JP4158943B1 - Manufacturing method of cosmetic material - Google Patents

Abstract

Disclosed is a woodgrain-like decorative material that has little secular change such as peeling, swelling and cracking and is essentially non-flammable. Also, it can be applied to a base material having a three-dimensional curved surface or a base material having a step or unevenness on the surface, and provides a cosmetic material that is safe for the human body without using an organic solvent. . Furthermore, it provides cosmetic materials that can be produced at low cost and in large quantities by mechanization and automation without special skills.
A decorative material of the present invention has an inorganic water retention layer, an inorganic water retention background layer, and a woodgrain-like upper pattern layer having streaky irregularities on the surface on an inorganic base material.
[Selection] Figure 1

Description

  The present invention relates to a decorative material such as a flooring, a joinery, a table top, or furniture. In particular, the present invention relates to a grain-like decorative material having a texture of natural wood. The present invention also relates to a method for manufacturing a cosmetic material that does not require technical skill and is inexpensive and can be mass-produced.

  In the past, natural wood with excellent design has been used for decorative materials such as flooring, joinery, table tops, and furniture, but due to depletion of wood resources and rising prices of wood, plywood or particle board, etc. Wood processed products have come to be used. In addition, a technology has been developed in which a veneer formed by thinly slicing natural wood is applied to the surface of the base material. In addition, a decorative sheet is formed by printing a woodgrain pattern on the sheet in advance, and then applied to the surface of the base material. Cosmetic materials formed by applying decorative sheets have come to be widely used.

  For example, decorative sheets used in the manufacture of decorative materials include decorative sheets that are printed with a pattern such as wood grain on the surface of paper sheets, but paper-based decorative sheets have surface characteristics such as wear resistance and water resistance. Inferior, because it prints on paper, the printed pattern lacks the sharpness and is not suitable for applications that require a high-class feeling. On the other hand, a decorative sheet that uses a thermoplastic resin sheet instead of a paper sheet is excellent in surface physical properties and design properties, and therefore can be used in applications that require a high-class feeling.

  As the thermoplastic resin sheet used for the decorative sheet, a cheap and excellent processability polyvinyl chloride sheet or a polyolefin sheet having little adverse effect on the environment is widely used. By sticking to the surface of the base material, the desired design properties are expressed, so that it is necessary to hide unfavorable colors and scratches of various base materials.

  As a method for improving the concealability of the base material, for example, a cosmetic material in which a decorative sheet in which a concealed solid print layer and a pattern print layer are laminated on a base material sheet made of a thermoplastic resin containing a concealable pigment is attached to the base material. Is known (see Patent Document 1). This decorative sheet is disclosed that the concealability is supplemented by the thermoplastic resin layer containing the concealing pigment, so that the thickness of the concealed solid print layer and the blending ratio of the concealing pigment can be suppressed, and the interlayer adhesion strength is excellent. ing.

  However, a cosmetic material for sticking a veneer or a decorative sheet to a base material is harmful to the human body because the adhesive used to attach the base plate to the base material contains an organic solvent. Moreover, since it passes through the process which affixes a veneer or a decorative sheet to a base material, it cannot affix on the base material which has a three-dimensional curved surface, or the surface which has a level | step difference. Furthermore, it is vulnerable to heat and easily burns, and is likely to peel, swell, and crack over the years.

On the other hand, coating materials used for decorative materials such as flooring, joinery, table tops, and furniture include vinyl paint, water-based paint, and oil stainless steel, but coating materials such as vinyl paint and water-based paint are based on The surface of the material is colored in a single color, and the surface of the base material cannot be decorated with woodgrain. In addition, a coating material such as oil stainless steel is used to make use of the wood grain of the base material, and is not a technique for decorating the surface of the base material in the same manner.
JP 2000-343649 A

  An object of the present invention is to provide a cosmetic material that has little secular change such as peeling, blistering, or cracking, is essentially nonflammable, and does not generate toxic gas when heated. In addition, it is possible to apply wood-grained decorative coating to a substrate having a three-dimensional curved surface or a substrate having a step or unevenness on the surface, and does not use an organic solvent. Is to provide. It is another object of the present invention to provide a manufacturing method that can produce a low-cost and large-scale wood-grained cosmetic material with high aesthetics by mechanization and automation without requiring special skills.

The method for producing a decorative material according to the present invention includes a step of forming an inorganic water retention layer containing an inorganic binder, an inorganic filler, and a water retention agent by coating an inorganic water retention paint on an inorganic substrate and drying the coating. Coating an inorganic water-retaining colored paint on the inorganic water-retaining layer and drying to form an inorganic water-retaining undercoat layer containing an inorganic binder, an inorganic filler, a water-retaining agent, and a coloring pigment; and A method for producing a cosmetic material comprising a step of forming an upper pattern layer on the water-retaining undercoat layer, wherein the step of forming the upper pattern layer comprises a step of applying a colored paint on the inorganic water-retaining lower layer, Covering a colored paint layer with a water-resistant sheet, removing air between the water-resistant sheet and the colored paint layer, drying, and peeling the water-resistant sheet , water-resistant sheet-like body covering the colored paint layer, a plurality A sheet having a fold approximately in one direction, a method for producing a decorative material having a top pattern layer of wood with a streaky irregularities on the surface.

