JP2024050901A - Manufacturing method of surface material - Google Patents

Abstract

[Problem] To provide a manufacturing method for a surface material having aesthetic properties such as a three-dimensional effect. [Solution] The present invention is a manufacturing method for a surface material having a recess, the surface material having a colored layer and a colored transparent coating, the colored layer being formed from a composition containing granular inorganic particles and having a recess on its surface, and the colored transparent coating being unevenly distributed around the edge of the recess in the colored layer. [Selected Figure] Figure 2

Description

The present invention relates to a method for producing a novel surface material. The surface material of the present invention can be applied to surface coating of buildings, civil engineering structures, etc., and specifically, can be applied to pattern finishing of building walls, etc.

For building walls and the like, aesthetic appeal is required from a scenic perspective. In recent years, pattern finishes that evoke natural stone, soil, plants, etc., have been attracting attention from this perspective.

As such patterned finishing materials, for example, decorative sheets that express the texture of natural stone are used, using a mixture prepared by mixing synthetic resin as a binder with fine aggregate made by crushing natural stone or the like (for example, Patent Document 1 and Patent Document 2). In such decorative sheets, the aggregate is fixed with a small amount of resin to create an appearance similar to natural stone.

Japanese Patent Application Laid-Open No. 11-138731 JP 2000-153570 A

However, in the case of decorative sheets like those described above, if the amount of resin in the mixed material is set to a small amount, the surface strength is insufficient and the sheet may become brittle and break. In particular, in the case of decorative sheets with uneven patterns, the areas around the concave and convex parts (corners, etc.) are prone to damage such as scratches and scuffs. Also, although uneven patterns can be formed, they are lacking in variation and it is difficult to express a three-dimensional effect.

The present invention was made to solve the above problems, and aims to provide a surface material that is highly scratch-resistant and has a high aesthetic appearance, such as a three-dimensional effect.

After extensive research, the inventor came up with the idea of a surface material having a recess, a colored transparent coating unevenly distributed around the edge of the recess, and a specific transparent coating on the outermost surface, thus completing the present invention.

That is, the face material of the present invention has the following characteristics.
1. A method for manufacturing a surface material having a recess, comprising the steps of:
The surface material has a colored layer and a colored transparent coating on the surface of the colored layer ,
The colored layer has a recess on its surface,
the colored transparent coating is unevenly distributed on the edge portion of the recess of the colored layer,
The colored layer is formed from a colored layer composition containing granular inorganic particles and a resin, and the colored transparent film is formed from a colored transparent coating material,
The method includes a step of applying the colored transparent coating material to the inner surface of a mold, drying and curing the material, filling the colored layer composition, and demolding the mold after the material has cured.
The method for manufacturing a surface material is characterized in that the formwork has a flat portion and a plurality of protrusions on its inner surface .
2. The method for manufacturing a surface material according to 1., wherein the colored transparent coating material contains a silicone resin and a synthetic resin other than the silicone resin.
3. The method for manufacturing a surface material according to 1. or 2., characterized in that, when viewed from the front, the edge of the recess and the remaining portion have different color tones. 4. The method for manufacturing a surface material according to any one of 1. to 3., characterized in that a transparent coating material is further applied to the surface of the surface material after demolding and dried to form a transparent film on the outermost surface.

The present invention provides a surface material that is highly scratch-resistant and has a three-dimensional appearance and other aesthetic benefits.

FIG. 2 is a front view showing an example of the face material of the present invention. 1 is a schematic cross-sectional view showing an example of a face material of the present invention. 1 is a schematic cross-sectional view showing an example of a face material of the present invention. 1A to 1C are schematic cross-sectional views showing variations of the colored layer of the surface material of the present invention.

A. Surface material A1: Concave portion A2: Convex portion A3: Concave edge portion 1: Colored layer 11: Concave portion (11': Concave flat portion)
12: Convex portion (12': flat portion of convex portion)
13: Recess edge portion 2: Colored transparent coating layer

The following describes how to implement the present invention.

Figure 1 is a schematic cross-sectional view showing an example of the face material of the present invention.

