JPS58162340A - Manufacture of gypsum decorative board - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a gypsum decorative board having irregularities or embossing on its surface. More specifically, by creating a gypsum decorative board that integrates a plate-like base material and a gypsum layer, it is easy to manufacture, efficient, easy to handle, has excellent measurement and workability, and can take advantage of the texture of gypsum. Concerning how to create decorative boards.

Conventionally, with ordinary decorative gypsum boards, the hardened gypsum material is wrapped in the board base paper and the plaster does not come out on the surface, so the texture of the gypsum can be utilized. However, it was not possible to form irregularities or embossing on the surface. In other words, when it comes to large boards, they tend to crack due to their own weight, so it becomes necessary to make the gypsum board thicker than a certain level, which also increases the weight and makes it difficult to use it for ceiling materials etc. This was a construction problem.

The present invention has been made to improve the above-mentioned points. Specifically, a water barrier layer is formed on the upper surface of a plate-shaped base material, an adhesive layer is applied to bond the water barrier layer and a gypsum layer, and then a gypsum slurry is applied to the gypsum slurry. A gypsum decoration characterized in that a sheet for shaping, which is previously formed into an uneven or embossed shape, is brought into close contact with the upper surface of the gypsum slurry in an uncured state, and the sheet for shaping is released after the gypsum slurry has hardened. This is a method for manufacturing a board, and according to the present invention, a gypsum decorative board is obtained in which a plate-like base material and a gypsum layer are integrated, and the surface has irregularities and embossing, and furthermore,
By using a shaping sheet having a pattern that can be transferred to the gypsum layer as the shaping sheet, it is possible to apply the pattern to the gypsum layer along with the uneven embossing.

The manufacturing method of the present invention will be explained in detail based on FIGS. 1 to 6 showing the process order. First, the plate-shaped base material (
1) is coated with a water-resistant resin or laminated with a water-resistant plastic film to form a water-blocking layer (2). This water barrier layer (2) has the function of preventing the plate-shaped base material (1) from being attacked and deteriorated in strength by moisture contained in the gypsum slurry that will be applied later. After that, an adhesive layer (3) is applied to bond the water barrier layer (2) and the gypsum layer.
gypsum slurry (4) is poured on top of this. In addition, in Fig. 3, frames (51
is provided. °When this gypsum slurry IJ-(41) is uncured, a molding sheet (6) made of a plastic film, etc. previously formed into an uneven shape or an embossed shape is covered from above, and the molding sheet (6) is placed on the cliff surface. Smooth it evenly with a pressure roll, etc., and then add the molding sheet (6) and the gypsum slurry (
4) Closely adhere. (Then, the surface layer of the gypsum slurry (4) is formed into the shape of the shaping sheet (6) and becomes the gypsum layer (7). After the slurry hardens, the surface layer of the gypsum slurry (4) is formed into the shape of the shaping sheet (6). The sheet (6) is peeled off and dried to remove excess moisture in the plaster layer (7), and if necessary, a top coat layer (8) for surface protection is applied (see Figure 6).

Here, lightweight board materials such as veneer plywood and particle board are suitable for use as the plate-like base material (1), but other materials include gypsum board, asbestos slate board, gypsum slag board, and silicon board. As the next water barrier layer (2), a coating layer of acrylic resin, unsaturated polyester, or urethane resin, or a film layer of polyvinyl chloride, polyester, polypropylene, or the like can be used. Furthermore, as an example of the adhesive layer (3), good results can be obtained by using an acrylic adhesive or an ethylene-vinyl acetate copolymer adhesive, but the present invention is not limited thereto. In addition, gypsum slurry (41 includes hemihydrate gypsum,
Anhydrous gypsum, trihydrate, gypsum slag, etc. alone or in combination are mixed with an appropriate amount of water and used in the form of a slurry. It is also possible to mix reinforcing materials such as synthetic resins and glass fibers into the rice slurry (ゝO) Finally, regarding the molding sheet (6), polyethylene, polyester, polyvinyl chloride, etc. have excellent moldability. In addition, if the fine surface of a natural product such as wood is to be reproduced as it is, a molding sheet in which the molding silicone layer is reinforced with a backing film can also be used.

Alternatively, it is practical to simultaneously apply molding and decoration to the plaster layer by using a shaping sheet (6) that can transfer a pattern to the plaster layer. An example of such a shaping sheet is the Japanese Patent Application Laid-Open No. 55-7 proposed by the present inventors.
Examples include those described in Publication No. 16on.

