Method for manufacturing decorative panel, decorative panel, and wall structure

Abstract

To provide a method for manufacturing decorative panels capable of improving adhesive strength with a decorative film and suppressing swelling and peeling of the decorative film in a substrate having fine pores in its surface layer.SOLUTION: A method for manufacturing a decorative panel comprises: a first base application process for applying a first base coating material to a surface of a substrate having fine pores in its surface layer; a second base application process for applying a second base coating material to the surface of the substrate applied with the first base coating material; and a decorative film stretching and attaching process for stretching and attaching a decorative film after the second base coating material is applied. A second base coating layer formed by the second base coating material is continuously formed on the surface of the substrate having the fine pores on its surface layer at least in a range where the decorative film is stretched and applied to the substrate having the fine pores on its surface layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a decorative panel, a decorative panel, and a wall structure. [Background technology]

[0002] 2. Description of the Related Art Decorative panels intended to give the appearance of a plurality of bricks, stones, tiles, blocks, etc. stacked or pasted together in succession are widely used in architectural wall panels used for exterior and interior decoration.

[0003] Traditionally, paint has been widely used for exterior wall finishes of buildings, while decorative films have been widely used for interior finishes. When trying to reproduce deep colors, colors, metallics, etc., paint has issues such as uneven paint application and the inability to adjust colors in the first place, while decorative films can express the fine colors, gloss, and patterns of prints, and can be said to have a much higher designability than paint.

[0004] If a film is applied directly to an aerated concrete (ALC) panel, an extruded cement board (ECP), a wood-based substrate, etc., the adhesive strength may not be sufficient, and the film may swell. It is believed that the swelling occurs due to the thermal expansion pressure of the moisture contained within these substrates and the moisture in unattached voids. Measures to prevent this include reducing the movement of moisture from inside the substrate and ensuring adhesive strength that exceeds the expansion pressure.

[0005] For example, Patent Document 1 proposes a decorative panel that is inexpensive and effectively prevents the resin sheet from floating or peeling off by forming a water-repellent layer on at least the area of ​​the core panel where the resin sheet is attached. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 5731705 Summary of the Invention [Problem to be solved by the invention]

[0007] However, the technology described in Patent Document 1 only addresses the swelling cause of moisture migration from the core material, and assumes that the core panel is a flat plate made of calcium silicate with a smooth surface for use in interior decoration.

[0008] In particular, cementitious materials such as ALC and ECP are often used for interior and exterior walls, but these materials have many fine pores on the surface and are deeply uneven when viewed in cross section, so the technology described in Patent Document 1 cannot prevent the movement of moisture within the voids and the adhesion is insufficient.

[0009] In particular, the environment in which exterior walls are used can be hotter than interior walls, and there are issues with the adhesive strength not being sufficient, as well as issues with the film swelling due to moisture transfer when the base material is made of a hydrous material. As a result, it has currently been difficult to use decorative panels on exterior walls.

[0010] The present invention has been proposed in consideration of the above-mentioned conventional situation, and an object of the present invention is to provide a method for manufacturing a decorative panel that can improve the adhesive strength between a decorative film and a substrate having fine pores on the surface, thereby suppressing swelling and peeling of the decorative film, and a decorative panel and wall structure that suppress swelling and peeling of the decorative film. [Means for solving the problem]

[0011] Such an object can be achieved by the present invention described below. [1] A first base coating material application step of applying a first base coating material to a surface of a substrate having fine holes in a surface layer; A second base coating material application step of applying a second base coating material to the surface of the base material to which the first base coating material has been applied; A decorative film attachment step of attaching a decorative film after applying the second base coating material, A method for manufacturing a decorative panel, characterized in that, in at least the area of ​​the substrate having fine holes in its surface layer where the decorative film is attached, a second base coating layer formed by the second base coating material is formed continuously on the surface of the substrate having fine holes in its surface layer. [2] The method for manufacturing a decorative panel described in [1], wherein the second base coating material has a viscosity before application of 3000 mPa·s or more and 110000 mPa·s or less. [3] The amount of the second undercoat coating material applied is 0.1 kg / m 2 More than 1.1kg / m 2 A method for manufacturing a decorative panel according to [1] or [2] below. [4] The method for producing a decorative panel according to any one of [1] to [3], wherein the thickness of the second base coating material layer is 40 μm or more and 800 μm or less. [5] The method for producing a decorative panel according to any one of [1] to [4], wherein the arithmetic mean roughness Ra of the surface of the second base coating material layer is 1 μm or more and 10 μm or less. [6] The method for manufacturing a decorative panel according to any one of [1] to [5], further comprising a grinding step of performing a grinding process on the surface of a substrate having fine holes in the surface layer prior to the first base coating material application step. [7] The method for producing a decorative panel according to any one of [1] to [6], wherein the arithmetic mean roughness Ra of the surface of the substrate having fine pores in the surface layer is 1 μm or more and 40 μm or less. [8] The method for producing a decorative panel according to any one of [1] to [7], wherein the substrate having fine pores on the surface layer thereof is a cementitious substrate. [9] The method for manufacturing a decorative panel according to any one of [1] to [8], wherein the second base coating layer penetrates into pores on the surface of a substrate having fine pores on the surface layer to seal the pores.

[10] A method for manufacturing a decorative panel described in any one of [1] to [9], further comprising a third base coating application process for applying a third base coating material onto the second base coating material layer between the second base coating application process and the decorative film attachment process.

[11] The present invention comprises a substrate having fine pores on a surface layer, a first base coating layer provided on the surface layer and / or surface of the substrate having fine pores on the surface layer, a second base coating layer provided on the first base coating layer, and a decorative film attached to the second base coating layer; A decorative panel characterized in that, in at least the area of ​​the substrate having fine holes in the surface layer where the decorative film is attached, the second base coating layer is formed continuously on the surface of the substrate having fine holes in the surface layer.

