Interior decorative material and method for producing interior decorative material

Abstract

To provide an interior decorative material capable of inhibiting condensation in high-humidity conditions while exhibiting superior decorative properties.SOLUTION: An interior decorative material includes at least a substrate layer containing aluminum, a decorative layer superposed on one side of the substrate layer and subjected to decoration by baking coating, and a hydrophilic layer superposed on one side of the decorative layer, the hydrophilic layer comprising a hydrophilic resin and having a thickness of 1.5 μm or more and 100 μm or less.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an interior decorative material and a method for producing the interior decorative material. [Background technology]

[0002] The present invention relates to an interior decorative material suitable for use in areas of a building where condensation is likely to occur, and a method for producing the interior decorative material.

[0003] In bathrooms and kitchens in residential buildings, food processing plants, and other places, excessive water vapor can cause condensation on ceilings and walls. This condensation can lead to mold growth. Furthermore, in food processing plants, there is concern that food could be contaminated by the condensed water droplets that fall. To address these issues, interior decorative materials that can suppress condensation even in high-humidity environments are known.

[0004] For example, Patent Documents 1 to 5 disclose bathroom ceiling panels that can suppress the occurrence of condensation. These ceiling panels are said to be able to suppress the occurrence of condensation even in high-humidity environments by forming a hydrophilic coating on the outermost surface. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 55-139258 [Patent Document 2] Japanese Patent Application Publication No. 55-139259 [Patent Document 3] Japanese Patent Application Laid-Open No. 2000-026634 [Patent Document 4] Patent No. 4373717 [Patent Document 5] Japanese Patent Application Laid-Open No. 2005-02555 Summary of the Invention [Problem to be solved by the invention]

[0006] However, conventional ceiling panels such as those disclosed in Patent Documents 1 to 5 do not have sufficient anti-condensation function, and also have problems with their decorativeness as interior decorative materials.

[0007] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide an interior decorative material that suppresses the occurrence of condensation even in a high humidity environment and has excellent decorative properties. [Means for solving the problem]

[0008] The decorative material for interior use of the present invention has the following configuration. (1) A first aspect of the present invention provides a decorative material for interior use, comprising at least a base layer containing aluminum, a decorative layer disposed on one side of the base layer and decorated by baking paint, and a hydrophilic layer disposed on one side of the decorative layer and containing a hydrophilic resin, the hydrophilic layer having a thickness of 1.5 μm or more and 100 μm or less.

[0009] (2) The second aspect of the present invention is an interior decorative material according to the first aspect, characterized in that it has a heat insulating layer made of foamed resin, which is placed on the other side of the base material layer.

[0010] (3) The third aspect of the present invention provides an interior decorative material according to the first or second aspect, characterized in that the interior decorative material is a non-combustible material as defined in Article 2, item 9 of the Building Standards Act of Japan or a quasi-non-combustible material as defined in Article 1, item 5 of the Enforcement Order of the Building Standards Act.

[0011] (4) A fourth aspect of the present invention is an interior decorative material according to the second aspect, characterized in that an aluminum layer is further disposed on top of the heat insulating layer.

[0012] (5) A fifth aspect of the present invention is an interior decorative material according to any one of the first to fourth aspects, characterized in that the hydrophilic layer has a contact angle of 45° or less.

[0013] (6) A sixth aspect of the present invention is an interior decorative material according to any one of the first to fifth aspects, characterized in that the hydrophilic layer is made of an acrylic ultraviolet curable resin.

[0014] The method for producing an interior decorative material of the present invention has the following configuration. (7) A seventh aspect of the present invention relates to a method for manufacturing an interior decorative material, which is a method for manufacturing an interior decorative material according to any one of the first to sixth aspects, and is characterized by comprising a decorative layer forming step of forming the decorative layer on one side of the base layer by baking paint, and a hydrophilic layer forming step of applying an acrylic ultraviolet curing resin to one side of the decorative layer and then curing it by irradiating it with ultraviolet light to form the hydrophilic layer.

