JP2000240251A - Surface decorative material for building or structure and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a surface decorative material with natural stone type patterns for a building or a structure and its manufacturing method efficiently showing mica thin pieces on the surface side, having its cleavage almost along the surface of the decorative material, and fully exhibiting its scaly brightness. SOLUTION: A first coating material 3 containing synthetic resin emulsion and mica thin pieces 2 is relatively thinly applied on a plate 1 having mold releasing performance and dried, a second coating 5 containing synthetic resin emulsion and aggregate 4 is applied thereon and dried, concrete 6 is poured therein and solidified, and then a frame 7 and the plate 1 are removed therefrom.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thick and deep natural stone-like decorative material for decoration of interior and exterior walls or floors of buildings and for surface finishing of structures, and a method of manufacturing the same. .

[0002]

2. Description of the Related Art (1) A coating material containing a synthetic resin emulsion and a marble powder or other aggregate is coated on a cold gauze made of synthetic fiber, glass fiber or other inorganic fiber, nonwoven fabric, other fabrics, or an appropriate solid substrate. The decorative material, which is applied to the natural stone-like pattern by spraying gun or iron, etc. by appropriate means, is used to decorate the interior or exterior wall or floor of a building or the surface of a building or the surface of a building. (JP-A-4-76151, JP-A-3-2795)
No. 61).

(2) There is also a known finishing method for applying various natural stone patterns by applying a synthetic resin emulsion and an aggregate directly onto the interior / exterior wall surface or floor surface of a building or the surface of a building using a synthetic resin emulsion and an aggregate. I have.

[0004]

According to the above methods (1) and (2), it is possible to finish the surface of a building or a building having an appearance and texture close to that of natural stone, but to break natural stone peculiar to a certain kind of natural stone. In such a case, it is not possible to impart the characteristic scaly brilliancy exhibited by the crystal part developed on the cleavage plane. In other words, for example, natural granite represented by granite is the most typical one made of fine crystals such as feldspar, quartz, muscovite, biotite, etc., and exhibits a peculiar scale-like glitter. ing.

[0005] In order to obtain scaly glittering properties, a coating material containing a synthetic resin emulsion and an aggregate is further mixed with mica flakes in order to artificially obtain a natural stone-like decorative material. As a method, it is conceivable to spray this on a suitable base material with a spray gun or the like and dry it.However, in the decorative material thus obtained, mica flakes are buried inside the decorative material, and There is a problem that it does not appear so much. Even if it appears on the surface, the cleavage plane of the mica flakes does not always appear along the surface of the decorative material, for example, a shape close to perpendicular to the surface of the decorative material ( In other words, there are many cases where the cleavage plane of the mica flake is present on the surface of the decorative material instead of the cleavage plane (of course, it is required that the cleavage plane of the mica flake be completely parallel to the surface of the decorative material). It doesn't matter, and it's fine to have a slight angle.) The mica flakes in such a state have a small light-reflecting surface, so that the scale-like glitter cannot be sufficiently exhibited. Therefore, in the above-mentioned method, even if a relatively expensive mica flake is added, the probability that the mica flake appears on the surface of the decoration material is small, and the probability that the cleavage plane of the mica flake exists substantially along the surface of the decoration material is also low. There is a problem that the efficiency of using small mica flakes is inferior, which is not very practical.

[0006] The present invention solves the above-mentioned problems, and the cleavage plane of the mica flakes exists substantially along the surface of the decorative material, and the scaly brilliancy is sufficiently exhibited. Providing a surface decoration material for a building or building having a natural stone pattern having
The mica flakes efficiently appear on the surface side of the decoration material, and the cleavage plane of the mica flakes exists almost along the surface of the decoration material, and the scale-like brilliancy is sufficiently exhibited, and therefore, has a thickness closer to natural stone An object of the present invention is to provide a method for easily manufacturing a surface decoration material for a building or a building having a natural stone pattern.

[0007]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides the following surface decoration materials for buildings or structures and a method for producing the same.

(1) Mica flakes are dispersed and fixed on the surface layer of a layer in which the aggregate is dispersed in a synthetic resin matrix, with the cleavage plane thereof being substantially along the surface of the decorative material,
A surface decoration material for a building or a building having a natural stone pattern on the surface formed by laminating a concrete layer or a cloth on the back side surface.

(2) The surface decoration material for buildings or structures according to the above (1), further comprising a top coat layer made of a transparent synthetic resin thin film layer on the outermost surface side.

(3) The size of the mica flake is 0.5 to 10 m
m. The surface decoration material for buildings or structures according to any one of the above (1) or (2), wherein m is m.

(4) The surface decoration material for a building or a structure according to any one of the above (1) to (3), wherein the aggregate is an aggregate having a particle size of 0.01 to 3 mm.

(5) The ratio of the synthetic resin solids to the aggregate in the layer in which the aggregate is dispersed in the synthetic resin matrix is as follows:
The surface decoration material for buildings or structures according to any one of the above items (1) to (4), wherein the ratio of the synthetic resin solid content is 5 to 20 parts by weight with respect to 00 parts by weight.

