JP7438803B2 - Face material - Google Patents

Description

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

Aesthetics are required for building walls and the like from a landscape perspective. In recent years, from this point of view, for example, patterned finishes with images of natural stones, soil, plants, etc. have been attracting attention.

As such a pattern finishing material, for example, a mixed material prepared by mixing synthetic resin as a binding material with fine aggregate-like aggregate made by crushing natural stone, etc. can be used to create the texture of natural stone. Decorative sheets and the like are used (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 a natural stone-like appearance.

Japanese Patent Application Publication No. 11-138731 Japanese Patent Application Publication No. 2000-153570

However, in the decorative sheet as described above, if the amount of resin in the mixed material is set to be small, the surface strength may be insufficient, and the sheet may become brittle and break. In particular, in the case of a decorative sheet having an uneven pattern, the area around the concave portions and convex portions (corners, etc.) is susceptible to defects such as abrasions and scratches.

The present invention was made in order to solve the above problems, and an object of the present invention is to provide a surface material with excellent scratch resistance.

As a result of intensive studies, the present inventors came up with a face material having a recessed portion and having a specific transparent coating on the outermost surface thereof, and completed the present invention.

That is, the facing material of the present invention has the following characteristics.
1. A face material having a recess,
The above-mentioned surface material has a colored layer and a transparent coating on its surface,
The colored layer is formed of a composition containing granular inorganic particles, and has concave portions and flat convex portions on the surface thereof, and
The surface material is characterized in that the transparent film is a thick film at least in a portion (edge of the recess) spanning between the recess and the projection of the colored layer.
2. 1. The colored transparent film contains a silicone resin and a synthetic resin other than the silicone resin. Surface materials listed in.

According to the present invention, a facing material with excellent scratch resistance can be obtained.

FIG. 2 is a front view showing an example of the face material of the present invention. FIG. 1 is a schematic cross-sectional view showing an example of the face material of the present invention. FIG. 1 is a schematic cross-sectional view showing an example of the face material of the present invention. It is a cross-sectional schematic diagram which shows the variation of the colored layer of this invention surface material.

A. Face material A1: Recessed part A2: Convex part A3: Recessed part edge 1: Colored layer 11: Recessed part (11': Recessed part flat part)
12: Convex part (12': Convex flat part)
13: Concave edge 2: Transparent coating layer

EMBODIMENT OF THE INVENTION Hereinafter, the form for implementing this invention is demonstrated.

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

(face material)
The face material A of the present invention has a colored layer 1 and a transparent film 2, and as shown in FIG. 1, when viewed from the front, it has a recess A1 on its surface. In the present invention, a portion that protrudes beyond the recess A1 is defined as a convex portion A2. FIG. 2 shows a cross-sectional view taken along line XX' in FIG. 1. As shown in FIG. 2, when viewed from the cross-sectional direction, the colored layer 1 of the face material A of the present invention has recesses 11 on its surface. Furthermore, the transparent film 2 is characterized in that it is unevenly distributed on the edge 13 of the colored layer recess 11 (hereinafter also referred to as "recess edge 13"). As shown in FIG. 3 (an enlarged schematic view of the Y part in FIG. 2), the transparent coating 2 is provided on the surface of the colored layer 1, and is thicker near the edge 13 of the colored layer recess 11 than in other parts. It is unevenly distributed to form a

In the face material A of the present invention having such characteristics, the strength of the recess edge A3 can be efficiently increased, defects such as abrasions and scratches can be suppressed, and excellent scratch resistance can be exhibited. . In the present invention, the recess edge refers to a region including at least a portion spanning between the recess and the projection, as shown in FIG.

(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 exhibiting 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. Further, the colored layer 1 may have a plurality of colored regions having different tones. In this case, the colored layer can be formed by curing a plurality of colored layer compositions having different tones.

