Face material

Abstract

To provide a face material capable of expressing a pattern with beauty and a natural feeling by a three dimensional effect or the like.SOLUTION: A face material of the present invention is a face material having a flat portion and a recessed portion, the face material comprising: a design layer having a plurality of discontinuous recessed portions, a base color region P1 and a pattern color region P2 in a front view, and a pattern color region P2' at a boundary portion between the flat portion and the recessed portion; and a transparent layer on the design layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a novel surface 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 patterned finishes on building walls, etc. [Background technology]

[0002] BACKGROUND ART Beautiful appearance is required for the walls of buildings and the like from the viewpoint of landscape. From this viewpoint, in recent years, attention has been paid to natural pattern finishes that evoke, for example, natural stone, soil, plants, and the like. As such patterned finishes, many sheets have been developed, such as those disclosed in Patent Document 1, in which various designs are imparted by colored printed layers. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-042993 Summary of the Invention [Problem to be solved by the invention]

[0004] However, such sheets are flat and lack variation, making it difficult to express a three-dimensional effect. Furthermore, when viewed up close, they are easily perceived as artificial. Furthermore, they may have poor weather resistance and are prone to deterioration.

[0005] The present invention has been made to solve the above problems, and aims to provide a surface material that has aesthetic appeal due to its three-dimensional appearance, can express natural patterns, and can maintain its three-dimensional appearance and aesthetic appeal for a long period of time. [Means for solving the problem]

[0006] After extensive research, the inventor came up with the idea of ​​a surface material having a flat portion and a recessed portion, which surface material has a design layer and a transparent layer on the surface of the design layer, and which has a specific pattern color area or the like on the flat portion, and thus completed the present invention.

[0007] That is, the face material of the present invention has the following characteristics. 1. A surface material having a flat portion and a recessed portion, The surface material has a design layer and a transparent layer on the surface of the design layer, The design layer is formed by fixing powder particles with a resin component, The powder or granules include a base color powder or granule component (p1) and a pattern color powder or granule component (p2) having a color different from that of the base color powder or granule component (p1), The recessed portion has a plurality of discontinuous recessed portions, A face material characterized in that, when viewed from the front, it has a base color region P1 based on the base color powder or granular component (p1), a pattern color region P2 based on the pattern color powder or granular component (p2), and a pattern color region P2' in which the pattern color powder or granular component (p2) is densely fixed at the boundary between the flat portion and the recess. 2. The surface material according to 1., characterized in that, when viewed from the front, the recess has a base color region P1. 3. The surface material according to 1., characterized in that, when viewed from the front, the pattern color region P2 forms a striped pattern. [Effects of the Invention]

[0008] According to the present invention, a surface material capable of expressing a beautiful appearance with a three-dimensional effect and a natural pattern can be obtained. Furthermore, the three-dimensional effect and beautiful appearance can be maintained for a long period of time due to improved weather resistance, stain resistance, etc. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a front view showing an example of a face material of the present invention. [Figure 2] 1 is a cross-sectional view showing an example of a face material of the present invention. [Figure 3]1 is a cross-sectional view showing an example of a face material of the present invention. [Explanation of symbols]

[0010] 1. Surface material 11: Flat part 12: Recess 13: Boundary between flat and recessed areas A: Design layer B: Transparent layer P1: Base color area P1 P2: Pattern color area P2 (P2': Pattern color area P2') DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, an embodiment of the present invention will be described.

[0012] FIG. 1 shows an example of a front view of the face material of the present invention. The surface material of the present invention is a surface material having flat portions and recessed portions, and has a design layer and a transparent layer on the surface of the design layer. The design layer is made of powder particles fixed with a resin component and exhibits a color tone based on the powder particles. The present invention is characterized in that the powder contains a base color powder component (p1) and a pattern color powder component (p2) of a different color from the base color powder component (p1), thereby making it possible to present a color tone based on the base color powder component (p1) and a color tone based on the pattern color powder component (p2) of a different color from the base color powder component (p1).

[0013] When viewed from the front, the surface material of the present invention has a plurality of discontinuous recesses on its surface, and has a base color region P1 [Figure 1: P1] based on the base color powder component (p1), and a pattern color region P2 [Figure 1: P2] based on the pattern color powder component (p2). When viewed from the front, such a surface material has a recessed pattern made up of multiple discontinuous recesses, a base color region P1 [Figure 1: P1], and a pattern color region P2 [Figure 1: P2], and a design that is a mixture of these is visible.

[0014] Specifically, when viewed from the front, the flat portion of the surface material has a base color region P1 [Fig. 1: P1] and a pattern color region P2 [Fig. 1: P2], and a design in which these colors are mixed can be seen through the transparent layer. In this invention, the flat portion refers to an area that appears flat when viewed from the front, and is an area other than the recessed portions. As long as the recessed portions are visible, the surface of the flat portion can have fine irregularities, undulations, etc. The recesses visible in a front view may be either the base color region P1 or the pattern color region P2, but in the present invention, it is preferable that the design having the base color region P1 is visible. This allows the recesses to be seen in a color based on the base color powder / granular component (p1), further enhancing the three-dimensional effect. In the present invention, the recess visible in a front view refers to the bottom of the recess, and it is sufficient if the bottom of the recess satisfies the above conditions.

