JP7405673B2 - Building materials and building material manufacturing methods - Google Patents

Description

The present invention relates to a building material having a design surface and a method for manufacturing the same.

BACKGROUND ART As base materials for building materials for constructing the outer and inner walls of buildings, for example, inorganic boards such as ceramic siding boards and ceramic boards, fiberboards such as particle boards, and resin boards are used. In order to express, for example, a sandstone-like texture with fine irregularities on the design surface of the base material, we use a paint obtained by blending granular materials such as minute color beads and colored sand into a clear paint (a clear paint containing granular materials). paints) may be spray applied to the surface of the substrate. Such spray painting is carried out, for example, using a spray device equipped with a nozzle for spraying paint. Techniques related to spray painting of building materials are described, for example, in Patent Document 1 below.

JP2019-188343A

However, when spraying a clear paint containing particulate matter, conventionally, the nozzle of the spraying device tends to become clogged. The more likely the nozzle of a spraying device is to clog, the more nozzle cleaning work is required to prevent and eliminate clogging, and the productivity of building materials decreases.

The present invention was conceived under these circumstances, and provides a building material that is suitable for manufacturing with high productivity as a building material that expresses a texture with fine irregularities, and a method for manufacturing the same. The purpose is to.

According to a first aspect of the present invention, a building material is provided. This building material includes a base material having a designed surface, a first coating film that includes a first film-forming material and a first granule and is located on the designed surface side of the base material, and a base material in the first coating film. It includes a dot printing film located on the opposite side and a second granule located on the opposite side of the base material in the first coating film. The first coating film has a first convex surface that projects on the opposite side from the base material at a location where the first film-forming material covers the first particles. The dot printing film has a curved surface along the first convex surface. The second granules are at a different position from the first convex surface in the spreading direction of the base material.

A building material having such a configuration is based on the size and shape of the dot printing film having a curved surface, the color of the dot printing film having a curved surface, the size and shape of the second granules, and the material color of the second granules. It is suitable for expressing textures such as sandstone with fine irregularities due to the composite combination of . The above-mentioned configuration in which the dot printing film has a curved surface along the first convex surface of the first coating film, and the second grains are at a different position from the first convex surface in the direction of spread of the base material, can express a predetermined texture. In doing so, we used a curved dot printing film to express colors that were more suitable for printing than for granular material colors, while also creating colors that were more suitable for granular material color expression than for printing colors. Suitable for expression by a second granule.

In addition, in this building material, as described above, the first convex surface (projecting on the opposite side from the base material) is formed in the first coating film at the location where the first film-forming material covers the first granules. , and the dot printing film is located on the opposite side of the first coating film from the base material and has a curved surface along the first convex surface of the first coating film. The dot-printed film is, for example, printed on the first film-forming material that covers the surface of the first particles.

Such a configuration is suitable for reducing the diameter of the first granules used, and therefore, when forming the first coating film by spraying the paint containing the first granules in the manufacturing process of this building material, the spray Suitable for preventing clogging of paint spray nozzles used for painting. Suppressing clogging in this way helps reduce the amount of cleaning work required for used nozzles and increases the productivity of building materials.

As described above, the building material according to the first aspect of the present invention is suitable for manufacturing with high productivity as a building material suitable for expressing a texture such as a sandstone-like texture with fine irregularities.
The present building material preferably has a second convex surface located on the opposite side of the first coating film from the base material, including a transparent film forming material and the above-mentioned second granules, and along the first convex surface of the first coating film. and a third convex surface protruding on the opposite side from the base material at a location where the transparent film forming material covers the second particles.
Such a configuration is suitable for fixing the dot printing film on the design surface when the dot printing film is located on the opposite side of the clear coating film from the base material, and the dot printing film is located on the opposite side of the clear coating film to the first coating film. When located between the dot printing film and the clear coating film, it is suitable for protecting the dot printing film.

Preferably, the first granules are smaller than the second granules. Such a configuration is suitable for reducing the diameter of the first granules used, and therefore suppresses clogging of the nozzle used when forming the first coating film by spray coating a paint containing the first granules. suitable for

Preferably, the second granules are white .

Such a configuration is preferable for easily expressing white in a predetermined texture.

Specifically, when forming a dot printing film by, for example, inkjet printing, in which four colors of cyan, magenta, yellow, and black are often used, white second grains can be printed without using a separate white printing device. This is preferable because the white color in a predetermined texture can be easily expressed depending on the body.

The present building material may further include a second coating film located between the first coating film and the clear coating film and having a fourth convex surface along the first convex surface of the first coating film.

Such a configuration is suitable for reducing the diameter of the first granules used, and therefore suppresses clogging of the nozzle used when forming the first coating film by spray coating a paint containing the first granules. suitable for When the dot-printed film is located between the second coating film and the clear coating film, such dot-printed film is placed along the first convex surface of the first coating film via the second coating film, The curved surface may have a larger radius of curvature than the case where the curved surface is in direct contact with the convex surface and along the first convex surface. When the dot-printed film is located on the opposite side of the clear coating from the substrate, such dot-printed film is applied to the first convex surface of the first coating through the clear coating in addition to the second coating. Along the curve, the curved surface may have a larger radius of curvature.

When the present building material includes a second coating film, preferably the second coating film includes a second film-forming material and a third granule, and the second film-forming material covers the third granule. It has a fifth convex surface that protrudes on the opposite side from the base material at the location where the base material is located. Along with this, the clear coating film has a sixth convex surface along the fifth convex surface of the second coating film. Along with this, the position of the second grain is different from the fifth convex surface in the spreading direction of the base material. Along with this, the present building material further includes a dot printing film located on the opposite side of the second coating film from the base material and having a curved surface along the fifth convex surface.

