JPH11156818A - Decorative board with pattern and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a decorative board with a pattern which has design characteristics and an aesthetic and uniform tone as a whole by forming an aggregate layer which is formed of aggregates scattered densely, while an applied coat on the projecting part is still tacky, on the projecting surface of the uneven face of a base material for an object to be coated, and a topcoat layer to be formed by coating on the surface of the aggregate layer. SOLUTION: An undercoat is applied to the entire surface of a base material 20 for an object to be coated with an uneven plane, and a dry and cured undercoat 60 with an uneven plane is formed. In addition, a tacky coat 30, an aggregate layer 40 and a topcoat layer 50 are sequentially formed on the projecting surface of the dry undercoat 60 and the tacky coat 30 and the topcoat layer 50 are allowed to set. The decorative board 104 has the topcoat 50 applied to not only the surface of the aggregate layer 40 but also into the recessed parts 64 of the dry undercoat 60. The topcoat 50 is applied in such a manner that it covers the entire surface of the aggregate layer 40 and the recessed part 64 in almost a uniform coat thickness along the surface contour of both aggregate layer 40 and recessed parts 64. Thus it is possible to finish the recessed parts 64 with a naturally looking joint pattern with unique design characteristics and without impairing a good massive feeling, as no aggregates are present in the recessed parts 64 of the base material 20 for the object to be coated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board having a pattern and a method for producing the decorative board. More specifically, the present invention relates to a decorative board having a more realistic texture such as a stone texture, and a method of manufacturing such a decorative board that can be mass-produced easily and at low cost.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a decorative board having a pattern having, for example, a tiled uneven portion and a concave portion and a convex portion having different color tones, a spray coating method using a ricin gun or the like is known. This spray coating method is a method in which a cement lysine paint containing sand, a colored inorganic pigment, etc. is usually sprayed to the object to be painted, and the same paint adheres to the entire uneven portion of the object. Putting paint only on the convex part,
It is impossible to prevent application to the concave portions.

On the other hand, Japanese Patent Application Laid-Open No. Hei 8-259860 discloses a process of coating the entire surface of a ceramic building material plate 1 with a joint color paint 2 as shown in FIG. A step of applying the undercoat paint 3 using a roll coater, and further using a roll coater only in the non-joint portion 3 of the ceramic building material board, containing two types of colored aggregates, a light-transmitting aggregate, and a coating-forming resin. There is disclosed a method of forming a stone-like pattern in which a step of applying a stone-like coating composition 4 to be dried so as to have a dry film thickness of 10 to 100 μm is sequentially performed.

According to the publication, when preparing the above-mentioned stone-like coating composition, the above-mentioned components for preparing the composition are blended in a predetermined ratio and uniformly mixed to obtain an emulsion paint. (Stone-like coating composition 4) is applied only to the surface of the non-joint undercoating film 3 of the ceramic building material plate 1 by a roll coater.

[0005] However, even if a stone-like pattern is formed on the surface of a ceramic building material plate by the method described in this publication, the amount of aggregate that can be incorporated into the stone-like coating composition 4 is limited, and the method is excellent. Stone-like patterned ceramic building boards are not available.

For this reason, there has been a demand for the development of a coating method which can be applied to line production in factories and the like, and which can produce a decorative board having a color tone having a design with a simpler process at a low cost. .

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to solve the problems associated with the prior art as described above. A large amount of aggregate is evenly dispersed in the base, and its natural texture is exhibited, and there is no aggregate in the concave part of the base material, resulting in a natural joint finish. It is an object of the present invention to provide a decorative board with a pattern.

The present invention is applicable to line production in factories and the like, and disperses a large amount of aggregate uniformly in the convex portions of the base material and reduces the presence of the aggregate in the concave portions of the base material in fewer steps. It is an object of the present invention to provide a method capable of manufacturing a decorative board having a uniform color tone having a design property, that is, an aesthetic property as a whole.

[0009]

SUMMARY OF THE INVENTION The first patterned decorative board according to the present invention comprises:
A substrate to be coated having an uneven surface (a), a convex coating film (b) applied and formed on the convex surface of the surface, and the coating film surface while the convex coating film is in an adhesive state. Characterized by having an aggregate layer (c) formed by densely scattering aggregates, and a top coat layer (d) applied and formed on the surface of the aggregate layer.

[0010] The second patterned decorative sheet according to the present invention comprises a substrate (a) having an uneven surface, an undercoat dry film (e) formed on the entire surface thereof, The convex coating film (b) applied and formed on the convex surface of the dried coating film surface, and the bone formed by densely scattering the aggregate on the coating film surface while the convex coating film is in an adhesive state. It has a material layer (c) and a top coat layer (d) applied and formed on the surface of the aggregate layer.

In the present invention, it is preferable that the underlayer dried coating film (e) is a light-impermeable one. In the present invention, it is preferable that the aggregate is at least one selected from mica, silica sand, glass beads, crushed glass, glass powder, and a colored material thereof.

In the present invention, the amount of aggregate in a plane parallel to the above-mentioned aggregate layer is preferably 50 to 500 g / m ² , and the average particle diameter φ of this aggregate is 0.05 to 500 g / m ^2. 3.0
mm.

In the present invention, the top coat layer (d) formed on the surface of the aggregate layer is preferably a clear coating film. In the first method for producing a patterned decorative sheet according to the present invention, a pressure-sensitive adhesive film (b) is applied by a roll coater on a convex surface of a surface of a substrate (a) having an uneven surface. Formed, the aggregate is sprayed on the surface of the coating film on which the adhesive coating film (b) is formed, and the aggregate is applied to the surface of the coating film (b). Is characterized in that a top coat is applied and cured on the aggregate.

In a second method for producing a decorative decorative sheet according to the present invention, a base coating composition is applied to the entire surface of a substrate (a) having an uneven flat surface, dried and cured. An adhesive coating (b) is applied and formed by a roll coater on the convex surface of the dried coating (e) surface, and an aggregate is sprayed on the surface of the coating on which the adhesive coating (b) is formed. The method is characterized in that the aggregate is applied to the surface of the coating film (b) of the lever, and then a top coat is applied and cured on the aggregate.