As the granular inorganic particles, both natural products and artificial products can be used as long as the parent material is inorganic. The granular inorganic particles preferably include at least granular colored inorganic particles. As such granular colored inorganic particles, opaque particles with a light transmittance of less than 3% are particularly preferred, and particles with a light transmittance of 2% or less are more preferred. Specific examples of such granular colored inorganic particles include marble, granite, serpentine, granite, sandstone, slate, basalt, gabbro, diorite, andesite, limestone and crushed products thereof, and crushed ceramics. , ceramic pulverized products, metal particles, etc. Fluorite, agarite, feldspar, silica, silica sand, crushed products thereof, crushed glass, glass beads, etc., colored so as to satisfy the above conditions, can also be used.

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

In addition to the above-mentioned granular colored inorganic particles, it may also contain granular transparent inorganic particles. The use of such granular transparent inorganic particles is suitable for improving the aesthetic appearance. As the granular transparent inorganic particles, those having a light transmittance of 3% or more (more preferably 3 to 50%, still more preferably 10 to 30%) are suitable. Examples of granular transparent inorganic particles include silica, agarite, feldspar, silica, etc., and crushed products thereof, crushed glass, and glass beads. Either type can be used. In the present invention, "α to β" is synonymous with "above α and below β".

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 still more preferably 0.03 to 0.8 mm. By combining various granular inorganic particles with different particle sizes, the range of design possibilities can be expanded. 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 preferably has a transparent coating. Examples of the form of such resins include solvent-soluble resins, non-aqueous dispersible resins, non-solvent resins, water-dispersible resins, and water-soluble resins. Examples of the type of resin include acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, vinyl acetate resin, acrylic silicone resin, fluorine resin, silicone resin, polyvinyl alcohol, cellulose derivative, etc., or composites thereof. It will be done. Such resin may have the property of causing a crosslinking reaction.

The ratio of the resin is preferably 1 part by weight or more and 50 parts by weight or less, more preferably 2 parts by weight or more and 30 parts by weight or less, and even more preferably 3 parts by weight, based on the solid content of the total 100 parts by weight of the granular inorganic particles. It is not less than 20 parts by weight. With such a ratio, it is easy to provide a design that takes advantage of the aesthetic appearance due to the connection (agglomeration) of granular inorganic particles. That is, it is easy to obtain a colored layer consisting of aggregates of granular inorganic particles. In addition, the gloss is suppressed, making it easier to create a matte appearance. Furthermore, even when visually recognized through the transparent film described below, an agglomerated pattern (for example, a stone pattern, etc.) having a fine uneven shape derived from the granular inorganic particles can be visually recognized.

The colored layer composition may contain components (additives) other than those mentioned above, as necessary, as long as the effects of the present invention are not significantly impaired. Such ingredients include, for example, plasticizers, algaecides, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, antifoaming agents, crosslinking agents, film forming aids, antifreeze agents, and colorants. Examples include pigments, extender pigments, bright pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, and the like.

The colored layer 1 of the present invention is characterized by having recesses 11 on its surface. The recesses 11 form at least a recessed pattern in the colored layer 1 . The pattern of the colored layer 1 is not particularly limited, and may be of various shapes, such as stone-like patterns, wood-grain patterns, joint patterns, etc. Among them, natural stones, soil, plants, etc. This is suitable for cases where the material has a concave pattern, such as a hole-like shape, a moth-eaten shape, a bark pattern, etc.

Although the size of the recess 11 depends on the shape of the uneven pattern, its maximum diameter (longer axis) is preferably 0.2 to 50 mm (more preferably 0.5 to 30 mm). Further, the depth of the recess 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).

Further, in the present invention, it is preferable that the colored layer 1 has a plurality of recesses 11, and the shapes thereof may be constant (same) or different. Furthermore, although the arrangement of the plurality of recesses 11 may be regular or random, in the present invention, it is preferable to form a linear pattern, a striped pattern, or the like. In such a case, it is easy to express a pattern inspired by natural stone, soil, plants, etc., and it is possible to obtain a surface material with excellent aesthetic appearance. In particular, the present invention is suitable for expressing patterns of natural stone (in particular, travertine, etc.).

