JP2014237268A - Laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a laminate which is excellent in appearance and physical properties, including flexibility and strength.SOLUTION: A laminate has a decorative layer which is laminated on a substrate and comprises a synthetic resin (A), colored particles (B) of an average particle size of 10-1,000 μm and chemical fibers (C) of an average fiber length of 0.1-5 mm, in a content of the colored particles (B) of 100-4,000 pts. mass and a content of the fibers of 1-100 pts. mass, relative to 100 pts. mass of the resin (A).

Description

  The present invention relates to a novel laminate. The laminate of the present invention can be used, for example, as a building material applied to inner and outer wall surfaces of buildings.

Aesthetics are required for building materials used for building interiors and exteriors from the viewpoint of landscape. In recent years, as a building material, for example, an image of natural stone has been attracting attention, and a material having a relatively thick thickness and being given a heavy feeling by various uneven patterns has been adopted.
Examples of such building materials include molded products mainly composed of colored particles such as natural aggregate and artificial aggregate and a binder. However, when such a material is applied to the curved surface of the building interior / exterior surface, it may not be easy to fold, or even if it can be folded, it may cause a problem that impairs aesthetics. There is.

  For example, in Patent Document 1, a spraying material (decorative composition) in which a binder and colored particles are blended is laminated on a reinforcing layer (base material) made of a synthetic resin fiber fabric. Furthermore, a decorative material having a transparent sheet formed on the surface via an adhesive is described. Such a combination of the decorative composition and the reinforcing material is an effective means for increasing the flexibility and strength of the material.

JP-A-4-347251

  However, for materials that are relatively thick and have a profound feeling, such as materials that contain a large amount of colored particles, simply laminating the base material is highly demanding in terms of improving physical properties such as flexibility. It may not be enough to satisfy and there is still room for improvement.

  This invention is made | formed in view of such a problem, and it aims at obtaining the laminated body which was excellent in flexibility, intensity | strength, etc. while having the outstanding aesthetics.

  As a result of intensive studies to achieve the above object, the present inventor has found that the synthetic resin (A), the colored particles (B) having an average particle diameter of 10 μm or more and 500 μm or less, and the average fiber length of 0.1 mm are formed on the substrate. The inventors have conceived of a laminate in which a decorative layer containing a chemical fiber (C) having a specific weight ratio of 5 mm or less is laminated, and has completed the present invention.

That is, the laminate of the present invention has the following characteristics.
1. A laminate in which a decoration layer is laminated on a substrate,
The decorative layer includes a synthetic resin (A), colored particles (B) having an average particle diameter of 10 μm to 1000 μm, and chemical fibers (C) having an average fiber length of 0.1 mm to 5 mm,
A laminate comprising 100 to 4000 parts by weight of the component (B) and 1 to 100 parts by weight of the component (C) with respect to 100 parts by weight of the component (A).
2. The chemical fiber includes at least one selected from regenerated fiber, semi-synthetic fiber, and synthetic fiber. The laminated body as described in.
3. The chemical fiber is hydrophilic. Or 2. The laminated body as described in.
4). The synthetic resin contains a synthetic resin emulsion. ~ 3. The laminated body in any one of.

  The laminate of the present invention is obtained by laminating a decorative layer on a base material, and has excellent aesthetics by laminating a specific decorative layer, and also has excellent flexibility, strength and other physical properties. Can be obtained.

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

  The laminate of the present invention has a decorative layer on a substrate. This laminate is mainly applicable as an interior / exterior building material of a building, and is used by being attached to a building exterior surface (base).

(Base material)
Although it does not specifically limit as a base material of this invention, For example, paper, a synthetic paper, a noncombustible paper, a resin sheet, a metal sheet, a braid, a woven fabric, a nonwoven fabric etc. are mentioned. These may be subjected to surface treatment or the like as necessary. The thickness is preferably 0.05 mm or more (more preferably 0.1 to 5 mm). If it is in such a range, it is suitable at points, such as intensity and elasticity.