[12] The decorative panel according to

[11] , wherein the thickness of the second base coating layer is 40 μm or more and 800 μm or less.

[13] The decorative panel according to

[11] or

[12] , wherein the arithmetic mean roughness Ra of the surface of the second base coating layer is 1 μm or more and 10 μm or less.

[14] The decorative panel according to any one of

[11] to

[13] , wherein the first base coating layer and the second base coating layer are waterproof.

[15] The decorative panel according to any one of

[11] to

[14] , wherein the arithmetic mean roughness Ra of the surface of the substrate having the fine pores in the surface layer is 1 μm or more and 40 μm or less.

[16] The decorative panel according to any one of

[11] to

[15] , wherein the substrate having fine pores on the surface layer thereof is a cementitious substrate.

[17] The decorative panel according to any one of

[11] to

[16] , wherein the second base coating layer penetrates into pores on the surface of the substrate having fine pores on the surface layer to seal the pores.

[18] The decorative panel according to any one of

[11] to

[17] , wherein a third base coating layer is laminated between the second base coating layer and the decorative film.

[19] The decorative panel described in any of

[11] to

[18] , wherein the base material has a cutout portion provided along the periphery of at least one side, for forming a joint recess by butting the end faces of two base materials together, and the first base coating layer, the second base coating layer, and the decorative film are arranged in that order in the cutout portion as well.

[20] A wall structure comprising the decorative panel according to any one of

[11] to

[19] . Effect of the Invention

[0012] According to the present invention, it is possible to provide a method for manufacturing a decorative panel that can improve the adhesive strength between a substrate having fine pores on the surface layer and a decorative film and suppress swelling and peeling of the decorative film, as well as a decorative panel and wall structure that suppress swelling and peeling of the decorative film. [Brief description of the drawings]

[0013] [Figure 1] 1 is a cross-sectional view showing a schematic configuration example of a decorative panel of the present invention. [Diagram 2] 1 is a cross-sectional view showing a schematic example of a method for manufacturing a decorative panel of the present invention. [Diagram 3] 1 is a cross-sectional view showing a schematic example of a method for manufacturing a decorative panel of the present invention. [Figure 4] 4 is a cross-sectional view showing a panel butt joint portion of a decorative panel. FIG. [Diagram 5] 4 is an enlarged cross-sectional view showing a panel butt portion of the decorative panel. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] An exemplary embodiment of the present invention (hereinafter, abbreviated as "the present embodiment") will be described in detail below. The present invention is not limited to the present embodiment, and can be practiced with various modifications within the scope of the gist of the present invention. In the present specification, the upper and lower limits of each numerical range can be arbitrarily combined.

[0015] [Decorative panel] First, the decorative panel of the present invention produced by the decorative panel producing method of the present invention will be described. FIG. 1 is a cross-sectional view that illustrates a schematic configuration example of a decorative panel of the present invention. The decorative panel 1 of the present invention comprises a substrate 10 having fine holes 10a in a surface layer, a first base coating layer 11, a second base coating layer 12, and a decorative film 20, which are laminated in this order on the surface layer and / or the surface of the substrate 10 having fine holes 10a in the surface layer, This method is characterized in that the second base coating layer 12 is formed continuously on the surface of the substrate 10 having fine holes 10a on its surface, at least in the area of ​​the substrate 10 where the decorative film 20 is attached.

[0016] In the decorative panel 1 of the present invention, the second base coating layer 12 is formed continuously on the surface of the substrate 10 without any gaps between it and the decorative film 20, that is, the second base coating layer 12 is formed so as to cover over the numerous fine holes 10a (voids) present on the surface of the substrate 10.

[0017] In order to attach a decorative film to a substrate 10 having fine holes 10a on the surface, it is necessary to ensure both adhesion and suppress moisture migration. In the present invention, in order to ensure adhesion, a second base coating layer 12 is provided with the main aim of increasing the adhesion area with the decorative film 20.

[0018] The second base coating layer 12 fills the fine holes 10a on the surface of the substrate 10, making the surface smooth. This increases the adhesion area of ​​the decorative film 20 to the substrate 10 having the fine holes 10a on the surface. As a result, the adhesive strength between the decorative film 20 and the substrate 10 having the fine holes 10a on the surface increases, and peeling of the decorative film 20 can be suppressed.

[0019] In addition, the presence of the second base coating layer 12 suppresses the migration of moisture from the fine pores 10a (voids) in the surface layer of the substrate 10 having fine pores 10a in the surface layer, thereby suppressing swelling and peeling of the decorative film 20.

[0020] Moreover, the first base coating layer 11 (primer layer for the second base coating) ensures adhesive strength between the substrate 10 having the fine pores 10a on the surface layer and the second base coating layer 12.

[0021] <Substrate with fine pores on the surface> An example of the substrate 10 having the fine pores 10a on the surface layer thereof is a substrate made of a porous material.

[0022] In particular, examples of the substrate 10 having fine pores 10a on the surface layer include cementitious substrates, wood substrates, foamed plastic substrates, porous substrates, etc. Examples of the cementitious substrates include an aerated lightweight concrete (ALC) panel and an extruded cement board (ECP).

[0023] Conventionally, it has been difficult to apply a decorative film to a cementitious substrate having fine pores on the surface layer. That is, the cementitious substrate contains (has water inside) because it is hardened by a hydration reaction. There is a risk that the decorative film will easily swell if the water inside the substrate moves to the surface layer, but by adopting an embodiment of the present invention, it has become possible to apply the decorative film 20 while suppressing swelling of the decorative film 20.

