Surface material

Abstract

This material offers superior contrast in texture, clarity, and gloss, enabling the expression of natural-looking designs. [Solution] The present invention relates to a surface material having a patterned layer, wherein the patterned layer is made up of inorganic particles (P) fixed with a resin component, and the surface of the patterned layer is characterized by having an exposed portion (X) where the inorganic particles (P) are exposed and a covered portion (Y) where the inorganic particles (P) are covered with a resin component.

Description

Technical Field

[0001] The present invention relates to a novel facing material. The facing material of the present invention can be applied to the surface coating of buildings, civil engineering structures, etc., and specifically can be applied as a decorative sheet used for, for example, the pattern finishing of building walls.

Background Art

[0002] In the case of building walls, etc., aesthetic properties are required from the perspective of landscape. In recent years, from such a perspective, for example, a natural-looking pattern finish imitating natural stones, soil, plants, etc. has attracted attention. As such a pattern finish, for example, many decorative sheets formed from a composition containing an aggregate and a resin component as in Patent Document 1 have been developed. In Patent Document 1, a plurality of compositions having different color tones are applied onto a base sheet in a strip or streak shape to form a pattern imitating sedimentary rock or marble.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, the pattern formed in Patent Document 1 described above may easily become monotonous in terms of pattern, texture, and glossiness, and may lack vividness of the pattern.

[0005] The present invention has been made to solve the above problems, and an object thereof is to provide a facing material that is excellent in the contrast of texture, vividness, and glossiness and can express a natural design.

Means for Solving the Problems

[0006] As a result of diligent research, the inventors conceived of a surface material having a specific patterned layer in which inorganic particles are immobilized with a resin component, and thus completed the present invention.

[0007] In other words, the surface material of the present invention has the following characteristics. 1. A surface material having a patterned layer, The above patterned layer is formed by inorganic particles (P) being fixed with a resin component. The surface of the patterned layer is characterized by having an exposed portion (X) where the inorganic particles (P) are exposed and a covered portion (Y) where the inorganic particles (P) are covered with a resin component. 2. The surface of the patterned layer has an exposed portion (X) where the first inorganic particles (P1) are exposed and a covered portion (Y) where the second inorganic particles (P2) are covered with a resin component. The surface material according to 1, characterized in that the particle size D80 of the first inorganic particle (P1) is smaller than the particle size D80 of the second inorganic particle (P2). 3. The surface material according to 1, characterized in that the exposed portion (X) has a pattern. 4. The surface material according to 1, characterized in that the surface of the patterned layer is flat. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a surface material that has excellent contrast in texture, clarity, and gloss, and has a natural-looking patterned layer. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is an example of a front view of the surface material of the present invention. [Figure 2] Figure 2 is an example of an enlarged schematic cross-sectional view of A-A' in Figure 1. [Figure 3] Figure 3 is an example of an enlarged schematic diagram of the area around section Z in Figure 2. [Figure 4] Figure 4 is an example of a front view of the surface material of the present invention. [Figure 5] Figure 5 is an example of a schematic diagram of an enlarged section of A-A', B-B', and C-C' in Figure 4. [Explanation of Symbols]

[0010] 1. Surface material 10: Pattern layer 11: Exposed part (X) 12: Covering part (Y) 13: Inorganic particle (P) (first inorganic particle (P1)) 14: Inorganic particle (P) (second inorganic particle (P2)) 15: Resin components 16: Recessed pattern [Modes for carrying out the invention]

[0011] The following describes embodiments for carrying out the present invention.

[0012] The present invention relates to a surface material having a patterned layer, wherein the patterned layer is made up of inorganic particles (P) fixed with a resin component.

[0013] First, let's explain the components that make up the pattern layer. The inorganic particles (P) constituting the patterned layer of the present invention are inorganic particles (preferably granular particles) made of a matrix material, and can be either natural or artificial. The inorganic particles (P) preferably include at least colored inorganic particles. Such colored inorganic particles are particularly preferably opaque with a light transmittance of less than 3%, and more preferably have a light transmittance of 2% or less. Specific examples of such colored inorganic particles include marble, granite, serpentinite, sandstone, slate, basalt, gabbro, diorite, andesite, limestone and their crushed products, ceramic crushed products, metal granules, etc. Furthermore, fluorite, cressite, feldspar, silica, silica sand and their crushed products, glass crushed products, glass beads, etc., can also be used, colored with dyes, glazes, coloring coatings, etc., to satisfy the above conditions. These can be used individually or in combination of two or more. The colored inorganic particles of the present invention preferably include at least colored silica sand.

