JPH01127330A - Decorative material of natural lumber tone and its manufacture - Google Patents

Abstract

PURPOSE:To enable mass production of a decorative sheet of a natural lumber tone displaying a color tone possessing reality repeatedly, by a method wherein a press contacting of a patterned sheet or a film displaying a texture pattern of natural lumber on the surface of soft mortar is performed and a pattern is transferred. CONSTITUTION:Various patterns are formed realistically on a pattern surface 11a of a patterned sheet 11. For example, if the patterned sheet 11 is for manufacturing of a decorative material in a grained tone, a projected line 12 corresponds to an annual ring part of wood and a comparatively flat part 13 shows the woody parts between the annual rings of the wood. The surface of a recessed part 14 is finished smooth, which forms a smooth part 4 on the decorative material. A rough surface part 15 where a large number of fine unevenness have been formed forms a glossless porous part 5. Pressure contacting of the patterned sheet 11 like this to the surface of a soft mortar material 1' is performed and force P is applied uniformly to the whole area. Then the mortar material 1' is dried while the patterned sheet 11 is kept stuck close to the surface of the mortar material 1'.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a decorative material such as a woodgrain or natural stone look produced using mortar, a method for producing the same, and a novel patterned sheet used in the method. It is related to.

[Background of the invention] When finishing a building, such as a concrete exterior wall, a woodgrain or natural stone finish is often required, but relying on individual skills to finish the concrete surface is time consuming. The reality is that not only are the labor costs high and it is completely impractical, but the results are only artificial or poor-looking patterns, making it difficult to obtain customer satisfaction.

Nevertheless, when constructing hotels, lodges, villas, etc., there is a strong demand for exterior and interior finishes that look like natural materials, and the required patterns and colors are diverse, such as woodgrain tones and natural stone tones. Something with a high level of sexuality or realism is often desired.

A natural wood-like finish with such a high degree of realism, reproducibility, and mass production is impossible to achieve by hand work that relies on individual skill, and even if there is a conventional demand for it, it is impossible to achieve it. There was a total lack of means.

[Object of the Invention] Therefore, in view of the above background, the present invention provides a decorative material that has a natural material-like pattern and color tone that has a high degree of realism, is repeatable, and can be mass-produced. The purpose is to

[Summary of the Invention] In order to achieve the above object, the present invention uses cement mortar or resin mortar as a base material, and the surface thereof is provided with a separately prepared natural wood-like pattern, such as a natural stone-like pattern. A realistically formed pattern sheet (or design film) is pressed. When the pattern sheet is peeled off after the base material dries, the surface of the base material has unevenness, smoothness, and roughness corresponding to the unevenness and the mixture of smooth (or flat) and rough (or porous) parts that the pattern sheet had. The pattern consisting of the rough surface is faithfully transferred. Since the degree of pressure applied by the pattern sheet crimping differs between the concave portions and the convex portions, the density near the surface is non-uniform. Furthermore, the smooth portion and the rough surface portion have different surface roughnesses and have different reflectances of light rays.

A desired paint, for example, a wood color, is applied to the surface of the mortar base material onto which the pattern has been transferred by coating or spraying. Preferably, a semi-transparent paint is used as the paint. (a) Due to the difference in water absorption caused by the non-uniform density of the base material surface, some areas are darkly colored and others are lightly colored; , (b) The paint flows using the unevenness of the surface, and more paint accumulates in the concave areas and less in the convex areas, resulting in differences in shading, for example, between tree rings and other (c) The smooth part of the base material surface formed by pressing the smooth part on the pattern sheet and the porous part formed by pressing the rough surface show a change in color tone corresponding to the wood quality. Because of the different reflections, smooth areas become glossy and shine like, for example, hard knots of wood, while rough areas lack luster, giving them the rough appearance of wood.

In addition to translucent paint, transparent paint can also be used, but in this case, it is necessary to first color the patterned surface of the base material, and the coloring agent should be the same as in (a) and (b) above. For the same reason, shades appear. When a transparent paint is applied thereon, it exhibits gloss due to the reason (C) above.

The pattern sheet used in the present invention is a plastic film or sheet, such as a PVC-based, polyethylene-based, or polypropylene-based film or sheet, or paper, which has good releasability from dry mortar, and has unevenness, flatness, and roughness. The material is made of a material that can be molded to express a pattern, and the background pattern of wood or natural stone is expressed using photolithography technology, so it has a high degree of realism similar to that of natural materials. Moreover, the same pattern can be repeatedly mass-produced. Since the pattern sheet can be shipped in a rolled form, the present invention can be easily practiced anywhere.