(6) The aggregate is natural stone powder, silica sand, ceramic powder,
The above (1), which is an aggregate selected from the group consisting of glass powder.
A building or a surface decoration material for a building according to any one of (1) to (5).

(7) The building or building according to any one of the above (1) to (6), wherein the mica flakes are at least one kind of mica flakes selected from non-artificial colored mica and artificial colored mica. Surface decoration materials.

(8) The building or surface decoration material for a building according to any one of the above (1) to (7), wherein the synthetic resin is an acrylic synthetic resin.

(9) The surface decoration material for a building or a structure according to any one of the above (1) to (8), which has a smooth surface and a polished natural stone pattern.

(10) The surface decoration material for a building or a structure according to any one of the above (1) to (8), which has an uneven surface and a three-dimensional uneven pattern.

(11) First including a synthetic resin emulsion and mica flakes, or a synthetic resin emulsion, mica flakes and aggregates on the inner lower surface or plate of a mold having releasability.
Is applied relatively thinly, and dried or in an undried state, a second coating material including a synthetic resin emulsion and an aggregate is applied thereon, and the second coating material is not dried. Laminating and drying the fabric thereon to fix the fabric, or after the second coating material is dried, pour concrete onto it and solidify, and then remove the formwork or plate-like material A method for producing a surface decoration material for a building or a building having a natural stone pattern on the surface, characterized by the following.

(12) On the inner lower surface or plate-like material of the mold having releasability, first, a clear coating of synthetic resin which becomes transparent when dried is applied and dried to form a top coat layer. The method for producing a building or a surface decoration material for a building according to the above (11).

(13) The building or structure according to any one of the above (11) or (12), wherein the applied amount of the first coating material is 50 g to ² kg / m ² in the amount applied after drying. Of surface decoration materials for automobiles.

(14) The above (11) to (1), wherein the applied amount of the second coating material is 1 to 10 kg / m ² in terms of the applied amount after drying.
3) The method for producing a building or a surface decoration material for a structure according to any one of the above items.

(15) The first coating material contains a synthetic resin emulsion and mica flakes, and the synthetic resin emulsion has a resin solid content of 50 to 1000 parts by weight based on 100 parts by weight of the mica flakes. 14) The method for producing a building or a surface decoration material for a building according to any one of the above items.

(16) The first coating material contains a synthetic resin emulsion, mica flakes and aggregates, and the synthetic resin emulsion has a resin solid content of 50 to 10 per 100 parts by weight of the mica flakes.
(1) wherein the amount of the aggregate is 20 to 500 parts by weight and the aggregate is 20 to 500 parts by weight.
The method for producing a building or a surface decoration material for a building according to any one of 1) to (14).

(17) The above (11) to (11) wherein the second coating material contains a synthetic resin emulsion and an aggregate, and the synthetic resin emulsion has a resin solid content of 5 to 20 parts by weight based on 100 parts by weight of the aggregate. 16) The method for producing a building or a surface decoration material for a structure according to any one of the above items.

(18) The size of the mica flake is 0.5 to 10
The method for producing a surface decoration material for a building or a structure according to any one of the above (11) to (17), which is mm.

(19) The method according to any one of the above (11) to (18), wherein the aggregate is an aggregate having a particle size of 0.01 to 3 mm.

(20) For a building or a structure according to any one of (11) to (19), wherein the aggregate is an aggregate selected from the group consisting of natural stone powder, silica sand, ceramic powder, and glass powder. Manufacturing method of surface decoration material.

(21) The building or building according to any one of (11) to (20) above, wherein the mica flakes are at least one kind of mica flakes selected from non-artificial colored mica and artificial colored mica. Manufacturing method of surface decoration material.

(22) The above (11) to (21) wherein the synthetic resin emulsion is an acrylic synthetic resin emulsion.
Item 14. A method for producing a building or a surface decoration material for a structure according to any one of the above items.

(23) The building according to any one of the above (11) to (22), wherein at least the surface of the inner bottom surface of the formwork or the plate-like material to which the coating material is applied is a flat surface. Alternatively, a method for producing a surface decoration material for a building.

(24) The building or the building according to any one of the above (11) to (22), wherein at least the inner lower surface of the formwork or at least the surface of the plate-like object to which the coating material is applied is irregular. A method for producing a surface decoration material for a building.

[0032]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In order to facilitate understanding of the present invention, first, an embodiment of a method for manufacturing a surface decoration material for a building or a building according to the present invention will be described with reference to the drawings.
The embodiment described with reference to the drawings is an example, and the present invention is not limited to the illustrated embodiment.

FIG. 1 shows the use of a plate-like material having a releasing property.
It is sectional process drawing which shows the process of forming the building or the surface decoration material for structures of this invention on this.

As shown in FIG. 1 (a), first, on a plate 1 having releasability, a first material containing a synthetic resin emulsion and mica flakes, or a synthetic resin emulsion and mica flakes and an aggregate is used. Is applied relatively thinly. First applied
The coating material layer may be left undried or may be dried if necessary. Reference numeral 2 denotes a mica flake, and reference numeral 3 denotes a first coating material including the mica flake. In this case, the surface side of the decorative material finally obtained becomes smooth, and the cleavage plane of the mica flake 2 is substantially in the direction along the surface of the decorative material. Although the illustrated coating of the first coating material does not cover the entire surface of the plate-like material 1, it may be applied so as to cover the entire surface according to the purpose.