[0015] (8) An eighth aspect of the present invention is a method for producing an interior decorative material according to the seventh aspect, characterized in that in the decorative layer forming step, the formed decorative layer is further modified. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a schematic cross-sectional view showing an interior decorative material according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, an interior decorative material according to one embodiment of the present invention and a method for manufacturing this interior decorative material will be described with reference to the drawings. The following embodiment is specifically described to provide a better understanding of the gist of the invention, and does not limit the present invention unless otherwise specified. Furthermore, the drawings used in the following description may show essential parts enlarged for the sake of clarity, and the dimensional proportions of each component may not necessarily be the same as those in reality.

[0018] [Interior decorative materials] FIG. 1 is a schematic cross-sectional view showing an interior decorative material according to one embodiment of the present invention. The interior decorative material 10 of this embodiment includes at least a base layer 11, a decorative layer 12 disposed on one surface 11a of the base layer 11, and a hydrophilic layer 13 disposed on one surface 12a of the decorative layer 12. Furthermore, it is preferable that a heat insulating layer 15 and an aluminum layer 16 are disposed on the other surface 11b of the base layer 11 in this order.

[0019] The interior decorative material 10 of this embodiment meets the standards for non-combustible materials set forth in Article 2, Paragraph 9 of the Building Standards Act of Japan. That is, among building materials, it is a material that conforms to the technical standards set forth in the Cabinet Order regarding non-combustible performance (meaning that it will not burn due to the heat of a normal fire, and other performances set forth by Cabinet Order), and is set forth by or certified by the Minister of Land, Infrastructure, Transport and Tourism. Alternatively, it meets the standards for quasi-non-combustible materials set forth in Article 1, Paragraph 5 of the Enforcement Order of the Building Standards Act. That is, among building materials, it is a material that conforms to the technical standards set forth in the Cabinet Order regarding quasi-non-combustible performance (meaning that it will not burn due to the heat of a normal fire, and other performances set forth by Cabinet Order), and is set forth by or certified by the Minister of Land, Infrastructure, Transport and Tourism.

[0020] (base material layer) The substrate layer 11 is a thin plate made of aluminum or an alloy containing aluminum. The thickness of the substrate layer 11 may be, for example, in the range of 0.2 mm to 0.6 mm. The surface of the substrate layer 11 may be a smooth surface such as a mirror finish, or a rough surface.

[0021] (decorative layer) The decorative layer 12 is a decorative layer formed by baking a paint containing acrylic resin or polyester resin onto one surface 11a of the base layer 11. Any desired color and design can be formed on the decorative layer 12 using the paint. This allows for a design effect that matches the atmosphere of the installation location when the interior decorative material 10 is viewed from the outside through the hydrophilic layer 13. The decorative layer 12 may have a thickness in the range of, for example, 10 μm to 40 μm, and may have a surface roughness (arithmetic mean surface roughness Sa) in the range of, for example, 1 μm to 5 μm.

[0022] (hydrophilic layer) The hydrophilic layer 13 is made of a hydrophilic material, particularly an organic hydrophilic material. As the organic hydrophilic material, a film containing a binder having a hydrophilic group is preferred from the viewpoint of preventing falling water due to condensation, etc. Preferred examples of the hydrophilic group include a sulfonic acid group or a salt thereof, a hydroxyl group, a carboxy group or a salt thereof, a poly(oxyalkylene) group, and an ammonium salt.

[0023] Specific examples of organic hydrophilic materials that constitute the hydrophilic layer 13 include a film containing a polymer of a bifunctional (meth)acrylate having a sulfonic acid group or its salt; a film containing a polymer of a vinyl monomer having an N-methylol group or an N-alkoxymethylol group, a vinyl monomer having a sulfonic acid group, and an alkyl (meth)acrylate monomer; a film containing a polymer having a hydrophilic group and an alkoxysilyl group; and the like.