[0015] The shape of the pattern imparted by the pattern color region P2 is not particularly limited, and examples thereof include islands, stripes, lines, grids, spots (dots), etc., with stripes as shown in Fig. 1 being preferred in the present invention. Examples of patterns formed on the surface material by this pattern region P2 include stone-like patterns, rock-like patterns, wood-grain patterns, joint patterns, tile-like patterns, brick-like patterns, geometric patterns, random patterns, etc. In the present invention, stone-like patterns, rock-like patterns, wood-grain patterns, etc. are preferred.

[0016] The shape of the recesses may be constant (identical) or different. Examples of the shape of the recesses when viewed from the front include polygons such as triangles, quadrilaterals (squares, rectangles, trapezoids, and diamonds), pentagons, and hexagons, shapes with curved surfaces such as circles, ellipses, and drop shapes, and irregular shapes, as well as shapes that are combinations of these.

[0017] The distribution (arrangement) of the multiple recesses may be regular or random. In the present invention, it is preferable that the multiple recesses are randomly distributed to form a recess pattern. By combining such a recess pattern with the pattern imparted to the surface material by the pattern color region P2, a natural pattern reminiscent of natural stone, soil, plants, etc. can be expressed, resulting in a surface material with even more excellent aesthetics. For example, as shown in Figure 1, it is preferable that the multiple recesses are distributed along the striped pattern imparted to the surface material by the pattern color region P2.

[0018] The recessed pattern is not particularly limited and may have various shapes, such as a stone-like pattern, a rock-like pattern, a wood-like pattern, a joint pattern, a tile-like pattern, a brick-like pattern, a geometric pattern, a random pattern, etc. Among these, the recessed pattern is suitable for a pattern having a shape such as a burrow-like, worm-eaten, or bark-like pattern, which is formed in natural stone, soil, plants, etc. For example, as shown in Fig. 1, the recessed pattern is suitable for expressing a natural-looking pattern in which a plurality of recesses such as burrow-like, worm-eaten, or bark-like patterns are distributed along the striped pattern of the pattern color region P2, such as a stone-like pattern (particularly a travertine pattern) or a wood-like pattern (e.g., a bark pattern or a knotty wood pattern).

[0019] The size of the recesses (the size of each recess) may be appropriately set depending on the desired pattern, but the maximum diameter (longer diameter) is preferably 0.2 to 50 mm, more preferably 0.5 to 30 mm, and the depth of the recesses is preferably 0.1 to 5 mm, more preferably 0.2 to 3 mm. In the present invention, "α to β" is synonymous with "α or more and β or less."

[0020] Figure 2 shows an example of a cross-sectional schematic view (enlarged cross-sectional view of the vicinity of the recess) of the X-X' portion in Figure 1. In the face material of Figure 2, the upper side of the cross section is the surface of the face material. As shown in Figure 2, when viewed from the cross-sectional direction, the surface material of the present invention has a flat portion [Figure 2: 11] and a recessed portion [Figure 2: 12], and has a design layer and a transparent layer on the surface of the design layer. In addition, when viewed from the cross-sectional direction, the design layer is composed of powder particles whose main component is a base color powder particle component (p1) continuously fixed by a resin component, and a pattern color powder particle component (p2) of a different color from the base color powder particle component (p1) is fixed to the surface layer of the design layer so as to form an arbitrary pattern. Specifically, the surface layer of the pattern layer has an area (the base color area P1) where the pattern color powder component (p2) is not fixed, and an area (the pattern color area P2) where the pattern color powder component (p2) is fixed. Furthermore, it is preferable that the pattern color area P2 has areas where the density of the pattern color powder component (p2) is sparse and areas where it is dense. This allows the shading (intensity) of the color tone to be expressed, further enhancing the three-dimensional effect.

[0021] The present invention is characterized in that the design layer has a pattern color region P2' in which the pattern color powder component (p2) is densely fixed at the boundary [Figure 2:13] between the flat portion [Figure 2:11] and the recessed portion [Figure 2:12]. Specifically, the pattern color region P2' is in a state where the pattern color powder component (p2) is unevenly distributed at the boundary portion [Figure 2:13], and the density of the pattern color powder component (p2) (the proportion of the pattern color powder component (p2) per unit area in the cross section of the surface material) is higher than in other regions, and the pattern color powder component (p2) is unevenly distributed and fixed. In the face material of the present invention having such a characteristic design layer, the color based on the pattern color powder component (p2) is strongly visible in the pattern region P2', which emphasizes the sense of depth rather than the actual depth of the recess, enhancing the three-dimensional effect. In the present invention, the boundary between the flat portion and the recessed portion [Fig. 2: 13] refers to the region (edge ​​of the recessed portion) including at least the portion spanning the flat portion [Fig. 2: 11] and the recessed portion [Fig. 2: 12], as shown in Fig. 2. Furthermore, although the shape of the boundary is shown as an angular shape (a shape where two straight lines intersect at one point) in Fig. 2, it may also be a rounded shape (curved shape), etc.

[0022] FIG. 3 shows an example of a schematic cross-sectional view (enlarged cross-sectional view of the vicinity of the recess) taken along the line YY' in FIG. As shown in Figure 3, in the face material of the present invention, it is sufficient that among the multiple recesses in the design layer, at least one recess has the pattern color region P2' at the boundary, and it is also possible to have recesses that do not have the pattern color region P2' at the boundary. The formation of such a recess pattern can further enhance the three-dimensional effect.