The means for coating is not particularly limited, but may be any such as a spray gun, a trowel, a brush, a roller, etc., as long as the object can be achieved.

Next, as shown in FIG. 1B, the first coating material layer 3
A second coating material 5 containing a synthetic resin emulsion and an aggregate is applied to the surface on which is formed. Reference numeral 4 schematically shows the aggregate in the second coating material. The means for coating is not particularly limited, but may be any such as a spray gun, a trowel, a brush, a roller, etc., as long as the object can be achieved.

Next, after drying the second coating material 5, FIG.
As shown in (c), concrete 6 is poured. At this time, if the concrete is fluid, it is surrounded by an appropriate frame 7 so as not to flow until the concrete is solidified.

Thus, after the concrete is solidified, the plate-like material 1 and the frame 7 are removed, and as shown in FIG. 1 (d), the decorative material of the present invention is obtained. Note that FIG. 1D is upside down from FIG. 1C.

Although not shown, if it is desired to apply a transparent top coat layer to the surface, it is first dried in the step of FIG. The synthetic resin clear paint may be applied thinly and dried to form a top coat layer. In addition, FIG.
A top coat may be applied to the surface of the decorative material obtained in (d) later.

FIG. 3 is a plan view of the decorative material thus obtained as viewed from the front side. 2a is a muscovite flake, 2b is a biotite flake, and these mica flakes appear with their cleavage planes almost along the surface of the decorative material, and the scale-like brilliancy is sufficiently exerted. A natural stone-like decorative material similar to natural stone can be obtained. (Of course, the cleavage plane of the mica flake is not required to be completely parallel to the surface of the decorative material. The same applies to the embodiments described below.) And
In this case, since the surface is flat, it is possible to obtain a surface decoration material for a building or a building having a heavy natural stone pattern with a polished finish.

Next, FIG. 2 is a cross-sectional view showing the steps of another embodiment in which a building or a surface decoration material for a building of the present invention is formed on a plate-like material having releasability. The process diagram is shown. This embodiment is different from the embodiment shown in FIG. 1 in that an embodiment in which fabrics such as a nonwoven fabric and a cold gauze are stacked instead of stacking concrete on the back side.

The steps of FIGS. 2A and 2B correspond to the steps of FIG.
Since the steps shown in FIG. 1A and FIG. 1B are substantially the same, the same parts are denoted by the same reference numerals and the description thereof will not be repeated.

What is slightly different is that the second coating material 5 in FIG.
2 is applied, and before the second coating material 5 dries, FIG.
This is the point where the fabrics 8 are stacked as shown in FIG. By laminating the fabric 8 before the second coating material 5 is dried, the fabric 8 is laminated on the second coating material layer without using an adhesive or the like by appropriately applying pressure from above the fabric 8. 5 can be adhered.

Thus, this is dried and the second coating material layer 5
After the solidification, the plate-like material 1 is removed, and the decorative material of the present invention is obtained as shown in FIG.

Although not shown, if it is desired to apply a transparent top coat layer to the surface, in the step of FIG. The synthetic resin clear paint may be applied thinly and dried to form a top coat layer. In addition, FIG.
A top coat may be applied to the surface of the decorative material obtained in (d) later.

The plan view of the decorative material thus obtained as viewed from the front side is almost the same as that shown in FIG. The mica flakes appear with their cleavage planes substantially along the surface of the decorative material, exhibiting scaly glittering properties, and providing a natural stone-like decorative material that is very close to natural stone. In this case, since the surface is flat, it is possible to obtain a building or a surface decoration material for a building having a heavy natural stone pattern in a polished finish. The decorative material of this embodiment is generally applied to a building or a desired portion of a building by bonding with an adhesive or the like. Further, the decorative material of this embodiment has flexibility and flexibility, and can be attached to a curved surface such as a surface of a round pillar, for example.

As described above, in the steps described with reference to FIGS. 1 and 2, an example in which a plate-like object having a flat surface is used as the plate-like object 1 has been described. May have an appropriate uneven three-dimensional pattern. When a relatively thin sheet or film is used as the plate, the front and back surfaces of the plate have irregularities like a corrugated plate, but such a plate may be used.

Next, referring to FIG. 4, an embodiment of a sectional process diagram showing a process of forming a building or a surface decoration material for a building according to the present invention with a mold using a mold having releasability. explain. 1 and 2 in that a mold is used instead of a plate-like object, and the other steps are essentially the same as those described in FIGS. 1 and 2.

As shown in FIG. 4 (a), first, a mold having releasability, in which the inner lower surface (the part where the surface of the finally obtained decorative material is in contact) is uneven. A first coating material containing a synthetic resin emulsion and mica flakes, or a first coating material containing a synthetic resin emulsion, mica flakes and aggregates, is applied relatively thinly so as to cover part or all of the uneven surface of No. 10. The applied first coating material layer may be in an undried state, or may be dried as necessary. Reference numeral 2 denotes a mica flake, and reference numeral 3 denotes a first coating material including the mica flake. In this case, the surface side of the decorative material finally obtained becomes uneven, but the cleavage plane of the mica flake 2 is also substantially in the direction along the surface of the decorative material. Although the illustrated coating of the first coating material does not cover the entire surface of the uneven surface inside the mold 10, it may be applied so as to cover the entire surface according to the purpose.

