JPH0221304B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing a decorative board having a design pattern. In recent years, paints containing synthetic resins, cement, aggregates, or fillers, for example, are not applied smoothly to the surface of decorative boards, and droplets are scattered randomly on the surface, creating a pattern of many convexities. Decorative boards coated with paint are known. In addition, before the paint completely dries and hardens, the many convexities on the surface of this decorative board can be pressed down with a roller to flatten only the convexities to an appropriate degree, thereby creating a decorative finish that enhances the design effect. Boards are also known. Decorative boards with this design pattern are particularly widely used for architectural purposes such as wall materials and ceiling materials. However, conventionally, the decorative board with this design pattern has been manufactured directly at a construction site, and the decorative board with the pattern itself has not been produced in a factory. In short, it is relatively easy to apply paint to a target plate-like object so that droplets form on its surface by spraying it with a spray gun, etc. During work that presses the surface, commonly known as ridge pressing, there is paint adhesion to the roller surface, and there are problems such as the ridge pressing cannot be done evenly and in some cases, the paint may peel off. Currently, depending on the object, it is carried out (manufactured) at the construction site by skilled engineers. In view of the above-mentioned circumstances, the present inventor conducted various studies in order to find a method for uniformly and continuously producing decorative laminates with the above-mentioned design patterns in a factory. The inventors of the present invention have completed the present invention by discovering that when the process is carried out continuously, there is almost no adhesion of paint to the rollers, uniform ridge pressing is achieved, and decorative laminates of stable quality can be manufactured continuously. That is, the gist of the present invention is to transport a decorative board coated with paint on a conveyor while it is still wet so that paint droplets are randomly scattered on the surface and a large number of convex patterns are created. While letting
Rotatably driven in the direction opposite to the moving direction of the a conveyor provided at least in the upper lateral direction of the conveyor at a position in contact with the convex pattern of the decorative board;
Or, in the same direction as the moving direction of the conveyor b,
What's more, the pressure roller rotates at more than twice the speed of the transport conveyor.
The present invention resides in a method for manufacturing a decorative board having a design pattern, characterized in that the convex pattern is subjected to a pressure treatment. The present invention will be explained in detail below. The decorative laminate base materials targeted by the present invention usually include metal plates, synthetic resin plates, wood boards, plywood, gypsum boards,
Ceramic siding plates such as silicon plates, laminates thereof, etc. may be used, and the thickness and size of these plates are not particularly limited. In the present invention, decorative boards coated with paint are treated so that droplets are randomly scattered on the surface of these plate-like objects and a large number of convex patterns are formed. The coating is applied in accordance with a conventional method, for example, using a spray gun adjusted to spray large droplets. The size and density of the convex pattern formed on the surface of the decorative board can be arbitrarily adjusted according to the requirements at that time. In addition, the paint can usually be water-based or oil-based, but it usually contains suitable solid particles such as synthetic resin, cement, aggregate, or filler in order to make the pattern stand out. Preferably. If the viscosity of the paint is too low, proper droplets will not form on the surface, so a paint with a viscosity of, for example, 30 to 300 poise is usually used by adjusting the concentration or adding additives. In the present invention, a decorative board having a design pattern is continuously manufactured by pressing the surface of the decorative board with the convex pattern as described above in a wet state using a specific method. In the present invention, while the decorative board is moved on a conveyor, the convex pattern on the decorative board is pressed by a self-driven pressing roller provided in the upper transverse direction of the decorative board. An example in which the method of the present invention is implemented using the apparatus shown in FIG. 1 will be explained. In FIG. 1, a pressure roller 2 is provided in the upper lateral direction of the conveyor 1. Then, the decorative board A is moved from one end to the other end in close contact with the upper part of the conveyor 1, and the surface of the convex part B of the decorative board A is pressed by the pressing roller 2 during the movement. . The conveyor 1 is not particularly limited as long as it can move the decorative board horizontally, but normally, if the top belt part has a suction mechanism, the decorative board A and the conveyor 1 The adhesion of the decorative board A is improved, and as a result, the warpage of the decorative board A is reduced, so that the convex pattern is pressed uniformly, which is preferable. For example, the conveyor 1 with a suction mechanism may have a table portion of the conveyor in the form of a closed box with a large number of suction holes only on the top surface, a wide punching belt on the outside surface, and a turbine-type fan or the like installed from inside the table. One example is one that allows air to be extracted. In addition, the moving speed of the belt on the conveyor 1 is usually 10 to 60 m/