  The decorative material of the present invention has a high aesthetic wood grain, and preferably has a high-quality natural wood texture. Moreover, it is highly stable over the years, is essentially non-flammable, and does not generate toxic gases when heated. The method for producing a decorative material according to the present invention can mass-produce a wood-tone decorative material having excellent design properties without technical skill. Furthermore, even when the base material has a three-dimensional curved surface or when the surface of the base material has a step or unevenness, it is easy to apply a wood-tone decorative material. Can be provided. Moreover, it is possible to provide a method for producing a cosmetic material that is highly safe for the human body without using an organic solvent.

(Cosmetic materials)

  A cross-sectional view of the decorative material of the present invention is shown in FIG. As shown in FIG. 1, this decorative material includes an inorganic water retention layer 2, an inorganic water retaining undercoat layer 3, and an upper pattern layer 4 on an inorganic substrate 1, and the upper pattern layer 4 is formed on the surface. It has streak-like irregularities and has a grain of wood. The appearance of the decorative material has a high aesthetic wood grain, and preferably has a high-quality texture like natural wood, so that, for example, by using a fine and elegant wood texture, It is useful as a decorative material for wall materials, floor materials, joinery, frame materials, counter tops, table tops or furniture. In addition, based on an inorganic base material, the main components are an inorganic water retaining layer and an inorganic water retaining base layer mainly composed of cement material, etc., so it is essentially non-flammable, and has high stability and safety. .

  The inorganic base material is preferably made of calcium silicate, calcium carbonate, ceramics, metal, concrete, glass, mortar, or the like. Examples of metal base materials include base materials made of iron, stainless steel, aluminum, copper, etc. In addition, tin plates (steel-plated steel plates), zinc plates (zinc-plated steel plates), etc. Can be used. In addition, the inorganic base material constituting the decorative material of the present invention is not only a base material made of only an inorganic material, but also, for example, a plaster board that is a plaster board whose surface is covered with cardboard with gypsum as a core material. Although not an inorganic base material, a base material whose main composition is made of an inorganic material is also included. The gypsum board is excellent in fire resistance and sound insulation and can be easily processed, and therefore can be preferably used as a base material for a decorative material. The cosmetic material of the present invention includes an aspect in which the surface on which the inorganic water retention layer of the inorganic base material is formed has a three-dimensional curved surface such as a concave surface, a convex surface, or a corrugated shape, or an aspect having a step or an unevenness.

As shown in FIG. 1, the inorganic water retention layer 2 is disposed between the inorganic base material 1 and the inorganic water retention background layer 3. In the case where a colored paint is applied to form the inorganic water-retaining undercoat layer 3 by arranging the inorganic water-retaining layer 2, the inorganic water-retaining layer 2 is formed even when the color paint bleeds into the inorganic base material 1 quickly. In order to retain the paint, it is possible to form an inorganic water-retaining undercoat layer 3 that represents a natural color change in a woody tone. On the other hand, in the case where the colored paint soaks into the inorganic base material 1 slowly, the inorganic water-retaining layer 2 stores the paint, so that an inorganic water-retaining undercoat layer 3 that similarly represents a natural color change in woody form is formed. can do. Based on such a viewpoint, the water retention of the inorganic water retention layer is preferably 0.4 g / cm ³ or more, and more preferably 2 g / cm ³ or more. On the other hand, if the water retention capacity of the inorganic water retention layer is too large, it takes a long time to dry the inorganic water retention layer, resulting in a decrease in production efficiency and an increase in the viscosity of the paint for forming the inorganic water retention layer. Tend to decrease. For this reason, the water retention of the inorganic water retention layer is preferably 30 g / cm ³ or less, and more preferably 10 g / cm ³ or less. In this specification, the water retention is determined by the following equation.
Water retention (g / cm ³ ) = {Mass when wet (g) −Mass when dried (g)} ÷ Volume (cm ³ )

  By arranging the inorganic water retention layer 2, the familiarity with the inorganic base material 1 is improved, so that the adhesiveness with the inorganic base material is improved, and cracks, blisters, or peeling occur even after years after manufacture. It is difficult to increase the stability of the decorative material. In addition, it is possible to provide a structure with high dimensional stability while suppressing the occurrence of deviation. From such a viewpoint, the composition of the inorganic water retention layer is preferably an embodiment in which an inorganic binder, an inorganic filler and a small amount of water retention agent are blended, and in addition, if necessary, a small amount of an antifoaming agent, a curing agent, and a dustproof agent. Color pigments and the like can be added.

  The binder used for the inorganic water retention layer is preferably an inorganic binder. When an organic binder such as urea resin, phenol resin, melamine resin or resorcinol resin is used, a large amount of formaldehyde is emitted from the cosmetic material after the production. When an organic binder such as epoxy resin or urethane resin is used, volatile organic substances such as toluene and xylene are emitted from the cosmetic material. By using an inorganic binder, it is possible to provide a cosmetic material that is gentle to the human body and highly safe. As the inorganic binder, a cement binder, a silica binder, or a ceramic binder is preferable.

  Examples of the cement-based binder include ordinary Portland cement (JIS R5210), early-strength Portland cement (JIS R5210), ultra-early strong Portland cement (JIS R5210), super-hard cement, alumina cement, moderately hot Portland cement (JIS R5210), Low heat Portland cement (JIS R5210), Low alkali type Portland cement (JIS R5210), Blast furnace cement (JIS R5211), Flash eye cement (JIS R5213), Silica cement (JIS R5212), Eco cement (JIS R5214), Expandable cement , White Portland cement, ultrafine particle cement and the like can be preferably used.

