Covering base material and method for producing covering base material

Abstract

To prevent or reduce degradation of an intermediate coat layer formed of an alkali metal silicate coating material due to a factor such as moisture in the air.SOLUTION: An interior finishing material 10 includes: a wooden board 20; an undercoat layer 110 formed by applying a first organic coating material 111 to a plate surface 23 of the wooden board 20; an intermediate coat layer 120 formed by applying an alkali metal silicate coating material 121 to a surface 113 of the undercoat layer 110 with a setback from an end 22 of the wooden board 20; and a top coat layer 131 formed by applying a second organic coating material 131 from a surface 123 of the intermediate coat layer 120 to a surface 122 of the undercoat layer 120 so as to cover an end 122 of the intermediate coat layer 120 and so as to be overlapped with an end 112 of the undercoat layer 110.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a coated substrate and a method for making the coated substrate. [Background technology]

[0002] Patent Document 1 discloses a technique relating to a coated substrate and a manufacturing method thereof. In this prior art, the coated substrate includes a combustible substrate and an alkali metal silicate layer provided on the combustible substrate, and the alkali metal silicate layer contains fibers.

[0003] Patent Document 2 discloses technology related to heavily corrosion-protective coated steel materials such as steel pipe piles, steel pipe sheet piles, and steel sheet piles. In this prior art, a composite coating is formed on the surface of a steel material, with a first primer layer, a corrosion-protective coating layer, a second primer layer, and a protective coating layer laminated on top of each other in that order from bottom to top, and the edges of this composite coating have extensions where the primer layers extend outward beyond the edges of the corrosion-protective coating layers, and these layers are surface-bonded together, resulting in a coating structure in which the edges of the corrosion-protective coating layers are enclosed between the primer layers and the edges of the protective coating layers are bonded to the steel material via the extensions of the primer layers.

[0004] Patent Document 3 discloses a technique for painting the surface of an object to be painted, such as an automobile body, with a first color paint and a second color paint in two different colors. In this prior art, a first color paint is applied to the surface of the object to be painted, on which a base coat has been formed, to form a first coat film, and without baking or curing, a clear coat is applied to the surface to form a clear coat film, and then both coats are baked and cured simultaneously. Next, a masking material is applied to the paint separation part of the clear coat to mask the first coat film side, and further, a colored clear coat is applied to the parts other than this masked part to form a second coat film, which is baked and cured, and then the masking material is removed.

[0005] Patent Document 4 discloses a painting method, particularly a technique for applying a multicolor paint such as a two-tone paint to a surface to be painted. This prior art includes the steps of forming a clear coating layer on a first coating layer formed on the surface to be painted, forming a second coating layer on an area of ​​the first coating layer that is not masked by a masking sheet, and forming a clear coating layer on the second coating layer. The clear coating layer is formed while the first coating layer is masked with a clear masking sheet, and this clear masking is performed while the edge of the clear masking sheet on the side of the parting line between the first and second coating layers is raised to form a gap between the clear masking sheet and the first coating layer. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2018-114724 [Patent Document 2] Japanese Patent Application Publication No. 2019-209670 [Patent Document 3] Japanese Patent Publication No. 136269 / 1983 [Patent Document 4] Japanese Patent Application Laid-Open No. 2016-137436 Summary of the Invention [Problem to be solved by the invention]

[0007] A coated substrate is known that comprises a primer layer formed by applying an organic paint to a flammable substrate, an intermediate coat layer formed by applying an alkali metal silicate paint to the surface of the primer layer, and a top coat layer formed by applying an organic paint to the surface of the intermediate coat layer.

[0008] However, at the edges of the coated substrate, the intermediate coating layer formed from a water-soluble alkali metal silicate paint is exposed to the air, and therefore deterioration due to moisture in the air progresses from the edges, causing peeling, discoloration, etc., and there is a risk of a decrease in fire resistance.

[0009] In view of the above, an object of the present invention is to prevent or inhibit deterioration of an intermediate coating layer formed from an alkali metal silicate paint due to moisture in the air, etc. [Means for solving the problem]

[0010] The first aspect is a coated substrate comprising: a combustible substrate; a primer layer formed by applying a first organic paint to the surface of the combustible substrate; an intermediate coat layer formed by applying an alkali metal silicate paint to the surface of the primer layer and set back from an edge of the combustible substrate; and a top coat layer formed by applying a second organic paint from the surface of the intermediate coat layer to the surface of the primer layer, covering the edge of the intermediate coat layer and overlapping the edge of the primer layer.