[0024] The lightweight aerated concrete panel is a concrete member that can be used as an exterior wall material, specifically, an lightweight aerated concrete panel (ALC panel) such as "Hebel" (registered trademark).

[0025] The thickness of the substrate 10 is, for example, about 98 mm to 152 mm.

[0026] The arithmetic mean roughness Ra of the surface of the substrate 10 having the fine pores 10a on the surface layer is preferably 1 μm or more and 40 μm or less. By making the surface of the substrate 10 smoother, the adhesion area of ​​the decorative film 20 can be increased, and higher adhesive strength can be ensured.

[0027] <First base coating layer> The first base coating layer 11 is provided on the surface layer and / or the front surface of a substrate 10 having fine pores 10a in the surface layer. The first base coating layer 11 is also formed along the inner surfaces of the holes 10a in the surface layer of the substrate 10. In the figure, for ease of explanation, the first base coating layer 11 is shown as being formed on the surface of the substrate 10, but the first base coating applied to the surface of the substrate 10 may penetrate into the surface layer of the substrate 10. Therefore, the first base coating layer 11 may be provided so that at least a part or all of it penetrates into the surface layer of the substrate 10.

[0028] The first base coating layer 11 is a primer layer that serves as an adhesive undercoat layer for the second base coating layer 12, and the first base coating layer 11 ensures adhesion between the substrate 10 and the second base coating layer 12.

[0029] The first base coating layer 11 is preferably waterproof. This makes it possible to further suppress the movement of moisture from the base material 10 side.

[0030] Specifically, for example, the first base coating layer 11, preferably the first base coating layer 11 and the third base coating layer 13 described later, are preferably composed of a base coating material using lightweight aerated concrete as a substrate and having a water permeability of 10 mm or less measured in accordance with 7.12 Water Permeability Test Method A of JIS A 6909:2021. In this way, by using a base coating material with excellent waterproofing properties, the migration of water from inside the substrate 10 can be more reliably prevented.

[0031] The coating material for the first base coating layer 11 is not particularly limited in terms of constituent materials, type, etc., and may be, for example, a synthetic resin emulsion sealer used as an undercoat for interior and exterior finishing coatings such as concrete and cement mortar for buildings.

[0032] Specific examples of the coating material for the first base coating layer 11 include acrylic resin emulsions, epoxy resin emulsions, vinyl chloride emulsions, cationic water-based primers, anionic water-based primers, nonionic water-based primers, and other solvent-based sealers.

[0033] The amount of the first base coating material to be applied is not particularly limited, but is preferably 0.1 kg / m 2 More than 0.4kg / m 2 This ensures sufficient adhesive strength between the substrate 10 and the second base coating material layer 12, and also provides sufficient waterproofing.

[0034] <Second base coating layer> The second base coating layer 12 is formed continuously (over the holes 10a) on the surface of the substrate 10 having fine pores 10a on the surface layer.

[0035] The coating material for the second base coating layer 12 may be a coating material specified in JIS A 6909 Architectural Finishing Coating Materials and JIS A 6916 Architectural Base Adjusting Coating Materials, or a fluororesin paint, a weak solvent type fluororesin paint, or an organic resin filler material. There are no particular limitations on the organic resin-based filler, so long as it is a pigment dispersed in a resin component.

[0036] The type of resin is not particularly limited as long as the pigment is dispersed in the component, and any known resin can be used as is, such as acrylic resin, epoxy resin, urethane resin, amino resin, styrene resin, vinyl acetate resin, and modified resins thereof.

[0037] It is preferable that the second base coating layer 12 penetrates into minute pores 10a in the surface layer of the substrate 10 and blocks the pores 10a. This allows the second base coating layer 12 to be suitably formed continuously on the surface of the substrate 10. In addition, the contact area of ​​the second base coating layer 12 with the first base coating layer 11 also increases, suppressing the movement of air and moisture from the holes 10a of the substrate 10, and more reliably suppressing swelling and peeling of the decorative film 20.

[0038] The second base coating layer 12 may be at least partially inserted into the holes 10a of the substrate 10, but it is preferable that the holes 10a are filled with the second base coating layer 12. This makes the above-mentioned effects more pronounced.

[0039] The second base coating layer 12 is preferably waterproof. This makes it possible to further suppress the movement of moisture from the base material 10 side.

[0040] Specifically, for example, the second base coating layer 12 is preferably formed of a material (base coating material) that satisfies the water permeability test method B described in JIS A 6909. This makes it possible to more reliably prevent the decorative film 20 from swelling or peeling off due to the movement of moisture within the voids (pores 10a) of the base material 10.

[0041] The thickness of the second base coating layer 12 is preferably 40 μm or more and 800 μm or less, and more preferably 150 μm or more and 400 μm or less. The thickness of the second base coating layer 12 is the value from the top of the unevenness of the substrate 10. The coating amount of the second base coating material is 0.1 kg / m 2 More than 1.1kg / m 2 It is preferable to set it to 0.4 kg / m or less. More preferable is 0.4 kg / m 2 More than 0.7kg / m 2 The following should be used. By appropriately setting the amount of the second base coating material applied and the thickness of the second base coating layer 12, the second base coating layer 12 can be suitably formed continuously on the surface of the substrate 10 by straddling the holes 10a on the surface of the substrate 10, preferably by entering the holes 10a on the surface of the substrate 10 and blocking the holes 10a. In addition, the strength and smoothness of the second base coating layer 12 can be ensured. The second base coating material and other coating materials can be applied using a spray, trowel, brush, roller, etc. Also, the coating material may be applied (applied) by attaching a sheet or film-like material that will become the base coating material.