[0023] The thickness (thickness of the flat portion) of the surface material (design layer and transparent layer) of the present invention is preferably 0.5 to 10 mm, more preferably 0.8 to 5 mm. Even with such a thin surface material, the above-mentioned effects make it possible to express beautiful, natural patterns with a three-dimensional effect and the like.

[0024] The components constituting the face material of the present invention will be described. The face material of the present invention has a design layer and a transparent layer on the surface of the design layer. The design layer of the present invention is formed by fixing powder particles with a resin component. The powder particles are preferably granular inorganic particles whose base material is inorganic, and both natural and artificial particles can be used. A preferred embodiment of the granular inorganic particles includes at least granular colored inorganic particles. Such granular colored inorganic particles are particularly preferred, with opaque particles having a light transmittance of less than 3%, and more preferably particles having a light transmittance of 2% or less. Specific examples of such granular colored inorganic particles include marble, granite, serpentine, granite, sandstone, slate, basalt, gabbro, diorite, andesite, limestone, and their crushed products, crushed ceramics, crushed ceramics, and metal particles. Also usable are fluorite, galesite, feldspar, silica, silica sand, and their crushed products, crushed glass, glass beads, and the like, colored to satisfy the above conditions. The powder particle component of the present invention preferably includes at least colored silica sand.

[0025] The light transmittance is the total light transmittance measured by a turbidimeter. In this measurement, a sample of granular inorganic particles is filled into a transparent glass cell with an inner thickness of 5 mm, and then water is gradually added. After that, air bubbles in the cell are removed by shaking.

[0026] In the present invention, the powder or granule may contain granular transparent inorganic particles in addition to the granular colored inorganic particles. The use of such granular transparent inorganic particles is preferable in terms of improving aesthetic appearance. The granular transparent inorganic particles preferably have a light transmittance of 3% or more, more preferably 3 to 50%, and even more preferably 10 to 30%. Examples of granular transparent inorganic particles include silica, glazing, feldspar, quartz, etc., and crushed products thereof, crushed glass, glass beads, etc., and either colorless or colored types can be used as long as they satisfy the above-mentioned light transmittance.

[0027] The particle size of the powder or granules can be appropriately set within a range that allows recesses to be formed in the facing material. In the present invention, it is desirable that the powder or granules contain powder or granules with a particle size at least smaller than the size of the recesses. The particle size of the powder or granules is preferably 0.01 mm to 5 mm, more preferably 0.02 mm to 2 mm, and even more preferably 0.03 to 0.8 mm. The range of design possibilities can be expanded by combining various powder or granules with different particle sizes. The particle size of the powder or granules is measured by sieving using a metal mesh sieve as specified in JIS Z8801-1:2000.

[0028] In the present invention, the base color powder component (p1) is prepared using one or more, preferably two or more, selected from the above powder components so as to provide the base color of the facing material. The pattern color powder component (p2), which is a color different from the base color powder component (p1), is prepared using one or more selected from the above powder components so as to provide an accent color that imparts a pattern (design) to the facing material. The different colors may be any color tone that can be visually recognized as different. For example, the color difference (ΔE) between the base color powder or granular component (p1) and the pattern color powder or granular component (p2) is preferably 0.5 or more, more preferably 0.5 to 50, even more preferably 0.8 to 30, and particularly preferably 1 to 20.

[0029] The color difference (△E) is a value measured using a colorimeter. * value, a* value, b * It can be calculated from the value using the following formula: <Formula> △E={(L *1 -L *2 ) 2 +(a *1 -a *2 ) 2 +(b *1 -b *2 ) 2} 0.5 In the formula, L *1 , a *1 , b *1 are the L of the base color powder component (p1), respectively. * , a * , b * L *2 , a *2 , b *2 are the L of the pattern color powder component (p2), respectively. * , a * , b * The L*, a*, and b* values ​​of the powder or granular component can be calculated from the L*, a*, and b* values ​​(average values ​​of three randomly selected points) of the coating when a composition prepared by mixing 100 parts by mass of the powder or granular component with 36 parts by mass of acrylic resin emulsion (solid content 50% by mass) is applied to a standard white paper so as to give a dry film thickness of 2 mm, and the coating is dried for 48 hours under standard conditions (temperature 25°C, relative humidity 50%; the same applies below).

[0030] It is desirable that the color tone based on the base color powder component (p1) and the color tone based on the pattern color powder component (p2) each exhibit a color tone obtained by juxtaposition color mixing. Juxtaposition color mixing is when, when an observer views the colors from a certain distance or more, multiple juxtaposed colors appear to blend together without being individually distinguishable. In the present invention, juxtaposition color mixing of two or more types (two colors) of powder or granules is adopted, rather than color mixing using pigments, dyes, etc., thereby enhancing a natural feel, etc.

[0031] The resin component constituting the design layer of the present invention contains at least a synthetic resin. The synthetic resin is preferably one whose coating has transparency. Examples of the form of such synthetic resin include solvent-soluble resin, non-aqueous dispersion resin, solventless resin, water-dispersed resin, and water-soluble resin. Examples of the type of resin include acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, vinyl acetate resin, acrylic silicone resin, fluororesin, silicon resin, polyvinyl alcohol, cellulose derivatives, and the like, as well as composites thereof. These can be used alone or in combination of two or more.