In this invention, it is preferable to use a woven fabric or a nonwoven fabric as a base material, and it is especially preferable to use the woven fabric or nonwoven fabric containing an inorganic fiber. Moreover, what laminated | stacked 1 or more types of base materials different from this on the woven fabric or the nonwoven fabric etc. can be used conveniently. Specifically, what laminated | stacked 1 or more types, such as a glass mesh, glass cloth, a ceramic paper, a synthetic paper, a nonflammable paper, etc. can be used suitably for a woven fabric or a nonwoven fabric. As such a woven fabric or non-woven fabric, a thickness of 0.05 to 1.5 mm (more preferably 0.1 to 1.2 mm, still more preferably 0.2 to 1 mm), a basis weight of 5 to 300 g / m ² , (More preferably, it is 10-250 g / m < ² >, More preferably, it is 20-200 g / m < ² >). By using such a base material, a laminate having excellent aesthetics can be obtained, and the laminate can be stably supported when the laminate is applied to the ground.

(Decoration layer)
The decorative layer of the present invention is a layer that is formed on the substrate and imparts design properties to the laminate. This decorative layer has a pattern of colored particles.

  The decorative layer comprises a synthetic resin (A) (hereinafter also referred to as “component (A)”), colored particles (B) (hereinafter also referred to as “component (B)”), and a chemical having an average fiber length of 0.1 to 5 mm. It is formed by a composition for a decorative layer containing fiber (C) (hereinafter also referred to as “component (C)”).

  The component (A) of the present invention mainly plays a role of immobilizing the component (B). Various synthetic resins can be used as such component (A). Examples of the resin include acrylic resin, silicone resin, acrylic silicon resin, fluorine resin, vinyl acetate resin, acrylic / vinyl acetate resin, vinyl chloride resin, urethane resin, acrylic / urethane resin, epoxy resin, alkyd resin, polyvinyl Examples thereof include alcohol resins, polyester resins, ethylene resins, polyvinyl alcohol, cellulose and derivatives thereof, and composites thereof. Such a resin component may have a property of causing a crosslinking reaction after the coating film is formed.

  (A) The glass transition temperature of a component becomes like this. Preferably it is -60 degreeC-60 degreeC, More preferably, it is -40 degreeC-30 degreeC, More preferably, it is -30 degreeC-20 degreeC. When the glass transition temperature of the component (A) is in such a range, it is possible to impart moderate flexibility. The glass transition temperature is a value determined by the Fox formula.

Examples of the synthetic resin of the present invention include water-dispersed, water-soluble, NAD, solvent-soluble, non-water-dispersed, and solvent-free types. One-component type, two-component type, etc. It is not particularly limited and can be used. In the present invention, it is particularly preferable to include a water dispersion type (synthetic resin emulsion). In such a case, the effect of the present invention can be enhanced by the interaction with the component (C).

  The colored particles (B) of the present invention play a role of imparting a pattern to the decorative layer. By using the component (B), the component (B) is visually recognized as a pattern, and an excellent color tone and texture can be imparted, unlike the case of using a general color pigment having a small particle diameter. Moreover, (B) component forms microscopic unevenness | corrugation in the decoration layer surface, and can also contribute to provision of a three-dimensional design.

  The component (B) is not particularly limited as long as it is a solid particle having some color, and the material can be either inorganic or organic, and either natural or artificial can be used. . Specifically, for example, heavy calcium carbonate, mica, kaolin, clay, porcelain clay, china clay, talc, aluminum hydroxide, magnesium hydroxide, shells, barite powder, marble, granite, serpentine, granite, fluorite, Crushed materials such as cryolite, feldspar, silica stone, quartz sand, etc., ceramic pulverized materials, ceramic pulverized materials, metal particles, metal powder, glass beads, pulverized glass and other inorganic particles, resin beads (resin particles), resin pulverized materials, rubber And organic particles such as plastics, plant fibers and plant pieces. Moreover, what gave these coloring can also be used. These can be used alone or in combination of two or more.

  (B) The average particle diameter of a component is 10 micrometers or more and 1000 micrometers or less (preferably 20 micrometers or more and 800 micrometers or less, More preferably, they are 30 micrometers or more and 500 micrometers or less). In such a range, the component (B) is visually recognized as a pattern, and an excellent color tone and texture can be imparted. Moreover, in this invention, aesthetics can be improved further by combining the (B) component which has a particle size structure of an average particle diameter of at least 2 types or more, Preferably 3 types or more. A preferred embodiment includes a combination of colored particles having an average particle size of 53 μm or more and less than 125 μm and colored particles having an average particle size of 125 μm or more and less than 500 μm. As a more preferred embodiment, a combination of colored particles having an average particle diameter of 53 μm or more and less than 125 μm, colored particles having an average particle diameter of 125 μm or more and less than 212 μm, and colored particles having an average particle diameter of 212 μm or more and less than 500 μm can be mentioned. In addition, the average particle diameter of (B) component is a value obtained by sieving using the metal net sieve prescribed | regulated to JISZ8801-1: 2000, and calculating the average value of the weight distribution.