The means for coating is not particularly limited, but may be any such as a spray gun, a trowel, a brush, a roller, etc., as long as the object can be achieved.

Next, as shown in FIG. 4B, the first coating material layer 3
A second coating material 5 containing a synthetic resin emulsion and an aggregate is applied to the surface on which is formed. Reference numeral 4 schematically shows the aggregate in the second coating material. The means for coating is not particularly limited, but may be any such as a spray gun, a trowel, a brush, a roller, etc., as long as the object can be achieved.

Next, after drying the second coating material 5, FIG.
As shown in (c), concrete 6 is poured.

Thus, after the concrete has solidified, the mold 10 is removed, and the decorative material of the present invention is obtained as shown in FIG. 4 (d). Note that FIG. 4 (d) is upside down from FIG. 4 (c).

Although not shown, if it is desired to apply a transparent top coat layer to the surface, it is first dried in the step of FIG. Thin synthetic resin clear paint on the inside lower surface of the formwork,
Then, it may be dried to form a top coat layer.
If necessary, a top coat may be applied to the surface of the decorative material obtained in FIG.

The plan view of the decorative material thus obtained, viewed from the surface side, is almost the same as that shown in FIG. 3 except that the surface has an uneven three-dimensional pattern and a masonry-like three-dimensional pattern is formed. A similar situation results. And the mica flake appears on the surface of the decorative material with its cleavage plane almost along the surface,
A scaly glittering property is sufficiently exhibited, and a natural stone-like decorative material very similar to natural stone can be obtained. Then, in this case, when the surface is uneven, and when the shape of the unevenness is made of natural stone, a surface decoration material for a building or a building having a heavy natural stone pattern of natural stone split skin tone is obtained. be able to. In addition, as shown in the figure, when the unevenness inversion relief pattern provided on the inner lower surface of the formwork is a masonry-like pattern, a building or building surface decorative material having a masonry-like heavy natural stone-like pattern is used. Obtainable.

Although not shown, when a fabric such as a nonwoven fabric or a cold gauze is laminated in place of the concrete 6 of the embodiment shown in FIG. 4, similarly to the case described with reference to FIG.
After the second coating material 5 is applied in (b), before the second coating material 5 is dried, the cloth is laminated on the second coating material 5 in the same manner as described in FIG. I just need.

Further, a mold having an uneven three-dimensional pattern on the inner lower surface was used as the mold, but the shape of the unevenness may be any shape according to the purpose, and a smooth surface without imparting the uneven three-dimensional pattern may be used. In such a case, a decorative material having a polished finish with a smooth surface as described above can be obtained.

Thus, for example, it is possible to obtain a building or a surface decoration material for a building which has a natural stone-like pattern which is very close to a natural stone, exhibiting a granite-like heavy scale-like brilliancy. In particular, it is suitable for obtaining a surface decoration material for a building or a building having a masonry natural stone pattern or a masonry natural stone pattern.

Next, each material used in the present invention,
The construction application target and the like will be described in more detail.

The material of the mold is not particularly limited as long as it can fulfill the role of the mold, and various materials such as plastic, metal, wood, stone, and ceramic can be used. Is preferred.
Various plastics can be used, but polyethylene, polypropylene, polystyrene,
Polyvinyl chloride and the like are preferable because they are inexpensive. In the case of a material having poor releasability, an appropriate release agent may be applied to the inner surface of the mold. Among plastics, foams are relatively light and easy to handle, and because they are relatively inexpensive, polyethylene, polypropylene, polystyrene,
A foam such as polyvinyl chloride is preferably used.

There is no particular limitation on the plate-like material as long as the object can be achieved, and various materials such as plastics, metals, woods, stones, and ceramics similar to those described in the above-described molds are used. As in the case of the mold, plastics are inexpensive and preferable, and foams can be used. In the case of a material having a small rigidity when formed into a film or a sheet, the work may be performed on a table having an appropriate flat surface, so that the plate may be flexible.

Further, as in the embodiment described with reference to FIG. 2, when the fabric is laminated on the back side, the fabric may be, for example, a woven or non-woven fabric made of synthetic fiber or inorganic fiber, for example, specifically, acrylic fiber or polyester fiber. Fabrics such as cold gauze, non-woven fabric, glass fiber woven fabric, glass wool non-woven fabric, and synthetic paper are used. In particular, cold gauze and non-woven fabrics made of acrylic fiber or polyester fiber are relatively inexpensive, hydrophobic and have relatively low water absorption, and do not easily expand due to moisture absorption when laminated, and thus the decorative material warps after drying. It is preferable because there is no possibility that the decorative material layer is cracked.