Such a configuration depends on the size and shape of the dot printing film having a curved surface along the first convex surface, the color exhibited by the dot printing film having a curved surface along the first convex surface, and the size and shape of the second particles. , due to a complex combination of the material color of the second grain, the size and shape of the dot printing film having a curved surface along the fifth convex surface, and the color exhibited by the dot printing film having a curved surface along the fifth convex surface. , suitable for expressing textures such as sandstone with fine irregularities.

When the present building material includes the above-mentioned clear coating film, in one preferred embodiment of the present building material, the dot printing film is located on the opposite side of the clear coating film from the base material. Such a configuration is suitable for fixing the design surface of the dot printing film.

When the present building material includes the above-mentioned clear coating film, in another preferred embodiment of the present building material, the dot printing film is located between the first coating film and the clear coating film. Such a configuration is suitable for protecting the dot printing film.

When the present building material includes the above-mentioned second coating film in addition to the above-mentioned clear coating film, in one preferred embodiment of the present building material, the dot printing film is located between the second coating film and the clear coating film. Such a configuration is suitable for protecting the dot printing film.

According to a second aspect of the present invention, a method of manufacturing building materials is provided. This building material manufacturing method includes the following first step, second step, and third step.

In the first step, a first paint containing a first film-forming material and a first granule is applied to the design surface side of a base material having a design surface, and the first film-forming material forms the first granule. A first coating film having a first convex surface protruding toward the side opposite to the base material is formed at the covered location.

In the second step, a dot printing film having a curved surface along the first convex surface is formed on the opposite side of the first coating film to the base material.

In the third step, a paint containing a transparent film forming material and a second granule disposed at a position different from the first convex surface in the spreading direction of the base material is applied to the side opposite to the base material in the first coating film, A clear coating film is formed having a second convex surface along the first convex surface and a third convex surface protruding on the opposite side from the base material at a location where the second granules are covered with the transparent film forming material.

In a preferred embodiment of the present building material manufacturing method, the third step is carried out after the second step. In another preferred embodiment of the present building material manufacturing method, the third step is carried out before the second step.

According to such a building material manufacturing method, the above-mentioned building material according to the first aspect of the present invention can be manufactured. Therefore, according to the present building material manufacturing method, the same technical effects as described above regarding the first aspect of the present invention can be enjoyed in the manufactured building materials.

FIG. 1 is a partial cross-sectional view of a building material according to a first embodiment of the present invention. It represents the manufacturing method of the building material shown in FIG. FIG. 3 is a partial cross-sectional view of a building material according to a second embodiment of the present invention. FIG. 7 is a partial cross-sectional view of a building material according to a third embodiment of the present invention. 4 represents a method for manufacturing the building material shown in FIG. 4. It is a partial sectional view of the building material concerning the 4th embodiment of the present invention. It is a partial sectional view of the building material concerning the 5th embodiment of the present invention. It represents the manufacturing method of the building material shown in FIG. It is a partial sectional view of the building material concerning the 6th embodiment of the present invention.

FIG. 1 is a partial sectional view of a building material X1 according to a first embodiment of the present invention. The building material X1 has a laminated structure including a base material S, a coating film 10, a coating film 20, and a coating film 30, and includes a plurality of dot printing films 40 in the laminated structure.

The base material S has a design surface Sa on which a design is applied. Examples of the base material S include wood fiber-reinforced cement boards, fiber-reinforced cement boards, ceramic siding boards such as fiber-reinforced cement/calcium silicate boards, slag gypsum boards, metal siding boards, and fiberboards such as particle boards. , and resin plates.

The coating film 10 is an undercoat coating film located on the designed surface Sa of the base material S, and for example, seals the base of the designed surface Sa and coats various elements such as a coating film that is laminated on the designed surface Sa. It has the function of ensuring adhesion and fixation.

The coating film 10 includes a film forming material 11 . Examples of the film forming material 11 include resin. Examples of the resin include acrylic resin, acrylic urethane resin, urethane resin, fluororesin, and acrylic silicone resin, and preferably acrylic resin is used. Such a coating film 10 is, for example, a cured product of a composition (paint) containing a resin as the film-forming material 11. The thickness of the coating film 10 is, for example, 5 to 30 μm, preferably 10 to 20 μm.

The coating film 20 is an intermediate coating film located between the coating film 10 and the coating film 30. The coating film 20 in this embodiment corresponds to the first coating film in the present invention, and is located on the design surface Sa side of the base material S and includes a film forming material 21 (first film forming material) and particles 22 (first film forming material). Contains 1 grain). This coating film 20 has a convex surface 23 (first convex surface) protruding toward the side opposite to the base material S at a location where the film forming material 21 covers the particles 22 . The thickness T1 of the coating film 20 other than the portion where the coating film 20 has the convex surface 23 is, for example, 10 to 50 μm, preferably 20 to 30 μm.

Examples of the film forming material 21 include resin. Examples of the resin include acrylic resin, acrylic urethane resin, urethane resin, fluororesin, and acrylic silicone resin, and preferably acrylic resin is used.

Examples of the constituent material of the grains 22 include resin, glass, sand, and metal. Examples of the resin constituting the particles 22 include polyacrylonitrile resin, polymethacrylonitrile resin, polyvinylidene chloride resin, polyacrylic acid ester resin, and polystyrene resin, and preferably polyacrylonitrile resin is used.

Examples of the shape of the grains 22 include a spherical shape and an ellipsoidal shape. The particles 22 may be colorless or colored. The particle diameter of the particles 22 is, for example, 10 to 100 μm, preferably 20 to 50 μm, as long as it is larger than the above-mentioned thickness T1 of the coating film 20. The above-described convex surface 23 is formed by the coating film 20 containing such particles 22 .

