JPH0263823A - Printed concrete panel and production thereof - Google Patents

Abstract

PURPOSE:To form a printed pattern which is clear an excellent in durability on the surface of an ALC panel by superposing a primer layer, a coating layer having substantially water-impermeability and a printed pattern layer in order on the surface of the ALC panel. CONSTITUTION:Firstly a primer coating having affinity for ALC is applied on the surface of an ALC panel 1 to form a primer 2. Then a first coated layer 3 which is substantially water-impermeable is formed on this surface. There by the comparatively deep unevennesses on the surface are sufficiently filled and this surface is made smooth. Thereafter when the coating layer 3 is dried, contraction due to drying is slightly caused. Therefore synthetic resin emulsion coating is thinly applied to form a second coating layer 4. Then after this coated layer 4 is dried, transfer paper 5 with a natural stone pattern printed thereon is overlapped on the coating layer 4 and pressed by a heating roller 6. Thereafter when the mount of transfer paper 5 is peeled, the printed pattern layer 5a of transfer paper 5 adheres and remains on the coating layer 4 and the natural stone pattern is formed on the surface. A top coating layer 7 is formed on the whole surface and the printed pattern is completed.

Description

[Detailed Description of the Invention] [Objective of the Invention] (Industrial Application Field) The present invention relates to a printed concrete panel made by printing patterns, colors, characters, etc. on the surface of a lightweight aerated concrete (hereinafter referred to as rALcJ) panel; It relates to its manufacturing method.

(Prior Art and Problems to be Solved by the Invention) A conventional method for manufacturing concrete products having patterns etc. printed on their surfaces is disclosed in Japanese Patent Laid-Open No. 102824/1983. When pouring cement slurry into a formwork to form a concrete product, a transfer sheet with the necessary pattern printed on it is placed on the inside of the formwork in advance, and after the slurry has hardened, it is removed from the mold and placed on the surface of the product. This method involves peeling off the attached transfer sheet, leaving only the printed pattern on the surface of the product.

However, this method cannot be directly applied to ALC panels. This is because ALc panels are manufactured by generating a large amount of air bubbles in the raw material slurry during the molding process, which creates minute irregularities on the panel surface, resulting in a loss of sharpness in the printed pattern. be. Furthermore, since this method allows patterns to be applied only to the surface of the molded product, only one patterned panel can be formed using one mold. For this reason, it is not possible to adopt the currently widely used manufacturing method suitable for mass production, in which a large number of panels are cut out from a large block, resulting in a disadvantage of poor productivity.

On the other hand, it is also conceivable to form a printed pattern by applying a unique transfer technique after forming an ALC panel or cutting it out into a panel shape. However, even if such a method is adopted, there is a special circumstance that the ALC panel used for profiteering is highly water-absorbent and water-containing, so the transferred printed pattern layer may be deteriorated by the influence of moisture inside the panel. The printed pattern layer tends to peel off or bulge partially, and as a result, it is not possible to form a good printed pattern layer that is beautiful and durable.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a printed concrete panel that has a clear, large, and highly durable printed pattern on its surface even though it is based on an ALC panel, and which can be manufactured with high productivity. Our goal is to provide the best possible production methods.

[Structure of the Invention] (Means for Solving the Problems) In order to solve the above problems, the printed concrete panel of the present invention includes a primer layer and a substantially water-impermeable coating film on the surface of the ALC panel. A structure in which a layer and a printed pattern layer are sequentially stacked is adopted (invention of claim 1).

Further, a top coat layer may be further provided on the surface of the printed pattern layer (invention of claim 2).

In manufacturing a printed concrete panel with such a configuration, there is a step of forming a primer layer having an affinity for this on the surface of the ALC panel, and a first coating layer is formed on the primer layer using a flattening means. a step of forming;
forming a second coating layer on the surface of the first coating layer by spraying; forming a printed pattern layer on the surface of the second coating layer; and forming a top coat layer on the surface of the printed pattern layer. It is preferable to carry out the steps of forming the same in order (invention of claim 3).

(Function) According to the invention of claim 1, a primer layer and a substantially water-impermeable coating layer are interposed between the surface of the ALC panel and the printed pattern layer (I structure). .

For this reason, the printed pattern layer is not an uneven surface unique to ALC,
It is formed on top of a sufficiently smooth coating layer, resulting in a clear printed pattern.