[0042] The arithmetic mean roughness Ra of the surface of the second base coating layer 12 is preferably 1 μm or more and 10 μm or less, and more preferably 1 μm or more and 7 μm or less. By making the surface of the second base coating material layer 12 smoother, the adhesion area of ​​the decorative film 20 can be increased, and higher adhesive strength can be ensured. In this specification, the arithmetic mean roughness Ra of the surface of the second base coating layer 12 and the arithmetic mean roughness Ra of the surface of the substrate 10 are values ​​measured using a surface roughness profiler Surfcom 130A (manufactured by Tokyo Seimitsu Co., Ltd.).

[0043] <Third base coating layer> In the decorative panel 1, a third base coating layer 13 may be laminated between the second base coating layer 12 and the decorative film 20.

[0044] The third base coating layer 13 is a primer layer as an adhesive undercoat layer for the decorative film 20, and the third base coating layer 13 ensures adhesion between the second base coating layer 12 and the decorative film 20. The second base coating layer 12 improves the adhesion area, and synergistically ensures a higher adhesive strength of the decorative film 20.

[0045] The constituent materials and types of such a third base coating layer 13 are not particularly limited, and can be appropriately set according to the material of the decorative film 20.

[0046] Examples of the coating material for the third base coating layer 13 include a solvent-based synthetic resin-based primer, a solvent-based synthetic rubber-based primer, a water-based synthetic resin-based primer, a water-based synthetic rubber-based primer, a silane coupling agent, and a polymeric silane coupling agent.

[0047] The amount of the third base coat applied is 20ml / m 2 More than 80ml / m 2 This ensures sufficient adhesive strength between the second base coating layer 12 and the decorative film 20.

[0048] For example, if an adhesive layer is formed in advance on the decorative film 20 and the adhesive layer can ensure sufficient adhesion to the decorative film 20, the third base coating layer 13 does not need to be provided on the second base coating layer 12. In that case, the decorative film 20 is attached directly onto the second base coating layer 12.

[0049] <Decorative film>

[0050] The decorative film 20 is composed of a base film with decoration or functionality (sensor, lighting, power generation, liquid crystal, etc.), or a decorative layer formed by directly printing or painting the base film, or by arranging a glass layer, microchip, photoelectric conversion layer, etc. on the base film.

[0051] The base film and the contents of the decoration may be any of those conventionally known. The substrate film may be a resin substrate film, a metal substrate film, or the like. Examples of the resin for the resin substrate film include polyolefin resins such as vinyl chloride, polyethylene, polypropylene, polymethylpentene, polybutene, ionomer, ethylene-propylene copolymer, ethylene-propylene-butene copolymer, and olefin thermoplastic elastomer. Examples of the metal substrate film include aluminum foil, nickel foil, copper foil, stainless steel foil, gold foil, tin foil, and brass foil.

[0052] Various known additives can be added to the resin substrate film as necessary, such as colorants for coloring treatment, flame retardants, ultraviolet absorbers, light stabilizers, extender pigments, etc.

[0053] The decoration of the resin substrate film may be appropriately selected from various types of decorative treatments conventionally known for decorative films depending on the application, such as coloring treatment by kneading a colorant into the resin substrate film, forming a decorative layer on the resin substrate film by printing or the like, forming a concave-convex pattern by embossing, adjusting the surface gloss or forming a surface resin layer for the purpose of surface protection, etc., and these decorative treatments may be appropriately combined.

[0054] The pattern of the decorative layer is, for example, a wood grain pattern, a stone grain pattern, a sand grain pattern, a tiled pattern, a brickwork pattern, a fabric pattern, a leather-striped pattern, a geometric figure, letters, symbols, various abstract patterns, or a solid surface, etc. Also used as the decorative layer is a metal thin film layer formed by a method such as vacuum deposition or sputtering using a metal such as aluminum, chromium, gold, silver, or copper. The metal thin film layer is provided partially in a pattern or over the entire surface.

[0055] The thickness of the decorative film 20 is not particularly limited, but is, for example, 50 μm to 300 μm, and preferably 150 μm to 250 μm. The elongation percentage of the decorative film 20 is also not particularly limited, but, for example, the elongation of the film according to JIS A 5759:2016 is preferably 60% or more. When the elongation of the decorative film 20 is 60% or more, the adhesive strength between the substrate 10 and the decorative film 20 can be improved, and swelling or peeling of the decorative film 20 can be suppressed in some cases.

[0056] In this way, in the decorative panel 1 of the present invention, the fine holes 10a present on the surface of the base material 10 are filled with the second base coating layer 12 to smooth the surface properties, thereby increasing the adherend area of ​​the decorative film 20 and ensuring sufficient adhesive strength with the decorative film 20.

[0057] This ensures an adhesive strength equal to or greater than the thermal expansion pressure of moisture from inside the substrate, and makes it possible to manufacture a decorative panel 1 that suppresses peeling of the decorative film 20. In addition, the second base coating layer 12 suppresses moisture migration from the voids (holes 10a) in the substrate 10, making it possible to more reliably suppress swelling and peeling of the decorative film 20.

[0058] In this way, a highly designed panel with almost no design limitations can be realized by finishing with the decorative film 20. Specifically, in addition to dark colors, colored colors, and metallics that have a high risk of causing paint spots with conventional paint finishes, the decorative film 20 can realize designs such as wood grain patterns and stone wall patterns that cannot be reproduced with paint.

[0059] In such a decorative panel 1, the substrate 10 may be exposed on the surface opposite to the surface on which the decorative film 20 is attached and on the side connecting both surfaces (edge ​​surface), or a moisture-permeable coating layer may be formed, or a film having a predetermined function such as moisture permeability may be attached. By covering the edge surface with the base coating layer and the decorative film 20, it may be possible to improve waterproofing against rainwater, etc. entering from the edge.