[0014] The above-mentioned light transmittance refers to the total light transmittance value measured by a turbidimeter. In this measurement, a sample of inorganic particles is packed into a transparent glass cell with an inner thickness of 5 mm, then water is gradually added, and air bubbles in the cell are removed by vibration.

[0015] In the present invention, the inorganic particles (P) can also include transparent inorganic particles in addition to the colored inorganic particles described above. The use of such transparent inorganic particles is preferable in terms of improving aesthetics. The transparent inorganic particles are preferably those with a light transmittance of 3% or more, more preferably 3 to 50%, and even more preferably 10 to 30%. Examples of transparent inorganic particles include silica, fossilite, feldspar, silica, and their pulverized products, glass pulverized products, glass beads, etc., and both colorless and colored types can be used as long as they satisfy the above light transmittance requirements. In this invention, "α~β" is synonymous with "α or greater and β or less".

[0016] In the present invention, the total amount of inorganic particles (P) preferably contains 50 to 100% by mass, more preferably 55 to 98% by mass, and even more preferably 60 to 95% by mass of the colored inorganic particles, and preferably contains 0 to 50% by mass, more preferably 2 to 45% by mass, and even more preferably 5 to 40% by mass, of the transparent inorganic particles. In this case, a patterned layer with even better aesthetic appeal can be formed.

[0017] The particle size range (particle diameter) of the inorganic particles (P) is preferably 20 μm to 1000 μm, more preferably 25 μm to 850 μm, and even more preferably 32 μm to 600 μm. The particle size range of the inorganic particles (P) is measured by sieving using a metal mesh sieve as specified in JIS Z8801-1:2019, and refers to the range from the minimum particle diameter to the maximum particle diameter. By combining various inorganic particles (P) with different particle sizes in this way to set the particle size range, it is possible to broaden the range of design possibilities.

[0018] The patterned layer of the present invention exhibits color through juxtaposition color mixing of the inorganic particles (P) described above. Juxtaposition color mixing refers to the phenomenon where, when an observer views the colors from a certain distance or more, multiple juxtaposed colors appear to blend together without being individually distinguishable.

[0019] The resin component constituting the patterned layer of the present invention includes at least a synthetic resin. The synthetic resin is preferably one whose film is transparent. Examples of such synthetic resins include solvent-soluble resins, non-aqueous dispersion resins, solvent-free resins, aqueous dispersion resins (resin emulsions), and water-soluble resins. Examples of resin types include acrylic resins, urethane resins, epoxy resins, vinyl chloride resins, vinyl acetate resins, acrylic silicone resins, fluororesins, silicon resins, polyvinyl alcohol, cellulose derivatives, or composites thereof. These can be used individually or in combination of two or more. As the synthetic resin, aqueous dispersion resins and / or water-soluble resins are preferred.

[0020] In the patterned layer of the present invention, it is preferable to include 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 that can react with the reactive functional group can be used. In this case, the reaction between the synthetic resin and the crosslinking agent forms a film having a three-dimensional crosslinked structure, which allows the inorganic particles (P) to be sufficiently immobilized and improves physical properties such as strength. Preferably, the crosslinking agent is one that can be applied to water-dispersible resins, such as water-soluble crosslinking agents, water-dispersible crosslinking agents, and self-emulsifying crosslinking agents.

[0021] As synthetic resins having reactive functional groups, for example, those having one or more reactive functional groups selected from carboxyl groups, carbodiimide groups, epoxy groups, aziridine groups, oxazoline groups, hydroxyl groups, isocyanate groups, carbonyl groups, hydrazide groups, epoxy groups, amino groups, and alkoxysilyl groups can be used. As a crosslinking agent, a combination of reactive functional groups of the resin can be used. Examples of reactive functional group combinations include carboxyl groups and carbodiimide groups, carboxyl groups and epoxy groups, carboxyl groups and oxazoline groups, carboxyl groups and aziridine groups, hydroxyl groups and isocyanate groups, carbonyl groups and hydrazide groups, epoxy groups and amino groups, and alkoxysilyl groups, and one or more of these can be used.

[0022] In particular, the patterned layer of the present invention preferably has a synthetic resin having a carboxyl group and a crosslinking agent having one or more reactive functional groups selected from carbodiimide groups, epoxy groups, and oxazoline groups.