(Surface material)
The surface material A of the present invention has a colored layer 1 and a colored transparent coating 2, and as shown in FIG. 1, when viewed from the front direction, it has a recess A1 on its surface. In the present invention, the part protruding from the recess A1 is called a protrusion A2. FIG. 2 shows a cross-sectional view of the X-X' part in FIG. 1. As shown in FIG. 2, when viewed from the cross-sectional direction, the colored layer 1 of the surface material A of the present invention has a recess 11 on its surface. In addition, the colored transparent coating 2 is characterized in that it is unevenly distributed at the edge 13 of the colored layer recess 11 (hereinafter also referred to as the "recess edge 13"). As shown in FIG. 3 (an enlarged schematic view of the Y part in FIG. 2), the colored transparent coating 2 is provided on the surface of the colored layer 1, and is unevenly distributed in the vicinity of the edge 13 of the colored layer recess 11 so as to form a thicker film than other parts.

The surface material A of the present invention, which has these characteristics, can efficiently increase the strength of the recess edge A3, suppress defects such as scratches and scuffs, exhibit excellent scratch resistance, and impart a three-dimensional effect. In the present invention, the recess edge refers to the area that includes at least the portion spanning between the recess and the protrusion, as shown in Figure 3.

In addition, the surface material A of the present invention can be made such that the color tone of the recess edge A3 is different from that of the other parts (recess A1, protrusion A2) when viewed from the front. This can further enhance the sense of unevenness and three-dimensionality.

The difference in color tone may be such that it is visible to the naked eye, but can be adjusted, for example, by the color tone of the colored transparent coating 2. Specifically, for example, if the colored layer and the colored transparent coating 2 are of the same color, a dark colored part (or a light colored part) is formed at the recess edge A3, which can provide a calm design. On the other hand, if the colored layer 1 and the colored transparent coating 2 are not of the same color, an accent pattern is formed at the recess edge A3, which can provide a design with contrast. In addition to different color tones, differences in gloss and texture, etc., can enhance the three-dimensional effect as long as they do not impair the features of the present invention.

(Colored Layer)
The colored layer 1 of the present invention can be formed by curing a composition (such as a colored layer composition) containing granular inorganic particles and a resin. As a result, the granular inorganic particles are fixed by the resin, and a colored layer having a color tone based on the granular inorganic particles is obtained. That is, the color tone of the colored layer is based on the color tone of the granular inorganic particles. The colored layer 1 may also have a plurality of colored regions having different color tones. In this case, the colored layer can be formed by curing a plurality of colored layer compositions having different color tones.

As the granular inorganic particles, either natural or artificial products can be used as long as the base material is inorganic. As the granular inorganic particles, an embodiment containing at least granular colored inorganic particles is preferable. As such granular colored inorganic particles, particularly opaque ones with a light transmittance of less than 3% are preferable, and those with a light transmittance of 2% or less are more preferable. Specific examples of such granular colored inorganic particles include marble, granite, serpentine, granite, sandstone, slate, basalt, gabbro, diorite, andesite, limestone, and crushed products thereof, crushed ceramics, crushed ceramics, metal particles, etc. In addition, fluorite, galespar, feldspar, silica, silica sand, and crushed products thereof, crushed glass, glass beads, etc., colored to satisfy the above conditions can also be used.

The light transmittance mentioned above is the total light transmittance measured by a turbidimeter. In this measurement, a sample of granular inorganic particles is filled into a transparent glass cell with an inner thickness of 5 mm, and then water is gradually added, after which air bubbles in the cell are removed by vibration.

In addition to the above-mentioned granular colored inorganic particles, the composition may also contain granular transparent inorganic particles. The use of such granular transparent inorganic particles is preferable in terms of improving aesthetics. Suitable granular transparent inorganic particles have a light transmittance of 3% or more (more preferably 3 to 50%, and even more preferably 10 to 30%). Examples of granular transparent inorganic particles include silica, sapphire, feldspar, quartz stone, and crushed products thereof, crushed glass, glass beads, and the like. Both colorless and colored types can be used as long as they satisfy the above-mentioned light transmittance. In the present invention, "α to β" is synonymous with "α or more and β or less".

The particle size of the granular inorganic particles is preferably 0.01 mm to 5 mm, more preferably 0.02 mm to 2 mm, and even more preferably 0.03 to 0.8 mm. The range of design possibilities can be expanded by combining various granular inorganic particles with different particle sizes. The particle size of the granular inorganic particles is measured by sieving using a metal mesh sieve as specified in JIS Z8801-1:2000.