  Since each cement has preferable characteristics, it is selected and used according to the application. Ordinary Portland cement is readily available. Since early strength Portland cement, super early strength Portland cement, ultrafast cement and alumina cement can provide strength in a short time, production efficiency can be increased even at low temperatures in winter. Medium-heated Portland cement, low heat Portland cement and low alkali Portland cement have a low alkali-aggregate reaction, and thus can improve durability. Blast furnace cement is resistant to seawater. Flash eye cement is suitable for an inorganic base material having a small drying shrinkage rate and hardly allowing water to pass through. Silica cement has high chemical resistance. The expandable cement is effective in suppressing cracks in the inorganic water retention layer. Moreover, white Portland cement has high whiteness and is useful also when coloring an inorganic water retention layer.

  Silica-based binders are mainly composed of silica sol, alumina sol, etc., exhibit excellent fixability to ceramic substrates such as cordierite, and have durability. On the other hand, ceramic binders are mainly composed of ceramics such as alumina, magnesia, zirconia, and contain binders such as silicates or phosphates, and show strong bonding strength with metal substrates or ceramic substrates. . For example, as a ceramic binder mainly composed of alumina, Aremco Products Inc. For example, Cerama Bond 671 and Cerama Bond 835M can be used.

  Calcium carbonate, calcium hydroxide, titanium oxide, kaolin, clay, etc. can be used as the inorganic filler, but when using a cement binder as an inorganic binder, the fluidity of the paint is maintained for a long time. And calcium carbonate and calcium hydroxide are suitable at the point which raises the intensity | strength of an inorganic water retention layer. This is because the calcium ions of calcium carbonate and calcium hydroxide are taken into the cement together with water, so that the total amount of water used is not immediately used for the hydration reaction of the cement. It is thought that fluidity is maintained.

  Calcium carbonate and calcium hydroxide are effective when used alone or in combination. When used alone, the content of calcium carbonate or calcium hydroxide in the inorganic water retention layer is higher than the cement binder content in terms of increasing the strength of the inorganic water retention layer and maintaining the fluidity of the paint. 30 mass% or more is preferable, and 40 mass% or more is more preferable. On the other hand, the content of calcium carbonate or calcium hydroxide is used from the viewpoint of preventing the relative content of the cement-based binder from decreasing and the strength of the inorganic water retention layer from decreasing, and improving the fluidity of the paint. Since the effect is not sufficiently recognized, the content is preferably 70% by mass or less, and more preferably 60% by mass or less with respect to the content of the cementitious binder.

  The same applies to the embodiment in which calcium carbonate and calcium hydroxide are used in combination, and the total content of calcium carbonate and calcium hydroxide in the inorganic water retention layer increases the strength of the inorganic water retention layer and maintains the fluidity of the paint. The content of the cement binder is preferably 30% by mass or more, and more preferably 40% by mass or more. On the other hand, the total content of calcium carbonate and calcium hydroxide is preferably 70% by mass or less, preferably 60% by mass with respect to the content of the cement-based binder, from the viewpoint of preventing the strength of the inorganic water retention layer from decreasing. The following is more preferable.

  The water retention agent used in the inorganic water retention layer has a function of increasing the water retention and bonding strength of the coating film and increasing the viscosity of the coating liquid. Examples of water retention agents include carboxymethylcellulose, cellulose xanthate, methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, methylhydroxyethylcellulose, hydroxypropylmethylcellulose, and other cellulose compounds, ammonium polyacrylate, sodium polyacrylate, and ammonium polymethacrylate. , Acrylic acid polymer, acrylic emulsion copolymer, vinyl pyrrolidone copolymer, polyvinyl acetate emulsion, vinyl acetate-ethylene copolymer emulsion, acrylic acid compounds such as polyethylene oxide and polyacrylamide, vinyl compounds such as polyvinyl alcohol, alginate Gum, gum arabic, starch, karaya gum, guar gum, locust Plant thickeners such as gum, pectate, natural gum, styrene-butadiene polymer, acrylonitrile-butadiene polymer, polychloroprene, butyl rubber, polyurethane, polybutene, polyacrylate, polyethylene There are preferred embodiments that are used in combination according to type.

The preferred amount of the water retention agent varies depending on the type of the water retention agent, but in general, it maintains sufficient water retention and suppresses the occurrence of cracks after curing, with respect to the total solid content of the inorganic water retention layer. , 0.5% by mass or more is preferable, and 3% by mass or more is more preferable. On the other hand, the amount of the water retention agent is preferably 15% by mass or less and more preferably 9% by mass or less with respect to the total solid content of the inorganic water retention layer in order to maintain the fluidity of the coating liquid and improve workability. . Although the water-retaining agent has a large amount of organic matter, the amount of the water-retaining agent is small, so that the water-retaining agent is an inorganic water-retaining layer as a whole and can provide an essentially incombustible cosmetic material. The inorganic water retention layer differs depending on its water retention and the characteristics of the inorganic water retention color paint to be coated on the inorganic water retention layer, but in general, the amount to be applied is the point that maintains the fluidity of the inorganic water retention color paint. In terms of solid content, it is preferably 50 g / m ² or more, more preferably 80 g / m ² or more. On the other hand, the inorganic moisture-holding layer, since the water retention levels off, the amount of paint, in terms of solid content, preferably 300 g / m ² or less, more preferably 150 g / m ² or less.

