JP2007098849A - Manufacturing method of decorative sheet and decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a decorative sheet which manufactures simply the decorative sheet having excellent aesthetic performance having deepness. <P>SOLUTION: The manufacturing method of the decorative sheet comprises a first step of pouring into a mold having an unevenness pattern a color clear coating which contains a synthetic resin and a coloring pigment whose viscosity is ≤5.0 Pa s, and the coating film formed by the method has a covering percentage of ≥10% and ≤90%; a second step of pouring a base coating which contains a synthetic resin, a coloring pigment and/or an aggregate; and a third step of releasing from the mold after the color clear coating and the base coating have been hardened. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a decorative sheet manufacturing method and a decorative sheet.

In recent years, building interiors and exterior walls, etc. have attracted attention for the finishing with rich design such as brick tone, tile tone and natural stone tone.
There is a case where a decorative sheet is used as a material for such finishing. This decorative sheet is a building material in which a composition containing various colorants and a binder such as a synthetic resin is formed into a sheet shape. Various designs can be achieved by adjusting the types and ratios of the colorants, the uneven shape of the surface, and the like. Sex can be expressed.

Recently, in order to express deeper aesthetics, decorative sheets that have been devised in various ways have been developed.
For example, in Patent Document 1, at least one of the first coating materials in which a first coating material is applied to a mold having a sedimentary rock split skin-like unevenness relief pattern, and the unevenness relief pattern is also applied on a convex portion. A method for producing a decorative material having a cave-skin-like uneven surface pattern by removing a part or all, then applying a second coating material having a color tone different from that of the first coating material, and removing a mold. Are listed.
By such a method, it is possible to manufacture a decorative material having a sedimentary rock fractured surface uneven pattern capable of producing a depth and heavyness similar to or similar to the fractured surface of natural sedimentary rock. (Described in paragraph 0008.)
However, in the method of Patent Document 1, a step of removing the first coating material is essential, and it cannot be said that it can be easily manufactured. In addition, there is room for further improvement in order to express a deeper sense of nature and design.

Japanese Patent No. 2791279

  The present invention has been made in view of the above-described problems, and provides a decorative sheet that can be easily manufactured and has excellent depth and beauty.

  As a result of intensive studies, the present inventor has found that the above problem can be solved by pouring a specific color clear paint into a mold having a concavo-convex pattern, then pouring a base paint, and removing the mold. It came to complete.

That is, the present invention has the following characteristics.
1. To formwork with uneven pattern,
A first step of pouring a color clear paint containing a synthetic resin and a colored pigment, having a viscosity of 5.0 Pa · s or less and a concealment ratio of the formed coating film of 10% or more and 90% or less;
A second step of pouring a base paint comprising synthetic resin, color pigments and / or aggregates;
A third step of demolding after the color clear paint and base paint are cured;
A method for producing a decorative sheet, comprising:
2.1. A decorative sheet obtained by the production method described in 1.

  In the production method of the present invention, a decorative sheet having a deep and excellent aesthetic appearance can be easily produced.

  Hereinafter, the best mode for carrying out the present invention will be described.

The method for producing the decorative sheet of the present invention comprises:
To formwork with uneven pattern,
Contains a synthetic resin and a colored pigment, and has a viscosity of 5.0 Pa · s or less (preferably 0.001 Pa · s to 3.0 Pa · s, more preferably 0.01 Pa · s to 1.0 Pa · s). A first step of pouring a color clear paint having a coating film hiding ratio of 10% to 90% (preferably 15% to 85%, more preferably 20% to 80%);
A second step of pouring a base paint comprising synthetic resin, color pigments and / or aggregates;
A third step of demolding after the color clear paint and base paint are cured;
It is characterized by including.

In such a method, by pouring a color clear paint, the film thickness is continuously changed so that the film thickness is maximized at the concave portion of the mold and the film thickness is minimized at the convex portion. A clear coating film can be formed.
Therefore, the surface finally obtained by demolding can express deep aesthetics due to a change in hue due to a continuous change in the thickness of the color clear coating film.

The material for the mold is not particularly limited, and known materials can be used.
For example, silicon rubber, polyurethane resin, epoxy resin, polyester resin and the like can be mentioned.
The formwork used in the present invention has a concavo-convex pattern, and finally forms a concavo-convex pattern on a decorative sheet. The degree of unevenness is not particularly limited, but the height is preferably about 0.5 to 30 mm (preferably about 1 to 20 mm). Moreover, it is preferable that the space | interval is about 0.5-30 mm (preferably about 1-20 mm).
For example, when silicon rubber is used, using a cosmetic building material having a concavo-convex pattern, the silicon rubber is poured onto the surface of the cosmetic building material, and after the silicon rubber is cured, the silicon rubber is peeled off from the surface of the cosmetic building material. Thus, a mold having a concavo-convex pattern can be easily produced.