The synthetic resin emulsion constituting the first coating material and the second coating material is not particularly limited, but preferably has properties after drying such as weather resistance, alkali resistance, acid rain resistance, and the like. Synthetic resin emulsions satisfying water resistance, water absorption resistance and the like are preferable. For example, acrylic resin emulsions (including acrylic-urethane resin emulsions and acrylic-silicone resin emulsions), vinyl acetate resin emulsions, and vinyl chloride resin emulsions And urethane-based resin emulsions. Above all, although acrylic resin emulsions are relatively inexpensive, they are excellent in terms of weather resistance and are used for a long time, such as when applied as a decorative layer for surface finishing of buildings and structures such as interior and exterior walls or floors of buildings. And is preferred.

The aggregate is indispensable for the second coating material and is not necessarily required for the first coating material. In any case, the aggregate may be marble powder such as cold water stone, granite powder or other natural stone powder. Inorganic materials and plastic materials such as silica sand, glass powder, ceramic powder, and plastic pieces (all of which may be non-artificially colored or artificially colored) are preferably used. Of course, these may be used in combination, or aggregates having different colors may be used in combination. The size of the aggregate is not particularly limited, but those having a particle size (the major axis of the particle, that is, the maximum diameter portion) of about 0.01 mm to 3 mm are preferably used. In particular, when the first coating material contains an aggregate, the particle size is preferably 0.1 to 3 mm, more preferably 0.2 to 1 m.
m, more preferably 0.2 to 0.6 mm aggregate is used. When an aggregate having a very small particle size is used, the hiding power is increased as if a usual pigmented paint was applied. Therefore, the lower limit of the particle size is used so that the portion other than the mica flakes of the portion where the first coating material is applied does not strongly cover the pattern of the lower second coating material layer, The pattern of the underlying second coating material layer can be seen through like a blurred pattern, and a calm and harmonious natural stone tone decorative material can be obtained, which is preferable.

The mixing ratio of the aggregate and the synthetic resin emulsion constituting the second coating material differs depending on what kind and what kind of texture of the decorative material is used. The solid content is preferably about 5 to 20 parts by weight, particularly preferably about 5 to 10 parts by weight, based on 100 parts by weight of the aggregate.

By adopting a preferred embodiment in this range, the aggregate can be firmly held by the synthetic resin matrix.
Therefore, it is possible to obtain a decorative material that is not too brittle and has a durable strength while maintaining a heavy and deep texture. If the amount of aggregate is too large, the mechanical strength of the obtained decorative material tends to decrease because the ratio of the synthetic resin also having a function as a binder tends to decrease.On the other hand, if the ratio of the aggregate is too low, it becomes heavy. A deep texture tends to decrease, and when applied and dried and solidified, shrinkage and the like tend to occur and cracks tend to occur.

The second coating material in which the aggregate is mixed with the synthetic resin emulsion may further contain a filler, a film-forming aid,
A thickener, an antifoaming agent, a pH adjuster, or the like may be added, or water or an appropriate solvent may be added to adjust the viscosity.
These additives are almost the same in the first coating material.

As the thickener, for example, a methylcellulose-based thickener (eg, “Hymetrose 90SH-3000”)
0 ", manufactured by Shin-Etsu Chemical Co., Ltd.), as a film-forming aid, for example, butyl carbitol acetate, as a defoaming agent, for example," Nopcosant NXZ "(manufactured by San Nopcosan), etc. For example, concentrated aqueous ammonia is preferably used, but is not limited thereto.

Next, as the mica flakes to be mixed in the first coating material, those having a size (major axis) of 0.5 mm or more are preferable, and if too small, the effect of exhibiting flaky luster is not sufficiently exhibited. . Those which are usually easily available are up to about 10 mm in size. Therefore, a mica flake having a size (major axis) of about 0.5 to 10 mm is preferably used.

Examples of the mica flakes include crushed natural mica such as muscovite, phlogopite and biotite (non-artificial colored mica) or artificially colored mica flakes obtained by artificially coloring them with a paint containing a pigment. And the like, and it is more preferable to use two or more of these. As the color of artificially colored mica,
White, black, yellow, red, beige and the like. Although not particularly limited, it is preferable to use mica flakes in which 50% by weight or more of the mica flakes are non-artificially colored mica flakes. Natural mica flakes that are not artificially colored are transparent, so they do not completely conceal the surface of the underlayer, and can form well-harmonic and well-decorated decorative materials with the underlayer. . Using artificially colored mica appropriately,
It is preferable to provide a contrasting surface pattern to the decorative material.

The size of the mica flakes to be used may be changed depending on the texture to be developed.
For example, a mica flake having a larger size, for example, a size of 4 to 10 mm may be used when a material having a size of about 4 mm is mainly used or a texture in which a larger crystal exists is desired. However, since a large-sized one may clog the nozzle of the spray gun, in such a case, an appropriate application method such as application using a brush or a trowel may be adopted.

In the case where the first coating material comprises a synthetic resin emulsion and mica flakes, 100 parts by weight of the mica flakes
The synthetic resin emulsion preferably has a resin solid content in the range of 50 to 1000 parts by weight. If the ratio of the mica flakes is too large, the mica tends to peel off from the surface of the obtained decorative material because it has cleavage, and if the ratio of the mica flakes is too small, the effect of using the mica flakes is small. Tend to be.

