JPH10323592A - Production of sheet for surface finishing of building and apparatus for production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently form a coating layer and to improve productivity by making it possible to uniformly form surface decoration patterns of the coating layer on a base material surface, to make the thickness of this coating layer uniform over the entire part and to adjust a spraying range. SOLUTION: The base material 12 consisting of a nonwoven fabric is transported in a specified direction by a roller 13, etc. A coating material 14 is applied on the surface of the base material 12 by a knife coater 15 on the upstream side of the transported base material 12, by which the ground surface coating layer 39 is formed. The coating material 14 is sprayed to the surface of the ground surface coating layer 39 from plural spraying nozzles 21 to 23 which are arranged in the position above the base material 12 and move in the direction intersecting with the moving direction of the base material 12, by which a finish coating layer 40 is formed, on the downstream side of the base material 12. The coating material is sprayed from the plural spraying nozzles 21 to 23 in such a manner that the spraying ranges on the base material surface overlap on each in nearly the specified range.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a sheet for finishing a building surface used for finishing a wall surface of a building.

[0002]

2. Description of the Related Art A method of continuously producing such a sheet for building surface finishing is disclosed in, for example, Japanese Patent Laid-Open No. 6-101316.
No. 6,086,045. That is, the substrate is moved from upstream to downstream, and at least one nozzle is disposed above the upstream side of the substrate, and at least two nozzles are disposed above the downstream side of the substrate. At least 2 downstream
The individual nozzles move in a direction crossing the moving direction of the substrate.

[0003] By spraying spraying materials having different colors from each nozzle, a coating layer having a predetermined decorative pattern can be continuously formed on the surface of the base material.

[0004]

However, the coating layer formed on the substrate surface is formed by spraying from a plurality of nozzles, and the spraying range of each nozzle is different.
There has been a problem that surface decorative patterns such as color tones and patterns become uneven. Further, there is a problem that the thickness of the coating layer becomes uneven and it is difficult to obtain a uniform thickness as a whole.

[0005] In addition, if the coating layer is formed on the surface of the base material only by spraying from a nozzle, the coating layer cannot be formed efficiently over the entire width of the base material, resulting in poor productivity. Was.

The present invention has been made by focusing on the problems existing in the prior art as described above. An object of the present invention is to provide a method for manufacturing a sheet for building surface finishing and a device for manufacturing the same, in which a surface decorative pattern of a coating layer on a substrate surface can be made uniform and the thickness of the coating layer can be made uniform overall. It is in. It is another object of the present invention to provide a method for manufacturing a sheet for building surface finishing, which can efficiently form a coating layer and improve productivity, and an apparatus for manufacturing the same.

[0007]

In order to achieve the above-mentioned object, a first aspect of the invention of a method for manufacturing a sheet for building surface finishing is to transport a base material in a certain direction, and to set the base material above the base material. From a plurality of spray nozzles arranged at a position and moving in a direction intersecting the transport direction of the substrate, the distance or the spray range of the spray nozzle with respect to the substrate can be adjusted, and the spray range on the surface of the substrate Is sprayed onto the base material so as to overlap a certain range, thereby forming a coating layer on the base material surface.

According to a second aspect of the present invention, there is provided a building surface finishing sheet manufacturing apparatus, comprising:
It is arranged above the base material and moves in the direction intersecting with the conveyance direction of the base material, and the distance or spray range of the spray nozzle with respect to the base material is adjustable, so that the spray range on the base material surface is And a plurality of spray nozzles for spraying the coating material toward the base material so as to overlap a predetermined range.

[0009]

According to the first or second aspect of the present invention, the base material is conveyed in a certain direction, and a plurality of spray nozzles arranged above the base material move in a direction intersecting the conveyance direction of the base material. Is done. Then, the application material is sprayed from the plurality of spray nozzles such that the spray range on the surface of the base material overlaps a predetermined range, and a coating layer is formed on the surface of the base material.

