JPS6159786B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing a decorative board with a cast-like uneven pattern. More specifically, the present invention relates to a method for forming a decorative pattern with a three-dimensional effect by painting and finishing the flat surfaces of the convex portions and the concave portions of a cast-like uneven pattern in a different color. Currently, cast-like textured decorative boards are widely used for finishing textured surfaces on the interior and exterior walls of buildings, architectural boards, and the like. As a method for finishing such a cast-like uneven pattern, the following methods are generally used. For example, a spraying material made by mixing aggregate, pigment, inorganic powder, etc. with a cement-based binder and/or synthetic resin emulsion, or a binder such as an organic solvent-based epoxy resin can be applied to a wall or construction board surface in an uneven pattern. When the spraying material is semi-hardened, press the tops of the projections to an appropriate level with a roller, trowel, etc., or after the spraying material has completely dried, press the tops of the projections with a knife edge. , cut or polished using a sander or the like to make it reasonably flat. In addition, in line with the generalization of such cast-like textured pattern finishes, asbestos cement boards, asbestos calcium silicate boards, and Pal
We are also working on the practical application of methods for forming architectural molded boards such as cement boards, wood wool cement boards, wood powder cement boards, gypsum boards, rock wool boards, glass fiber reinforced cement boards, and concrete boards into the above-mentioned cast-like uneven patterns. It is progressing. By the way, as a method for coloring such a cast-like uneven pattern surface, the most common method is to uniformly finish the entire pattern surface with paint. However, according to this method, since the coloring is limited to a single color, the resulting decorative board has the disadvantage that it has a flat finish with little variation. As a method to improve this drawback, for example, there is a known method (Japanese Patent Publication No. 48-5092) in which a different color paint is applied with a roller only to the flat surfaces of the convex portions of the above-mentioned painted surface. The outline of the color difference at the border became extremely clear, and as a result it was not possible to form a finish with great depth. The present invention improves these drawbacks, and the color tones of the concave portions and the flat surfaces of the convex portions of the cast-like uneven pattern are different, and the color tone gradually changes as the depth of the concave portions increases from the edge of the flat surface of the convex portions. The purpose is to form a pattern with depth and depth. That is, the present invention provides the following steps: (a) applying a colored paint to the entire patterned surface of a base material having a cast-like uneven pattern; (b) drying the colored paint until it is at least dry to the touch; and (c) applying the coloring paint upward. And on the entire painted surface kept almost horizontally, apply a color clear paint that has a viscosity of 30 seconds or less according to food cup No. 4, has a solid content of 10% by weight or more, and has a different color from the colored paint. (d) Immediately spray a gas stream, such as an air stream or a water vapor stream, or spray water onto the painted surface;
The present invention relates to a method for manufacturing a cast-like uneven pattern decorative board, comprising the steps of: causing most of the color clear paint on the flat surface of the convex portion to flow down into the concave portion, and then (e) drying the paint. In the cast pattern plate obtained according to the present invention, the thickness of the coating film formed by the color clear paint that has flowed down into the recesses increases as the depth of the recesses increases, and as a result, the color clear paint gradually increases in thickness. The color of the paint becomes darker. On the other hand, a small amount of the color clear paint remains on the flat surface of the convex portion, but since the color clear paint has significantly greater transparency than the colored paint, the flat surface mainly exhibits the color of the underlying colored paint. Therefore, according to the present invention, it is possible to form a profound and deep pattern as a whole. The base material used in the present invention is formed of, for example, a spray material such as a commercially available tile-shaped spray material. The spraying material is mainly composed of inorganic and/or organic binders and aggregates, and if necessary, colored pigments, inorganic powders, etc. are mixed in and the viscosity is adjusted to be suitable for spray painting with a mortar gun. This is what I did. As the spray material, for example, JIS-
Multi-layer pattern sprayed materials specified in A6910 C (uses cement-based binder), E (uses synthetic resin emulsion-based binder), RE (uses reaction-curing synthetic resin emulsion-based binder), and RS (reaction-cures synthetic resin) using resin solution binder), or C, E and
Examples include mixed compositions of two or more types of RE. The base material having a cast-like uneven pattern used in the present invention will be further explained below. First, the above-mentioned spray material is applied to a base material having a smooth surface.
For example, use a mortar gun to create uneven patterns on architectural board materials such as plywood, particle board, hardboard, pulp cement board, asbestos slate, precast concrete board, foamed concrete board, steel plate, galvanized steel plate, aluminized steel plate, and aluminum plate. Spray paint on. For spray painting, use a mortar gun with a nozzle diameter of about 2 to 12 mm, and adjust the spray pressure
