JPH07116587A - Production of plate for building - Google Patents

Abstract

PURPOSE:To reduce the number of production processes to cut working cost and to perform natural patterning having streoscopic effect by blowing air onto a coating material curtain falling to shake it and forming a flow patterned coating consisting of a thick film part and a thin film part on a base coat. CONSTITUTION:After the surface of a base plate consisting of a calcium silicate plate is subjected to sealer treatment with a damp cured urethane coating material, an acrylic urethane enamel coating material is applied by a curtain flow coater to form a base coat 2 of the same color as that of a natural stone to express. Next, curtain flow coating is applied on the base coat 2 by the curtain flow coater 3 and also air is blown from the side by an air nozzle 9 onto a coating material curtain 4 which flows down from a slit 8 between a pair of rolls 6, 7 in the bottom part of the curtain flow coater 3. By shaking the coating material curtain 4 by intermittent blowing, a flow patterned coating is formed on the base coat 2 on the base plate 1 transferred by a belt conveyor 17.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a construction in which a sealer layer and a base coat are formed on the surface of a substrate, if necessary, and curtain flow coating is applied on the sealer layer and the base coat to express, for example, a marble or other natural stone-like pattern. More particularly, it relates to a method for forming a pattern coat such as a flow pattern on a substrate. Such building boards are mainly used as wall materials in equipment units such as bathroom units and toilet units.

[0002]

2. Description of the Related Art As a wall material for a bathroom unit or the like, a natural stone plate is preferred because of its luxurious appearance. However, because of the cost of the natural stone, the plate material is heavy, fragile, and difficult to construct. Artificial marble boards are being developed. As a method of manufacturing such a building board, a printing paper is impregnated with a diallyl phthalate resin, the impregnated paper is pressed onto a substrate, a white base coat is applied to the substrate, and then a pattern is transferred onto the substrate to form a transparent surface. There are methods such as painting.

Further, in Japanese Patent Laid-Open No. 26670/1990, a base coat of a masking paint is provided on a substrate having irregularities, and a first pattern coat in the form of a masking paint and a spot of a paint having a small masking property are provided on the base coat. Japanese Patent Application Laid-Open No. 2-26671 discloses a method for manufacturing a building board in which a second patterned coat is formed and a top coat of clear paint is formed on the second patterned coat. For construction in which spot-shaped first pattern coat of hiding paint and spot-shaped second pattern coat of less hiding paint are formed on top, clear paint top coat is formed on it, and the surface is polished A method of making a plate is disclosed.

[0004]

However, the method of using the impregnated paper and the method of patterning by transfer can only form a planar pattern and cannot give a feeling of unevenness.

Also, a patterning method by painting is disclosed in JP-A-2-
In the method of 26670 and JP-A-2-26671, the number of steps is large and the processing cost is high accordingly. In addition, Japanese Patent Laid-Open No. 2-2
The methods of 6670 and JP-A-2-26671 have a drawback that a granite pattern can be formed, but a flow pattern cannot be formed.

In view of these points, an object of the present invention is to form a natural stone-like pattern coat, thereby producing a construction board having a feeling of unevenness between a pattern portion and a non-pattern portion in a small number of steps. To provide a way to do it.

[0007]

A first object of the present invention is to apply a curtain of paint flowing down when a curtain flow coating is applied on a sealer layer and a base coat formed on the surface of the substrate, if necessary. A method for manufacturing a building board, characterized in that a flow pattern coat composed of a thick film portion and a thin film portion is formed on a base coat by blowing air to shake the paint curtain.

In the second aspect of the present invention, after the sealer layer and the base coat are formed on the surface of the substrate, if necessary, the flow rate of the coating material from the curtain flow coater is changed when the curtain flow coating is applied thereon. By doing so, a pattern coat comprising a thick film portion and a thin film portion is formed on the base coat, which is a method for manufacturing a building board.

According to a third aspect of the present invention, a sealer layer and a base coat are formed on the surface of the substrate, if necessary, and then curtain flow coating is applied thereon. Is applied or a paint of a different color from the curtain paint is supplied to the curtain flow coater to form a flow pattern coat of a plurality of colors on the base coat.

In the first, second and third inventions, a substrate having a flat surface or a substrate having irregularities is used as the substrate. As a material of the substrate, a calcium silicate plate, an asbestos cement plate, a gypsum slag plate, a gypsum board, an FRP plate, a plywood, a wood plate, etc. are used. If necessary, a sealer treatment is applied to the surface of the substrate with a moisture-curable urethane resin paint or the like, and then a base coat made of a coating film of the same color as the natural stone to be expressed is formed. As a sealer treatment method or a base coat coating method, a method using a roll coater, a curtain flow coater, a spray, or the like is used alone or in combination. As a paint for the base coat, a paint having a concealing property such as an acrylic urethane enamel paint is often used.

To apply curtain flow coating on a substrate or a base coat, a curtain flow coater is used to drip the paint, and the formed paint curtain is dropped in layers on the base coat of the substrate running in a direction orthogonal to this. As a paint for curtain flow coating, a paint having a concealing property such as an acrylic urethane enamel paint, or an acrylic urethane color clear paint (clear paint with a pigment added for coloring) is used. The paint used is of low viscosity and either overflows the weir of the curtain flow coater or flows out of the bottom slot.

