JPH03153307A - Manufacture for decorative wall panel - Google Patents

Abstract

PURPOSE:To manufacture a decorative wall panel which can form easily on a concrete wall a pattern which is rich in a delicate and complicated cubic effect, by a method wherein a mask into which a desired pattern is formed into a state of a through hole is fitted to a mold original sheet against which a grinding grain is blown and a recessed pattern is formed into the surface. CONSTITUTION:A mask 2 having a pattern 1 in a state of a through hole corresponding to a desired pattern is fitted onto a mold original sheet 3 and blast processing is performed by blasting a grinding grain 4 against a mask 2 side. Only a part of the pattern 1 in the state of the through hole of the mold original sheet 3 is ground with the grinding grain 4 through the mask 2, a recessed state pattern 5 corresponding to a desired pattern is formed and a mold 6 is formed. Then the mold 6 is fitted to the inside of a vessel-like mold shuttering 7 into which panel raw material 8 such as cement or mortar are cast, demolded after cure and a decorative wall panel 9 is obtained. In addition, at the time of applying of blast processing to the mold original sheet, since the mold original sheet is covered with the mask to blast only a patterned part, at the time of manufacturing of the blast processing, a method to make the wall panel by making use of electron radiation curing resin and that with cutting processing are available.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing decorative wall panels, and more particularly to a method for forming delicate three-dimensional patterns on concrete surfaces such as interior and exterior walls of buildings and floor members. .

[Conventional technology]

BACKGROUND ART It has been conventional practice to impart arbitrary three-dimensional patterns to concrete structures such as the inner and outer walls of buildings, fences, and roads. Taking a concrete wall as an example, a known method for imparting a three-dimensional pattern to the concrete wall is to create a decorative wall panel with a three-dimensional pattern and attach the panel to a wall base material by adhesive or the like. A known method for manufacturing panels is to pour concrete into a container-shaped formwork having a bottom surface with an uneven pattern corresponding to the surface, and to remove the concrete from the mold after hardening. A three-dimensional ELL is formed on the surface of the obtained panel in accordance with the uneven pattern on the inner surface of the form.

Formwork is usually produced by press-molding a plastic sheet into a container shape, but conventionally, when forming an uneven pattern on the bottom of the formwork, a mold with an uneven pattern engraved is used to heat press. method was adopted.

[Problem to be solved by the invention]

With the conventional method of manufacturing decorative wall panels using formwork, it is possible to express large patterns or simple patterns, but it is difficult to express delicate patterns, such as thin lines or complex patterns. . In addition, it is difficult to arbitrarily change the surface condition of a concrete wall to a glossy surface or matte surface because the material of the mold part is different. Therefore, the design is also restricted and you can freely create a desired pattern on the concrete surface. The drawback was that it was difficult to express it three-dimensionally.

In addition, in order to form a pattern on the formwork using a mold, when manufacturing wall panels with the same pattern, when manufacturing one type of panel with multiple types of different patterns, the number of types It is necessary to prepare a plurality of formworks according to the requirements, which requires time and effort to create the formworks, and also has the disadvantage that the formworks are bulky to transport to the construction site.

The present invention has been made in view of the drawbacks of the above-mentioned prior art.
We have developed a method for manufacturing decorative wall panels that can easily create delicate, complex, three-dimensional patterns on concrete walls.
The purpose is to provide.

[Means to solve the problem]

As a result of intensive research in order to solve the above problems, the present inventors formed a concave pattern on a mold blank by blasting using a mask having a perforated pattern, and combined the thus obtained mold with a formwork. It was discovered that by using this material, delicate three-dimensional patterns can be created.

That is, in the present invention, (+1) a mask formed by forming a desired pattern in the form of punched holes is attached to one surface of a mold blank, and abrasive particles are sprayed from the mask side to form the surface of the mold blank corresponding to the punched hole pattern. A concave pattern is formed on the surface of the mold blank by blasting, a mold having the concave pattern obtained in this way is attached to the inner surface of a container, the panel raw material is poured into the mold, and the mold is hardened and demolded. A manufacturing method for decorative wall panels featuring features;
(2) A mask in which a desired pattern is photographed to make an exposure film, an electron beam is irradiated to the electron beam-cured resin through the exposure film, and a development process is performed to form a perforated pattern in the unexposed areas. The method for manufacturing a decorative wall panel according to (1) above, characterized in that the mask is manufactured and this mask is attached to one side of a mold plate, and (3) a mask formed by forming a hole-like pattern by cutting. A method for manufacturing a decorative wall panel as described in (1) above, characterized in that the method is used.

