JPS6112507B2 - - Google Patents

Description

[Detailed Description of the Invention] This invention provides a painting having cracks in a mesh pattern,
The present invention relates to a method for producing a decorative plate in the form of a ceramic plate that is rich in elegance and expresses patterns.

Conventionally, this type of decorative board has been widely used for interior decoration of buildings, and is manufactured by the following method.

That is, as shown in FIG. 1A, a picture or pattern is drawn directly on the substrate 1 or on its surface,
Alternatively, a base coat 2 is formed on the surface of the base coat 2 after coloring, or an original image member 3 on which a picture, pattern, or color is printed or the like is adhered to the surface of the substrate 1 using an adhesive, as shown in FIG. 1B. , a base coat 2 is formed on the surface thereof, and then a starch glue solution is uniformly applied to the surface of both base coats 2, and the starch glue solution is dried to form a cracking layer 4 with mesh-like cracks 5 appearing on the entire surface. Form. This crack 5 also reaches the base coat 2. Thereafter, if desired, a coloring material 6 is rubbed on the surface of the cracking layer 4 and penetrated into the cracks 5 to emphasize the cracks, and then the excess coloring material 6 on the surface of the cracking layer 4 is wiped off with a cloth or the like and colored. After drying of the material 6, a transparent top coat 7 is further formed on the surface of the cracking layer 4 to complete the decorative plates A and A'.

At this time, as the substrate 1, gypsum board, asbestos board, fire-resistant board, wood board, plywood, metal plate, slate, etc. are used, and as the synthetic resin emulsion or paint used for the base coat 2, vinyl acetate or its copolymer is used. , styrene-butadiene copolymer, vinyl chloride-vinylidene chloride copolymer, butadiene-acrylontrile copolymer, or acrylic copolymer, etc., a water-dispersed emulsion of a synthetic resin that forms a relatively flexible film, or Paints whose main raw materials are these synthetic resins are used. Further, the cracking layer 4 is formed using an aqueous solution of starch glue, and the coloring material 6 is formed using an aqueous solution of starch glue.
Examples include oil paint, oil-based paint (with pigments),
Dyes etc. are used. Furthermore, as the top coat 7, a transparent coating suitable for the purpose of use as a decorative board is selected from among lacquer, varnish and other various paints, and water glass.

Conventional decorative plates A and A' manufactured using the materials and manufacturing methods described above use a relatively flexible film-forming material as the base coat 2 and a cracking layer in order to obtain cracks of appropriate size and shape. Since a brittle material is intentionally used as layer 4, the laminated structure is not only weak in terms of physical properties and stability, but also the width of the colored cracks in the cracking layer 4 is further increased as shown in Figure 2A. Changes over time called "lag" occur, such as spreading or cracking in new areas. This "backward" 8 further progresses and grows into a crack that reaches the surface of the top coat 7. For this reason, in the conventional decorative boards A and A', cracking of the cracking layer 4 occurs due to cracks in the top coat 7.
Not only is the starch further accelerated by the direct influence of the external atmosphere (the influence of temperature, humidity, etc.), but the starch repeatedly swells and dries, causing the insect bite phenomenon B shown in Figure 2 B. However, this part not only becomes discolored and its aesthetic value is significantly reduced, but also has the disadvantage of causing peeling of the laminated structure. In other words, the conventional decorative boards A and A' are not only completely unusable for the exterior of buildings, but also because the base coat 2 is relatively flexible, the cracking layer 4 is weak, and the top coat 7 is cracked. However, even for interior use, its use is limited in harsh environments with high humidity such as baths, or in areas where surface hardness is required, resulting in poor versatility.

The present invention was made based on the above-mentioned circumstances, and uses a base coat material that provides robust physical properties after complete curing, and removes the cracking layer from the laminated structure of the final manufactured decorative board. In particular, it is an object of the present invention to provide a method for manufacturing a decorative board that eliminates the numerous drawbacks of the conventional decorative boards described above.