It's a minute. On the other hand, the pressing roller 2 is provided so as to be able to press the entire surface of the decorative board in the lateral direction of the conveyor 1, but the decorative board A can pass through the gap between the pressing roller 2 and the transport conveyor 1, and This is at least enough for the pressure roller 2 to come into contact with the convex pattern B of the decorative board A and press the surface thereof. For example, when the gap (x) between the two is expressed in relation to the thickness (y) of the decorative board, it is usually preferable to set it within the range expressed by the following formula. y≦x<y+5 (mm) In the present invention, the pressure roller 2 rotates in the direction opposite to the moving direction of the transport conveyor a, or b
It is essential to rotate in the same direction as the transport conveyor and at a specific speed relative to the moving speed of the transport conveyor. That is,
In the present invention, the pressure roller 2 has a convex pattern B on the decorative board A.
It is necessary to reduce the shearing force at the point of contact when it comes into contact with the pressure roller 2, and as a result, adhesion of paint to the surface of the pressure roller 2 is prevented.
For example, in the same direction as the conveyor 1, and
If the pressure treatment is performed using a pressure roller that rotates at the same speed as the moving speed of the conveyor 1, the shearing force at the contact point becomes large, and the paint adheres to the surface of the pressure roller. Therefore, in this case, it is not possible to continuously produce decorative laminates of constant quality. When the pressure roller 2 is driven to rotate in the opposite direction to the conveyor 1, the rotation speed can be selected from a relatively wide range, and usually
It is 0.5 to 5 times the moving speed of . Also,
When the pressure roller 2 is driven to rotate in the same direction as the conveyor 1, the speed needs to be at least twice as fast as the conveyor 1, preferably 2.5 to 3 times as fast. Note that the rotational speed of the pressure roller 2 in the present invention refers to the speed at the outer periphery of the pressure roller 2. In the present invention, as described above, the convex pattern B of the decorative board A is pressed by the press roller 2 which is rotated in a specific manner.
Press roller 2 rotating in the opposite direction to the moving direction of
It is preferable to carry out the pressure treatment because there is less paint adhesion to the surface of the pressure roller 2 and stable treatment can be carried out for a long period of time. The material of the pressure roller 2 is usually synthetic resin such as polyethylene, polypropylene, polyvinyl chloride, fluororesin; copper, chromium, nickel,
Examples include metals such as aluminum; inorganic materials such as ceramics and glass. For example, polyethylene and polyvinyl chloride are preferable because they have particularly low adhesion to water-based paints. Further, the size of the pressure roller 2 in the present invention is not particularly limited, but
Usually, a diameter of about 100 to 300 m/m is preferable. The pressure roller 2 may be driven by directly connecting the pressure roller 2 and a drive device, but for example, a doctor roller 3 for supplying a mold release agent may be used to drive the pressure roller 2.
The pressure roller 2 may be driven together by connecting the pressure roller 2 and the pressure roller 2 with a gear and driving the doctor roller 3. In the present invention, a release agent is normally continuously applied to the surface of the pressure roller 2. For example, a doctor roller 3 that rotates in contact with the pressure roller 1 is provided to apply the release agent on the surface of the pressure roller 2. By supplying the mold release agent, it is possible to apply the mold release agent to the surface of the pressure roller 2 as the pressure roller 2 rotates. In this case, the material of the doctor roll 3 is usually preferably rubber or sponge rubber, but it may also be cloth, soft ceramic, or the like. In addition, the diameter of the doctor roller 3 is, for example, relative to the diameter of the pressure roller 2.
It is about 0.5 to 0.8 times. This doctor roller 3
It is usually preferable that the rotational speed of the pressure roller 2 is approximately the same as that of the pressure roller 2. Alternatively, a method of spraying the release agent directly onto the surface of the pressure roller 2 may be used. Furthermore, depending on the case,
It is also possible to adopt a method of directly applying a mold release agent to the surface of the decorative board to be treated without applying the mold release agent to the pressure roller 2. The type of release agent used in the present invention is the pressure roller 2.
It varies depending on the material and type of paint, but usually,
It is preferable that the SP value (wetting coefficient) is about the same as that of the material of the pressure roller 2, and has a value that is significantly different from that of the paint. Specific examples of mold release agents that are actually used include known ones such as kerosene, toluene, xylene, oil, water repellents, and activators. For reference, the pressure roller,
Examples of SP values for materials commonly used as paint materials and mold release materials are shown in the table below.