In the first invention, the blowing of air is
It may be done for the entire paint curtain or for a part thereof. The blowing direction of air is from the front side of the paint curtain, diagonally above the front side, from the side, etc., and is appropriately selected according to the target pattern. Examples of the air blowing method include a method of spraying at intervals with time, a method of spraying while changing the spraying force, and the like. The air blowing interval is appropriately selected depending on the substrate transfer speed, the target pattern, and the like.

In the second aspect of the invention, as a method for changing the amount of paint flowing out from the curtain flow coater, the amount of paint overflowing from the weir of the curtain flow coater is adjusted, or the width of the slot at the bottom of the curtain flow coater is changed. Then, there is a method of adjusting the amount of paint flowing out from the slot. Although the amount of paint flowing down is not limited,
For example, 5 to 20 gr / m ² to 100 to 20 for 10 seconds
Increased to 0 gr / m ² and again 5 to ² in the next 10 seconds
Reduce to 0 gr / m ² . The amount of paint spilled and the duration of the increase or decrease are preferably varied randomly.

In the first and second aspects of the invention, after the pattern coat is formed in this way, a top coat may be formed thereon, if necessary. The top coat will be described in detail in the description of the third invention.

In the third aspect of the invention, the paint of a different color is usually sprayed from the front side of the paint curtain, but the spraying direction is not limited. As the paint to be sprayed, a paint having the same quality as the curtain paint but a different color is preferably used. At this time, if the paint curtain formed by the curtain flow coater is prevented from flowing by the spray pressure, the coating film thickness can be controlled to be substantially constant. If the spray is applied intermittently, the flow pattern is formed more effectively, and a delicate color can be expressed.

When a paint different in color from the curtain paint is supplied onto the roll of the curtain flow coater, it is necessary that these different kinds of paint are not uniformly mixed as a whole.
For example, it is preferable to supply a small amount of different color paint onto the roll of the curtain flow coater.

The ratio of the amount of the curtain paint to the amount of the different color paint added thereto is preferably 5 to 10 parts by weight with respect to 100 parts by weight of the former.

Since there is a case where the feeling of depth of natural stone cannot be expressed only by forming the flow pattern coat, a top coat of clear paint is formed on the flow pattern coat. The thickness of the clear paint may be increased in order to more effectively give the depth feeling of natural stone by forming the top coat of the clear paint.
Acrylic urethane clear paints are examples of clear paints that apply top coat. As a method for applying the clear paint, the same method as the method for forming the base coat layer can be carried out.

[0019]

In the first invention, air is blown to the paint curtain to shake the paint curtain, and in the second invention, the outflow amount of the paint is changed, and in the third invention, a paint of a different color is sprayed to the paint curtain. Alternatively, since a paint different in color from the curtain paint is supplied to the curtain flow coater, a pattern coat which is rich in variety can be formed in one coating process, and the processing cost can be reduced by reducing the number of processes.

Further, since the thickness of the paint is thicker in the patterned portion than in other portions, a feeling of unevenness is obtained between the patterned portion and the non-patterned portion, and a natural pattern with a three-dimensional effect can be obtained.

Further, in the third aspect of the invention, since the clear coat top coat is formed on the flow pattern coat, a marble-like depth feeling can be obtained. The first, second and third inventions can be combined.

[0022]

Embodiments of the present invention will be specifically described with reference to the drawings.

Example 1 In FIGS. 1 to 3, a flat surface of a substrate (1) made of a calcium silicate plate having a thickness of 5 mm was sealed with a moisture-curing urethane paint (V-Celan # 100 sealer manufactured by Dainippon Paint Co., Ltd.). After the treatment, an acrylic urethane-based enamel paint (V-Seran # 100 enamel manufactured by Dainippon Paint Co., Ltd.) was applied by a curtain flow coater to form a base coat (2) of the same color as the natural stone to be expressed.

Next, the curtain flow coater (3) is used to apply the curtain flow coating on the base coat (2), and at the same time, the slit (between the pair of rolls (6) (7) at the bottom of the curtain flow coater (3) ( Air was sprayed from the side with the air nozzle (9) to the paint curtain (4) flowing from 8). The air was blown for 0.5 seconds at 0.5 second intervals. As the paint for this curtain flow coating, acrylic urethane color clear paint (V-Seran # 100 color clear, manufactured by Dainippon Paint Co., Ltd.)
Was used.

The substrate (1) transferred by the belt conveyor (17) by thus intermittently blowing air
A flow pattern coat (5) was formed on the base coat (2) of. Moreover, there was a feeling of unevenness between the patterned portion and the non-patterned portion, and a natural patterning with a three-dimensional effect was obtained.

Example 2 In FIGS. 4 to 6, the surface of the substrate (1) was subjected to a sealer treatment in the same manner as in Example 1, and a base coat (2) was formed on this.

