JPS5847332B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative laminate having an uneven surface pattern, and more specifically, the present invention relates to a method for manufacturing a decorative board having an uneven surface pattern, and more specifically, a hydraulic inorganic slurry is hardened in contact with a pattern sheet coated with a foaming agent in a pattern. The present invention relates to a method for manufacturing a decorative board, which is characterized by forming recesses on the surface corresponding to a coating pattern caused by gas generated by decomposition of a foaming agent.

BACKGROUND OF THE INVENTION Inorganic decorative boards having an uneven surface pattern are widely used mainly as interior or exterior materials for buildings.

The method of imparting such an uneven pattern is to use a roller or plate to create a mold with an embossed pattern on the surface, and mechanically press the surface to be molded, or to pour an inorganic slurry into a mold and harden it. There is a way to do it.

However, while these methods have the advantage of being able to form patterns faithfully to the mold, the molds used are expensive and have poor workability, and they often require complicated auxiliary equipment and work.
.

Alternatively, instead of a mold, an elastomer sheet such as urethane rubber with an embossed pattern is laid in a mold, and slurry is injected and hardened.

However, although this method also makes the rubber sheet quite expensive, residual monomers in the rubber sheet gradually polymerize and cause the sheet to shrink. There is a drawback that the uneven patterns given to the plate are different.

The present invention eliminates the drawbacks of the conventional method for manufacturing inorganic decorative laminates as described above, and allows decorative laminates with various uneven patterns to be easily manufactured in a consistent process from manufacturing molds to manufacturing inorganic decorative laminates. The object of the present invention is to provide a method for manufacturing such an inorganic decorative board.

That is, the method of the present invention is for manufacturing a decorative board from a hydraulic inorganic slurry, and is characterized by including the following steps.

(B) A step of preparing a master sheet having a coated pattern layer of ink containing a blowing agent having the property of reacting with the components in the hydraulic inorganic slurry to generate gas on one side of the base sheet; (B) ) A step of laminating the prototype sheet and the hydraulic inorganic slurry so that the surface having the coated pattern layer of the prototype sheet and one layer of the hydraulic inorganic slurry are in close contact with each other. , a step of forming a concave portion on the contact surface corresponding to the ink coating pattern of the master sheet due to gas generation from the foaming agent, and (
YO Process of peeling the original sheet from the cured product.

The basic aspects of the present invention will be explained in more detail with reference to the drawings.

The hydraulic inorganic slurry used in the present invention uses a hydraulic cement such as Portland cement, gypsum hemihydrate, or other inorganic binder as a binder, and if necessary, a filler such as sand or crushed stone. Reinforcing materials such as aggregate, glass fiber, colorants such as pigments or dyes, plasticizers, stabilizers, curing accelerators or retarders, wetting agents, emulsifiers, thickeners, blowing agents, natural or synthetic resins. It is made by adding additives such as , etc. and mixing it with water.

Further, a foaming aid for promoting the reaction with the foaming agent described below can be added as necessary.

Note that the term "slurry" is not necessarily intended to limit the viscosity or consistency; it can range from fluidity suitable for casting to paste-like material suitable for wall coating. It is used to include things such as.

This hydraulic inorganic slurry is used in combination with a master sheet.

FIG. 1 is a schematic cross-sectional view of an example of a prototype sheet used in the present invention.

In FIG. 1, a prototype sheet A is formed by providing on one surface of a base sheet 1 a coated pattern layer 2 of ink containing a foaming agent.

As the blowing agent, one having the property of generating gas by reacting with the components in the above-mentioned hydraulic inorganic slurry is used.

Examples of such blowing agents include carbide powder that reacts with water to generate acetylene gas, metal powder such as aluminum powder that reacts with alkaline or acidic water to generate hydrogen, and carbon dioxide gas that reacts with acidic water. Examples include sodium bicarbonate, which generates

In order to facilitate the gas-generating reaction of the blowing agent, acids, alkalis, etc. are added to the hydraulic inorganic slurry as blowing aids, if necessary.

Generally, Portland cement slurry has a pH of 12 to 1.
Amphoteric metal powders such as aluminum powder or carbide powders which are alkaline such as No. 3 and react with such alkaline water are preferred blowing agent materials.

The foaming agent is, for example, 10 to 500 to make it easier to form into ink.
The particle size is adjusted to μ.

Further, the blowing agent powder may be pretreated with an antioxidant such as stearic acid prior to forming into an ink to maintain its activity, if necessary.