As shown in FIG. 1, the inorganic water-retaining undercoat layer 3 is disposed between the inorganic water-retaining layer 2 and the upper pattern layer 4. In the step of applying the colored paint to form the upper picture layer 4 by arranging the inorganic water-holding undercoat layer 3, the inorganic water-holding undercoat layer 3 holds the paint of the upper picture layer 4. The pattern layer 4 having a natural texture can be formed. From such a viewpoint, the water retention of the inorganic water retention undercoat layer is preferably 0.4 g / cm ³ or more, and more preferably 2 g / cm ³ or more. On the other hand, if the water retention of the inorganic water-retaining undercoat layer is too large, it takes a long time to dry the coating, so that the production efficiency decreases, the viscosity of the coating increases, and the workability tends to decrease. For this reason, the water retention of the inorganic water retention undercoat layer is preferably 30 g / cm ³ or less, more preferably 10 g / cm ³ or less.

  By disposing the inorganic water-retaining undercoat layer 3, familiarity with the inorganic water-retaining layer 2 is improved, so that the adhesiveness with the inorganic water-retaining layer 2 is increased and the aging of the cosmetic material is less likely to occur. In addition, it is possible to provide a decorative material with high dimensional stability. From such a point of view, the composition of the inorganic water-retaining undercoat layer is preferably an embodiment in which an inorganic binder, an inorganic filler, a water retention agent and a color pigment are blended. In addition, an antifoaming agent, a curing agent, a dustproofing agent, etc. Can be added. The binder used for the inorganic water-retaining undercoat layer is preferably an inorganic binder from the viewpoint of providing a highly safe cosmetic. As the inorganic binder, a cement binder, a silica binder, or a ceramic binder is preferable, and the aforementioned binders can be used.

  Calcium carbonate, calcium hydroxide, titanium oxide, kaolin, clay, etc. can be used as the inorganic filler, but when using a cement binder as an inorganic binder, the fluidity of the paint is maintained for a long time. In view of increasing the strength of the inorganic water-retaining undercoat layer, calcium carbonate and calcium hydroxide are preferred. The content of calcium carbonate or calcium hydroxide is preferably 30% by mass or more, more preferably 40% by mass or more, and more preferably 70% by mass or less with respect to the content of the cement-based binder from the same viewpoint as the inorganic water retention layer. Preferably, 60 mass% or less is more preferable. Further, the total content of calcium carbonate and calcium hydroxide is preferably 30% by mass or more, more preferably 40% by mass or more, and preferably 70% by mass or less, based on the content of the cement binder. The following is more preferable.

The water-retaining agent used in the inorganic water-retaining undercoat layer has a function of increasing the water-retaining and bonding strength of the coating film and increasing the viscosity of the coating liquid, and the water-retaining agent blended in the inorganic water-retaining layer is preferably used. be able to. The amount of water retention agent varies depending on the type of water retention agent, but in general, it maintains sufficient water retention and suppresses the occurrence of cracks after curing, compared to the total solid content of the inorganic water retention background layer. Therefore, it is preferable to mix 0.5% by mass or more, and more preferable to mix 3% by mass or more. Further, in terms of maintaining the fluidity of the coating liquid and improving workability, the blending amount of the water retention agent is preferably 15% by mass or less, and preferably 9% by mass or less, based on the total solid content of the inorganic water-retaining undercoat layer. More preferred. Thus, since there are few compounding quantities of a water retention agent, it is an inorganic layer as a whole, and can provide an essentially nonflammable cosmetic material. The inorganic water-retaining undercoat layer differs depending on its water-retaining property and the characteristics of the colored paint to be coated on the inorganic water-retaining undercoat layer, but in general, the amount applied is solid in order to maintain the fluidity of the colored paint. In terms of minutes, 50 g / m ² or more is preferable, and 80 g / m ² or more is more preferable. On the other hand, inorganic water retention sketch layer, since the water retention levels off, the amount of paint, in terms of solid content, preferably 300 g / m ² or less, more preferably 150 g / m ² or less.

  The pattern layer formed on the inorganic water-retaining base layer represents a wood grain pattern, and the inorganic water-retaining base layer represents a wood texture that is the base of the wood grain pattern. For this reason, a coloring agent is mix | blended with an inorganic water retention background layer. Colorants include inorganic pigments and organic pigments, and inorganic pigments are preferred from the standpoint of obtaining nonflammable cosmetics, and being excellent in light resistance and chemical resistance. Since the ratio of the occupying pigment is small, an organic pigment can be appropriately used. Inorganic pigments include yellow lead, yellow iron oxide, cadmium yellow, titanium yellow, barium yellow, aureolin, molybdate orange, cadmium red, petal, red lead, cinnabar, mars violet, manganese violet, cobalt violet, cobalt blue, Cerulean blue, ultramarine blue, bitumen, emerald green, chrome vermilion, chromium oxide, viridian, iron black, carbon black, titanium oxide (titanium white, titanium white), zinc oxide (zinc white), basic lead carbonate (lead white) , Basic lead sulfate, zinc sulfide, lithopone, titanox, silica, calcium carbonate, barium sulfate. On the other hand, organic pigments include azo pigments, lake pigments, anthraquinone pigments, phthalocyanine pigments, isoindolinone pigments, dioxazine pigments and the like. Since the decorative material of the present invention has a wood texture, it is often blended with a tea-based pigment, but the wood texture varies widely depending on the type of wood, production area, aging, etc. It is preferable to use a combination of two or more pigments as appropriate.