[0011] In the coated substrate of the first embodiment, the intermediate coat layer formed with the alkali metal silicate paint is covered by the top coat layer of the second organic paint and is not exposed, so the intermediate coat layer is protected from moisture in the air, etc. Therefore, deterioration of the intermediate coat layer due to moisture in the air, etc. is prevented or suppressed.

[0012] A second aspect is the coated substrate according to the first aspect, wherein a cloth made of glass fiber is embedded in the intermediate coating layer.

[0013] In the coated substrate of the second embodiment, a cloth made of glass fiber is embedded in the intermediate coating layer, which has the effect of suppressing cracking in the intermediate coating layer, suppressing peeling and falling off of the intermediate coating layer from the flammable substrate, and maintaining the thickness of the intermediate coating layer.

[0014] A third aspect is the coated substrate according to the second aspect, wherein the fabric is set back from the end of the intermediate coating layer and embedded therein.

[0015] In the coated substrate of the third embodiment, the glass fiber cloth is set back from the edge of the intermediate coating layer and embedded, preventing the cloth from protruding. Therefore, the glass fiber cloth is not exposed, and the intermediate coating layer is protected from moisture in the air, preventing or suppressing a decrease in fire resistance, peeling, discoloration, etc.

[0016] A fourth aspect is a method for producing a coated substrate, comprising the steps of: applying a first organic paint onto a flammable substrate to form a primer layer; a masking step of applying masking tape onto edges of the primer layer after the primer layer has dried; applying an alkali metal silicate paint onto the primer layer including the masking tape to form an intermediate layer; removing the masking tape together with the edges of the intermediate layer before the intermediate layer dries; and applying a second organic paint so that the second organic paint covers the edges of the intermediate layer and overlaps the edges of the primer layer after the intermediate layer has dried to form a top layer.

[0017] In the fourth embodiment of the method for producing a coated substrate, the intermediate coat layer formed with the water-soluble alkali metal silicate paint is covered by the top coat layer of the second organic paint and is not exposed, so the intermediate coat layer is protected from moisture in the air, etc. Therefore, deterioration of the intermediate coat layer due to moisture, etc. is prevented, thereby preventing a decrease in fire protection performance.

[0018] A fifth aspect is the method for producing a coated substrate according to the fourth aspect, further comprising a step of laying a cloth made of glass fiber on the intermediate coat layer, excluding the edge portions of the primer layer, after the primer layer has dried and before the intermediate coat layer is formed.

[0019] In the fifth embodiment of the method for producing a coated substrate, a cloth made of glass fiber is embedded in the intermediate coating layer, which has the effect of suppressing cracking in the intermediate coating layer, suppressing peeling and falling off of the intermediate coating layer from the flammable substrate, and maintaining the thickness of the intermediate coating layer.

[0020] A sixth aspect is the method for producing a coated substrate according to the fifth aspect, wherein the fabric is laid at a setback from a position that will become an end of the intermediate coating layer.

[0021] In the sixth embodiment of the method for producing a coated substrate, the glass fiber cloth is set back from the edge of the intermediate coating layer and embedded, preventing the cloth from protruding. Therefore, the glass fiber cloth is not exposed, and the intermediate coating layer is protected from moisture in the air, preventing or suppressing a decrease in fire resistance, peeling, discoloration, etc. [Effects of the Invention]

[0022] According to the present invention, deterioration of an intermediate coating layer formed from an alkali metal silicate paint due to moisture in the air or the like can be prevented or suppressed. [Brief explanation of the drawings]

[0023] [Figure 1] 1 is a cross-sectional view taken along the thickness direction of a fireproof layer of a coated substrate according to one embodiment of the present invention. [Figure 2] FIG. 2 is a plan view of a coated substrate according to an embodiment of the present invention, viewed from the thickness direction of a fireproof layer. [Figure 3] 1 is a process diagram of a manufacturing process for a coated substrate according to one embodiment of the present invention. [Figure 4] FIG. 2 is a cross-sectional view taken along the thickness direction of the fireproof layer of the coated substrate of the comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0024] <Embodiment> A coated substrate according to one embodiment of the present invention will be described with reference to the drawings.