The resin for fixing the granular inorganic particles is preferably one whose coating has transparency. Examples of the form of such resin include solvent-soluble resin, non-aqueous dispersion resin, solventless resin, water-dispersed resin, water-soluble resin, etc. Examples of the type of resin include acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, vinyl acetate resin, acrylic silicone resin, fluororesin, silicon resin, polyvinyl alcohol, cellulose derivatives, etc., or composites of these. Such resins may have the property of causing a crosslinking reaction.

The ratio of the resin is preferably 1 to 50 parts by weight, more preferably 2 to 30 parts by weight, and even more preferably 3 to 20 parts by weight, based on 100 parts by weight of the total amount of the granular inorganic particles, calculated as solid content. With such a ratio, it is easy to impart a design that takes advantage of the aesthetic appearance due to the connection (aggregation) of the granular inorganic particles. In other words, it is easy to obtain a colored layer made of the connection (aggregation) of the granular inorganic particles. In addition, it is easy to suppress the gloss and to present a matte appearance. Furthermore, even when viewed through a transparent coating described later, an aggregate pattern (e.g., a stone texture pattern, etc.) having a fine uneven shape derived from the granular inorganic particles can be visually recognized.

The color layer composition may contain other components (additives) as necessary, as long as they do not significantly impair the effects of the present invention. Examples of such components include plasticizers, anti-algae agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoamers, crosslinking agents, film-forming aids, antifreeze agents, color pigments, extender pigments, photoluminescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, etc.

The colored layer 1 of the present invention is characterized by having a recess 11 on its surface. The recess 11 forms at least a recessed pattern in the colored layer 1. The pattern of such a colored layer 1 is not particularly limited, and may have various shapes, such as a stone-like pattern, a wood-grain pattern, and a joint pattern. Among these, it is preferable to have a recessed pattern in the shape of, for example, a burrow, an insect hole, a bark pattern, etc., as formed in natural stone, soil, plants, etc.

The size of the recesses 11 depends on the shape of the uneven pattern, but the maximum diameter (long diameter) is preferably 0.2 to 50 mm (more preferably 0.5 to 30 mm). The depth of the recesses 11 depends on the thickness of the colored layer 1, but is preferably 0.1 to 5 mm (more preferably 0.2 to 3 mm).

Furthermore, in the present invention, it is preferable that the colored layer 1 has a plurality of recesses 11, the shape of which may be fixed (identical) or different. Furthermore, the arrangement of the plurality of recesses 11 may be regular or random, but in the present invention, it is preferable that they form a linear pattern, a striped pattern, or the like. In such a case, it is easy to express a pattern reminiscent of natural stone, soil, plants, etc., and a surface material with excellent aesthetics can be obtained. In particular, the present invention is suitable for expressing a pattern of natural stone (especially travertine-like, etc.).

Specifically, the colored layer 1 expressing the above-mentioned pattern has an uneven pattern formed of recesses 11 and protrusions 12 when the colored layer 1 is viewed in a cross-sectional direction. For example, as shown in FIG.
(a) having random depressions 11 and protrusions 12 on its surface;
(b) A surface having a concave portion 11 and a convex portion flat portion 12', where the convex portion 12 is flat;
(c) A plate having a flat portion 11' where the recess 11 is flat, and a protrusion 12 on its surface;
and combinations of the above (a) to (c). The present invention is particularly effective when it includes the uneven pattern of the above (b) and/or (c).

In the above (a) to (c), the recess edge 13 is an area that includes at least the portion spanning between the recess 11 and the protrusion 12.

(colored transparent coating)
The colored transparent coating 2 is provided on the surface of the colored layer 1, and is characterized by being unevenly distributed at the recess edge portion 13 of the colored layer 1. As a result, when the surface material A of the present invention is viewed from the front, the recess edge portion A3 and the other portions (recess portion A1, protrusion portion A2) have different appearances (e.g., color tone, etc.), and a surface material with high aesthetics due to unevenness, three-dimensionality, etc. can be obtained.

Such a colored transparent film 2 is preferably formed by uneven distribution of the colored transparent coating material. The colored transparent coating material may be a composition containing a resin component and a coloring component, and the coating may have transparency. The medium for the colored transparent coating material may be either solvent-based or water-based, but in the present invention, it is preferable that the medium contains water. This makes it easier for the colored transparent coating material to be unevenly distributed on the edge portion 13 of the recess in the colored layer 1, and a surface material with excellent scratch resistance and three-dimensional effect can be obtained.

