Coated building material, and manufacturing method of coated building material

Abstract

To provide a coated building material imparted with a detailed design.SOLUTION: A coated building material 1 comprises a substrate 2, a base coating film 4 formed on a surface of the substrate 2, and a color clear coating film 3 formed so as to cover the base coating film 4. The base coating film 4 has a wrinkled recessed pattern portion 41 formed on its surface. In plan view, a color of the color clear coating film 3 located in the recessed pattern portion 41 is darker than color clear coating film 3 located in other portions than the recessed pattern portion 41.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a painted building material and a method for manufacturing the painted building material, and more particularly, to a painted building material suitable for improving designability and a method for manufacturing the painted building material.

Background Art

[0002] Conventionally, there has been a demand for building boards with excellent designability. For this reason, for example, Patent Document 1 proposes a building board including a base material having unevenness formed on the surface, an underlayer provided in close contact with the entire surface of the base material, a colored layer provided on a part of the surface of the underlayer, and an ink layer provided so as to cover the underlayer and the colored layer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the building board as in Patent Document 1, its designability is imparted by the printing pattern when providing each of the underlayer, the colored layer, and the ink layer. For this reason, even if the printing pattern is adjusted, it has been difficult to impart a fine design to the building board.

[0005] The present invention has been made in view of the above points, and an object of the present invention is to provide a painted building material with a fine design imparted thereto and a method for manufacturing the painted building material.

Means for Solving the Problems

[0006] The painted building material according to the present invention includes a base material, a base coating film formed on the surface of the base material, and a color clear coating film formed so as to cover the base coating film. The base coating film has a wrinkled concave mold-like portion formed on its surface. In plan view, the color of the color clear coating film located in the concave mold-like portion is darker than the color of the color clear coating film located in the portion other than the concave mold-like portion.

[0007] In the painted building material according to the present invention, the concave mold-like portion may be formed by checking of the base coating film.

[0008] In the painted building material according to the present invention, a concave portion may be formed on the surface of the base material, and the base coating film provided with the concave mold-like portion may be formed in the concave portion.

[0009] In the painted building material according to the present invention, the concave portion may be formed in a groove shape and may be formed so that the ratio of its width to depth is within the range of 0.5 to 5 mm: 0.3 to 5 mm.

[0010] The manufacturing method of the painted building material according to the present invention includes a base coating film forming step of forming a base coating film on the surface of a base material, a pattern forming step of forming a wrinkled concave mold-like portion on the surface of the base coating film, and a color clear coating film forming step of forming a color clear coating film so as to cover the base coating film after the pattern forming step. In plan view, the color of the color clear coating film located in the concave mold-like portion is darker than the color of the color clear coating film located in the portion other than the concave mold-like portion.

Advantages of the Invention

[0011] According to the present invention, by forming a wrinkled concave mold-like portion on the surface of the base coating film, a painted building material with a fine design can be obtained.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

MODE FOR CARRYING OUT THE INVENTION

[0013] Hereinafter, a mode for carrying out the present invention will be described.

[0014] <Painted building material> The painted building material 1 according to an embodiment of the present invention will be described with reference to FIGS. 1 and 2.

[0015] The painted building material 1 includes a base material 2, a base coating film 4 formed on the surface of the base material 2, and a color clear coating film 3 formed so as to cover the base coating film 4. The base coating film 4 has a wrinkled concave die-like portion 41 formed on its surface. Such a painted building material 1 can be used as an inner wall material or an outer wall material constituting a wall structure of a building or the like.

[0016] The base material 2 is formed in a plate shape. The base material 2 is preferably formed from a material that can be used as a building material. Examples of the base material 2 include ceramic plates (hardened products of hydraulic materials including cement), plastic plates, wooden plates, and metal plates. The base material 2 can include a concavo-convex structure formed on its surface. This concavo-convex structure is composed of a plurality of concave portions 22 and a plurality of convex portions 21. And the concave portion 22 and the convex portion 21 are formed adjacent to each other. Among such concavo-convex structures, a female die-like portion 41 is formed in the concave portion 22. The concave portion 22 may be formed in a groove shape. In this case, the female die-like portion 41 may be formed along the planar shape of the concave portion 22. The groove-shaped concave portion 22 is preferably formed so that the ratio of its width:depth is within the range of 0.5 to 5 mm:0.3 to 5 mm. The width of the concave portion 22 is the distance H between a first side and a second side that are adjacent to each other with the concave portion 22 interposed therebetween in a plan view among a pair of convex portions 21, 21. In this case, the first side is included in the outer peripheral edge surrounding the top surface of one of the convex portions 21, and the second side is included in the outer peripheral edge surrounding the top surface of the other convex portion 21. The depth of the concave portion 22 is the distance D between the bottom surface of the concave portion 22 and the top surface of the convex portion 21. When the heights of the convex portions 21 are different, the depth of the concave portion 22 is preferably the distance between the top surface of the lower one of the convex portions 21, 21 adjacent to each other with the concave portion 22 interposed therebetween and the bottom surface of the concave portion 22. Also, the female die-like portion 41 may be formed in the base coating film 4 of the portion corresponding to the convex portion 21. Examples of the surface shape of the base material 2 having a concavo-convex structure include a stone pattern, a wood grain, a tile shape, and a satin finish. Such a concavo-convex structure can be formed by press molding or roll molding for molding the base material 2.