[0023] Examples of crosslinking agents having a carbodiimide group include those described in Japanese Patent Publication No. 10-60272, Japanese Patent Publication No. 10-316930, Japanese Patent Publication No. 11-60667, Japanese Patent Publication No. 2000-7642, Japanese Patent Publication No. 2000-119539, Japanese Patent Publication No. 2000-319351, Japanese Patent Publication No. 2013-112755, Japanese Patent Publication No. 2016-196612, Japanese Patent Publication No. 2016-196613, WO2017 / 6950, etc. Examples of crosslinking agents having epoxy groups 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, sorbitol polyglycidyl ether, and the like. Examples of crosslinking agents having an oxazoline group include 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, which are copolymerized with monomers copolymerizable with these compounds to produce resins. These can be used individually or in combination of two or more.

[0024] The ratio of the above synthetic resin is preferably 1 to 50 parts by mass, more preferably 2 to 30 parts by mass, and even more preferably 3 to 20 parts by mass, based on solid content, per 100 parts by mass of the total amount of inorganic particles (P). With such a ratio, it is easy to impart a design that takes advantage of the aesthetic appearance created by the bonding (aggregation) of inorganic particles (P). In other words, a patterned layer consisting of bonded (aggregated) inorganic particles (P) can be obtained.

[0025] The patterned layer of the present invention may contain components (additives) other than those listed above, as necessary, as long as they do not significantly impair the effects of the present invention. Examples of such components include coloring pigments, extender pigments, plasticizers, anti-algal agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoaming agents, crosslinking agents, film-forming aids, antifreeze agents, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, and the like.

[0026] <Surface material> The surface material of the present invention has a patterned layer formed by the above-mentioned constituent components. Specific embodiments of the surface material of the present invention will be described below. The present invention is not limited to these embodiments.

[0027] (Embodiment 1) Embodiment 1 of the present invention of the facing material will be described below. Figure 1 shows an example of a front view of the facing material of the present invention. Figure 2 shows an example of a schematic cross-sectional view (enlarged cross-sectional view) of section A-A' in Figure 1. Furthermore, Figure 3 shows an example of an enlarged schematic view of the area around section Z in Figure 2.

[0028] The surface material of Embodiment 1 of the present invention is characterized in that, when viewed from the front (when viewed from the front direction), the surface of the patterned layer has an exposed portion (X) [Figure 1:11] in which inorganic particles (P) are exposed and a covered portion (Y) [Figure 1:12] in which the inorganic particles (P) are covered with a resin component. Furthermore, when viewed from a cross-sectional direction, the patterned layer [Figure 2:10] consists of inorganic particles (P) fixed with a resin component, and its surface forms an exposed portion (X) [Figure 2:11] where the inorganic particles (P) are exposed, and a covered portion (Y) [Figure 2:12] where the inorganic particles (P) are covered with the resin component.

[0029] In this invention, as shown in Figure 3, the portion of the inorganic particle (P) [Figure 3:13] whose surface is exposed without being covered by the resin component is called the exposed portion (X), and the portion of the inorganic particle (P) [Figure 3:14] whose surface is covered by the resin component [Figure 3:15] is called the covered portion (Y). Furthermore, the inorganic particles (P) constituting the exposed portion (X) are also referred to as first inorganic particles (P1), and the inorganic particles (P) constituting the covered portion (Y) are also referred to as second inorganic particles (P2).

[0030] In the present invention, as described above, by having exposed portions (X) on the surface of the patterned layer in which inorganic particles (P) are exposed, a natural-looking patterned layer can be obtained that takes advantage of the contrast in texture, vividness, and gloss derived from the inorganic particles (P).

[0031] In Embodiment 1, the patterned layer is preferably flat on its surface. "Flat" means that it is substantially flat (the surface of the patterned layer is substantially on the same plane). Furthermore, in Embodiment 1, the boundary between the exposed portion (X) and the covered portion (Y) is also flat.

[0032] In this invention, even if the surface of the patterned layer is flat, by having exposed portions (X) on the surface of the patterned layer, a natural-looking patterned layer can be obtained that takes advantage of the contrast of texture, vividness, and gloss derived from inorganic particles (P).

[0033] The exposed portion (X) can be arbitrarily formed on the surface of the patterned layer, and it is preferable to form a desired pattern (more preferably a discontinuous pattern). In such a case, the contrast between the texture and gloss of the exposed portion (X) and the covered portion (Y) further enhances the vividness of the exposed portion (X) and allows for the formation of an excellent pattern. Examples of patterns formed by the exposed portion (X) include island patterns, striped patterns, linear patterns, grid patterns, and spotted (dot-like) patterns. In the present invention, striped patterns and linear patterns as shown in Figure 1 are preferred. In such cases, the contrast between texture and gloss can create striped and linear patterns with excellent visual appeal.

