JP7463135B2 - Decorative Panel - Google Patents

Description

The present invention relates to decorative panels.

Traditionally, interior materials (decorative boards) using inorganic boards such as gypsum boards, calcium silicate boards, and fiber-reinforced cement boards as base materials have been known. Extruded cement boards are panels made from cement, calcium silicate, and inorganic fibers, extruded into a hollow board shape. Extruded cement boards are lightweight building materials that are strong, weather-resistant, fire-resistant, and earthquake-resistant, and also have aesthetic appeal and design features. Extruded cement boards are not limited to flat shapes, and can be given ribbed or embossed patterns on the surface depending on the shape of the nozzle used when extruding, allowing for a high degree of design freedom.

JP 2000-43185 A

However, when adding a design to a conventional extruded cement board, it was common to apply a single-color paint to the surface.

This creates a technical problem that needs to be solved: how to give decorative panels a high level of design. The present invention aims to solve this problem.

In order to achieve the above-mentioned object, the decorative board of the present invention comprises an inorganic base material on which a primer layer, a toned base layer, and a sputter layer containing a sputter paint consisting of colored pigment particles and a translucent resin are laminated in this order from the bottom , the amount of resin contained in the sputter layer is set to 4 wt % or more, and the sputter layer is formed by scattering the sputter paint in dots on the flat base layer .

According to this configuration, the decorative board has a sputter layer formed by spraying a sputter paint that is a mixture of pigment particles and resin, which gives the decorative board a high level of design. In addition, by mixing the pigment particles with the resin, the pigment particles are more easily fixed, improving the adhesion of the coating film on the decorative board. Furthermore, the presence of a primer layer that covers fine irregularities (unevenness) on the surface of the inorganic material smoothes the surface of the decorative board and further improves the adhesion of the coating film on the decorative board.

Furthermore , by setting the resin content of the sputtered layer to 4 wt % or more, the pigment particles become more easily fixed.

In addition, in the decorative board according to the present invention, the inorganic substrate is preferably a fiber-reinforced cement board.

It is now possible to impart a high level of design to the surface of inorganic boards, which previously could only be painted in a single color.

FIG. 1 is a vertical cross-sectional view showing a configuration of a decorative board according to the present invention.

The embodiment of the present invention will be described with reference to the drawings. Note that in the following, when referring to the number, numerical value, amount, range, etc. of components, unless otherwise specified or when it is clearly limited to a specific number in principle, it is not limited to that specific number, and it may be more or less than the specific number.

In addition, when referring to the shape or positional relationship of components, etc., this includes things that are substantially similar or similar to that shape, etc., unless otherwise specified or considered in principle to be clearly different.

In addition, drawings may exaggerate characteristic parts to make the features easier to understand, and the dimensional ratios of components may not be the same as in reality. In addition, in cross-sectional views, hatching of some components may be omitted to make the cross-sectional structure of the components easier to understand.

The decorative board 1 of the present invention has a primer layer 3, a base layer 4, and a sputtered layer 5 laminated on an inorganic substrate 2.

Materials for the inorganic substrate 2 include cement boards, fiber-reinforced cement boards, volcanic glass laminate boards, calcium silicate boards, magnesium silicate boards, etc., and these substrates have high flame retardancy and excellent strength.

In particular, a fiber-reinforced cement board, which has excellent strength, impact resistance, and dimensional stability, is preferred as the material for the inorganic substrate 2. A fiber-reinforced cement board can be obtained by mixing cement as a matrix with reinforcing fibers, silica powder, and pigments, adding water and kneading, extruding, and then curing in an autoclave.

The cement is not particularly limited, and examples include ordinary Portland cement, blast furnace cement, silica cement, mixed cement such as fly ash cement, alumina cement, etc.

Reinforcing fibers include inorganic fibers such as glass fiber, carbon fiber, and wollastonite, natural organic fibers such as pulp fiber, and organic synthetic fibers such as polyethylene fiber, polypropylene fiber, vinylidene fiber, and aramid fiber.

The silica component of the silica powder reacts hydrothermally with the calcium component in the cement during autoclave curing to form calcium silicate crystalline material, improving strength.