  The ratio of the component (B) is usually 100 parts by weight or more and 4000 parts by weight or less, preferably 200 parts by weight or more and 3000 parts by weight or less, more preferably 500 parts by weight, in terms of solid content, with respect to 100 parts by weight of the component (A). More than 2000 parts by weight. If it is such a ratio, the design property which utilized the texture of (B) component will be provided.

  The chemical fiber (C) of the present invention plays a role of imparting flexibility to the decorative layer. The average fiber length of the component (C) is from 0.1 mm to 5 mm, preferably from 0.3 mm to 3 mm. In such a range, physical properties such as flexibility and strength of the decorative layer can be improved. Component (C) in the present invention is an organic fiber, for example, rayon fiber, cupra fiber, polynosic fiber, regenerated fiber such as tencel fiber, semi-synthetic fiber such as acetate fiber, triacetate fiber, promix fiber, vinylon fiber, One type or two or more types selected from synthetic fibers such as nylon fiber, aramid fiber, vinylidene fiber, polyvinyl chloride fiber, polyester fiber, acrylic fiber, polyethylene fiber, polypropylene fiber, and polyclar fiber can be used.

Such a component (C) can impart flexibility and strength to the decorative layer without impairing the design of the decorative layer. The mechanism of these actions is not clear, but is presumed as follows.
-Since the difference in refractive index between the component (A) and the component (C) is small, the component (C) is assumed to be in a substantially transparent state in the decorative layer, so that it is presumed that the design is not hindered.
-Since the difference in specific gravity between the component (A) and the component (C) is small, the component (C) is uniformly dispersed in the component (A), so that flexibility and strength can be effectively imparted. It is guessed.
-The component (C), which is an organic fiber, has a higher elongation rate (elongation) than inorganic fibers such as stainless steel fibers and rock wool, and it is assumed that it can effectively impart flexibility and strength. Is done. In the present invention, the elongation of the component (C) is preferably 5% or more (more preferably 7% or more).

  In the present invention, it is particularly preferable that the component (C) is hydrophilic. Thereby, when the flexibility of a decoration layer and a laminated body improves further, and the said (A) component contains a synthetic resin emulsion, the further outstanding effect can be exhibited. The mechanism of its action is not clear, but the component (C) is uniformly dispersed in the synthetic resin emulsion, and in the decorative layer formed, the components (B) are present uniformly in the components (A) and (C). It is presumed that it can be fixed in a state where Examples of such hydrophilic fibers include rayon fibers, cupra fibers, acetate fibers, vinylon fibers, nylon fibers, and aramid fibers. In the present invention, it is particularly preferable to include vinylon fibers. In addition, the hydrophilic property of this invention has a property which is easy to become familiar with water, and is easy to get wet, and means a fiber whose official moisture content exceeds 2% (preferably 3-10%).

  The ratio of the component (C) is usually 1 part by weight or more and 100 parts by weight or less, preferably 5 parts by weight or more and 50 parts by weight or less with respect to 100 parts by weight of the component (A) in terms of solid content. If it is such a ratio, the outstanding flexibility and intensity | strength will be provided.

  Moreover, in addition to the said component, this invention can contain another component as needed, unless the effect of this invention is impaired remarkably. Examples of such components include plasticizers, light stabilizers, anti-algae agents, antibacterial agents, deodorants, adsorbents, flame retardants, colored pigments, extender pigments, glitter pigments, phosphorescent pigments, fluorescent pigments, bones Examples thereof include materials, fibers, ultraviolet absorbers, antioxidants, and catalysts.

  The decorative layer of the present invention preferably has a microscopic uneven shape derived from the component (A) on the surface thereof. This microscopic unevenness is caused by the particle size, aggregation state, etc. of the component (A), preferably 1.5 mm or less (more preferably 0.005 mm or more and 1.2 mm or less, more preferably 0.01 mm). 1 mm or less, most preferably 0.02 mm or more and 0.8 mm or less).