[0034] In the patterned layer of the present invention, the particle size, hue, material, etc., of the first inorganic particles (P1) constituting the exposed portion (X) and the second inorganic particles (P2) constituting the covering portion (Y) can be appropriately set according to the desired design.

[0035] For example, in the present invention, the first inorganic particles (P1) and the second inorganic particles (P2) can be inorganic particles with the same particle size, hue, and material. In this case, a subdued pattern is formed by the contrast between the texture and gloss of the exposed portion (X) and the covered portion (Y). For example, a design can be presented in which the contrast changes depending on the irradiation of light such as sunlight or artificial lighting.

[0036] Furthermore, in the present invention, it is preferable to use first inorganic particles (P1) and second inorganic particles (P2) with different particle sizes, and it is even more preferable to use first inorganic particles (P1) with a particle diameter D80 smaller than that of second inorganic particles (P2). This further enhances the effects of the present invention. The mechanism of action is not limited, but when the particle diameter of the first inorganic particles (P1) is relatively smaller than that of the second inorganic particles (P2), the surface area of ​​the exposed particles increases, allowing the color tone of the first inorganic particles (P1) to be more clearly visible and achieving excellent clarity. In addition, the increased surface area of ​​the exposed particles makes it easier to create gloss contrast. As a result, in addition to the contrast due to texture and gloss, a pattern with excellent clarity can be exhibited. In this invention, the particle size D80 of the inorganic particles (P1)(P2) refers to the 80% cumulative particle size D80, which is the particle size that, when screened, accumulates to 80% by mass from the fine particle side.

[0037] The particle size (range of particle diameter) of the above-mentioned first inorganic particles (P1) is preferably 20 μm to 600 μm, more preferably 25 μm to 500 μm, and even more preferably 32 μm to 425 μm. Furthermore, the particle size D80 of the first inorganic particle (P1) is preferably 75 μm to 300 μm, more preferably 106 to 250 μm, and even more preferably 150 to 212 μm. Furthermore, the content of particles with a particle diameter exceeding 300 μm in the total amount of the first inorganic particles (P1) is preferably 8% by mass or less, more preferably 5% by mass or less, and even more preferably 3% by mass or less. On the other hand, the particle size range (particle diameter) of the second inorganic particles (P2) is preferably 20 μm to 1000 μm, more preferably 25 μm to 850 μm, and even more preferably 32 μm to 600 μm. Furthermore, the particle size D80 of the second inorganic particle (P2) is preferably 150 to 425 μm, more preferably 212 to 355 μm, and even more preferably 250 to 300 μm. Furthermore, the content of particles with a particle diameter exceeding 300 μm in the total amount of the second inorganic particles (P2) is preferably 10% by mass or more, more preferably 15% by mass or more. In this invention, the particle size of the first inorganic particles (P1) and the second inorganic particles (P2) can be adjusted, for example, using a metal mesh sieve as specified in JIS Z8801-1:2019.

[0038] Furthermore, in the present invention, it is preferable to use first inorganic particles (P1) and second inorganic particles (P2) of different colors. In such cases, the second inorganic particles (P2) are prepared using one or more, preferably two or more, selected from the above-mentioned inorganic particles (P) so as to be the base color of the surface material. In the present invention, it is preferable that the second inorganic particles (P2) include transparent inorganic particles in addition to colored inorganic particles. Furthermore, the first inorganic particles (P1) can be of a different color from the second inorganic particles (P2) so as to act as an accent color that adds a pattern (design) to the surface material. The first inorganic particles (P1) are prepared using one or more, preferably two or more, selected from the inorganic particles (P) above. In the present invention, it is preferable that the first inorganic particles (P1) include colored inorganic particles.

[0039] In addition, "different colors" refers to any color tone that is visually distinguishable as a different color. For example, the color difference (△E) between the first inorganic particle (P1) and the second inorganic particle (P2) is preferably 0.5 or more (more preferably 0.5 to 25, and even more preferably 1 to 20). In such cases, a pattern (design) with excellent visibility can be created.

[0040] The above color difference (△E) is a value measured using a colorimeter, and each L * value, a * value, b * The value can be calculated 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 respectively the L * , a * , b * L *2 , a *2 , b *2 of the second inorganic particle (P1), respectively * , a * , b<00000​​​​​​​​​​​​​​​​​​​​​​​​The thickness of the patterned layer of the present invention is preferably 0.5 to 10 mm, more preferably 0.8 to 5 mm. Even with such a thin patterned layer, it is possible to express a pattern that is visually appealing and natural due to the above-mentioned effects such as vividness, contrast of gloss, etc.