When the first coating material contains a synthetic resin emulsion, mica flakes and aggregates, the synthetic resin emulsion has a resin solid content of 50 to 10 based on 100 parts by weight of the mica flakes.
The range of 00 parts by weight and the amount of the aggregate is preferably 20 to 500 parts by weight. If the amount of the added aggregate is too large, the ratio of covering the surface of the mica flakes becomes too large, and the tendency to inhibit the scale-like glittering effect of the mica flakes increases. If the amount is too small, the above-described effect of using the aggregate becomes difficult to exert. However, as described above, the first coating material does not need to use an aggregate, and thus is not particularly limited.

When the top coat layer is formed on the outermost surface of the decorative material, a clear synthetic resin paint which becomes transparent when dried may be used. As a specific example, not the synthetic resin emulsion exemplified as the synthetic resin emulsion constituting the first coating material and the second coating material, or the emulsion type, but these synthetic resin coating materials using a solvent as a solvent may be a solution type. And the like are used. Particularly preferably, those having excellent weather resistance are used, and among acrylic resin emulsions and solution types, acryl-urethane resin emulsions and solution types, and acryl-silicone resin emulsions and solution types are more preferable. The top coat layer is generally used when it is desired to impart a surface gloss to a decorative material, or when it is desired to further impart properties such as weather resistance, water resistance, and stain resistance. The coating thickness of the top coat layer is not particularly limited, but is about 10 to 1000 μm in thickness after drying.

The decorative material of the present invention exhibits an excellent scale-like shine that cannot be achieved by a conventional synthetic product, and is therefore suitable for a natural stone-like building or building having a rich, deep and luxurious feel. Can be obtained. Therefore, the decorative material of the present invention can be applied to the surface of a building or a structure, for example,
Building exterior and interior walls and ceilings, floor surfaces, pillar surfaces, fence surfaces, slopes for residential land development, retaining walls for buildings, exterior surfaces of elevated walls and bridges, etc., exterior walls of pedestrian crossings, earth and stone It is suitably used as a decorative material for surface finishing such as a slope of a stop, a revetment wall, a revetment staircase, an entrance to a tunnel, and the like.

The decorative material of the present invention can be manufactured while being constructed on site, for example. Although all the steps can be performed on site, for example, taking the step shown in FIG. 4 as an example, the steps up to (a) and (b) in FIG. This is brought to, for example, a construction site where a building wall is to be constructed, and the concrete shown in FIG. The concrete is held so as to fill the space between the backup plate surface and the formwork shown in FIG. If the formwork is removed when the concrete is hardened, it is possible to decorate the surface simultaneously with the construction of the wall.

[0077]

EXAMPLES Hereinafter, the present invention will be further described with reference to more specific examples, but the present invention is not limited to only these examples. In the following examples, the amount of application and the amount of concrete applied indicate the amount of application and the amount of application in a state after drying.

Example 1 A decorative material was manufactured by the steps described with reference to FIG.

A polyethylene foam sheet is placed as a plate-like material 1 on a flat plate base, and then, as a first coating material, a synthetic resin emulsion: an acrylic resin-based emulsion (“Polytron E300” manufactured by Asahi Kasei Kogyo Co., Ltd.) 35
00g (of which resin solid content is 49% by weight), mica flakes: 500 g of non-artificial colored natural muscovite [“No. 3” (size about 1 to 3 mm) manufactured by Kirara Co., Ltd.], artificially colored biotite [diamond Industrial Co., Ltd. "Dia chip DM-
5 black "(size of about 2 to 5 mm)] using a first coating material adjusted to 250 g and using a caberon gun caliber 6 mm (manufactured by Toyooka Seisakusho) as a coating tool so that the coating amount becomes about 0.3 kg / m ^2. Was spray-dried at a rate so as to cover about 50% of the surface area of the polyethylene foam sheet (see FIG. 1A).

Next, as a second coating material, a synthetic resin emulsion: an acrylic resin emulsion (“Polytron E300” manufactured by Asahi Kasei Kogyo Co., Ltd.) 20
00g (of which 49% is resin solid content), Aggregate: natural stone aggregate (cold water stone) ["KD-1" (particle size: 0.35 to 0.55 mm) manufactured by Dowa Calfine) 75
00g and natural stone aggregate (cold water stone) [“KD-100” manufactured by Dowa Calfine Co., Ltd. (particle size 0.075 to 0.15 m)
m)] 2000 g, colored aggregate gray-based colored calcined silica sand [“20N-3” manufactured by Shinto Tohoku Co., Ltd. (particle size: 8:
Particle size: 0.18 to 0.25 mm)] 500 g The coating amount is about 3.10 g using a ricing gun having a diameter of 6 mm (manufactured by Toyooka Seisakusho) as a coating tool.
Sprayed to 5 kg / m ² and dried (Fig. 1
(B)).

Next, as shown in FIG. 1 (c), a wooden frame 7 is set so as to surround the periphery, and concrete is poured from above so that the working amount is 50 kg / m ² and solidified. Then, the wooden foam 7 and the polyethylene foam sheet of the plate-like material 1 were removed, and thus a calm, polished and decorative material of a granite tone having a profound feeling and a scaly luster was obtained (FIG. 1 (d)). reference).

