the surface of the base material 2. However, each layer except the first clear layer 31 may or may not be formed.

In the above embodiment, the first clear layer 31 (granular substance-containing clear layer 31) is formed on a part of the surface of the colored layer 7, but may be formed on the entire surface of the colored layer 7.

4. Summary As described above, in the method for producing the decorative building material (1) according to the first aspect, the granular material-containing clear paint obtained by blending the granular material (4) with the clear paint is used as the base material (2). Includes the process of spray painting the surface.

According to this aspect, it is possible to manufacture a decorative building material (1) having a natural texture without any trouble.

In the method for producing the decorative building material (1) according to the second aspect, in the first aspect, the viscosity of the granular material-containing clear paint is in the range of 0.60 Pa · s or more and 1.0 Pa · s or less.

According to this aspect, it is possible to prevent the granular material (4) from settling in the granular material-containing clear paint. Further, the thickness of the granular material-containing clear layer (31) can be made uniform. Further, the granular material (4) can be uniformly dispersed in the granular material-containing clear paint.

In the method for producing the decorative building material (1) according to the third aspect, in the first or second aspect, the average particle size of the granular material (4) is within the range of 0.08 mm or more and 0.4 mm or less.

According to this aspect, a more natural texture can be imparted to the decorative building material (1). Further, it is possible to suppress clogging of nozzles such as spray guns when spray painting.

In the method for producing the decorative building material (1) according to the fourth aspect, in any one of the first to third aspects, the content of the granular material (4) is 20 with respect to the total mass of the granular material-containing clear paint. It is in the range of mass% or more and 30 mass% or less.

According to this aspect, a more natural texture can be imparted to the decorative building material (1). Further, it is possible to suppress the dropping of the granular material (4) from the granular material-containing clear layer (31).

In the method for producing a decorative building material (1) according to a fifth aspect, in any one of the first to fourth aspects, the surface of the base material (2) has a recess (21). The inclination angle (θ; θa, θb) of the inner surface surface (210; 210a, 210b) of the recess (21) is within the range of 50 ° or more and 70 ° or less.

According to this aspect, the boundary between the concave portion (21) and the non-recessed portion (22) can be clarified. Further, it is possible to prevent the granules (4) from accumulating on the bottom surface (211) of the recess (21).

The method for producing a decorative building material (1) according to a sixth aspect further includes, in any one of the first to fifth aspects, a step of applying a clear paint to the surface of the base material (2).

According to this aspect, by covering the first clear layer (31) with the second clear layer (32), it is possible to suppress the dropping of the granular material (4) from the first clear layer (31).

The decorative building material (1) according to the seventh aspect includes a base material (2) and a granular material-containing clear layer (31) existing on the base material (2). The granular material-containing clear layer (31) contains the granular material (4).

According to this aspect, a decorative building material (1) having a natural texture can be obtained.

In the seventh aspect of the decorative building material (1) according to the eighth aspect, the average particle size of the granular material (4) is within the range of 0.08 mm or more and 0.4 mm or less.

According to this aspect, a more natural texture can be imparted to the decorative building material (1). Further, it is possible to suppress clogging of nozzles such as spray guns when spray painting.

In the decorative building material (1) according to the ninth aspect, in the seventh or eighth aspect, the content of the granular material (4) is 20% by mass or more with respect to the total mass of the granular material-containing clear layer (31). It is within the range of 30% by mass or less.

According to this aspect, a more natural texture can be imparted to the decorative building material (1). Further, it is possible to suppress the dropping of the granular material (4) from the granular material-containing clear layer (31).

In any of the seventh to ninth aspects, the decorative building material (1) according to the tenth aspect has a concave portion (21) on the surface of the base material (2). The inclination angle (θ; θa, θb) of the inner surface surface (210; 210a, 210b) of the recess (21) is within the range of 50 ° or more and 70 ° or less.

According to this aspect, the boundary between the concave portion (21) and the non-recessed portion (22) can be clarified. Further, it is possible to prevent the granules (4) from accumulating on the bottom surface (211) of the recess (21).

The decorative building material (1) according to the eleventh aspect is the second clear layer (32) on the granular material-containing clear layer (31) which is the first clear layer (31) in any one of the seventh to tenth aspects. ) Is further provided.

According to this aspect, by covering the first clear layer (31) with the second clear layer (32), it is possible to suppress the dropping of the granular material (4) from the first clear layer (31).

1 Decorative building material 2 Base material 21 Recesses 210, 210a, 210b Inner side surface 31 First clear layer (clear layer containing granules)
32 Second clear layer 4 Granules θ, θa, θb Tilt angle

Claims (5)

Including a step of spray-coating an arbitrary region of the surface of the base material with a granular material-containing clear paint obtained by blending a granular material with the clear paint to form a granular material-containing clear layer .
The viscosity of the granular material-containing clear paint is in the range of 0.60 Pa · s or more and 1.0 Pa · s or less .
Manufacturing method of decorative building materials. The average particle size of the granules is in the range of 0.08 mm or more and 0.4 mm or less.
The method for producing a decorative building material according to claim 1 . The content of the granular material is in the range of 20% by mass or more and 30% by mass or less with respect to the total mass of the granular material-containing clear paint.
The method for producing a decorative building material according to claim 1 or 2 . The surface of the base material has recesses and has recesses.
The inclination angle of the inner surface of the recess is within the range of 50 ° or more and 70 ° or less.
The method for producing a decorative building material according to any one of claims 1 to 3 . Further including a step of applying a clear paint to the surface of the granular material-containing clear layer ,
The method for producing a decorative building material according to any one of claims 1 to 4 .

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