[0032] The design layer of the present invention preferably contains a crosslinking agent in addition to the synthetic resin. In this embodiment, a resin component containing a synthetic resin having reactive functional groups and a crosslinking agent capable of reacting with the reactive functional groups can be used. In this case, the reaction between the synthetic resin and the crosslinking agent forms a coating with a three-dimensional crosslinked structure, which can sufficiently fix the powder particles, form the desired depression pattern, and improve physical properties such as strength. The crosslinking agent is preferably one that can be applied to a water-dispersible resin, and suitable examples include a water-soluble crosslinking agent, a water-dispersible crosslinking agent, and a self-emulsifying crosslinking agent.

[0033] Examples of synthetic resins having reactive functional groups that can be used include those having one or more reactive functional groups selected from a carboxyl group, a carbodiimide group, an epoxy group, an aziridine group, an oxazoline group, a hydroxyl group, an isocyanate group, a carbonyl group, a hydrazide group, an epoxy group, an amino group, and an alkoxysilyl group. The crosslinking agent may be a combination of a crosslinker capable of reacting with the reactive functional groups of the resin. Examples of the combination of reactive functional groups include a carboxyl group and a carbodiimide group, a carboxyl group and an epoxy group, a carboxyl group and an oxazoline group, a carboxyl group and an aziridine group, a hydroxyl group and an isocyanate group, a carbonyl group and a hydrazide group, an epoxy group and an amino group, and an alkoxysilyl group. One or more of these may be used.

[0034] In particular, it is preferable that the design layer of the present invention has a synthetic resin having a carboxyl group and a crosslinking agent having one or more reactive functional groups selected from a carbodiimide group, an epoxy group, and an oxazoline group.

[0035] Among these, examples of crosslinking agents having a carbodiimide group include those described in JP-A-10-60272, JP-A-10-316930, JP-A-11-60667, JP-A-2000-7642, JP-A-2000-119539, JP-A-2000-319351, JP-A-2013-112755, JP-A-2016-196612, JP-A-2016-196613, WO2017 / 6950, and the like. Examples of crosslinking agents having an epoxy group include ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyhydroxyalkane polyglycidyl ether, and sorbitol polyglycidyl ether. Examples of crosslinking agents having an oxazoline group include resins obtained by copolymerizing polymerizable oxazoline compounds such as 2-vinyl-2-oxazoline, 2-vinyl-4-methyl-2-oxazoline, 2-vinyl-5-methyl-2-oxazoline, and 2-isopropenyl-2-oxazoline with monomers copolymerizable with the compounds. These can be used alone or in combination of two or more.

[0036] The ratio of the synthetic resin, calculated as solid content, is preferably 1 to 50 parts by weight, more preferably 2 to 30 parts by weight, and even more preferably 3 to 20 parts by weight, per 100 parts by weight of the total powder and granules. Such a ratio facilitates the creation of a design that takes advantage of the aesthetic appeal of the interconnected (aggregated) powder and granules. That is, a design layer made of interconnected (aggregated) powder and granules can be obtained. A design layer made of such interconnected (aggregated) powder and granules can have fine irregularities (e.g., microscopic irregularities with a height difference of less than 0.1 mm) originating from the powder and granules on the flat and recessed portions. This reduces gloss, making it easier to achieve a matte appearance, resulting in a surface material that can express a more natural pattern.

[0037] The resin component may contain components (additives) other than synthetic resins as needed, as long as the effects of the present invention are not significantly impaired. Examples of such components include plasticizers, anti-algae agents, antibacterial agents, deodorizers, adsorbents, flame retardants, thickeners, antifoaming agents, crosslinking agents, film-forming aids, antifreeze agents, coloring pigments, extender pigments, photoluminescent pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, and catalysts.

[0038] The face material of the present invention is characterized by having a transparent layer on the surface of the design layer. The transparent layer of the present invention can be provided on the surface of the design layer (preferably on the entire surface so as to cover the design layer).

[0039] The transparent layer of the present invention can be formed from a transparent coating material containing at least a synthetic resin. The synthetic resin is preferably one whose coating has transparency. Examples of the form of such synthetic resin include solvent-soluble resin, non-aqueous dispersion resin, solventless resin, water-dispersed resin, and water-soluble resin. Examples of the type of resin include acrylic resin, urethane resin, acrylic silicone resin, fluororesin, silicone resin, and composites thereof. These can be used alone or in combination of two or more.

[0040] The transparent layer of the present invention preferably contains a crosslinking agent in addition to the synthetic resin. In such an embodiment, a resin component containing a synthetic resin having a reactive functional group and a crosslinking agent capable of reacting with the reactive functional group can be used. In this case, a coating having a three-dimensional crosslinked structure is formed by the reaction between the synthetic resin and the crosslinking agent, which makes it possible to improve physical properties such as weather resistance, durability, and stain resistance. The crosslinking agent is preferably one that can be applied to a water-dispersible resin, and suitable examples include a water-soluble crosslinking agent, a water-dispersible crosslinking agent, and a self-emulsifying crosslinking agent.