Specifically, the colored layer 1 expressing the above-mentioned pattern has an uneven pattern formed by concave portions 11 and convex portions 12 when the colored layer 1 is viewed from the cross-sectional direction, for example, as shown in FIG. like,
(a) having random concave portions 11 and convex portions 12 on its surface;
(b) one in which the concave part 11 and the convex part 12 have a flat convex part 12' on the surface;
(c) one having a concave flat part 11' with a flat concave part 11 and a convex part 12 on its surface;
and combinations of the above (a) to (c). The present invention is particularly effective when the uneven pattern of the above (b) and/or (c) aspects is included.

Note that in (a) to (c) above, the recess edge 13 is a region including at least a portion spanning between the recess 11 and the projection 12.

(transparent film)
The transparent film 2 is formed of a transparent coating material, and is formed unevenly on the edge of the recess of the colored layer. The transparent coating material of the present invention is not particularly limited as long as it contains a synthetic resin. The medium for the transparent coating material may be either solvent-based or water-based, but in the present invention it is preferable that the medium contains water. As a result, the transparent coating material is likely to be unevenly distributed on the recess edge 13 of the colored layer 1. Thereby, the effect of scratch resistance can be enhanced.

Furthermore, in the present invention, it is preferable that the transparent film contains a silicone resin and a synthetic resin other than silicone resin as the synthetic resin. By using these together, the transparent coating material tends to be unevenly distributed at the edges of the recesses of the colored layer, increasing the scratch resistance effect, suppressing gloss, and obtaining a surface material with a calm and excellent appearance. .

Examples of silicone resins include silicone oils and resins made of dialkylpolysiloxanes such as dimethylpolysiloxane, polyarylsiloxanes such as polydiphenylsiloxane, and polyalkylarylsiloxanes such as methylphenylpolysiloxane, amino-modified silicones, and epoxy resins. Examples include modified silicone oils and modified silicone resins such as modified silicones, carboxyl-modified silicones, alcohol-modified silicones, and polyether-modified silicones. The silicone resin may be in any form such as water-soluble resin, water-dispersible resin, solvent-soluble resin, solvent-free resin, or non-aqueous dispersion type resin. ) is preferred.

Examples of synthetic resins other than silicone resins include ethylene resin, vinyl acetate resin, vinyl chloride resin, acrylic resin, acrylic styrene resin, polyester resin, polyether resin, polyolefin resin, ethylene resin, fluororesin, butadiene resin, and urethane resin. , acrylic/vinyl acetate resin, acrylic/urethane resin, phenol resin, epoxy resin, melamine resin, alkyd resin, acrylic/silicon resin, polyvinyl alcohol resin, organic resin such as cellulose resin and its derivatives, water glass-based and other metal alkoxide compounds Examples include inorganic resins such as. In addition, the synthetic resin may be in any form such as water-soluble resin, water-dispersible resin, solvent-soluble resin, solvent-free resin, or non-aqueous dispersion type resin, but in the present invention, water-dispersible resin ( resin emulsions) are preferred.

In particular, in the present invention, an embodiment containing an acrylic resin emulsion and/or an acrylic styrene emulsion as the synthetic resin other than the silicone resin is preferred. The glass transition temperature of the acrylic resin is preferably 5 to 100°C (more preferably 10 to 80°C). Thereby, the effects of the present invention can be further enhanced.

The solid 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, still more preferably 15:85 to 60:40). ). In such a case, the transparent coating material is likely to be unevenly distributed at the edges of the colored layer recesses, and the scratch resistance can be improved.