That is, as shown in FIG. 7, a film material such as polyethylene, polyvinyl chloride, or polyester having excellent moldability is used as a base sheet (9), and a water-soluble release varnish layer α1 is formed on one side of the base sheet (9). A molding sheet (131) in which a porous ink pattern layer On containing a filler is printed and a porous and therefore water-permeable adhesive layer α2 is arranged thereon. imprinting sheet)Q
31, it is possible to transfer all the ink pattern layers to the surface of the gypsum layer at the stage when the gypsum slurry hardens. (This makes it compatible with the present invention.)

The present invention is as described above.According to the present invention, a normal gypsum board production line and a polyester decorative board production line can be used, and the imprinting sheet used can be used repeatedly. This saves money and makes manufacturing efficient, inexpensive, and easy. In addition, if a lightweight board material such as plywood is used as a plate-like base material, the plaster layer will be thinner, resulting in a lightweight and sturdy decorative board, increasing the workability as a ceiling material.Furthermore, it will create an uneven texture and embossed pattern that were not available before. It can express itself well and is also an excellent interior material.

Examples of the present invention will be described below.

[Example 1] A veneer plywood was used as a plate-like base material, and a polyvinyl chloride film was laminated thereon using an acrylic emulsion as an adhesive to form a water barrier layer. Afterwards, acrylic emulsion product name Movinyl 761H (manufactured by Hoechst Synthesis ■)
was applied to a thickness of 40 P/m" (when dry), and a gypsum slurry with the following formulation was poured. Then, a 200 μm thick polyvinyl chloride film with stucco-like embossing was covered from the top, and the plaster was applied with a pressure roll. When the slurry and the film were brought into close contact with each other and the embossed film was released after the plaster had hardened, a lightweight decorative board with excellent design and an emphasis on the texture of the plaster was obtained.

Gypsum slurry formulation (parts by weight) 10 parts water 35 parts glass fiber (61111 length) 06 parts water reducing agent
Part 2 [Example 2] A gypsum slag board (product name: Elite: manufactured by Mitsubishi Cement Kenzai ■) was coated with an unsaturated polyester resin layer to form a water barrier layer, the surface of which was sanded, and then an acrylic emulsion was applied to the Example. As in Example 1, the coating was applied at 40 f/h during drying, and a gypsum slurry having the same formulation as in Example 1 was applied. Then, a transfer molding sheet with travertine-like embossing (see below) was applied from the top surface, the plaster slurry and the molding sheet were brought into close contact with each other with a pressure roll, and the molding sheet was released after the plaster had hardened. A decorative board with excellent design and a deep, heavy feel was obtained.

The recipe for the transfer type imprinting sheet is as follows.

A non-plasticized vinyl chloride sheet with a thickness of 200 μm is used as a base sheet, and one side thereof is coated with a varnish having the following formulation using a gravure printing machine to form a release varnish layer.

Varnish recipe Next, print a marble pattern ink pattern layer on the release varnish layer using the ink with the following recipe using a gravure printing machine. Then, a porous adhesive layer was formed and a transfer sheet was prepared.

Porous adhesive layer formulation

[Brief explanation of the drawing]

FIG. 1 to FIG. 6 are explanatory diagrams showing an example of the method for manufacturing a gypsum decorative board of the present invention in the order of steps, and FIG. 7 is a schematic cross-sectional view showing an example of a transfer-type shaping sheet. . (1)...Plate base material (2)...Water blocking layer (
3)...Adhesive layer (4)...Gypsum slurry IJ -
(51... Frame (6)... Imprinting sheet (7
)...Gypsum layer (8)...Top coat layer Patent applicant Toppan Printing Co., Ltd.

Claims (2)

[Claims] (1) Water is blocked on the top surface of the plate-shaped base material! After applying an adhesive layer to bond the water barrier layer and the gypsum layer, a gypsum slurry is applied, and when the gypsum slurry is in an uncured state, it is pre-formed into an uneven or embossed shape. A method for manufacturing a gypsum decorative board in which a plate-like base material and a gypsum layer are integrated, the method comprising: bringing a sheet into close contact with the upper surface of the gypsum slurry; and releasing the shaping sheet after the gypsum slurry has hardened. . (2) The method for manufacturing a gypsum decorative board according to claim 1, wherein the second shaping sheet is a transfer-type shaping sheet capable of transferring a pattern onto the gypsum layer.