Example 2 A decorative material was manufactured by the steps described with reference to FIG.

The plate-like material used, the first coating material, the second coating material,
The application amount and the like were the same as in the example. What is different from Example 1 is that after the second coating material is applied, the cloth 8 made of a polyester non-woven fabric is applied to the second coating material layer as shown in FIG. 2C before the second coating material layer dries. Was placed on the surface of the plate and pressed by a sponge roller, and then dried. The polyethylene foam sheet of the plate-like material 1 was removed, and thus a calm, granite-like polished finish-like decorative material having a solid feeling and a scaly glittering property was obtained (see FIG. 2 (d)). The obtained decorative material had flexibility and could be applied to a curved surface.

Example 3 A decorative material was manufactured by the steps described with reference to FIG.

As the mold 10, a polypropylene foam mold was used in which an inverted relief having a natural stone-like texture was formed on the inner lower surface of the mold and a release material was thinly applied on the inner surface of the mold. Next, as a first coating material, a synthetic resin emulsion: an acrylic resin emulsion (“Polytron E300” manufactured by Asahi Kasei Kogyo Co., Ltd.) 50
00g (of which 49% is resin solid content), aggregate:
Natural stone aggregate (cold water stone) [“K” manufactured by Dowa Calfine Co., Ltd.
D-1 ″ (particle size: 0.35 to 0.55 mm)] 1500
g, mica flakes: 500 g of non-artificial colored natural muscovite [“No. 3” (size about 1 to 3 mm) manufactured by Kirara Co., Ltd.], and artificially colored biotite [Diachip DM-
5 black "(size of about 2 to 5 mm)] using a first coating material adjusted to 250 g and using a caberon gun caliber 6 mm (manufactured by Toyooka Seisakusho) as a coating tool so that the coating amount is about 0.3 kg / m ^2. Was sprayed at a rate so as to cover about 50% of the surface area of the inner lower surface of the polypropylene foam mold, and then dried (see FIG. 4A).

Next, as a second coating material, a synthetic resin emulsion: an acrylic resin emulsion (“Polytron E300” manufactured by Asahi Kasei Kogyo Co., Ltd.) 20
00g (of which 49% is resin solid content), Aggregate: natural stone aggregate (cold water stone) ["KD-1" (particle size: 0.35 to 0.55 mm) manufactured by Dowa Calfine) 75
00g and natural stone aggregate (cold water stone) [“KD-100” manufactured by Dowa Calfine Co., Ltd. (particle size 0.075 to 0.15 m)
m)] 2000 g, colored aggregate beige-based colored baked silica sand [“20Y205” manufactured by Shinto Tohzo Co., Ltd. (particle size: 8)
No .: particle size: 0.18 to 0.25 mm)] 500 g, and the coating amount is about 3.
It was sprayed so as to be 5 kg / m ² .

[0086] The layer was kept at room temperature for 24 hours and dried to form a layer composed of the second coating material (see FIG. 4B).
Thereafter, concrete is poured from above so that the working amount becomes 50 kg / m ² (see FIG. 4 (c)), and after solidification, the polypropylene foam mold of the mold 10 is removed.
Thus, a decorative material having calmness, a profound feeling and a scaly glittering property having a granite tone and a split-tone unevenness pattern was obtained (see FIG. 4D).

[0088]

According to the decorative material of the present invention, the cleavage plane of the mica flakes is present substantially along the surface of the decorative material, and the scale-like brilliancy is sufficiently exhibited, and therefore, the weight is closer to that of natural stone. The present invention provides a surface decoration material for a building or a structure having a natural stone pattern having a natural texture.

Further, according to the decorative material manufacturing method of the present invention, the mica flakes efficiently appear on the surface side of the decorative material,
A surface decoration for a building or a building having a natural stone-like pattern, in which the cleavage plane of the mica flake exists substantially along the surface of the decorative material and the scale-like brilliancy is sufficiently exhibited, and thus has a thickness closer to that of the natural stone A method for easily manufacturing a material is provided.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a step of forming a building or a surface decoration material for a building according to the present invention.

FIG. 2 is a cross-sectional view showing another embodiment of the step of forming a building or a surface decoration material for a building according to the present invention.

FIG. 3 is a plan view of a building or a decorative material for a building according to one embodiment of the present invention as viewed from the front side.

FIG. 4 is a sectional view showing still another embodiment of the step of forming a building or a surface decoration material for a building according to the present invention.

