JP4810178B2 - Decorative sheet manufacturing method and decorative sheet - Google Patents

Description

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

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

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

Japanese Patent No. 2791279

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

  As a result of intensive studies, the inventor poured a specific clear paint into a mold having a concavo-convex pattern, and further poured a base paint having a specific pigment volume concentration before the clear paint was cured, It has been found that the above-mentioned problems can be solved by molding, and the present invention has been completed.

That is, the present invention has the following characteristics.
1. To formwork with uneven pattern,
Synthetic resin as a binding material, the clear coating contrast ratio of the formed coating film is less than 10%, the first step of pouring in usage ^{50g / m 2 ~500g / m 2} ,
Before the clear coating is cured, a second coating is performed by pouring a base coating containing a synthetic resin and a coloring pigment and having a pigment volume concentration of 0.01% to 40% at a usage amount of 500 g / m ² or more. Process,
A third step of demolding after the clear paint and base paint are cured;
A method for producing a decorative sheet, comprising:
2. 1. The viscosity of the clear paint is 5.0 Pa · s or less. The manufacturing method of the decorative sheet as described in 2.
3.1. Or 2. A decorative sheet obtained by the production method described in 1.

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

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

The method for producing the decorative sheet of the present invention comprises:
To formwork with uneven pattern,
Synthetic resin as a binding material, the clear coating contrast ratio of the formed coating film is less than 10%, the first step of pouring in usage ^{50g / m 2 ~500g / m 2} ,
Before the clear coating is cured, a second coating is performed by pouring a base coating containing a synthetic resin and a coloring pigment and having a pigment volume concentration of 0.01% to 40% at a usage amount of 500 g / m ² or more. Process,
A third step of demolding after the clear paint and base paint are cured;
It is characterized by including.

In such a method, after the clear paint is poured and before the clear paint is cured, the base paint is poured, so that the color pigment contained in the base paint gradually penetrates into the clear paint and is colored to some extent. Since it hardens | cures when a pigment penetrate | infiltrate, the manufactured decorative sheet will have the deep outstanding aesthetics by the penetration | invasion degree of a colored pigment.
The degree of penetration of the color pigment is determined by the curing rate of the clear paint, the particle diameter of the color pigment, the amount of the color pigment, and the like, and by adjusting them, various deep aesthetics can be expressed.

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

  In the production method of the present invention, first, as a first step, a clear paint having a concealment ratio of the formed coating film of less than 10% is poured into a mold having such an uneven pattern using a synthetic resin as a binder.

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

  The clear paint used in the present invention is characterized in that the formed coating film has a concealment ratio of less than 10% (preferably 1% to 9%, more preferably 1% to 8%). When the concealment rate is less than 10%, it combines with the hue of the base coating film formed from the base paint and the hue of the color pigment that has penetrated into the clear paint from the base paint to express a deep design feeling. Can be issued.

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

  In such a clear paint, a color pigment and an aggregate can be mixed as long as the effects of the present invention are not impaired. By being a color clear paint, in addition to the hue of the base paint, the hue of the clear paint can be combined to obtain a deeper aesthetic appearance.

  In addition, for clear coatings, film-forming aids, water repellents, plasticizers, antiseptics, antifungal agents, antialgae agents, antifoaming agents, leveling agents, pigment dispersants, antisettling agents, dripping You may contain paint additives, such as an inhibitor, a matting agent, and a ultraviolet absorber.

  Examples of color pigments include inorganic color pigments such as titanium oxide, zinc oxide, carbon black, ferric oxide (bengal), lead chromate (molybdate orange), yellow lead, yellow iron oxide, ultramarine, and cobalt green. , Azo, naphthol, pyrazolone, anthraquinone, perylene, quinacridone, disazo, isoindolinone, benzimidazole, phthalocyanine, quinophthalone, and other organic color pigments, pearl pigments, fluorescent pigments, phosphorescent Examples thereof include pigments and metallic pigments.