Furthermore, by making the transparent coating material satisfy the solid content weight ratio of the silicone resin and the synthetic resin, a stable matting effect can be obtained without using a powder component such as a known matting agent. In addition, the formed transparent film is less likely to cause uneven gloss (glossy unevenness) regardless of its thickness, and can form a uniform matte surface. Therefore, it is possible to obtain a surface material with a calm and highly aesthetic appearance without uneven gloss without impairing the design properties such as the color tone of the colored layer.

The solid content of the transparent coating material is preferably 2 to 50% by weight (more preferably 5 to 30% by weight). Moreover, the transparent coating material can be diluted with various solvents at the time of application. The dilution ratio of the coating material is preferably 0 to 1000% by weight (more preferably 0 to 800% by weight) based on the transparent coating material, and the solid content at the time of application is preferably 0.1 to 1000% by weight. The amount is 50% by weight (more preferably 0.2 to 30% by weight, even more preferably 0.3 to 20% by weight). In such a case, the transparent coating material is likely to be unevenly distributed at the edges of the colored layer recesses, and the effects of the present invention can be enhanced.

Further, the coating amount of the transparent coating material per unit area is preferably 10 to 500 g/m ² (more preferably 20 to 400 g/m ² , even more preferably 30 to 300 g/m ² ), and is calculated in terms of solid content. Then, it is preferably 1 to 150 g/m ² (more preferably 1.5 to 80 g/m ² , even more preferably 2 to 40 g/m ² ). In such a case, the transparent coating material tends to be unevenly distributed at the edges of the colored layer recesses, and sufficient scratch resistance can be obtained.

The transparent coating material is one that forms a colorless transparent film, or contains some coloring components (color pigments, dyes, dispersions thereof), etc., and forms a colored transparent film, as long as it does not impede the effects of the present invention. It may be something. Furthermore, these transparent coating materials contain, for example, plasticizers, algaecides, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, antifoaming agents, film-forming agents, antifreeze agents, and water repellents. Contains agents, hydrophilizing agents, crosslinking agents, matting agents, extender pigments, bright pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, etc. It's okay.

The transparent coating 2 of the present invention is provided on the surface of the colored layer 1, and is characterized in that it is unevenly distributed on the edge 13 of the recess of the colored layer 1. As a result, the strength of the concave edges (especially near the corners) of the facing material A of the present invention can be efficiently increased, and defects such as abrasions and scratches can be suppressed, and excellent scratch resistance can be exhibited. I can do it. For example, the transparent coating 2 may be unevenly distributed, for example, if the transparent coating 2 is unevenly distributed.
(I) A mode in which it is not provided on the convex portion 12 (convex flat portion 12') but only on the concave edge 13,
(II) A mode in which the film is provided over the entire area including the recess 11 (recess flat part 11') and the convex part 12 (convex flat part 12'), and the film is thick at the recess edge 13;
(III) A mode in which the concave portion 11 (concave flat portion 11 ′) and the convex portion 12 (convex flat portion 12 ′) are discontinuously (spotted) provided on the entire concave portion edge 13;
(IV) It is discontinuously (spotted) provided throughout the entire area including the recess 11 (recess flat part 11') and the projection 12 (projection flat part 12'), and the thick film is formed at the recess edge 13. The manner in which it has become,
etc.

In the present invention, as in (I) to (IV) above, the transparent film 2 is unevenly distributed so as to frame the recessed portion edge 13 of the colored layer 1. Thereby, the scratch resistance can be improved. In addition, when the colored layer 1 has a plurality of recesses, the transparent coating 2 may be provided on all the recess edges 13 or on some of the recess edges 13.

(Reinforcement material)
The surface material of the present invention may have a reinforcing material. Such a reinforcing material can 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, and the like. The reinforcing material may be made of two or more of the above materials. By using such a reinforcing material, the strength etc. of the face 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 employed. One example is a method using a formwork. In this method, first, a mold is prepared in which concave portions and convex portions (concave portions of the colored layer) corresponding to a desired pattern are formed. The formwork is not particularly limited, but for example, a formwork made of silicone resin, urethane resin, or the like, a formwork provided with release paper, etc. can be used. When manufacturing using a mold, the inner surface of the mold becomes the surface of the facing material, so by adjusting the shape of the inner surface of the mold, a desired uneven pattern can be imparted to the surface of the facing material.