The present invention will be explained in more detail based on the drawings. As shown in FIG. 1, a mask 2 having a hole-shaped pattern L corresponding to a desired pattern is attached onto a mold blank 3, and abrasive particles 4 are sprayed from the side of the mask 2 to perform blasting. 4
However, only the perforated pattern 10 portion of the mold blank 3 is ground through the mask 2 to form a concave pattern 5 corresponding to the desired pattern as shown in FIG. As shown in FIG. 3, a panel raw material 8 such as cement or mortar is poured into the inner surface of a container-shaped formwork 7, hardened, and then removed from the mold to obtain the decorative wall panel 9 of the present invention. The mask used in this is a mask that is used to cover the mold plate in order to only cover the pattern when blasting the mold plate.
There are two methods: one using electron beam curing resin and the other using cutting.

〔Example〕

Embodiments of the present invention will be described with reference to the drawings. The present invention uses a mask with a hole-like pattern formed thereon, but as a method for manufacturing this mask, the following describes the case where an electron beam curing resin is used.
The creation of the mask 2 will be explained based on FIGS. 5(a) and 5(b). First, a photograph was taken of a document depicting a desired pattern, and a negative or positive exposure film 11 was prepared. This exposure film 11 is stacked on a layer in which an ultraviolet curing resin 12 is held by a cover film 13 and a base film 14, and ultraviolet rays 15 are irradiated from above the exposure film. The resin portions corresponding to the transparent portions are cured by the ultraviolet rays that have passed through the film. When the development process is performed, the unexposed portions of the resin are washed away, leaving only the exposed and hardened portions, and a mask 2 having a hole-shaped pattern 1 is obtained.

Using this mask 2, as shown in FIG. 1, abrasive particles 4 are sprayed onto a mold plate 3 using the pressure of a compressor to perform a plastic process. The part of the mold master plate 3 corresponding to the hole-like pattern 1 of the mask 2 is ground by grinding particles 4,
A concave pattern 5 corresponding to the perforated pattern of the mask 2 is formed, and a mold 6 shown in FIG. 2 is obtained.

Note that resins that are cured by active energy rays other than ultraviolet rays can also be used.

As shown in FIG. 6, a plastic seam 6 of a predetermined thickness is pasted on the entire surface of one side of the mold plate 3, and a base paper 17 with the desired pattern removed is directly pasted onto the sheet 16 using an adhesive or the like. wear. Cut along the desired pattern on the base paper with a cutter knife 18.

Cut out the plastic sheet up to 161ii in Figure 6 (b
) A perforated pattern 1 is formed as shown in FIG.

In this way, the mask 2 is manufactured by cutting.

In this case, the mask is pasted on the mold plate, so
If this is directly subjected to plastic processing, a mold 6 having a concave pattern 5 as shown in FIG. 2 can be similarly obtained.

In the present invention, it is also possible to use both the creation of a mold using an electron beam cured resin and the creation of a mold by cutting. Figure 7 (
As shown in a), a plastic sheet 16 is pasted on one side of a pattern master plate 3, and a base paper 1 with a desired pattern drawn thereon.
7 and cut out the pattern part with a cutter knife along with the plastic sheet to form a mask in the same way as described above. Then, abrasive particles 4 are sprayed on the plastic sheet to create a concave shape as shown in Figure (b). A mold 6 having a pattern 5 is obtained. Furthermore, an exposure film is made from the manuscript with a desired pattern drawn thereon, and a mask 2 with a perforated pattern 1 formed by irradiating and developing it with ultraviolet rays using an ultraviolet curing resin is placed on top of the mold 6, as shown in the same figure. As shown in C), a blast process is further performed to give a pattern different from the already formed concave pattern. An example of using these two methods of molding is forming a leaf pattern. That is, a mask obtained by cutting is used to create the outline and overall pattern of the leaf, and a mask made of ultraviolet curable resin is used to perform a plastic process on the leaf outline pattern to create the fine veins of the leaf. Forms a concave pattern. In this way, contour patterning and internal patterning can be used properly.

In the present invention, a mold 6 created by the above method with a convex pattern 19 formed thereon using a separate member can be used as a mold (FIG. 8); in this case, the concave part formed by the concave pattern 5 The level difference between the convex portion and the convex portion due to the convex pattern 19 becomes very large, and a pattern with a rich three-dimensional effect can be formed. Furthermore, by making the material of the convex pattern different from that of the original plate, it is possible to give the surface of the panel a different surface condition.

In addition, the mold 6 of the present invention allows the depth of the concave pattern to be freely changed. In other words, when performing plastic blast processing, the concave pattern in the desired portion can be changed by changing conditions such as processing time, pressure, and the type of grinding particles. The depth of the pattern can be changed arbitrarily, thereby making it possible to form a stepped pattern as shown in FIG.