In the present invention, it is preferable that the base coating composition is light-impermeable. In the method for producing a decorative panel with a pattern according to the present invention, in any of the above cases, the aggregate is sprayed on the surface of the substrate to be coated as described above, and the bone is coated on the surface of the adhesive coating film (b). After applying the material,
Aggregate once scattered by suction or air blow in the concave portion of the substrate to be coated, and extra bone that is not adhered to the adhesive coating film among the aggregates scattered on the surface of the adhesive coating film It is preferred to remove the aggregate and then apply and cure a topcoat over the aggregate as described above.

In the present invention, the aggregate is mica, silica sand,
It is preferably at least one selected from glass beads, crushed glass, glass powder, and colored materials thereof.

In the present invention, the amount of aggregate applied is 50 to 5
It is preferably 00 g / m ² . In the present invention, it is preferable that the average particle diameter of the aggregate is 0.05 to 3.0 mm.

In the present invention, the top coating applied to the surface of the aggregate layer is preferably a clear coating. In the present invention, the base coating composition layer (e) containing no aggregate may be applied in advance to the entire surface of the substrate (a) having the uneven surface.

In the present invention, the above-mentioned aggregate is preferably at least one selected from mica, silica sand, glass beads, crushed glass, glass powder, and colored materials thereof.

The patterned decorative panel according to the present invention can be produced in a line in a simple process at a factory or the like, and a large amount of aggregate is well and uniformly dispersed on the flat surface of the base material, and the texture of the aggregate is exhibited. And, in the substrate recesses, that is, joints, there is no aggregate, natural joint finish, brightness, saturation, hue, uniform color tone including the texture of the decorative board as a whole, without unevenness, Rich in design, such as stone and tile.

According to the present invention, it is possible to adapt the line production in a factory or the like, and it is possible to manufacture the decorative board having the pattern as described above by a simpler process.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings, with respect to a decorative board with a pattern and a method of manufacturing the same according to the present invention.

FIGS. 1, 2, 3 and 4 are longitudinal sectional views showing first, second, third and fourth embodiments of a decorative panel according to the present invention, respectively. FIG. 5 shows a conventional example.

[Patterned Decorative Plate] First, the patterned decorative plate 10 shown in FIG.
And a convex coating film 30 formed on the convex flat surface 22 of the base material surface, and the coating film 3 while the convex coating film is in an adhesive state.
Aggregate layer 40 formed by densely dispersing the aggregate on the surface of
And an overcoat layer 5 applied to the surface of the aggregate layer 40.
0.

Hereinafter, each layer constituting such a decorative board with a pattern will be sequentially described. <Substrate to be Coated> As the substrate to be coated 20, its material is not particularly limited as long as it has uneven surfaces 24 and 22 on its surface. For example, resin, wood, metal, slate, calcium silicate plate, Examples thereof include a wood chip cement board, and the external shape is not particularly limited, such as a schematic plate shape, a sheet shape, a nonwoven fabric shape, and a three-dimensional shape. In addition, the size is not particularly limited, but from the viewpoint of factory productivity, convenience of handling, and the like, usually, the height is 1 to 3 m.
× 0.3 to 1 m in width × 0.01 to 0.05 m in thickness in many cases. The surface of the substrate 20 may be subjected to a sealer treatment or the like, if necessary. <Protrusion coating film> The projection coating film 30 may be transparent or opaque. Examples of the coating film forming material include acrylic resin, acrylic-urethane resin, acrylic silicone resin, and acetic acid. Conventionally known resins such as vinyl resin, urethane resin, epoxy resin and alkyd resin are included. Such a convex coating film forming material contains, in addition to these resins, coloring pigments, extender pigments, fillers, bactericides, preservatives, fungicides, weathering stabilizers, matting materials such as silica, and the like. You may. In particular, in a preferred embodiment of the present invention, an opaque coating film containing the above-mentioned resin component, a color pigment and the like is preferable from the standpoint of grasping the thickness of the coating film during production.

The dry film thickness of the projection coating 30 is not particularly limited, but is usually about 5 to 100 μm, preferably about 10 to 30 μm. <Aggregate layer> In the aggregate layer 40, the aggregate particles are densely arranged and deposited on the surface of the convex coating film 30, and in detail, the lower side in contact with the coating film 30 of many aggregate particles. Part of the convex coating film 30
Adhered or partially buried and adhered to the convex coating film 30,
Alternatively, the aggregate as a whole may be fitted or sandwiched between aggregates partially adhered and buried in such a way that the aggregate particles adhere to the entire surface of the convex coating film 30 in a layered state. It seems to be. Such an amount of aggregate, when measured on a plane parallel to the layer, is usually 50 to 500 g / m ² , preferably 100 to 300 g / m ² , particularly preferably 15 to 500 g / m ² .
It is desirably 0 to 300 g / m ² . The amount of aggregate or the amount of aggregate attached is calculated from the amount of aggregate (Y) that has been removed by a method such as suction removal or air blowing from the amount of aggregate (X) g scattered over the entire surface of the substrate 20 to be coated. G) is subtracted, and the amount of the remaining aggregate (X-Y) g is defined as the amount of the aggregate adhered to the surface of the adhesive coating 30, and the area (Z) m ^{2 of the} adhesive coating 30
｛[(X−Y) / Z] g / m
² ｝.

The average particle diameter φ of the aggregate is usually 0.1.
The thickness is preferably from 0.05 to 3.0 mm, and more preferably from 0.2 to 1.0 mm, from the viewpoint of excellent designability and excellent workability of dispersing aggregates during the production of a decorative board having a pattern described later.

Examples of the aggregate constituting the aggregate layer 40 include mica, silica sand, glass beads, crushed glass, glass powder, and colored materials thereof. These aggregates are 1
It is used in combination of two or more species.