Paint at around 1.5-10Kg/ ^cm2 . At this time, there is a method of forming an uneven pattern layer in one coat, or a method of applying spray material diluted to a slightly low viscosity to an almost uniform thickness over the entire surface of the base material, and then applying the spray material in scattered spots. Alternatively, a method can be applied in which the spraying material is applied dotted on the surface of the base material, and then the spraying material diluted to a slightly lower viscosity is applied to the entire surface to a substantially uniform thickness.
The coating amount is preferably about 500 to 3000 g/m ² . Then (a) while the sprayed material is in a semi-cured state, only the convex parts of the uneven pattern are pressed so that they are appropriately flat with a roll, trowel, hand roller, etc., or (b)
After the sprayed material has completely dried, only the convex portions of the concave-convex pattern are cut or polished using a knife edge, sander, etc. so that they are appropriately flat, thereby forming a cast-like concavo-convex pattern in which the tops of the convex portions are flat. 〓〓〓〓〓
Moreover, a construction board material having a cast-like uneven pattern formed on the board surface can also be used as the base material. These are, for example, asbestos cement boards, asbestos calcium silicate boards, pulp cement boards, wood wool cement boards, wood powder cement boards, gypsum boards, rock wool boards, glass fiber reinforced cement boards, etc., which are usually formed by wet and dry methods. In this method, by performing pressing, embossing, pouring, etc. using the mold forming the cast-like uneven pattern, it is possible to manufacture the molded board material in substantially the same process as the manufacturing process of conventional molded board materials for construction. In particular, an asbestos cement board produced by a wet method has high strength and is suitable as a substrate for use in the present invention. The "colored paint" used in the present invention may be any of water-based paints, organic solvent diluted paints, high solids paints, non-solvent paints, and powder paints, including known water-soluble acrylic melamine paints,
Water-based paints such as acrylic emulsion, vinyl acetate emulsion, and vinyl acetate-acrylic copolymer emulsion, and organic solvent-diluted paints such as acrylic, acrylic urethane, polyester urethane, acrylic melamine, vinyl chloride resin, and epoxy resin. , melamine-based, acrylic-based, epoxy-based high-solids paints or powder coatings, and epoxy-based solvent-based paints can be used. The colored paint is applied under normal coating conditions to obtain a uniform coating film. In this case, the substrate is generally porous, and the degree of porousness varies, and those skilled in the art will readily be able to employ various modifications. For example, on a substrate with large suction, a uniform colored coating film can be formed even with a colored coating material having a viscosity comparable to that of the color clear coating material. In addition, by applying colored paints with several different viscosities,
The appropriate coating viscosity for the substrate can be easily determined. Furthermore, if the coating viscosity is moderately high, the coating workability will be reduced, and if it is excessively low, the paint will tend to flow after coating, and in either case, it tends to be difficult to perform a homogeneous coating. Therefore, when using a water-based paint as a coloring paint, the solid content concentration is generally 20%.
~70% by weight, up to about 80% by weight in the case of high solids type paints, and 90 to 100% by weight in the case of non-solvent type paints are suitable. The above-mentioned "color clear paint" used in the present invention is a dye that is usually used as a coloring agent for coloring plastic moldings and/or an organic and inorganic coloring pigment used in colored paints, and a resin solid fraction. It is contained in a proportion of about 0.01 to 15% by weight. In the above, if the amount of colorant is less than 0.01% by weight, a sufficient change in color tone cannot be obtained;
If the amount exceeds % by weight, the transparency of the formed coating film will decrease, making it impossible to obtain a deep change in color tone. Particularly preferred is one in which the amount of colorant is approximately 0.05 to 10% by weight. In addition, when the architectural molded board material obtained by the method of the present invention is used for the exterior of a building, it is required that the coating film does not fade, so it is preferable to use inorganic and organic pigments as the coloring agent. As the resin component of the color clear paint, the same water-based resins and organic solvent diluted resins as those used in the colored paints can be used. Next, the manufacturing steps (a to e) of the cast-like uneven pattern decorative board according to the present invention will be explained. First, a colored paint is applied to the entire surface of the base material having the cast-like uneven pattern (step a). For the coating, conventional methods such as spray coating, flow coating, shower coating, and roll coating using a roll having a flexible surface layer can be used. In particular, a method of painting while transporting the substrate using a transport device such as a conveyor is suitable for industrial manufacturing. The amount of colored paint applied is the amount in normal painting,
For example, the amount is preferably such that the dry film thickness is about 5 to 100 microns. If the dry film thickness is less than 5μ, it becomes difficult to achieve uniform coloring, and if it is thicker than 100μ, not only is the paint was wasted, but it is also difficult to dry the paint film uniformly. Subsequently, the colored paint is dried to a state that is more than dry to the touch (step b). This is to prevent color bleeding due to re-dissolution of the colored paint film by the solvent or dispersion medium of the color clear paint when the color clear paint is applied again in the next step c. The required degree of dryness varies depending on the solubility of the solvent or dispersion medium, but any dryness may be used as long as the dryness does not substantially cause color bleeding. The drying method may be either normal temperature drying or heat drying, but in the case of factory painting, it is preferable to use a hot air dryer, an infrared dryer, or the like. Especially conveyor for painted substrates.