  In the production method of the present invention, as a first step, the mold having such a concavo-convex pattern contains a synthetic resin and a color pigment, the viscosity is 5.0 Pa · s or less, and the concealment rate of the formed coating film is 10 Color clear paint that is not less than 90% and not more than 90% is poured.

The synthetic resin is not particularly limited, and those that can be normally used can be used. For example, ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, urethane resin, phenol resin, melamine resin, amino resin, polycarbonate resin, acrylic silicon resin, acrylic vinyl acetate resin, acrylic Examples thereof include water-soluble resins such as urethane resins, silicon resins, and fluorine resins, water-dispersed resins, and combinations thereof, and one or more of them can be used.
In the present invention, in particular, an acrylic resin, a urethane resin, an acrylic silicon resin, or the like is preferably used.

Examples of color pigments include inorganic color pigments such as titanium oxide, zinc oxide, carbon black, ferric oxide (bengal), lead chromate (molybdate orange), yellow lead, yellow iron oxide, ultramarine, and cobalt green. Azo, naphthol, pyrazolone, anthraquinone, perylene, quinacridone, disazo, isoindolinone, benzimidazole, phthalocyanine, quinophthalone, and other organic color pigments, pearl pigments, fluorescent pigments, phosphorescents Examples thereof include pigments and metallic pigments.
The pigment volume concentration of the color pigment in the color clear coating is preferably 0.01% to 50% (more preferably 0.05% to 40%, more preferably 0.1% to 30%).

The color clear paint used in the present invention has a viscosity of 5.0 Pa · s or less (further 0.001 Pa · s or more and 3.0 Pa · s or less, further 0.01 Pa · s or more and 1.0 Pa · s or less). It is characterized by that.
With such a viscosity, the color clear paint can be easily poured into the uneven pattern portion of the mold, and when the color clear paint is poured, the film thickness is maximum at the concave portion and the film thickness at the convex portion. The coating film can be formed in a state where the film thickness is continuously changed so as to be minimized.
Therefore, the surface finally obtained by demolding can express deep aesthetics due to a change in hue due to a continuous change in the thickness of the color clear coating film.
When the viscosity is greater than 5.0 Pa · s, the film thickness is not continuously changed, resulting in a monotonous design.

  The viscosity of the color clear coating is a value measured at a temperature of 23 ° C. with a BH viscometer at a rotation speed of 20 rpm.

The color clear coating used in the present invention has a concealment ratio of a formed coating film of 10% to 90% (preferably 15% to 85%, more preferably 20% to 80%). Features. When the concealment ratio is in such a range, the hue of the base coating film formed from the base paint, the hue of the color clear coating film, and the continuous hue change of the color clear coating film are combined, and there is a depth. A sense of design can be expressed.
When the concealment rate is greater than 90%, the hue of the base coating film and the hue of the color pigment are concealed, and a deep design feeling cannot be expressed.

  In addition, the concealment rate of the formed coating film formed from the color clear coating was determined by using a test body coated on the concealment rate test paper so that the coating thickness (dry film thickness) was 0.3 mm. It is the value which measured and calculated the luminous reflectance of the black ground coating film and the white ground coating film using a color difference meter "CR-300" (made by Minolta Co., Ltd.).

  For color clear coatings, aggregates, film-forming aids, water repellents, plasticizers, antiseptics, antifungal agents, anti-algae agents, antifoaming agents, leveling agents, pigment dispersants, sedimentation agents, as necessary You may contain additives for coating materials, such as an inhibitor, a sagging inhibitor, a matting agent, and an ultraviolet absorber.

  Aggregates include, for example, quartz sand, crushed stone, cryogenic stone, river sand, mountain sand, marble ground, granite ground, obsidian ground, limestone ground, ceramic ground, glass beads, glass ground, resin beads, porous Resin beads, metal particles, silica gel, zeolite, alumina, allophane, diatomaceous earth, siliceous shale, sepiolite, attabargite, montmorillonite, zonolite, imogolite, shell powder, Otani stone powder, activated clay, charcoal, activated carbon, wood powder, etc., or Surface treatment with pigments, dyes, glazes, etc., heavy calcium carbonate, clay, kaolin, talc, precipitated barium sulfate, barium carbonate, white carbon, diatomaceous earth, glitter powder, etc. Can be mentioned.

The method for pouring such a color clear paint into the mold is not particularly limited, and a usual method can be used. For example, it can be poured using a pressure feed spray gun or the like, can be poured using a flow coater or the like, or can be painted using a painting tool such as a brush, roller, spray or trowel.
The color clear coating, as the amount ^{is, 50g / m 2 ~500g / m} 2 ( preferably ^{60g / m 2 ~300g / m 2} , more preferably ^{80g / m 2 ~200g / m 2} ) becomes Just pour in.
When the coating amount is more than 500 g / m ² , the difference in film thickness of the color clear coating film formed from the color clear coating with the concave and convex portions becomes small, and it is difficult to obtain a deep color.