In the present invention, the aggregate layer 40 preferably contains colored mica and / or colored silica sand in order to improve the design of the decorative board. In the present invention, conventionally known "other coloring materials" may be used together with such aggregates. Examples of such a coloring material include pigments and dyes of various colors such as red iron oxide, yellow, and gray. Other coloring materials, such as red petals,
It may be used in an amount of usually 1 to 50 parts by weight, preferably 5 to 20 parts by weight, based on 100 parts by weight of the above-mentioned aggregate.

The average thickness of the aggregate layer 40 varies depending on the particle size of the aggregate and the method of spraying the aggregate, for example, sprinkling of the aggregate by natural fall, mechanical spraying with an air gun or the like. Although it depends on the state of the convex coating film 30 on which the material is sprayed, that is, the degree of the tacky state or the non-dry state, and is not determined unconditionally, it is usually about the same as the average particle diameter φ of the aggregate to be sprayed. Degree, in other words 50-2000 μm thickness, preferably 200-1000 μm
m thickness. <Overcoat Layer> The dry film thickness of the overcoat layer 50 formed on the surface of the aggregate layer 40 is not particularly limited, but is usually 5 to 200 μm, preferably 10 to 100 μm.
It is about μm thick.

When such a top coating layer 50 is formed on the surface of the aggregate layer 40, the falling off and scattering of silica sand (sand) constituting the aggregate layer 40 can be effectively prevented, and the weather resistance is also improved. I do. Such a top coat layer 50 is preferably a transparent clear coating film containing the same resin component as the convex coating film 30. Further, such a top coat layer 50 may contain a matting agent or the like, similarly to the convex coating film 30. When the top coat layer 50 is formed of the clear coating film in this manner, the texture of the aggregate appears well, and excellent design properties are exhibited.

In such a decorative panel with a pattern, the difference (groove depth) between the convex surface 52 and the concave portion 24 of the top coating layer 50 is not particularly limited, but is, for example, preferably 1.5 mm or more. Is preferably about 2.0 to 5.0 mm because a clear pattern appears.

Such a patterned decorative board 10 can be produced in a line in a simpler process in a factory or the like, has a high aggregate content per unit area in the aggregate layer, is excellent in uniform dispersibility, and has a uniform color tone. (Including lightness, saturation, hue, and texture), there is no unevenness in the joints, natural joint finish is achieved, and the design is very rich in stone-grain tone and tile tone.

FIG. 2 is a schematic sectional view showing a second embodiment of the patterned decorative board according to the present invention. The same components as those of the decorative board 10 with a pattern in FIG. 1 are denoted by the same reference numerals.

As shown in FIG. 2, the patterned decorative plate 10a is different from the patterned decorative plate 10a in that a base dry film 60 is previously provided on the entire surface of the substrate 20 having an uneven surface. It is different from the decorative plate 10 with the attachment.

As described above, when the undercoat film 60 is provided on the entire uneven surface of the substrate 20 to be coated, the protrusion coating film 30 provided on the protrusion surface 62 of the undercoat film 60 is provided. Is
Convex surface 2 of substrate 20 to be coated via base coat 60
2 and firmly adheres to and adheres to the surface 22 of the substrate 20,
24 has a tendency to be more excellent in design, because the entirety is concealed by the undercoat film 60.

As the material of the undercoating film 60, a conventionally known material is used, and acrylic resin, acrylic resin and the like are used.
Urethane resin, acrylic silicone resin, etc., the same resin component and pigment as the material of the convex coating film 30, such as a coloring pigment,
Those containing an extender are preferred. Such a base coat 60 tends to be in close contact with the base material, conceal the surface thereof, and have excellent weather resistance. The thickness of the underlayer dried coating film 60 is
The surface is not particularly limited as long as the uneven surfaces 62 and 64 as shown in FIG. 2 appear on the surface thereof.
The thickness is preferably about 40 to 80 μm.

FIG. 3 is a schematic sectional view showing a third embodiment of a decorative panel with a pattern according to the present invention. 1 and 2 are denoted by the same reference numerals.

As shown in FIG. 3, the decorative decorative board 10b has a base coat 60 previously provided on the entire surface of the substrate 20 on which the convex coat 30 is formed. 2 is different from the patterned decorative board 10 in that the top coat layer 50 is formed not only on the surface of the aggregate layer 40 but also on the concave surface 64 of the base dried coating film 60. For example, it differs from the patterned decorative board 10a in that the top coat layer 50 is applied so as to cover the entire surface of the aggregate layer 40 and the underlayer dried coating film 60.

As shown in FIG. 3, the top coat 50
Is applied so as to cover the entire surface of the aggregate layer 40 and the base dried coating film 60, and the decorative board 10a having a pattern shown in FIG.
As compared with, delamination is less likely to occur, and in particular, there is a tendency to be excellent in design and weather resistance.

FIG. 4 is a schematic sectional view showing a fourth embodiment of the patterned decorative board according to the present invention. The decorative veneer 10c shown in FIG. 4 is the same as the decorative veneer 10b shown in FIG. 3 except that the undercoat 60 is not provided on the decorative veneer 10b shown in FIG.

[Production Method of Patterned Veneer] A preferred production method of the patterned veneer according to the present invention will be described below with reference to the drawings. <Coating for Convex Coating Film and Its Application> In order to manufacture the decorative board 10 with a pattern shown in FIG. 1, first, a roll coater is placed on the convex flat surface 22 of the substrate 20 having an uneven flat surface. Then, an adhesive coating film 30 for forming the convex coating film 30 is applied and formed. As described above, when the surface of the uneven substrate to be coated 20 is coated by the roll coater, the coating applied to the roll coater is:
The adhesive coating film 30 is formed only on the convex portions 22 of the substrate 20 to be coated, because the adhesive film 30 is transferred only to the convex portions 22 of the substrate 20 to be coated and not to the concave portions 24.