[0041] Examples of synthetic resins having reactive functional groups that can be used include those having one or more reactive functional groups selected from a carboxyl group, a carbodiimide group, an epoxy group, an aziridine group, an oxazoline group, a hydroxyl group, an isocyanate group, a carbonyl group, a hydrazide group, an epoxy group, an amino group, and an alkoxysilyl group. The crosslinking agent may be a combination of a crosslinker capable of reacting with the reactive functional groups of the resin. Examples of the combination of reactive functional groups include a carboxyl group and a carbodiimide group, a carboxyl group and an epoxy group, a carboxyl group and an oxazoline group, a carboxyl group and an aziridine group, a hydroxyl group and an isocyanate group, a carbonyl group and a hydrazide group, an epoxy group and an amino group, and an alkoxysilyl group. One or more of these may be used.

[0042] In particular, it is preferable that the transparent layer of the present invention has a synthetic resin having a carboxyl group and a crosslinking agent having one or more reactive functional groups selected from a carbodiimide group, an epoxy group, and an oxazoline group.

[0043] Examples of crosslinking agents having these carbodiimide groups include those described in JP-A-10-60272, JP-A-10-316930, JP-A-11-60667, JP-A-2000-7642, JP-A-2000-119539, JP-A-2000-319351, JP-A-2013-112755, JP-A-2016-196612, JP-A-2016-196613, WO2017 / 6950, and the like. Examples of crosslinking agents having an epoxy group include ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyhydroxyalkane polyglycidyl ether, and sorbitol polyglycidyl ether. Examples of crosslinking agents having an oxazoline group include resins obtained by copolymerizing polymerizable oxazoline compounds such as 2-vinyl-2-oxazoline, 2-vinyl-4-methyl-2-oxazoline, 2-vinyl-5-methyl-2-oxazoline, and 2-isopropenyl-2-oxazoline with monomers copolymerizable with the compounds. These can be used alone or in combination of two or more.

[0044] Furthermore, the crosslinking agent for the transparent layer of the present invention preferably contains a crosslinking agent that can also react with the synthetic resin having a reactive functional group in the design layer. This allows the formation of a coating having a three-dimensional crosslinked structure between the design layer and the transparent layer, further improving physical properties such as weather resistance, durability, and stain resistance.

[0045] The transparent coating material forming the transparent layer may contain, in addition to the above resin component, for example, a water repellent, a stain-reducing agent, a matting agent, a color pigment, etc. The transparent coating layer may be a colored transparent coating layer as long as the effects of the present invention are not significantly impaired. When the transparent coating material contains a color pigment, a colored transparent coating layer can be formed.

[0046] In the present invention, by providing such a transparent layer, the weather resistance, durability, etc. of the surface material can be improved, and the texture, gloss, etc. of the surface can also be adjusted.

[0047] The face 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 design layer. Examples of reinforcing materials include woven fabric, nonwoven fabric, ceramic paper, synthetic paper, mesh, cloth, gypsum board, plywood, slate board, and metal plate. The reinforcing material may be made of two or more of the above materials. The use of such a reinforcing material can increase the strength of the face material.

[0048] The method for producing the face material of the present invention is not particularly limited, and various methods can be employed. One example is a method using a mold. In this method, a mold is first prepared with convex portions (portions that will become concave portions of the face material) corresponding to the desired pattern. The mold is not particularly limited, but molds made of silicone resin, urethane resin, etc., or molds provided with release paper, etc., can be used. When manufacturing using a mold, the inner surface of the mold becomes the surface of the face material, so by adjusting the shape of the inner surface of the mold, the desired concave pattern can be imparted to the surface of the face material.

[0049] Using the above mold, for example, [1] A method in which a pattern color powder component (p2) is scattered on the inner surface of a formwork so as to form a desired pattern, and then a composition containing a base color powder component (p1) and a resin component (hereinafter also referred to as a "base composition") is applied to the entire inner surface of the formwork, and the pattern color powder component (p2) and the base composition are integrated and hardened, and then the mold is removed to form a design layer, and then a transparent coating material is applied; [2] A method in which a composition containing a pattern color powder component (p2) and a resin component (hereinafter also referred to as a "pattern composition") is partially applied to the inner surface of a formwork so as to form a desired pattern, and after curing as necessary, a base composition is applied to the entire inner surface of the formwork, and after curing, the formwork is demolded to form a design layer, and then a transparent coating material is applied; In either of the above [1] and [2], the mold can be set with the inner surface facing upward, and the spraying, coating, etc. steps can be carried out. The surface material obtained by the above method has a pattern of depressions formed by the inversion of the convex portions on the inner surface of the formwork.

[0050] In the present invention, the above method [1] is preferred. When the pattern color powder component (p2) is sprayed, it is sprayed so as to form a desired pattern, for example, in stripes, spots, etc. In the present invention, spraying in stripes is preferred. In the present invention, by scattering the pattern color powder component (p2), the distribution of the pattern color powder component (p2) easily forms sparse and dense areas, making it possible to impart a natural pattern. Furthermore, by scattering the pattern color powder component (p2) near the convex parts of the inner surface of the formwork, the scattered pattern color powder component (p2) tends to be unevenly distributed and densely distributed (accumulate) at the base of the convex parts. On the other hand, the pattern color powder component (p2) is less likely to accumulate at the top of the convex parts (the parts that become the bottoms of the concave parts of the face material). This makes it possible to efficiently form a pattern color region P2' in which the pattern color powder component (p2) is densely fixed. Moreover, the recesses (particularly the bottoms of the recesses) of the resulting face material tend to have the base color region P1. In particular, when the convex portions of the formwork have a sloped or rounded shape (for example, a convex, parabolic, or curved shape), the pattern color powder component (p2) tends to be more unevenly distributed at the base of the convex portions, and the pattern color powder component (p2) is less likely to accumulate at the top of the convex portions. This allows for the full expression of a beautiful, three-dimensional appearance and a natural-looking pattern.