Therefore, the surface decorative pattern of the coating layer formed on the substrate becomes uniform, and the thickness thereof becomes uniform as a whole. Further, the coating layer can be efficiently formed on the base material.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment embodying the present invention will be described below with reference to FIGS. As shown in FIGS. 1 and 2, a substrate 12 made of a nonwoven fabric and wound around a shaft core 11 is stretched and supported by rollers 13, and is pulled by a predetermined tension by a transport device (not shown). ing. In this embodiment, the moving speed of the substrate 12 is 0.5 to 5
m / min. The knife coater 15 in which the coating material 14 is accommodated is supported at a position above the roller 13 so as to uniformly apply the coating material 14 to a predetermined thickness (about 2 mm in this embodiment) over the entire width of the substrate 12. Apply.

As the coating material 14, in addition to a material composed of a synthetic resin and an aggregate, a material composed of a pigment, a filler, and a binder is used. As the synthetic resin, a urethane resin, an acrylic resin, a vinyl acetate resin, a vinyl chloride resin, or the like is used in the form of an aqueous emulsion dispersed in water or a resin solution dissolved in an organic solvent. This synthetic resin is one of the binders. Sand, natural stone, crushed artificial ceramics, and the like are used as the aggregate. As the pigment, an inorganic pigment such as iron oxide, lead oxide, lead carbonate, titanium dioxide, and zinc oxide, and an organic pigment such as an azo pigment and quinacridone are used. The solid content of the coating material 14 is about 80% by weight, but is set in consideration of the viscosity and the like according to the purpose.

The reciprocating coater 16 is arranged at an upper position on the downstream side of the substrate 12. The slider 17 is attached to a chain 20 mounted between a pair of gears 18 and 19 so as to reciprocate in a direction perpendicular to the direction in which the substrate 12 moves. In this embodiment, the slider 17 is 3
It is reciprocated at a speed of 0 to 100 m / min.

The three spray nozzles 21, 22, 23
The connecting rods 24 are arranged in the same direction as the moving direction of the base material 12.
And is supported by the slider 17 via the support rod 25. The three coating material supply pipes 26, 27, 28
It is connected to each of the spray nozzles 21 to 23 via a pump 29, and supplies the coating material 14 from a coating material storage tank (not shown) to each of the spray nozzles 21 to 23 at a predetermined pressure. The three air supply pipes 30, 31, and 32 are connected to spray nozzles 21 to 23, respectively, and supply compressed air to each of the nozzles 21 to 23.
And sprays the coating material 14 toward the base material 12.

In this embodiment, the coating material 14 sprayed from each of the nozzles 21 to 23 is the same as that supplied to the knife coater 15.
It has different colors of black and brown. It is desirable that at least one of the coating materials 14 sprayed from the plurality of nozzles 21 to 23 has a different color in order to obtain an excellent appearance of a coating layer described later.

As shown in FIG. 4, the spray nozzles 21 to 2
3, air supply pipes 30 to 32 are disposed at the center, and around the air supply pipes 26 to 28,
4 is supplied. Further, the replacement nozzle port 33 is screwed into the nozzle body 34 with a screw portion 35 so that the nozzle port 33 can be replaced with a nozzle port 33 having a different diameter or the inside can be cleaned.

As shown in FIG. 3, the spray range Ra of the coating material 14 sprayed from each of the nozzles 21 to 23 onto the substrate 12 is such that the nozzles 21 to
The distance and angle of 3 are adjusted. That is, the axes of the nozzles 21 to 23 are set so as to substantially intersect (focus) on the surface of the base material 12. With the movement of the slider 17, each of the nozzles 21 to 23 also reciprocates in a direction perpendicular to the direction of travel of the base material 12, and
Spray against. Then, the finish coating layer 40 having the same surface decorative pattern can always be formed on the base material 12. The surface decorative pattern is a three-dimensional decorative pattern formed at random by a combination of random particle size and color tone of the coating material 14. In this embodiment, the thickness of the finish coating layer 40 is about 4 mm.

Here, as described above, the plurality of nozzles 21-
Since the nozzles 23 are arranged in the same direction as the transport direction of the base material 12, if the spray range Ra of the coating material 14 from each of the nozzles 21 to 23 is slightly shifted, for example, if the spray range Ra is shifted to the downstream side, The surface decoration pattern that appears due to the shifted part,
The spraying range Ra formed thereafter is erased by a certain range of surface decorative patterns.