That is, the present invention provides painting directly onto a plain color or surface;
An emulsion of a film-forming synthetic resin or A paint is applied to form a base coat, the base coat is dried to a semi-fluid or semi-cured state, and then a starch glue solution is applied to the surface of the base coat to form a cracking layer, and the cracking layer is dried to form a cracking layer and a cracking layer. A decorative board is manufactured by forming appropriate cracks in the base coat, then removing the cracking layer by washing with water, and then completely drying and curing the base coat.

The present invention will be explained in detail below in accordance with the above-mentioned process order.

Conventionally known plate materials can be used for the substrate, but metal plates (e.g. steel plates, aluminum plates), glass plates, etc. are preferably used, and even if the substrate is plain, it can be used with pictures, patterns, colors, etc. directly applied to the surface. It may also be a material in which an original drawing material (for example, paper, synthetic resin film, etc.) representing a painting, pattern, color, etc. is adhered to the surface using an adhesive.

Note that the above-mentioned substrate is subjected to surface treatment such as sanding, primer coating, etc., as necessary, in order to improve the adhesion with the base coat layer in a subsequent step. Further, this substrate must have a surface quality that will not be altered by the base coat's solvent (water, organic solvent, etc.), and must be able to withstand the curing temperature of the base coat. Further, in order to obtain uniform cracking in the subsequent process, it is desirable to use a smooth plate.

The film-forming synthetic resin emulsion or paint used for the base coat is of a reaction-curing type or a thermosetting type, and is cured by forced drying by heating, baking, or the like. Even if it is an air-dry type, it can be used as long as it has a slow curing rate that does not completely cure under the drying conditions of a starch paste solution. These are not limited to transparent or pigmented types, water-soluble types, or solvent types, but at least they can be dissolved in water in a semi-liquid or semi-hardened state in the preliminary drying process , it is necessary to have water resistance to the extent that it does not peel off from the substrate due to water content. Examples of the above-mentioned synthetic resins include melamine crosslinked acrylic resins, self-crosslinked acrylic resins, aminoalkyd resins thermosetting polyester resins, epoxy resins, one-component polyurethane resins,
There are two-component curing polyurethane resins, etc.

These resins are selected as appropriate depending on the intended use of the decorative board. For example, when used for exterior purposes, acrylic baking paints with excellent surface hardness, water resistance, and weather resistance are desirable. .

The above synthetic resin is rendered fluid with water or an organic solvent and then applied onto a substrate to form a base coat. The coating method at this time can be spray, brush coating, roll coater, curtain coater, etc., but it is desirable to make the coating thickness uniform in order to obtain highly uniform cracking in the subsequent process.

Thereafter, the base coat is pre-dried by air-drying at room temperature or by heating to a state where some fluidity remains (semi-fluid) or a semi-cured state.

The relationship between the hardness of the base coat during drying and the drying conditions (mainly temperature and time) can be roughly divided into stages, as shown in Figure 3, depending on the base coat material used. There is. In Figure 3, the stage has the properties at the time of application and has high fluidity, the stage still maintains fluidity during the process of volatilization of the solvent (water or organic solvent), and the stage only contains solid content (or resin content). This results in a semi-cured (semi-fluid) state, and the resin progresses to hardening at this stage, and curing ends at this stage.

As shown in Figure 3A, with thermosetting paints such as acrylic resin, curing will hardly proceed even if the drying time is increased unless the temperature after the stage is higher than the specified temperature. A typical drying and curing curve is obtained. On the other hand, with reaction-curing paints such as polyurethane resins, the curing pattern does not change significantly depending on the temperature, so
The result is a gentle drying and curing curve as shown in Figure B.

Pre-drying of the base coat refers to drying the base coat from the latter half to the first half of the process. When selecting a base coat material, be aware of its drying and curing properties, and set pre-drying conditions that will provide the desired flexibility for crack treatment. Generally, it can be said that pre-drying under conditions such as the stage shown in FIG. 3A is easy to control.

After pre-drying the base coat, a starch glue solution is applied to the surface of the base coat to form a cracking layer. The starch paste solution used at this time needs to be viscous enough to not be repelled when applied to the base coat. In addition, the dry film has adhesion to the extent that it does not peel off from the base coat during crack treatment, and it swells and redissolves with water.
It is necessary that it can be removed by washing with water in a subsequent process.