Such blowing agents include dextrin, glue, casein, shellac, gum arabic, starch, protein, polyvinyl alcohol, polyacrylic acid amide, sodium polyacrylate, polyvinyl methyl ether, copolymer of methyl vinyl ether and maleic anhydride, acetic acid. Copolymers of vinyl and itaconic acid, polyvinylpyrrolidone, or cellulose derivatives such as cellulose, acetylcellulose, acetylbutylcellulose, nitrocellulose, ethylcellulose, carboxymethylcellulose, methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, etc. alone or in combination. The mixture is then kneaded with a solvent inert to a blowing agent such as lower alcohol and water, and optional additives to form an ink.

The composition of a typical ink is as follows.

Next, the obtained ink is applied to one side of the base sheet 1 at a rate of, for example, 0.1 to IOP/m'' (solid content) to form a coated pattern layer 2, thereby obtaining a master sheet A.

Examples of the base sheet include plastic film,
Materials that are not substantially affected by adverse effects such as deformation by the hydraulic inorganic slurry may be optionally used, such as paper treated with a preventive treatment or foamed plastic sheets.

Next, this original sheet A is laid in a formwork 3 with the surface having the coated pattern layer 2 facing upward, and a hydraulic inorganic slurry 4 is injected from above to form a laminated structure as shown in FIG. Let it be body B.

If the laminated structure B is left in this state, the hardening of the inorganic slurry layer 4 progresses, and the applied pattern layer 2 is foamed by the gas generated by the reaction between the components in the inorganic slurry and the foaming agent, as shown in FIG. 2a, and a corresponding recess is provided on the contact surface of the inorganic slurry layer 4.

After further curing the inorganic slurry layer 4 to the extent that it has at least self-shape retention, the laminated structure B
is demolded, the original sheet A is peeled off, and if necessary, further hardening and drying is performed to obtain a decorative board C according to the present invention made of a hardened inorganic material 4c having concave portions q as shown in FIG.

The decorative surface of the thus obtained decorative board C having the concave portions q is further coated with gloss paint or colored paint as necessary on the entire surface or selectively on the convex portions or concave portions to increase the cosmetic effect. What is done is done.

In the above, the most basic aspect of the method for manufacturing a decorative board according to the present invention has been described.

However, the method of the present invention can be implemented by variously modifying the above embodiments.

For example, the following illustrates some such variations.

First, if a coloring agent made of dye or pigment is included in the ink-coated pattern layer 2 of the original sheet A, in the manufacturing process of the decorative board explained in FIGS. An effect is obtained in which the concave portion q is colored at the same time as the concave portion q is formed.

Such pattern transfer is possible because the coated pattern layer 2 is water-soluble, but a better transfer effect can be obtained if the colorant is water-soluble.

Further, in addition to the ink coating pattern layer 2 for providing the concave portions q on the decorative board C, an ink coating pattern layer 5 for imparting a colored transfer pattern may be formed on one surface of the base sheet to form the prototype sheet A). (Figure 5).

At least one of the binder and the colorant constituting the ink coating pattern layer 5 needs to be water-soluble.

The principle of such colored pattern transfer, binders and colorants that can be used are described in Japanese Patent Application Laid-Open No. 52-529.
Publications No. 65 to No. 53-168115 are detailed and can be referred to as needed.

Further, on top of the ink coated pattern layers 2 to 5 of the master sheet A shown in FIG. 1 or FIG. This can improve the stability of the foaming agent in the coated pattern layer 2, prevent the colored ink pattern layer 5 from flowing out, and improve the retention of foaming gas.

Furthermore, in order to obtain a laminate consisting of a master sheet and a single layer of hydraulic inorganic slurry, instead of casting the inorganic slurry as described above,
It is also possible to first apply an inorganic slurry to a wall base material, etc., and then paste the master sheet thereon.

Furthermore, heating the laminate of the original sheet and one layer of hydraulic inorganic slurry is effective in accelerating the gas release reaction of the blowing agent.

In the case of casting, such heating is achieved by heating the hydraulic inorganic slurry to, for example, 120° C. or lower.

