JPH01189372A - Manufacturing method of surface decorative 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 (Industrial Field of Application) This invention is a construction board that is applied to the interior and exterior walls, ceilings, floors, fences, etc. of buildings. The present invention relates to a method for manufacturing a decorative board in which decorative aggregate made of carcass is adhesively fixed, and is intended to improve the finished state of the board surface.

(Prior technology) The finishing condition of the surface of a decorative board with decorative aggregate applied to the board surface, especially the visual texture such as depth and solidity, is improved to create a more natural texture. It is effective to avoid uniformity of surface properties, such as by mixing multiple types of decorative aggregates with different colors, shapes, sizes, textures, etc., or by making the patterns that appear in the fixed state irregular. be. As a conventional technique for obtaining such irregularities, for example, there is a technique in which a mottled uneven surface is formed by embossing on the surface of the substrate, and a decorative aggregate such as sand is bonded and fixed there.
1-7346M, JP-A-53-103619).

(Problems to be Solved by the Invention) As described above, in the method of adhesively fixing decorative aggregate according to a pre-formed irregular pattern, an irregular pattern can only be obtained within the range of the embossing roll, for example. The degree of pattern change is small. Therefore, in many cases, when these surface decorative sheet metals are placed adjacent to each other, the same pattern will appear in the same place, making it difficult to obtain a natural texture as an overall impression of the wall surface.

Further, such surface decorative boards are usually manufactured by applying adhesive paint to the surface of the substrate and scattering decorative aggregate such as sand on the top surface. However, with traditional manufacturing methods,
The distribution of decorative aggregate after dispersion is difficult due to the fact that the particle size of the decorative aggregate is aligned within a certain range, and that the decorative aggregate is supplied at a constant level with just the right amount and shortage. The problem was that the surface was uniform and too homogeneous, and only a monotonous surface condition could be obtained, making it difficult to obtain a natural texture.

This invention solves the above-mentioned problems, and by improving the method of supplying decorative aggregate such as sand, the amount and adhesion pattern of decorative aggregate attached to the substrate can be continuously changed.
The purpose is to obtain a surface decorative board with a more natural texture.

(Means for Solving the Problems) In this invention, by dispersing decorative aggregate non-uniformly and continuously changing the shape and adhesion pattern of the decorative aggregate that adheres to the substrate, ! To obtain irregularity of texture on the four senses.

Specifically, as shown in Fig. 1, the waterproof layer (3), base layer (4), and contact MR (5) were sequentially formed on the surface of the substrate (2) on this contact layer (5). In the process of dispersing the decorative aggregate (6) into the hopper (11), the decorative aggregate (6) is
The amount of decorative aggregate (6) to be sprinkled is continuously changed by a scattering roll (13) interposed in the falling path. That is, a large number of depressions (15) are irregularly formed on the circumferential surface of the scattering roll (13), and the decorative aggregate (6) is spread while rotating the scattering roll (13).

Here, a process of forming a scattering layer of the decorative aggregate (6), that is, sequentially forming a waterproof layer (3), a base layer (4), and an adhesive layer (5), and then scattering the decorative aggregate (6). is the board (2)
In addition to applying it to the entire surface, it may be applied only to a part of the surface.

For example, if the surface of the substrate (2) is uneven, the coating may be applied only to the protrusions.

(Function) As a result, in this invention, the decorative aggregate (6) that has fallen from the hopper (11) is first caught by the scattering roll (13), and falls onto the substrate (2) as it rotates. Go. At this time, since the roll surface is provided with a depression (15), the part of the depression (15) has more decorative aggregate (
6) is accepted. Then, depending on the position and shape of the depression (15), the timing at which the decorative aggregate (6) slides from there varies, and the falling amount changes in size depending on the width and circumferential direction of the scattering roll (13). .

Due to this non-uniform distribution, the adhesive layer (5) of the substrate (2)
On the top, as shown in FIG. 5, the decorative aggregate (6) is sprinkled in an excessive amount in some areas and in an insufficient amount in some areas, resulting in an irregular pattern of density and density in the overall size. Adhesive layer (5
) Even after removing the excess decorative aggregate (6) that did not adhere to the pattern, the coarse and dense pattern still remains, which causes visual irregularity in texture. In addition, in the sumo-like part, the distribution of granules is seen depending on the mixing state, almost regardless of the size of the particles, and a texture different from that in other parts is produced. Therefore, a surface decorative board with a natural texture rich in depth and solidity can be obtained as a whole.

(Example) 1 to 5 show embodiments of the invention.

The surface decorative board (1) goes through the production line shown in Figure 2! j
J is built. In Figure 2, the manufacturing line consists of two substrates (2
) fS! (A> and this board (2
) and a base treatment step (B) of sequentially forming a waterproof layer (3) and a base layer (4) on the surface of the base I! Step (C) of applying an adhesive paint to the outer surface of (4) to form a contact layer (5), and dispersing decorative aggregate (6) made of granules on this contact layer (5); , consists of a step (D) of removing excess decorative aggregate (6), and a step (E) of forming an overcoat layer (7) on the outer surface of the decorative aggregate (6), and each step is arranged in alphabetical order. They are arranged consecutively. Blank states corresponding to each process are shown in FIGS. 3(A) to 3(E).