[0025] [structure] The structure of an interior material 10 as an example of a coated substrate according to this embodiment will be described below with reference to Figures 1 and 2. Figure 1 is a cross-sectional view of the interior material 10 taken along the thickness direction of a fireproof layer 100 (described later). Figure 2 is a plan view of the fireproof layer 100 of the interior material 10 as seen from the thickness direction.

[0026] It should be noted that each drawing is merely a schematic illustration. Furthermore, the dimensions, ratios, etc. of each element shown in the drawings may not necessarily correspond to the actual ones. Furthermore, the dimensions, ratios, number, etc. of each element may not necessarily correspond between multiple drawings. Furthermore, in this embodiment, explanations of configurations not directly related to the present invention and well-known configurations may be omitted or simplified.

[0027] 2, if the layers described later are opaque, only the topmost top coat layer 130 described later will be visible, and the glass fiber nonwoven fabric 140 and the like will not be visible. Even if the layers described later are transparent or translucent, the boundaries between the layers may be difficult or impossible to distinguish visually. However, each part is shown with a solid line to make the structure easier to understand.

[0028] The interior material 10 of this embodiment shown in FIG. 1 is a component that forms the wall or ceiling surface of a building. The interior material 10 is composed of a wooden board 20, which is rectangular in plan view and serves as an example of a combustible substrate, and a fireproof layer 100 provided on one board surface 23 of the wooden board 20 (see also FIG. 2). The fireproof layer 100 has a three-layer structure including a primer layer 110, an intermediate layer 120, and a top coat layer 130. The fireproof layer 100 is provided on the surface that faces the interior when the interior material 10 is installed indoors. A region 102 at a distance L1 from an end 112 of the primer layer 110 (described below) does not contain the intermediate layer 120 and consists of only two layers, the top coat layer 130 and the primer layer 110. This region is not included in the three-layer fireproof layer 100 that ensures fire resistance. Note that these areas are indicated on the right side of FIG. 1.

[0029] In this embodiment, the undercoat layer 110 is approximately 50 μm, the intermediate coat layer 120 is approximately 280 μm, and the top coat layer 130 is approximately 50 μm, but these thicknesses are not limited to these. Each of these layers may be transparent, semi-transparent, or opaque.

[0030] The primer layer 110 is formed by applying a first organic paint 111 over the entire or nearly entire surface of the board surface 23 of the wood board 20. The intermediate coat layer 120 is formed by applying an alkali metal silicate paint 121 to the surface 113 of the primer layer 110, set back a distance L1 from the end 22 of the wood board 20. From another perspective, the intermediate coat layer 120 is formed by applying an alkali metal silicate paint 121 to the surface 113 of the primer layer 110, set back a distance L1 from the end 112 of the primer layer 110.

[0031] 2, the intermediate coating layer 120 is formed by setting back from the end 22 of each of the four sides of the wood board 20. The area between the end 112 of the primer layer 110 and the end 122 of the intermediate coating layer 120 is defined as an area 102.

[0032] Here, "setback" means that, in a plan view, the end of the upper member is not aligned with the end of the lower member, but is set back in a direction away from the end.

[0033] As shown in Figure 1, the top coat layer 130 is formed by applying a second organic paint 131 from the surface 123 of the intermediate coat layer 120 to the region 102 on the surface 113 of the primer layer 110, covering the end 122 of the intermediate coat layer 120 and overlapping the end 112 of the primer layer 110.

[0034] In the intermediate coating layer 120 of this embodiment, a glass fiber nonwoven fabric 140 having a rectangular shape in plan view, which is an example of a fabric made of glass fiber, is embedded (see FIG. 2). In this embodiment, the glass fiber nonwoven fabric 140 is embedded at a setback distance L2 from the end 122 of the intermediate coating layer 120. As shown in FIG. 2, the glass fiber nonwoven fabric 140 is embedded at a setback distance from the end 122 (see FIG. 1) on each of the four sides of the intermediate coating layer 120.

[0035] In this embodiment, the distance L1 by which the intermediate coating layer 120 is set back is 5.0 mm, but is not limited to this. Similarly, the distance L2 by which the glass fiber nonwoven fabric 140 is set back is 5.0 mm, but is not limited to this.