[0051] The amount of the pattern color powder component (p2) to be sprayed is preferably 5 to 200 g / m 2 , more preferably 10 to 100 g / m 2 In such a case, the above-mentioned action can be fully obtained, and the effect of the present invention can be further enhanced. After the pattern color powder component (p2) is sprayed, a wetting agent such as a resin component or water can be sprayed, if necessary.

[0052] The loading of the base composition is preferably 1 to 10 kg / m 2 , more preferably 3 to 8 kg / m 2 In such a case, the effects of the present invention can be fully obtained. In filling the base composition, known tools such as a spray, roller, trowel, brush, reciprocator, coater, etc. can be used.

[0053] Also, when introducing reinforcement materials, e.g. a method in which, after filling the base composition, a reinforcing material is embedded and / or laminated before hardening, and then hardened; A method in which a reinforcing material is laminated on the back surface of the face material with an adhesive or the like after the base composition has hardened (before or after demolding); etc.

[0054] Furthermore, the transparent layer is formed by, for example, applying a transparent coating material to the surface (preferably the entire surface) of the design layer after demolding and drying it. The amount of the transparent coating material applied is preferably 5 to 200 g / m 2 , more preferably 10 to 150 g / m 2 is.

[0055] The surface material of the present invention can be adjusted to a desired texture, gloss, etc. by the transparent layer. For example, to impart a calm and elegant aesthetic appearance, the gloss at 60 degrees is preferably 8 or less, more preferably 1 to 7, and even more preferably 1.5 to 6. The gloss at 85 degrees is preferably 8 or less, more preferably 1 to 7, and even more preferably 1.5 to 6. Furthermore, the difference in gloss at 60 degrees and 85 degrees is preferably 2 or less, more preferably 1.5 or less, and even more preferably 1 or less. By having the gloss at 60 degrees and 85 degrees satisfy the above ranges, unevenness in gloss due to the viewing angle (direction) can be suppressed, and the calm and elegant appearance can be further enhanced. On the other hand, by setting the gloss at 60 degrees and 85 degrees to exceed the above range, it is possible to impart aesthetic qualities such as a 30% gloss finish, semi-gloss finish, glossy finish, mirror finish, etc. The gloss level in the present invention is a value measured in accordance with JIS K5600-4-7 "Specular Gloss Level." Specifically, it is the 60° or 85° specular gloss level measured with a gloss meter, and is the average value of measurements taken at 10 random locations on the surface of the surface material.

[0056] The facing material of the present invention can be used as a material for decorating buildings, for example, walls (exterior and interior), pillars, etc. The dimensions of the face material can be set appropriately within the range of, for example, length x width = 200 mm to 3000 mm x 200 mm to 3000 mm. The thickness of the face material is preferably 0.5 to 10 mm, more preferably 0.8 to 5 mm. When fixing the surface material of the present invention to a wall surface or the like, for example, adhesive, adhesive tape, nails, screws, bolts, rails, etc. may be used. Examples of substrates that constitute building walls and the like include concrete, mortar, siding boards, extruded boards, gypsum boards, perlite boards, plywood, bricks, plastic boards, metal boards, glass, porcelain tiles, etc. These substrates may have a coating (existing coating, primer coating, etc.) already formed on their surfaces, or may have wallpaper attached, etc. Furthermore, by imparting flexibility (pliability), the surface material of the present invention can be easily fixed (applied) to the substrate even if it has a curved surface. [Example]

[0057] Examples and comparative examples will be given below to clarify the features of the present invention.

[0058] (Preparation of powder and granules) Base color powder component (p1-1) A mixture of 90 parts by mass of granular colored inorganic particles [a mixture of white silica sand, beige silica sand, and brown silica sand (mass ratio) = 60:30:10, particle size 0.03 to 0.6 mm, light transmittance less than 1%] and 10 parts by mass of granular transparent inorganic particles [kansui stone; particle size 0.1 to 0.4 mm, light transmittance 16%]. ·Pattern color powder component (p2-1) Granular colored inorganic particles [a mixture of yellowish silica sand and beigeish silica sand (mass ratio) = 80:20, particle size 0.05 to 0.3 mm, light transmittance less than 1%], Color difference (△E) from base color powder component (p1-1) = 16.3

[0059] Base color powder component (p1-2) A mixture of 90 parts by mass of granular colored inorganic particles [a mixture of white silica sand, gray silica sand, and yellow silica sand (mass ratio) = 80:10:10, particle size 0.03 to 0.6 mm, light transmittance less than 1%] and 10 parts by mass of granular transparent inorganic particles [kansui stone; particle size 0.1 to 0.4 mm, light transmittance 16%]. ·Pattern color powder and granular components (p2-2) Granular colored inorganic particles [a mixture of white silica sand and gray silica sand (mass ratio) = 90:10, particle size 0.05 to 0.3 mm, light transmittance less than 1%], Color difference (△E) from base color powder component (p1-2) = 8.5