[0024] The thickness of the hydrophilic layer 13 may be in the range of 1.5 μm to 100 μm, preferably in the range of 1.5 μm to 10 μm, and more preferably in the range of 2.0 μm to 5.0 μm. If the thickness of the hydrophilic layer 13 is 1.5 μm or more, the generation of water droplets due to condensation or the like can be sufficiently suppressed. If the thickness of the hydrophilic layer 13 is 100 μm or less, for example, when forming the hydrophilic layer 13 from an ultraviolet curable resin, it is easy to apply the hydrophilic layer 13 to the decorative layer 12.

[0025] It is preferable to design the interior decorative material 10 so that the thickness of the hydrophilic layer 13 is equal to or greater than the surface roughness of the decorative layer 12, since the entire outermost layer on one side of the interior decorative material 10 becomes the hydrophilic layer 13. It is preferable to apply the hydrophilic layer 13 to the decorative layer 12 in one go from the standpoint of reducing labor and costs, but it may be applied in two or more steps as necessary.

[0026] Furthermore, the contact angle (wettability), which is the standard for the hydrophilicity of the hydrophilic layer 13 in the present invention, is 45° or less. The contact angle is the angle between the tangent of a droplet and the solid surface, and if the contact angle is approximately 45° or less, it is considered that hydrophilicity is exhibited in the present invention.

[0027] In addition to the hydrophilic materials described above, the hydrophilic layer 13 may further contain an antifungal agent, an antibacterial agent, an antiviral agent, a matting material, etc. By including an antifungal agent, an antibacterial agent, or an antiviral agent, it is possible to inhibit the occurrence and proliferation of mold, bacteria, and viruses caused by moisture adhering to the hydrophilic layer 13. Furthermore, by including a matting material, it is possible to suppress the shine (gloss) of the surface of the hydrophilic layer 13 and further inhibit the adhesion of grease such as fingerprints, thereby maintaining the aesthetic appearance.

[0028] It is also preferable to increase the surface area and further improve the hydrophilic function of the hydrophilic layer 13 by making the surface of the hydrophilic layer 13 have a fine uneven structure (rough surface). The specific roughness of such a rough surface (arithmetic mean surface roughness Sa) is preferably 2.0 μm or less, and more preferably 1.5 μm or less.

[0029] (insulating layer) The heat insulating layer 15 is a functional layer that provides heat insulation to the interior decorative material 10 of this embodiment, and is made of foamed resin (porous resin). Examples of foamed resin that makes up the heat insulating layer 15 include foamed polyurethane, foamed polystyrene, foamed polyethylene, phenolic foam, and foamed polyvinyl chloride. In this embodiment, foamed polyurethane is used as the heat insulating layer 15.

[0030] The thickness of the heat insulating layer 15 may be, for example, in the range of 5.0 mm to 20 mm, preferably in the range of 7.0 mm to 10 mm. By making the thickness of the heat insulating layer 15 in the above range, the necessary heat insulating properties can be ensured and peeling of the heat insulating layer 15 can be prevented.

[0031] The mass of the foamed resin constituting the heat insulating layer 15 is 0.3 kg / m 2 More than 0.5kg / m 2 The density of the foamed resin should be within the following range: 3 More than 50kg / m 3The following ranges are sufficient. By setting the mass and density of the foamed resin that makes up the insulating layer 15 within the above-mentioned ranges, it is possible to achieve a reduction in the weight of the interior decorative material 10 while maintaining the insulating performance of the insulating layer 15.

[0032] (aluminum layer) The aluminum layer 16 may be a foil or sheet made of aluminum or an alloy containing aluminum. Such an aluminum layer 16 protects the back side of the interior decorative material 10. The thickness of the aluminum layer 16 may be, for example, in the range of 0.01 mm to 0.1 mm.

[0033] When the interior decorative material 10 of this embodiment, configured as described above, is applied to places where excessive water vapor generates and the environment becomes high humidity, such as the bathroom or kitchen of an ordinary residential building or a food processing factory, the hydrophilic layer 13, which contains a hydrophilic resin and has a thickness of 1.5 μm to 100 μm and is formed on the outermost surface, makes it difficult for water vapor to condense, thereby preventing the water vapor from turning into droplets and falling. This prevents unpleasant wetting caused by falling droplets and, in food processing factories, makes it possible to prevent food from being contaminated by falling droplets.