The mortar used in the present invention may be cement-based mortar, such as a cement-based mortar mixed at a ff1ffi ratio of 1:1 sand: 2, and mixed with water, or a resin-based mortar, such as a water-based emuldimin-like resin and sand mixed in a 1:1 ratio. It is preferable to mix them in a weight ratio. The mixed soft mortar is placed in a suitably shaped mold to form a plate or other shape with a thickness of, for example, several meters to 2 cm, and the above pattern sheet is pressed onto the surface to form a three-dimensional pattern. Perform transcription.

As for the finish, resin-based mortar absorbs more paint and has a higher gloss than cement-based mortar.

[Embodiments of the Invention] Examples of the present invention will be described in detail with reference to the drawings. 1st
The figure is a perspective view showing an example of the decorative material itself manufactured according to the present invention, and FIG. 2 is a perspective view of a pattern sheet used in manufacturing the decorative material of FIG. 1.

In Fig. 1, mortar base material 1 constituting the decorative material
A large number of patterns of grooved stripes 2 and relatively convex flat portions (convex flat portions) 3 between the grooved stripes 2 are formed on one surface. Depending on the location, a concave smooth portion 4 is formed, and a porous rough surface portion 5 is also formed.

The four stripes 2 are darkly colored, and the convex and flat portions 3 are lightly colored, so when viewed as a whole, the texture of the wood grain is clearly expressed.

Reference numeral 4 denotes a smooth portion that protrudes further than the convex flat portion 3 and has a smooth surface, and is glossy and looks like a knot in a tree. On the other hand, the portion 5 has a relatively rough surface and is a rough (porous) portion with a rough feel, and has no luster.

Such unevenness, rough texture, and color shading are determined by the surface pattern of the pattern sheet used for manufacturing the decorative material. An example of a pattern sheet corresponding to the decorative material shown in FIG. 1 is shown in a perspective view in FIG. 2. For convenience of illustration, the sheet is shown to have a certain thickness, but in reality, it may be a thinner film-like sheet. This pattern sheet 1
1 has a large number of protrusions 12 corresponding to the grooves 2 in FIG.

There are flat portions 13 between the protrusions 12, which form the convex and flat portions 3 of the decorative material 1. A concave smooth surface 14 is further formed in the area where the concave flat part 13 is formed, and this is for forming the smooth convex part 4 of the decorative material 1. On the other hand,
The portion where the concave flat portion 13 is formed is a rough surface portion 15 in which countless fine, microscopic projections are formed, and this forms the porous portion 5 of the decorative material 1. The pattern sheet 11 is preferably formed from a vinyl chloride film, but may be made of other materials as long as they have good releasability from the mortar base material.

Next, the method for manufacturing the decorative material of the present invention will be explained with reference to FIG. 3 and subsequent figures. These figures are all enlarged partial cross-sectional views.

In FIG. 3, 1' is a pliable mortar material leveled in a suitable mold (not shown), still fully moistened. A pattern sheet 11 is placed facing the surface 1a of the mortar material 1' with its patterned surface 11a facing down.

Various patterns are realistically formed on the pattern surface 11a of the pattern sheet 11. - As an example, pattern sheet 11
If this is for manufacturing a wood-grained decorative material, the protruding stripes 12 correspond to the annual rings of the wood as shown in Figure 2, and the relatively flat portions 13 correspond to the annual rings. This represents the quality of the wood between the two. The recessed portion 14 has a smooth surface and is used to form a smooth portion 4 in the decorative material. The rough surface portion 15 having a large number of fine irregularities is used to form a dull porous portion 5 of the decorative material.

In addition to this, the pattern sheet 11 shown in FIG. 3 is also formed with a rough surface portion 16 having a convex shape. This also forms a porous portion in the decorative material, which will be discussed in detail below with respect to FIG.

As shown in FIG. 4, such a pattern sheet 11 is pressed onto the surface of a soft mortar material 1', and a force P is applied uniformly to the entire surface. In order to bring the patterned surface 11a of the patterned sheet 11 into close contact with the mortar surface 1a, light vibration or slight vibration may be applied. The mortar material 1' is dried while the pattern sheet 11 is kept in close contact with the mortar material 1'.

Drying is usually sufficient for day and night.

After the mortar has sufficiently dried, the pattern sheet 11 is peeled off. The uneven and flat patterns of the pattern sheet 11 are faithfully transferred onto the surface of the dried mortar base material 1 in complementary shapes.

A paint is applied to the surface of such mortar base material 1. It is preferable to use a semi-transparent paint.