The substrate (2) is made of an inorganic hydraulic raw material mainly composed of cement, gypsum, gypsum slag, blast furnace slag, calcium silicate, lime, etc., or a hydraulic raw material containing an organic substance, and is manufactured by extrusion molding or paper forming. It is molded by a molding method or a press dehydration molding method. Structurally, solid,
Regardless of whether it is hollow, the surface condition may be flat, uneven with parallel or grid-like grooves, or with a satin finish or mottled background pattern. You can.

In the base treatment step (B), a sealer is applied to the entire surface of the substrate (2) to form a waterproof layer (3), and after drying, the primer is waterproofed! A base layer (4) is formed by coating the outer surface of (3) and drying.

The sealer and primer may be applied by any coating method such as roll coating, flow coater coating, or spray coating. Sealers and primers include organic coating materials such as acrylic, urethane, epoxy, vinyl, fluorine, polyester, phenyl, and amine materials, as well as inorganic sodium silicate materials. They may be different species or the same species.

In the spraying step (C), first, an adhesive paint is applied to the outer surface of the base layer (4) and the adhesive is applied to the outer surface of the base layer (4). Form I(5).

Then, before the J1 adhesion layer (5) loses its adhesiveness, the substrate (2) is moved using the transport bag @ (9), and the dispersion device [(
10) Adhesion by passing below! ! (5)
Decorative aggregate (6) is sprinkled on top and dried. The adhesive paint is the same paint as the primer, and is mixed with decorative aggregate (6
) is used by coloring it in a similar color to the basic color, but if necessary, a different color may be used. Although the coating method does not need to be specified as in the case of the primer, roll coating is preferred in view of viscosity.

In Figure 1, the scattering device [(10) is the decorative aggregate (6).
A hopper (11) for supplying water and a supply port (1
2) and a wire mesh (14) arranged below the spreading roll (13). The widths of the supply port (12), the scattering roll (13), and the wire mesh (14) are set slightly larger than the width of the substrate (2). In order to spread the decorative aggregate (6) non-uniformly, a large number of depressions (15) are irregularly formed on the circumferential surface of the spreading roll (13). As shown in Figure 4, the depression (15)
The recesses are formed to have different opening shapes, frontage areas, cross-sectional shapes, inclinations near the opening edges, etc., and depending on the case, roughening or smoothing is applied to the recessed surfaces.

The decorative aggregate (6) is made of silica sand, crushed rock, crushed ceramic, crushed glass, etc., and has various shapes such as spherical, scaly, and acicular, and has a maximum diameter of 51 mm or less, preferably 0.0 mm. 5
~3wm is used. Then, by mixing multiple types of the granules, or by mixing multiple types of granules colored with paint, dye, etc., and further mixing multiple types of granules adjusted to a constant particle size, etc. Mix to avoid uniformity in color, shape, size, and texture.

The decorative aggregate (6) supplied from the supply port (12) of the hopper (11) is received by the scattering roll (13),
It moves as it rotates and falls along the roll plane. At this time, the inside of the depression (15) is filled with the decorative aggregate (6). Therefore, a larger amount of decorative aggregate (6) falls at the position where the depression (15) is formed than at other locations. In addition, the depression (15) has a generally shallow concave shape, and depending on its cross-sectional shape, the decorative aggregate (6) on the roll surface that is in the same phase position may move earlier or slightly later than the decorative aggregate (6) in the depression (15). Decorative aggregate (6) falls. In other words, depending on the formation position and shape of the depression (15), the decorative aggregate (
6) There is a difference in the timing of the fall. This deviation also changes slightly depending on the mixed composition of the decorative aggregate (6) in the depression (15). Therefore, the decorative aggregate (6) is distributed by the scattering roll (
13) are dispersed non-uniformly not only in the width direction but also in the circumferential direction (over time), and the state of dispersion changes slightly with each rotation of the roll.

By performing such non-uniform dispersion, the substrate (2
) on the tangent Wffl(5), there is a depression (1
5) where the aggregate has fallen from the roll surface (F) and the densely distributed area (G) where the decorative aggregate (6) has been partially oversprayed.
) and a coarse scattering area (H) in which the decorative aggregate (6) is partially dispersed in an insufficient manner are formed irregularly in a mottled pattern.

In the step (D) of removing excess decorative aggregate (6), first, the entire substrate (2) is turned over using a reversing machine (not shown) or tilted at an angle of more than 90 degrees to remove the decorative material that did not adhere to the adhesive 11 (5). If a groove is formed in the aggregate (6) or the substrate (2), the surplus decorative aggregate (6) etc. that have fallen into this groove are allowed to fall. Compressed air is then blown onto the front surface of the substrate (2) to completely remove the decorative aggregate (6) that is likely to fall off and the excess decorative aggregate (6) in the grooves. Even after this step, the coarse and dense pattern formed in the scattering step (C) still remains, although the density is slightly reduced.