The resin component is not particularly limited, but examples thereof include ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, acrylic styrene resin, acrylic silicone resin, urethane resin, fluororesin, silicone resin, etc., or composite resins of these. The resin component may be in the form of any of water-soluble resin, water-dispersible resin, solvent-soluble resin, solventless resin, non-water-dispersible resin, etc., but in the present invention, water-dispersible resin (resin emulsion) is preferred.

In the present invention, a preferred embodiment contains a silicone resin and a synthetic resin other than a silicone resin as the resin component. By using these resin components in combination, the colored transparent coating material is more likely to be unevenly distributed around the edges of the recesses in the colored layer, which enhances the effect of scratch resistance and reduces gloss, resulting in a surface material with a calm and excellent aesthetic appearance. Furthermore, the color tone of the edges of the recesses becomes clearer, further enhancing the aesthetics such as the three-dimensional effect.

Specific examples of silicone resins include silicone oils and silicone resins made of dialkyl polysiloxanes such as dimethyl polysiloxane, polyaryl siloxanes such as polydiphenyl siloxane, and polyalkylaryl siloxanes such as methylphenyl polysiloxane, as well as modified silicone oils and modified silicone resins such as amino-modified silicone, epoxy-modified silicone, carboxyl-modified silicone, alcohol-modified silicone, and polyether-modified silicone. The silicone resin may be in the form of a water-soluble resin, a water-dispersible resin, a solvent-soluble resin, a solventless resin, or a non-water-dispersible resin, but in the present invention, a water-dispersible resin (resin emulsion) is preferred.

Furthermore, a preferred embodiment includes an acrylic resin emulsion and/or an acrylic styrene emulsion as a synthetic resin other than a silicone resin. The glass transition temperature of the acrylic resin is preferably 5 to 100°C (more preferably 10 to 80°C). This can further enhance the effects of the present invention.

The solids weight ratio of the silicone resin to the synthetic resin other than the silicone resin is preferably 5:95 to 90:10 (more preferably 10:90 to 80:20, and even more preferably 15:85 to 60:40). In such a case, it is possible to improve scratch resistance, and it is possible to obtain a surface material in which the colored transparent coating is easily distributed unevenly and which has excellent three-dimensionality.

The coloring component may be a known coloring component (coloring pigment, dye, etc.), and preferably includes coloring pigments such as organic coloring pigments and inorganic coloring pigments. The mixing ratio is preferably 0.01 to 30 parts by weight (more preferably 0.02 to 20 parts by weight, and even more preferably 0.05 to 10 parts by weight) of the coloring component per 100 parts by weight of the resin component (solid content). When mixing the coloring pigment with the resin component, it can be mixed in the form of a dispersion of each pigment.

The colored transparent coating material can be diluted with various solvents when applied. The solid content of the colored transparent coating material when applied is preferably 0.1 to 50% by weight (more preferably 0.2 to 30% by weight, and even more preferably 0.3 to 20% by weight), and the application amount per unit area is preferably 10 to 500 g/m ² (more preferably 20 to 400 g/m ² , and even more preferably 30 to 300 g/m ² ). In such cases, the colored layer tends to be unevenly distributed at the edge of the recessed portion, making it easier to obtain the effects of the present invention and improving the aesthetic appearance.

Furthermore, the colored transparent coating material may contain, for example, plasticizers, anti-algae agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoamers, film-forming aids, antifreeze agents, water repellents, hydrophilizing agents, crosslinking agents, matting agents, extender pigments, photoluminescent pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, etc.

The colored transparent coating 2 of the present invention is provided on the surface of the colored layer 1, and is characterized by being unevenly distributed on the recess edge 13 of the colored layer 1. This makes it possible to efficiently increase the strength of the recess edge (particularly near the corners) of the surface material A of the present invention, suppress defects such as scratches and scuffs, and exhibit excellent scratch resistance, while emphasizing the sense of depth (depth) more than the actual recess, enhancing the three-dimensional effect.

In the present invention, an embodiment in which the colored transparent coating 2 is unevenly distributed is, for example, the case in which the colored transparent coating 2 is
(I) An embodiment in which the protective film is not provided on the convex portion 12 (flat portion 12′ of the convex portion) but only on the edge portion 13 of the concave portion;
(II) A mode in which the protective film is provided on the entire surface including the recess 11 (recess flat portion 11′) and the protrusion 12 (protrusion flat portion 12′), and is a thick film at the recess edge portion 13;
(III) An embodiment in which the recess 11 (recess flat portion 11') and the protrusion 12 (protrusion flat portion 12') are provided discontinuously (scattered) over the entire surface including the recess 11 (recess flat portion 11') and the protrusion 12 (protrusion flat portion 12'), and are provided on the recess edge portion 13;
(IV) An embodiment in which the insulating layer is provided discontinuously (scattered) over the entire surface including the recess 11 (recess flat portion 11') and the protrusion 12 (protrusion flat portion 12'), and is a thick film at the recess edge portion 13;
etc.