[0043] The surface material of the present invention may have a reinforcing material in addition to the patterned layer. Such a reinforcing material can be provided inside and / or on the back surface of the patterned layer. Examples of reinforcing materials include woven fabric, nonwoven fabric, ceramic paper, synthetic paper, mesh, cloth, gypsum board, plywood, slate board, metal plate, etc. The reinforcing material may consist of two or more of the above materials. By using such a reinforcing material, the strength of the surface material can be increased.

[0044] (Embodiment 2) Embodiment 2 of the present invention of the facing material will be described below. Figure 4 shows an example of a front view of the facing material of the present invention. Figure 5 also shows an example of a schematic cross-sectional view (enlarged cross-sectional view) of sections A-A', B-B', and C-C' in Figure 4. The surface material of the present invention may have an uneven pattern on the surface of the patterned layer. Such uneven patterns are not particularly limited and can take various shapes, such as stone-like patterns, rock-like patterns, wood-grain patterns, joint patterns, tile-like patterns, brick-like patterns, geometric patterns, random patterns, etc. Among these, it is preferable to have recessed patterns in shapes such as burrow-like, insect-eaten, or bark-like patterns, as shown in Figure 4.

[0045] The surface material of Embodiment 2 of the present invention is characterized in that, when viewed from the front (when viewed from the front direction), the surface of the patterned layer has an exposed portion (X) [Figure 4:11] in which inorganic particles (P) are exposed and a covered portion (Y) [Figure 4:12] in which the inorganic particles (P) are covered with a resin component, and the patterned layer has a recessed pattern [Figure 4:16]. Furthermore, when viewed from a cross-sectional direction, the patterned layer consists of inorganic particles (P) fixed with a resin component, and its surface forms exposed portions (X) [Figure 5:11] where the inorganic particles (P) are exposed and covered portions (Y) [Figure 5:12] where the inorganic particles (P) are covered with the resin component, resulting in a discontinuous recessed pattern [Figure 5:16].

[0046] In this invention, as described above, by having exposed portions (X) on the surface of the patterned layer in which inorganic particles (P) are exposed, a natural-looking patterned layer can be obtained that takes advantage of the contrast in texture, clarity, and gloss derived from the inorganic particles (P). Furthermore, by having recessed patterns, a three-dimensional design such as a sense of depth can be added.

[0047] The patterned layer of Embodiment 2 is flat and has arbitrarily discontinuous recessed patterns. In Embodiment 2, the flat surface has recessed patterns and does not have raised patterns. In this embodiment 2, at least the boundary between the exposed portion (X) and the covered portion (Y) is flat and has a region [Figure 5: A-A'], and furthermore, recessed patterns are optionally formed on the exposed portion (X) and the covered portion (Y) [Figure 5: B-B', C-C']. In this invention, it is preferable that the bottom of the recessed pattern portion [Figure 5: 16] forms the covered portion (Y). This enhances the three-dimensional design, such as a sense of depth.

[0048] In this invention, even if the surface of the patterned layer is flat, by having exposed portions (X) on the surface of the patterned layer, a natural-looking patterned layer can be obtained that takes advantage of the contrast of texture, clarity, and gloss derived from inorganic particles (P). Furthermore, by having recessed patterns, in addition to the contrast of texture and gloss, a three-dimensional design such as a sense of depth can be added.

[0049] The exposed portion (X) can be arbitrarily formed on the surface of the patterned layer, and it is preferable to form a desired pattern (more preferably a discontinuous pattern). In such a case, the contrast between the texture and gloss of the exposed portion (X) and the covered portion (Y) further enhances the vividness of the exposed portion (X) and allows for the formation of an excellent pattern. Examples of patterns formed by the exposed portion (X) include island patterns, striped patterns, linear patterns, grid patterns, and spotted (dot-like) patterns. In the present invention, striped patterns and linear patterns as shown in Figure 4 are preferred. In such cases, the contrast between texture and gloss can create striped and linear patterns with excellent visual appeal.

[0050] In the patterned layer of the present invention, the particle size, hue, material, etc., of the first inorganic particles (P1) constituting the exposed portion (X) and the second inorganic particles (P2) constituting the covering portion (Y) can be appropriately set according to the desired design. These can be set in the same manner as in Embodiment 1 above.