The material of the mold plate 6 used in the present invention includes sheet glass,
Various materials include metal plates such as stainless steel, brass, copper, and iron, stones such as marble and granite, resins such as acrylic, polycarbonate, polypropylene, and vinyl chloride, and wood such as china veneer, spesis, and cedar. Among these, plate glass is particularly preferred.

Sheet glass is easy to etch, can be deeply engraved, and is readily available. The thickness of the mold plate 6 is preferably 5 to 20 m, and preferably 8 to 19 m+s.

As the electron beam curing resin used for making the mask, conventionally known resins can be used. As the plastic sheet used to create the mask 2 by cutting, sheets of vinyl chloride, polyethylene, polypropylene, etc. are used. The material for forming the convex pattern shown in FIG. 8 may be any material such as foamed polystyrene or wood.

In addition to the method of directly pasting the base paper onto the plastic sheet, transfer techniques such as stacking the base paper on the plastic sheet and transferring the pattern onto the plastic surface by pressure can also be used to impart the pattern of the base paper onto the plastic sheet. .

FIG. 10 shows a formwork 7 for manufacturing panels using the mold created as described above. created by molding. As shown in FIG. 11(a), insert the mold 6 into the mold frame 7 with the concave pattern 5 of the mold 6 facing upward,
It is fixed to the bottom of the formwork 7 with an adhesive. Next, the same figure (
As shown in b), pour the mortar 2I and, while it is still tacky, pour the concrete 22.

After the mortar and concrete had hardened, they were removed from the mold to obtain a decorative wall panel 9 having a fine pattern 2 on its surface as shown in FIG. 11(c). The panel raw material is not limited to mortar and concrete, but also cement, Ceracola, lysine, etc. can be used.

When forming a wall using the decorative wall panel obtained in this way, it is possible to attach the decorative wall panel directly to the wall base using an adhesive. The adhesive used is a tile adhesive. In addition, it can also be attached to the wall base using metal fittings.In this case, the metal fittings are attached in advance to the surface of the wall base and the back of the decorative wall panel, and then joined using methods such as lining or welding. Installation can be fixed. When the decorative wall panel obtained by the present invention is used to construct the interior and exterior walls, ceiling, floor, or fence of a house, the present invention can apply a design to the surface using a plastic process using a mask and grinding particles. Since the mold pattern is created using the method, it is possible to give the mold a finer three-dimensional pattern compared to the conventional method of forming a mold pattern using heat press.

Therefore, the decorative wall panel manufactured by the method of the present invention has a delicate three-dimensional pattern compared to the decorative wall panel manufactured from a conventional heat press mold, and it is possible to provide an unprecedented design. This has the effect of

Furthermore, the mold master plate is subjected to plastic processing using grinding particles,
In order to form a desired pattern on the mold, fine irregularities are formed on the bottom of the concave pattern of the mold. As a result, according to the present invention,
A three-dimensional pattern corresponding to the concave pattern of the mold can be obtained, and this three-dimensional pattern can be made into a matte pattern.

[Brief explanation of the drawing]

Figures 1 to 4 are explanatory diagrams showing an outline of the method for manufacturing a decorative wall panel of the present invention, and Figures 5 (a) and (b) are diagrams showing a method for manufacturing a mask using ultraviolet curing resin. 6(a) and (b) are explanatory diagrams showing a method of manufacturing a mask by cutting, and FIGS. 7(a) to (c) are masks manufactured using ultraviolet curing resin. FIGS. 8 and 9 are longitudinal sectional views showing other structural examples of the mold according to the present invention, and FIG. FIGS. 11(a) to 11(c), which are perspective views of a form used in manufacturing a decorative wall panel, are explanatory diagrams showing a method of manufacturing a decorative wall panel using a mold. 1. Hole pattern 2. Mask 3. Mold original plate 4. Grinding particles 5. Concave pattern 6. Mold 7. Formwork 8. Mold raw material 9. Decorative wall panel

Claims (3)

[Claims] (1) A mask with a desired pattern formed in the shape of punched holes is attached to one side of the mold plate, and abrasive particles are sprayed from the mask side to form the mold by blasting the surface of the mold plate corresponding to the punched hole pattern. A feature is that a concave pattern is formed on the surface of the original plate, a mold having the concave pattern thus obtained is attached to the inner surface of a container-shaped formwork, the panel raw material is poured into the formwork, and the mold is removed after curing. A method for manufacturing a decorative wall panel. (2) A mask in which a desired pattern is photographed to make an exposure film, an electron beam is irradiated to the electron beam-cured resin through the exposure film, and a development process is performed to form a perforated pattern in the unexposed areas. 2. The method of manufacturing a decorative wall panel according to claim 1, wherein the mask is attached to one surface of a pattern master. (3) The method for manufacturing a decorative wall panel according to claim 1, characterized in that a mask having a hole-like pattern formed by cutting is used.