Further, the arrangement density of the particles 22 in the coating film 20 (that is, the arrangement density of the particles 22 in the spreading direction of the base material S) is, for example, 10 to 100 pieces/mm ² , preferably 30 to 50 pieces/mm 2 It is ² .

Such a coating film 20 is, for example, a cured product of a composition (paint) containing a resin as a film-forming material 21 and particles 22. The coating film 20 may be colored by containing a coloring material such as a pigment or a dye. When the coating film 20 is colored, a coloring agent is blended into the composition for forming the coating film 20.

The coating film 30 includes a transparent film forming material 31 and granules 32 (second granules), and is located on the opposite side of the coating film 20 from the base material S (therefore, the granules 32 in the coating film 30 (also located on the opposite side of the coating film 20 from the base material S). This coating film 30 has a convex surface 33 (second convex surface) along the convex surface 23 of the coating film 20 via a dot printing film 40 (described later), and the transparent film forming material 31 covers the particles 32. It has a convex surface 34 (third convex surface) that protrudes on the opposite side from the base material S at the location where the base material S is located. Such a coating film 30 corresponds to a clear coating film in the present invention. The thickness T2 of the coating film 30 other than the portions where the coating film 30 has convex surfaces 33 and 34 is, for example, 10 to 50 μm, preferably 20 to 30 μm.

Examples of the transparent film forming material 31 include transparent resin. Examples of the transparent resin include acrylic silicone resin, epoxy resin, fluororesin, and urethane resin, and preferably acrylic silicone resin is used.

The granules 32 are located at different positions from the convex surface 23 of the coating film 20 in the spreading direction of the base material S. Different positions of elements (convex surfaces, grains, etc.) in the spreading direction of the base material S means that their positions in the spreading direction of the base material S are not completely the same. This includes deviations. As the constituent material of the grains 32, for example, the same materials as those described above as the constituent material of the grains 22 can be mentioned, and polyacrylonitrile resin is preferably used. Examples of the shape of the grains 32 include a spherical shape and an ellipsoidal shape. Moreover, the granules 32 are colored, preferably white.

The particle size of the particles 32 is, for example, 50 to 300 μm, preferably 80 to 200 μm, as long as it is larger than the above-mentioned thickness T2 of the coating film 30. Further, the grains 32 are preferably larger than the grains 22 described above. That is, the grains 22 are preferably smaller than the grains 32.

Further, the arrangement density of the particles 32 in the coating film 30 (that is, the arrangement density of the particles 32 in the spreading direction of the base material S) is, for example, 2 to 50 particles/mm ² , preferably 3 to 30 particles/mm 2 It is ² .

Such a coating film 30 is, for example, a cured product of a composition (paint) containing a resin as a transparent film forming material 31 and particles 32.

The dot printed film 40 is a dotted printed film formed by a printing method, is located on the opposite side of the coating film 20 from the base material S, and has a curved surface along the convex surface 23 of the coating film 20. Each dot printed film 40 may have a curved surface along the convex surface 23 in its entirety, or may have a curved surface partially along the convex surface 23 (the entire dot printed film 40 may have a curved surface along the convex surface 23). ). In this embodiment, the dot printing film 40 is located between the coating film 20 as the first coating film and the coating film 30 as a clear coating film. Such dot printing film 40 is preferably a printing film formed by full-color inkjet printing, and each of them exhibits a predetermined color.

The dot size of the dot printing film 40 is, for example, 1 to 200 μm, preferably 20 to 50 μm. Further, the arrangement density (stippling density) of the dot printing film 40 in the spreading direction of the base material S is, for example, 10 to 100 pieces/mm ² , preferably 30 to 50 pieces/mm ² . Such a dot printing film 40 may be formed with one dot, or may be formed with a plurality of dots. In the manufacturing process of the building material X1 as described below, when the dot printing film 40 is formed with a plurality of small dots, after the color ink droplets for forming the dot printing film 40 land on the convex surface 23, This is preferable because the movement of the ink droplets is suppressed and it is easier to form the dot printing film 40 along a curved surface. Further, when the dot printing film 40 is formed by a plurality of small dots, it is preferable because various color tones can be easily expressed by the combination of colors exhibited by each dot.

The building material X1 may include an additional clear coating film (not shown) on the opposite side of the base material S in the coating film 30, which is a clear coating film. Such a configuration helps protect the design surface of the building material X1. The fact that such an additional clear coating film may be provided also applies to building materials according to other embodiments described later.

FIG. 2 shows a method of manufacturing the building material X1 shown in FIG. This manufacturing method is a method of manufacturing building materials while conveying the base material S in a building material manufacturing line, and includes the following undercoating process, intermediate coating process, printing process, and clear coating film forming process. In the building material production line, a spray coating device is installed for each coating film to be formed, and a printing device for forming a dot printing film is installed. Each spray painting device includes a plurality of nozzles for spraying paint. The printing device is preferably a full color inkjet printing device.

First, in the undercoating step, a coating film 10 is formed on the design surface Sa of the base material S, as shown in FIG. 2(a). In this step, for example, a paint containing a resin and a solvent as the film-forming material 11 is spray-coated onto the design surface Sa to form a coating film 10 of a predetermined thickness. Examples of the solvent include toluene, xylene, and butyl acetate (the same applies to the solvents for each paint described later). The coating 10 is dried.

Next, in the intermediate coating step, as shown in FIG. 2(b), a coating film 20 as a first coating film is formed on the coating film 10 on the design surface Sa side of the base material S. In this step, for example, a paint (first paint) containing a resin as a film-forming material 21 (first film-forming material), granules 22 (first granules), and a solvent is sprayed onto the coating film 10. The coating is applied to form a coating film 20 of a predetermined thickness. The coating film 20 is dried.