[0036] [material] Next, the materials of the components that make up the interior material 10 will be described.

[0037] (wood board) The wooden board 20 is a board material that is rectangular in plan view and is made primarily of wood (see FIG. 2). Materials that can be used for the wooden board 20 include solid wood, plywood, laminated lumber, LVL (Laminated Veneer Lumber), CLT (Cross Laminated Timber), structural panels (oriented strand board (OSB)), particle board, and fiberboard.

[0038] (undercoat layer) The primer layer 110 is formed by applying a first organic paint 111, and is a layer that functions to improve adhesion between the wood board 20 and the intermediate coat layer 120. The first organic paint 111 is a water-insoluble organic paint, such as an acrylic resin, polyurethane resin, polyester resin, epoxy resin, or alkyd resin paint. The primer layer 110 may also contain inorganic materials such as silica and alumina.

[0039] (Intermediate coating layer) The intermediate coating layer 120 is formed by applying an alkali metal silicate paint 121 and functions to impart fire resistance to the interior material 10. The alkali metal silicate paint 121 is a water-soluble paint made from alkali metal silicate primarily composed of M2O·nSiO2. Here, M is Na, K, Li, or a combination thereof. n is a molar ratio indicating the number of moles of SiO2 relative to the number of moles of M2O. In this embodiment, the molar ratio is 2.0 to 3.8, preferably 2.0 to 3.3, but is not limited thereto. The alkali metal silicate paint 121 is a paint primarily composed of alkali metal silicate and may contain substances other than alkali metal silicate, such as phosphates and borates.

[0040] (glass fiber nonwoven fabric) The glass fiber nonwoven fabric 140 is a nonwoven fabric made of glass fibers, and is a member having the function of preventing cracks in the intermediate coating layer 120. The glass fiber nonwoven fabric 140 is a nonwoven fabric whose main material is glass fibers.

[0041] (top coat layer) The top coat layer 130 is formed by applying a second organic paint 131, and is a layer that has the function of protecting the intermediate coat layer 120. The second organic paint 131 is a water-insoluble organic paint, and examples of the paint that can be used include acrylic resin-based, polyurethane resin-based, polyester resin-based, silicone resin-based, and fluororesin-based paints.

[0042] [Manufacturing method] Next, a description will be given of an example of a method for manufacturing the interior material 10. In this embodiment, the paints are applied using rollers, but the present invention is not limited to this.

[0043] First, as shown in FIG. 3(A), a first organic paint 111 is applied to the entire surface 23 of the wood board 20 to form an undercoat layer 110.

[0044] As shown in Figure 3(B), after the primer layer 110 has dried, masking tape 30 and glass fiber nonwoven fabric 140 are laid on top of the primer layer 110. The masking tape 30 is laid a distance L1 from the end 112 of the primer layer 110 so as to cover the setback area 102 (see also Figures 1 and 2). The glass fiber nonwoven fabric 140 is laid at a position that will become the end 122 of the intermediate coat layer 120, i.e., a distance L2 setback from the end 32 of the masking tape 30 (see Figures 1 and 2).

[0045] 3(C), an alkali metal silicate paint 121 is applied onto the undercoat layer 110 to form an intermediate coat layer 120. At this time, the alkali metal silicate paint 121 is applied onto the masking tape 30 and the glass fiber nonwoven fabric 140.

[0046] As shown in FIG. 3(D), the masking tape 30 is peeled off before the intermediate coating layer 120 dries, exposing the area 102 of the primer layer 110.

[0047] As shown in FIG. 3(E), after the intermediate coating layer 120 has dried, a second organic coating material 131 is applied on the intermediate coating layer 120 and on the exposed areas 102 of the primer layer 110 to form a top coating layer 130.

[0048] [Effect] Next, the operation of this embodiment will be described. First, an interior material 11 of a comparative example to which the present invention is not applied, as shown in FIG.

[0049] In the comparative interior material 11 shown in Fig. 4, an edge 122 of an intermediate coating layer 120 formed of a water-soluble alkali metal silicate paint 121 is exposed. Therefore, deterioration of the intermediate coating layer 120 progresses from the edge 122 due to moisture in the air, carbon dioxide, etc., and there is a risk that the fire prevention performance will decrease.

