JPS6241108B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board in which a concave pattern rich in three-dimensional effect is formed on a mineral fiberboard.

Conventionally, methods for creating concave patterns on the surface of a substrate made of mineral fiberboard include a pressing method in which the surface of the substrate is pressed using an embossing press, and a travertine pattern in which the surface of the substrate is pressed with a molding material with small protrusions such as pins in close contact with it. A method of carving a concave pattern such as the above, and a method of excavating by spraying abrasive grains such as walnut shells with a shot blaster while a punched pattern plate is in contact with the surface of the substrate are known.

However, the method using an embossing press has the disadvantage that the substrate is compressed and its structure is destroyed, resulting in a decrease in the strength of the substrate, while the method of carving a concave pattern with a mold material with densely planted pins does not allow the surface of the substrate to be removed when the pins are pulled out. When the part is pulled up, the board and surface coating will bulge around the concave pattern, damaging the appearance. In addition, it is necessary to crush the board deeply with pins to form the concave pattern, resulting in a decrease in strength. There is.

Moreover, according to the method of drilling with a shot blaster while the punched pattern board is in contact with the substrate surface, if the punched pattern board is severely damaged and the adhesion between the pattern board and the board is poor, It has the disadvantage that the excavated concave pattern becomes unclear, and furthermore, it is impossible to form an annular concave pattern having a convex pattern within the concave pattern, and the design is limited and only a pattern with little variation can be obtained. Can not.

Furthermore, mineral fiberboards cannot be partially excavated by imparting strength to the fibers themselves using the action of softeners or hardeners, unlike wood fiberboards.

The present invention eliminates these drawbacks and provides a method for manufacturing a decorative board that can easily and efficiently form a clear and three-dimensional concave pattern on a mineral fiberboard.

To explain the drawings showing the embodiment, a kneaded material mainly composed of an inorganic powder substance and a synthetic resin is applied to the entire surface of a substrate 1 made of mineral fiberboard using a roll coater or a flow coater, and the applied layer is dried. Then, a coating layer 2 having a harder hardness than the substrate 1 is formed.

The material to be mixed to form the coating layer 2 includes synthetic resin emulsions and aqueous solutions such as vinyl acetate resin, acrylic resin, and urea resin, as well as inorganic powder materials such as calcium carbonate, silica, diatomaceous earth, titanium oxide, and other inorganic powder materials, as well as other inorganic powder materials as needed. A material having a solid content of 64 to 85% by weight and a viscosity of 20,000 to 60,000 cps mixed with a thickener etc. can be used, and is applied so that the coating layer after drying is 0.2 mm or more.

Here, the synthetic resin strengthens the coating layer 2 by increasing its bonding strength, and the inorganic powder substance prevents the synthetic resin from penetrating into the substrate 1 to form the coating layer 2. The coating layer 2 is provided with a suitable hardness.

After the coating layer 2 is formed on the surface of the substrate 1 in this manner, the substrate 1 is introduced into a drying chamber equipped with a dryer or a vacuum burner and subjected to a drying process.

In addition, in order to form the coating layer 2 even thicker, the steps of applying and drying the kneaded material may be repeated multiple times.

Next, by pressing a flat plate 4 or a roll or the like on which protrusions 3 such as pins are provided in a pattern on the surface of the substrate 1 provided with the coating layer 2, the protrusions 3 are immersed into the coating layer 2. As shown in FIG. 2, the coating layer 2 is partially destroyed in a pattern.

At this time, since it is not possible to obtain the desired concave pattern by simply bringing the protrusions 3 into contact with the coating layer 2, the protrusions 3 are immersed into at least the interior of the coating layer 2, preferably to the surface layer of the substrate below the coating layer. This destroys the coating layer 2.

Note that the coating layer 2 may be destroyed by a molding material such as an embossing plate.

When the covering layer 2 is destroyed in a pattern in this way, many cracks occur in the destroyed portion 2a, and the destroyed covering layer portion 2a adheres to the surface of the substrate 1 in a state where it is easily peeled off. Also, at the same time, the board 1
The coating layer of is also weakened by the pressure from the protrusion 3,
The surface layer of the substrate becomes extremely easy to excavate.

Note that the destroyed coating layer portion 2a may be peeled off while being partially sandwiched between pins, etc. that constitute the protrusion 3, and whether or not it remains on the surface layer of the substrate is particularly important. This is not a problem, and it is sufficient that it is destroyed by causing a large number of cracks in a state where it is easy to peel off.

Next, as shown in FIG. 3, a shot blaster 4 sprays walnut shells, steel balls, or other granular materials over the entire surface of the substrate 1 to excavate the substrate below the previously destroyed coating layer 2a. do.