As described above, the coating film 20 formed by spraying the paint containing the particles 22 protrudes to the side opposite to the base material S at the portion where the film forming material 21 covers the particles 22. It has a convex surface 23. This step of forming the coating film 20 as the first coating film corresponds to the first step in the present invention.

The content of the particles 22 in the paint used in this step is, for example, 5 to 180% by volume, preferably 10 to 80% by volume. Such a configuration is suitable for realizing the above-described arrangement density of the grains 22. Moreover, the above-mentioned thickness T1 of the coating film 20 formed can be adjusted, for example, by adjusting the viscosity of the paint used in this step.

Next, in the printing process, a plurality of dot printing films 40 are formed on the coating film 20, as shown in FIG. 2(c). Specifically, in this step, using the above-mentioned printing device, colors of cyan, magenta, yellow, and black are printed on various parts of the surface of the coating film 20 (first coating film) on the opposite side from the base material S. Make color ink droplets land. Thereby, a dot printing film 40 having a curved surface along the convex surface 23 (first convex surface) of the coating film 20 is formed. The dot printing film 40 is dried as necessary. This step of forming the dot printing film 40 corresponds to the second step in the present invention. In this step, the dot print film 40 may be formed with one dot, or may be formed with a plurality of dots. When the dot printing film 40 is formed with a plurality of small dots, after the color ink droplets mentioned above land on the convex surface 23, the movement of the ink droplets on the convex surface 23 is suppressed, and the dots are formed more along the curved surface. This is preferable because the printed film 40 can be easily formed. Further, when the dot printing film 40 is formed by a plurality of small dots, it is preferable because various color tones can be easily expressed by the combination of colors exhibited by each dot.

As described above, the dot size of the dot printing film 40 formed in this step is, for example, 1 to 200 μm, preferably 20 to 50 μm. The arrangement density (stippling density) of the dot printing film 40 in the spreading direction of the base material S is, as described above, for example 10 to 100 pieces/mm ² , preferably 30 to 50 pieces/mm ² . These configurations are suitable for forming the dot printing film 40 having a curved surface along the convex surface 23 of the coating film 20 containing the particles 22 at the above-mentioned arrangement density.

Next, in the clear coating film forming step, as shown in FIG. form. In this step, for example, a paint containing a resin as the transparent film forming material 31, granules 32 (second granules), and a solvent is spray-coated onto the coating film 20 and the dot printing film 40 to a predetermined thickness. A coating film 30 is formed. The coating 30 is dried. As described above, the formed coating film 30 has a convex surface 34 that protrudes on the opposite side from the base material S at the location where the transparent film forming material 31 covers the particles 32.

In this embodiment, by forming the coating film 30 in this manner, the particles 32 are arranged on the opposite side of the coating film 20 from the base material S at a position different from the convex surface 23 of the coating film 20 in the spreading direction of the base material S. be done. This main step corresponds to the third step in the present invention.

The content of the particles 32 in the paint used in this step is, for example, 5 to 150% by volume, preferably 10 to 80% by volume. Such a configuration is suitable for realizing the above-described arrangement density of the grains 32. Further, the above-mentioned thickness T2 of the formed coating film 30 can be adjusted, for example, by adjusting the viscosity of the paint used in this step.

Building material X1 can be manufactured in the manner described above.

As described above, the building material X1 includes the base material S having the designed surface Sa, the film forming material 21 (first film forming material) and the grains 22 (first grains), and the design surface of the base material S The coating film 20 located on the Sa side, the dot printing film 40 located on the opposite side of the coating film 20 to the base material S, and the particles 32 (second granules). As described above, the coating film 20 has a convex surface 23 (first convex surface) that protrudes on the opposite side from the base material S at a location where the film forming material 21 covers the particles 22 . The dot printing film 40 has a curved surface along the convex surface 23 of the coating film 20, as described above. As described above, the granules 32 are at different positions from the convex surface 23 of the coating film 20 in the spreading direction of the base material S.

The building material X1 having such a configuration is based on the size and shape of the dot printing film 40 having a curved surface, the color of the dot printing film 40 having a curved surface, the size and shape of the grains 32, and the material color of the grains 32. It is suitable for expressing textures such as sandstone-like textures with fine irregularities through complex combinations. The configuration in which the dot printing film 40 has a curved surface along the convex surface 23 of the coating film 20 and the position of the particles 32 is different from the convex surface 23 of the coating film 20 in the spreading direction of the base material S is such that a predetermined texture can be obtained. In terms of expression, the dot printing film 40 with a curved surface expresses a color that is more suitable for expression in printing colors than expression in granular material colors, and is more suitable for expression in granular material colors than expression in printing colors. The particles 32 are suitable for expressing different colors.

Further, in the building material X1, as described above, the convex surface 23 (projecting on the opposite side to the base material S) is formed in the coating film 20 at the location where the film forming material 21 covers the particles 22, and On the opposite side of the film 20 from the base material S, the dot printing film 40 has a curved surface along the convex surface 23 of the coating film 20 .

Such a configuration is suitable for reducing the diameter of the particles 22 used, and therefore, in the manufacturing process of the building material X1, as described above with reference to FIG. When forming the coating film 20, it is suitable for suppressing clogging of a paint spray nozzle used for the spray coating. Suppressing clogging in this way helps reduce the cleaning work of the used nozzles and increases the productivity of the building material X1.

As described above, the building material X1 is suitable for producing with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities.