  Next, as a second step, the color clear paint is poured, and then the base paint is poured.

  Examples of such a base paint include those containing a synthetic resin as a binder and a color pigment and / or an aggregate.

The synthetic resin is not particularly limited, and those that can be normally used can be used. For example, ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, urethane resin, phenol resin, melamine resin, amino resin, polycarbonate resin, acrylic silicon resin, acrylic vinyl acetate resin, acrylic Examples thereof include water-soluble resins such as urethane resins, silicon resins, and fluorine resins, water-dispersed resins, and combinations thereof, and one or more of them can be used.
In the present invention, in particular, an acrylic resin, a urethane resin, an acrylic silicon resin, or the like is preferably used.

Examples of color pigments include inorganic color pigments such as titanium oxide, zinc oxide, carbon black, ferric oxide (bengal), lead chromate (molybdate orange), yellow lead, yellow iron oxide, ultramarine, and cobalt green. Azo, naphthol, pyrazolone, anthraquinone, perylene, quinacridone, disazo, isoindolinone, benzimidazole, phthalocyanine, quinophthalone, and other organic color pigments, pearl pigments, fluorescent pigments, phosphorescents Examples thereof include pigments and metallic pigments.
The pigment volume concentration of the color pigment in the base paint is preferably 0.01% to 50% (more preferably 0.05% to 40%, more preferably 0.1% to 30%).

  Aggregates include, for example, quartz sand, crushed stone, cryogenic stone, river sand, mountain sand, marble ground, granite ground, obsidian ground, limestone ground, ceramic ground, glass beads, glass ground, resin beads, porous Resin beads, metal particles, silica gel, zeolite, alumina, allophane, diatomaceous earth, siliceous shale, sepiolite, attabargite, montmorillonite, zonolite, imogolite, shell powder, Otani stone powder, activated clay, charcoal, activated carbon, wood powder, etc., or Surface treatment with pigments, dyes, glazes, etc., heavy calcium carbonate, aluminum hydroxide, clay, kaolin, talc, precipitated barium sulfate, barium carbonate, white carbon, diatomaceous earth, glitter Examples thereof include powders.

  In addition, for the base paint, a film-forming aid, a water repellent, a plasticizer, an antiseptic, an antifungal agent, an algae-proofing agent, an antifoaming agent, a leveling agent, a pigment dispersant, an antisettling agent, You may contain paint additives, such as an inhibitor, a matting agent, a ultraviolet absorber, and a fiber.

  The concealment rate of such a base paint is not particularly limited, but is preferably about 80% or more and 100% or less.

  In addition, the concealment rate of the formed coating film formed from the base paint is as follows. The test sample was applied on the concealment rate test paper so that the coating thickness (dry film thickness) was 0.5 mm. It is the value which measured and calculated the luminous reflectance of the black ground coating film and the white ground coating film using the color difference meter "CR-300" (made by Minolta Co., Ltd.).

  The color tone of such a base paint is not particularly limited. In the present invention, decorative sheets having various color tones can be produced by appropriately setting the color tone of the color clear paint and the color tone of the base paint. For example, by adjusting the color tone of the color clear paint and the color tone of the base paint to a similar color tone, it is possible to express a more calm and aesthetic appearance.

The timing of pouring the base paint used in the present invention is not particularly limited, and may be before or after the color clear paint is completely cured.
In the present invention, it is particularly preferable that the base paint is poured before the color clear paint is completely cured. In such a case, some of the color pigments contained in the color clear paint penetrate into the base paint, and in combination with the hue of the base paint, deeper aesthetics can be obtained. Further, when the base paint contains a color pigment, the color pigment contained in the base paint penetrates into the color clear paint, and a deeper aesthetics can be obtained. Specifically, it is usually preferably about 0 to 180 minutes (preferably 0.5 to 120 minutes) after pouring the color clear paint.
In addition, before the base paint is poured, the veil paint can be poured after the aggregate or the like is sprayed on the color clear paint.

Moreover, the penetration degree of a color pigment can also be adjusted by adjusting the timing at which the base paint is poured.
The amount of the base coating composition, 500 g / ^{m 2} or more, preferably ^{500g / m 2 ~10000g / m 2} , more preferably it Nagashikome so as to 1000g ^{/ m 2} ~6000g ^/ m 2 approximately.

