JPH0257618B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Conventionally, in order to form a transparent layer by coating the surface of a substrate with ceramics, a long period of high temperature was required, as typified by glazes. In addition, thermal spraying has been used as a ceramic coating method that is practically carried out at room temperature, but the coating layer obtained by this method is opaque and lacks aesthetic appearance in terms of color.

As a result of intensive research into creating a ceramic coating layer that is transparent even at room temperature, the inventor of the present invention found that by controlling the size of the ceramic powder to be used below a certain level, This invention was completed knowing that all of the above-mentioned conventional drawbacks could be overcome.

This invention will be explained in detail below using examples.

In the drawings, 1 is a base material such as plywood, hardboard, particle board, steel plate, aluminum plate, asbestos cement board, valve cement board, calcium silicate board, gypsum board, etc., and the board material is covered with a filler coating and a base material. Boards that have undergone surface treatment such as painting, sealer coating, thin paper pasting, resin-impregnated paper pasting, etc.
All kinds of materials can be used, such as board materials or board materials whose surface has been subjected to decorative treatments such as pattern printing or pasting of decorative sheets, decorative sheets such as decorative papers, decorative cloths, and decorative synthetic resin sheets. 2
is a transparent layer formed by welding ceramic powder with a particle size of 3μ or less on its surface. To form the transparent layer 2 made of ceramic powder on the surface of the base material 1, a technique of thermally spraying ceramic powder is used. As thermal spraying methods, gas powder spraying, gas explosion spraying, and plasma spraying are known, and among these, gas explosion spraying is most suitable for this invention. However, it is of course possible to use gas powder spraying or plasma spraying.

The particle size of the ceramic powder used in this invention must be 3 μm or less. Preferably it is 1μ or less. This is because if it is too large, even if the ceramic powder welds together on the surface after thermal spraying to form a layer, many voids will remain, and the voids will not become transparent but will become cloudy. be. In addition, even if the particle size is 3μ or less, even if there are some particles with a particle size exceeding 3μ,
Of course, it is sufficient that a substantially desired transparent layer can be obtained.

Further, the ceramic powder used is generally a powder of mullite, α-alumina, silica, etc., but is not limited thereto.

Also, if colored powder is mixed into ceramic powder and thermal sprayed, a colored transparent layer of ceramics can be obtained.
It is possible to change the surface properties of decorative materials.

In addition, in order to adjust the transparency of the ceramic transparent layer, ceramic particles with a particle size of more than 3 μm are added to the ceramic powder in a proportion of 0.1 to 50% of the total ceramic powder to be thermally sprayed.
It may be incorporated in an amount by weight, preferably from 0.1 to 20% by weight.

Further, in order to impart functions such as water repellency and mold releasability to the decorative material, a small amount of synthetic resin powder such as Teflon or polyethylene may be mixed in depending on the function.

Since the present invention is configured as described above, it is possible to provide a decorative material having a transparent layer on the surface of any base material with excellent abrasion resistance, scratch resistance, water resistance, and chemical resistance. .

[Example 1] Approximately α-alumina powder with a particle size of 1μ or less was applied to the surface of 1mm thick stainless steel (SUS-27) using an acetylene-oxygen gas explosion spraying machine.
When sprayed to a thickness of 100μ, a transparent ceramic film with a smooth surface was obtained.

[Comparative Example 1] Thermal spraying was carried out under the same conditions as in Example 1, except that α-alumina with a particle size of about 5μ was used instead of α-alumina with a particle size of 1μ or less, and the surface condition was better than that in Example 1. Only a rough, cloudy ceramic film was obtained.

[Example 2] A plasma spraying machine was used to coat the surface of a reinforced plastic bathtub with a thickness of about 3 mm with particle sizes of 1 to 1.
Alumina powder of 3μ and a very small amount of colored powder (iron oxide yellow and carbon black) are thermally sprayed to form a powder of approximately 200μ.
When the film thickness was set to , a marble-like ceramic film with a smooth surface and a deep pale yellow color was obtained.

[Example 3] Green glass powder with a particle size of 2 to 3 μm was sprayed onto the surface of a 6 mm thick calcium silicate plate using a gas spraying machine to give a film thickness of approximately 40 μm, resulting in a smooth surface. A transparent ceramic film colored pale green was obtained.

[Example 4] After bonding a veneer of precious wood to the surface of particle board with a thickness of 20 mm, this surface was coated with mullite powder with a particle size of 1 to 2 μm using an acetylene-oxygen gas explosion spraying machine. When a very small amount (5% by weight of the total) of mullite powder of 5 to 10 microns was thermally sprayed to a film thickness of about 30 microns, a translucent ceramic film with a slightly rough surface was obtained.

[Example 5] α-alumina powder with a particle size of 1 μm or less and a very small amount of Teflon powder were sprayed onto the surface of a 1 mm thick steel plate using an acetylene-oxygen gas explosion spraying machine. When the film thickness was set to , a ceramic film with a smooth and water-repellent surface was obtained.

[Brief explanation of the drawing]

The drawing is a sectional view showing an embodiment of the present invention. In the drawings, 1 indicates a base material and 2 indicates a transparent layer.

Claims (1)

[Scope of Claims] 1. A decorative material in which ceramic powder having a particle size of 3 μm or less is welded together on the surface of a base material to form a transparent layer. 2. The decorative material according to claim 1, wherein the transparent layer is a colored transparent layer. 3. The decorative material according to claim 1, wherein the transparent layer is semitransparent. 4. The decorative material according to claim 1, wherein a synthetic resin is mixed in the transparent layer. 5. A method for manufacturing a decorative material, which involves spraying ceramic powder with a particle size of 3 μm or less on the surface of a base material using a thermal spraying method to form a transparent layer. 6. The method for producing a decorative material according to claim 5, characterized in that a colorant is mixed into ceramic powder having a particle size of 3 μm or less and then thermally sprayed. 7 Ceramics powder with a particle size of 3μ or less, 3μ
Claim 5 is characterized in that the thermal spraying is carried out by mixing a small amount of ceramic particles with a particle size exceeding
Method for manufacturing the decorative material described in Section 1. 8. The method for producing a decorative material according to claim 5, characterized in that ceramic powder having a particle size of 3 μm or less is mixed with synthetic resin powder and thermally sprayed.