[0060] The edge of the substrate 10 may be continuously covered with the base coating layer (the first base coating layer 11 to the third base coating layer 13) and the decorative film 20 from the outdoor surface to a range of 1 / 10 to 4 / 10 of the thickness of the substrate 10. This can improve the waterproofing at the edge. If the entire edge is covered, there is a possibility that the thickness of the decorative film 20 may be shifted as the substrate 10 is built up in the panel width direction, so it is preferable to cover it to 4 / 10 or less. In addition, if the distance covering the edge is too short, sufficient waterproofing may not be obtained, so it is preferable to cover it to 1 / 10 or more. The edge of the substrate 10 may be flat, or may have a main processing 5 having an uneven shape, for example, as shown in FIG. 4.

[0061] Also, a joint may be formed at the edge. At least one of the main surfaces of the base material 10, specifically, the main surface 1a that faces the outside when used as an exterior wall material, may have a cutout 2 formed along the periphery. When the end surfaces of two panels 1 are butted together, a butt joint 1b is formed by the butt joint, and a recess (joint recess) 3 is formed by the cutouts 2 that face each other across the butt joint 1b. As shown in FIG. 5, the shape of the recess 3 when viewed in cross section is a rectangle with one side open.

[0062] In addition, the corners of the base material 10 may be chamfered 4 so that the panel is not damaged during transportation, installation, etc. of the base material 10 .

[0063] The substrate 10 has fine holes 10a as described above even in the surface layer of such joints. For example, as shown in FIG. 5, the first base coating layer 11, the second base coating layer 12, and the decorative film 20 may be arranged on the side or the side and bottom of the joint recess 3 of the substrate 10. In addition, the third base coating layer 13 may be laminated between the second base coating layer 12 and the decorative film 20. Note that FIG. 5 shows only the decorative film 20. Note that, when the joint recess 3 is approximately right-angled from the side to the bottom, from the viewpoint of adhesion of the decorative film 20, it is preferable that the decorative film 20 is arranged in the range from the outside of the room to the side.

[0064] Furthermore, a configuration can be adopted in which a backup material 30 is placed on the decorative film 20 placed on the bottom surface of the joint recess 3, a primer layer 31 is provided on the backup material 30 and on the side surface of the joint recess 3, and a sealant 32 is provided on the primer layer 31. At the end portion of the decorative film 20 which is prone to peeling, peeling of the decorative film 20 can be prevented by rolling up the small edge and pressing it with the sealant 32.

[0065] Even in such a joint, it is preferable that the area from the outdoor surface to 1 / 10 to 4 / 10 of the thickness of the substrate 10 is continuously covered with the base coating layer (first base coating layer 11 to third base coating layer 13) and the decorative film 20. Furthermore, by pressing with the sealant 32, peeling of the decorative film 20 can be suppressed and waterproofing can be improved.

[0066] The backup material 30 can be made of a commonly used material such as a polyethylene foam, a non-flammable inorganic fiber material, etc. Also, a bond breaker can be used as the backup material 30.

[0067] The sealing material 32 may be made of various materials such as polysulfide, acrylic urethane, polyurethane, silicone, polyisobutylene, or modified silicone.

[0068] In the above embodiment, the decorative film 20 is provided on one surface of the substrate 10, but the present invention is not limited to this, and the decorative film 20 may be provided on both surfaces of the substrate 10. In that case, the decorative film 20 is similarly attached to the other surface from the surface layer and / or surface of the substrate 10 via the first base coating layer 11 and the second base coating layer 12. A third base coating layer 13 may be disposed between the second base coating layer 12 and the decorative film 20. Furthermore, the end surface of the base material 10 may be subjected to a waterproofing treatment or the like.

[0069] [Manufacturing method of decorative panels] Next, an embodiment of a manufacturing method for a decorative panel according to the present invention will be described. 2 and 3 are cross-sectional views that diagrammatically show an example of a method for producing a decorative panel of the present invention. The method for manufacturing a decorative panel of the present invention includes a first base coating material application step of applying a first base coating material to the surface of a substrate 10 having fine holes 10a in a surface layer, a second base coating material application step of applying a second base coating material to the surface of the substrate 10 to which the first base coating material has been applied, and a decorative film attachment step of attaching a decorative film 20 after applying the second base coating material. This is characterized in that, at least in the area of ​​the substrate 10 having fine pores 10a on its surface where the decorative film 20 is attached, the second base coating layer 12 formed by the second base coating material is formed continuously on the surface of the substrate 10 having fine pores 10a on its surface.

[0070] In the present invention, the second base coating layer 12 is formed continuously on the surface of the substrate 10 without any gap between the decorative film 20, specifically, the second base coating layer 12 is formed across the holes 10a on the surface of the substrate 10, thereby increasing the adhesion area of ​​the decorative film 20. By increasing the adhesion area of ​​the decorative film 20, the adhesive strength is increased, and a decorative panel 1 in which peeling of the decorative film 20 is suppressed can be manufactured.

[0071] Furthermore, by forming the second base coating material layer 12, the movement of moisture from the voids (pores 10a) in the surface layer of the substrate 10 can be suppressed, and swelling and peeling of the decorative film 20 can be suppressed.

[0072] Furthermore, by forming the first base coating layer 11 (primer layer for the second base coating), the adhesive strength between the substrate 10 and the second base coating layer 12 can be ensured.

[0073] <Grinding process> As shown in Fig. 2(a), a cementitious substrate is an example of a substrate 10 having fine pores 10a on the surface layer. Examples of the cementitious substrate include an aerated lightweight concrete (ALC) panel, an extruded cement board (ECP), a wood substrate, a foamed plastic substrate, a porous substrate, and the like.