  As shown in FIG. 1, the upper picture layer 4 is disposed on the inorganic water-retaining lower picture layer 3, and the upper picture layer 4 has streak-like irregularities on the surface. Since the convex portion 4a has a partially thick upper pattern layer, the color of the upper pattern layer appears dark, and the convex portion 4a is arranged in a streaky pattern on the inorganic water-retaining underlying layer 3. When viewed from above the pattern layer, it is observed as a woodgrain pattern. On the other hand, since the thickness of the upper pattern layer is partially thin, the concave portion 4b has a lighter color of the upper pattern layer, and the background color of the inorganic water-retaining underlying layer is relatively strong. The grain of 4a is emphasized. Therefore, it is possible to provide a cosmetic material with a high commercial value having a woodgrain pattern. In the normal mode, the color of the upper pattern layer 4 is low and the brightness of the inorganic water retaining lower layer 3 is high. However, since the grain is varied depending on the type of wood, the brightness of the upper pattern layer 4 is different. A mode in which the coloration is high and the lightness of the inorganic water-retaining undercoat layer 3 is low is also effective depending on the cosmetic material to be expressed.

The composition of the upper pattern layer 4 is preferably an embodiment in which a coloring pigment and a binder are blended. In addition, an inorganic filler, an antifoaming agent, a curing agent, a dustproofing agent, a dispersing agent, a wetting agent and the like are blended as necessary. Can do. The binder used for the upper pattern layer is preferably the inorganic binder described above in terms of providing a highly safe cosmetic material. However, the proportion of the upper pattern layer in the cosmetic material is small, and therefore, as necessary. Resin compositions such as polyolefin resins, acrylic resins, ethylene- (meth) acrylic acid copolymer resins, (meth) acrylic acid-butadiene copolymer resins, and polyester resins can be used as appropriate. Color pigments include inorganic pigments and organic pigments, and the above-mentioned inorganic pigments are preferred in terms of obtaining a non-flammable cosmetic material and excellent in light resistance and chemical resistance. Since the ratio of the pigment to the whole is small, the above-mentioned organic pigment can be used as appropriate, and two or more pigments can be used in combination according to a desired color tone. The upper pattern layer varies depending on the water retention of the inorganic water-retaining undercoat layer and the characteristics of the colored paint applied on the inorganic water-retaining undercoat layer. Is preferably 10 g / m ² or more, more preferably 25 g / m ² or more in terms of solid content. On the other hand, the upper pattern layer is in terms of ease of drying, amount of paint, in terms of solid content, preferably 60 g / m ² or less, 40 g / m ² or less is more preferable.

  An embodiment in which the decorative material of the present invention has a protective film on the surface is shown in FIG. An embodiment having a protective film is preferred in that it can improve surface properties such as water resistance, weather resistance and chemical resistance. For example, as shown in FIG. 2, the decorative material of this aspect is a wood grain-like upper picture layer provided with an inorganic water retention layer 22, an inorganic water retention background layer 23, and streaky irregularities on the surface, on an inorganic base material 21. 24 and a protective film 25. The structure of the inorganic base material 21, the inorganic water retaining layer 22, the inorganic water retaining lower picture layer 23, and the upper picture layer 24 is the same as that described above. FIG. 2 illustrates an embodiment in which the outer surface of the protective film 25 has irregularities, but an embodiment in which the outer surface of the protective film is flat is also included in the decorative material of the present invention. For the protective film 25, a transparent or translucent synthetic resin is used. For example, a polyolefin resin, a polyester resin, an acrylic resin, a styrene resin, a polyamide resin, an epoxy resin, a melamine resin, a urethane resin, Phenol resins, alkyd resins, cellulose resins, polycarbonate resins, ultraviolet curable acrylic resins, ultraviolet curable epoxy resins, thermosetting epoxy resins, and the like are suitable, and can be used together as necessary. In addition, a polishing agent, a sliding material, an antistatic agent, an anti-condensation agent, an antibacterial agent, an antifungal agent, and the like can be appropriately blended in the protective film. Although the protective film varies depending on the material of the protective film, generally, the film thickness is preferably 10 μm or more, more preferably 25 μm or more, from the viewpoint of improving the surface characteristics of the decorative material. On the other hand, the protective film is preferably 60 μm or less, more preferably 40 μm or less, from the viewpoint of easy drying.

(Manufacturing method of cosmetic material)
The method for producing a decorative material of the present invention includes a step of forming an inorganic water retaining layer on an inorganic base material, a step of forming an inorganic water retaining base layer, and a step of forming an upper pattern layer. The process of forming the color is to apply a colored paint on the inorganic water-retaining undercoat layer, and to coat the colored paint layer with a water-resistant sheet-like body to remove air between the water-resistant sheet-like body and the colored paint layer. A step of drying, a step of drying, and a step of peeling off the water-resistant sheet-like body. By this method, even without technical skill, it is possible to produce a large amount of a cosmetic material that has streaky irregularities on the surface and has a high aesthetic wood grain-like pattern layer. In addition, even when the base material has a three-dimensional curved surface, or when the surface of the base material has steps or irregularities, it is easy to provide a wood-tone decorative material even when it is difficult to attach a decorative sheet. can do. Moreover, it is possible to provide a method for producing a cosmetic material that is highly safe for the human body without using an organic solvent.