The viscosity and amount of the coating for forming the convex coating film used at this time are not particularly limited as long as the coating does not drip or adhere to the concave portions 24 when the roll coater is applied. Although it depends on the distance between adjacent concave portions and convex portions on the surface of the coating substrate and the difference in height of the concave and convex portions of the substrate, that is, the depth h, in the present invention, such a convex coating film is formed. Is applied to the convex surface 22 of the substrate to be coated by a roll coater, and the viscosity at the time of application (measured by a Stormer viscometer) is determined by a concave portion adjacent to the surface of the substrate to be coated. The distance is different depending on the distance between the convex portions, the distance between the convex portions, the depth of the concave portions, and the like, and is not determined unconditionally. However, it is usually preferably 40 to 90 ku, preferably 50 to 80 ku. This viscosity is 30
If it is less than ku, it will be cast over the entire surface of the uneven portion of the substrate to be coated and the whole will become the same color, and it will not be possible to obtain a patterned substrate of two or more colors. And the coating efficiency tends to decrease.

In the present invention, the coating composition having such a viscosity is used in an amount of usually 20 to 70 m / min, preferably 30 to 50 m / min.
It is desirable to paint at a speed of minutes. In addition, the coating amount is usually 5 to 200 g / m ² , preferably 30 to 100 g / m ² per application. The total thickness of the adhesive coating film 30 formed by repeatedly applying the coating composition once to several times as described above is usually 30 to
It is desirable that the thickness be 150 μm, preferably 50 to 100 μm. After the aggregate 40 is sprayed and the adhesive coating 30 is dried and cured as described later, the dry film thickness is not particularly limited, but is usually 5 to 200 μm.
The thickness is preferably about 10 to 100 μm.

The paint for the adhesive film 30 may be any of solvent-based, water-based, and solvent-free paints, and may be an opaque enamel paint containing a pigment, or a translucent paint containing a pigment. Although it may be a color clear paint, a clear paint containing no pigment, or a solvent-based varnish containing no pigment, in the present embodiment, the clear paint is adhered to the substrate 20 to be coated, and the surface of the substrate is The opaque enamel paint is preferable in consideration of the fact that the paint can be concealed, has excellent weather resistance, and makes it easy to grasp the state of application of the paint on the surface of the convex portion 22 of the workpiece substrate 20. The curing method may be any of UV curing, heat curing, and room temperature curing.

The solvent-based paint may be any of conventionally known types such as thermosetting and thermoplastic. The coating film forming component contained in the paint for the adhesive coating film 30 is not particularly limited, and may be any of a synthetic resin, a natural resin, and a rubber. Examples of the synthetic resin-based coating film forming components include acrylic resin, acrylic urethane resin, acrylic silicon resin, vinyl acetate resin, urethane resin, epoxy resin, alkyd resin, hydrocarbon resin, and vinyl butyral. Resin-based and phenolic-based ones are mentioned, and among these coating film forming components, acrylic resin-based, acrylic urethane-based, and acrylic silicon resin-based ones are preferable.

Examples of the solvent or thinner include aliphatic or aromatic hydrocarbons, alcohols, ketones, ethers, esters, and the like.
PGM-AC (official name: Propylene glycol methyleth)
It is desirable that a substance having a low volatilization speed, such as acetic acid, etc., adheres well to aggregates such as sprayed sand. In addition, the water of the dispersion / diluting medium in the water-based paint described below is also preferable because the volatilization speed is low and the same effect as that of the above-mentioned xylene or the like can be obtained.

Among the solvent-based paints containing such film-forming components, the thermosetting paints include two-pack acrylic urethane resin paints and 2-hydroxyethyl (meth)
Examples include (co) polymers of a hydroxyl group-containing ethylenically unsaturated monomer such as an acrylate, a thermosetting acrylic resin coating compounded with a melamine resin and a polyisocyanate, and examples of the thermoplastic type coating include an acrylic lacquer. Can be

In addition, various additives such as a coloring pigment, an extender, a thickener, a dispersant, an antifoaming agent, a film-forming aid, a preservative, and the like are further compounded in such a paint as required. Is also good. Water-based paints are paints that can be dispersed or diluted with water or water and a small amount of an organic solvent. A hydrophobic resin used as a paint binder is composed of emulsion, dispersion, aqueous solution, powder suspension (slurry). Acrylic emulsion paints, vinyl acetate emulsion paints, etc., which have been made water-soluble in the paint in the form of a composite type or the like, preferably in the form of an emulsion.

As the dispersion / diluting medium for the water-based paint, water or a small amount of water, for example, 20 parts by weight with respect to 100 parts by weight of water.
A dispersion medium comprising an organic solvent or the like in an amount of not more than part by weight is exemplified. Such acrylic resin for water-based paint, for example,
An acrylic monomer in water in the presence of a surfactant, or obtained by emulsion polymerization of an acrylic monomer and a small amount of the following copolymerizable monomer, for example, having a particle size of about 0.1 to several μm, in the polymerization solution Acrylic resin is dispersed in water. In addition, as the above copolymerized monomer, for example,
Examples include vinyl acetate, maleic acid ester, and acrylic acid ester.

The vinyl acetate resin for water-based paints can be prepared, for example, by adding vinyl acetate as a monomer, or vinyl acetate and a copolymerizable monomer having a double bond described below, in an aqueous solution containing a protective colloid, in the presence of a catalyst. It is obtained by emulsion polymerization below. The double bond-containing copolymerizable monomer includes ethyl acrylate, dibutyl maleate, vinyl alcohol ester, ethylene, and the like, and the protective colloid includes polyvinyl alcohol, hydroxymethyl cellulose, and the like.

In such a water-based paint, the above-mentioned components for forming a coating film, various additives and the like can be used. <Spraying bone / removal of excess bone> Next, in this example,
The above-mentioned aggregate is sprayed on the surface of the substrate to be coated on which the adhesive coating film 30 is formed, and the aggregate is applied to the surface of the adhesive coating film.

The aggregate, such as sand and glass beads, to be sprayed may be only on the surface of the adhesive film 30, but usually, not only the surface of the adhesive film 30, but also 2
4, the concave portion 24 of the substrate 20 and the adhesive coating 30 are formed on the entire exposed surface including the concave portion of the substrate 20.
The aggregate is sprayed so that the surface is not visible (not shown).