[0074] Prior to the first base coating material application step, a grinding step may be included in which a grinding treatment is performed on the surface of the substrate 10. This reduces the unevenness of the surface of the substrate 10, increases the area to be adhered to the decorative film 20, and ensures adhesive strength. Furthermore, when the substrate 10 is a cementitious substrate, the adhesive strength with the decorative film 20 can be ensured by removing the brittle layer (latence layer) present on the surface of the substrate 10 by grinding.

[0075] The arithmetic mean roughness Ra of the surface of the substrate 10 having the fine pores 10a on the surface layer is preferably 1 μm or more and 40 μm or less. By making the surface of the substrate 10 smooth, the adhesion area of ​​the decorative film 20 can be increased, and a higher adhesive strength can be ensured. In the present invention, even if the surface of the substrate 10 has an arithmetic mean roughness Ra of 22 μm to 40 μm, the adhesive strength can be ensured by appropriately controlling the viscosity and application amount of the second base coating material, the thickness of the second base coating material layer 12, etc.

[0076] The above-mentioned numerical value of the surface roughness Ra includes both the ground and unground surfaces of the substrate 10. When the surface roughness Ra of the untreated substrate 10 exceeds the upper limit, the surface roughness Ra can be brought within the above range by subjecting the substrate 10 surface to a grinding treatment.

[0077] Furthermore, even if the arithmetic mean roughness Ra of the surface of the substrate 10 exceeds 40 μm, it is possible to increase the adherend area of ​​the decorative film 20 and ensure adhesive strength by forming the second base coating layer 12 thick (for example, thicker than 40 μm).

[0078] <First base coating process> As shown in Fig. 2(b), in the first base coating application step, a first base coating material is applied to the surface of a substrate 10 having fine holes 10a on the surface layer. A first base coating layer 11 is formed by the first base coating material.

[0079] As the first base coating material, a synthetic resin emulsion sealer or the like as described above can be used.

[0080] By forming the first base coating layer 11 (primer layer for the second base coating), the adhesive strength between the substrate 10 and the second base coating layer 12 can be ensured. The first base coating layer 11 is formed not only on the upper surface (convex portion) of the substrate 10 but also along the inner surface of the hole 10a (concave portion). The first base coating material may be permeated into the surface layer of the substrate 10. Therefore, the first base coating material layer 11 may be formed on the surface of the substrate 10, or may be formed by permeating into the surface layer of the substrate 10.

[0081] Furthermore, if the surface of the substrate 10 is uneven, even if the second base coating layer 12 is directly placed on the surface of the substrate 10, it will not be possible to ensure sufficient adhesion between the second base coating layer 12 and the substrate 10. Therefore, it is important that the first base coating layer 11 is formed at least between the convex parts of the surface of the substrate 10 and the second base coating layer 12 in order to increase the adhesion between the second base coating layer 12 and the substrate 10.

[0082] <Second base coating process> As shown in Fig. 2(c), in the second base coating application step, a second base coating material is applied onto the first base coating layer 11. A second base coating layer 12 is formed by the second base coating material. By forming the second base coating layer 12, the movement of moisture from the voids (holes 10a) in the substrate 10 is suppressed, thereby making it possible to manufacture a decorative panel 1 in which swelling and peeling of the decorative film 20 is suppressed.

[0083] Even if the second base coating layer 12 could be formed up to the bottom of the hole 10a, the contact area with the decorative film 20 would not be sufficient. Therefore, the second base coating material needs to have a viscosity sufficient to fill the hole 10a (void) on the surface of the substrate 10 while suppressing absorption into the substrate 10.

[0084] For this reason, it is preferable to use a second base coating material whose viscosity before application is 3000 mPa·s or more and 110000 mPa·s or less, and it is even more preferable to use one whose viscosity is 80000 mPa·s or more and 110000 mPa·s or less. The viscosity of the coating material can be measured using a B-type or BH-type viscometer at a rotation speed of 20 rpm and a coating material temperature of 23°C. The rotor number (spindle) can be changed according to the viscosity to be measured.

[0085] In this way, by using a second base coating material with a relatively high viscosity, when the base coating material is applied to the substrate 10 on which the first base coating layer 11 has been formed to form the second base coating layer 12, the second base coating layer 12 can be formed continuously on the surface of the substrate 10, spanning over the voids (holes 10a) on the surface of the substrate 10, while suppressing absorption of the second base coating material into the substrate 10.

[0086] If the viscosity of the second base coating material is less than 3000 mPa·s, it will become highly fluid and will penetrate too far into the bottom of the holes 10a in the substrate 10, making it difficult to achieve a smooth surface for the second base coating material layer 12 and making it more likely for gaps to form between the second base coating material layer 12 and the decorative film 20. This may ultimately lead to a decrease in the adhesion between the second base coating layer 12 and the decorative film 20. On the other hand, if the viscosity exceeds 110,000 mPa·s, the fluidity decreases, the workability during application (for example, trowel application) decreases, and the second base coating material becomes difficult to penetrate into the holes 10a of the substrate 10, making it difficult to finish the surface smoothly. In consideration of ensuring the smoothness and adhesive strength of the second base coating layer 12, it is more preferable to use a coating material with a viscosity of 80,000 mPa·s or more and 110,000 mPa·s or less.

[0087] As the second undercoat coating material, the above-mentioned organic resin-based filler material or the like can be used.

[0088] When the second base coating material is an organic resin-based filler material, it is preferable that the acrylic resin emulsion is 5% to 30% by weight, and the pigment is 50% to 90% by weight. By setting the blending amounts of the acrylic resin emulsion and the pigment within the above ranges, the performance (film-forming properties, waterproof properties, smoothness, etc.) of the second base coating material layer 12 can be maintained.