  Moreover, what is necessary is just to set the thickness of a decoration layer suitably according to the objective, Preferably it is 0.1 mm-5 mm, More preferably, it is 0.2 mm-3 mm. In such a range, it is easy to obtain a decorative layer having excellent design properties.

(Laminate manufacturing method)
In the present invention, as long as the decorative layer is laminated on the substrate, the production method is not particularly limited, and examples thereof include the following production methods.
(A) A method of forming a decorative layer by applying a composition for a decorative layer containing a component (A), a component (B), and a component (C) on a substrate.
(A) A method of laminating a substrate after pouring a composition for a decorative layer containing the component (A), the component (B), and the component (C) into a mold.

In the above (a), when applying the decorative layer composition, a known application method such as spray, roller, wrinkle, brush application, reciprocation, coater, pouring, etc. can be used. Here, if the viscosity of the composition for decoration layers is set to about 5-100 Pa.s, the target laminated body will be obtained easily. In addition, the viscosity said here is a viscosity in 20 rpm by a BH type viscometer, and measurement temperature is 23 degreeC.

In the above (a), as a formwork to be used, for example, a formwork made of silicon resin, urethane resin, metal, or the like, or a formwork provided with release paper can be used. Moreover, as a method of laminating the base material, for example,
(I) A method of pouring a composition for a decoration layer into a mold, drying and demolding to mold a decoration layer, and then laminating the substrate with an adhesive or the like,
(II) The method for pouring the composition for decoration layers into a formwork, laminating | stacking a base material before this composition for decoration layers dries, and drying and demolding etc. are mentioned.
Moreover, when pouring the composition for decoration layers in said (I) (II), the application method similar to said (a) is employable.

A reinforcing layer can be provided in the middle of the decorative layer for the purpose of improving the physical properties such as flexibility and strength of the laminate as long as the effects of the present invention are not significantly impaired.

  As the reinforcing layer, for example, the same material as that of the substrate can be used. In this invention, it is preferable to use a different thing from the said base material, As a more preferable aspect, the aspect which uses a woven fabric or a nonwoven fabric as a base material, and uses a braid as a reinforcement layer is mentioned. In such a case, the effect of the present invention can be further enhanced.

Moreover, in this invention, an uneven | corrugated pattern can be formed in a decoration layer for the purpose of improving a decoration property etc., or a decoration material can also be spread | dispersed. Examples of the decorative material include colored aggregates, mica, shells, plants, alumina flakes, glass flakes, metals, rubbers, plastics, and the like.
For example, when manufacturing by the method of said (a), formation of an uneven | corrugated pattern and dispersion | distribution of a decoration material should just be performed before the composition for decoration layers hardens | cures. For the formation of the concavo-convex pattern, a method using a trowel, embossing, a roller or the like can be employed. A known or commercially available spreader or the like can be used for spraying the decorative material. Moreover, when manufacturing with the method of said (a), since a mold form side becomes a laminated body surface, formation of an uneven | corrugated pattern can be provided by adjusting the shape inside a mold form. When the decorative material is sprayed, the decorative layer composition may be poured after the decorative material is scattered on the bottom surface of the mold using a known or commercially available sprayer.

Furthermore, an overcoat layer can be laminated on the decorative layer for the purpose of improving the surface protection of the laminate. Such an overcoat layer may be a transparent layer (clear layer), and in this case, the design properties (hue) of the laminate can be utilized as they are. The overcoat layer may be a color clear layer to which various pigments are added within a range having transparency. Such an overcoat layer can be formed by applying a known water-based or solvent-type coating material.
These coatings may be performed by a known coating method, and a coating tool such as a spray, a coater, a roller, or a brush can be used.

  The laminate of the present invention can be applied mainly as an interior / exterior building material of a building. That is, it can be finished by being attached to each part of the building interior / exterior surface. Specifically, it can be applied to walls, partitions, doors, ceilings, etc. in houses, condominiums, schools, hospitals, stores, offices, factories, warehouses, restaurants, etc. Examples of the base constituting such a part include gypsum board, plywood, concrete, mortar, tile, fiber-mixed cement board, cement calcium silicate board, and slag cement pearlite board. These bases may be those having an existing coating film on the surface thereof, or those already having wallpaper attached thereto.