In the final step (E), an overcoat layer (7) is formed by spraying a transparent acrylic, urethane, or fluorine paint over the entire surface of the substrate (2). This overcoat layer (7) prevents the decorative aggregate (6) from peeling off and improves the weather resistance of the decorative surface board (1). Furthermore, the entire surface of the surface decorative board (1) is given luster and luster, and complex light reflection is caused particularly at the locations where the decorative aggregate (6) is attached.

According to the surface decorative board (1) obtained as described above, the coarse and dense patterns, which are irregular in size and small, are irregularly continuous in the vertical and horizontal directions. Also,
The visual texture is different between the phase pattern part and the concave pattern part, and the boundaries between each pattern part become unclear. Therefore, on the entire board surface, the irregularity of the color, shape, size, etc. of each decorative aggregate (6) and the irregularity of the appearing pattern, the base layer (4) in the rough pattern area, the contact @1 (5) ) etc. background color and decorative aggregate (6
) and the complex light reflection in overcoat m1 (7), it is possible to improve the visual texture such as depth and solidity, resulting in a decorative surface board with a natural texture. .

(Modified example) In the above embodiment, the substrate (2) was formed from a hydraulic material containing inorganic or organic material, but this is not necessarily necessary, and the substrate (2) can also be formed from a metal plate or a plastic plate. Metal plates include galvanized steel plates, vinyl chloride coated r
There are surface-treated steel plates such as fI steel plates and painted steel plates, aluminum plates, and stainless steel plates. Furthermore, examples of the plastic board include a vinyl chloride board.

The scattering roll (13) is connected to the supply port (1) of the hopper (11).
2) and the adhesive layer (5) of the substrate (2), the decorative aggregate (
It may be provided anywhere as long as it falls along the fall path of 6). For example, a spreading roll without depressions (15) is placed at the supply port (12).
A spreading roll (13) provided with a recess (15) immediately below the
) can be provided below the wire mesh (14) to achieve non-uniform distribution. Further, the depressions (15) may be formed by irregularly arranging a plurality of types of geometric patterns in addition to irregular patterns such as mottled, crater-like, or erosional patterns, and their shapes, sizes, etc. The number, distribution density, etc. are not limited at all.

(Effects of the Invention) As explained above, in the present invention, the decorative aggregate (6) is
By dispersing the material unevenly to form a coarse and dense pattern that is irregular both vertically and horizontally and in size, the visual texture of each coarse and dense pattern can be made different.
Due to these irregularities and the individual irregularities of the decorative aggregate (6), it became possible to obtain a decorative surface board (1) with a natural texture rich in depth and solidity as a whole.

In addition, since the amount of decorative aggregate (6) is spread unevenly to create an irregular pattern, even if the scattering is performed under the same conditions, the pattern that appears will change slightly, resulting in a more natural coarse and dense pattern. This is advantageous in that the pattern can vary widely.

Furthermore, if an overcoat layer (7) is provided as in the above embodiment, weather resistance can be improved and changes in the pattern can be made more conspicuous by complex light reflection.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, and FIG. 1 is a vertical sectional side view of a spraying device, FIG. 2 is an explanatory diagram showing an outline of a manufacturing line for surface decorative laminates, and FIG. 4 is a cross-sectional view showing a blank state of a surface decorative board corresponding to each manufacturing process, FIG. 4 is a perspective view of a spreading roll, and FIG. 5 is a plan view showing a spreading pattern. (1)...Surface decorative board, (2)...Substrate, (3)...
... Waterproof layer, (4) ... Base layer, (5) ... Adhesive layer, (6) ... Decorative aggregate, (10) ... Spreading device,
(11)...hopper, (13)...spreading roll,
(15) ... depression. 1st Figure 185F HF

Claims (2)

[Claims] (1) A base treatment step of forming a waterproof layer (3) on the surface of the substrate (2), and then a base layer (4) on the outer surface of the waterproof layer (3), and an adhesive layer on the outer surface of the base layer (4). a spraying step of applying a paint to form an adhesive layer (5) and scattering a decorative aggregate (6) made of granules onto the adhesive layer (5); (6) into the hopper (1
1), a scattering roll (13) with a large number of irregularly formed depressions (15) on the circumferential surface is interposed in the fall path of the decorative aggregate (6), and this scattering Decorative aggregate (
6) to apply the decorative aggregate (6) to the adhesive layer (5).
A method for manufacturing a surface decorative board, characterized by continuously changing the amount of spraying. (2) The surface of the substrate (2) is formed into an uneven surface, and a waterproof layer and a base layer (4) are sequentially formed on the substrate (2), and then an adhesive layer (5) is formed on the convex portions of the substrate (2). Claim (1) characterized in that the decorative aggregate (6) is dispersed by forming a
The method for manufacturing the surface decorative board described above.