For example, using the above formwork,
・A method of filling the inner surface of the mold with a composition for a colored layer, removing it from the mold after curing, applying a transparent coating material to the surface of the colored layer, drying and curing,
・A method of applying a transparent coating material to the inner surface of the mold, drying and curing, filling with a composition for a colored layer, and removing the mold after curing,
The face material can be manufactured by, for example,

In applying and filling the composition for the colored layer and the transparent coating material, known instruments such as sprayers, rollers, trowels, brushes, reciprocators, coaters, etc. can be used. When introducing a reinforcing material, for example, the reinforcing material may be embedded inside the colored layer or the reinforcing material may be laminated on the back surface of the colored layer before curing of the colored layer composition.

Specifically, the face materials shown in FIGS. 1 to 3 are preferably manufactured, for example, by the following method.
(1) A transparent coating material is produced by mixing and stirring a synthetic resin (preferably a silicone resin and a synthetic resin other than silicone resin) and, if necessary, additives using a conventional method. Further, a composition for a colored layer is produced by mixing and stirring granular inorganic particles, a resin, and optionally additives using a conventional method.
(2) Prepare a formwork (a formwork onto which the desired uneven pattern has been transferred) that has the desired concave and convex parts (forming the concavities of the colored layer) on the inside surface, and apply a transparent coating material to the inside surface of the formwork. , dry and harden.
(3) Next, the colored layer composition is filled into the mold, and after curing, the mold is removed.

In the surface material obtained by the above method, the convex portions on the inner surface of the mold are reversed to form concave portions of the colored layer. Further, the colored layer has a transparent film on its surface, and the transparent film is unevenly distributed at the edge of the recess. This makes it possible to exhibit scratch resistance. When a transparent coating material is applied to a formwork having concave portions and convex portions, the above-mentioned transparent coating material is likely to be unevenly distributed at the foot of the convex portions. In particular, the above-mentioned transparent coating material was applied to a formwork having a flat part and a convex part, and the convex part having a sloped or rounded shape (for example, a mountain shape, a parabola shape, a curved shape). In this case, the transparent coating material can be even more unevenly distributed at the base of the protrusion. Thereby, a face material that can fully exhibit the effects of the present invention can be efficiently manufactured.

In (2) above, it is preferable to dry and harden the transparent coating material after applying it. During the drying and curing process, the transparent coating material tends to be more unevenly distributed at the base of the convex parts on the inner surface of the formwork. Therefore, when the transparent coating material is filled with the colored layer composition of (3) in a cured state rather than in an uncured state, the effects of the present invention can be fully exhibited. In addition, the curing in the above (2) may be any degree of dryness to the touch or higher (preferably semi-cured, more preferably hardened and dry). Furthermore, in the present invention, by using a colored transparent coating material to which a colored pigment is added to the transparent coating material in step (2) above, aesthetic appearance with contrast, three-dimensional feeling (sense of depth), etc. can be imparted. I can do it.

In the present invention, after steps (1) to (3) above, for example, as step (4), a transparent coating material is further applied and dried on the surface of the face material after demolding (preferably on the entire surface) to form a transparent film. can be provided. As a result, a transparent coating can be further unevenly distributed (laminated) on the edge of the recess where the transparent coating of the face material manufactured in (1) to (3) above is unevenly distributed, so that it is even more durable. Scratch resistance can be improved. Moreover, by using a colored transparent coating material to which a colored pigment is added to the transparent coating agent in the step (4), it is also possible to impart aesthetic properties with contrast, three-dimensional effect (sense of depth), and the like.