Granules 22 are preferably smaller than grains 32, as described above. Such a configuration is suitable for reducing the diameter of the particles 22 used, and therefore, when forming the coating film 20 by spraying a paint containing the particles 22 as described above with reference to FIG. 2(b), It is suitable for suppressing clogging of the nozzle used. Such technical effects due to the grains 22 being smaller than the grains 32 can also be enjoyed in building materials according to other embodiments described later.

The granules 32 are colored, and as mentioned above, are preferably white. Such a configuration is preferable for easily expressing white in a predetermined texture. Specifically, when the dot printing film 40 is formed by full-color inkjet printing, it is preferable because the white particles 32 can easily express white in a predetermined texture without using a separate white printing device. Such technical effects due to the white granules 32 can also be enjoyed in building materials according to other embodiments described later.

As described above, the dot printing film 40 in the building material X1 is located between the coating film 20 and the coating film 30 which is a clear coating film. Such a configuration is suitable for protecting the dot printing film 40.

FIG. 3 is a partial cross-sectional view of building material X2 according to the second embodiment of the present invention. The building material X2 has a laminated structure including a base material S, a coating film 10, a coating film 20, and a coating film 30, and also includes a plurality of dot printing films 40. The building material X2 has the above-mentioned structure in that the dot printing film 40 is located on the side opposite to the base material S in the coating film 30 instead of the configuration in which the dot printing film 40 is located between the coating films 20 and 30. Different from building material X1. Except for this point, the building material X2 has the same configuration as the building material X1.

Such a building material It can be manufactured by the same manufacturing method as the building material X1 except that the printing step is performed after the film forming step. Formation of the dot printing film 40 on the coating film 30, which is a clear coating film, is suitable for fixing the dot printing film 40 on the design surface.

Building material X2 is suitable for manufacturing with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above with respect to building material X1.

FIG. 4 is a partial sectional view of building material X3 according to the third embodiment of the present invention. The building material X3 has a laminated structure including a base material S, a coating film 10A, a coating film 20A, and a coating film 30, and includes a dot printing film 40 in the laminated structure. The building material X3 differs from the above-described building material X1 in that it includes coating films 10A and 20A instead of the coating films 10 and 20. Except for this point, building material X3 has the same configuration as building material X1.

The coating film 10A is an undercoat coating film similar to the above-mentioned coating film 10, and for example, seals the base of the design surface Sa and allows various elements such as a coating film to be laminated and formed on the design surface Sa to adhere and fix. It has the function of ensuring sex.

The coating film 10A corresponds to the first coating film in the present invention, is located on the design surface Sa side of the base material S, and includes the film forming material 11 (first film forming material) and the particles 12 (first particles). including. This coating film 10A has a convex surface 13 (first convex surface) protruding toward the opposite side from the base material S at a location where the film forming material 11 covers the particles 12. The thickness T3 of the coating film 10A other than the portion where the coating film 10A has the convex surface 13 is, for example, 5 to 30 μm, preferably 10 to 20 μm.

The coating film 10A differs from the above-described coating film 10 in that it includes particles 12 in addition to the film forming material 11 in terms of its constituent components. Such a coating film 10A is, for example, a cured product of a composition (paint) containing a resin as a film-forming material 11 and particles 12.

Examples of constituent materials of the particles 12 include resin, glass, and metal. Examples of the resin constituting the particles 12 include polyacrylonitrile resin, polymethacrylonitrile resin, polyvinylidene chloride resin, polyacrylic acid ester resin, and polystyrene resin, and preferably polyacrylonitrile resin is used.

Examples of the shape of the grains 12 include a spherical shape and an ellipsoidal shape. The particles 12 may be colorless or colored. The particle diameter of the particles 12 is, for example, 5 to 50 μm, preferably 5 to 40 μm, as long as it is larger than the above-mentioned thickness T3 of the coating film 10A. The above-mentioned convex surface 13 is formed by the coating film 10A containing such particles 12.

Further, the arrangement density of the particles 12 in the coating film 10A (that is, the arrangement density of the particles 12 in the spreading direction of the base material S) is, for example, 10 to 100 pieces/mm ² , preferably 30 to 50 pieces/mm 2 It is ² .

The coating film 20A is an intermediate coating film like the coating film 20 described above. The coating film 20A in this embodiment corresponds to the second coating film in the present invention, is located between the coating film 10A (first coating film) and the coating film 30 (clear coating film), and is located on the convex surface of the coating film 10A. 13 (first convex surface).

The coating film 20A differs from the above-described coating film 20 in that it contains the film forming material 21 but does not contain the particles 22 in terms of its constituent components. Such a coating film 20A is, for example, a cured product of a composition (paint) containing a resin as the film forming material 21. The thickness of the coating film 20A is, for example, 10 to 50 μm, preferably 20 to 30 μm.

In this embodiment, the dot-printed film 40 is located between the coating film 20A and the coating film 30, and the curved surface of each dot-printed film 40 is connected to the coating film 10A (first coating film) via the coating film 20A. Along the convex surface 13 (first convex surface).

In this embodiment, the coating film 30 is located on the opposite side of the coating film 20A from the base material S, and each convex surface 33 of the coating film 30 is connected to the coating film 10A ( along the convex surface 13 (first convex surface) of the first coating film).

FIG. 5 shows a method of manufacturing building material X3 shown in FIG. 4. This manufacturing method is a method of manufacturing building materials while conveying the base material S in a building material manufacturing line, and includes the following undercoating process, intermediate coating process, printing process, and clear coating film forming process. In the building material production line, a spray coating device is installed for each coating film to be formed, and a printing device for forming a dot printing film is installed. Each spray painting device includes a plurality of nozzles for spraying paint. The printing device is preferably a full color inkjet printing device.