[0017] The base coating film 4 is formed in close contact over the entire surface of the base material 2. The base coating film 4 is composed of a cured product of a base paint applied to the base material 2. Examples of such a base paint include acrylic emulsion enamel paint. This acrylic emulsion enamel paint is obtained by adding a pigment to an acrylic emulsion paint. Further, the base coating film 4 is provided with a wrinkled concave die-like portion 41. Here, the "wrinkled" in the present embodiment means a shape in which the concave die-like portion 41 is densely provided so that the surface of the base coating film 4 shrinks. Further, the concave die-like portion 41 is formed so as to recess from the surface of the base coating film 4 toward the base material 2. In this case, the bottom of the concave die-like portion 41 may be separated from the surface (coated surface) of the base material 2 or may be located on the surface of the base material 2. When the bottom of the concave die-like portion 41 is separated from the surface of the base material 2, the concave die-like portion 41 is formed by checking of the base coating film 4. When the bottom of the concave die-like portion 41 is located on the surface of the base material 2, the concave die-like portion 41 is formed by cracking of the base coating film 4. Here, the "checking" in the present embodiment includes a shallow concave structure formed due to strain generated in the base paint located in the surface layer among the base paints applied to the base material 2 during curing of the surface layer portion of the base paint. In this case, the surface layer of the base paint is located on the side opposite to the base material 2 in the thickness direction of the applied base paint (or the base coating film 4). Further, "cracking" includes a deep concave structure formed due to strain generated in the base paint during curing of the base paint reaching the surface of the base material 2 in the thickness direction among the base paints applied to the base material 2. At least one of such concave structures, that is, checking and cracking, is formed such that the concave die-like portion 41 is continuously or discontinuously connected along the surface of the coated building material 1 as shown in FIG. 2. The size of the concave die-like portion 41 is, for example, a depth of 100 μm or less and a width of 1 mm or less. In this case, the lower limits of the depth and width of the concave die-like portion 41 are not particularly limited. Examples of the surface shape of the base coating film 4 include a brushed shape and a satin finish shape.

[0018] The coated building material 1 can include a colored layer 5 formed between the color clear coating film 3 and the base coating film 4. In this case, a plurality of colored layers 5 are provided in close contact with a part of the surface of the base coating film 4. The colored layer 5 is formed, for example, in a portion corresponding to the top surface of the convex portion 21 of the base material 2 on the surface of the base coating film 4. The colored layer 5 preferably exhibits an arbitrary color different from that of the base coating film 4. In this case, the portion corresponding to the top surface of the convex portion 21 can be imparted with design properties.

[0019] The colored layer 5 can include a first colored layer 51. In this case, a plurality of first colored layers 51 are provided in close contact with a portion corresponding to the top surface of the convex portion 21 of the base material 2 on the surface of the base coating film 4. The first colored layer 51 is composed of a cured product of an enamel paint applied by a roll coater or the like. Not limited thereto, the first colored layer 51 may be formed by any printing such as flexographic printing, gravure printing, and inkjet printing. In this case, ink can be printed on a portion corresponding to the top surface of the convex portion 21 of the base material 2, and a dried product of the printed ink can be formed as the first colored layer 51. When forming the first colored layer 51 by printing, any ink can be selected according to the purpose. Further, the colored layer 5 can further include a second colored layer 52. The second colored layer 52 exhibits a color different from that of the first colored layer 51 and is formed in close contact with a part of the surfaces of a plurality of first colored layers 51. In this case, the colored layer 5 including only the first colored layer 51 and the colored layer 5 including the first colored layer 51 and the second colored layer 52 are separately formed on the surface of the base coating film 4. The second colored layer 52 is composed of a dried product or a cured product of ink printed by flexographic printing, gravure printing, inkjet printing, or the like. When forming the second colored layer 52 by such printing, any ink can be selected according to the purpose.

