JP7438804B2 - 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. Further, although it is possible to form a concavo-convex pattern, there is little variation and it is difficult to express a three-dimensional effect.

The present invention has been made in order to solve the above-mentioned problems, and an object of the present invention is to provide a surface material with excellent abrasion resistance and aesthetic appearance with excellent three-dimensional effect.

As a result of extensive studies, the present inventors came up with a surface material having a recessed portion, a colored transparent coating unevenly distributed on the edge of the recessed portion, and a specific transparent coating on the outermost surface thereof, and the present invention. I was able to complete it.

That is, the facing material of the present invention has the following characteristics.
1. A face material having a recess,
The above-mentioned face material has a colored layer and a colored 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
A face material characterized in that the colored transparent coating is a thick film at least in a portion of the colored layer spanning between the concave portion and the convex portion (the edge of the concave portion ).
2. 1. The colored transparent film contains a silicone resin and a synthetic resin other than the silicone resin. Surface materials listed in.
3. 1. The color tone is different between the edge of the recess and other parts when viewed from the front. or 2. Surface materials listed in.
4. 1. characterized by having a transparent film on the outermost surface; ~3. Surface materials listed in any of the above.

According to the present invention, a surface material with excellent scratch resistance and excellent aesthetic appearance due to three-dimensional effect, etc. 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: Colored 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 colored transparent coating 2, and as shown in FIG. 1, has a recess A1 on its surface when viewed from the front direction. 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. Further, the colored transparent coating 2 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 colored 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 film.

With the surface material A of the present invention having such characteristics, it is possible to efficiently increase the strength of the recess edge A3, suppress defects such as abrasions and scratches, and exhibit excellent scratch resistance. It can give a feeling. 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.

In addition, in the face material A of the present invention, when viewed from the front, the recessed portion edge A3 and the other portions (recessed portion A1, convex portion A2) may have different color tones. Thereby, the unevenness, three-dimensional effect, etc. can be further enhanced.

The difference in color tone only needs to be visible to the naked eye, and can be adjusted by changing the color tone of the colored transparent film 2, for example. Specifically, for example, when the colored layer and the colored transparent film 2 have similar colors, a dark colored part (or a light colored part) is formed at the recessed part edge A3, and a calm design can be imparted. . On the other hand, when the colored layer 1 and the colored transparent film 2 are not of similar color, an accent pattern is formed on the edge A3 of the recessed portion, and a contrasting design can be imparted. In addition to different color tones, the three-dimensional effect can be enhanced by different gloss levels, textures, etc., as long as the features of the present invention are not impaired.

(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 color 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 and not more 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 express a matte appearance. Further, even when visually recognized through a 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.

(Colored transparent film)
The colored transparent film 2 is provided on the surface of the colored layer 1 and is characterized in that it is unevenly distributed on the recessed portion edges 13 of the colored layer 1. As a result, when the facing material A of the present invention is viewed from the front, the appearance (for example, color tone, etc.) is different between the recessed part edge A3 and other parts (recessed part A1, convex part A2), and the unevenness and three-dimensional appearance are different. A surface material with high aesthetic appearance can be obtained.

It is preferable that such a colored transparent film 2 is formed by unevenly distributing a colored transparent coating material. The colored transparent coating material may be any composition as long as it contains a resin component and a coloring component and has a transparent film. Further, the medium for the colored transparent coating material may be either solvent-based or water-based, but in the present invention it is preferable that the medium contains water. Thereby, the colored transparent coating material is likely to be unevenly distributed on the concave edge 13 of the colored layer 1, and a surface material with excellent scratch resistance and three-dimensional effect can be obtained.

The resin component is not particularly limited, but includes, for example, ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, acrylic styrene resin, acrylic silicone resin, urethane resin, fluororesin, Examples include silicone resins and composite resins thereof. Further, the resin component 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 the present invention, a preferred embodiment includes a silicone resin and a synthetic resin other than silicone resin as the resin component. By using these resin components together, the colored transparent coating material tends to be unevenly distributed around the edges of the colored layer recesses, increasing the scratch resistance effect, suppressing gloss, and obtaining a surface material with a calm and excellent appearance. be able to. Furthermore, the color tone of the edge of the recess becomes clearer, and the aesthetics such as the three-dimensional effect can be further enhanced.

Specifically, silicone resins include, for example, silicone oils and silicone resins made of dialkylpolysiloxanes such as dimethylpolysiloxane, polyarylsiloxanes such as polydiphenylsiloxane, polyalkylarylsiloxanes such as methylphenylpolysiloxane, or silicone resins such as amino acids. Examples include modified silicone oils and modified silicone resins such as modified silicones, epoxy-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.

Moreover, an embodiment containing an acrylic resin emulsion and/or an acrylic styrene emulsion as the synthetic resin other than the silicone resin is preferable. 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, it is possible to improve the abrasion resistance, and also to obtain a surface material in which the colored transparent film is likely to be unevenly distributed and has an excellent three-dimensional effect.