[0051] The thickness of the pattern layer in the present invention is preferably 0.5 to 10 mm, more preferably 0.8 to 5 mm. Even with such a thin pattern layer, the above effects make it possible to express aesthetically pleasing and natural-looking patterns with a sense of three-dimensionality.

[0052] The surface material of the present invention may have a reinforcing material in addition to the pattern layer described above. Such a reinforcing material can be the same as that used in Embodiment 1 and can be laminated.

[0053] The surface material of the present invention may have a transparent layer on the surface of the patterned layer, as long as the effects of the present invention are not significantly hindered.

[0054] <Manufacturing method for facing materials> The method for manufacturing the surface material of the present invention will be described below. The method for manufacturing the surface material of the present invention is not particularly limited, and various methods can be employed. In the present invention, a method using a formwork is preferred. For example, (1) A step of scattering first inorganic particles (P1) on the inner surface of the formwork in a desired pattern, (2) A step of filling with a composition containing second inorganic particles (P2) and resin components (hereinafter also referred to as the "base composition") (3) A step of forming a pattern layer by integrating the first inorganic particles (P1) and the base composition, curing them, and then demolding them. It can be manufactured by a method that includes [a specific component]. In the surface material obtained by the above method, the first inorganic particles (P1) form exposed portions (X) on the surface of the pattern layer, and the base composition forms a covered portion (Y).

[0055] In step (1) above, a mold corresponding to the desired pattern layer can be used. When manufacturing using a mold, the inner surface of the mold becomes the surface of the material, so by adjusting the shape of the inner surface of the mold, the surface of the material (pattern layer) can be made flat or a desired uneven pattern can be applied to the surface of the material (pattern layer). The formwork is not particularly limited, but for example, formwork made of silicone resin, urethane resin, or formwork with release paper can be used.

[0056] In the present invention, it is preferable to use a mold having a durometer A hardness of 5 to 60 (more preferably 10 to 55). Furthermore, a mold made of silicone resin that satisfies the above durometer A hardness is preferable. In such a case, the first inorganic particles (P1) scattered in step (1) above can be stably placed on the inner surface of the mold. As a result, the first inorganic particles (P1) can be scattered in a desired pattern. Furthermore, in step (2) above, when filling with the base composition, it is possible to suppress the base composition from getting between the mold and the first inorganic particles (P1), so that the first inorganic particles (P1) can form exposed portions (X).

[0057] The durometer hardness is a value measured in accordance with JIS K7215. Here, in addition to durometer A hardness, there is also durometer D hardness. JIS K7215 explains that "when the value is 90 or higher on a type A durometer, it is desirable to use a type D durometer, and when the value is 20 or lower on a type D durometer, it is desirable to use a type A durometer." Therefore, in the present invention, a mold that can be measured with a "type A durometer" is preferred.

[0058] In step (1) above, when scattering the first inorganic particles (P1), it is preferable to scatter them in a desired pattern, such as stripes or spots. In the present invention, scattering them in stripes or lines is preferable. In this invention, by scattering the first inorganic particles (P1), the distribution of the first inorganic particles (P1) can be made to form areas of sparseness and density. This makes it possible to provide a natural contrast in shade and gloss. The means for scattering the first inorganic particles (P1) is not particularly limited and can be scattered using known scattering devices.

[0059] In step (1) above, the amount of the first inorganic particles (P1) to be scattered is preferably 5 to 200 g / m². 2 Comfortable 10-100g / m 2 In such cases, the above effects can be fully obtained, and the effects of the present invention can be further enhanced. Furthermore, after spraying the first inorganic particles (P1), a wetting agent such as water may be sprayed as needed.

[0060] In step (2) above, the solid content of the base composition at the time of filling is preferably 50 to 90% by mass, more preferably 55 to 80% by mass. The viscosity of the base composition (at 25°C) is preferably 2 to 35 Pa·s, more preferably 3 to 30 Pa·s. The viscosity of the base composition is measured using a BH-type viscometer at a rotation speed of 20 rpm, and the measurement temperature is 23°C. Furthermore, the filling amount of the base composition is preferably 1 to 10 kg / m². 2, more preferably 2-8 kg / m 2 In such cases, the effects of the present invention can be fully obtained. The above base composition can be filled at room temperature (15-30°C). Known equipment such as sprayers, rollers, trowels, brushes, reciprocators, and coaters can be used for filling.