A method of drying while transporting is suitable. Next, with the painted surface facing upward and the substrate horizontally or almost horizontally, paint the colored paint with a viscosity measured by food cup No. 4 (paint temperature 20°C) of 30 seconds or less, a solid content of 10% by weight or more, and A different color clear paint is applied to the entire surface to be painted (step c).
As the coating method, the same method as in the case of the colored paint can be used. In this case as well, the method of painting while transporting the painted substrate as described above is suitable for factory painting. The amount of color clear paint applied is approximately 50~
1000 g/m ² (However, the area means the area of a plane parallel to the uneven patterned substrate). The viscosity of the color clear paint (foed cup)
No. 4, 20° C.) for more than 30 seconds, the color clear paint lacks fluidity, resulting in insufficient change in color tone between the flat surface of the convex portion and the concave portion. On the other hand, the lower the viscosity of the clear paint, the better its fluidity, but in order for the clear paint to flow down into the recesses and provide the necessary coloring, the solid content must be at least 10% by weight.
The viscosity of this clear paint is almost the same as that of general organic solvents (about 8 seconds). If the applied amount of the color clear paint is more than 1000 g/m ² , the color clear paint unnecessarily closes the recesses, resulting in a decrease in the three-dimensional effect especially when viewed from an oblique direction. On the other hand, if the amount of color clear paint applied is less than 50 g/m ^{2 ,} it will not be possible to obtain a sufficient change in color tone depending on the height difference of the three-dimensional surface. In particular, the viscosity is about 9 to 15 seconds, and the application amount is about 80 seconds.
It is preferably ~500g/ ^m2 . Next, the substrate is kept in a horizontal or almost horizontal state, and a gas stream such as air or water vapor is immediately injected onto the painted surface, or water is sprayed to coat the color clear paint on the flat surface of the convex portion. Most of the liquid is allowed to flow down into the recess (step d). The effect of promoting the flow of the color clear paint by the above-mentioned air flow, water vapor jet, or water spray (hereinafter referred to as air jet jet, etc.) changes depending on the flow velocity of the air or the like. Furthermore, when the substrate is moved on a conveyor, the flow promoting effect changes depending on the moving speed and the like. It is possible to easily adjust these conditions to suit each embodiment so that the flow can be carried out efficiently. In the case of air jetting, etc., the flow velocity or amount of air, etc. may be extremely increased, or the angle of the air flow, etc. relative to the substrate (determined by the direction of the air flow, etc. and the moving speed of the substrate). ) should be avoided as this will push the color clear paint in the recesses onto the convex parts. Moreover, it is natural that the effect of promoting the flow of the clear paint decreases as the uniform air flow rate and the amount of air decrease. The above water spraying is particularly suitable when a water-based paint such as a water-soluble resin paint or an emulsion resin paint is used as the color clear paint. The compressed air for the above-mentioned injection and atomization can be obtained by a conventional compressor, the pressurized steam by a boiler, and the pressurized water by pneumatic delivery by a compressor or by a plunger pump. As the means for injecting the air flow, a nozzle in the form of a fine hole or a slit can be used. Finally, the above paint is dried (step e). The same drying method as for colored paints can be used. In particular, while the color clear paint has high fluidity, it is necessary to dry the substrate while keeping it horizontal or almost horizontal so that the color pattern formed by flowing the color clear paint does not collapse. . In the present invention, the above-mentioned color clear paint and blue paint are used in combination with mutually different colors. In particular, if the color clear paint has the same hue as the blue paint, but has slightly different lightness and/or saturation, a deep pattern will be formed. The present invention will be explained below with reference to Examples. In addition, prior to the Examples, a composition for molding an asbestos cement board, a colored paint for architectural spray materials, and a color clear paint were prepared as follows. In the following, "parts" and "%" refer to parts by weight and % by weight, respectively. [Composition for molding asbestos cement board] 65 parts of cement, 35 parts of asbestos, and 32.5 parts of water were uniformly mixed to prepare a molding composition. Incidentally, the molding composition is subjected to molding immediately after being prepared. [Architectural spray material] 14 parts of thickener aqueous solution (1% solution), 45 parts of silica powder with an average particle size of about 260 mesh, and 45 parts of silica powder with an average particle size of about 260 mesh
Mix in 25 parts of 80 mesh silica powder with stirring.
Then epoxy resin emulsion (50% aqueous solution)
Add 10 parts of to make a homogeneous mixture. Especially polyamine〓〓〓〓〓
Prepare 6 parts and mix both evenly just before use.
Use for spray painting. [Colored Paints A and B] Acrylic copolymer resin emulsion (average molecular weight approximately 60,000, solid content 50%), color pigment, water, film forming aid, etc. were uniformly mixed with the formulation shown in Table 1, and colored paints A and B were mixed uniformly. B was prepared.