As the coloring component, known coloring components (coloring pigments, dyes, etc.) can be used, and preferably coloring pigments such as organic coloring pigments and inorganic coloring pigments are mentioned. The mixing ratio is preferably 0.01 to 30 parts by weight (more preferably 0.02 to 20 parts by weight, still more preferably 0.05 to 0.05 parts by weight) of the coloring component to 100 parts by weight of the resin component (solid content). 10 parts by weight). In addition, when mixing a coloring pigment with a resin component, it can mix in the form of a dispersion liquid of each pigment.

The colored transparent coating material can be diluted with various solvents at the time of application. The solid content of the colored transparent coating material when applied is preferably 0.1 to 50% by weight (more preferably 0.2 to 30% by weight, even more preferably 0.3 to 20% by weight), and the unit The coating amount per area is preferably 10 to 500 g/m ² (more preferably 20 to 400 g/m ² , still more preferably 30 to 300 g/m ² ). In such a case, the colored layer is likely to be unevenly distributed at the edge of the recess, and the effects of the present invention can be easily obtained, and the aesthetic appearance can be improved.

Furthermore, colored transparent coating materials include, for example, plasticizers, algaecides, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, antifoaming agents, film-forming agents, antifreeze agents, and water repellents. , hydrophilizing agents, crosslinking agents, matting agents, extender pigments, bright pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, etc. Good too.

The colored 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 recess edge 13 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. At the same time, the sense of depth is emphasized more than the actual depression, and the three-dimensional effect is enhanced.

In the present invention, as an aspect in which the colored transparent coating 2 is unevenly distributed, for example, the colored transparent coating 2 is
(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 provided discontinuously (spotted) 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 colored transparent coating 2 is unevenly distributed so as to frame the concave edge 13 of the colored layer 1. As a result, the scratch resistance can be improved, and the sense of depth is emphasized more than the actual dent, thereby increasing the three-dimensional effect. In addition, when the colored layer 1 has a plurality of recesses, the colored transparent coating 2 may be provided on all the recess edges 13 or on some of the recess edges 13.

(transparent film)
The face material of the present invention can also be provided with a transparent coating 3 on the outermost surface. The transparent film 3 is formed of a transparent coating material. The transparent coating material of the present invention is not particularly limited as long as it contains a resin component. The medium 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. Thereby, the scratch resistance can be further improved.

Furthermore, in the present invention, it is preferable that the transparent film 3 contains a silicone resin and a synthetic resin other than the silicone resin as a resin component. The solid weight ratio of the silicone resin to the synthetic resin other than the silicone resin is preferably 5:95 to 95:5 (more preferably 10:90 to 80:20, still more preferably 15:85 to 60:40). ). In such a case, the scratch resistance can be improved. Furthermore, it is possible to obtain a stable matting effect without using powder components such as known matting agents, and the formed transparent film has uneven gloss (uneven luster) 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 and the colored transparent coating.

In the present invention, the resin component of the transparent coating material is preferably the same type or the same as the resin component of the colored transparent coating material. Thereby, the above effects can be further enhanced.

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). In such a case, the effects of the present invention can be enhanced.

Further, 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 preferably 1 to 200 g/m ² in terms of solid content. (more preferably 1.5 to 100 g/m ² , even more preferably 2 to 80 g/m ² ). In such a case, 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 3 of the present invention is provided on the surface having the colored layer 1 and the colored transparent coating 2, and may be provided on the entire surface or discontinuously (spotted). . In addition, in the present invention, it is preferable that the transparent coating 3 is provided on at least the edge of the recess (particularly near the corner) (more preferably the entire area including the edge of the recess) of the face material A. Strength can be further increased, defects such as abrasions and scratches can be suppressed, and excellent scratch resistance can be exhibited.

(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. Although the mold is not particularly limited, for example, a mold made of silicone resin or urethane resin, a mold provided with release paper, or the like 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 colored transparent coating material to the surface of the colored layer, and drying and curing.
・A method of applying a colored 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 colored layer composition and the colored transparent coating material, known instruments such as sprays, rollers, trowels, brushes, reciprocaters, 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) Produce a composition for a colored layer and a colored transparent coating material.
(1-1) A colored layer composition is produced by mixing and stirring granular inorganic particles, a resin, and optionally additives using a conventional method.
(1-2) A colored transparent coating material is produced by mixing and stirring a resin component and a colored component using a conventional method.
(2) Prepare a formwork (a formwork onto which the desired uneven pattern has been transferred) that has desired concavities and convexities (forming the concavities of the colored layer) on the inside surface, and apply a colored transparent coating material to the inside surface of the formwork. Apply, 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. In addition, the colored layer has a colored transparent coating on the surface thereof, and the colored transparent coating is unevenly distributed at the edge of the recess, and can exhibit aesthetics with contrast, three-dimensional effect (sense of depth), and the like.