The inorganic base material 2 is extruded using, for example, a screw-type extruder. If the autoclave curing conditions are 110 to 200°C and a holding time of 1 to 24 hours, a lightweight, high-strength fiber-reinforced cement board will be produced.

The thickness of the inorganic base material 2 is preferably 50 mm to 100 mm in terms of strength and ease of handling. The density of the inorganic base material 2 is also preferably 0.5 to 2.0 g/cm3. If the density is below the lower limit, the primer layer 3 is likely to be absorbed, and if the density exceeds the upper limit, the base material becomes heavy and is likely to be difficult to handle.

The surface of the inorganic substrate 2 is smoothed by surface grinding using sandblasting, shot blasting, diamond rolls, sandpaper, etc.

The primer layer 3 laminated on the inorganic substrate 2 prevents the alkaline components of the inorganic substrate 2 from eluting. The primer layer 3 is formed by applying a primer paint onto the inorganic substrate 2.

Primer paints can be made from nylon resin, alkyd resin, epoxy resin, acrylic resin, acrylic-modified silicone resin, chlorinated rubber resin, urethane resin, phenol resin, polyester resin, melamine resin, alkyl silicate or its hydrolysis condensate, etc. Titanium oxide may also be added to the primer paint to improve hiding power.

The amount of primer paint applied should be about 10 to 100 μm thick, and can be applied using a known roll coater, flow coater, spray coater, etc. If the amount applied is less than the lower limit, adhesion to the base layer 4 is likely to be poor, and if the amount applied is more than the upper limit, foaming is likely to occur, and the appearance of the finished product is likely to be poor.

The base layer 4 is laminated on the primer layer 3. The base layer 4 is formed by applying a base paint that is toned to a color such as white or black onto the primer layer 3.

Examples of base paints include organopolysiloxane resin paints, fluororesin paints, two-component curing acrylic urethane resin paints, acrylic resin paints, epoxy resin paints, polyurethane resin paints, vinyl chloride resin paints, vinylidene chloride resin paints, and acrylic silicone resin paints. An appropriate paint is selected taking into consideration the drying properties of the paint film, the surface hardness of the paint film, adhesion to the primer layer 3, and the chemical resistance and contamination resistance of the paint film.

The amount of base paint applied should be about 10 to 100 μm thick, and can be applied using a known roll coater, flow coater, spray coater, etc. If the amount applied is less than the lower limit, adhesion to the primer layer 3 is likely to be poor, and if the amount applied is more than the upper limit, foaming is likely to occur, and the appearance of the finished product is likely to be poor.

A sputtered layer 5 is laminated on the base layer 4. The sputtered layer 5 is formed on the base layer 4 by sputter coating.

Sputter coating is performed by applying a sputter paint made of a mixture of colored pigment particles and translucent resin. This causes the colored pigment particles to be scattered in dots on the decorative board 1. The pigment particles can be, for example, silver pearl powder or black microparticles. The surfaces of the pigment particles are coated with resin, which improves the adhesion of the sputter layer 5.

Examples of pearl paints containing an appropriate amount of pearl powder include organopolysiloxane resin paints, fluororesin paints, two-component curing acrylic urethane resin paints, acrylic resin paints, epoxy resin paints, polyurethane resin paints, vinyl chloride resin paints, vinylidene chloride resin paints, and acrylic silicone resin paints. They are selected appropriately taking into consideration the drying properties of the coating film, the surface hardness of the coating film, adhesion to the undercoat layer 4, the chemical resistance and contamination resistance of the coating film, and the degree of dispersion of the pearl. The amount of resin contained in the sputter layer 5 is preferably at least 4 wt% or more. This is because at 4 wt%, the pigment particles are difficult to adhere, and it is necessary to add 4 wt% or more of resin.

The amount of pearlescent paint applied should be about 10 to 100 μm thick, and can be done using a known roll coater, flow coater, spray coater, etc. If the amount applied is less than the lower limit, adhesion to the base layer 4 is likely to be poor, and if the amount applied is more than the upper limit, foaming is likely to occur, and the appearance of the finished product is likely to be poor.

The amount of pearl powder added can be adjusted as desired within a range that allows the sputtered layer 5 to have the luster characteristic of pearls and prevents the pearls from settling within the sputtered layer 5.