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

The clear paint used in the present invention has a viscosity of 5.0 Pa · s or less (further 0.001 Pa · s or more and 3.0 Pa · s or less, furthermore 0.01 Pa · s or more and 1.0 Pa · s or less). Is preferred.
With such a viscosity, the clear paint can be easily poured into the uneven pattern portion of the formwork, and when the clear paint is poured, the film thickness is maximum in the concave portion and the film thickness is minimum in the convex portion. Thus, the coating film can be formed with the film thickness continuously changed.
Therefore, the surface finally obtained by demolding is a change in hue due to a continuous change in the thickness of the clear coating, a continuous change in the hue of the base coating, or a color pigment that has penetrated into the clear coating. Deep aesthetics can be expressed by changing the hue according to the amount.
When the viscosity is larger than 5.0 Pa · s, the film is not formed in a state in which the film thickness is continuously changed, and the coloring pigment is less likely to penetrate into the clear paint, so that there is a high possibility that the design becomes monotonous.

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

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

Next, as a second step, before the clear paint is cured, a base paint containing a synthetic resin and a color pigment and having a pigment volume concentration of 0.01% to 40% is used in an amount of 500 g. Pour at / m ² or more.

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

  Examples of color pigments include inorganic color pigments such as titanium oxide, zinc oxide, carbon black, ferric oxide (bengal), lead chromate (molybdate orange), yellow lead, yellow iron oxide, ultramarine, and cobalt green. , Azo, naphthol, pyrazolone, anthraquinone, perylene, quinacridone, disazo, isoindolinone, benzimidazole, phthalocyanine, quinophthalone, and other organic color pigments, pearl pigments, fluorescent pigments, phosphorescent Examples thereof include pigments and metallic pigments.

The pigment volume concentration of the color pigment in the base paint is 0.01% to 40% (more preferably 0.05% to 30%, more preferably 0.1% to 20%). By being in such a range, the amount of the color pigment penetrating into the clear paint can be controlled to some extent, and thereby the design feeling of the finally obtained decorative sheet can be adjusted. .
When the pigment volume concentration of the base paint is larger than 40%, it is difficult to express a deep design feeling because the colored pigment penetrates too much into the clear paint, and the strength of the decorative sheet may be adversely affected. There is sex. If it is less than 0.01%, the amount of the color pigment penetrating into the clear paint is small, and the above effect is difficult to obtain.

  For base paints, aggregates, film-forming aids, water repellents, plasticizers, antiseptics, antifungal agents, anti-algae agents, antifoaming agents, leveling agents, pigment dispersants, anti-settling agents as necessary Additives for paints such as agents, anti-sagging agents, matting agents, ultraviolet absorbers, and fibers may be contained.

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

The timing of pouring the base paint used in the present invention is not particularly limited as long as the clear paint is completely cured. Usually, about 0 to 180 minutes (preferably 0.5 to 120 minutes) after the clear paint is poured is preferable. By pouring at such timing, the colored pigment in the base paint penetrates into the clear paint, and a deep and excellent aesthetic appearance can be obtained. If the clear coating is completely cured, the color pigment is difficult to penetrate and a deep aesthetics cannot be obtained.
The method for pouring such a base paint is not particularly limited, and a usual method can be used. For example, it can be poured using a pressure feed spray gun or the like, can be poured using a flow coater or the like, or can be painted using a painting tool such as a brush, roller, spray or trowel.
In addition, the veil paint can be poured after the aggregate or the like is sprayed on the clear paint before pouring the base paint.

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

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

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

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

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

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

Claims (3)

To formwork with uneven pattern,
Synthetic resin as a binding material, the clear coating contrast ratio of the formed coating film is less than 10%, the first step of pouring in usage ^{50g / m 2 ~500g / m 2} ,
Before the clear coating is cured, a second coating is performed by pouring a base coating containing a synthetic resin and a coloring pigment and having a pigment volume concentration of 0.01% to 40% at a usage amount of 500 g / m ² or more. Process,
A third step of demolding after the clear paint and base paint are cured;
A method for producing a decorative sheet, comprising:   The method for producing a decorative sheet according to claim 1, wherein the viscosity of the clear paint is 5.0 Pa · s or less. A decorative sheet obtained by the production method according to claim 1 or 2.