The method of spraying the aggregate is not particularly limited, and a conventionally known method can be adopted, and specific examples include spraying with a hand, a sieve or a sanding machine, and spraying with an air gun.

The average particle size of the aggregate to be sprayed is usually 0.0
5 to 3.0 mm, preferably 0.2 to 1.0 mm
Therefore, the aggregate having such an average particle size can be used for spraying workability and design.
Both tend to excel. The amount of aggregate sprayed depends on the convexity of the substrate to be coated.
As long as the surface of the adhesive film 30 is completely covered with bone
Although not particularly limited, it is usually 0.5 to 3.5 kg / m.
^Two, Preferably 1.0 to 3.0 kg / m^TwoSpray in moderate amount
Is done.

When the aggregate 40 in such an amount is sprayed by the above-described method, the aggregate 40 adheres only to the surface of the coating film 30 which is in a sticky state, that is, in a non-touch dry state. 2
4 does not substantially adhere. For this reason, in the present embodiment, the base material 20 on which the convex adhesive film 30 is provided
After the aggregate is scattered on the entire surface of the substrate and the aggregate is applied to the surface of the adhesive coating, the aggregate is scattered in the concave portion of the substrate to be coated, and the aggregate is scattered on the surface of the adhesive coating. It is preferable from the viewpoint of work efficiency and the like to remove excess aggregate that is not adhered to the adhesive coating film from the aggregates thus obtained. In the case where the number of projections and depressions per unit area of the surface of the substrate 20 is small and the shape is a rectangle, a triangle, or the like, an aggregate is applied only to the surface of the adhesive coating film 30 and applied. It is possible to do
In general, in order to exhibit a design property such as a natural product such as a stone texture, when the surface of the substrate to be coated 20 has a complicated indentation and irregularities, the above-described structure is used. Full application of bone is efficient.

Also, of the aggregates thus scattered on the surface of the adhesive coating film, the excess aggregates not adhered to the adhesive coating film 30 and the concave portions 24 of the substrate 20 to be coated are scattered. In order to remove the aggregate, the excess aggregate or the like is scattered and removed by suction removal or air blow, or the base material on which the aggregate is scattered as described above is leaned against a wall surface or the like, or It is also possible to employ a means such as hitting the substrate from the back side of the substrate to be coated 20 with the surface of the material to be sprayed downward. It is desirable to remove unreacted aggregate from the viewpoint of work efficiency and worker safety.

As described above, when the excess aggregate is scattered and removed by suction removal, air blow, or the like, the remaining amount of the aggregate is determined by the amount of the adhesive coating 30 applied to the projection 22. Although it is not determined unconditionally by the amount of application, the size of the bone, etc., in the present embodiment, the amount of the remaining bone on the convex adhesive film 30 is usually 50 to 500 g / m ² , preferably 100 to 500 g / m ² .
It is desirably 〜300 g / m ² . In this example, if necessary, by a conventionally known method such as hot air drying,
The adhesive coating 30 may be dried.

Next, in this embodiment, the adhesive coating film 3
When a top coat 50 containing no aggregate is applied by a roll coater and cured on the surface 40 of the aggregate 40, the patterned decorative board 10 shown in FIG. 1 is obtained.

As described above, the top coat layer 50 is formed on the aggregate layer 40.
When the aggregates 40 such as sand are provided on the projections 22,
It is preferable because the coating and fixing can prevent the aggregates such as sand from scattering and falling off, and can improve the weather resistance of the patterned decorative board.

At this time, it is desirable that the amount of the top coat used is usually 5 to 300 g / m ² , preferably 50 to 200 g / m ² per application. The dry film thickness of the top coat layer formed by repeatedly applying the coating composition once to several times as described above is usually 5 to 20.
It is desirable that the thickness is 0 μm, preferably 10 to 100 μm.

As a method for drying the top coat film, a method similar to the above-mentioned method for drying the adhesive film 30, such as hot air drying, can be employed. In addition, drying of the adhesive coating film 30,
It is more efficient if the following top coat layer is dried simultaneously.

As the top coat, the above-mentioned adhesive film 3
The same paint as the paint for the adhesive film 30 can be used, but the top coat paint is a paint containing the same resin component and an organic solvent or water as the paint for the adhesive film 30 and is preferably a transparent paint. It is preferable to use a resin varnish containing the resin component, a solvent and the like in the transparent paint,
Clear paints, transparent color clear paints, and the like are included. It is preferable to use such a transparent paint because the texture of the dispersed aggregate is not impaired. In addition, in addition to the matting agent such as silica, the above-mentioned various additives may be blended in the top coat.

As shown in a conventional example to be described later, even if an aggregate-containing paint containing sand or the like is applied to the surface of the adhesive coating film 30 with this roll coater, the sand is densely applied to the adhesive coating film. 3
Therefore, it cannot be adhered to the surface 0, and a decorative board having a desired design and excellent in design cannot be obtained. Furthermore, when this bone compound-containing paint is entirely coated with a ricin gun, a brush, or the like, a decorative board having a pattern with extremely poor design is obtained.

On the other hand, the convex adhesive film 30 is formed on the convex portion 22 of the base material 20 as in the embodiment of the present invention, the aggregate layer 40 is formed on the surface thereof, and the aggregate is further mixed on the upper surface thereof. When the uncoated top coat layer 50 is applied and cured, the densely adhered aggregate is less likely to scatter, the weather resistance of the patterned decorative board is increased, and excellent design properties can be maintained for a long time.

The applied adhesive coating film 30 and the overcoat layer 50 are finally cured, but the curing method differs depending on the type of paint used and the like. The method is not determined, and includes methods such as heat curing, room temperature curing, and UV curing.

In order to manufacture the decorative board 10a having a pattern shown in FIG. 2, first, an undercoat is applied to the entire surface of the substrate 20 having an uneven surface by applying an undercoat, preferably an undercoat having an uneven surface. Forms a dried and cured base dried coating film 60, and forms the same adhesive coating film 30, aggregate layer 40,
The top coat layer 50 may be sequentially formed, and the adhesive coating 30 and the top coat layer 50 may be cured.