In addition, because the sputter layer 5 is translucent, the color of the decorative board 1 can be adjusted according to the color tone of the base layer 4. In other words, the design of the appearance of the sputtered dots scattered on the surface of the decorative board 1 can be changed by combining the color tone of the base layer 4 and the color tone of the pigment particles contained in the sputter layer 5.

The amount of sputter coating to be applied should be about 10 to 100 μm in thickness, and can be done using a known roll coater, flow coater, spray coating, etc. If the amount applied is less than the lower limit, adhesion to the base layer 4 is likely to be poor, and if the amount applied is more than the upper limit, foaming is likely to occur, and the appearance of the finished product is likely to be poor.

It is preferable to laminate a topcoat layer 6 on the sputtered layer 5 in order to improve the chemical resistance of the decorative board 1. Furthermore, by laminating the topcoat layer 6, a sense of depth can be imparted to the sputtered layer 5. The topcoat layer 6 is formed by applying a topcoat paint on the sputtered layer 5.

Topcoat paints include organopolysiloxane resin paints, fluororesin paints, two-component curing acrylic urethane resin paints, acrylic resin paints, epoxy resin paints, polyurethane resin paints, vinyl chloride resin paints, vinylidene chloride resin paints, and acrylic silicone resin paints, and are selected appropriately taking into consideration the drying properties of the coating film, the surface hardness of the coating film, adhesion to the sputter layer 5, and the chemical resistance and contamination resistance of the coating film.

The amount of topcoat paint applied should be about 10 to 100 μm thick, and is applied using a known roll coater, flow coater, spray coater, etc. If the amount applied is less than the lower limit, adhesion to the sputtered layer 5 is likely to be poor, and if the amount applied is more than the upper limit, foaming is likely to occur, and the appearance of the finished product is likely to be poor.

In addition, by using the same paint (e.g., fluororesin paint) for the base layer 4, the sputtered layer 5, and the topcoat layer 6, a coating film with excellent weather resistance can be formed on the surface of the decorative board 1.

Next, we will explain the present invention in detail using examples and comparative examples.

[Example 1]
The decorative board 1 according to the first embodiment is constructed in the following manner.
[Inorganic substrate (fiber-reinforced cement board)]
As an extrusion molded cement board, Mace (registered trademark) MHN-6060A (manufactured by Aikatec Building Materials Co., Ltd., thickness 60 mm) is prepared.

[Primer layer]
The surface of the inorganic substrate 2 was ground with a diamond roll and sandpaper, and a primer paint was sprayed onto the inorganic substrate 2 so that the thickness of the primer layer 3 was 35 to 45 μm, and then the primer paint was dried at 120° C. for 20 minutes.
Base material: Eponix Ceramic Primer Base material (manufactured by Dai Nippon Paint Co., Ltd., epoxy resin type)
Hardener: Eponix Ceramic Primer Hardener (Amine-based, manufactured by Dai Nippon Paint Co., Ltd.)
Mixing ratio: Base agent: Hardener = 85:15

[Base layer]
The undercoat paint was sprayed onto the primer layer 3 so that the undercoat layer 4 had a thickness of 30 to 40 μm, and then dried at 120° C. for 20 minutes.
Base material: V-Flon #200 top coat base material (manufactured by Dai Nippon Paint Co., Ltd., fluorine-based resin)
Hardener: V-Flon #200 topcoat hardener (manufactured by Dai Nippon Paint Co., Ltd., isocyanate type)
Mixing ratio: Base agent: Hardener = 90:10

[Sputtered layer]
The sputtered layer 5 was applied to a predetermined thickness on the undercoat layer 4 using a pearlescent paint by spraying, and then dried at 120° C. for 20 minutes.
Paint: Pearl sputter paint (manufactured by Dai Nippon Toryo Co., Ltd., fluororesin), pearl additive amount 5%

[Topcoat layer]
The topcoat paint was sprayed onto the sputtered layer 5 so that the topcoat layer 6 had a thickness of 30 to 40 μm, and then dried at 12° C. for 20 minutes.
Base material: V-Flon #200 Clean Layer Base material (manufactured by Dai Nippon Paint Co., Ltd., fluorine-based resin)
Hardener: V-Flon #200 Clean Layer hardener (manufactured by Dai Nippon Paint Co., Ltd., isocyanate type)
Mixing ratio: Base agent: Hardener = 80:20

[Example 2]
The decorative board 1 of Example 2 was produced in the same manner as Example 1, except that the sputtered layer 5 of Example 1 was replaced with the following sputtered layer 5 (enamel).