[0060] Base color powder component (p1-3) A mixture of 90 parts by mass of granular colored inorganic particles [a mixture of white silica sand, beige silica sand, and brown silica sand (mass ratio) = 50:25:25, particle size 0.03 to 0.6 mm, light transmittance less than 1%] and 10 parts by mass of granular transparent inorganic particles [kansui stone; particle size 0.1 to 0.4 mm, light transmittance 16%]. ·Pattern color powder and granular components (p2-3) Granular colored inorganic particles [mixture of white silica sand: brown silica sand (mass ratio) = 70:30, particle size 0.05 to 0.3 mm, light transmittance less than 1%], Color difference (△E) from base color powder component (p1-3) = 5.3

[0061] (Production of base composition 1) Base composition 1 was produced by uniformly mixing 100 parts by mass of the base color powder component (p1-1), 30 parts by mass of the resin component [acrylic resin emulsion, solid content 50% by weight, medium: water], and 25 parts by mass of additives [antifoaming agent, film-forming agent, water, etc.] in a conventional manner.

[0062] (Production of base composition 2) Base composition 2 was produced by uniformly mixing 100 parts by mass of the base color powder component (p1-2), 35 parts by mass of the resin component [carboxyl group-containing acrylic resin emulsion, solid content 50% by weight, medium: water], 0.3 parts by mass of a crosslinking agent (epoxy group-containing crosslinking agent), and 25 parts by mass of additives [antifoaming agent, film-forming aid, water, etc.] in a conventional manner.

[0063] (Production of base composition 3) Base composition 3 was produced by uniformly mixing 100 parts by mass of the base color powder component (p1-3), 30 parts by mass of the resin component [acrylic silicone resin emulsion, solid content 50% by mass, medium: water], and 25 parts by mass of additives [antifoaming agent, film-forming agent, water, etc.] in a conventional manner.

[0064] (Production of pattern composition 1) Pattern composition 1 was produced by uniformly mixing 100 parts by mass of the pattern color powder component (p2-1), 30 parts by mass of the resin component [acrylic resin emulsion, solid content 50% by weight, medium: water], and 25 parts by mass of additives [antifoaming agent, film-forming agent, water, etc.] in a conventional manner.

[0065] (Manufacturing transparent coating materials) A transparent coating material was produced by uniformly mixing 60 parts by mass of the resin component (carboxyl-group acrylic silicone resin emulsion, solids content 50% by weight, medium: water), 2 parts by mass of the crosslinking agent (carbodiimide group-containing crosslinking agent, solids content 40% by weight), and 38 parts by mass of the additives (antifoaming agent, film-forming agent, water, etc.) in a conventional manner.

[0066] Example 1 A rectangular mold (300 mm x 600 mm) capable of forming a travertine pattern having multiple convex portions (height of the convex portions: 0.2 to 2 mm, major diameter of the convex portions: 0.2 to 10 mm) on a flat portion was used. Pattern composition 1 was applied to the mold in stripes (mass per unit area: 100 g / m). 2 ), and pattern composition 1 was unevenly distributed at the base of the convex portion of the formwork, and then dried and cured (at 65°C for 30 minutes). Next, the base composition 1 was applied (mass per unit area: 5.0 kg / m 2 After curing (at 65°C for 24 hours), the resin was demolded to produce a design layer. Furthermore, a transparent coating material is applied to the entire surface of the design layer (mass per unit area: 100 g / m 2 ) and dried and hardened (at 80°C for 30 minutes) to produce face material (I) (dimensions: 300 mm x 600 mm, thickness: 3 mm). Aesthetic evaluation The obtained surface material (I) had flat portions and recessed portions, and when viewed from the front, had a base color region P1 based on the base color powder / granular component (p1-1) and a striped pattern color region P2 based on the pattern color powder / granular component (p2-1). Furthermore, the boundary between the flat portion and the recessed portion had a pattern color region P2' in which the pattern color powder and granular component (p2-1) was densely fixed, and a pattern with an excellent natural feel was obtained. Furthermore, since the bottom of the recess has the base color region P1, the sense of depth is emphasized and an excellent three-dimensional effect is achieved. Weather resistance evaluation The obtained surface material (I) was exposed outdoors for six months, and the appearance of the surface material was observed. The results showed that the degree of deterioration and staining was slight, and the aesthetic appearance was maintained.