The starch paste solution is applied using a brush, curtain coater, etc. to make the coating thickness almost uniform.

The cracking layer is uniformly air-dried or heated at room temperature to form a crack pattern over the entire layer, and the drying is stopped when the crack pattern reaches an aesthetically appropriate size. The size and shape of the cracks, as well as the width and depth of the cracks, can be varied depending on the material of the base coat, pre-drying conditions, the type of starch used in the cracking layer, and the drying conditions. When this cracking layer cracks, a similar crack pattern is formed in the underlying base coat. If the cracks reach deep into the base coat or penetrate through the base coat, the pattern can be emphasized simply by contrasting the color of the substrate and the base coat. If the cracks in the base coat are shallow, or if you want to sharply emphasize the cracks, rub the desired coloring material into the cracking layer, or apply the coloring material into the cracks in the base coat by spraying, brushing, dipping, etc. Fill, impregnate. The coloring materials used in this case are preferably oil paints, oil-based paints (containing pigments), dyes, and other oil-based or solvent-based materials, but among these, those that have good fixation properties on the base coat layer and can be removed relatively easily by wiping from the surface of the layer, etc. It is preferable to choose something.

Further, when the above-mentioned coloring material is used, excess coloring material remaining on the surface of the cracking layer is wiped off.

Next, the cracking layer is swollen and dissolved with water and completely removed by washing with water. The specific method is as follows.

That is, by immersing the intermediate product of the decorative board up to this point in water and washing the cracking layer with running water or impact washing while swelling the cracking layer, the cracking layer is peeled off from the base coat. This method is possible even when the coloring agent of the coloring material is not sufficiently cured, and the coloring material does not bleed or become disordered. Moreover, it does not damage the base coat surface.

Furthermore, when a coloring agent with good fixing properties is used, it is also possible to sprinkle water on the surface of the cracking layer to swell it and then wipe it off directly with a sponge or the like.

After removing the cracking layer as described above, the base coat is heated and dried. By heating and drying, the base coat is completely cured to the state shown in FIG. 3. Prior to this heating, water droplets remaining on the surface of the base coat may leave "dark circles" during heating and drying, so it is best to blow away these water droplets with pressurized air in advance. Further, if the coloring material is not sufficiently cured up to the above steps, it may be cured at the same time during this heating step.

Next, a transparent top coat is formed on the surface of the base coat, if necessary, for the purpose of protecting the base coat and its cracks and improving the fixation of the coloring material. It is desirable to use a material substantially similar to the base coat material as the top coat material, since this allows the top coat and base coat to be cured simultaneously and improves adhesion.

In addition, if the base coat material is selected from a viewpoint other than performance as a top coat, such as adhesion to the substrate, a material other than the base coat may be used to protect the entire surface of the base coat and improve the surface properties. After curing, reapply
It is also possible to dry and cure to form a top coat.

According to the present invention comprising the above steps, the fourth
Decorative plates having various laminated structures as shown in the figures can be manufactured.

That is, in FIG. 4, (A) forms a base coat 12 on a substrate 11, and the cracks 13 formed in the base coat 12 are not filled with a coloring material, and (B) shows a case where a coloring material is filled into the cracks 13 of (A) above. 14, and C and D are the same as A and B above, respectively, with a top coat 15 formed thereon.

These decorative boards do not have a cracking layer in their laminated structure, so they do not suffer from the "lag" phenomenon that occurs with conventional decorative boards over time, and the choice of base coat material and/or top coat material Since the surface hardness can be improved, according to the present invention, it is possible to obtain a highly versatile decorative board that retains its aesthetic value for a long period of time and can be widely used for interior and exterior applications.

Examples will be described below.

Example 1 A water-soluble thermosetting transparent acrylic paint was spray applied to the surface of a plain pre-coated color aluminum plate, and then this paint layer (base coat) was dried under different conditions as follows.

I left it in the room for half a day to dry.

It was dried at 80°C for about 1 hour.