In the present invention, as in (I) to (IV) above, the colored transparent coating 2 is unevenly distributed so as to frame the recess edge 13 of the colored layer 1. This enhances scratch resistance, and emphasizes the sense of depth (depth) more than the actual recess, enhancing the three-dimensional effect. Note that when the colored layer 1 has multiple recesses, the colored transparent coating 2 may be provided on all of the recess edge 13, or only on some of them.

(Transparent coating)
The surface material of the present invention may also have a transparent film 3 on the outermost surface. The transparent film 3 is formed of a transparent coating material. The transparent coating material of the present invention is not particularly limited as long as it contains a resin component. The medium of the transparent coating material may be either a solvent-based or water-based medium, but in the present invention, it is preferable that the medium contains water. This can further improve the scratch resistance.

Furthermore, in the present invention, it is preferable that the transparent coating 3 contains a silicone resin and a synthetic resin other than the silicone resin as the resin component. The solid weight ratio of the silicone resin to the synthetic resin other than the silicone resin is preferably 5:95 to 95:5 (more preferably 10:90 to 80:20, and even more preferably 15:85 to 60:40). In such a case, the scratch resistance can be improved. Furthermore, a stable matte effect can be obtained without using powder components such as known matting agents, and the formed transparent coating is unlikely to cause gloss unevenness (gloss unevenness) regardless of its film thickness, and a uniform matte surface can be formed. Therefore, a surface material with a calm and highly aesthetic appearance without gloss unevenness can be obtained without compromising the design such as the color tone of the colored layer and the colored transparent coating.

In the present invention, it is preferable that the resin component of the transparent coating material is the same type or the same as the resin component of the colored transparent coating material. This can further enhance the above-mentioned effects.

The transparent coating material preferably has a solids content of 2 to 50% by weight (more preferably 5 to 30% by weight). The transparent coating material can be diluted with various solvents when applied. The dilution ratio of the coating material is preferably 0 to 1000% by weight (more preferably 0 to 800% by weight) relative to the transparent coating material, and the solids content when applied is preferably 0.1 to 50% by weight (more preferably 0.2 to 30% by weight). In such cases, the effect of the present invention can be enhanced.

The amount of the transparent coating material applied per unit area is preferably 5 to 500 g/m ² (more preferably 10 to 300 g/m ² ), and in terms of solid content, is preferably 1 to 200 g/m ² (more preferably 1.5 to 100 g/m ² , and even more preferably 2 to 80 g/m ² ). In such a case, sufficient scratch resistance can be obtained.

The transparent coating material may be one that forms a colorless, transparent film, or one that contains some coloring components (coloring pigments, dyes, dispersions thereof), etc., and forms a colored, transparent film, so long as the effect of the present invention is not impaired. Furthermore, these transparent coating materials may contain, for example, plasticizers, anti-algae agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoamers, film-forming aids, antifreeze agents, water repellents, hydrophilizing agents, crosslinking agents, matting agents, extender pigments, photoluminescent pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, UV absorbers, light stabilizers, antioxidants, catalysts, etc.

The transparent coating 3 of the present invention is provided on a surface having a colored layer 1 and a colored transparent coating 2, and may be provided over the entire surface or may be provided discontinuously (scattered). In addition, in the present invention, it is preferable that the transparent coating 3 is provided at least on the edge of the recess (particularly near the corners) (more preferably, the entire surface including the edge of the recess) of the surface material A, which can further increase the strength of the edge of the recess, suppress defects such as scratches and scuffs, and exhibit excellent scratch resistance.

(Reinforcing material)
The surface material of the present invention may have a reinforcing material. Such a reinforcing material may be provided inside and/or on the back surface of the colored layer. Examples of the reinforcing material include woven fabric, nonwoven fabric, ceramic paper, synthetic paper, mesh, cloth, gypsum board, plywood, slate board, metal plate, etc. The reinforcing material may be made of two or more of the above materials. By using such a reinforcing material, the strength of the surface material can be increased.

