Functional building material, building, and method for manufacturing functional building material

Abstract

To provide a functional building material capable of obtaining high air cleaning performance.SOLUTION: The functional building material 1 includes a base material 10 and a coating film 20 formed on a front face of the base material 10, wherein at least the front face side of the base material 10 is made of wood, and the base material 10 has recesses 13 and projections 14 formed by embossing on the front face thereof, and a height from bottoms of the recesses 13 to tops of the projections 14 is 0.4 to 4mm.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a functional building material, a building, and a method for producing a functional building material. [Background technology]

[0002] Patent Document 1 discloses an air purification method for purifying the indoor space of a building, in which an aqueous coating composition containing charcoal powder is applied to the wall surfaces that make up the indoor space, and the coating surface is negatively charged to capture positively charged particles.

[0003] In this air purification method, the charcoal powder contained in the aqueous paint composition contains both large and small particle sizes, and when it is applied to a wall surface or the like, the small particle size charcoal powder gets into the spaces between the large particle size charcoal powder, thereby increasing the filling rate of the charcoal powder and improving the conductivity of the aqueous paint composition. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2018 / 229850 Summary of the Invention [Problem to be solved by the invention]

[0005] The above-mentioned conventional air purification methods can effectively achieve not only conductivity but also the adsorption of harmful substances, deodorization, humidity control, etc. by increasing the filling rate of charcoal powder in the coating film. However, since there is a limit to the thickness of the coating film of the aqueous paint composition formed on the wall surface, etc., there is room for further improvement in terms of increasing the amount of charcoal powder retained on the wall surface, etc., and thereby improving the air purification performance.

[0006] Therefore, an object of the present invention is to provide a functional building material and building that can provide high air purification performance, as well as a method for producing the functional building material. [Means for solving the problem]

[0007] The object of the present invention is achieved by a functional building material comprising a substrate and a coating film formed on the surface of the substrate, wherein at least the surface side of the substrate is made of wood and has recesses and protrusions formed on the surface by a raised finish process, the height from the bottom of the recesses to the top of the protrusions being 0.4 to 4 mm, and the coating film is formed by filling the recesses with a coating composition containing carbon powder and covering the protrusions.

[0008] In this functional building material, it is preferable that the coating composition further contains coral powder.

[0009] The above object of the present invention is also achieved by a building equipped with the above functional building material.

[0010] The object of the present invention is also achieved by a method for producing a functional building material, comprising the steps of: forming recesses and protrusions on a surface of a substrate, at least the surface side of which is made of wood, by a raised finish process; and applying a coating composition containing carbon powder to the surface of the substrate to form a coating film, wherein the height from the bottom of the recesses to the top of the protrusions is 0.4 to 4 mm, and the coating film is formed by filling the recesses with the coating composition containing carbon powder and covering the protrusions. [Effects of the Invention]

[0011] According to the functional building material and building, and the method for producing a functional building material of the present invention, high air purification performance can be obtained. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a schematic cross-sectional view showing a main part of a functional building material according to one embodiment of the present invention. [Figure 2] FIG. 2 is a process diagram for explaining a method for producing the functional building material shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Fig. 1 is a schematic cross-sectional view showing the main parts of a functional building material according to one embodiment of the present invention. As shown in Fig. 1, the functional building material 1 comprises a substrate 10 and a coating film 20 formed on the surface of the substrate 10, and can be used as, for example, a wall material, a ceiling material, a floor material, a door material, furniture, a shelf board, a partition, etc.

[0014] The substrate 10 is made of wood and formed into a flat plate. The type of wood constituting the substrate 10 is not particularly limited, but it is preferably a coniferous wood such as cedar, cypress, or pine, so as to easily ensure a sufficient level of unevenness on the surface of the substrate 10 by the floating finish process described below. The substrate 10 does not necessarily need to be made entirely of wood in the thickness direction; it is sufficient that at least the surface side is made of wood, for example, by laminating a wooden board on another board.

[0015] The coating film 20 is formed from a coating composition containing carbon powder. As disclosed in the above-mentioned Patent Document 1, a specific example of the coating composition is preferably an aqueous coating composition containing approximately 30% by weight of charcoal powder with a median particle size of 5 to 10 μm, based on the total amount. However, any composition may be used as long as it exhibits functions such as deodorization, air purification, and humidity control, as well as good electrical conductivity after the coating film 20 is formed, and the particle size and content of the charcoal powder are not particularly limited. In this embodiment, charcoal powder is used as the carbon powder, but other porous powders such as binchotan charcoal or activated carbon may also be used.

[0016] The coating composition that forms the coating film 20 further contains coral powder. The median particle size of the coral powder may be similar to that of the charcoal powder, but it is preferably smaller than that of the charcoal powder. This makes it easier for the coral powder to be retained inside the micropores of the charcoal powder, allowing the coral powder to exert its functions of deodorization, antioxidant, VOC decomposition, air purification, antibacterial and antiviral properties for a long period of time. The content of the coral powder is not particularly limited, but can be, for example, about 1 to 9 wt % of the total amount of the aqueous coating composition.

[0017] The functional building material 1 having the above-mentioned configuration can be manufactured by a manufacturing method including a step of forming recesses 13 and protrusions 14 on the surface of the substrate 10 by a embossing process, and a step of applying a coating composition to the surface of the substrate 10 to form a coating film 20.

[0018] The wood (especially coniferous wood) that constitutes at least the surface side of the substrate 10 has a large difference in hardness between the early wood 11 and the late wood 12. Therefore, when the flat surface of the substrate 10 shown in Figure 2(a) is subjected to a floating process by brushing or blasting, only the soft early wood 11 is scraped off, and recesses 13 and protrusions 14 are formed on the surface of the substrate 10, as shown in Figure 2(b).

[0019] 2(b), the height H from the bottom of the recess 13 to the top of the protrusion 14 is made sufficiently larger than the height difference between the recesses and protrusions caused by a typical raised finish applied to decorative boards and the like, so that a large amount of coating composition can be filled into the recess 13, easily increasing the amount of coating film 20 applied to the substrate 10. If the height H is too small, it is difficult to achieve the effect of increasing the amount of coating film, while if it is too large, it becomes difficult to carry out the raised finish and maintain the coating film, so the height H is 0.4 to 4 mm, preferably 0.6 to 1.5 mm, and more preferably 1.0 to 1.5 mm.

[0020] The coating film 20 can be formed on the surface of the substrate 10 by applying the coating multiple times using, for example, a medium-pile roller, and even when there is a large difference in height between the recesses 13 and the protrusions 14 as in this embodiment, the coating film 20 can be formed so that the coating composition fills the entire recesses 13 and covers the entire protrusions 14, thereby easily increasing the amount of coating film 20 applied to the substrate 10. The coating film 20 formed on the recesses 13 is preferably formed so as to rise above the tops of the protrusions 14.

[0021] Because the carbon powder and coral powder contained in the coating composition are both porous, even if the thickness of the coating film 20 is increased due to an increase in the amount applied, the functions of the charcoal powder and coral powder can be effectively exerted throughout the entire thickness of the coating film 20. The coating film 20 of this embodiment contains both charcoal powder and coral powder, but it may also be configured to contain charcoal powder without coral powder.

[0022] The functional building material 1 of this embodiment is preferably placed so that the coating film 20 faces the interior space of various buildings such as wooden warehouses (wooden refrigerators, etc.) and poultry facilities, and by charging the coating film 20 to a negative voltage using a negative voltage generator, it can easily adsorb particles and the like in the interior space.

[0023] To verify the effectiveness of the present invention, three types of sample boards (sample boards 1 to 3) with different surface irregularity heights were prepared, and the coating weight and coating resistance were measured after forming a coating on each surface. Each sample board was made from cedar boards cut to 150 mm x 300 mm. Sample board 1 was left smooth without any surface processing, while sample boards 2 and 3 were subjected to a raised finish. The irregularity height of sample board 2 (height H in Figure 2(b)) was 0.6 mm, and that of sample board 3 was 1.0 mm.

[0024] For each of sample plates 1 to 3, the sides were covered with masking tape to prevent the paint from spilling over, and then a water-based paint composition containing charcoal powder (product name: Health Protect, manufactured by Artec Co., Ltd.) was applied twice using a medium-pile roller. The coating weight and coating resistance after drying are shown in Table 1. Three sheets of each of sample plates 1 to 3 were prepared, and the coating weight was calculated by converting the average value into weight per square meter. Furthermore, the coating resistance was calculated by averaging five points using a tester with a terminal distance of 2.5 cm.

[0025] [Table 1]

[0026] As shown in Table 1, the coating weight of sample plates 2 and 3 was clearly increased compared to that of sample plate 1, with a particularly notable increase of approximately 15% observed for sample plate 3. Both sample plates 2 and 3 were able to retain the coating on their surfaces without peeling. The coating resistance of sample plates 1-3 was below the standard value of 10 kΩ, demonstrating good conductivity. [Explanation of symbols]

[0027] 1 Functional building materials 10 Base material 13 Recess 14 Convex part 20 Paint film

Claims

1. A substrate and a coating film formed on the surface of the substrate, the substrate has at least a surface side made of wood, and has recesses and protrusions formed on the surface by a floating finish, and the height from the bottom of the recesses to the top of the protrusions is 0.4 to 4 mm; The coating film is a functional building material formed by filling the recesses with a coating composition containing carbon powder and covering the protrusions.

2. The functional building material according to claim 1 , wherein the coating composition further comprises coral powder.

3. A building comprising the functional building material according to claim 1 or 2.

4. A step of forming recesses and protrusions on a surface of a substrate, at least the surface side of which is made of wood, by a embossing process; and applying a coating composition containing carbon powder to the surface of the substrate to form a coating film, the height from the bottom of the recess to the top of the protrusion is 0.4 to 4 mm; The coating film is formed by filling the recesses and covering the protrusions with a coating composition containing carbon powder.

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