As the base paint for the base dry film 60,
The above-mentioned adhesive coating film 30, the same resin component as the top coating layer 50,
Solvents, those containing additives, etc. are used, especially,
As the base coating material, an enamel coating material that adheres to the substrate 20 to be coated and can conceal the surface of the substrate, that is, is light-impermeable and weather-resistant is preferable. In addition, the enamel paint usually contains a pigment and an organic solvent as a solvent, but in the present specification, a paint containing water as a solvent in place of the organic solvent is also included in the enamel paint unless otherwise specifically intended. Include. As such a light-impermeable enamel paint, for example, acrylic, acrylic urethane, resin varnish containing an organic solvent and a resin component such as acrylic silicone,
Examples thereof include an organic solvent-based enamel paint containing a color pigment, an extender pigment and the like, a water-based acrylic emulsion paint containing a color pigment, an extender pigment, water and the like.

More specifically, examples of such a base coating material include the following. (i) Two-pack type acrylic urethane enamel paint: Thinner is used as a main agent and a curing agent constituting "EP Coat No. 300-30H" (manufactured by China Paint Co., Ltd.), and a curing agent is added to 100 parts by weight of a main agent. ~ 15 parts by weight, 30 ~ 100 thinner
(Ii) Acrylic resin emulsion: "Primal E-3"
57 "(manufactured by Rohm & Haas) or" Movinyl 74 "
9J "(manufactured by Hoechst Gosei Co., Ltd.) 60 to 90 parts, 2 to 15 parts of a film-forming aid (butyl cellosolve), 1 to 10 parts of water (100 parts of all components), and the like.

The undercoating material 60 is applied to the substrate 20 to be coated.
Conventionally known methods such as ricin gun, spraying, brushing, and immersion can be adopted for coating the entire surface. Also,
The drying method is appropriately selected depending on the type of the paint, such as heat curing, room temperature curing, and ultraviolet curing.

In this case, it is desirable that the amount of the base coating material used at this time is usually 5 to 300 g / m ² , preferably 50 to 200 g / m ² per application. In addition, the film thickness of the base coating film 60 obtained by repeatedly applying the coating composition once to several times and drying and curing is usually 5 to 200 μm thick, preferably 10 to 100 μm thick. .

When the adhesive coating film 30, the aggregate layer 40, and the top coating layer 50 are formed on the base dried coating film 60 in the same manner as in the case of the decorative decorative plate 10 shown in FIG.
The undercoat layer 60 is in close contact with the substrate 20, and the layers provided on the convex portions of the undercoat layer 60 are also in close contact with each other. This makes it difficult to obtain, and the surface of the base material is concealed, so that a decorative board 10a with excellent design can be obtained.

In order to manufacture the patterned decorative board 10b shown in FIG. 3, in the patterned decorative board 10a shown in FIG. What is necessary is just to apply also to the recessed part 64 of 60. In this case, the coating may be applied so as to cover the entire surface of the aggregate layer 40 and the concave portion 64 so as to have a substantially uniform film thickness along the surface shape. Other points are the same as in the case of the decorative board 10a with a pattern shown in FIG.

As described above, when the top coating layer 50 is provided on the entire surface of the substrate on which the base dry coating film 60, the convex adhesive coating film 30, the aggregate layer 40 and the like are provided, the aggregates fall off. It is more preferable because delamination hardly occurs, weather resistance is improved, and design is improved.

In order to provide the overcoat layer 50 on the entire surface, a method such as spraying, brushing, dipping, etc. may be adopted instead of the roll coater used in the production of the patterned decorative board 10a.

The present invention is not limited to the above-described example, and may be applied to a substrate 2 to be coated, such as a patterned decorative board 10c shown in FIG.
The adhesive coating 30 for coating the convex portion is provided on the surface convex portion 22 of No. 0, an aggregate layer 40 is provided on the surface of the adhesive coating 30, and the surface of the aggregate layer 40 and the substrate 20 to be coated are formed. An overcoat layer 50 may be provided so as to cover the entire recess 24.

The patterned decorative board according to the present invention as described in detail above can be applied to line production in factories and the like. Can manufacture decorative veneers.

The decorative boards 10, 10a, 10b, and 10c thus manufactured are coated with an adhesive or the like on the back side or nailed with a nail or the like, and are made of wood, plywood, metal board, or synthetic resin board. , Lath (wire mesh) or concrete (building) surface, etc.

Preferred combinations of (A) substrate to be coated / (B) undercoat / (C) convex coating / (D) aggregate / (E) topcoat in the present invention are described below. (A) Nichiha siding board for exterior wall / (b) Two-pack acrylic urethane enamel paint without aggregates / (c) Two-pack acrylic urethane enamel paint without aggregates / (d) Aggregate (colored silica sand) / ((E) Two-pack acrylic urethane tank paint, (a) Nichiha siding board for exterior wall / (b) Two-pack acrylic urethane enamel paint without aggregates / (c) Two-pack acrylic urethane enamel without aggregates Paint / (d) Aggregate (glass beads) / ((e) Two-pack acrylic urethane tank paint.

[0080]

The patterned decorative sheet according to the present invention is not impaired to the extent that its texture is almost impaired since aggregates such as sand are present only in the convex portions of the substrate to be coated. Since there is no aggregate in the concave part of the coating substrate, the concave part has a natural joint finish, stone-like, tile-like, mosaic pattern, etc.
It is full of realism like a natural thing and has remarkably excellent design.

According to the method for producing a decorative decorative board according to the present invention, a decorative decorative board close to a natural product as described above can be easily obtained in a small number of steps. In addition, in this method, even if the decorative board is manufactured by operating a manufacturing line in a factory or the like for a long time, the stability of the pattern can be maintained, and the productivity can be improved and the cost can be reduced.

[0082]

EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited to such examples.

The composition of each component used in the following Examples and Comparative Examples is as follows. Two-pack acrylic urethane enamel paint (Product name: EP
Coat No. 300-30H, manufactured by China Paint Co., Ltd.) Two-component acrylic urethane tank rear paint [trade name: EP Coat No. 300-70H, manufactured by China Paint Co., Ltd.]