[Table] Furthermore, in the present invention, a blade 4 for scraping off paint adhering to the surface of the pressure roller 2 may be provided as necessary. This blade 4 is usually provided so that its tip is in close contact with the entire surface of the pressure roller 2. Even if a small amount of paint adheres to the surface of the pressure roller 2, it can be easily removed, allowing for more stable continuous production of decorative laminates. In addition, as shown in FIG. 2, a roll 5 whose tip is in contact with the entire surface of the pressure roller 2 is provided,
The tip of the blade 4 may be brought into contact with the roll 5 so that if a small amount of paint adheres to the paint receiver 6, it can be collected. As described above, according to the present invention, by using the above-mentioned pressing device to press the decorative board on the conveyor with a specific pressing roller, almost no paint adheres to the pressing roller, and the paint is uniformly coated. Pressure processing can be performed. Therefore, the industrial value of the present invention is extremely large, since it is possible to continuously manufacture decorative boards having the design pattern of the present invention, and mass production can be carried out in a factory rather than at a construction site. Next, the present invention will be explained in more detail with reference to examples, but the present invention is not limited to the methods described in the following examples unless the gist thereof is exceeded. Examples 1 to 6 Wet decorative boards (width
60 cm, thickness 12 m/m) was subjected to pressing treatment to form a convex pattern on the surface using the pressing device shown in FIG. 20 pieces of the decorative board A from one end of the conveyor 1
While conveying at a speed of m/min, the pressure roller 2 (diameter 21 cm) made of the material shown in Table 1 rotates at the same speed in the opposite direction to the conveyor provided on the entire surface in the upper transverse direction. The surface of the decorative board was pressed. The mold release agent shown in Table 1 was supplied between the doctor roller 3 (diameter 12.5 cm) and the pressure roller 2, and was uniformly applied to the surface of the pressure roller 2. Continuously process the decorative board as described above,
In this case, the state of adhesion of the paint to the pressure roller 2 and the processing time required to continuously obtain decorative laminates of a constant quality were measured, and the results are shown in Table 1. Examples 7 to 10 and Comparative Examples 1 to 9 In the method of Example 3, similar pressure was applied using a pressure roller 2 that rotates in the same direction as the moving direction of the conveyor 1 and at the speed shown in Table 2. Table 2 shows the results of the treatment. From the above results, when the rotation direction of the pressure roller is the same as the movement direction of the transport conveyor, and the rotation speed is about the same as the movement speed of the transport conveyor, paint adhesion to the pressure roller is significant and continuous processing is virtually impossible. It turns out it can't be done. On the other hand, as defined in the present invention, even if the rotation direction is the same, the moving speed of the pressing roller is twice or more faster than the moving speed of the conveyor (Examples 7 to 10), or
When the rotation direction of the pressure roller is different (Example 1)
It can be seen that stable and good pressing processing can be performed in cases 6) to 6).

【table】

【table】

【table】 [Brief explanation of drawings]

FIG. 1 and FIG. 2 are explanatory diagrams showing a pressing device of an embodiment used for pressing processing of decorative laminates of the present invention,
1 is a conveyor, 2 is a pressure roller, 3 is a doctor roller, 4 is a blade, 5 is a cleaning roll, and 6 is a paint receiver.

Claims (1)

[Claims] 1. While transporting a decorative board coated with paint in a wet state on a conveyor so that paint droplets are randomly scattered on the surface and a large number of convex patterns are created, (b) Rotationally driven in the opposite direction to the moving direction of the conveyor (a) provided at a position in contact with the convex pattern of the decorative board, or (b) in the same direction as the moving direction of the conveyor, and A method for manufacturing a decorative board having a design pattern, characterized in that the convex pattern is pressed by a pressure roller that is rotated at twice or more the moving speed.