[0061] In step (3) above, when the first inorganic particles (P1) and the base composition are integrated and cured, the curing temperature is preferably 30 to 80°C and the curing time is preferably 2 to 24 hours.

[0062] Furthermore, if reinforcing material is introduced to the surface material, for example, as in step (2) above, (2-1) A step of filling a composition (base composition) containing second inorganic particles (P2) and resin components, (2-2) A step of embedding / laminating a reinforcing material before the base composition above hardens, Methods including, and / or, After step (3) above, (4) A step of laminating a reinforcing material on the back surface of the patterned layer with an adhesive, It can be manufactured by a method that includes [a specific component].

[0063] Furthermore, if a transparent coating layer is to be provided within a range that does not significantly impair the effects of the present invention, a transparent coating layer can be provided after step (3) above, for example, by applying and drying the transparent coating material on the surface (preferably the entire surface) of the patterned layer after demolding. Also, if step (4) above is performed, the transparent coating material can be applied before or after step (4). The amount of transparent coating material to be applied is preferably 10 to 300 g / m². 2 , comfortably 20~200g / m 2 That is the case.

[0064] (Method of manufacturing the facing material of Embodiment 1) The facing material of Embodiment 1 described above is, for example, (1) A step of scattering first inorganic particles (P1) in a striped pattern on the inner surface of a silicone mold with a flat inner surface. (2) A step of filling with a composition (base composition) containing second inorganic particles (P2) and resin components, (3) A method of forming a pattern layer by integrating the first inorganic particles (P1) and the base composition, curing them, and then demolding them. It can be manufactured by [method]. In the surface material obtained by the above method, the surface of the pattern layer is flat, with the first inorganic particles (P1) forming exposed areas (X) and the base composition forming covered areas (Y).

[0065] In step (1) above, by scattering the first inorganic particles (P1), the distribution of the first inorganic particles (P1) can be made into a striped pattern with sparse and dense areas, thereby providing a natural pattern.

[0066] (Method for manufacturing the facing material of Embodiment 2) The facing material of the above-described embodiment 2 is, for example, (1) A step of scattering first inorganic particles (P1) in a striped pattern onto the inner surface of a silicone mold having protrusions (recesses in the surface material) corresponding to a desired pattern on the inner surface of the mold, (2) A step of filling with a composition (base composition) containing second inorganic particles (P2) and resin components, (3) A method of forming a pattern layer by integrating the first inorganic particles (P1) and the base composition, curing them, and then demolding them. It can be manufactured by [method]. The surface material obtained by the above method has a flat surface on the pattern layer, and the convex parts on the inner surface of the formwork are reversed to form a recessed pattern, with the first inorganic particles (P1) forming exposed parts (X) and the base composition forming covered parts (Y).

[0067] In step (1) above, by scattering the first inorganic particles (P1), the distribution of the first inorganic particles (P1) easily forms areas of sparseness and density, thereby creating a natural pattern. Furthermore, by scattering the first inorganic particles (P1) onto a mold having protrusions, the scattered first inorganic particles (P1) tend to concentrate and accumulate densely at the base of the protrusions. This makes it possible to form regions where the first inorganic particles (P1) are densely fixed. On the other hand, since the first inorganic particles (P1) are less likely to accumulate at the top of the protrusions (the bottom of the recesses in the surface material), the recesses (especially the bottom of the recesses) in the resulting surface material are more easily formed by the base composition. In particular, when the protrusions of the formwork have a sloping or rounded shape (for example, a mountain-like, parabolic, or curved shape), the first inorganic particles (P1) tend to be unevenly distributed at the base of the protrusions, while they do not tend to accumulate at the top of the protrusions. As a result, it is possible to fully express aesthetic qualities such as a three-dimensional effect due to the contrast between the exposed (X) and covered (Y) parts, and to create a natural-looking pattern.

[0068] The surface material of the present invention can be used as a material for decorating buildings, such as walls (exterior and interior), columns, etc. The dimensions of the facing material can be appropriately set within the range of, for example, length × width = 200 mm to 3000 mm × 200 mm to 3000 mm. The thickness of the facing material is preferably 0.5 to 10 mm, more preferably 0.8 to 5 mm. When fixing the facing material of the present invention to a wall or the like, for example, adhesive, adhesive tape, nails, screws, bolts, rails, etc., can be used. Examples of base materials that make up the walls of buildings include concrete, mortar, siding boards, extruded boards, gypsum boards, perlite boards, plywood, bricks, plastic sheets, metal sheets, glass, porcelain tiles, etc. These base materials may already have a coating (existing coating, primer coating, etc.) formed on their surface, or may have wallpaper attached to them. Furthermore, by providing flexibility to the facing material of the present invention, it can be easily fixed (installed) even if the base material is curved. [Examples]

[0069] Examples and comparative examples are shown below to further clarify the features of the present invention.