[Colored paint C-F]

Acrylic copolymer resin varnish (average molecular weight approximately 15,000, resin content 50% solution, butyl acetate 3.57%, xylene 42.8% and methyl isobutyl ketone 3.57%) and colored pigments are uniformly mixed in the formulation shown in Table 2 to create a colored paint. C to F were prepared.

【table】

[Colored paint G~K]

Acrylic copolymer resin varnish with the formulation shown in Table 3 (average molecular weight 15000, OH value of resin solid content 40, resin content 50% solution, toluene 25%, butyl acetate 10.5%,
Aromatic petroleum naphtha 3.0%, ethylene glycol monobutyl ether acetate 7.0%) and colored pigments were uniformly stirred and mixed to prepare colored paint bases G to K. When used, a non-yellowing isocyanate resin solution (50% isocyanate resin with NCO% of 21%, toluene 25%, butyl acetate 10.5%, aromatic petroleum naphtha 3.0%, ethylene glycol monobutyl ether acetate 7.0%) is added to the base resin. The mixture was mixed uniformly and used.

[Table] 〓〓〓〓〓

[Color clear paint A and B]

Color clear paints A and B were prepared using the acrylic copolymer resin emulsion used in the preparation of colored paint A and having the formulations shown in Table 4.

【table】

[Color clear paint C-F]

Color clear paints C to F were prepared using the acrylic copolymer resin varnishes used in the preparation of colored paint C, according to the formulations shown in Table 5.