After that, it was further dried at 100°C for about 30 minutes.

After drying, an aqueous solution of starch glue was uniformly applied to the surface of the base coat using a curtain flow coater and dried in a dry air stream at room temperature, resulting in the appearance of network cracks in the glue layer (cracking layer). The degree of cracking in the base coat caused by this cracking was as follows when compared to the drying conditions of the base coat. That is, during drying, the base coat remains fluid and the cracks are wide and penetrate through the base coat, resulting in a relatively large pattern. Upon drying, the cracks became narrower but extended much deeper into the base coat, resulting in a medium-sized crack pattern. Also,
When drying, the cracks reached the top of the base coat and a small pattern was obtained. After rubbing these surfaces with a cloth impregnated with an oil-based dye diluted with thinner and staining the cracked areas, the cracking layer and water are removed, and any remaining water droplets on the base coat surface are completely blown away with pressurized air. ~150℃
Cured by heating for 30 minutes.

The manufactured decorative boards all had an elegant ceramic plate-like surface with mesh-like cracks, and the cracked parts were concave and had a rich texture.

These were highly versatile for interior and exterior use, with no change over time such as "backward" and excellent surface properties such as surface hardness, water resistance, and weather resistance.

Example 2 As the base coat in Example 1, a color tone that contrasts with the base material was used, and after making cracks appear in the same manner as in Example 1,
The cracking layer was removed by washing with water without any coloring treatment. The subsequent steps were performed simultaneously with Example 1.

The obtained decorative board had the excellent performance described in Example 1, with the substrate exposed and the cracks standing out.

Example 3 Electrodeposition paint for aluminum sash (thermosetting acrylic O/W emulsion, clear) was electrocoated slightly thickly on the surface of an aluminum plate that had been subjected to anodization (alumite) treatment, and washed with water. Afterwards, it was air-dried at a temperature close to room temperature to form a base coat. Next, an aqueous solution of starch glue was uniformly applied using a curtain flow coater and dried at 60°C for 30 minutes, resulting in the appearance of cracks in the glue layer in a network pattern. After rubbing oil paint onto this surface to color the cracks, the glue layer was removed by washing with water and air-dried. A transparent water-soluble thermosetting acrylic paint was sprayed onto this surface to form a top coat. Next, the base coat and top coat were simultaneously heated and cured at a predetermined temperature to obtain a decorative board with a robust surface texture and an elegant appearance in which the crack pattern appeared to be floating in a transparent film.

Example 4 A paint (enamel) containing a solvent-based thermosetting acrylic pigment was applied to a primer-treated steel plate by spray and dried at room temperature for about 30 minutes to form a base coat. Next, a starch glue solution was brushed onto the surface and dried at room temperature to form a cracking layer. Even when cracking occurred, the cracking layer did not separate from the base coat. After coloring the cracks by rubbing oil paint diluted with thinner into the cracks, the excess oil paint is wiped off, the cracking layer is washed away with water, the moisture on the exposed surface of the base coat layer is removed, and a transparent coat of the same type as the base coat is applied. Paint (varnish) was applied by spray and cured by heating at the same time as the base coat. The obtained decorative board had a poorer surface texture than the decorative boards obtained in Examples 1 and 2, but was rich in gloss and had improved surface properties. It also had a rich porcelain feel, with a sharp crack pattern.

Example 5 A thin steel plate treated with zinc phosphate was coated with a thin layer of synthetic rubber adhesive and a plate with a picture printed on it was attached as a base material. A modified transparent polyurethane paint was applied by spray and dried to the touch at 80°C to form a base coat. Next, in the same manner as in Example 3, cracking treatment, coloring, and washing and removal of the cracking layer were performed, and the exposed base coat layer surface was air-dried, and then the same polyurethane paint as the base coat was sprayed to form a top coat. The base coat and top coat are force-dried at 80℃ at the same time.
hardened.

Through the above treatment, a decorative board for an old painting with cracks all over the surface was obtained. This decorative board was highly water resistant and had physical properties such as a solid surface that made it suitable for use as an interior material.