[0089] If the content of the acrylic resin emulsion is less than 5% by weight, the waterproofness of the second base coating layer 12 is insufficient. If the content exceeds 30% by weight, the cost becomes high and it takes time for the moisture to escape from the second base coating layer 12 after application, resulting in a lack of film-forming properties. If the pigment is less than 50% by weight, the viscosity of the second base coating material will be low, making it difficult to achieve a smooth surface for the second base coating material layer 12 after formation.

[0090] It is preferable that the second base coating layer 12 penetrates into the pores 10a on the surface of the substrate 10 having fine pores 10a in the surface layer, and blocks the pores 10a. The contact area between the second base coating layer 12 and the first base coating layer 11 is also increased, and the air and moisture coming out of the holes 10a of the substrate 10 can be more effectively suppressed. In addition, the strength and smoothness of the second base coating layer 12 can be ensured.

[0091] It is preferable to use a second base coating material that satisfies the water permeability test method B specified in JIS A 6909. Swelling and peeling of the decorative film 20 caused by the movement of moisture within the voids (pores 10a) of the base material 10 can be suppressed.

[0092] The thickness of the second base coating layer 12 is preferably 40 μm or more and 800 μm or less, and more preferably 150 μm or more and 400 μm or less. By forming the second base coating layer 12 thicker, the second base coating layer 12 can be preferably formed continuously on the surface of the substrate 10 by straddling the holes 10a on the surface of the substrate 10, preferably by penetrating the holes 10a on the surface of the substrate 10 and blocking the holes 10a. In addition, the strength and smoothness of the second base coating layer 12 can be preferably ensured.

[0093] If the thickness of the second base coating layer 12 is too thick, the workability during application of the second base coating material is reduced, and the shrinkage of the second base coating material is increased. If the thickness of the second base coating layer 12 is too thin, the above-mentioned purpose cannot be achieved.

[0094] The arithmetic mean roughness Ra of the surface of the second base coating layer 12 is preferably 1 μm or more and 10 μm or less, and more preferably 1 μm or more and 7 μm or less. The smoother surface of the second base coating layer 12 allows the area to which the film is adhered to to be increased, ensuring higher adhesive strength.

[0095] <Third base coating process> Prior to the decorative panel attaching step, a third base coating material application step of applying a third base coating material onto the second base coating material layer 12 may be further provided.

[0096] As shown in Fig. 3(d), in the coating step, a third base coating material is applied onto the second base coating material layer 12. A third base coating material layer 13 is formed by the third base coating material. By forming the third base coating layer 13 (primer layer for decorative film), it is possible to ensure the adhesive strength between the second base coating layer 12 and the decorative film 20. Combined with the improvement in the adhesion area by the second base coating layer 12, it is possible to synergistically ensure a higher adhesive strength.

[0097] As the third undercoat coating material, a known material known as an adhesive primer as described above can be used.

[0098] The first base coating material is a primer for the base material, and the third base coating material is a primer for the decorative film. By selecting the appropriate one for each, compatibility with the object to be bonded is improved, and as a result, adhesive strength can be improved more effectively.

[0099] <Decorative film application process> As shown in FIG. 3(e), in the decorative film attaching step, a decorative film 20 is attached onto the third base coating material layer 13. Conventionally, it has been difficult to apply a decorative film to a cementitious substrate having fine pores on the surface, but in the method of the present invention, the fine pores 10a present on the surface of the substrate 10 are filled with the second base coating layer 12 to smooth the surface properties, thereby increasing the adhesion area of ​​the decorative film 20 and ensuring sufficient adhesive strength with the decorative film 20. This ensures an adhesive strength equal to or greater than the thermal expansion pressure of moisture from inside the substrate, and makes it possible to manufacture a decorative panel 1 that suppresses peeling of the decorative film 20. In addition, the second base coating layer 12 suppresses moisture migration from the voids (holes 10a) in the substrate 10, making it possible to more reliably suppress swelling and peeling of the decorative film 20.

[0100] Furthermore, by forming the third base coating layer 13, the adhesive strength between the second base coating layer 12 and the decorative film 20 can be secured. Combined with the improvement in the adhesion area by the second base coating layer 12, a synergistically higher adhesive strength can be secured.

[0101] For example, if an adhesive layer is formed on the decorative film 20 in advance and the adhesive layer can ensure sufficient adhesion to the decorative film 20, the third base coating material application step does not need to be performed. In that case, the decorative film 20 is attached directly onto the second base coating material layer 12.

[0102] Through the above steps, the decorative panel 1 as shown in FIG. 1 is manufactured.

[0103] In addition, in the manufacturing method for the decorative panel of this embodiment, at the small edge of the substrate 10, the base coating layers (first base coating layer 11 to third base coating layer 13) and the decorative film 20 may be laminated continuously from the surface of the substrate 10 to a range of 1 / 10 to 4 / 10 of the thickness of the substrate 10 from the outdoor side.

[0104] The manufacturing method for the decorative panel of this embodiment may further include a step of forming a moisture-permeable coating layer on the side of the substrate 10 opposite to the side to which the decorative film 20 is attached, or may include a step of attaching a film having a specified function such as moisture permeability. In addition, a step of subjecting the edge surface of the base material 10 to a waterproofing treatment or the like may be included.

[0105] For example, when the substrate 10 has a joint recess 3, the first base coating layer 11, the second base coating layer 12, and the decorative film 20 may be disposed on the side or the side and bottom of the joint recess 3 of the substrate 10. In addition, the third base coating layer 13 may be laminated between the second base coating layer 12 and the decorative film 20.

[0106] Furthermore, a backup material 30 may be placed on the decorative film 20 placed on the bottom surface of the joint recess 3, a primer layer 31 may be provided on the backup material 30 and on the side surface of the joint recess 3, and a sealant 32 may be provided on the primer layer 31.