[0034] Furthermore, if a heat insulating layer 15 is provided on the other surface 11b of the base material layer 11, it is possible to block cold and hot air radiated from the inner wall surfaces of the building and suppress temperature changes inside the room.

[0035] [Method of manufacturing interior decorative materials] When manufacturing the interior decorative material 10 of this embodiment, first, a thin plate made of aluminum or an aluminum-containing alloy is prepared, and a paint containing acrylic resin or polyester resin is baked onto one side of the thin plate to form a decorative layer 12 (decorative layer forming process). Such decorative layer 12 can be formed with any color and design using the paint. Next, a roll forming process is performed to form a base layer 11. Then, a foamable resin base material is filled into the other side 11b of this base layer 11. Next, an aluminum layer 16 is attached to and superimposed on this foamable resin base material.

[0036] The expandable resin substrate is then expanded and cured by heating or the like to form the heat insulating layer 15. In this manner, the heat insulating layer 15 and the aluminum layer 16 are formed in this order on the other surface 11b of the substrate layer 11.

[0037] If necessary, the formed decorative layer 12 may be subjected to a modification treatment. Examples of the modification treatment include a primer treatment, a plasma treatment, a corona discharge treatment, and a polishing treatment. By performing such a modification treatment, the adhesion between the hydrophilic coating agent (described later) and the decorative layer 12 is improved.

[0038] Next, the hydrophilic layer 13 is formed on the one surface 12a of the decorative layer 12 (hydrophilic layer forming step). The hydrophilic layer 13 may be formed, for example, by applying a hydrophilic coating agent to the one surface 12a of the decorative layer 12 and drying it.

[0039] Examples of methods for applying the hydrophilic coating agent include roll coating, spray coating, curtain coating, flow coating, bar coating, brush coating, etc. Among these, roll coating is preferred because it reduces the amount of hydrophilic coating agent used and allows efficient coating of long objects.

[0040] Thereafter, the hydrophilic coating agent is dried and solidified to form a hard film, the hydrophilic layer 13. The hydrophilic coating agent can be dried by any drying method such as natural drying, heat drying, or ventilation drying.

[0041] Although the embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as defined in the claims. [Example]

[0042] The effects of the present invention were verified. For the verification, the following samples were prepared. (Example 1 of the present invention) A decorative layer is formed on one side of a 0.4 mm thick aluminum plate by baking an acrylic paint to a thickness of 20 μm, and then an acrylic UV-curable resin is applied on top of that at a rate of 2.3 g / m. 2 The coating was applied and cured to form a hydrophilic layer with a thickness of 1.5 μm and a surface roughness of 1.6 μm. A urethane foam layer with a thickness of 8.0 mm was applied to the other side of the aluminum plate as a heat insulating layer, and then a 0.02 mm thick aluminum foil was attached. The decorative layer was a monotonous white with a surface roughness of 1.8 μm.

[0043] (Example 2 of the present invention) Acrylic UV-curable resin applied at a rate of 7.0 g / m 2 The procedure was the same as in Example 1 of the present invention, except that the coating was applied so that the composition was cured to form a hydrophilic layer having a thickness of 5.0 μm and a surface roughness of 0.9 μm.

[0044] (Example 3 of the present invention) Acrylic UV-curable resin applied at a rate of 14g / m 2 The procedure was the same as in Example 1 of the present invention, except that the coating was applied so that the composition was cured to form a hydrophilic layer having a thickness of 10 μm and a surface roughness of 0.7 μm.

[0045] (Example 4 of the present invention) This was the same as Example 2 of the present invention, except that the surface roughness of the hydrophilic layer was 1.6 μm and the decorative layer had a black cedar pattern and a surface roughness of 2.3 μm.

