JPS5853406A - Manufacture of decorative inorganic 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 provides a highly efficient method for manufacturing a cosmetic hydration-cured inorganic board that has irregularities and patterns on its surface, has good performance, and is excellent in design. In general, there are the following products and methods for applying cosmetics to hydration-curable inorganic materials, but all of them have the following problems.

(1) There are two methods for manufacturing decorative gypsum boards: one is to stamp the board base paper in advance, then pour gypsum slurry and harden the gypsum to create the board, and the other is to directly create the board after creating the gypsum board! 11
There are two methods, either by laminating the printed sheet or by laminating the printed sheet to create a pattern, but in either case, there is a major drawback in terms of design that it is not possible to create large irregularities on the surface, and with regard to the former method. In this case, a good printing effect cannot be obtained because a base paper is used. Regarding the latter, printing effects can be expected, but the three-dimensional effect on the surface cannot be expected, and the high cost and poor workability cancel out the benefits of printing effects.

(2) When painting a molded object, it is not possible to form the substrate in advance so that it has irregularities. Therefore, methods are limited to those using special printing methods such as tacho printing, and methods of laminating the base material and the printed sheet using vacuum lamination. However, the former problem has the problem that the ink is on the surface and has poor abrasion resistance, so a top coat is indispensable.As the ink film cannot be thick, the color of the base material cannot be hidden. There is a problem that it must be kept constant, and both of these are fatal in terms of cost. The latter vacuum lamination method requires multiple molds to pre-form the base material, as well as equipment to integrate the base material and sheet, and the base material itself is also breathable. This is undesirable because it is limited due to the necessity, and it has three major problems: cost, workability, and base material selection.

(3) At the same time as molding, a transfer sheet with special ink is molded, a hydrated and hardened slurry is poured onto it, and when the slurry hardens, the transfer is completed and the mold is removed, but this method also applies. Because special ink is used, there is a problem of high i = t, the ink film cannot be thickened and the color of the material must be constant, and it is susceptible to abrasion, so a top coat is required, resulting in high costs. There are a variety of problems, including problems and being limited to transferable substrates.

Therefore, the inventors of the present invention investigated to solve the above-mentioned drawbacks, and as a result, they cast a hydrated and hardened slurry onto a pre-formed stamp sheet and integrated it with the sheet when the slurry hardened and dried, thereby achieving an efficient and low-cost solution. We have completed a method for manufacturing decorative inorganic boards.

The following two explanations of the present invention are as follows: The present invention involves applying an adhesive to a sheet with a pattern printed on it and molding it into a desired shape, or molding it into a desired shape and applying an adhesive, followed by hydration curing. This method of producing a decorative inorganic board is characterized in that the slurry is poured into the molded body, and the slurry is cured and dried to integrate the molded sheet having irregularities and the water-cured slurry.

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

First, as shown in Figure 1, the sheet is printed on the surface)
(Mold or emboss 11 into the desired shape to create unevenness.

The material of this printing sheet only needs to have moldability and printability, and may include vinyl chloride film, polyethylene film, polypropylene film, ABS film, polystyrene film, etc. alone or a laminate film made by laminating two or more of each of them. The composition of the printing sheet is not limited to, but is not limited to, printing the desired pattern on a colored original fabric and laminating it with a clear original fabric, printing the back of a clear original fabric, etc. The former is preferable when concealment is required and when the ink does not have hydration-curing slurry resistance such as alkali resistance. Next, a mold is created by molding the printed sheet so that the back side is the top side. Next, an adhesive (2) is applied to this molding frame as shown in FIG.

As for this adhesive, the present inventors selected an acrylic adhesive.

Until now, there was no known method for bonding a smooth sheet-like material and a slurry-like material, but ethylene - Emulsions of vinyl acetate copolymers are used at construction sites. It is true that ethylene-vinyl acetate copolymer resins are intertwined with water-curing slurry, but when it comes to actually applying it to a smooth sheet and adhering it to the slurry, there is a limit to the amount that can be applied. When the slurry hardens, the tangled parts are limited to the very surface layer of the cured product, resulting in a significant decrease in the strength of the adhesive layer, and the adhesive retention strength is far from practical strength, making it difficult to bond to the base material. Adhesion is difficult unless you use something that has an anchoring effect.

The present inventors concluded that the method of entangling the cured slurry and adhesive would have the opposite effect, and as a result of trying to bond without entangling the cured slurry at all, the surface layer of the cured slurry and the sheet were bonded using adhesive force. succeeded in retaining it.

The requirements for an adhesive for this purpose are that it must be resistant to moisture in the water-curing slurry, have strong adhesion, high cohesive strength, and have excellent weather resistance. I came to the conclusion that this adhesive is the best.

Of course, it goes without saying that adhesives other than acrylic adhesives can be used as long as they have the above-mentioned properties. The application of the adhesive and the forming of the mark@1j sheet can also be performed in the reverse process as shown in FIG. In this case, the acrylic adhesive needs to have heat resistance.