(Production method)
The method for manufacturing the surface material of the present invention is not particularly limited, and various methods can be adopted. One example is a method using a mold. In this method, a mold is first prepared in which recesses and protrusions (recesses of the colored layer) corresponding to a desired pattern are formed. The mold is not particularly limited, but for example, a mold made of silicone resin, urethane resin, or the like, or a mold provided with release paper, etc. can be used. When manufacturing using a mold, the inner surface of the mold becomes the surface of the surface material, so that the desired uneven pattern can be imparted to the surface of the surface material by adjusting the shape of the inner surface of the mold.

Using the above mold, for example,
A method in which a colored layer composition is filled into the inner surface of a mold, the composition is cured, the mold is removed, a colored transparent coating material is applied to the surface of the colored layer, and the coating material is dried and cured;
A method of applying a colored transparent coating material to the inner surface of a mold, drying and curing the material, filling the mold with a colored layer composition, and removing the material from the mold after the material has cured;
The surface material can be manufactured by the above methods.

When applying and filling the colored layer composition and the colored transparent coating material, known tools such as a spray, roller, trowel, brush, reciprocator, coater, etc. can be used. When introducing a reinforcing material, for example, the reinforcing material may be embedded inside the colored layer or laminated on the back surface of the colored layer before the colored layer composition hardens.

Specifically, the face materials shown in FIGS. 1 to 3 are preferably produced, for example, by the following method.
(1) A composition for a colored layer and a colored transparent coating material are produced.
(1-1) A composition for a colored layer is produced by mixing and stirring granular inorganic particles, a resin, and, if necessary, additives in a conventional manner.
(1-2) A colored transparent coating material is produced by mixing and stirring the resin component and the coloring component by a conventional method.
(2) Prepare a form (a form with a desired concave and convex pattern transferred onto it) having desired concave and convex portions (forming the concave portions of the colored layer) on its inner surface, and apply a colored transparent coating material to the inner surface of the form, followed by drying and hardening.
(3) Next, the color layer composition is filled into the mold, and after curing, the mold is removed.

The surface material obtained by the above method has a convex part on the inner surface of the formwork that is inverted to form a concave part in the colored layer. In addition, the surface of the colored layer has a colored transparent coating that is unevenly distributed around the edges of the concave parts, providing an aesthetic appearance with contrast, three-dimensionality (depth), etc.

In particular, in the above (2), when the colored transparent coating material is applied to a form having concave and convex portions, the colored transparent coating material tends to be unevenly distributed at the base of the convex portions. In particular, when the colored transparent coating material is applied to a form having flat and convex portions, and further the convex portions have a shape with a slope or roundness (for example, a mountain shape, a parabola shape, a curved shape), the colored transparent coating material can be unevenly distributed at the base of the convex portions even more. The mechanism by which the colored transparent coating material is unevenly distributed at the base of the convex portions on the inner surface of the form is not limited to the following, but it is considered that the colored transparent coating material tends to be unevenly distributed near the boundary between the flat and convex portions due to the effect of the surface tension of the colored transparent coating material and the effect of the viscosity. For this reason, in the present invention, it is preferable that the colored transparent coating material contains water, which has a high surface tension, as a medium, and further that the viscosity is set low as described above.

In addition, in the above (2), it is preferable to cure the colored transparent coating material after it has been applied. During the drying and curing process, the colored transparent coating material is more likely to be concentrated at the base of the convex parts on the inner surface of the formwork. Note that the curing in the above (2) means that the material is dry to the touch or more (preferably semi-cured, and more preferably cured and dried).

In the above (3), by filling the colored layer composition after the colored transparent coating material has hardened, a surface material having a desired appearance can be stably manufactured. Note that, when the colored layer composition is filled in the colored transparent coating material in a hardened state, rather than in an unhardened state, the effect of the present invention can be fully exerted.

In the present invention, after steps (1) to (3) above, for example, in step (4), a transparent coating material can be applied and dried to the surface (preferably the entire surface) of the face material after demolding to provide a transparent film. This allows a transparent film to be formed unevenly (laminated) on the edges of the recesses where the colored transparent film of the face material produced in steps (1) to (3) above is unevenly distributed, thereby further improving scratch resistance and enhancing the three-dimensional effect.