On the other hand, when a plurality of nozzles 21 to 23 are arranged in a direction perpendicular to the direction in which the substrate 12 is conveyed,
When the spraying range Ra of the application material 14 is shifted in the direction orthogonal to the transport direction of the base material 12, the decorative pattern that appears due to the shifted portion remains as a linear pattern. Therefore, when arranging the plurality of nozzles 21 to 23 in this way, it is necessary to consider such points in advance.

The collection container 36 having a rectangular box shape is provided with the nozzle 2
1 to 23 and the position below the base material 12, the nozzle 2
Excess coating material 14 sprayed from positions 1 to 23 and sprayed at positions protruding from both side edges of the base material is collected. The collection pipe 37 is led out from the lower central part of the collection container 36 and connected to the knife coater 15 via a pump 38, and excess coating material is collected from the collection container 36 to the knife coater 15. The collected coating material 14 is provided with three nozzles 21 to 23
Has a color tone in which the color tones (dark black and brown, and light white) of the three kinds of coating materials 14 blown out from are mixed.

Now, as shown in FIG.
The coating material 14 is accommodated in 5 and the base material 12 is moved at a predetermined speed by applying tension. At the same time,
The slider 17 starts reciprocating, and the spray nozzles 21 to 23
The coating material 14 is sprayed toward the base material 12. Then, a thin undercoating layer 39 is formed on the surface of the base material 12 by the knife coater 15, and then the undercoating layer 3 is formed.
9, the reciprocating motion of the spray nozzles 21 to 23 forms a thick finish coating layer 40. Excess coating material 14 sprayed laterally from both side edges of the base material 12 is collected in a collection container 36 and sent to the knife coater 15.

In this way, as shown in FIG. 5, the undercoating layer 39 by the knife coater 15 is
The finish coating layer 40 by the spray nozzles 21 to 23 is sequentially formed. The resulting sheet for building surface finishing is
It is used by bonding it to a desired place such as an outer wall, an inner wall, a door, a ceiling or a pillar of a building.

As described above, the three spray nozzles 21-
Since the spraying range Ra of the coating material 14 from 23 is set to be a constant range on the surface of the substrate 12, the finish coating layer 40 is made uniform and the spraying range of the coating material is increased. The coating efficiency can be improved.

That is, the three spray nozzles 21 to 23
The color of the coating material 14 from the spray nozzle 2
There is no possibility that a non-uniform surface decorative pattern will be formed without causing a color tone shift due to the reciprocating motion of 1 to 23.
Therefore, even if the surface of the finish coating layer 40 formed on the base material 12 is peeled off and a new surface is exposed, the same surface decorative pattern as before peeling can be obtained on the exposed surface. That is, a heavy decorative pattern of natural stone such as granite by mixing three colors can be obtained, and the appearance can be improved. Also, by polishing the surface of the finish coating layer 40, a decorative pattern such as a polished surface of natural stone can be obtained.

Thus, according to the method of this embodiment,
Base coat layer 39 and finish coat layer 4 on the surface of substrate 12
0 can be uniformly formed on the whole, and the productivity can be improved. Then, by using the base material 12 on which such a coating layer 40 is formed, the building surface can be finely finished.

Further, since the excess coating material 14 not applied to the base material 12 is recovered by the recovery container 36 and used by the knife coater 15, the manufacturing cost can be reduced. In addition, since the recovered coating material 14 is used as it is to form the base coating layer 39 that does not appear on the surface by the knife coater 15, there is no need to adjust the color tone, and the production efficiency can be increased.