[Explanation of symbols]

 Reference Signs List 1 plate-like material 2 mica flake 2a muscovite flake 2b biotite flake 3 first coating material 4 aggregate 5 second coating material 6 concrete 7 frame 8 fabric 10 mold

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) B44F 9/04 B44F 9/04 E04C 2/20 E04C 2/20 EB 2/26 2/26 RF term (reference) 2E110 AA57 AB04 AB05 AB22 AB23 BA03 BA12 BB03 BB38 EA09 GA23W GA33X GA43W GB20W GB23X GB42W GB44W 2E162 CA01 EA18 FA00 4F100 AA20H AC05B AC06H AE01C AG00H AK01A AK01D AK25 BA13 BA01 BA03 BA03 BA03 BA01 BAK HB11 HB11B JK15B JM01 YY00A YY00B

Claims (24)

[Claims] 1. A mica flake is dispersed and fixed to a surface layer of a layer in which an aggregate is dispersed in a synthetic resin matrix, with a cleavage plane thereof substantially along the surface of the decorative material, and a concrete layer is formed on the back side surface. Or, a surface decoration material for a building or a building having a natural stone-like pattern on a surface on which a fabric is laminated. 2. The building or surface decoration material for a building according to claim 1, further comprising a top coat layer made of a transparent synthetic resin thin film layer on the outermost surface side. 3. The building or surface decoration material for a building according to claim 1, wherein the size of the mica flake is 0.5 to 10 mm. 4. The surface decoration material for a building or a building according to claim 1, wherein the aggregate is an aggregate having a particle size of 0.01 to 3 mm. 5. A layer in which the aggregate is dispersed in a synthetic resin matrix, wherein the ratio of the solid content of the synthetic resin to the aggregate is 100%.
The surface decorative material for a building or a building according to any one of claims 1 to 4, wherein the proportion of the synthetic resin solid content is 5 to 20 parts by weight with respect to parts by weight. 6. The surface decoration material for a building or a building according to claim 1, wherein the aggregate is an aggregate selected from the group consisting of natural stone powder, silica sand, ceramic powder, and glass powder. 7. The surface decoration material for a building or a building according to claim 1, wherein the mica flakes are at least one kind of mica flakes selected from non-artificial colored mica and artificial colored mica. 8. The surface decoration material for a building or a building according to claim 1, wherein the synthetic resin is an acrylic synthetic resin. 9. The surface decoration material for a building or a building according to claim 1, wherein the surface has a smooth surface and a natural stone pattern with a polished finish. 10. The surface decoration material for a building or a building according to claim 1, wherein the surface is uneven and has a three-dimensional pattern. 11. A first coating material containing a synthetic resin emulsion and mica flakes or a synthetic resin emulsion and mica flakes and an aggregate on the inner lower surface or plate-like material of a mold having releasability. 2nd containing a synthetic resin emulsion and aggregate from above, applied thinly and dried or undried.
Applying the coating material, and laminating and drying the fabric before the second coating material is not dried, and fixing the fabric, or after the second coating material is dried, concrete is placed thereon. A method for producing a surface decoration material for a building or a building having a natural stone pattern on the surface, which comprises casting and solidifying and then removing the mold or plate. 12. A top coat layer is formed by applying a synthetic resin clear paint which becomes transparent when dried first on the inner lower surface or plate-like material of a mold release mold. Item 12. A method for producing a building or a surface decoration material for a structure according to item 11. 13. The production of a surface decoration material for a building or a building according to claim 11, wherein the application amount of the first coating material is 50 g to ² kg / m ² in a coating amount after drying. Method. 14. The production of a surface decorative material for a building or a building according to claim 11, wherein the applied amount of the second coating material is 1 to 10 kg / m ² as a coated amount after drying. Method. 15. The method according to claim 11, wherein the first coating material comprises a synthetic resin emulsion and mica flakes, and the synthetic resin emulsion has a resin solid content of 50 to 1000 parts by weight based on 100 parts by weight of the mica flakes. A method for producing a surface decoration material for a building or a structure according to the above embodiment. 16. The first coating material contains a synthetic resin emulsion, mica flakes and aggregates, and the synthetic resin emulsion has a resin solid content of 50 to 100 per 100 parts by weight of the mica flakes.
0 part by weight and 20 to 500 parts by weight of aggregate.
15. The method for producing a building or a surface decoration material for a building according to any one of items 14 to 14. 17. The second coating material contains a synthetic resin emulsion and an aggregate, and the synthetic resin emulsion has a resin solid content of 5 to 20 parts by weight based on 100 parts by weight of the aggregate.
17. A method for producing a building or a surface decoration material for a building according to any one of claims 16 to 16. 18. The size of the mica flake is 0.5 to 10 mm.
The method for producing a building or a surface decoration material for a building according to any one of claims 11 to 17, wherein 19. The method according to claim 11, wherein the aggregate is an aggregate having a particle diameter of 0.01 to 3 mm. 20. The aggregate according to claim 11, wherein the aggregate is selected from the group consisting of natural stone powder, silica sand, ceramic powder, and glass powder.
20. The method for manufacturing a building or a surface decoration material for a building according to any one of 19 to 19. 21. The production of a surface decoration material for a building or a building according to any one of claims 11 to 20, wherein the mica flakes are at least one kind of mica flakes selected from non-artificial colored mica and artificial colored mica. Method. 22. The method for producing a surface decoration material for a building or a building according to claim 11, wherein the synthetic resin emulsion is an acrylic synthetic resin emulsion. 23. The surface decoration for a building or a building according to claim 11, wherein at least the surface of the inner lower surface of the formwork or the plate-like object on the side to which the coating material is applied is a flat surface. The method of manufacturing the material. 24. An inner lower surface of a mold or at least a surface of a plate-shaped object to which a coating material is applied is uneven.
23. The method for producing a building or a surface decoration material for a building according to any one of 1 to 22.