[0046] (Example 5 of the present invention) Except for the fact that the surface roughness of the hydrophilic layer was 1.2 μm and the decorative layer had a black cedar pattern and a surface roughness of 2.3 μm, this example was the same as invention example 3. Note that invention example 5 was formed by repeating the hydrophilic layer coating method of invention example 2 twice.

[0047] (Comparative Example 1) The procedure was the same as in Example 1 of the present invention, except that no hydrophilic layer was formed.

[0048] (Comparative Example 2) Acrylic UV-curable resin applied at a rate of 1.4 g / m 2 The procedure was the same as in Example 1 of the present invention, except that the coating was carried out in such a manner that the thickness of the hydrophilic layer was 1.0 μm and the surface roughness was 1.8 μm. The surface roughness of each sample was measured using a digital microscope (DSX1000, manufactured by Olympus Corporation) at a magnification of 10 times.

[0049] The contact angle, which is an index of hydrophilicity, was measured for each of these samples at room temperature by dropping a water droplet onto the surface of each sample and measuring the contact angle using a contact angle meter (PCA-1, manufactured by Kyowa Interface Science Co., Ltd.). The total calorific value of each sample was measured 20 minutes after the start of heating using a cone calorimeter (C4: manufactured by Toyo Seiki Seisakusho Co., Ltd.) in accordance with the cone calorimeter test in accordance with ISO5660-1:2002. The results of these measurements are shown in Table 1.

[0050] [Table 1]

[0051] According to the results shown in Table 1, in Examples 1 to 5 of the present invention, in which the thickness of the hydrophilic layer was in the range of 1.5 to 100 μm, the contact angle considered to be hydrophilic was 45° or less. In addition, in Examples 1 to 5 of the present invention, the total calorific value was 8.0 MJ / m 2 It was confirmed that the flame retardancy was high. On the other hand, in Comparative Example 1, in which no hydrophilic layer was formed, and Comparative Example 2, in which the thickness of the hydrophilic layer was 1.0 μm, the contact angle exceeded 45°, confirming low hydrophilicity. In addition, in Comparative Examples 1 and 2, the total heat generation was 8.0 MJ / m 2 It was confirmed that the flame retardancy was high. From the above results, it was confirmed that the interior decorative material of the present invention is hydrophilic and is non-flammable even when a hydrophilic resin is applied as a hydrophilic layer. [Explanation of symbols]

[0052] 10...Interior decorative materials 11...Base material layer 12...Decorative layer 13…Hydrophilic layer 14...Buffer layer 15...Insulating layer 16...Aluminum layer

Claims

1. The decorative material for interior decoration is characterized by having at least a base layer containing aluminum, a decorative layer disposed on one side of the base layer and decorated by baking paint, and a hydrophilic layer disposed on one side of the decorative layer and containing a hydrophilic resin, with a thickness of 1.5 μm or more and 100 μm or less.

2. 2. The decorative material for interior use according to claim 1, further comprising a heat insulating layer made of foamed resin, which is disposed on the other side of the base material layer.

3. The decorative material for interior use according to claim 1 or 2, characterized in that the decorative material for interior use is a non-combustible material as defined in Article 2, Paragraph 9 of the Building Standards Act of Japan or a quasi-non-combustible material as defined in Article 1, Paragraph 5 of the Enforcement Order of the Building Standards Act.

4. 3. The decorative material for interior use according to claim 2, further comprising an aluminum layer disposed on the heat insulating layer.

5. 3. The decorative material for interior use according to claim 1, wherein the hydrophilic layer has a contact angle of 45° or less.

6. 3. The interior decorative material according to claim 1, wherein the hydrophilic layer is made of an acrylic ultraviolet curable resin.

7. A method for producing the interior decorative material according to claim 1 or 2, a decorative layer forming step of forming the decorative layer on one surface of the base layer by baking paint; and a hydrophilic layer forming step of applying an acrylic ultraviolet curing resin to one side of the decorative layer and then curing it by irradiating it with ultraviolet light to form the hydrophilic layer.

8. 8. The method for producing an interior decorative material according to claim 7, wherein the decorative layer forming step further comprises modifying the formed decorative layer.

Images