The present invention may be embodied by changing the configuration as follows, for example. (A) As shown in FIG. 6, a roll coater 41 is used in place of the knife coater 15 of the embodiment. That is,
An application roller 42 having substantially the same size as the roller 13 is disposed above the roller 13, and a small auxiliary roller 43 is disposed so as to be in contact with the upper portion of the application roller 42. Coating material 14
Put. The rotation of the application roller 42 causes the application material 14 to adhere to the peripheral surface of the application roller 42 while the substrate 1
2 Apply to the surface. (B) A flow coater or a brush coater is used as a means for forming the undercoat layer 39. (C) The connecting rods 24 of the spray nozzles 21 to 23 are formed of a single rod and are arranged horizontally so that the spray direction of each of the nozzles 21 to 23 can be adjusted. (D) The positions of the spray nozzles 21 to 23 are separated from the substrate 12 as much as possible, and the spray range Ra is set to be large to improve productivity. (E) Each of the spray nozzles 21 to 23 is reciprocated at the same angle while swinging in the direction orthogonal to the reciprocal coater 16. (F) The number of spray nozzles 21 to 23 is two or four or more. (G) The movement of the base material 12 is performed by a conveyor such as a belt conveyor or a chain conveyor. (H) As the substrate 12, a cloth formed of acrylic fiber, polyester fiber, polyamide fiber, or the like is used. (I) In the present invention, the color tone of the plurality of spray nozzles 21 to 23 can be freely selected.
3, the coating material 14 having a dark color tone is changed to an intermediate color (light brown). By doing so, an appearance like granite (natural stone) can be exhibited. (J) The surface of the base material 12 is previously treated with a primer,
(2) to improve the adhesiveness of the base coat layer 39 to the base material 2; (K) In the above embodiment, three spray nozzles 21 to
23 are arranged in an oblique direction so as to intersect with the moving direction of the substrate 12. (L) Supply a new coating material 14 in addition to the coating material 14 collected in the knife coater 15 or use only a new coating material without using the collected coating material 14. (M) Increasing the supply amount of the coating material 14 from the coating material supply pipes 26 to 28 and the supply amount of air from the air supply pipes 30 to 32 to increase production efficiency. (N) In the above embodiment, the formation of the undercoat layer 39 is omitted. (O) A clear finish is applied after the application material 14 is applied.

The technical ideas grasped from the above embodiment will be described below. (1) The method for manufacturing a sheet for building surface finishing according to claim 1, wherein the plurality of spray nozzles are reciprocated in a direction orthogonal to the moving direction of the base material. According to this method, the application material can be efficiently sprayed by shortening the reciprocating distance of the spray nozzle. (2) The apparatus for manufacturing a sheet for building surface finishing according to claim 2, wherein the spray nozzle has a replaceable spray port. According to this structure, it is possible to easily replace the spray nozzle with a different spray amount and to easily clean the inside of the spray nozzle. (3) The apparatus for producing a sheet for finishing a building surface according to claim 2, further comprising an application device for applying an application material to the surface of the base material upstream of the conveyed base material to form a base coating layer.
With this configuration, the undercoating layer can be easily formed, and the decoration effect of the coating layer by the spray nozzle can be improved.

[0029]

As described above in detail, according to the first or second aspect, the surface decorative pattern of the coating layer on the substrate surface can be made uniform, and the thickness of the coating layer can be reduced as a whole. It can be uniform. Further, the spraying range can be adjusted, the coating layer can be formed efficiently, and the productivity can be improved.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an apparatus for manufacturing a sheet for building surface finishing according to an embodiment.

FIG. 2 is a sectional view showing an apparatus for manufacturing a sheet for finishing a building surface in the same manner.

FIG. 3 is a front view showing a spray nozzle.

FIG. 4 is a sectional view showing a spray nozzle.

FIG. 5 is a perspective view showing a state in which a coating layer of a coating material is formed on a base material.

FIG. 6 is a sectional view showing a roll coater according to another embodiment of the present invention.

[Explanation of symbols]

12: base material, 14: coating material, 15: knife coater, 21
-23: spray nozzle, 36: collection container, 37: collection pipe, 39: base coating layer, 40: finish coating layer, 41:
Roll coater.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B05D 7/00 B05D 7/00 L

Claims (2)

[Claims] 1. A plurality of spray nozzles that convey a substrate in a certain direction and are arranged above the substrate and move in a direction intersecting with the direction in which the substrate is conveyed are sprayed on the substrate. Architectural surface finishing that allows adjustment of the nozzle distance or spraying range, sprays coating material onto the base material so that the spraying range on the base material surface overlaps a certain range, and forms a coating layer on the base material surface Manufacturing method of sheet for use. 2. A transport device for transporting a substrate in a certain direction, a transport device disposed at a position above the substrate and moving in a direction intersecting the transport direction of the substrate, and a distance of a spray nozzle with respect to the substrate. Production of a sheet for building surface finishing comprising a plurality of spray nozzles for spraying an application material onto a substrate so that the spray range can be adjusted and the spray range on the substrate surface overlaps a certain range. apparatus.