It is desirable that the amount of acrylic adhesive applied is 30 to 4 o gdry/rrt or higher to ensure sufficient adhesion retention.Next, as shown in Figure 4, inorganic water conservancy hardening is applied to the molding frame. A decorative inorganic board is created by casting the raw material slug IJ-(31), curing, drying, or curing it to integrate the sheet and the hydration-cured inorganic board.

Hydration hardening slurries to be cast include various types of gypsum such as hemihydrate gypsum and anhydrite gypsum, dihydrate gypsum + blast furnace slag made water-curable by adding an accelerator, and various cements such as portland cement and alumina cement. Or, mix the mixture with an appropriate amount of water and use it as a slurry. Various fillers, extenders, synthetic resins, reinforcing agents such as glass fiber, and blast furnace slag as a modifier may be added to this slurry.

The present invention, which produces a decorative inorganic board by the method described above, has the following effects.

fi+ There is no need to prepare an inorganic molded plate with irregularities in advance, and the process involves casting and painting the molded part, so the process is extremely simplified and can be produced efficiently.

(2) Compared to the transfer method, which has the same process of painting a cast molded part, it does not require any special ink, color stability of water-curing material, or slurry resistance of the ink, and there is no need for a top coat. Since there is no material, the cheapest structure can be used, and the material cost can be reduced considerably.

(3) If the molded sheet according to the present invention is used in place of board base paper in the current gypsum board manufacturing line, only an adhesive application device is installed, and the production line is far superior to the current decorative gypsum board. We can manufacture textured decorative gypsum boards that add to the design.

As described above, the decorative inorganic board produced according to the present invention can be produced in large quantities with low cost and efficiency, and can be applied to existing equipment, and can be produced without installing special large-scale equipment. It is particularly useful in the field of residential interior decoration.

Examples of the present invention are shown below.

[Example 1] A 100μ thick clear polyvinyl chloride film was laminated to protect the ink layer on a 100μ thick polyvinyl chloride colored film printed with a walnut grain pattern, and this was placed in a vacuum forming machine. The molded product was molded into a wood grain block shape with the pattern side facing down, and then the acrylic adhesive SK Dyne 1104 (
(manufactured by Souken Kagaku ■) at 40gdry/rI? A moderate amount was sprayed onto the inner surface of the molded product and allowed to dry.

Next, a slurry with the following composition was cast, and after curing, excess water was removed and a decorative plaster board with a wood grain block effect was formed.

The data of the physical property test of the decorative gypsum board obtained from the gypsum slurry formulation is shown below. For comparison, examples using an ethylene-vinyl acetate copolymer emulsion and a rewetting vinyl acetate emulsion (both of which are existing products for reinforcing mortar adhesion) are listed below.

7 points + sIP beam degree Planar tensile strength JAS water resistance C test implementation Example 6 to 9/
25m' 6.8kl/cd Good Comparative example (xfv-vinyl acetate=”) O1S & 9/25
m5 0.10 to 4/cd/) 11111 Comparative example (vinyl acetate) 0~α15~/25 rug width No strength /-t peeling [Example 2] Thickness 100/1i with stone grain pattern marked e11 PVC color display film with a thickness of 60 mm to protect the ink layer.
Clear polyvinyl chloride film of μ is laminated and molded to create a mold with unevenness.The mold is placed so that the pattern side is facing down, and then acrylic emulsion is applied onto it using a linear spray device. /, Movinyl 761 H (manufactured by Heggist Synthesis ■) 4 Q 9 d T'``y'/m
The inner surface of the molded product was spray-dried with a coating amount of about 20%.

Next, a lary having the following composition was cast, and after curing, excess water was removed to obtain a stone-grained decorative gypsum board.

When the physical properties of the decorative gypsum board obtained from the right front slurry formulation were tested, the results were as good as in Example 1.

[Brief explanation of drawings]

The drawings are explanatory diagrams showing an embodiment of the present invention, and Figures 1 to 3 show the steps up to manufacturing the formwork. The cross-sectional view and Figure 4 show the inorganic board by pouring slurry into the formwork. 2A and 2B are cross-sectional views illustrating two stages of manufacturing. ,'1)...Printing sheet (2)...Adhesive t,'(
+...Slurry of hydrated hardening material (3+'...Hardened slurry (4)...Decorative inorganic plate patent applicant Toppan Printing Co., Ltd. Representative Kazuo Suzuki Figure 1 ~------- 1-1

Claims (1)

[Claims] After or before molding the printing sheet into a desired shape with the pattern forming side facing downward, apply a water resistant and waterproof seal to the side on which the pattern is not formed. 1
A formwork is created by applying an adhesive with strong adhesion at each interface with one sheet and the slurry described below, and then a slurry of a hydration hardening material is poured into the formwork and cured, A method for producing a decorative inorganic board, which is characterized by drying or curing.