Example 6 The base material was a transparent glass plate with good heat resistance, or a part of the surface of which was painted with oil-based paint using a brush or spray. Decorative boards obtained using materials and treatments similar to those described above were elegant, with clear crack patterns on a transparent background, and were suitable for interior decoration. Furthermore, when a transparent thermosetting acrylic paint was used as the base coat and top coat material, physical properties such as light resistance and surface hardness were further improved, and a highly versatile decorative glass plate was obtained.

[Brief explanation of the drawing]

Figures 1A and 2B are cross-sectional views of a conventional decorative board, Figure 2A is a cross-sectional view illustrating the change over time of the same as above, B is a partial plan view of A, and Figure 3 shows the hardening state of the base coat material in the present invention. Explanatory drawings and FIGS. 4A, 4B, 4C, and 4 are cross-sectional views of decorative plates manufactured according to the present invention. 1, 11... Substrate, 2, 12... Base coat, 3... Original image member, 4... Cracking layer,
5,13...Crack, 6,14...Coloring material,
7,15...top coat, 8...behind.

Claims (1)

[Claims] 1. Film formation on a plain substrate or a substrate on which a painting, pattern, color, etc. is directly applied, or on which an original image member showing a painting, pattern, color, etc. is attached to the surface using an adhesive. A base coat is formed by applying a solution, emulsion, or paint of a reactive-curing or thermosetting resin, the base coat is dried to a semi-solid or semi-cured state, and then a starch glue solution is applied to the surface of the base coat. A decorative board characterized in that a cracking layer is formed, the cracking layer is dried to form moderate cracks in the cracking layer and the base coat, and then the cracking layer is removed by washing with water, and then the base coat is dried and cured. Production method. 2 Film-forming reaction-curable or Applying a thermosetting resin solution, emulsion, or paint to form a base coat, drying the base coat to a semi-fluid or semi-cured state, and then applying a starch glue solution to the base coat surface to form a cracking layer, The cracking layer is dried to form appropriate cracks in the cracking layer and the base coat, and then the cracking layer is washed away with water, and then the base coat is dried and cured, and a transparent film-forming reaction-curing type or 1. A method for producing a decorative board, which comprises applying a thermosetting resin emulsion or paint to form a top coat, and drying and curing the top coat. 3 Film-forming reaction-curable or Applying a thermosetting resin solution, emulsion, or paint to form a base coat, drying the base coat to a semi-fluid or semi-cured state, and then applying a starch glue solution to the base coat surface to form a cracking layer, Drying the cracking layer to form appropriate cracks in the cracking layer and the base coat, filling the cracks in the base coat with a desired colorant via the cracks in the cracking layer, and then removing the cracking layer by washing with water. and then drying and curing the base coat. 4 Film-forming reaction-curable or Applying a thermosetting resin solution, emulsion, or paint to form a base coat, drying the base coat to a semi-fluid or semi-cured state, and then applying a starch glue solution to the base coat surface to form a cracking layer, The cracking layer is dried to form appropriate cracks in the cracking layer and the base coat, and a desired coloring material is filled into the cracks in the base coat via the cracks in the cracking layer, and then the cracking layer is removed by washing with water. After that, the base coat is dried and cured, a transparent film-forming reaction-curing or thermosetting resin emulsion or paint is applied to the surface of the base coat to form a top coat, and the top coat is dried and cured. A method of manufacturing a decorative board. 5 The reaction-curing or thermosetting resin is a melamine crosslinking acrylic resin, a self-crosslinking acrylic resin, an aminoalkyd resin, a thermosetting polyester resin, an epoxy resin, a one-component polyurethane resin, or a two-component curing polyurethane resin. A method for manufacturing a decorative board according to claim 1, characterized in that: 6 The reaction-curing or thermosetting resin is a melamine crosslinking acrylic resin, a self-crosslinking acrylic resin, an aminoalkyd resin, a thermosetting polyester resin, an epoxy resin, a one-component polyurethane resin, or a two-component curing polyurethane resin. A method for manufacturing a decorative board according to claim 2, characterized in that: