Building board and method for manufacturing the same

Abstract

A building board includes an undercoat coating, an overcoat coating having lower pigment content than the undercoat coating and having different hue from the undercoat coating and having variations in position and thickness, an inkjet coating having different hue from the overcoat coating and is applying partially, and a clear coating successively formed on surface of inorganic base material having a plurality of wood board patterns. There also is provided a method for manufacturing a building board including the steps of applying an undercoat paint to surface of inorganic base material having a plurality of wood board patterns, applying an overcoat paint having lower pigment weight concentration than the undercoat paint and having different hue from the undercoat paint, scraping off a part of the applied overcoat paint before the overcoat paint cures, partially applying inkjet painting having different hue from the overcoat paint, and applying a clear paint.

Claims

1. A building board having on an upper surface thereof a plurality of wood board patterns containing a horizontal, linearly arranged recessed groove for separating at least two of the plurality of the wood board patterns and a plurality of obliquely formed grooved recessed portions for forming the plurality of wood board patterns, the building board comprising: an inorganic base material; an undercoat coating; an overcoat coating; and an inkjet coating, wherein the inorganic base material, the undercoat coating, the overcoat coating, and the inkjet coating are successively formed on the surface of the inorganic base material, the inorganic base material has on an upper surface thereof a plurality of wood board patterns containing a horizontal, linearly arranged recessed groove for separating at least two of the plurality of the wood board patterns and a plurality of obliquely formed grooved recessed portions for forming the plurality of wood board patterns, the undercoat paint has a pigment weight concentration (PWC) of 40 to 60%, the overcoat coating has a lower pigment weight concentration (PWC) than that of the undercoat paint, the undercoat coating and the overcoat coating have different hues, the wood board patterns of the building board have different depths of color due to variations in the position and the thickness of the overcoat coating, and the wood board patterns of the building board have different hues due to partial arrangement of the inkjet coating having a different hue from the overcoat coating.

2. The building board according to claim 1, which has a portion in which the undercoat coating is seen through the overcoat coating.

3. The building board according to claim 1, wherein the overcoat coating is a colored clear coating.

4. The building board according to claim 1, which has a portion in which the overcoat coating is absent on the undercoat coating.

5. The building board according to claim 1, further comprising a clear coating on the inkjet coating.

6. The building board according to claim 1, wherein the building board is produced by a method comprising the steps of: conveying the inorganic base material; applying an undercoat paint to the upper surface of the inorganic base material to form the undercoat on the surface of the inorganic base material; applying an overcoat paint on the undercoat paint to form the overcoat coating; wiping off a part of the applied overcoat paint from the upper surface of the inorganic base material by a roller before the overcoat paint cures, while conveying the inorganic base material, wherein the applied overcoat paint is wiped off from the upper surface of the inorganic base material by rotating the roller in the same direction as the direction in which the inorganic base material is conveyed; drying the overcoat paint by a dryer; and after drying the overcoat paint by the dryer, performing inkjet painting to the upper surface of the inorganic base material, so that a different hue is formed by partially applying an ink having a different hue from that of the overcoat paint by inkjet printing, wherein in the steps of applying the overcoat paint and wiping off a part of the applied overcoat paint, the overcoat paint having a different hue from the undercoat paint is applied and the position and an amount of the overcoat paint applied are varied to make differences in the depth of color among the wood board patterns of the building board.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front view of a building board according to the present invention.

(2) FIG. 2 is a front view of another building board according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(3) Next, embodiments of the present invention will be described.