Moreover, what is necessary is just to stick to a base | substrate using an adhesive agent, an adhesive, an adhesive tape, a nail, a wrinkle, etc. when constructing this invention laminated body. In addition, it can also be fixed using pins, fasteners, rails or the like. Especially, it is preferable to stick the laminated body of this invention to the foundation | substrate using an adhesive agent.

It does not specifically limit as an adhesive agent, What is necessary is just to use a well-known thing. For example, the synthetic resin used for the adhesive is not particularly limited. 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 styrene resin, acrylic urethane resin, silicone resin, water-soluble type such as fluororesin, water dispersion type, etc., and one or two of these The above can be used.
In addition, in order to give various performances such as workability, finish, adhesive strength, fire resistance, etc. to the adhesive, powder components, hollow particles, porous particles, fibers, etc. are added, if necessary, Commonly used additives such as coloring materials, extenders, dispersants, viscosity modifiers, antifoaming agents, antifungal agents, preservatives, and algaeproofing agents can be added as appropriate.

When a laminated body is affixed with an adhesive, adjacent laminated bodies can be abutted and affixed, or joints can be provided between the laminated bodies. When affixing and affixing, it is preferable that the adhesive does not protrude. Moreover, when providing a joint, the space | interval at the time of sticking a laminated body is not specifically limited, What is necessary is just about 1 mm-30 mm. If it is such a range, the finishing which utilized a joint pattern can be performed. Moreover, you may smooth the adhesive of a joint part with a spatula etc. as needed. The ambient temperature at which the adhesive is cured can be set as appropriate, but is usually room temperature.

  Examples are given below to clarify the features of the present invention.

(Compositions 1-9 for decorative layer)
According to the formulation shown in Table 1, decorative materials Compositions 1 to 9 were produced by mixing and stirring the respective raw materials by a conventional method. In addition, the following were used as a raw material.

Synthetic resin 1 (acrylic resin emulsion, solid content 50% by weight, glass transition temperature 0 ° C.)
-Colored particles 1: colored silica sand (black, average particle size 90 μm)
Colored particles 2: colored silica sand (black, average particle size 160 μm)
Colored particles 3: colored silica sand (black, average particle size 300 μm)
-Chemical fiber 1: Vinylon fiber (average fiber length 1 mm, official moisture content 5.0%, elongation 12-26%)
-Chemical fiber 2: Polyester fiber (average fiber length 1 mm, official moisture content 0.4-0.5%, elongation 28-45%)
・ Inorganic fiber 1: Stainless steel fiber (average fiber length 1 mm, official moisture content 0%, elongation 1-2%)

(Test Example 1)
On the base material (glass fiber-containing non-woven fabric, thickness 0.3 mm), the decorative layer composition 1 was applied with a coater so as to have a dry thickness of 2 mm, dried at 60 ° C. for 60 minutes, and laminate 1 Got. The obtained laminate was excellent in aesthetics.
(Evaluation 1)
After the obtained laminate 1 was bent by 90 °, the appearance of the surface was visually evaluated. The results are shown in Table 2.
The evaluation criteria were “no abnormality” as A and “abnormality was recognized” as C, and evaluation was performed in three stages of A>B> C.

(Test Examples 2 to 9)
Laminates 2 to 9 were produced in the same manner as in Test Example 1 except that the decorative layer composition 1 was replaced with the decorative layer compositions 2 to 9, respectively. Laminates 2-9 were all excellent in aesthetics. The laminate 9 was slightly inferior in design due to the inorganic fibers.
About the obtained laminated body, the test similar to Test Example 1 was done. The results are shown in Table 2.

Claims (4)

A laminate in which a decoration layer is laminated on a substrate,
The decorative layer includes a synthetic resin (A), colored particles (B) having an average particle diameter of 10 μm to 1000 μm, and chemical fibers (C) having an average fiber length of 0.1 mm to 5 mm,
A laminate comprising 100 to 4000 parts by weight of the component (B) and 1 to 100 parts by weight of the component (C) with respect to 100 parts by weight of the component (A).   The laminate according to claim 1, wherein the chemical fiber includes at least one selected from recycled fiber, semi-synthetic fiber, and synthetic fiber.   The laminate according to claim 1 or 2, wherein the chemical fiber is hydrophilic. The laminate according to any one of claims 1 to 3, wherein the synthetic resin includes a synthetic resin emulsion.