[0020] As described above, the color clear coating film 3 is formed so as to cover the base coating film 4. And the color clear coating film 3 is formed in close contact with at least a part of the base coating film 4. When the coated building material 1 includes the colored layer 5, the color clear coating film 3 is formed in close contact with the base coating film 4 and the colored layer 5. Also, the color clear coating film 3 exhibits a color different from that of the base coating film 4. The color clear coating film 3 preferably exhibits a color different from that of the colored layer 5. The color clear coating film 3 is composed of, for example, a cured product of a color clear paint applied by spraying. Among the color clear paint thus applied, the uncured color clear paint flows into the concave pattern portion 41, so that a streak-like pattern is formed along the planar shape of the concave pattern portion 41. Therefore, there is a difference in the thickness of the color clear coating film 3 between the portion where the concave pattern portion 41 is located in plan view and the portion where the concave pattern portion 41 is not formed. In the coated building material 1 having such a streak-like pattern, in its plan view, the color of the color clear coating film 3 located at the concave pattern portion 41 is darker than that of the color clear coating film 3 located at the portion other than the concave pattern portion 41. Also, on the surface of the color clear coating film 3 located above the concave pattern portion 41, a portion where the recess 31 is formed and a portion where the recess 31 is not formed may be provided. When the recess 31 is formed, the recess 31 is formed so as to recess from the surface of the color clear coating film 3 toward the bottom of the concave pattern portion 41. Such a recess 31 is considered to be formed due to the coating amount of the color clear paint and the size of the concave pattern portion 41. Specifically, the recess 31 tends to become larger according to the size of the concave pattern portion 41, and the recess 31 tends to become smaller as the coating amount of the color clear paint increases. Examples of the color clear paint include enamel paint.

[0021] The coated building material 1 may further include a functional layer formed on the surface of the color clear coating film 3. The functional layer is located outside the coated building material 1 and is configured to transmit visible light and have antifouling properties, weather resistance, and water repellency. Since the functional layer has water repellency, it is possible to suppress the adhesion of dirt to the functional layer located on the outermost surface of the coated building material 1, and even if dirt adheres to the functional layer, this dirt can be easily washed away with water or the like.

[0022] The functional layer is a cured product of a coating composition applied by spraying or the like. This coating composition preferably contains a known organopolysiloxane-based resin. By the functional layer containing an organopolysiloxane-based resin, the weather resistance of the coated building material 1 can be improved.

[0023] When imparting antifouling properties to the functional layer, it is preferable to contain a photocatalyst such as titanium oxide in the functional layer. Thereby, when sunlight or the like hits the functional layer located on the outermost surface of the coated building material 1, dirt such as organic compounds adhering to the functional layer can be decomposed by the photocatalyst. Since the decomposed dirt can be easily washed away with water or the like, the antifouling properties of the coated building material 1 can be further improved.

[0024] When imparting water repellency to the functional layer, for example, it is preferable to contain in the functional layer a substance having a functional group such as a saturated fluoroalkyl group, an alkylsilyl group, a fluorosilyl group, or a long-chain alkyl group.

[0025] <Manufacturing method of coated building material> Next, the manufacturing method of the coated building material 1 will be described with reference to FIGS. 3A to 3D. For the detailed description of each component labeled in FIGS. 3A to 3D, reference can be made to the description of the coated building material 1.

[0026] This manufacturing method includes a base coating film forming step, a pattern forming step, and a color clear coating film forming step performed after the pattern forming step.

[0027] In the base coating film forming step, the base paint 4a is applied to the surface of the base material 2 so as to have a predetermined thickness capable of forming the concave pattern portion 41, and the applied base paint 4a is cured to form the base coating film 4. When applying the base paint 4a to the base material 2, the surface temperature of the base material 2 is preferably 40°C or lower. In this case, the lower limit of the surface temperature is not particularly limited, but may be 25°C in practical use. Further, as the coating method of the base paint 4a, for example, an airless spray can be mentioned.

[0028] In this manufacturing method, the pattern forming step is carried out during the base coating film forming step, that is, at a stage prior to completely curing the base paint 4a. The pattern forming step is a step of forming a wrinkled concave pattern portion 41 on the surface of the base coating film 4. When forming the concave pattern portion 41, the base material 2 provided with the uncured base paint 4a is placed in a heating furnace. In this case, it is preferable that the installation period from the end of the application of the base paint 4a to the time of placement in the heating furnace is within 5 seconds. After installation, the base material 2 and the base paint 4a are heated in the heating furnace, and in particular, a part of the base paint 4a located on the surface layer is heated and cured. By such heating, a part of the base paint 4a coated on the base material 2 located on the surface layer instantaneously cures and shrinks, and convection occurs in the inner uncured base paint 4a. In this case, due to the convection generated in the uncured base paint 4a, a force (shrinking force) for shrinking the surface layer of the base paint 4a is generated unevenly during curing. That is, there is a bias in the distribution of the shrinking force. For this reason, strain occurs in the base paint 4a during curing, and due to this strain, the concave pattern portion 41 is formed on the surface of the base coating film 4. In particular, the surface shape of the portion where the concave pattern portions 41 are densely formed becomes wrinkled. When a concave portion 22 is formed on the surface of the base material 2, the base paint 4a is applied to a predetermined thickness at which the concave pattern portion 41 can be formed. Thereafter, by heating, along the planar shape of the concave portion 22 in plan view, the above-described strain is likely to occur, and due to this strain, the concave pattern portion 41 is formed. Further, after the concave pattern portion 41 is formed, the base material 2 and the base paint 4a are further heated in the heating furnace. Thereby, the base paint 4a is completely dried and cured to form the base coating film 4. When heating the base material 2 and the base paint 4a in the heating furnace, it is preferable that the temperature in the furnace is 100 °C or higher and the heating time is 2 minutes or longer. If the base paint 4a can be completely cured in the base coating film forming step, the upper limits of the furnace temperature and the heating time are not particularly limited.