[Color clear paint G~K]

Using the acrylic copolymer resin varnish and non-yellowing isocyanate resin solution used in the preparation of colored paint G, color clear paints G to K were prepared using the formulations shown in Table 6.
(Similar to colored paint G, the main ingredient and isocyanate resin solution are mixed at the time of use. The viscosity in the table is the viscosity after mixing.) was prepared. 〓〓〓〓〓

[Air injection device A]

A slit with a width of 2 mm is provided on the side of an iron pipe with an inner diameter of 10 cm and a length of 120 cm along the central axis of the pipe, extending almost the entire length of the pipe except for both ends, allowing compressed air to be supplied from the compressor to both ends of the pipe via a pressure-resistant hose. I did it like that. Immediately after the color clear paint coating device on the conveyor line, the iron pipe is placed so that the pipe is perpendicular to the traveling direction of the conveyor, and the height from the conveyor to the pipe and the angle between the air flow injected from the slit and the conveyor surface are the same. Arranged so that each can be changed freely. [Air injection device B] A device that removes the paint supply hose from a normal air spray gun so that it can be sprayed dry by pulling the trigger of the gun. The spread of the airflow ejected from the nozzle of this gun can be adjusted from 5 to 90 degrees, and the gun can also be adjusted manually by controlling the air pressure of the compressor, the distance between the board and the gun, and the angle between the airflow and the board. The air injection conditions can be easily adjusted. Example 1 An asbestos slate board with a thickness of about 6 mm and smooth on both sides was formed by a normal pressing method using the asbestos cement board molding composition, and then, while the slate board was in a semi-hardened state, a cast-like structure was formed on one side. The uneven pattern was embossed using the embossing method. After the slate board is completely cured, the surface temperature of the board is approximately 50°C in a hot air drying oven while being conveyed on a conveyor with the uneven pattern side facing up.
Immediately, colored paint C was applied uniformly over the entire surface by flow coating, and after setting for about 1 minute, the coating film was dried in a hot air drying oven at 80° C. for 10 minutes. Next, apply color clear paint D.
Flow coating was applied to the entire surface at a coating weight of 100 g/m ² , and immediately an air stream was sprayed onto the substrate surface using air spray device A, causing most of the clear paint on the flat surface of the convex portion to flow down into the concave portion. For air injection, we adjusted the air pressure of the compressor, the height from the board surface to the pipe slit, and the angle between the air flow and the direction of board movement, resulting in an air pressure of 5 kg/cm ² , a height of 15 cm, and an angle of 45 cm.
It was found that good results could be obtained at . Also,
When the clear paint was allowed to flow down by gravity, it required 5 minutes of setting, but by using air injection, the conveyor line could be significantly shortened. The paint was then heated and dried in a hot air drying oven at 80°C for 10 minutes. The resulting decorative board had a pale cream color on the flat surfaces of the convex portions, and the yellow tone gradually deepened as the depth of the concave portions increased, giving it a solid and deep appearance as a whole. The dry film thickness of the colored paint is 50μ〓〓〓〓〓
Ta. Example 2 The surface of a commercially available asbestos slate board was cleaned and the above-mentioned architectural spray material was adjusted to a viscosity of 150 poise (25°C), and a portion was shaped to form a convex portion using a mortar gun (diameter 7 mm, pressure 5 Kg/cm ² ). It was applied. When the convex part is dry to the touch, dilute the construction spray with water to adjust the viscosity to 55KU (25°C), and apply it to the entire surface with a spray gun (3 mm diameter, 4 Kg/cm ² pressure). Then, an uneven pattern surface was formed. When the uneven patterned surface was semi-hardened, a roller was pressed and rotated over the entire surface to flatten the vicinity of the tops of the convex portions to form a cast-like uneven pattern. After the uneven pattern layer was completely cured, the colored paint A was spray-coated uniformly over the entire surface, and immediately passed through an infrared drying oven until the paint was dry to the touch. Next, color clear paint A was spray-painted on the entire surface at a coating amount of 200 g/m ² , and most of the clear paint on the flat surface of the convex portion was flowed down into the concave portion using the air injection device B. At this time, the spread of the air flow from the air spray gun is approximately 60 degrees, the air pressure of the compressor is 5 Kg/cm ² , the distance between the board surface and the spray gun nozzle is 10 to 20 cm, and the air flow (center of the flow, (same below) and the substrate surface were set at an angle of 30 to 60°. Subsequently, the painted surface was heated in an infrared drying oven for 10 minutes to dry the paint. The obtained decorative board had a pale green color on the flat surfaces of the convex portions, and the green color of the concave portions gradually became darker and deeper as the depth increased. The film thickness of the colored paint, which was measured after being completely dried separately, was approximately 30 μm. Example 3 Decorative laminates (Nos. 1 to 10) were prepared in the same manner as in the previous example under the conditions shown in Table 7. The appearance of the decorative pattern is also shown in Table-7. 〓〓〓〓〓