[0107] In addition, for example, in the above-mentioned embodiment, the decorative film 20 is attached to one surface of the substrate 10, but the present invention is not limited to this, and the decorative film 20 may be attached to both surfaces of the substrate 10. In that case, the decorative film 20 is attached to the other surface by forming the first base coating layer 11 and the second base coating layer 12 in order from the surface of the substrate 10 in the same manner. A third base coating layer 13 may be formed between the second base coating layer 12 and the decorative film 20.

[0108] <Wall structure> The wall structure of the present invention comprises the decorative panel 1 as described above. This makes it possible to provide a wall structure including a decorative panel 1 that improves the adhesive strength between the base material 10 having fine pores 10a on the surface layer and the decorative film 20, thereby preventing the decorative film 20 from swelling or peeling off.

[0109] <Buildings> Furthermore, the technical concept of the present invention is intended to extend to a building provided with the decorative panel or wall structure as described above.

[0110] The decorative panel or wall structure of the present invention as described above is used, for example, as the exterior wall of a building, but is not limited thereto, and may also be used as the interior wall, partition wall, ceiling wall, floor material, etc. of a building.

[0111] Although the embodiment of the present invention has been described above, the present invention is not limited to this, and can be modified as appropriate without departing from the spirit of the invention. [Industrial Applicability]

[0112] By using the decorative panel according to the present invention, swelling and peeling of the decorative film can be suppressed, and the decorative panel can be widely used as a wall panel for buildings, etc. [Explanation of symbols]

[0113] 1: Decorative panel 1a: Main surface 1b: Butt joint 2: Notch 3: Joint recess 4: Chamfering 5: Real processing 10: Base material 10a: hole 11: First base coating layer 12: Second base coating layer 13: Third base coating layer 20: Decorative film 30: Back-up material 31: Primer layer 32: Sealing material

Claims

1. A first base coating material application step of applying a first base coating material to a surface of a substrate having fine holes in a surface layer; A second base coating material application step of applying a second base coating material to the surface of the base material to which the first base coating material has been applied; A decorative film attachment process for attaching a decorative film after applying the second base coating material; A method for manufacturing a decorative panel, characterized in that, in at least the area of ​​the substrate having fine holes in the surface layer where the decorative film is attached, a second base coating layer formed by the second base coating material is formed continuously on the surface of the substrate having fine holes in the surface layer.

2. The method for manufacturing a decorative panel according to claim 1, wherein the second base coating material has a viscosity before application of 3000 mPa·s or more and 110000 mPa·s or less.

3. The amount of the second base coating material applied is 0.1 kg / m ２ 1.1kg / m or more ２ The method for producing a decorative panel according to claim 1 or 2, wherein:

4. The method for manufacturing a decorative panel according to claim 1 or 2, wherein the thickness of the second base coating material layer is 40 μm or more and 800 μm or less.

5. The method for manufacturing a decorative panel according to claim 1 or 2, wherein the arithmetic mean roughness Ra of the surface of the second base coating material layer is 1 μm or more and 10 μm or less.

6. The method for manufacturing a decorative panel according to claim 1 or 2, further comprising a grinding step of performing a grinding process on a surface of a substrate having fine holes in a surface layer prior to the first base coating material application step.

7. The method for producing a decorative panel according to claim 1 or 2, wherein the arithmetic mean roughness Ra of the surface of the substrate having the fine pores in the surface layer is 1 μm or more and 40 μm or less.

8. The method for producing a decorative panel according to claim 1 or 2, wherein the substrate having fine pores on the surface layer is a cementitious substrate.

9. The method for manufacturing a decorative panel according to claim 1 or 2, wherein the second base coating layer penetrates into pores on the surface of the substrate having fine pores in the surface layer to block the pores.

10. 3. The method for manufacturing a decorative panel according to claim 1 or 2, further comprising a third base coating application step of applying a third base coating material onto the second base coating layer between the second base coating application step and the decorative film attachment step.

11. The present invention comprises a substrate having fine holes in a surface layer, a first base coating layer provided on the surface layer and / or surface of the substrate having fine holes in the surface layer, a second base coating layer provided on the first base coating layer, and a decorative film attached to the second base coating layer; A decorative panel characterized in that, at least in the area of ​​the substrate having fine holes in the surface layer where the decorative film is attached, the second base coating layer is formed continuously on the surface of the substrate having fine holes in the surface layer.

12. The decorative panel according to claim 11, wherein the thickness of the second base coating layer is 40 μm or more and 800 μm or less.

13. The decorative panel according to claim 11 or 12, wherein the arithmetic mean roughness Ra of the surface of the second base coating layer is 1 μm or more and 10 μm or less.

14. The decorative panel according to claim 11 or 12, wherein the first base coating layer and the second base coating layer are waterproof.

15. The decorative panel according to claim 11 or 12, wherein the arithmetic mean roughness Ra of the surface of the substrate having the fine pores in the surface layer is 1 μm or more and 40 μm or less.

16. The decorative panel according to claim 11 or 12, wherein the substrate having fine pores on the surface layer is a cementitious substrate.

17. The decorative panel according to claim 11 or 12, wherein the second base coating layer penetrates into pores on the surface of the substrate having fine pores on the surface layer to block the pores.

18. The decorative panel according to claim 11 or 12, wherein a third base coating layer is laminated between the second base coating layer and the decorative film.

19. The decorative panel described in claim 11 or 12, wherein the base material has a cutout portion provided along the periphery of at least one surface, for forming a joint recess by butting the end faces of two base materials together, and the first base coating layer, the second base coating layer, and the decorative film are arranged in order in the cutout portion as well.

20. A wall structure comprising the decorative panel according to claim 11 or 12.

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