[0029] This manufacturing method can further include a colored layer forming step of forming a colored layer 5 on a part of the surface of the base coating film 4. In this step, the colored layer 5 can be formed by combining a step of applying an enamel paint with a roll coater or the like and a step of printing ink by a printing method such as flexographic printing, gravure printing, and inkjet printing. When performing the colored layer forming step, the temperature of the base material 2 is preferably within a range of, for example, 25 to 40°C. When the colored layer 5 includes a first colored layer 51, the first colored layer 51 can be formed by applying an enamel paint to a part of the surface of the base coating film 4 with a roll coater or the like or printing ink by a printing method such as flexographic printing, gravure printing, and inkjet printing. In particular, it is preferable to form the first colored layer 51 by applying an enamel paint to a part of the surface of the base coating film 4 by roll coater printing and drying and curing the applied enamel paint. When the colored layer 5 includes a second colored layer 52, the second colored layer 52 can be formed by printing ink on a part of the first colored layer 51 by a printing method such as flexographic printing, gravure printing, and inkjet printing. In particular, it is preferable to form the second colored layer 52 by applying ink to a part of the first colored layer 51 by flexographic printing and drying or curing the applied ink.

[0030] In this manufacturing method, after the pattern forming step or after the colored layer forming step, a color clear coating film forming step is performed. The color clear coating film forming step is a step of forming a color clear coating film 3 so as to cover the base coating film 4. In this step, a color clear paint is applied by spraying or the like, and the applied color clear paint is dried and cured to form the color clear coating film 3. When performing the color clear coating film forming step, the temperature of the base material 2 is preferably within a range of, for example, 25 to 40°C. Also, before drying and curing the color clear paint, that is, from the time of painting to immediately after the completion of painting of the color clear paint, the uncured color clear paint is allowed to flow into the concave pattern portion 41. In this way, streak-like patterns are formed along the planar shape of the concave pattern portion 41. By forming such streak-like patterns, in the planar view of the coated building material 1, the color of the color clear coating film 3 located in the concave pattern portion 41 becomes darker than the color of the color clear coating film 3 located in the portions other than the concave pattern portion 41.

[0031] This manufacturing method can further include a functional layer forming step of forming a functional layer on the surface of the color clear coating film 3 after the color clear coating film forming step. In this method, a coating composition is applied by spraying or the like, and the applied coating composition is cured to form the functional layer. The coating composition can contain any functional component such as an organopolysiloxane-based resin.

[0032] By performing the manufacturing method as in this embodiment, it is possible to manufacture the coated building material 1 provided with the above-described effects.

Explanation of Reference Numerals

[0033] 1 Coated building material 2 Base material 3 Color clear coating film 4 Base coating film 41 Concave pattern portion

Claims

1. A coated building material comprising a base material, a base coating film formed on the surface of the base material, and a color clear coating film formed so as to cover the base coating film. The base coating film has a wrinkled concave pattern portion formed on its surface. In plan view, the color of the color clear coating film located at the concave pattern portion is darker than that of the color clear coating film located at portions other than the concave pattern portion. A coated building material.

2. The coated building material according to Claim 1, wherein the concave pattern portion is formed by checking of the base coating film.

3. The coated building material according to Claim 1 or 2, wherein a recess is formed on the surface of the base material, and the base coating film having the concave pattern portion is formed in the recess.

4. The coated building material according to Claim 3, wherein the recess is formed in a groove shape, and the ratio of its width to depth is in the range of 0.5 to 5 mm: 0.3 to 5 mm.

5. A method for manufacturing a coated building material, comprising: a base coating film forming step of forming a base coating film on the surface of a base material; a pattern forming step of forming a wrinkled concave pattern portion on the surface of the base coating film; a color clear coating film forming step of forming a color clear coating film so as to cover the base coating film after the pattern forming step, wherein in plan view, the color of the color clear coating film located at the concave pattern portion is darker than that of the color clear coating film located at portions other than the concave pattern portion. A method for manufacturing a coated building material.

Images