[Table] 〓〓〓〓〓

[Table] Example 4 In Example 2, except that a paint supply hose was connected to air injection device B, water was put into the paint tank at the end of the hose, and water was sprayed instead of air jet. Painting and drying of the paint film were carried out in the same manner. The decorative board obtained had depth similar to that of Example 2. Example 5 In Example 2, the air supply hose of air injection device B was connected to a steam boiler with a safety valve,
Painting and drying of the paint film were carried out in the same manner except that the steam pressure of the empty boiler was set to 5 kg/cm ² and a steam stream was injected instead of an air stream. The decorative board obtained had depth similar to that of Example 2. Comparative Example 1 Using the combination of the substrate, colored paint (), and colored paint () shown in Table 8, the colored paint () was first applied to the entire surface of the cast-like uneven surface of the board, and after the coating film had almost completely dried, the colored paint was applied. () was applied to the flat surface of the convex portion using a rubber roller brush, and the paint was allowed to dry. Table 8 shows the appearance of the decorative board obtained. 〓〓〓〓〓

[Table] Comparative Example 2 In Example 1, Color Clear Paint D was mixed with methyl isobutyl ketone and toluene in a weight ratio of 5/5.
Painting and drying of the paint film were carried out in the same manner except that a clear paint diluted with a mixed solvent of No. 45 to a solid content of 8% by weight was used instead of the color clear paint D. The obtained decorative board had a light cream color that was almost the same in both the convex and concave areas and lacked a sense of depth. Comparative Example 3 A color clear paint with a viscosity of 32 seconds (paint temperature 20°C) according to the food cup No. 4 using 10 parts of water in the composition of color clear paint A in Table 4 above was used instead of color clear paint A. Coating and drying of the coating film were carried out in the same manner as in Example 2 except for the use of the coating material. The obtained decorative board had an approximately equal pale green color in both the convex and concave areas, and lacked a sense of depth. 〓〓〓〓〓

Claims (1)

[Claims] 1. (a) applying a colored paint to the entire patterned surface of a base material having a cast-like uneven pattern; (b) drying the colored paint to at least a touch-dry state; (c) ) A colored clear paint with a viscosity of 30 seconds or less according to food cup No. 4, a solid content of 10% by weight or more, and a color different from the colored paint is applied to the entire painted surface, which is kept facing upward and almost horizontally. (d) Immediately spray a stream of air or water vapor or spray water onto the painted surface to cause most of the color clear paint on the flat surface of the convex portion to flow down into the concave portion, and (e) A method for producing a decorative board with a cast-like uneven pattern, which comprises the steps of drying the paint. 2. The method for producing a cast-like uneven pattern decorative board according to claim 1, wherein the colored paint has a dry film thickness of 5 to 100 μm. 3 The amount of the above color clear paint applied is 50~
Claim 1 or 2 which is 1000g/m ²
A method for manufacturing a cast-like uneven pattern decorative board as described in 2. 4. The method for manufacturing a cast-like uneven pattern decorative board according to claim 1, 2, or 3, wherein the colored paint is dried by heating. 5. The method for manufacturing a cast-like uneven pattern decorative board according to claim 1, 2, 3, or 4, which comprises heating and drying the color clear paint. 6. The cast according to claim 1, 2, 3, 4, or 5, which performs the steps a to e while continuously conveying the substrate on a conveyor. A method for manufacturing a decorative board with an uneven pattern.