JPH04133800A - Manufacture of wall surface material - Google Patents

Abstract

PURPOSE:To manufacture easily a wall surface material which appears like a tile-laid surface or a natural stone-laid surface by embossing one surface of a foamed synthetic resin to form an uneven part, then printing a projecting part to form a pattern and applying a transparent coat all over the surface. CONSTITUTION:A soft foamed synthetic resin sheet 2 is embossed using an embosser to form a square projecting part 3 and a square recessed part of groove shape surrounding the projecting part 3 over the entire embossed resin sheet 2. In addition, the projecting part 3 is at 2mm or more different level from the recessed part 4. The available materials for the foamed synthetic resin sheet are polyvinyl chloride, ethylene/vinyl acetate/vinyl chloride copolymer, polyethylene, polypropylene, etc. Next, an appropriate pattern 5 such as marble pattern is provided only the projecting part 3 with the recessed part 4 printed entirely over the surface remaining unpatterned. The projecting part 3 is printed using gravure and silk screen printing techniques. Thus it is possible to make an appearance of a complicated and fine pattern which is extremely difficult to obtain by patterning a photographic image. After that, a weather- proof, water-proof protecting layer is formed on the surface of a foamed synthetic resin sheet 2 by applying a transparent coat 6 entirely on said surface.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to a method of manufacturing a wall material particularly suitable as an exterior wall material.

Conventional technology Previously, wall materials with raised patterns such as tiles were printed in advance on the surface of a synthetic resin sheet to form the printed pattern, and then embossed to form uneven parts. The printed pattern was uniformly formed on both sides, the pattern on the convex parts did not stand out, and even when the tiles were embossed, the concave parts did not look like joints, making it visually clearly different from real tiling. .

Also, if you print a pattern excluding the areas corresponding to the joints and then try to emboss it, the position of the pattern must be precisely matched with the position of the mold, which requires very precise processing. This type of processing is not only possible when the shape of the convex portion is irregular.

Problems to be Solved by the Invention The purpose of the present invention is to easily produce a wall material in which the pattern of convex parts stands out clearly, the concave parts look like joints, and gives the appearance of real tiles or natural stone. The goal is to provide a way to do so.

Means for Solving the Problems The method for manufacturing a wall material of the present invention involves embossing one side of a foamed synthetic resin sheet to form an uneven portion, then printing on the uneven portion to form a pattern, and then, A transparent film is coated on the one surface.

Embodiments Hereinafter, embodiments of the present invention will be described in detail based on the drawings.

2 to 5 show the manufacturing process of the wall material 1. First,
A soft foamed synthetic resin sheet 2 with a thickness of 3 mm or more is embossed using an embosser, as shown in Fig. 3.
A rectangular convex portion 3 and a groove-shaped concave portion 4 surrounding the convex portion 3 are formed on one surface thereof, and the step difference between the convex portion 3 and the four portions 4 is set to be 2 mm or more.

Materials for foamed synthetic resin sheets include polyvinyl chloride, Ever vinyl chloride, and polyethylene.

Examples include polypropylene.

Next, printing is performed on the one surface, and as shown in FIG. 4, an appropriate pattern 5 such as a marble pattern is provided only on the convex portions 3 while leaving the concave portions 4 unpatterned.

A method for printing on the convex portion 3 is gravure printing.

Gravure offset printing, silk screen printing, etc. are available, and by adding patterns to photographic images, it is possible to create complex and precise expressions that are extremely difficult to achieve with painting.

Thereafter, as shown in FIG. 5, the one surface of the foamed synthetic resin sheet 2 is coated with a transparent coating 6 to form a weather-resistant waterproof protective layer on the surface.

The material of the transparent coating 6 is preferably soft fluororesin clear, acrylic silicone resin clear, or acrylic-urethane resin clear.

In order to attach this wall material 1 to a wall surface, the release paper 8 of the adhesive-treated material is peeled off and the wall material 1 is attached as is. Also, for items that are not adhesive-treated, adhesive is usually applied to the wall and then attached. The wall material 1 can be attached on-site, but it can also be attached in advance to the surface of a factory-produced wall board such as an ALC board at a factory.

Note that the shape of the convex portion 3 is not limited to a rectangular shape, but may be any shape such as a circle, and the pattern 5 can be various patterns such as a natural stone pattern or a wood grain pattern.

Effects of the Invention According to the method for manufacturing wall material of the present invention, the pattern is provided only on the convex portions of the wall material, so the pattern on the convex portions stands out clearly, and the concave portions look like tile joints, making the wall surface look more appealing. It can give the appearance of a real tiled finish, the pattern is printed on the side of the convex part and the concave part, which does not spoil the aesthetic appearance, and since it is made of foamed synthetic resin, it is lightweight. In addition to having a heavy texture, it also has excellent heat insulation properties, and the surface is coated with a transparent film, so
It increases weather resistance and water resistance, and can be used as a finishing material for walls around water and exterior walls.

Compared to printing a pattern first and then embossing it, there is no need to precisely match the patterned area with the position of the embossed unevenness; Even if the shape of the convex portion changes or is irregular, the pattern can be easily printed.

[Brief explanation of the drawing]

1 is a perspective view of a wall material according to an embodiment of the present invention; FIG. 2 is a perspective view of a foamed synthetic resin sheet; FIG. 3 is a perspective view of a foamed synthetic resin sheet after embossing; The figure is a plan view of the foamed synthetic resin sheet after patterning, and FIG. 5 is a cross-sectional view of the wall material. 1... Wall material, 2... Foamed synthetic resin sheet, 3...
- Convex portion, 4... Concave portion, 5... Pattern, 6... Transparent film, 7... Adhesive layer, 8... Release paper. 4th concave entrance % prison figure

Claims (1)

[Claims] Manufacture of a wall material, characterized in that one side of a foamed synthetic resin sheet is embossed to form uneven portions, the raised portions are then printed to provide a pattern, and then the one side is coated with a transparent film. Method.