  The formation process of an inorganic water retention layer includes a process of applying an inorganic water retention paint on an inorganic substrate and a drying process. As a coating method, any method such as brush coating, spray gun coating or roll coating can be adopted, and coating can be performed a plurality of times as necessary. A conventional method for manufacturing a decorative material in which a veneer or a decorative sheet obtained by slicing wood is attached to a base material is used when the base material surface has a three-dimensional curved surface, such as furniture, joinery or ceramics. Is difficult to use if it has steps or irregularities. On the other hand, in the manufacturing method of the present invention, since the coating method is adopted, even when the substrate surface has a three-dimensional curved surface such as a concave surface, a convex surface, or a corrugation, or when the substrate surface has a step or an uneven surface. An inorganic water retention layer can be formed. When the surface of the inorganic base material is roughened by sandblasting or whisker treatment, corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, dichromic acid treatment, etc., the adhesion to the inorganic water retention layer is increased. Is preferable. For drying after applying the inorganic water-retaining paint, known methods such as natural drying and hot-air drying can be used. When firing in the atmosphere at 400 to 1100 ° C. for 1 to 24 hours, the substrate and the inorganic water retaining layer are used. It is preferable at the point which the adhesive force improves. After drying, if necessary, the surface of the inorganic water retention layer can be polished or ground to smooth the surface. Moreover, it is not dried completely and can be dried in the subsequent steps.

  The step of forming the inorganic water-retaining undercoat layer includes a step of applying an inorganic water-retaining colored paint on the inorganic water-retaining layer and a drying step. By forming the inorganic water-retaining undercoat layer, it is possible to obtain a background drawing representing a natural color change such as natural wood. As the coating method, any method such as brush coating, spray gun method or roll coating can be used, and coating can be performed a plurality of times as necessary. In the production method of the present invention, since the coating method is employed, the inorganic water-retaining undercoat layer can be formed even when the surface has a three-dimensional curved surface or when the surface has a step or unevenness. When the surface of the inorganic water retention layer is roughened by sandblasting or whisker treatment, corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, dichromic acid treatment, etc., the adhesion to the inorganic water retention layer is increased. Is preferable. For drying after the application of the inorganic water-retaining colored paint, a known method such as natural drying or hot air drying can be used. After drying, if necessary, the surface of the inorganic water-retaining undercoat layer can be polished or ground to smooth the surface. Moreover, it is not dried completely and can be dried in the subsequent steps.

  The upper pattern layer is formed by coating a colored paint on the inorganic water-retaining undercoat layer, coating the colored paint layer with a water-resistant sheet, and air between the water-resistant sheet and the colored paint layer. A step of removing water, a step of drying, and a step of peeling off the water-resistant sheet-like body. FIG. 3 shows a cross-sectional view of the decorative material in the upper picture layer forming step in the production method of the present invention. FIG. 3A is a cross-sectional view after an inorganic water retention layer 32 and an inorganic water retention background layer 33 are formed on an inorganic substrate 31, and a colored paint layer 34a is applied. FIG. 3B is a cross-sectional view after the colored paint layer 34b is covered with the water-resistant sheet-like body 35 and the air between the water-resistant sheet-like body 35 and the colored paint layer 34b is removed. FIG. 3 shows an example in which a sheet having a plurality of folds in approximately one direction is used as the water-resistant sheet-like body 35. In the example shown in FIG. 3A, the surface of the colored paint layer 34a is flat when the colored paint layer 34a is applied, but the water resistant sheet having a fold before the colored paint layer 34a is completely dried. When covered with the shaped body 35, as shown in FIG. 3B, in the water-resistant sheet-like body 35a, the colored paint layer forms a convex portion due to a capillary phenomenon or the like and rises. On the other hand, in the water-resistant sheet-like body 35b, the colored paint layer forms a concave portion and becomes thin. Then, it dries and peels a water-resistant sheet-like body, and an upper pattern layer is formed, and can provide the grain-like cosmetic material with high aesthetics.

  As a method for applying the colored paint layer, any method such as brush application, spray gun application or roll application can be used, and it can be applied a plurality of times as necessary. In the manufacturing method of the present invention, since the coating method is employed, the upper pattern layer can be formed even when the surface has a three-dimensional curved surface or when the surface has a step or unevenness. If the concentration of the colored paint is too high, the background layer is concealed, and therefore, an embodiment in which it is appropriately diluted and used is preferable.

  The air between the water-resistant sheet and the colored paint layer is removed by covering the entire colored paint layer with the water-resistant sheet and extruding the surface of the water-resistant sheet with a brush or a roll. Can do. Further, the air between the water-resistant sheet and the colored paint layer is removed by extruding the surface of the water-resistant sheet with a brush or a roll while covering the colored paint layer with the water-resistant sheet. Any aspect is included in the production method of the present invention. When the water-resistant sheet has a plurality of folds in approximately one direction, the air can be easily removed by removing the air along the crease direction of the water-resistant sheet. If the surface of the inorganic water-retaining undercoat layer is roughened by sandblasting or whisker treatment, corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, dichromate treatment, etc., the adhesion between the layers will increase. preferable. For drying after application of the colored paint, a known method such as natural drying or hot air drying can be used. After drying, if necessary, the surface of the upper pattern layer can be polished or ground to smooth the surface.