[0050] In contrast, in the interior material 10 of this embodiment shown in Figure 1 etc., the end 122 of the intermediate coat layer 120 formed with the water-soluble alkali metal silicate paint 121 is covered with the top coat layer 130 of the water-insoluble first organic paint 111 and is not exposed, so the intermediate coat layer 120 is protected from moisture in the air, etc. Therefore, deterioration of the intermediate coat layer 120 formed with the alkali metal silicate paint 121 due to moisture in the air, etc. is prevented or suppressed. Therefore, a decrease in fire resistance due to deterioration of the intermediate coat layer 120 is prevented or suppressed.

[0051] Furthermore, since the glass fiber nonwoven fabric 140 is embedded in the intermediate coating layer 120, the occurrence of cracks due to thermal expansion of the intermediate coating layer 120 during a fire is prevented or suppressed. This prevents or suppresses a decrease in fire resistance due to cracks in the intermediate coating layer 120. Furthermore, by embedding the glass fiber nonwoven fabric 140, it is possible to obtain effects such as suppressing peeling and falling off of the intermediate coating layer 120 from the wood board 20 and maintaining the thickness of the intermediate coating layer 120.

[0052] Furthermore, the glass fiber nonwoven fabric 140 is set back and embedded from the end 122 of the intermediate coating layer 120, preventing protrusion of the glass fiber nonwoven fabric 140. Therefore, the glass fiber nonwoven fabric 140 is not exposed, and the intermediate coating layer 120 is protected from moisture in the air, etc., preventing or suppressing a decrease in fire resistance, peeling, discoloration, etc.

[0053] Here, the protrusion of the glass fiber nonwoven fabric 140 will be described.

[0054] If the glass fiber nonwoven fabric 140 is not set back from the end 122 of the intermediate coat layer 120, there is a risk that the glass fiber nonwoven fabric 140 will fray or shift when the roller is used to apply the alkali metal silicate paint 121, causing the glass fiber nonwoven fabric 140 to overlap the region 102. If the glass fiber nonwoven fabric 140 overlaps the region 102, the glass fiber nonwoven fabric 140 will protrude from the top coat layer 130, which could reduce fire resistance.

[0055] However, in this embodiment, the glass fiber nonwoven fabric 140 is set back from the end 122 of the intermediate coat layer 120, so even if the glass fiber nonwoven fabric 140 frays or shifts when the alkali metal silicate paint 121 is applied with a roller, the glass fiber nonwoven fabric 140 is prevented or suppressed from protruding from the top coat layer 130. If the glass fiber nonwoven fabric 140 protrudes and penetrates the top coat layer 130 and becomes exposed, the penetration point may become the starting point for deterioration of the intermediate coat layer 120, resulting in a decrease in fire resistance. However, this can be prevented by setting back the glass fiber nonwoven fabric 140 to prevent protrusion.

[0056] Next, the fire resistance of the interior material 10 will be described.

[0057] In the interior material 10 of this embodiment, the intermediate coating layer 120 is formed by setting back from the end 22 on each of the four sides of the wood board 20. In other words, the intermediate coating layer 120 is not formed in the region 102 between the end 112 of the primer layer 110 and the end 112 of the intermediate coating layer 120. The end 122 of the intermediate coating layer 120 is tapered, and the layer thickness gradually decreases. Furthermore, the glass fiber nonwoven fabric 140 is set back from the end 122 of the intermediate coating layer 120 and embedded.

[0058] In this embodiment, the setback distances L1 and L2 are approximately 5.0 mm, so the fire resistance is low and not guaranteed in a width of approximately 10.0 mm from each side of the interior material 10. In particular, the area 102 at distance L1 does not have the intermediate coat layer 120, and has only two layers, the top coat layer 130 and the primer layer 110, so it does not have much fire resistance.

[0059] However, since the area where fire resistance is not guaranteed is small relative to the total area of ​​the board surface 23 of the wooden board 20, the impact on fire resistance is small.

[0060] <Other> The present invention is not limited to the above embodiment.

[0061] For example, in the above embodiment, the coated substrate is an interior material that forms the wall or ceiling surface of a building, but is not limited thereto. The coated substrate to which the present invention is applied can also be used for interior materials such as pillars, beams, flooring, stairs, fittings, and fixtures, and exterior materials such as roofing and exterior wall materials.