Further, even if moisture is contained in the ALC panel, the printed pattern layer will not be adversely affected by the moisture because the coating layer is water-impermeable.

According to the second aspect of the invention, the printed pattern layer can be reliably protected by the top coat layer, and the durability is further improved.

According to the third aspect of the invention, the printed concrete panel having the above structure can be easily manufactured. That is, since the first coating layer is formed by the flattening means, it is possible to easily form a coating film that has a thickness that can sufficiently fill the uneven surface peculiar to an ALC panel and has a smooth surface. In addition, the completed A as a base material
Since each process can be carried out for LC panels, it is possible to adopt a manufacturing method suitable for mass production, in which a large block is first formed and then a large number of panels are cut out, greatly increasing overall productivity. can be increased.

(Example) Hereinafter, an example of the present invention will be described with reference to the drawings.

First, the ALC panel 1 as a base material is basically manufactured by mass production means equivalent to conventional methods. That is, the raw material slurry is poured into a mold in which many sets of reinforcing bars have been arranged in advance, and the raw material slurry is foamed and semi-hardened within the mold. Thereafter, this semi-cured block is cut into many panel shapes using piano wire or the like, and then cured in an autoclave to be completely cured.

Now, the ALC panel 1 manufactured as described above has numerous irregularities unique to ALC on its surface, as shown in an enlarged view in FIG. 2. Therefore, first, a primer paint having affinity with ALC is applied to the surface of the ALC panel 1, for example, by spraying or brushing, to form a primer layer 2 as shown in FIG. Next, as shown in FIG. 4, a substantially water-impermeable first coating layer 3 is formed by applying, for example, a synthetic resin emulsion paint to the surface of the primer layer 2 using a blade coater serving as a flattening means. Ru. Since the first coating layer 3 formed by the blade coater is flat and relatively thick, the ALC
Relatively deep irregularities on the surface of the panel 1 are sufficiently filled in and the surface becomes smooth.

As the synthetic resin emulsion paint used here, acrylic, silicone, and other water-repellent resin emulsion paints can be used, and among them, acrylic emulsion paints are most suitable.

After that, when the first coating layer 3 is dried, it undergoes some drying shrinkage as shown in FIG. Therefore, a thin layer of synthetic resin emulsion paint is applied to the surface of the first coating layer 3 by spraying, and as shown in FIG. An Ii film layer 4 is formed. Next, after drying this second coating layer 4, a transfer paper 5 on which a pattern of natural stone such as marble or granite is printed is coated on a second coating layer 4.
It is placed on the coating layer 4 and pressed using, for example, a heating roller 6 as shown in FIG. After that, when the backing paper of the transfer paper 5 is peeled off, the printed pattern layer 5a of the transfer paper 5 becomes the second layer as shown in FIG.
It remains in close contact with the coating layer 4, and a natural stone pattern is formed on the surface of the ALC panel 1. Then, a top coat layer 7 is formed by applying a silica resin paint or a fluorine resin paint to the entire surface of the panel so as to cover the printed pattern layer 5a, thereby completing a printed concrete panel.

In printed concrete panels manufactured as described above, A
Since the substantially water-impermeable coating layer 3.4 is formed between the LC panel 1 and the printed pattern layer 5a, the ALC panel 1 is inherently highly water-absorbing and water-containing. Even if moisture penetrates into the ALC panel 1, it is possible to prevent the printed pattern layer 5a from being adversely affected by the moisture and causing peeling or swelling. This greatly improves the durability of the printed concrete panel. In addition, in order to obtain such an effect, the coating layer 3,
As for water impermeability of No. 4, it is desirable that the water permeability defined by JIS-A6910 is 0.51 or less.