First, in the undercoating step, a coating film 10A is formed on the design surface Sa of the base material S, as shown in FIG. 5(a). In this step, for example, a paint (first paint) containing a resin as the film-forming material 11 (first film-forming material), particles 12 (first grains), and a solvent is sprayed onto the design surface Sa. The coating is applied to form a coating film 10A having a predetermined thickness. The coating film 10A is dried.

As described above, the coating film 10A formed by spraying the paint containing the granules 12 protrudes to the side opposite to the base material S at the location where the film forming material 11 covers the granules 12. It has a convex surface 13. This step of forming the coating film 10A as the first coating film corresponds to the first step in the present invention.

The content of the particles 12 in the paint used in this step is, for example, 0.02 to 160% by volume, preferably 0.2 to 100% by volume. Such a configuration is suitable for realizing the above-described arrangement density of the grains 12. Further, the above-described thickness T3 of the formed coating film 10A can be adjusted, for example, by adjusting the viscosity of the paint used in this step.

Next, in the intermediate coating step, as shown in FIG. 5(b), a coating film 20A is formed on the coating film 10A. In this step, for example, a paint containing a resin and a solvent as the film forming material 21 is spray-coated onto the coating film 10A to form a coating film 20A with a predetermined thickness. The coating film 20A is dried. The coating film 20A formed on the coating film 10A by such spray painting has the convex surface 24 protruding on the side opposite to the base material S on the convex surface 13 of the coating film 10A, as described above.

Next, in the printing process, as shown in FIG. 5(c), a plurality of dot printing films 40 are formed on the coating film 20A. Specifically, in this step, color ink droplets of cyan, magenta, yellow, and black hues are landed at various locations on the surface of the coating film 20A on the opposite side from the base material S using the above-mentioned printing device. . Thereby, a dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10A is formed via the convex surface 24 of the coating film 20A. The dot printing film 40 is dried as necessary. The dot size and arrangement density (stippling density) of the dot printing film 40 to be formed are the same as those described above regarding the printing process shown in FIG. 2(c). This step of forming the dot printing film 40 corresponds to the second step in the present invention.

Next, in the clear coating film forming step, as shown in FIG. form. Specifically, this step can be carried out in the same manner as the clear coating film forming step described above with reference to FIG. 2(d). This main step corresponds to the third step in the present invention.

Building material X3 can be manufactured in the manner described above.

Building material X3 is suitable for producing with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above with respect to building material X1.

Furthermore, the building material X3 has a coating film 20A (second coating film) located between the coating film 10A (first coating film) and the coating film 30 (clear coating film) and having a convex surface 24 along the convex surface 13 of the coating film 10A. coating film). Such a configuration is suitable for reducing the diameter of the grains 12 (first grains) used. The dot printing film 40 runs along the convex surface 13 (first convex surface) of the coating film 10A (first coating film) via the coating film 20A (second coating film), and is in direct contact with the same convex surface 13 while being in direct contact with the same convex surface 13. This is because it can have a curved surface with a larger radius of curvature than if it were along the curve.

The reduction in the diameter of the particles 12 to be used is achieved when forming the coating film 10A by spray painting the paint containing the particles 12 as described above with reference to FIG. Suitable for preventing clogging of paint spray nozzles used in Suppressing clogging in this way helps reduce the cleaning work of the nozzles in use and increases the productivity of the building material X3.

FIG. 6 is a partial sectional view of building material X4 according to the fourth embodiment of the present invention. The building material X4 has a laminated structure including a base material S, a coating film 10A, a coating film 20A, and a coating film 30, and also includes a plurality of dot printing films 40. The building material X4 has the above-mentioned structure in that the dot printing film 40 is located on the opposite side of the base material S in the coating film 30 instead of the configuration in which the dot printing film 40 is located between the coating films 20A and 30. Different from building material X3. Except for this point, building material X4 has the same configuration as building material X3.

Such a building material It can be manufactured by the same manufacturing method as the manufacturing method of building material X3 except that the printing step is performed after the film forming step. Formation of the dot printing film 40 on the coating film 30, which is a clear coating film, is suitable for fixing the dot printing film 40 on the design surface.

Building material X4 is suitable for manufacturing with high productivity as a building material suitable for expressing a texture such as sandstone with fine irregularities for the same reason as described above with respect to building material X1.

Moreover, the building material coating film). Such a configuration is suitable for reducing the diameter of the grains 12 (first grains) used. The dot printing film 40 is applied along the convex surface 13 (first convex surface) of the coating film 10A (first coating film) via the coating film 20A (second coating film) and the coating film 30 (clear coating film), and the same convex surface This is because the curved surface can have a larger radius of curvature than the case where the convex surface 13 is in direct contact with the convex surface 13.

Reducing the diameter of the particles 12 used suppresses clogging of the paint spraying nozzle used for spray painting when forming the coating film 10A by spray painting the paint containing the particles 12 in the manufacturing process of the building material X4. suitable for Suppressing clogging in this way helps reduce the cleaning work of the used nozzles and increases the productivity of the building material X4.

FIG. 7 is a partial cross-sectional view of building material X5 according to the fifth embodiment of the present invention. The building material X5 has a laminated structure including a base material S, a coating film 10B, a coating film 20B, and a coating film 30, and includes a plurality of dot printing films 40 in the laminated structure. Building material X5 has coating film 10 instead of coating film 10 and 20.
It differs from the above-mentioned building material X1 in that it includes B, 20B. Except for this point, the building material X5 has the same configuration as the building material X1.

The coating film 10B is an undercoat coating film like the above-mentioned coating film 10, and for example, seals the base of the design surface Sa and allows various elements such as a coating film to be laminated and formed on the design surface Sa to adhere and fix. It has the function of ensuring sex.