Furthermore, the method for manufacturing a decorative board of the present invention essentially provides a decorative surface with concave portions, resulting in an uneven surface.
As shown in FIG. 6, a foamable resin sheet made of a thermoplastic resin such as polyvinyl chloride, an organic or inorganic blowing agent, and optional additives such as a plasticizer is used as the base sheet 1a, and the above-mentioned An ink coating pattern layer 2 containing a foaming agent and an ink coating pattern layer 6 containing a foaming suppressor having foaming suppressing properties against the foaming agent in the base sheet 1a are formed adjacently by printing or the like. Principle When sheet A is obtained and brought into contact with one layer of heated hydraulic inorganic slurry, the degree of foaming of the base material sheet Ha is suppressed in the portion corresponding to coated pattern layer 6, and relatively corresponds to coated pattern layer 2. The areas that touch the surface become convex portions, and furthermore, convex portions are formed by the reaction of the foaming agent in the coating pattern layer 2 on top of the convex portions, so that the convex and convex patterns formed on the surface of the decorative board in contact with these convex portions become deeper. You can get something.

If both the coated pattern layers 2 and 6 are formed by printing, such alignment can be easily achieved.

Note that the coated pattern layers 2 and 6 do not necessarily have to be in the above-mentioned adjacent relationship, and may be separated or partially overlapped.

By changing the arrangement in this way, various uneven patterns can be given to the decorative board.

Alternatively, the base sheet 1 may be foamed by heating the original sheet having the above-mentioned coated pattern layers 2 and 6 in advance, and then laminated in close contact with one layer of the hydraulic inorganic slurry.

Regarding the thermoplastic resin, foaming agent, foaming suppressor, etc. that can be used in this embodiment, the specification of Japanese Patent Application No. 106500/1989 is detailed and can be referred to as necessary.

The decorative board obtained by the present invention has excellent heat resistance and an uneven decorative surface, so it can be used as an interior/exterior material for construction, and can also be used as a template itself by utilizing the uneven surface.

As described above, according to the present invention, a basic sheet is formed by a simple method of forming a coating pattern on a base sheet by printing, etc., and by simply curing a hydraulic inorganic slurry while contacting with this master sheet. , a decorative board having an uneven surface is obtained.

Therefore, the overall manufacturing process is simple, and there is an advantage that various uneven patterns, which are colored as necessary, can be easily formed in accordance with the printed application pattern.

The present invention will be explained in more detail with reference to Examples below.

In the examples, "parts" and "%" are both based on weight.

Example 1 To 50 parts of stamped aluminum powder with a particle size of 52 to 74 μm and a purity of 99% obtained by adding stearic acid to aluminum foil and grinding it into a fine powder, a total of 0.5 parts was added to prevent oxidation.
Further add stearic acid to form part of the inorganic pigment (ulmarine blue).
0 parts, 100 parts of polyvinyl alcohol, and 200 parts of water-ethanol mixed solvent for 24 hours in a side mill.
It was kneaded and made into ink.

Using this ink, 2.0♂/
A prototype sheet was obtained by gravure printing at a dry rate of 3 cm (dry), and this was laid on the bottom of a metal formwork with an inner diameter of 900 x 1800 x 3 Q mm, and a reinforcing wire mesh with a diameter of 3 mm x @100 mm was placed.

On the other hand, white voltland cement) 100 parts and particle size mm
After dry-mixing 200 parts of Tagawa Kansuiseki in a mortar mixer for 3 minutes, 65 parts of 85°C warm water was added and kneaded for 5 minutes.

The obtained mortar at 60° C. and pH=12 to 130 was poured into a mold while being vibrated.

The formwork was placed outdoors and cured with water for 3 days, then removed from the mold.
A decorative laminate panel was obtained which had the desired colored embossment pattern 8 squares deep.

Furthermore, when 1.0 part of caustic soda is added to the mortar, the pH of the mortar becomes 13 to 14, the reaction rate with aluminum, that is, the emboss formation rate increases, and the depth of the emboss becomes <10 to 12 mm. Ta.

Example 2 Calcium carbide 10 micronized to 10-100μ
50 parts of organic dye (methylene blue), 100 parts of methyl cellulose, and 200 parts of ethanol were made into an ink, and 2.5 parts of the organic dye (methylene blue) was printed on a polyvinyl chloride film. / m” (dry)
A master sheet was obtained by gravure printing at a ratio of 20 mm, and this was placed on the bottom of an FRP mold with an inner diameter of 600 mm x 900 mm x 20 mm.

On the other hand, add ioo parts of α-type hemihydrate gypsum, 0.3 parts of E glass chopped strand fiber with fiber length of 611LrIL, 10 parts of acrylic resin emulsion, 42 parts of 60°C hot water, and 01 parts of 10% sodium citrate solution in an omnimixer. using 6
The mixture was kneaded for 0 seconds to obtain a gypsum slurry at 42°C.