In addition, there is a situation in which countless relatively deep unevenness occurs on the surface of the ALC panel 1.
Since the printed pattern layer 5a is smoothed by the process, it is possible to obtain a delicate and beautiful printed pattern without worrying that the printed pattern layer 5a will lose its sharpness, and even a complex pattern such as the natural stone pattern of this embodiment can be reliably reproduced. be able to. Furthermore, the coating layer 3.4 is A
Since it is applied to the ALC panel 1 via the primer layer 2 which has affinity for the LC panel 1, the ALC panel 1
water absorption is suppressed, and the adhesion between the first coating layer 3 and the ALC panel 1 is improved. For this reason, even if the coating layer 3.4 is formed relatively thick to fill in the irregularities on the surface of the ALC panel 1, the adhesion of the coating layer 3.4 to the ALC panel 1 is extremely large. From this point of view as well, durability can be improved, and the drying shrinkage of the coating layer 3.4 is reduced, further improving smoothness. Furthermore, unlike the conventional method in which transfer paper is placed in advance in the formwork and a printed pattern is applied at the same time as the panel is formed, the process for applying the printed pattern can be carried out separately from the forming of the ALC panel 1. Therefore, as in this embodiment, a manufacturing method suitable for mass production in which a large number of panels are cut out from a large block can be adopted as the manufacturing method of the ALC panel 1, and productivity can be greatly improved. Furthermore, according to this embodiment in which the top coat layer 7 is provided overlapping the printed pattern layer 5a,
The protection of the printed pattern layer 5a is ensured, making it possible to further improve durability and weather resistance, making it particularly suitable for panels to be used outdoors.

Note that the present invention is not limited to the above embodiments, and for example, the method for forming the printed pattern layer is not limited to the transfer method, but also a direct printing method in which printing is performed directly on the coating layer, and a method in which a printed sheet is pasted. can also be applied. Furthermore, the coating layer may be polished with sandpaper, puff, etc. before the formation of the printed pattern layer, and the top coat layer may be formed by a transfer method. A knife coater, a squeeze coater, a roll coater may be used, and the printed pattern is of course not limited to a natural stone pattern, and the present invention can be implemented with various modifications.

[Effects of the Invention] As described above, according to the printed concrete panel of the present invention, since the primer layer and the water-impermeable coating layer are provided between the ALC panel and the printed pattern layer, the ALC
Even if there are circumstances in which the printed pattern layer is inherently highly water-absorbing and water-containing, it is possible to reliably prevent curling, swelling, etc. from occurring in the printed pattern layer for a long period of time, and to obtain a clear printed pattern. In addition, it has many excellent effects such as greatly increasing productivity.

Furthermore, by providing a top coat layer, the durability is significantly improved and it becomes possible to withstand long-term outdoor use.

Furthermore, according to the method of forming the first coating layer by a flattening means and then forming the second coating layer by a spraying means, A.
Even if the surface of the LC panel is deeply uneven, it can be easily smoothed out, which not only allows for clear printed patterns, but also improves the productivity of the above-mentioned excellent panels. You will be able to obtain the effect of being able to produce with

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, in which Fig. 1 is a sectional view showing a printed concrete panel in a completed form, Fig. 2 is a sectional view of an ALC panel, and Fig. 3 is a sectional view after application of a primer layer.
Figure 4 is a cross-sectional view immediately after the formation of the first coating layer, and Figure 5 is a cross-sectional view of the first coating layer.
Figure 6 is a cross-sectional view after the coating layer has dried, Figure 6 is a cross-sectional view after the second paint layer is formed, Figure 7 is a cross-sectional view after the transfer paper has been suppressed, and Figure 8 is a cross-sectional view after the mount of the transfer paper has been peeled off. It is a later sectional view. In the drawing, 1 is an ALC panel (lightweight aerated concrete panel), 2 is a primer layer, 3 is a first coating layer, 4 is a second coating layer, 5 is a transfer paper, 5a is a printed pattern layer, and 7 is a top coat. It is a layer. Patent Applicant Onoda NLC Co., Ltd. Figure 1 Figure 2 Figure Figure Figure [11 Figure

Claims (1)

[Claims] 1. A lightweight aerated concrete panel is characterized in that a primer layer, a substantially water-impermeable coating layer, and a printed pattern layer are sequentially formed on the surface of the lightweight aerated concrete panel. printed concrete panels. 2. Printing characterized by forming a primer layer, a substantially water-impermeable coating layer, a printed pattern layer, and a top coat layer in this order on the surface of a lightweight cellular concrete panel. concrete panel. 3. Forming a primer layer on the surface of the lightweight aerated concrete panel that has an affinity for it; forming a first coating layer on top of the primer layer using a flattening means; A second coating layer is applied to the surface of the first coating layer.
It is characterized by sequentially performing a step of forming a coating layer, a step of forming a printed pattern layer on the surface of this second coating layer, and a step of forming a top coat layer on the surface of this printed pattern layer. A method for producing printed concrete panels.