  Water-resistant sheet-like materials include, for example, polyolefin resins such as polyethylene, polyester resins such as polyethylene terephthalate, acrylic resins, styrene resins, polyamide resins, epoxy resins, melamine resins, urethane resins, and phenol resins. A resin sheet made of resin, urea resin, alkyd resin, fiber resin, polycarbonate resin, polyvinyl chloride resin, polyvinylidene chloride resin, fluorine resin, or the like is preferable. In addition, a metal sheet made of iron, copper, stainless steel, brass, aluminum or the like, a paper sheet whose surface is water-resistant processed, and the like can be arbitrarily used.

  When the water-resistant sheet-like body has a plurality of folds in approximately one direction, a wood-tone decorative material can be obtained as described above. The plurality of folds can be easily formed by squeezing a water-resistant sheet-like body such as a thin resin sheet while pulling it left and right with a hand or a machine. If there are irregular streaks in the water-resistant sheet, a cosmetic material with a high-quality texture of natural wood can be obtained, and if you use a water-resistant sheet that crosses so that the creases lie close together, A decorative material having a tonal texture can be obtained. Moreover, when a water-resistant sheet-like body having a fold line parallel to one direction is used, a wood grain tone is obtained. Even when a water-resistant sheet-like body without folds is used, if it is a thin sheet, after covering the colored paint layer and removing the air, the water-resistant sheet-like body is naturally formed on the colored paint layer. Since there is a tendency to wrinkle, streaky irregularities are formed on the surface, and a decorative material having a wood grain-like pattern layer is obtained. In a conventional method for manufacturing a decorative material, a decorative sheet is formed by printing wood grain on a sheet such as paper or a resin sheet, and the decorative sheet is attached to the surface of a base material. On the other hand, according to the method for manufacturing a decorative material of the present invention, a wood-grained decorative material can be manufactured very easily by using a water-resistant sheet-like body after painting. The thin water-resistant sheet-like body can easily form fine creases, and even if it is a water-resistant sheet-like body without folds, as described above, it is easy to wrinkle and is a wood-grained decorative material The thickness is preferably 50 μm or less, and more preferably 20 μm or less in that it is easy to form. On the other hand, the thickness is preferably 3 μm or more, more preferably 5 μm or more, from the viewpoint of preventing damage during handling, such as covering and peeling. Moreover, the same effect can be acquired even if it uses a thick water-resistant sheet-like body and the uneven | corrugated process is given to the surface which touches a colored coating layer. The unevenness of the water-resistant sheet can be easily formed by embossing or extruding a metal sheet, a resin sheet or the like. Therefore, the method of the present invention makes it possible to produce a decorative material having a wide variety of grain.

  The protective film can be formed by applying a known method such as brush coating, spray gun coating, or roll coating. The surface of the upper pattern layer is roughened by sandblasting or whisker treatment, corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, dichromic acid treatment, etc. preferable. As the drying after the formation of the protective film material, natural drying, hot air drying, or the like can be used.

(Example 1)
An inorganic water retention coating was formed on a calcium silicate plate (thickness 6 mm), which is an inorganic substrate, and dried to form an inorganic water retention layer. The solid content composition of the inorganic water-retaining paint is
Cement-based binder (white Portland cement) 60% by mass
Calcium carbonate 30% by mass
Methyl cellulose 6% by mass
Others (dustproofing agent, curing agent, etc.) 4% by mass
The solid content concentration was 23 mass% (a mixture of 30 mass parts solid content and 100 mass parts water). The inorganic water-retaining paint was applied onto a calcium silicate plate with a spray gun and dried. The coating amount of the inorganic water retention layer after drying was 92 g / m ² , and the water retention of the inorganic water retention layer was 5 g / cm ³ .

Next, an inorganic water-retaining colored paint was applied on the inorganic water-retaining layer with a spray gun and dried to form an inorganic water-retaining undercoat layer. The inorganic water-retaining colored paint was prepared by mixing 10 parts by weight of the tea pigment with 100 parts by weight of the inorganic water-retaining paint described above. Burnt amber and burnt sienna (blending ratio 1: 4) were used as pigments. The coating amount of the inorganic water retaining base layer after drying was 90 g / m ² , and the water retaining property of the inorganic water retaining base layer was 6 g / cm ³ .

Next, an upper picture layer was formed on the inorganic water-retaining lower picture layer. In order to form the upper pattern layer, first, a colored paint was applied on the inorganic water-retaining lower layer with a spray gun. In order to suppress the concealing property, the coloring paint used was a paint in which 1 part by weight of a brown water-based paint and 10 parts by weight of water were mixed. The composition of this water-based paint is
40% by mass of pigment
Polyacrylic acid emulsion 30% by mass
15% by mass of water
Others (dispersant, wetting agent, etc.) 15% by mass
Met. Burnt amber, Benjamin Moore 2090, and Benjamin Moore 2166 (blending ratio 1: 1: 1) were used as pigments.