In (4) above, the coating amount of the transparent coating material 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, preferably 1 to 500 g/m ² (more preferably 10 to 300 g/m 2 ). 200 g/m ² (more preferably 1.5 to 100 g/m ² , still more preferably 2 to 80 g/m ² ). The above effects can be achieved.

In the present invention, in the above (4), even when a transparent film is provided over the entire surface of the facing material, problems such as uneven gloss are less likely to occur, and a calm aesthetic appearance can be exhibited. In particular, in the present invention, the colored layer is selected based on the fact that the colored layer is made of inorganic particles fixed with a small amount of resin, that the transparent coating material contains silicone resin, and that the amount of the transparent coating material to be applied is adjusted. By employing this means, the above effects can be obtained. This mechanism of action is not limited to the following, but when a transparent coating material is applied to the colored layer of the present invention, the transparent coating material penetrates into the surface of the colored layer and forms a film, so that the colored layer is It is possible to obtain a surface material that retains the shape of fine irregularities derived from the formed inorganic particles. It is presumed that this allows the above effects to be obtained.

The surface material obtained from the above (1) to (3) (furthermore, (4)) should have a gloss level of 8 or less (more preferably 1 to 7, still more preferably 1.5 to 6) at 60 degrees. preferable. If the glossiness is within this range, a calm and elegant appearance can be imparted. Furthermore, the surface material of the present invention preferably has a gloss level of 8 or less (more preferably 1 to 7, still more preferably 1.5 to 6) at 85 degrees. Further, it is preferable that the difference in gloss between 60 degrees and 85 degrees is 2 or less (more preferably 1.5 or less, even more preferably 1 or less). When the gloss levels at 60 degrees and 85 degrees satisfy the above ranges, unevenness in gloss due to viewing angles (directions) can be suppressed, and the sense of calmness and aesthetics can be further enhanced. Note that the glossiness in the present invention is a value measured according to JIS K5600-4-7 "Specular glossiness". Specifically, it is the value of 60 degree or 85 degree specular gloss measured by a gloss meter, and is the average value of measurements taken at 10 arbitrary locations on the surface of facing material A.

The surface material of the present invention can be used as a material for decorating walls of buildings and the like. For example, adhesives, adhesive tapes, nails, screws, bolts, rails, etc. may be used to fix the surface material of the present invention to a wall surface or the like. Examples of base materials constituting building walls include concrete, mortar, siding boards, extruded boards, gypsum boards, perlite boards, plywood, bricks, plastic boards, metal plates, glass, and porcelain tiles. These base materials may have a coating already formed on the surface thereof (existing coating, undercoat coating, etc.) or may have wallpaper pasted thereon.

Examples and comparative examples are shown below to clarify the characteristics of the present invention.

(Manufacture of colored layer composition)
At the mixing ratio shown in Table 1, each raw material was uniformly mixed by a conventional method to produce a composition for a colored layer. In addition, the raw materials shown below were used.
- Granular colored inorganic particles [mixture of brown silica sand: reddish brown silica sand: yellow silica sand (weight ratio) = 65:15:20), particle size 0.03 to 0.6 mm, light transmittance less than 1%]
・Granular transparent inorganic particles [kansuiite; particle size 0.1 to 0.4 mm, light transmittance 16%]
・Resin component [acrylic resin emulsion, solid content 50% by weight, medium: water]
・Additives [antifoaming agent, film forming aid, water, etc.]

(Production of transparent coating materials 1 to 10)
At the mixing ratio shown in Table 2, each raw material was uniformly mixed by a conventional method to produce a transparent coating material. In addition, the raw materials shown below were used.
・Silicone resin emulsion [polyoxyethylene alkyl ether emulsion of dimethylpolysiloxane, solid content 50% by weight, medium: water]
・Acrylic resin emulsion [solid content 50% by weight, glass transition temperature 40°C, medium: water]
・Additives [antifoaming agents, film forming aids, etc.]
(Manufacture of transparent coating material 1')
20 parts by weight of the above transparent coating material 1, colored dispersion (acrylic resin emulsion, pigment paste [mixture of orca pigment: red rust pigment: black pigment (weight ratio) = 25:55:20, solid content 50% by weight, resin) Solid content 40% by weight, pigment solid content 10% by weight, medium; Manufactured.