The coating film 10B corresponds to the first coating film in the present invention, is located on the design surface Sa side of the base material S, and includes the film forming material 11 (first film forming material) and the particles 12 (first particles). including. This coating film 10B has a convex surface 13 (first convex surface) protruding toward the side opposite to the base material S at a location where the film forming material 11 covers the particles 12. The constituent material and thickness (thickness T3) of the coating film 10B are the same as the constituent material and thickness T3 described above regarding the coating film 10A in the building material X3.

The coating film 10B differs from the coating film 10A in terms of the arrangement density of the particles 12 (that is, the arrangement density of the particles 12 in the spreading direction of the base material S). The arrangement density of the particles 12 in the coating film 10B is smaller than the arrangement density of the particles 12 in the coating film 10A, for example, from 1 to 25 particles/mm ² , preferably from 2 to 15 particles/mm ² .

The coating film 20B is an intermediate coating film like the coating film 20 described above. The coating film 20B in this embodiment corresponds to the second coating film in the present invention, is located between the coating film 10B (first coating film) and the coating film 30 (clear coating film), and is located between the film forming material 21 (second film forming material) and grains 22 (third grains). This coating film 20B has a convex surface 24 (fourth convex surface) along the convex surface 13 (first convex surface) of the coating film 10B, and has a base at a location where the film forming material 21 covers the particles 22. It has a convex surface 23 (fifth convex surface) that protrudes on the side opposite to the material S. The constituent material and thickness (thickness T1) of the coating film 20B are the same as the constituent material and thickness T1 described above regarding the coating film 20 in the building material X1.

The coating film 20B differs from the coating film 20 with respect to the arrangement density of the particles 22 (that is, the arrangement density of the particles 22 in the spreading direction of the base material S). The arrangement density of the particles 22 in the coating film 20B is smaller than the arrangement density of the particles 22 in the coating film 20, for example, from 1 to 25 particles/mm ² , preferably from 2 to 15 particles/mm ² .

In this embodiment, the plurality of dot printed films 40 are located between the coating film 20B and the coating film 30. Some of the dot printing films 40 among the plurality of dot printing films 40 have curved surfaces that follow the convex surface 13 (first convex surface) of the coating film 10B (first coating film) via the coating film 20B. Another part of the dot printing films 40 of the plurality of dot printing films 40 has a curved surface along the convex surface 23 (fifth convex surface) of the coating film 20B (second coating film).

In this embodiment, the coating film 30 is located on the side opposite to the base material S in the coating film 20B. In addition to the above-mentioned convex surface 33 (second convex surface) and convex surface 34 (third convex surface), this coating film 30 has a convex surface 35 ( 6th convex surface).

FIG. 8 shows a method of manufacturing building material X5 shown in FIG. 7. This manufacturing method is a method of manufacturing building materials while conveying the base material S in a building material manufacturing line, and includes the following undercoating process, intermediate coating process, printing process, and clear coating film forming process. In the building material production line, a spray coating device is installed for each coating film to be formed, and a printing device for forming a dot printing film is installed. Each spray painting device includes a plurality of nozzles for spraying paint. The printing device is preferably a full color inkjet printing device.

First, in the undercoating step, a coating film 10B is formed on the design surface Sa of the base material S, as shown in FIG. 8(a). In this step, for example, a paint (first paint) containing a resin as the film-forming material 11 (first film-forming material), particles 12 (first grains), and a solvent is sprayed onto the design surface Sa. The coating is applied to form a coating film 10B having a predetermined thickness. The coating film 10B is dried.

As described above, the coating film 10B formed by spraying the paint containing the granules 12 protrudes to the side opposite to the base material S at the location where the film forming material 11 covers the granules 12. It has a convex surface 13. This step of forming the coating film 10B as the first coating film corresponds to the first step in the present invention.

The content of the particles 12 in the paint used in this step is, for example, 0.01 to 80% by volume.
and preferably 0.1 to 50% by volume. Such a configuration is suitable for realizing the above-mentioned arrangement density of the particles 12 in the coating film 10B.

Next, in the intermediate coating step, as shown in FIG. 8(b), a coating film 20B is formed on the coating film 20B. In this step, for example, a paint containing a resin, particles 22 (third particles), and a solvent as the film forming material 21 (second film forming material) is spray-coated onto the coating film 10B to a predetermined thickness. A coating film 20B is formed. The coating film 20B is dried.

Next, in the printing process, as shown in FIG. 8(c), a plurality of dot printing films 40 are formed on the coating film 20B. Specifically, in this step, color ink droplets of cyan, magenta, yellow, and black hues are landed at various locations on the surface of the coating film 20B on the opposite side from the base material S using the above-mentioned printing device. . Thereby, a dot printed film 40 having a curved surface along the convex surface 13 of the coating film 10B via the coating film 20B and a dot printed film 40 having a curved surface along the convex surface 23 of the coating film 20B are formed. The dot printing film 40 is dried as necessary. The dot size and arrangement density (stippling density) of the dot printing film 40 to be formed are the same as those described above regarding the printing process shown in FIG. 2(c). This step of forming the dot printing film 40 corresponds to the second step in the present invention.

Next, in the clear coating film forming step, as shown in FIG. form. Specifically, this step can be carried out in the same manner as the clear coating film forming step described above with reference to FIG. 2(d). This main step corresponds to the third step in the present invention.

Building material X5 can be manufactured as described above.

Such building material X5 is suitable for manufacturing with high productivity as a building material suitable for expressing a texture such as sandstone-like texture with fine irregularities for the same reason as described above with respect to building material X1. In building material X5, the size and shape of the dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10B, the color exhibited by the dot printing film 40 having a curved surface along the convex surface 13 of the coating film 10B, and the coating film 20B. The size and shape of the dot printed film 40 having a curved surface along the convex surface 23 of the coating film 20B, the color exhibited by the dot printed film 40 having a curved surface along the convex surface 23 of the coating film 20B, the size and shape of the grains 32, and the grains. By combining the color of the material of the body 32 in a complex manner, it is possible to express a texture such as a sandstone-like texture with fine irregularities.