[0062] Also, for example, in this embodiment, the combustible substrate is a wooden board 20 made primarily of wood, but this is not limited to this and the combustible substrate may be a wooden substrate that is not in the shape of a board.

[0063] The combustible substrate may also be a combustible substrate formed from a combustible material other than wood, such as polyethylene, polypropylene, polystyrene, polyvinyl chloride, ABS, polycarbonate, methyl acrylate, polymethyl methacrylate, polyurethane, natural rubber, chloroprene rubber, EPDM, fluororesin, polyester, melamine, polyamide, or other resin materials.

[0064] Furthermore, for example, in the above embodiment, the glass fiber nonwoven fabric 140 of the intermediate coating layer 120 is set back, but this is not limited to this. It is sufficient that the end 142 of the glass fiber nonwoven fabric 140 does not protrude from the intermediate coating layer 120. Furthermore, even if the end 142 of the glass fiber nonwoven fabric 140 protrudes from the intermediate coating layer 120, it is sufficient that it does not protrude from the top coating layer 130 and the primer coating layer 110.

[0065] Furthermore, the intermediate coating layer 120 may be made of a cloth formed from glass fibers, such as a glass fiber woven fabric, instead of the glass fiber nonwoven fabric 140. It may also be made of a cloth formed from fibers other than glass fibers, such as ceramic fibers such as carbon fibers, alumina fibers, and silica fibers, resin fibers such as aramid fibers and polypropylene fibers, and metal fibers such as carbon steel fibers, stainless steel fibers, and plated steel fibers. Various fibers, such as the glass fibers described above, may also be dispersed in the intermediate coating layer 120. Any dispersion method may be used. The fibers contained in the intermediate coating layer 120 may be any fibers that can prevent or suppress a decrease in fire resistance due to cracks in the intermediate coating layer 120, for example.

[0066] Furthermore, it is not necessary to embed a cloth made of glass fiber or the like in the intermediate coating layer 120 or to disperse fibers such as glass fiber.

[0067] Furthermore, the present invention can be embodied in various forms without departing from the spirit and scope of the present invention. A plurality of embodiments and modifications can be implemented in combination as appropriate. [Explanation of symbols]

[0068] 10 Interior materials (examples of coated substrates) 20 Wood board (an example of a combustible substrate) 21 Plate surface (an example of the surface of a combustible substrate) 22 End 30 masking tape 100 fire protection layer 110 Undercoat layer 111 Daiichi Organic Paint 112 End 113 Surface 120 Intermediate coating layer 121 Alkali metal silicate paint 122 End 123 Surface 130 Top coat layer 131 Second organic paint 140 Glass fiber nonwoven fabric (an example of fabric made of glass fiber) 142 End

Claims

1. a flammable substrate; a primer layer formed by applying a first organic coating material to the surface of the combustible substrate; an intermediate coating layer formed by applying an alkali metal silicate paint to the surface of the primer layer, the intermediate coating layer being set back from the end of the combustible substrate; a topcoat layer formed by applying a second organic paint from the surface of the intermediate coat layer to the surface of the primer coat layer so as to cover the edge of the intermediate coat layer and overlap the edge of the primer coat layer; A coated substrate comprising:

2. A cloth made of glass fiber is embedded in the intermediate coating layer. The coated substrate of claim 1.

3. The fabric is set back from the end of the intermediate coating layer and embedded. The coated substrate of claim 2.

4. applying a first organic coating material onto a flammable substrate to form a primer layer; a masking step of applying masking tape over the edge of the primer layer after the primer layer has dried; a step of applying an alkali metal silicate paint on the undercoat layer including the masking tape to form an intermediate coat layer; removing the masking tape together with the edge of the intermediate coating layer before the intermediate coating layer dries; After the intermediate coating layer has dried, a second organic coating material is applied to cover the edge of the intermediate coating layer and overlap the edge of the primer coating layer to form a top coating layer; A method for producing a coated substrate comprising:

5. After the primer layer has dried and before the intermediate coat layer is formed, a step of laying a cloth made of glass fiber on the intermediate coat layer except for the end portion of the primer layer is provided. A method for producing the coated substrate according to claim 4.

6. The fabric is laid at a setback from the position that will become the end of the intermediate coating layer. A method for producing the coated substrate according to claim 5.

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