<Manufacture of face material (I)>
As a formwork, a rectangular formwork (30 cm x 60 cm) that can form a travertine pattern having multiple convex parts (height of the convex part 0.2 to 2 mm, long diameter of the convex part 0.2 to 10 mm) on the flat part. It was used. A transparent coating material was applied to the above formwork (weight per unit area: 100 g/m ² ), distributed unevenly at the base of the convex parts of the formwork, and then dried and cured (at 23°C for 24 hours). .
Next, a colored layer composition was applied onto the transparent film (weight per unit area: 3.3 kg/m ² ), and after curing (at 65° C. for 24 hours), the mold was demolded and a facing material ( I) was produced. The transparent coating material and colored layer composition were used in combinations shown in Table 3 (Examples 1 to 11).

<Manufacture of face material (II)>
The first transparent coating material was applied to the same formwork as above (weight per unit area: 100 g/m ² ), and after unevenly distributing it at the base of the convex part of the formwork, it was dried and cured (at 23°C, 24 hours).
Next, a colored layer composition was applied onto the first transparent film (weight per unit area: 3.3 kg/m ² ), cured (at 65° C. for 24 hours), and then demolded.
Furthermore, a second transparent coating material (weight per unit area: 140 g/m ² ) is further applied to the entire surface having the first transparent coating (a surface having a flat portion and a concave portion), and a second transparent coating layer is formed. A face material (II) provided with the following was manufactured. The transparent coating material and colored layer composition were used in the combinations shown in Table 3 (Examples 12 to 21).

<Manufacture of face material (III)>
Colored layer composition 1 was applied to the same mold as above (weight per unit area: 3.3 kg/m ² ), and after curing (at 65° C. for 24 hours), the mold was removed, and the facing material ( III) was produced (Comparative Example 1).

(Examples 1 to 21, Comparative Example 1)
The following tests were conducted on each face material manufactured by the above method. The results are shown in Table 3.
(scratch resistance)
After rubbing the surface of the obtained facing material 1000 times with a deck brush (made of resin), the surface of the facing material was visually evaluated. Evaluation was made on a four-level scale (A>B>C>D) with A indicating no defects and D indicating defects.

Examples 1 to 21 were good surface materials in the scratch resistance evaluation. On the other hand, in Comparative Example 1, defects were observed around the edge of the recess.

Furthermore, the appearance of the obtained face material was evaluated as follows. The results are shown in Table 3.
(Glossiness)
According to JIS K5600-4-7 "Specular gloss", measurements were taken at 10 arbitrary locations on the surface of face material A (measurement angles: 60 degrees and 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 uneven gloss was evaluated in 4 stages (A>B>C>D) (A: 1 Below, B: more than 1 and less than or equal to 2, C: more than 2 and less than or equal to 3, and D: more than 3).

The surface materials obtained in Examples 1 to 21 all had suppressed gloss and had a calm feel. Further, in Examples 20 and 21, the colored transparent film was unevenly distributed on the edges of the recesses on the surface of the colored layer, and the surface material had excellent aesthetic appearance and was given a three-dimensional effect.

Claims (2)

A face material having a recess,
The above-mentioned surface material has a colored layer and a transparent coating on its surface,
The colored layer is formed of a composition containing granular inorganic particles, and has concave portions and flat convex portions on the surface thereof, and
The surface material is characterized in that the transparent film is a thick film at least in a portion (edge of the recess) spanning between the recess and the projection of the colored layer. The face material according to claim 1, wherein the colored transparent film contains a silicone resin and a synthetic resin other than the silicone resin.

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