[0084]

Embodiment 1 Substrate 2 having irregularities as shown in FIG.
0 (outer wall siding board) was coated in the following manner.

(A) Step-1: Undercoating A two-pack type acrylic urethane enamel paint (product name: EP Coat No. 300-30H, manufactured by Chugoku Paint Co., Ltd.) is provided with a special thinner as a main agent and a curing agent. Main agent: curing agent: dedicated thinner = 16: 1: 12 (weight ratio) mixed by air spray at 80 to 90 g / m ² (average: 85)
g / m ² ) and dried with hot air at 100 ° C. for 5 minutes.

(B) Step-2: Convex part coating Two-pack type acrylic urethane enamel paint [trade name: EP Coat No. 300-30H, manufactured by Chugoku Paint Co., Ltd.)] and a dedicated thinner for the main component and the curing agent.
A mixture (viscosity: Iwata cup 22 seconds, 51 ku) mixed with a dedicated thinner = 16: 1: 5 (weight ratio) was applied to a sponge roll coater at 60 to 70 g / m ² (average: 65 g / m2).
m ² ).

Then, the following step-3: sand spraying was carried out in a tacky state before the paint became dry to the touch. (C) Step-3: Sand spraying / removal Commercially available colored silica sand [trade name: Shinto Color Sand, manufactured by Shinto Toyo Co., Ltd., 67-black: 67-red: 67-white: 67-buff = 40: 1: 20: 3 (weight ratio)] at 1.5 to 2.0 kg / m ² (average: 18) at the stage of the tacky state before the convex paint becomes dry to the touch in step-2.
After spraying the whole surface in an amount of ^{00g / m 2), 4kg /} cm 2
Excess sand was removed by air blow. The residual adhesion amount of the sand after the removal is 200 to 300 g / m ² (average: 25
0 g / m ² ).

(D) Step-4: Top coating Two-pack type acrylic urethane tank rear coating [trade name: EP Coat No. 300-70H, manufactured by China Paint Co., Ltd.] A mixture of a base material and a curing agent, a dedicated thinner, and a base material: hardening agent: dedicated thinner = 8: 1: 8 (weight ratio) is 180-80 by air spray. 200 g / m ² (average: 190 g
/ M ² ) After coating, it was dried with hot air at 100 ° C. for 20 minutes.

(E) Judgment of Designability Next, the amount of sand in the convex portions and the concave portions of the coating film was visually inspected, and the design property of the coating film was determined from the appearance of the convex portions and the appearance of the concave portions.

In the coating film, the amount of adhesion of the sand on the surface of the convex portion was large, and no adhesion of the sand on the surface of the concave portion was observed, and the design property was good (○). The results are shown in Table 1.

[0091]

Example 2 A surface of a substrate (outer wall siding board) having the same irregularities as in Example 1 was coated in the following manner.

(A) Step-1: Undercoating The coating was carried out in the same manner as in Example 1. (B) Step-2: Convex coating In Example 1, convex coating was performed in the same manner as in Example 1.

Next, the adhesiveness of the convex coating before the coating is dry to the touch
In the condition, as shown in the following process-3, instead of sand spraying,
The beads were sprayed. (C) Step-3: Spraying / removing glass beads Commercially available glass beads [trade name: UB-1012L, particle size
180-250 μm (average particle size: 220 μm), Co., Ltd.
Union], the convex paint of step-2 becomes dry to the touch
1.5 to 2.0 kg / m in the previous adhesive state^Two(flat
Average: 1800 g / m^Two4) after spraying over the entire surface
g / cm^TwoRemove excess glass beads by air blow
I left. The attached amount of glass beads after removal is 200 ~
300g / m ^Two(Average: 250 g / m^Two)Met.

(D) Step-4: Top coating Two-pack type acrylic urethane tank rear coating [trade name: EP Coat No. 300-70H, manufactured by China Paint Co., Ltd.] A mixture of a base material and a curing agent, a dedicated thinner, and a base material: hardening agent: dedicated thinner = 8: 1: 8 (weight ratio) is 180-80 by air spray. 200 g / m ² (average: 190 g
/ M ² ) After coating, it was dried with hot air at 100 ° C. for 20 minutes.

(E) Judgment of designability Next, the amount of sand in the convex portions and the concave portions of the coating film was visually inspected, and the design property of the coating film was determined from the appearance of the convex portions and the appearance of the concave portions.

In the coating film, the amount of adhesion of the sand on the surface of the convex portion was large, and no adhesion of the sand on the surface of the concave portion was observed, and the design property was good (○). The results are shown in Table 1.

[0097]

Comparative Example 1 On the same base material as in Example 1, in the same manner as in Example 1.
(A) Step-1: Undercoating, (B) Step-2: Convex coating.

Next, the following (c) step-3 was carried out as follows. (C) Step-3: Two-component acrylic urethane paint with a convex pattern [Product name: EP Coat N
o. 300-20H, manufactured by Chugoku Paint Co., Ltd.], a specialty thinner and a colored silica sand mixture used in Example 1 as a main component and a hardening agent, and a main material: a hardening agent: a specialty thinner: a colored silica sand mixture used in Example 1. = 20: 1: 5: 10 (weight ratio) by a sponge roll coater to apply 3 to only the convex portions of the substrate to be coated with the adhesive coating.
0 to 35 g / m ² (average: 33 g / m ² ) was applied.

(D) Step-4: Overcoating The coating was carried out in the same manner as in Step-4 of Example 1. (E) Judgment of Design Next, the amount of sand in the convex portions and the concave portions of the coating film was visually inspected, and the design of the coating film was determined from the appearance of the convex portions and the appearance of the concave portions.

In the coating film, the amount of sand adhering to the surface of the convex portion was insufficient, and no sand was adhering to the surface of the concave portion, and the design property was slightly poor (△). The results are shown in Table 1.