Then, curtain flow coating is applied on the base coat (2) using the curtain flow coater (3), and at the same time, the flow rate of the paint flowing out from the curtain flow coater (3) is changed from 20 gr / m ² to 200 per 10 seconds.
increased to gr / m ² and again 20 gr in the next 10 seconds
To / m ² was reduced. By repeating this, a natural pattern coat (12) having a thick film portion (10) and a thin film portion (11) was formed on the base coat (2). The flow rate of the paint was changed by moving one of the pair of rolls (6) (7) at the bottom of the curtain flow coater (3) and changing the width of the slit (8) between them. As the paint for this curtain flow coating, acrylic urethane color clear paint (V-Seran # 100 color clear, manufactured by Dainippon Paint Co., Ltd.)
Was used. After forming the pattern coat, clear acrylic urethane paint on the pattern coat (V top clear made by Dainippon Paint Co., Ltd.)
To form a top coat (13).

By changing the outflow amount of the curtain paint in this way, a patterned coat having a large change in film thickness was formed. Further, there was a feeling of unevenness between the thick film portion (10) and the thin film portion (11), and a natural patterning with a three-dimensional effect was obtained.

Example 3 In FIGS. 7 to 9, the surface of the substrate (1) was subjected to a sealer treatment in the same manner as in Example 1, and a base coat (2) was formed on this.

Then, when performing curtain flow coating on the base coat (2) using the curtain flow coater (3), the slit (8) between the pair of rolls (6) (7) at the bottom of the curtain flow coater (3) is used. ) From acrylic urethane enamel paint (manufactured by Dainippon Paint Co., Ltd., V-Seran # 100
The paint curtain (4) thus formed was intermittently sprayed with a paint of a different color. Spraying of the different color paint was performed from the front of the paint curtain (4) by the spray (14). As a spray paint, curtain
A paint of the same quality as the paint of (4) (a paint with a concealing property such as a urethane-based enamel paint) but of a different color was used. On this occasion,
The spray pressure was adjusted so that the paint curtain (4) formed by the curtain flow coater (3) did not flutter due to the spray pressure. Thus, the flow pattern coat (16) was formed on the base coat (2).

On the flow pattern coat (16), a top coat (15) of an acrylic urethane clear paint (V top clear, manufactured by Dainippon Paint Co., Ltd.) is formed by the same method as the above base coat layer forming method. did.

[0032]

In the first invention, air is blown onto the paint curtain to shake the paint curtain, and in the second invention the outflow amount of the paint is changed. In the third invention, a paint of a different color from the paint curtain is applied. Since it is sprayed or a different color from the curtain paint is supplied to the curtain flow coater, a variety of pattern coats can be formed in one coating process, reducing the processing cost by reducing the number of processes. Can be achieved.

Since the paint is thicker in the patterned portion than in other portions, unevenness can be provided between the patterned portion and the non-patterned portion, and a natural three-dimensional pattern can be applied. .

Further, in the third aspect of the invention, since the clear coat top coat is formed on the flow pattern coat, a marble-like depth feeling can be obtained.

[Brief description of drawings]

FIG. 1 is a cutaway perspective view showing a process of Example 1. FIG.

FIG. 2 is a cross-sectional view showing the building board obtained in Example 1.

FIG. 3 is a plan view showing a building board obtained in Example 1.

FIG. 4 is a vertical vertical sectional view showing the process of the second embodiment.

5 is a vertical cross-sectional view showing a building board obtained in Example 2. FIG.

6 is a plan view showing a building board obtained in Example 2. FIG.

FIG. 7 is a vertical vertical sectional view showing the process of Example 3;

8 is a vertical cross-sectional view showing a building board obtained in Example 3. FIG.

9 is a plan view showing a building board obtained in Example 3. FIG.

[Explanation of symbols]

 (1): Substrate (2): Base coat (3): Curtain flow coater (4): Paint curtain (5): Flow coat (6) (7): Roll (8): Slit (9): Air nozzle ( 10): Thick film part (11): Thin film part (12): Pattern coat (13) (15): Top coat (14): Spray (16): Flow pattern coat (17): Conveyor

Claims (3)

[Claims] 1. A substrate surface is provided with a sealer layer and a base coat, if necessary, and then, when curtain flow coating is applied thereon, air is blown to the dripping paint curtain to shake the paint curtain.
A method of manufacturing a building board, comprising forming a flow pattern coat comprising a thick film portion and a thin film portion on a base coat. 2. The base coat is formed by forming a sealer layer and a base coat on the surface of the substrate, and then applying a curtain flow coating on the sealer layer by changing the outflow amount of the paint from the curtain flow coater. A method for manufacturing a building board, which comprises forming a patterned coat composed of a thick film portion and a thin film portion. 3. A sealer layer and a base coat are formed on the surface of the substrate, if necessary, and then a curtain flow coating is applied thereon, by spraying a paint of a different color from that of the paint curtain flowing downward, or by a curtain. A method for manufacturing a building board, comprising forming a flow pattern coat of a plurality of colors on a base coat by supplying a paint of a color different from the curtain paint to the flow coater.