In particular, in (2) above, when a colored transparent coating material is applied to a formwork having concave portions and convex portions, the above-mentioned colored transparent coating material tends to be unevenly distributed at the foot of the convex portions. In particular, the colored transparent coating material described above is applied to a formwork that has a flat part and a convex part, and the convex part has a sloped or rounded shape (for example, a mountain shape, a parabola shape, a curved shape). In this case, the colored transparent coating material can be even more unevenly distributed at the foot of the convex portion. The mechanism by which the colored transparent coating material is unevenly distributed at the foot of the convex part on the inner surface of the formwork is not limited to the following, but is due to the effect of the surface tension of the colored transparent coating material, the influence of viscosity, etc. It is thought that it tends to be unevenly distributed near the boundary between the flat part and the convex part. Therefore, in the present invention, it is preferable that the colored transparent coating material contains water having a high surface tension as a medium and further has a low viscosity as described above.

Moreover, in the above (2), it is preferable to cure the colored transparent coating material after applying it. During the drying and curing process, the colored transparent coating material tends to be more unevenly distributed at the base of the convex portions on the inner surface of the formwork. 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).

In the above (3), after the colored transparent coating material is cured, the composition for a colored layer is filled, thereby making it possible to stably produce a face material having a desired appearance. In addition, when the composition for a colored layer is filled with the colored transparent coating material in a cured state rather than in an uncured state, the effects of the present invention can be fully exhibited.

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, it is possible to further unevenly distribute (laminate) and form a transparent coating on the edge of the recess where the colored transparent coating of the face material manufactured in (1) to (3) above is unevenly distributed. Not only can scratch resistance be improved, but also the three-dimensional effect can be improved.

In the present invention, in the above (4), when a transparent coating is provided on 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 from the following reasons: the colored layer is made of inorganic particles fixed with a small amount of resin, the transparent coating material contains silicone resin, and 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 glossiness at 60 degrees and 85 degrees satisfies the above range, unevenness in gloss due to viewing angles (directions) can be suppressed, and a calming feeling and aesthetic appearance 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 face 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 white silica sand: yellow silica sand: brown silica sand (weight ratio) = 80:10:10), 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 colored transparent coating materials 1 to 10 and transparent coating materials 1 to 10)
A colored transparent coating material and a transparent coating material were produced by uniformly mixing each raw material in a conventional manner at the mixing ratio shown in Tables 2 and 3. In addition, the raw materials shown below were used.
・Acrylic resin emulsion [solid content 50% by weight, glass transition temperature 40°C, medium: water]
・Silicone resin emulsion [polyoxyethylene alkyl ether emulsion of dimethylpolysiloxane], solid content 50% by weight, medium: water]
・Pigment dispersion liquid 1 [acrylic resin emulsion, mixed liquid of pigments (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 10% by weight, medium; water]
・Additives: antifoaming agents, film forming aids, etc.

<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 colored transparent coating material was applied to the above formwork (weight per unit area: 100g/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 for 24 hours). Ta.
Next, a composition for a colored layer was applied on the colored 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 was prepared. (I) was produced. The colored transparent coating materials and colored layer compositions were used in combinations shown in Table 4 (Examples 1 to 12).
<Manufacture of face material (I')>
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 ( I') was produced (Comparative Example 1).

(Examples 1 to 12, Comparative Example 1)
The following tests were conducted on each of the face materials (I) and (I') manufactured by the above method. The results are shown in Table 4.
(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.
(3D effect)
The obtained surface materials were visually observed and evaluated on a four-level scale (A>B>C>D), with A showing a three-dimensional effect and D showing a planar finish.

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

<Manufacture of face material (II)>
A colored 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°C). time).
Next, a colored layer composition was applied onto the colored transparent film (weight per unit area: 3.3 kg/m ² ), cured (at 65° C. for 24 hours), and then demolded.
Furthermore, a transparent coating material was applied to the entire surface having the colored transparent film (the surface having the flat portion and the concave portion) (weight per unit area: 140 g/m ² ), and the surface material provided with the transparent film layer. (II) was produced. The colored transparent coating material, the transparent coating material, and the colored layer composition were used in combinations shown in Table 5 (Examples 13 to 20).
<Manufacture of face material (II')>
Colored layer composition 1 was applied to the same mold as above (weight per unit area: 3.3 kg/m ² ), cured (at 65° C. for 24 hours), and then removed from the mold. Next, a transparent coating material 6 was applied (weight per unit area: 140 g/m ² ) to produce a face material (II') provided with a transparent film layer (Comparative Example 2).

(Examples 13 to 20, Comparative Example 2)
In addition to the scratch resistance and three-dimensional effect described above, the following tests were conducted on each of the facing materials (II) and (II') manufactured by the above method. The results are shown in Table 5.
(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).

All of the surface materials obtained in Examples 13 to 20 had suppressed gloss, a calm feeling, and a three-dimensional effect. In Comparative Example 2, the surface material had slightly uneven gloss and poor three-dimensional effect.

Claims (4)

A face material having a recess,
The above-mentioned face material has a colored layer and a colored 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
A face material characterized in that the colored transparent coating is a thick film at least in a portion of the colored layer spanning between the concave portion and the convex portion (the edge of the concave portion ). 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. The panel material according to claim 1 or 2, wherein the edge of the recess and other portions have different color tones when viewed from the front. The facing material according to any one of claims 1 to 3, characterized in that it has a transparent film on its outermost surface.

Images