[0101]

Comparative Example 2 On the same base material as in Example 1,
(A) Step-1: Undercoating, (B) Step-2: Convex coating.

Then, the following (c) step-3 was performed as follows. (C) Step-3: Top coating Two-pack type acrylic urethane tank rear coating [trade name: EP Coat No. 300-70H, manufactured by China Paint Co., Ltd.], using a thinner dedicated to the main component and the hardening agent, and a colored silica sand mixture used in step (c) -3 of Example 1; Colored silica sand mixture used in 1 = 8:
1: 8: 8 a mixture (weight ratio) at texture gun, the entire surface of the article to be coated substrates 300 to 400 g / m ² (average: 350 g / m ²⁾ was coated at 100 ° C. hot air 2
Dry for 0 minutes.

(E) Judgment of Designability Next, the amount of sand in the convex portions and the concave portions of the coating film was visually inspected, and the design of the coating film was determined from the appearance of the convex portions and the appearance of the concave portions.

In the coating film, the amount of adhesion of the sand on the surface of the convex portion and the surface of the concave portion was large, and the sand adhered to the entire surface of the base material, and the design property was poor (×). The results are shown in Table 1.

[0105]

[Table 1]

[Brief description of the drawings]

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory view schematically showing a cross section of a first patterned decorative board and a patterned decorative board according to the present invention, and is an explanatory view of a manufacturing method thereof.

FIG. 2 is an explanatory view schematically showing a cross section of the second patterned decorative board and the patterned decorative board according to the present invention, and is an explanatory view of a manufacturing method thereof.

FIG. 3 is an explanatory view schematically showing a cross section of a third patterned decorative board and a patterned decorative board according to the present invention, and is an explanatory view of a manufacturing method thereof.

FIG. 4 is an explanatory view schematically showing a cross section of a fourth decorative board and a decorative board according to the present invention, and is an explanatory view of a manufacturing method thereof.

FIG. 5 is an explanatory view of a conventional manufacturing method, and is an explanatory view schematically showing a cross section of a decorative board with a pattern obtained by this method.

[Explanation of symbols]

· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10, 10a, 10b, 10c · · · · Of the base material, 24 ... · concave portion of the substrate to be coated, 30 · · · adhesive coating, 40 · · · aggregate, aggregate layer, 50 · · · · top coating composition layer, 52 ··· Surface of the top coating composition layer, 60 ··· Dry base coat, 62 ··· Convex surface of base dry coat, 64 ··· Concave surface of base dry coat h: Depth of groove of substrate to be coated.

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Yoshiharu Nakagawa 2306, Mikami, Yasu-cho, Yasu-gun, Shiga Pref.

Claims (15)

[Claims] 1. A substrate (a) to be coated having an uneven surface, a convex coating film (b) applied and formed on the convex surface of the surface, and And an aggregate layer (c) formed by densely spraying an aggregate on the surface of the coating film, and a topcoat layer (d) applied and formed on the surface of the aggregate layer. Patterned decorative board. 2. A substrate (a) to be coated having an uneven surface, a dried base coat (e) coated and formed on the entire surface thereof, and a convex surface of the base dried coat (e). A convex part coating film (b) coated and formed on the surface; an aggregate layer (c) formed by densely spraying an aggregate on the surface of the coating film while the convex part coating film is in an adhesive state; A decorative veneer having a pattern, comprising: a top coat layer (d) applied to the surface of an aggregate layer. 3. The decorative board with a pattern according to claim 2, wherein the undercoat film (e) is light-impermeable. 4. The aggregate according to claim 1, wherein the aggregate is at least one selected from mica, silica sand, glass beads, crushed glass, glass powder, and colored materials thereof.
3. The decorative board with a pattern according to any one of 3. 5. The decorative board with a pattern according to claim 1, wherein the amount of the aggregate in the aggregate layer is 50 to 500 g / m ² . 6. An aggregate having an average particle diameter φ of 0.05 to 3.0 mm.
The decorative panel with a pattern according to any one of claims 1 to 5, wherein 7. An overcoat layer applied to the surface of an aggregate layer.
The patterned decorative board according to any one of claims 1 to 6, wherein (d) is a clear coating film. 8. An adhesive film (b) is formed by applying a pressure-sensitive adhesive film (b) on a convex surface of the surface of the substrate (a) having an uneven surface by a roll coater. The aggregate is sprayed on the surface of the coating film on which is formed, the aggregate is applied to the surface of the coating film (b), and then a top coat is applied on the aggregate on the surface of the adhesive coating film and cured. A method for producing a decorative board with a pattern, characterized in that: 9. An undercoat composition is applied to the entire surface of the substrate (a) having an uneven surface and dried, and a roll coater is applied on the convex surface of the undercoat film (e). An adhesive film (b) is applied to form an aggregate, and an aggregate is sprayed on the surface of the film on which the adhesive film (b) is formed, and the aggregate is coated on the surface of the coating film (b). And then applying and curing a coating composition on the aggregate. 10. The method according to claim 9, wherein the base coating composition is light-impermeable. 11. An aggregate is sprayed on the surface of a substrate to be coated, and the aggregate is applied to the surface of the adhesive coating film (b). Aggregate scattered in the recesses of the aggregate, and of the aggregate scattered on the surface of the adhesive coating film, to remove the excess aggregate that is not adhered to the adhesive coating, then, on the aggregate The method for producing a decorative board with a pattern according to any one of claims 8 to 10, wherein a top coat is applied and cured. 12. The method according to claim 8, wherein the aggregate is at least one selected from the group consisting of mica, silica sand, glass beads, crushed glass, glass powder, and colored materials thereof.
12. The method for producing a decorative panel with a pattern according to any one of items 11 to 11. 13. The method for producing a decorative board with a pattern according to claim 8, wherein the amount of aggregate applied is 50 to 500 g / m ² . 14. An aggregate having an average particle size of 0.05 to 3.0 mm.
The method for producing a decorative board with a pattern according to any one of claims 8 to 13. 15. The method according to claim 8, wherein the paint composition applied to the surface of the aggregate layer is a clear paint.