At this time, the walnut shells etc. sprayed from the shot blaster 4 cannot damage or excavate the coating layer 2, which is harder than the substrate 1, and the surface layer of the substrate 1 located below the previously destroyed coating layer 2a. Since the spraying is carried out under such conditions that the damaged coating layer 2a is peeled off and removed from the substrate surface, the surface layer of the substrate 1 is excavated to a desired depth as shown in FIGS. 4 and 5. A concave pattern portion 5 is formed.

The conditions for spraying the walnut shells, etc., are appropriately selected by adjusting the rotation speed of the impeller of the shot blaster and the amount of walnut shells, etc. sprayed per unit time.

Here, it goes without saying that if the hardness of the coating layer 2 is higher than that of the substrate 1, the concave pattern portion 5 described above cannot be formed; Saga Brinell hardness is approximately 0.1
When the substrate 1 is made of mineral fiberboard with a weight of Kg/mm ² , the coating layer 2 needs to have a hardness that will not be destroyed by the projection of walnut shells, etc., and the larger the difference in hardness between the substrate 1 and the coating layer 2, The surface hardness of the coating layer 2 is preferably 0.15 because it can easily form a deep concave pattern.
It is set to be at least Kg/mm ² .

In addition, when the thickness of the coating layer 2 is less than 0.2 mm, when spraying walnut shells etc. with the shot blaster 4, the coating layer 2 is coated so that the collision force does not affect the fragile substrate 1 made of mineral fiberboard. Even the layers may peel off or be damaged,
It is set to be 0.2 mm or more, preferably 0.4 mm or more.

After forming the concave pattern portion 5 on the substrate 1 in this way,
Apply an appropriate top coat of 150 to 300 paint over the entire surface of the board 1.
It is applied by spraying or the like at a ratio of g/m ² and then dried in a drying room to obtain a decorative board.

As described above, the present invention applies a kneaded material mainly composed of an inorganic powder substance and a synthetic resin to the entire surface of a substrate made of mineral fiberboard and dries it to form a coating layer with higher hardness than the substrate. The coating layer is destroyed in a pattern by an appropriate means, and then a concave pattern is formed by spraying walnut shells or other granular materials onto the substrate surface using a shot blaster and excavating the substrate portion below the destroyed coating layer. Since this method relates to a method for producing a decorative board with a concave pattern, the highly hard coating layer that remains on the substrate surface without being destroyed resists shot blasting and completely retains its shape. It can be held and made to appear as a convex pattern in contrast to the concave pattern, and in addition, if the pattern is simply engraved with a pin, the paint film will peel off at the edges of the concave pattern, damaging the appearance. In the invention, shot blasting is further applied to the part of the coating layer that has been destroyed with a pin, etc., so that such peeled-off parts of the coating film are peeled off and the coating layer is left with a clear concave pattern that appears conspicuously at the edge of the concave opening. Moreover, by pushing protrusions such as pins into the surface layer of the substrate and destroying the coating layer, the substrate below the destroyed coating layer can be easily excavated by shot blasting to form a three-dimensional structure. A decorative board having a concave pattern with excellent texture can be efficiently obtained.

Furthermore, unlike the shot blasting method using a template mask, the present invention can easily reveal a convex pattern part due to the remaining coating layer in a concave pattern part, and a decorative board having a varied appearance can be obtained. It is.

[Brief explanation of the drawing]

The drawings show embodiments of the present invention; FIG. 1 is a cross-sectional view of a substrate provided with a coating layer, FIG. 2 is a cross-sectional view showing the coating layer broken in a pattern, and FIG. 3 is a shot. FIG. 4 is a cross-sectional view of the obtained decorative board, and FIG. 5 is a perspective view thereof. DESCRIPTION OF SYMBOLS 1...Substrate, 2...Coating layer, 2a...Destroyed coating layer, 3...Protrusion, 5...Concave pattern.

Claims (1)

[Scope of Claims] 1. After applying a kneaded material mainly composed of an inorganic powder substance and a synthetic resin to the entire surface of a substrate made of mineral fiberboard and drying it to form a coating layer with higher hardness than the substrate, The coating layer is destroyed in a pattern by an appropriate means, and then a concave pattern is formed by blowing walnut shells or other granular materials onto the substrate surface using a shot blaster and excavating the substrate portion below the destroyed coating layer. A method for manufacturing a decorative board having a concave pattern. 2. A method for manufacturing a decorative board having a concave pattern according to claim 1, which comprises destroying the coating layer and the surface layer of the substrate in a pattern.