In the present invention, when a transparent coating is applied to the entire surface of the surface material in (4) above, defects such as uneven gloss are unlikely to occur, and a calm aesthetic appearance can be achieved. In particular, in the present invention, the above effect can be achieved by adopting a means selected from the following: the colored layer is made of inorganic particles fixed with a small amount of resin, the transparent coating material contains a silicone resin, and the amount of transparent coating material applied is adjusted. Although this mechanism of action is not limited to the following, when a transparent coating material is applied to the colored layer of the present invention, the transparent coating material penetrates the colored layer surface while forming a coating, so that a surface material can be obtained that retains the fine uneven shape derived from the inorganic particles that form the colored layer. It is presumed that the above effect can be achieved by this.

The surface material obtained from the above (1) to (3) (and further (4)) preferably has a glossiness of 8 or less at 60 degrees (more preferably 1 to 7, even more preferably 1.5 to 6). If the glossiness is within such a range, a calm and elegant aesthetic can be imparted. Furthermore, the surface material of the present invention preferably has a glossiness of 8 or less at 85 degrees (more preferably 1 to 7, even more preferably 1.5 to 6). Furthermore, it is preferable that the difference in glossiness between 60 degrees and 85 degrees is 2 or less (more preferably 1.5 or less, even more preferably 1 or less). By having the glossiness at 60 degrees and 85 degrees satisfy the above ranges in this way, unevenness in gloss due to the viewing angle (direction) can be suppressed, and the sense of calm and aesthetics can be further enhanced. The glossiness in the present invention is a value measured in accordance with JIS K5600-4-7 "Specular glossiness". Specifically, it is the 60-degree or 85-degree specular gloss value measured by a gloss meter, and is the average value of measurements taken at 10 random locations on the surface of surface material A.

The surface material of the present invention can be used as a material for decorating the walls of buildings, etc. When fixing the surface material of the present invention to a wall, etc., for example, adhesives, adhesive tapes, nails, screws, bolts, rails, etc. may be used. Examples of substrates that constitute the walls of buildings, etc. include concrete, mortar, siding boards, extrusion molding boards, gypsum boards, perlite boards, plywood, bricks, plastic boards, metal boards, glass, porcelain tiles, etc. These substrates may already have a coating (existing coating, undercoat coating, etc.) formed on their surface, or may have wallpaper attached, etc.

The following examples and comparative examples will clarify the features of the present invention.

(Production of Colored Layer Composition)
A color layer composition was produced by uniformly mixing the raw materials in the mixing ratio shown in Table 1 by a conventional method. The raw materials used were as follows.
Granular colored inorganic particles [a mixture of white silica sand, yellow silica sand, and brown silica sand (weight ratio) = 80:10:10), particle size 0.03-0.6 mm, light transmittance less than 1%]
- Granular transparent inorganic particles [Kansui stone; particle size 0.1-0.4 mm, light transmittance 16%]
Resin component [acrylic resin emulsion, solid content 50% by weight, medium: water]
・Additives [defoamers, film-forming agents, water, etc.]

(Production of Colored Transparent Coating Materials 1 to 10 and Transparent Coating Materials 1 to 10)
A colored transparent coating material and a transparent coating material were produced by uniformly mixing the raw materials in the mixing ratios shown in Tables 2 and 3 in a conventional manner. The raw materials used were as follows:
Acrylic resin emulsion [solid content 50% by weight, glass transition temperature 40°C, medium: water]
Silicone resin emulsion [dimethylpolysiloxane polyoxyethylene alkyl ether emulsion], solid content 50% by weight, medium: water]
Pigment dispersion 1 [acrylic resin emulsion, pigment (Oka pigment: Akasabi pigment: Black pigment (weight ratio) = 25:55:20) mixed solution, solid content 50% by weight, resin solid content 40% by weight, pigment solid content 10% by weight, medium; water]
Additives: antifoaming agents, film-forming agents, etc.

<Production of Face Material (I)>
A rectangular formwork (30 cm x 60 cm) capable of forming a travertine pattern with multiple convex parts (height of convex parts 0.2-2 mm, major axis of convex parts 0.2-10 mm) on a flat part was used. A colored transparent coating material was applied to the formwork (weight per unit area 100 g/m ² ) and unevenly distributed at the base of the convex parts of the formwork, and then dried and hardened (at 23°C for 24 hours).
Next, a colored layer composition was applied onto the colored transparent film (weight per unit area: 3.3 kg/m ² ), cured (at 65° C. for 24 hours), and then demolded to produce a surface material (I). The colored transparent coating material and the colored layer composition were used in the combinations shown in Table 4 (Examples 1 to 12).
<Production of Face Material (I')>
The colored layer composition 1 was applied (weight per unit area: 3.3 kg/m ² ) to the same mold as above, cured (at 65° C. for 24 hours), and then demolded to produce a surface material (I′) (Comparative Example 1).