(4) FIG. 1 is a front view of a building board according to the present invention. A building board A1 includes, as a base material, an inorganic board having on its surface a pattern designed to look like boards of wood joined together. Specifically, wood board patterns a1 to a12 are arranged and formed on the surface of the inorganic board as if they are joined together with a recessed groove interposed between them, and the wood board patterns a1 to a12 have different surface irregularities and different wood board pattern lengths. Moreover, the wood board patterns a1 to a12 are provided with saw blade patterns, which impart a wide variety of irregularities to the wood board patterns a1 to a12. More specifically, in the wood board pattern a1, a plurality of saw blade patterns are provided by forming a plurality of deep, wide, streaky recesses obliquely at intervals. In the wood board pattern a2, a plurality of saw blade patterns are provided by forming a plurality of shallow, narrow, streaky recesses vertically at intervals. In the wood board pattern a3, a plurality of saw blade patterns are provided by forming a plurality of shallow streaky recesses obliquely at intervals. In the wood board pattern a4, a plurality of saw blade patterns are provided by forming a plurality of deep, wide, streaky recesses obliquely at intervals. In the wood board pattern a5, a plurality of saw blade patterns are provided by forming a plurality of shallow streaky recesses obliquely at intervals. In the wood board pattern a6, a plurality of saw blade patterns are provided by forming a plurality of deep, wide, streaky recesses obliquely at intervals. In the wood board pattern a7, a plurality of saw blade patterns are provided by forming a plurality of shallow, narrow, streaky recesses vertically at intervals. In the wood board pattern a8, a plurality of saw blade patterns are provided by forming a plurality of shallow, narrow, streaky recesses obliquely at intervals. In the wood board pattern a9, a plurality of saw blade patterns are provided by forming a plurality of shallow, narrow, streaky recesses vertically at intervals. In the wood board pattern a10, a plurality of saw blade patterns are provided by forming a plurality of shallow, narrow, streaky recesses obliquely at intervals. In the wood board pattern a11, a plurality of saw blade patterns are provided by forming a plurality of deep, wide, streaky recesses obliquely at intervals. In the wood board pattern a12, a plurality of saw blade patterns are provided by forming a plurality of shallow streaky recesses obliquely. That is to say, in the wood board patterns, saw blade patterns of various depths and shapes are provided.

(5) To the surface of this inorganic board, about 10 g/(30.3 cm).sup.2 of a highly weatherproof acrylic emulsion paint containing a pigment at a PWC of about 50% was applied as an undercoat paint and dried with a dryer. Subsequently, about 8 g/(30.3 cm).sup.2 of a highly weatherproof acrylic emulsion paint containing acrylic beads and a pigment at a PWC of about 30% and having a different hue from the undercoat paint was applied to the surface as an overcoat paint. Then, before the overcoat paint cured, a rubber roller was brought into contact with the overcoat paint and rotated in the same direction as the direction in which the board was conveyed (conveyance direction), thereby scraping off the overcoat paint. As described above, since the wood board patterns a1 to a12 are provided with a plurality of saw blade patterns of various depths and shapes, even when the overcoat paint is scraped off uniformly, how the overcoat paint is scraped off varies, and therefore, in the wood board patterns a1 to a12, the position and the amount of the overcoat paint applied vary drastically. Then, after drying with a dryer, inkjet painting with a different hue from the overcoat paint was applied to the dried surface of the wood board patterns a1, a3, a5, and a10 and dried with a dryer. Furthermore, about 8 g/(30.3 cm).sup.2 of a highly weatherproof clear paint containing acrylic beads was applied to the dried surface, followed by drying with a dryer to obtain the building board A1.

(6) As described above, since the undercoat paint and the overcoat paint are applied to the surface of the inorganic board having on its surface the wood board patterns a1 to a12 in which a plurality of saw blade patterns of various depths and shapes are provided, and the overcoat paint is scraped off, the position and the amount of the overcoat paint applied vary drastically, presenting a three-dimensional appearance. Moreover, since inkjet painting is applied to the wood board patterns a1, a3, a5, and a10, the hue varies widely. Furthermore, as can be seen from the wood board patterns a2, a4, a6, a7, a8, a9, and a11, since there are portions where the undercoat coating is seen through the overcoat coating and portions where the overcoat coating is absent on the undercoat coating, the depth of color varies widely.

(7) FIG. 2 is a front view of another building board according to the present invention. A building board A2 also includes the same inorganic board as that in FIG. 1 as a base material. That is to say, wood board patterns b1 to b12 formed on the surface of the inorganic board are the same as the wood board patterns a1 to a12, and a plurality of saw blade patterns of various depths and shapes are provided therein.

(8) The building board was obtained by painting the inorganic board in the same manner as the building board shown in FIG. 1 except that a highly weatherproof clear paint containing acrylic beads and a pigment at a PWC of about 0.5% was applied to the surface of the inorganic board as the overcoat paint. However, in this building board as well, since the undercoat paint and the overcoat paint are applied to the inorganic board having on its surface the wood board patterns b1 to b12 in which a plurality of saw blade patterns of various depths and shapes are provided, and the overcoat paint is scraped off, the position and the amount of the overcoat applied vary drastically. In particular, since a colored clear paint is used as the overcoat paint, the undercoat coating is seen through the overcoat coating, the depth of the color varies widely, and a three-dimensional appearance is presented. Moreover, since inkjet painting is applied, the hue varies widely.

(9) Although embodiments of the present invention have been described above, the present invention is not limited to the above embodiments and can be implemented in various modified forms that fall within the scope of the invention as set forth in the appended claims.

(10) As described above, according to the present invention, it is possible to provide a building board that closely resembles wood and that presents a three-dimensional appearance and a manufacturing method therefor.