Next, the air between the water-resistant sheet and the colored paint layer was removed by a roll while the colored paint layer was covered with the water-resistant sheet. The water-resistant sheet-like body used was a bundle of polyethylene sheets (thickness: 5 μm), which was squeezed while gently pulling left and right with both hands to form a plurality of folds in approximately one direction. This sheet-like body had a form in which a plurality of irregular streaks were crossed so as to snuggle up. FIG. 4 is a perspective view (photograph) of the water-resistant sheet-like body used in this example. Then, it dried and peeled the water-resistant sheet-like body. The coating amount of the upper pattern layer was 31 g / m ² . FIG. 5 is a perspective view (photograph) of the decorative material after the upper pattern layer is formed in this embodiment. As shown in FIG. 5, this decorative material had a high-quality texture of natural wood, with the surface of the upper pattern layer having a woodgrain pattern. Moreover, it has confirmed that the surface of the upper picture layer had an unevenness | corrugation along the line-like grain.

  Finally, a protective film was formed on the upper pattern layer. The protective film was formed by applying a paint for protective film with a spray gun and then drying. As the coating for the protective film, Ceratop EC Clear (content of acrylic resin emulsion in solid content: 90.8% by mass) manufactured by Yamamoto Ceramics Co., Ltd. was used, and the thickness of the protective film after drying was 30 μm.

(Example 2)
A cosmetic material is produced in the same manner as in Example 1 except that a polyethylene sheet (thickness: 5 μm) that is not creased and is not squeezed with both hands as in Example 1 is used as the water-resistant sheet. did. FIG. 6 is a perspective view (photograph) of the decorative material after the upper pattern layer is formed in this embodiment. As shown in FIG. 6, this decorative material had a natural wood-like grain and had a texture of a fine wood-like texture. Moreover, it has confirmed that the surface of the upper picture layer had an unevenness | corrugation along the line-like grain.

(Comparative Example 1)
In order to form the upper pattern layer, a colored paint was applied on the inorganic water-retaining undercoat layer. However, the coated pattern layer was not covered with the water-resistant sheet, and was dried as it was. , Manufactured cosmetics. FIG. 7 is a perspective view (photograph) of the decorative material after the upper pattern layer is formed in this comparative example. As shown in FIG. 7, this decorative material had a flat surface and no grain pattern.

  Even without technical skill, it is possible to easily and inexpensively mass-produce wood-tone decorative materials with excellent design. In addition, it is possible to provide a highly safe cosmetic without using an organic solvent.

It is sectional drawing of the decorative material of this invention. It is sectional drawing which shows the aspect in which the decorative material of this invention has a protective film on the surface. It is sectional drawing of the cosmetics in the upper pattern layer formation process in the manufacturing method of this invention. 1 is a perspective view (photograph) of a water-resistant sheet-like body used in Example 1. FIG. It is a perspective view (photograph) of the cosmetic material after the upper picture layer formation in Example 1. FIG. It is a perspective view (photograph) of the decorative material after the upper picture layer formation in Example 2. FIG. It is a perspective view (photograph) of the decorative material after the upper picture layer formation in Comparative Example 1.

Explanation of symbols

  1. 1. inorganic substrate; 2. inorganic water retention layer; 3. inorganic water-retaining primer layer; Upper pattern layer, 25. Protective film, 35. Water-resistant sheet.

Claims (6)

Forming an inorganic water retention layer containing an inorganic binder, an inorganic filler, and a water retention agent by applying an inorganic water retention paint on an inorganic substrate and drying;
Forming an inorganic water-retaining undercoat layer containing an inorganic binder, an inorganic filler, a water-retaining agent, and a color pigment by applying an inorganic water-retaining colored paint on the inorganic water-retaining layer and drying;
A step of forming a top pattern layer on the inorganic water-retaining undercoat layer, wherein the step of forming the top pattern layer comprises:
Applying a colored paint on the inorganic water-retaining undercoat layer;
Coating the colored paint layer with a water-resistant sheet, and removing air between the water-resistant sheet and the colored paint layer;
A drying step;
Look including a step of removing the water-resistant sheet product, water resistant sheet product covering the colored paint layer is a sheet having a plurality of folds approximately in one direction, provided with a streaky irregularities on the surface A method for producing a cosmetic material having a woodgrain-like upper pattern layer. The inorganic water-retaining layer and inorganic water retention sketch layer manufacturing method of decorative material according to claim 1 water retention is ^{0.4g / cm 3 ~30g / cm 3} . In the inorganic water retention layer and the inorganic water retention background layer, the content of calcium carbonate or calcium hydroxide is 30% by mass to 70% by mass with respect to the content of cementitious binder, or calcium carbonate and hydroxide The method for producing a cosmetic material according to claim 1 or 2, wherein the total content with calcium is 30% by mass to 70% by mass with respect to the content of the cementitious binder. The said base material is a manufacturing method of the cosmetics in any one of Claims 1-3 in which the surface which forms an inorganic water retention layer has a three-dimensional curved surface, or has a level | step difference or an unevenness | corrugation. The said base material consists of calcium silicate, calcium carbonate, ceramics, a metal, a gypsum board, concrete, glass, or mortar , The manufacturing method of the cosmetics in any one of Claims 1-4. The manufacturing method of the cosmetic material in any one of Claims 1-5 which forms a protective film in the surface.