Moreover, the building material coating film). Such a configuration is suitable for reducing the diameter of the grains 12 (first grains) used. The dot printing film 40 runs along the convex surface 13 (first convex surface) of the coating film 10B (first coating film) via the coating film 20B (second coating film), and is in direct contact with the same convex surface 13. This is because it can have a curved surface with a larger radius of curvature than if it were along the curve.

The reduction in the diameter of the particles 12 to be used is achieved when forming the coating film 10B by spray painting the paint containing the particles 12 as described above with reference to FIG. Suitable for preventing clogging of paint spray nozzles used in Suppressing clogging in this way helps reduce the cleaning work of the nozzles in use and increases the productivity of the building material X5.

In addition, in the building material X5, the coating film 10B (first coating film) includes granules 12 (first granules), and the coating film 20B (second coating film) includes granules 22 (third granules). The arrangement is suitable for reducing the particulate content of paints used in spray coatings as described above with reference to FIGS. 8(a) and 8(b). A reduction in the granule content of the paint for spray painting is preferable in order to suppress clogging of the paint atomizing nozzle used for the spray painting, and it is also preferable to reduce the cleaning work of the used nozzle and increase the productivity of building material X5. useful for.

FIG. 9 is a partial cross-sectional view of building material X6 according to the sixth embodiment of the present invention. The building material X6 has a laminated structure including a base material S, a coating film 10B, a coating film 20B, and a coating film 30, and also includes a plurality of dot printing films 40. The building material X6 has the above-described structure in that the dot printing film 40 is located on the opposite side of the base material S in the coating film 30 instead of the configuration in which the dot printing film 40 is located between the coating films 20B and 30. Different from building material X5. Except for this point, building material X6 has the same configuration as building material X5.

Such a building material It can be manufactured by the same manufacturing method as building material X5 except that the printing step is performed after the film forming step. Formation of the dot printing film 40 on the coating film 30, which is a clear coating film, is suitable for fixing the dot printing film 40 on the design surface.

Building material X6 is suitable for manufacturing with high productivity as a building material suitable for expressing a texture such as sandstone-like texture with fine irregularities for the same reason as described above for building materials X1 and X5.

Further, like the building material X5, the building material X6 has a convex surface 24 located between the coating film 10B (first coating film) and the coating film 30 (clear coating film) and along the convex surface 13 of the coating film 10B. A coating film 20B (second coating film) is provided. This configuration is suitable for reducing the diameter of the granules 12 (first granules) used, as described above regarding the building material It helps to improve your sexuality.

Further, in building material X6, similarly to building material granules). Such a configuration is suitable for reducing the granule content of each paint used for spray painting, as described above regarding building material It helps to increase.

X1, X2, X3, X4, X5, X6 Building material S Base material Sa Design surface 10, 20, 30 Paint film 10A, 10B, 20A, 20B Paint film 11, 21 Film forming material 12, 22, 32 Granules 13, 23 , 24, 33, 34, 35 Convex surface 31 Transparent film forming material 40 Dot printing film

Claims (9)

A base material having a design surface;
The base material includes a first film-forming material and a first granule and is located on the design surface side of the base material, and the first film-forming material covers the first granule. a first coating film having a first convex surface protruding on the opposite side;
a dot printing film located on the opposite side of the first coating film from the base material and having a curved surface along the first convex surface;
a clear coating film located on the opposite side of the base material in the first coating film and containing a transparent film forming material and a second granule;
The clear coating film is
a second convex surface along the first convex surface of the first coating film;
a third convex surface protruding on the opposite side from the base material at a location where the transparent film forming material covers the second granules;
The second granules are a building material whose position is different from the first convex surface in the spreading direction of the base material. The building material according to claim 1, wherein the first granules are smaller than the second granules. The building material according to claim 1 or 2, wherein the second granules are white. Claims 1 to 3 further comprising a second coating film located between the first coating film and the clear coating film and having a fourth convex surface along the first convex surface of the first coating film. Building materials listed in . The second coating film includes a second film-forming material and a third granule, and the second film-forming material covers the third granule on the opposite side from the base material. has a fifth convex surface that protrudes;
The clear coating film has a sixth convex surface along the fifth convex surface of the second coating film,
The second granules are at a different position from the fifth convex surface in the spreading direction of the base material,
The building material according to claim 4, further comprising a dot printing film located on the opposite side of the second coating film from the base material and having a curved surface along the fifth convex surface. The building material according to any one of claims 1 to 5, wherein the dot printing film is located on the opposite side of the clear coating film from the base material. The building material according to claim 1, wherein the dot printing film is located between the first coating film and the clear coating film. The building material according to claim 4 or 5, wherein the dot printing film is located between the second coating film and the clear coating film. A first paint containing a first film-forming material and a first granule is applied to the design surface side of a base material having a design surface, and the first film-forming material covers the first granule. a first step of forming a first coating film having a first convex surface protruding on the opposite side from the base material at the location where the base material is located;
a second step of forming a dot printing film having a curved surface along the first convex surface on the opposite side of the first coating film to the base material;
Applying a paint containing a transparent film forming material and a second particle disposed at a position different from the first convex surface in the spreading direction of the base material to the side opposite to the base material in the first coating film, A clear coating film having a second convex surface along the first convex surface, and a third convex surface protruding on the opposite side from the base material at a location where the second granules are covered with the transparent film forming material. A building material manufacturing method comprising: a third step of forming.