(Examples 1 to 12, Comparative Example 1)
The following tests were carried out on each of the face materials (I) and (I') produced by the above-mentioned methods. The results are shown in Table 4.
(Scratch resistance)
The surface of the obtained facing material was rubbed 1000 times with a deck brush (made of resin), and then the facing material surface was visually evaluated. The surface was evaluated on a four-level scale (A>B>C>D), with A being no defects and D being defects.
(Three-dimensional effect)
The obtained surface materials were visually observed and rated on a four-level scale (A>B>C>D), with A being for those with a three-dimensional appearance and D being for those with a flat finish.

In Examples 1 to 12, the surface materials were excellent in terms of scratch resistance and three-dimensional effect. On the other hand, in Comparative Example 1, defects were observed around the edges of the recesses, and the surface material also had poor three-dimensional effect.

<Production of Face Material (II)>
A colored transparent coating material was applied (weight per unit area: 100 g/m ² ) to the same form as above, unevenly distributed at the base of the convex parts of the form, and then dried and hardened (at 23° C. for 24 hours).
Next, a color layer composition was applied onto the color transparent film (weight per unit area: 3.3 kg/m ² ), cured (at 65° C. for 24 hours), and then demolded.
Furthermore, a transparent coating material was applied (weight per unit area: 140 g/m ² ) to the entire surface having the colored transparent film (surface having flat and recessed portions) to produce a surface material (II) provided with a transparent film layer. The colored transparent coating material and the transparent coating material and colored layer composition were used in the combinations shown in Table 5 (Examples 13 to 20).
<Production of Face Material (II')>
The colored layer composition 1 was applied (weight per unit area: 3.3 kg/ ^m2 ) to the same mold as above, cured (at 65°C for 24 hours), and then demolded. Next, the transparent coating material 6 was applied (weight per unit area: 140 g/ ^m2 ) to produce a surface material (II') provided with a transparent coating layer (Comparative Example 2).

(Examples 13 to 20, Comparative Example 2)
The surface materials (II) and (II') produced by the above-mentioned method were subjected to the following tests in addition to the above-mentioned scratch resistance and three-dimensional effect. The results are shown in Table 5.
(Glossiness)
According to JIS K5600-4-7 "Specular gloss", 10 arbitrary locations on the surface of the surface material A were measured (measurement angles: 60 degrees, 85 degrees) and the average value was calculated. In addition, the difference (absolute value) between the minimum and maximum gloss values among the 10 measured locations was calculated, and the gloss (luster) unevenness was evaluated on a 4-level scale (A>B>C>D) (A: 1 or less, B: more than 1 and 2 or less, C: more than 2 and 3 or less, D: more than 3).

The surface materials obtained in Examples 13 to 20 all had a reduced gloss, a calm appearance, and a three-dimensional appearance. The surface material obtained in Comparative Example 2 had a slightly uneven gloss and was inferior in three-dimensional appearance.

Claims (4)

A method for manufacturing a surface material having a recess, comprising the steps of:
The surface material has a colored layer and a colored transparent coating on the surface of the colored layer ,
The colored layer has a recess on its surface,
the colored transparent coating is unevenly distributed on the edge portion of the recess of the colored layer,
The colored layer is formed from a colored layer composition containing granular inorganic particles and a resin, and the colored transparent film is formed from a colored transparent coating material,
The method includes a step of applying the colored transparent coating material to the inner surface of a mold, drying and curing the material, filling the colored layer composition, and demolding the mold after the material has cured.
The method for manufacturing a surface material is characterized in that the formwork has a flat portion and a plurality of protrusions on its inner surface . 2. The method for manufacturing a surface material according to claim 1, wherein the colored transparent coating material contains a silicone resin and a synthetic resin other than the silicone resin. 3. The method for manufacturing a surface material according to claim 1, wherein the edge of the recess and the remaining portion have different color tones when viewed from the front. The method for producing a surface material according to any one of claims 1 to 3 , further comprising applying a transparent coating material to the surface of the surface material after demolding and drying the material to form a transparent film on the outermost surface.

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