[Sputtered layer]
A sputtered layer 5 was formed by mixing a predetermined amount of black pigment particles with V-Flon #200 (a fluororesin manufactured by Dai Nippon Toryo Co., Ltd.) to obtain a predetermined thickness. The resulting sputtered paint was sprayed onto the undercoat layer 4 and then dried at 120°C for 20 minutes.

[Example 3]
The decorative board 1 according to Example 3 was prepared in the same manner as Example 1, except that the base layer 4 of Example 1 was omitted.

[Example 4]
The decorative board 1 according to Example 4 was prepared in the same manner as Example 2, except that the base layer 4 of Example 2 was omitted.

[Example 5]
The decorative board 1 of Example 5 was prepared in the same manner as Example 1, except that the topcoat layer 6 of Example 1 was omitted.

[Example 6]
The decorative board 1 of Example 6 was prepared in the same manner as Example 2, except that the topcoat layer 6 of Example 2 was omitted.

The following Comparative Examples 1 to 3 were prepared for comparison with Examples 1 to 6.

[Comparative Example 1]
Comparative Example 1 was carried out in the same manner as in Example 1, except that the primer layer 3 in Example 1 was omitted.

[Comparative Example 2]
Comparative Example 2 was carried out in the same manner as in Example 2, except that the primer layer 3 in Example 2 was omitted.

[Comparative Example 3]
Comparative Example 3 was carried out in the same manner as in Example 1, except that the sputtered layer 5 in Example 1 was replaced with the following sputtered layer 5.

[Sputtered layer]
Pearl powder (aluminum paste) was sprayed onto the undercoat layer 4 so that the sputtered layer 5 had a predetermined thickness, and then dried at 120° C. for 20 minutes.

The evaluation results for Examples 1 to 6 and Comparative Examples 1 to 3 are shown in Table 1.

The test and evaluation methods for Examples 1 to 6 and Comparative Examples 1 to 6 are as follows:

[Appearance test]
The specimen was visually inspected for any abnormal appearance such as cracks or blisters. If there was no abnormal appearance, it was marked with an ◯, and if there was an abnormal appearance, it was marked with an X.
[Adhesion test]
The cross-cut method was performed according to JIS K5600-5-4. If no peeling occurred in 25 squares spaced 4 mm apart, it was marked with an ◯, and if peeling occurred, it was marked with an X.

According to Table 1, for Examples 1 to 6, no abnormalities were found in the appearance test and adhesion test. On the other hand, when comparing Examples 1 to 2 and Comparative Examples 1 to 2, it can be seen that in Comparative Examples 1 to 2, if the primer layer 3 is omitted, the unevenness (irregularity) of the surface of the inorganic base material 2 becomes noticeable, tending to impair the appearance of the decorative board 1, and the unevenness of the surface of the inorganic base material 2 makes it difficult to ensure adhesion between the inorganic base material 2 and the undercoat layer 4, making the painted surface of the decorative board 1 prone to peeling. In addition, when comparing Example 1 and Comparative Example 3, it can be seen that in Comparative Example 3, the aluminum paste does not adhere well because it is not covered with resin.

Reference Signs List 1: Decorative sheet 2: Inorganic base material 3: Primer layer 4: Undercoat layer 5: Sputtered layer 6: Topcoat layer

Claims (2)

A primer layer, a toned undercoat layer, and a sputter layer containing a sputter coating material made of colored pigment particles and a translucent resin are laminated on an inorganic substrate in this order from the bottom ;
The amount of resin contained in the sputtered layer is set to 4 wt % or more.
The decorative board is characterized in that the sputtered layer is formed by scattering the sputtered paint in dots on the flat base layer . 2. The decorative board according to claim 1, wherein the inorganic base material is a fiber-reinforced cement board.

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