This is applied to the surface of the substrate, for example by spraying.

Due to the unevenness of the surface of the base material, a large amount of paint flows into the concave areas and is absorbed, so the color develops darkly as shown schematically by the density of the dots in the area of 4 stripes 2 in Figure 5, and the convex areas also The flat part 3 develops a light color. In addition, in Figure 5, for example, the area 4 is compressed by the pattern sheet to a lesser degree than other areas, and has a lower density, so it has greater water absorption and absorbs a larger amount of paint than other areas. In addition to developing a deep color, the pattern sheet 11 has been smoothed (14).

The top surface is smooth, giving it a glossy appearance. Moreover, although the convex rough surface portion 6 of the pattern sheet 11 is concave,
Because the degree of compression is large and the density is high, the water absorption is lower than other parts, and the color does not develop as intensely.

In this way, due to the non-uniform density and unevenness of the surface of the mortar base material 1, even the same paint develops different shades of color, and differences in surface roughness cause it to be divided into glossy areas and non-glossy areas. The wood grain pattern and color tone are expressed in a harmonious manner, making it a decorative material that looks like natural wood.

Such decorative materials can be used by being attached to the exterior or interior walls of buildings, and can also be used as exterior materials for park facilities, flower boxes, etc., and exhibit an elegant and beautiful appearance.

In the illustrated example, only a flat mortar base material is shown, but it is also possible to form a curved plate, a corrugated plate, or a cylindrical mortar base material. for example.

To create a board with a convex upward curve, fill a mold with such a shape with flexible mortar, tightly wrap the patterned surface of the pattern sheet around its outer periphery, and press the outside of the pattern sheet with a downwardly concave holding frame. Suppress and pressure.

Alternatively, it may be vibrated. If a corrugated or cylindrical mold is used for the formwork and restraint frame, a corrugated or cylindrical mortar base material can be obtained. The cylindrical holding frame may be divided into two parts. According to the present invention, since the pattern sheet is made of a soft or flexible material, it closely follows the shape of the mortar base material such as the above-mentioned curved shape, cylindrical shape, wave shape, etc., and forms the pattern in close contact with the pattern sheet. Can be transcribed.

[Effects of the Invention] According to the present invention, a pattern sheet or film showing the background pattern of a natural material is pressed onto a flexible mortar surface to transfer the pattern. It is possible to repeatedly mass-produce natural material-like decorative materials that exhibit a certain pattern and color tone.

According to the present invention, when a paint is normally applied onto a mortar substrate having a mechanically formed natural wood-like surface pattern,
Expected shades of color occur due to physical properties such as density and unevenness on the surface of the base material, and the presence or absence of gloss is determined by surface roughness, so individual differences can be avoided during painting. There is little room for it to appear, making it easy to reproduce the same pattern and color tone.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing the external appearance of an example of the decorative material according to the present invention, FIG. 2 is a perspective view illustrating the external appearance of a pattern sheet used to form the decorative material shown in FIG. 1, and FIG. FIG. 4 is an enlarged partial sectional view of a flexible mortar material and a pattern sheet schematically illustrating the first step of the method of the present invention for producing a decorative material; FIG. FIG. 5 is a schematic enlarged partial sectional view of the mortar base material after the pattern sheet has been peeled off and the paint has been applied. [Main code

Claims (1)

[Claims] 1. A paint is applied to a pattern formed on the surface of a mortar base material with uneven density, unevenness, and a mixture of smooth and rough areas to create a color tone with uneven shading and gloss. A decorative material made from natural materials. 2. i. Form a base material of the required thickness with cement-based mortar or resin-based mortar, and ii. While the surface of the base material is soft, use a separately prepared paper or paper with a pattern of unevenness and a mixture of smooth and rough areas. A pattern sheet made of a plastic film is pressed onto the mortar surface; iii. After the mortar has dried, the pattern sheet is peeled off from the mortar surface; iv. A pattern with uneven density, unevenness, and a mixture of smooth and rough areas is formed. A method for producing a natural-looking decorative material, which consists of applying a paint on the mortar surface and drying it. 3. The method according to claim 1, wherein the paint is a translucent paint. 4. The method according to claim 1, wherein the paint is a transparent paint, and the surface of the substrate is colored prior to application of the paint. 5. Forming a pattern on the surface of a paper or plastic film or sheet that has good releasability from mortar and is moldable, with a mixture of uneven parts and smooth and rough parts corresponding to wood grain, natural stone, etc. A pattern sheet for manufacturing natural material-like decorative materials.