After the base paint is cured, it is demolded to obtain the decorative sheet of the present invention. The base paint and the color clear paint may be cured by natural drying, or may be forcibly cured by applying heat or the like.
In the production method using such a mold, a decorative sheet having a color clear coating film as the outermost surface is obtained. According to the production method of the present invention, problems such as paint dripping and pinholes are less likely to occur compared to wet methods, etc., and excellent aesthetics can be easily obtained without requiring skill. Can do. In addition, the uneven pattern of the mold frame expresses a design feeling due to the unevenness, but it also acts on the matte effect of the clear coating film, etc., and a deeper aesthetics can be obtained.
In addition, a reinforcing layer can be provided on the base coating film side of the decorative sheet of the present invention for the purpose of reinforcement, smoothing and the like.

  The decorative sheet obtained in this way is applied by attaching it to the wall surface, pillar, etc. of buildings such as detached houses, apartment houses, stores, and various public facilities via adhesives or adhesives. . It does not specifically limit as an adhesive agent and an adhesive, A general purpose thing can be used. An adhesive tape or the like can also be used.

Example 1
150 g / m ^{2 of the} color clear paint 1 shown in Table 1 is poured into a silicon mold having a sandstone pattern at a temperature of 23 ° C., and after 1 minute, 2000 g / m ^{2 of the} base paint 1 shown in Table 1 is poured. After 24 hours, the mold was removed to obtain a sandstone-like decorative sheet.
The obtained decorative sheet had a deep color tone with unevenness and an aesthetic appearance with a deep brightness.

(Example 2)
150 g / m ^{2 of the} color clear paint 2 shown in Table 1 is poured into a silicon mold having a sandstone pattern at a temperature of 23 ° C., and after 1 minute, 2000 g / m ^{2 of the} base paint 1 shown in Table 1 is poured. After 24 hours, the mold was removed to obtain a sandstone-like decorative sheet.
The obtained decorative sheet exhibited a deep aesthetic appearance having a deep color tone with a sense of unevenness.

(Example 3)
150 g / m ^{2 of the} color clear paint 3 shown in Table 1 is poured into a silicon mold having a sandstone-like pattern at a temperature of 23 ° C., and after 1 minute, 2000 g / m ^{2 of the} base paint 1 shown in Table 1 is poured. After 24 hours, the mold was removed to obtain a sandstone-like decorative sheet.
The obtained decorative sheet had a deep color tone with unevenness and an aesthetic appearance with a deep brightness.

Example 4
150 g / m ^{2 of the} color clear paint 1 shown in Table 1 is poured into a silicon mold having a sandstone pattern at a temperature of 23 ° C., and after 1 minute, 2000 g / m ^{2 of the} base paint 2 shown in Table 1 is poured. After 24 hours, the mold was removed to obtain a sandstone-like decorative sheet.
The obtained decorative sheet had a deep color tone with unevenness and an aesthetic appearance with a deep brightness.

(Example 5)
150 g / m ^{2 of the} color clear paint 1 shown in Table 1 was poured into a silicon mold having a sandstone-like pattern at a temperature of 23 ° C., and after 4 hours the color clear paint 1 was cured, the base shown in Table 1 Paint 1 was poured at 2000 g / m ² , and after 24 hours, it was demolded to obtain a sandstone-like decorative sheet.
The resulting decorative sheet had an aesthetic appearance having a color tone with a sense of unevenness and a deep brightness.

(Comparative Example 1)
150 g / m ^{2 of the} color clear paint 4 shown in Table 1 is poured into a silicon mold having a sandstone pattern at a temperature of 23 ° C., and after 1 minute, 2000 g / m ^{2 of the} base paint 1 shown in Table 1 is poured. After 24 hours, the mold was removed to obtain a sandstone-like decorative sheet.
In Comparative Example 1, the concealment rate of the clear paint was not within the range of the present invention, so that the resulting decorative sheet could not express a deep color tone and became a monotone design.

The viscosities of various paints were measured at a temperature of 23 ° C. using a BH viscometer (rotation speed: 20 rpm). The measurement results are shown in Table 1.
In addition, the concealment ratio of various clear paints is such that the various clear paints are coated on the test paper so that the coating thickness (dry film thickness) is 0.3 mm, and the black ground paint film and the white ground paint film are viewed. The reflectance was measured and calculated using a color difference meter “CR-300” (manufactured by Minolta Co., Ltd.). The results are shown in Table 1.
In addition, the base paint is concealed by applying the base paint on the test paper so that the coating thickness (dry film thickness) is 0.5 mm. The rate was measured and calculated using a color difference meter “CR-300” (manufactured by Minolta Co., Ltd.). The results are shown in Table 1.

Claims (2)

To formwork with uneven pattern,
A first step of pouring a color clear paint containing a synthetic resin and a colored pigment, having a viscosity of 5.0 Pa · s or less and a concealment ratio of the formed coating film of 10% or more and 90% or less;
A second step of pouring a base paint comprising synthetic resin, color pigments and / or aggregates;
A third step of demolding after the color clear paint and base paint are cured;
A method for producing a decorative sheet, comprising: A decorative sheet obtained by the production method according to claim 1.