[0067] Example 2 A rectangular mold (300 mm x 600 mm) was used as the mold, which allows the formation of a travertine pattern with multiple convex portions (height of the convex portions: 0.2 to 2 mm, major diameter of the convex portions: 0.2 to 10 mm) on the flat portion. The pattern color powder component (p2-1) was scattered in stripes on the mold (mass per unit area: 60 g / m). 2) and unevenly distribute it at the base of the convex part of the formwork, and then, the base composition 1 is applied (weight per unit area 5.0 kg / m 2 After curing (at 65°C for 24 hours), the resin was demolded to produce a design layer. Furthermore, a transparent coating material is applied to the entire surface of the design layer (mass per unit area: 100 g / m 2 ) and dried and hardened (at 80°C for 30 minutes) to produce face material (II) (dimensions: 300 mm x 600 mm, thickness: 3 mm). Aesthetic evaluation The obtained face material (II) had flat portions and recessed portions, and in a front view had a base color region P1 based on the base color powder granular component (p1-1) and a striped pattern color region P2 based on the pattern color powder granular component (p2-1), giving it a three-dimensional and natural appearance. Moreover, a pattern color region P2' where the pattern color powder granular component (p2-1) was densely fixed was present at the boundary between the flat portions and the recessed portions, and a striped pattern due to the density of the pattern color powder granular component (p2-1) was formed in the flat portions, giving it a pattern that was superior in terms of natural appearance. Furthermore, since the bottom of the recess has the base color region P1, the sense of depth is emphasized and an excellent three-dimensional effect is achieved. Weather resistance evaluation The obtained surface material (II) was exposed outdoors for six months, and the appearance of the surface material was observed. The results showed that the degree of deterioration and staining was slight, and the aesthetic appearance was maintained.

[0068] Example 3 A rectangular mold (300 mm x 600 mm) was used as the mold, which could form a travertine pattern with multiple convex portions (height of the convex portions: 0.2 to 2 mm, major diameter of the convex portions: 0.2 to 10 mm) on the flat portion. The pattern color powder component (p2-2) was scattered in stripes on the mold (mass per unit area: 60 g / m). 2 ) and unevenly distribute it at the base of the convex part of the formwork, and then apply the base composition 2 (weight per unit area 5.0 kg / m 2 After curing (at 65°C for 24 hours), the resin was demolded to produce a design layer. Furthermore, a transparent coating material is applied to the entire surface of the design layer (mass per unit area: 100 g / m2 ) and dried and hardened (at 80°C for 30 minutes) to produce face material (III) (dimensions: 300 mm x 600 mm, thickness: 3 mm). Aesthetic evaluation The obtained face material (III) had flat portions and recessed portions, and in front view had a base color region P1 based on the base color powder granular component (p1-2) and a striped pattern color region P2 based on the pattern color powder granular component (p2-2), giving it a three-dimensional and natural feel. Moreover, a pattern color region P2' where the pattern color powder granular component (p2-2) was densely fixed was present at the boundary between the flat portions and the recessed portions, and a striped pattern due to the density of the pattern color powder granular component (p2-2) was formed in the flat portions, giving it a pattern that was superior in terms of natural feel. Furthermore, since the bottom of the recess has the base color region P1, the sense of depth is emphasized and an excellent three-dimensional effect is achieved. Weather resistance evaluation The obtained surface material (III) was exposed outdoors for six months, and the appearance of the surface material was observed. The results showed that the degree of deterioration and staining was slight, and the aesthetic appearance was maintained.

[0069] Example 4 A rectangular mold (300 mm x 600 mm) was used as the mold, which could form a travertine pattern with multiple convex portions (height of the convex portions: 0.2 to 2 mm, long diameter of the convex portions: 0.2 to 10 mm) on the flat portion. The pattern color powder component (p2-3) was scattered in stripes on the mold (mass per unit area: 60 g / m). 2 ) and unevenly distribute it at the base of the convex part of the formwork, and then apply the base composition 3 (weight per unit area 5.0 kg / m 2 After curing (at 65°C for 24 hours), the resin was demolded to produce a design layer. Furthermore, a transparent coating material is applied to the entire surface of the design layer (mass per unit area: 100 g / m 2 ) and dried and hardened (at 80°C for 30 minutes) to produce surface material (IV) (dimensions: 300 mm x 600 mm, thickness: 3 mm). Aesthetic evaluation The obtained surface material (IV) had flat portions and recessed portions, and in front view had a base color region P1 based on the base color powder granular component (p1-3) and a striped pattern color region P2 based on the pattern color powder granular component (p2-3), giving it a three-dimensional and natural appearance. Moreover, a pattern color region P2' where the pattern color powder granular component (p2-3) was densely fixed was present at the boundary between the flat portions and the recessed portions, and a striped pattern due to the density of the pattern color powder granular component (p2-3) was formed in the flat portions, giving it a pattern that was superior in terms of natural appearance. Furthermore, since the bottom of the recess has the base color region P1, the sense of depth is emphasized and an excellent three-dimensional effect is achieved. Weather resistance evaluation The obtained surface material (IV) was exposed outdoors for six months, and the appearance of the surface material was observed. The results showed that the degree of deterioration and staining was minor, and the aesthetic appearance was maintained.

Claims

1. A surface material having a flat portion and a recessed portion, The surface material has a design layer and a transparent layer on the surface of the design layer, The design layer is formed by fixing powder particles with a resin component, The powder or granules include a base color powder or granule component (p1) and a pattern color powder or granule component (p2) having a color different from that of the base color powder or granule component (p1), The recessed portion has a plurality of discontinuous recessed portions, A face material characterized in that, when viewed from the front, it has a base color region P1 based on the base color powder or granular component (p1), a pattern color region P2 based on the pattern color powder or granular component (p2), and a pattern color region P2' in which the pattern color powder or granular component (p2) is densely fixed at the boundary between the flat portion and the recess.

2. 2. The panel according to claim 1, wherein the recess has a base color region P1 in a front view.

3. 2. The panel material according to claim 1, wherein the pattern color region P2 forms a striped pattern when viewed from the front.

Images