JPS6050754B2 - Manufacturing method of patterned inorganic substrate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a concave pattern portion 2 on the surface of the wet mat 1 made of an inorganic material by embedding lumps of thermoplastic resin 3 on the surface of the wet mat 1 using a pressing device 7. A method for manufacturing a patterned inorganic substrate, which is characterized in that a thermoplastic resin 3 is placed in the concave pattern part 2, and the thermoplastic resin 3 is heated and melted to penetrate into the vicinity of the edge of the concave pattern part 2. ,
The aim is to ensure that the strength of the board does not deteriorate.
To provide a method for manufacturing a patterned inorganic substrate in which chipping is less likely to occur at the edges of concave pattern parts.

Conventionally, patterns have been applied to inorganic substrates such as rock wool, cement, and slate (used as interior and exterior materials such as ceiling panels and wall panels) using a pattern-imparting mold after drying (hardening).
However, in the case of rock wool substrates, the strength deteriorated by 30%.
%, and had a drawback that significantly reduced the strength of the plate material.

In addition, when embossing complex uneven patterns on cement, slate, plaster, etc. using a plate, roller, etc. in a wet mat state, there is a lot of cement, etc. adhering to the mold, so it is necessary to control the moisture content and add a mold release agent. The disadvantage was that it required complicated work. Further, when painting the patterned substrate 4, the area around the pattern 5 swells during the drying process due to the influence of water contained in the paint, creating so-called craters 6 as shown in Figure 3, and the surface becomes smooth. There was a drawback that the sex was impaired. The present invention aims to eliminate such conventional drawbacks, and will be described in detail below with reference to the accompanying drawings.

Figure 1 shows the process of the present invention, which includes cement, slate, gypsum, calcium silicate, magnesium carbonate, calcium aluminate monosulfate hydrate (M
A wet mat 1 of an inorganic substrate such as SH), calcium aluminate trisulfate hydrate (TSH), rock wool, glass wool, etc. is prepared as shown in Figure a by any method such as paper making or casting, and wet In the state of the mat 1 as it is, that is, before the curing reaction, a lump of an appropriate thermoplastic resin 3 such as polyethylene, polypropylene, polyamide, etc. is pressed onto the surface of the wet mat 1 using a pressing device 7 such as a roll or press as shown in the figure. Press and press to push in.
In this case, a concave pattern 2 is simultaneously formed on the surface of the wet mat 1, and a lump of thermoplastic resin 3 is embedded in the concave pattern 2. Then, during the drying process, the surface of the wet mat 1 is heated to, for example, about 120 to 200°C using an arbitrary heating device 3 such as a direct gas flame, hot air, or infrared rays, as shown in FIG. As shown in FIG. 2, the inorganic substrate 1 penetrates near the edge of the concave pattern part 2
A concave pattern part 2 is exposed on the surface of ``.'' In this figure, the double-crossed area is the part where the thermoplastic resin 3 has penetrated. Optimal conditions can be set depending on the type of plastic resin 3, the material of wet mat 1, etc.Next, paint is applied to the surface of the dried inorganic substrate 1'' using a coater 9 to apply makeup, and then surface finishing (transparent top, etc.). In the present invention, as described above, a concave pattern is provided on the surface of the wet mat, and since the concave pattern is applied to the surface of the deformable wet mat before hardening, the tissue is damaged. This has the advantage that the concave pattern can be provided without causing any damage, and deterioration in strength due to the provision of the concave pattern on the substrate can be prevented.

In addition, a thermoplastic resin is loaded into the concave pattern, and the thermoplastic resin is heated and melted so that it permeates near the edges of the concave pattern, so the periphery, bottom, etc. of the concave pattern are heated. Those reinforced with plastic resin have the advantage of preventing damage to the concave pattern parts, and even when finished with paint, preventing the formation of craters on the surface caused by swelling due to painting, resulting in a smooth surface. Furthermore, by embedding lumps of thermoplastic resin into the surface of the wet mat made of inorganic material using a pressing device, a concave pattern was created on the surface of the wet mat, and the thermoplastic resin was filled into the concave pattern. Thermoplastic resin can be filled into the concave pattern at the same time as the concave pattern is formed on the surface of the mat, similar to the case where the concave pattern is formed on the surface of the wet mat and then the thermoplastic resin is filled into the concave pattern. This method has the advantage that it does not require much time and effort, and the manufacturing of the patterned inorganic substrate can be simplified.

The present invention will be specifically described below based on examples.

〔Example〕

A wet mat is made by paper-making rock wool, and a lump of polyethylene is pressed and embedded on the surface of the wet mat before drying, and then dried at 150'C for 3 times to a specific gravity of 0.
A decorative board with 38 concave patterns was obtained.

In this case, the bending strength of the decorative board was 24 to 25 k9/d. This is a finished product with a specific gravity of 0.38 without the concave pattern.
There was almost no deterioration in strength compared to the bending strength of the original plate (25k9/d). Furthermore, even after drying and painting as described above, the edges of the concave pattern did not collapse, and no craters were observed as shown in FIG. [Comparative Example] After drying the wet mat made in the example, a concave pattern was applied using an embossing roll to obtain a decorative board having a specific gravity of 0.38.

This has a low bending strength of 17k9/c, which is about 30% compared to the bending strength of the original plate described in the above example.
strength deterioration had occurred. Furthermore, when the thus obtained decorative board was painted, the edges of the concave pattern swelled with the paint and craters were formed as shown in FIG. 3.

[Brief explanation of the drawing]

Figures 1 a to d are schematic process explanatory diagrams of an embodiment of the present invention;
FIG. 2 is an enlarged sectional view after painting near the concave pattern part after the same drying process as above, and FIG. 3 is a sectional view after painting near the concave pattern part of the decorative board obtained by the conventional example. 2 is a wet mat, 2 is a concave pattern, 3 is a thermoplastic resin, and 7 is a pressing device 7
shows.

Claims (1)

[Claims] 1 By embedding a lump of thermoplastic resin on the surface of an inorganic wet mat using a pressing device, a concave pattern is provided on the surface of the wet mat, and the thermoplastic resin is encased in the concave pattern. A method for producing a patterned inorganic substrate, which comprises heating and melting a resin to infiltrate the vicinity of the edge of the concave pattern.