This slurry was poured into the mold, left to stand for 2 hours, and then removed from the mold, yielding a gypsum board with a colored relief pattern of the desired design.

An acrylic urethane resin was sprayed onto this decorative surface and cured to obtain a beautiful relief board for architectural interiors having a colored relief pattern with a depth of 12 mm.

In addition, methylcellulose, which is a binder in the coated pattern layer of the original sheet, not only delays the hardening of the plaster and facilitates the generation of acetylene gas due to the reaction between carbide and water, but also suppresses the rapid progress of the above reaction and gradually was found to have the effect of generating acetylene gas.

Example 3 A base sheet was obtained by coating a polyvinyl chloride foamable sol to a thickness of 0.2 mm on a glass fiber nonwoven fabric (200 fl/m ) sheet, and a foaming inhibitor (trimellitic anhydride) was applied in a pattern on the base sheet. ) ], 22.55 parts binder (vinyl chloride 1 sulfuric acid vinyl copolymer) 8.5 parts, solvent methyl ethyl ketone 54.0 parts foam suppressor ink consisting of 1.09 parts
After gravure printing at a ratio of 202/m" (dry) on the remaining part and printing the ink containing the foaming agent of Example 10 on the remaining part at a ratio of 202/m" (dry), foaming in an open air at 200 ° C.
A prototype sheet was obtained, and this sheet was laid in a mold in the same manner as in Example 1.

On the other hand, in the mortar of Example 1, pearlite with a thread diameter of about Irnn was used instead of Tagawa Kansuiseki, and 01 parts of an anionic surfactant (Kao Atlas D3-D) and 0.5 parts of caustic soda were added. A foamed mortar slurry having a temperature of 59° C. or higher was obtained by mixing with a mortar mixer.

This slurry was poured into the mold and cured with water for 3 days in the same manner as in Example 1, and then removed from the mold to obtain a decorative panel having a colored embossed pattern with a depth of 15 mm.

[Brief explanation of the drawing]

1 to 6 are conceptual partial cross-sectional views in the thickness direction of a prototype sheet or a formwork in which the same is laid, for explaining the main steps of the decorative laminate manufacturing method according to the present invention.
Figures 5 and 6 are examples of the original sheet used in the present invention, Figure 2 is the state of the hydraulic inorganic slurry after foaming, Figure 3 is the state after foaming, and Figure 4 is the hardened and demolded book. Examples of decorative laminates according to the invention are shown. A: Prototype sheet, B: Laminated body of prototype sheet and inorganic slurry, C: Decorative board, 1.
... Base sheet, 2 ... Ink coating pattern layer containing foaming agent, 3 ... Formwork, 4 ... Hydraulic inorganic slurry, 5 ... ...Transferable colored pattern layer, 6...Ink coated pattern layer containing foaming inhibitor.

Claims (1)

[Scope of Claims] 1. A method for producing a decorative board from a hydraulic inorganic slurry, characterized by including the following steps. (B) A step of preparing a master sheet having a coated pattern layer of ink containing a blowing agent having the property of reacting with the components in the hydraulic inorganic slurry to generate gas on one side of the base sheet; (B) ) A step of laminating the prototype sheet and the hydraulic inorganic slurry so that the surface having the coated pattern layer of the prototype sheet and one layer of the hydraulic inorganic slurry are in close contact, ←→ Curing the one layer of the hydraulic inorganic slurry while bringing it into close contact with the prototype sheet, A step of forming a concave portion on the adhesion surface corresponding to the ink coating pattern of the master sheet due to gas generation from the foaming agent, and (Y) a step of peeling the master sheet from the cured product. 2. In step (B), hydraulic The method of item 1 above, in which the inorganic slurry is heated. 3. Step (b) is carried out by laying the original sheet in a mold with its pattern-coated side facing up, and injecting the hydraulic inorganic slurry from above. 4. The method according to the above item 1 or 2, wherein the ink containing the foaming agent further contains a coloring agent.
Any method from Section 3 to Section 3. 5. The method according to any one of items 1 to 4 above, wherein the original sheet has an overcoat layer of a water-soluble resin on the coated pattern layer. 6. The method according to any one of items 1 to 5 above, wherein the blowing agent is selected from metal powder, carbide powder, and sodium bicarbonate. 7. The method according to any one of Items 1 to 6 above, wherein the hydraulic inorganic slurry contains water and a hydraulic substance selected from hydraulic cement and hemihydrate gypsum.