[0070] (Preparation of inorganic particles (P)) ·Inorganic particles (1) Inorganic particles (I) were prepared by mixing 90 parts by mass of colored inorganic particles [a mixture of white silica sand, beige silica sand, and brown silica sand (mass ratio) = 60:30:10, with a particle size range of 45-600 μm and a light transmittance of less than 1%] and 10 parts by mass of granular transparent inorganic particles [Kansui stone; particle size 106-600 mm, light transmittance 16%]. The particle size D80 of these inorganic particles (1) was 250-300 μm, and the content of particles with a particle size exceeding 300 μm was 20% by mass of the total amount of inorganic particles (1). The hue was beige (L * Value = 65.0, a * Value = 4.0, b * The value was 16.5. ·Inorganic particles (2) Inorganic particles (2) were prepared by mixing 90 parts by mass of colored inorganic particles [a mixture of black silica sand, gray silica sand, and beige silica sand (mass ratio) = 80:5:15, particle size range 45-600 μm, light transmittance less than 1%] with 10 parts by mass of granular transparent inorganic particles [Kansui stone; particle size range 106-600 mm, light transmittance 16%]. The particle size D80 of these inorganic particles (2) was 250-300 μm, and the content of particles with a particle size exceeding 300 μm was 19% by mass of the total amount of inorganic particles (2). The hue was black (L * Value = 35.0, a * Value = 1.0, b * The value was 1.5. ·Inorganic particles (3) Colored inorganic particles [a mixture of yellow silica sand, red silica sand, and white silica sand (mass ratio) = 75:15:10, particle size range 45-425 μm, light transmittance less than 1%] were defined as inorganic particles (3) at a rate of 100 parts by mass. The particle size D80 of these inorganic particles (3) was 150-212 μm, and the content of particles with a particle size exceeding 300 μm was 2.8% by mass of the total amount of inorganic particles (3). The hue was brownish (L * Value = 58.5, a* Value = 3.0, b * The value was 15.0. ·Inorganic particles (4) Colored inorganic particles [a mixture of yellow silica sand, red silica sand, and white silica sand (mass ratio) = 75:15:10, particle size range 45-425 μm, light transmittance less than 1%] were defined as inorganic particles (4). The particle size D80 of these inorganic particles (4) was 250-300 μm, and the content of particles with a particle size exceeding 300 μm was 20% by mass of the total amount of inorganic particles (4). The hue was brownish (L * Value = 58.5, a * Value = 3.0, b * The value was 15.0. ·Inorganic particles (5) 100 parts by mass of colored inorganic particles [black silica sand, particle size range 45-425 μm, light transmittance less than 1%] were defined as inorganic particles (5). The particle size D80 of these inorganic particles (5) was 150-212 μm, and the content of particles with a particle size exceeding 300 μm was 2.8% by mass of the total amount of inorganic particles (5). The hue was black (L * Value = 29.1, a * Value = 1.3, b * The value was 0.9.

[0071] (Manufacturing of base composition 1) Base composition 1 was prepared by uniformly mixing 100 parts by mass of inorganic particles (1), 30 parts by mass of resin components [acrylic resin emulsion, solid content 50% by weight, medium: water], and 25 parts by mass of additives [antifoaming agent, film-forming aid, water, etc.] by a conventional method. The viscosity of the prepared base composition 1 (at 25°C) was 12.0 Pa·s, and the solid content at the time of filling was 74% by mass.

[0072] (Manufacturing of base composition 2) Base composition 2 was prepared by uniformly mixing 100 parts by mass of inorganic particles (2), 35 parts by mass of resin components [carboxyl group-containing acrylic resin emulsion, solid content 50% by weight, medium: water], 0.3 parts by mass of crosslinking agent (epoxy group-containing crosslinking agent), and 25 parts by mass of additives [antifoaming agent, film-forming aid, water, etc.] by a conventional method. The viscosity of the prepared base composition 2 (at 25°C) was 11.0 Pa·s, and the solid content at the time of filling was 73% by mass.

[0073] (Manufacturing of base composition 3) Base composition 3 was prepared by uniformly mixing 100 parts by mass of inorganic particles (4), 35 parts by mass of resin components [carboxyl group-containing acrylic resin emulsion, solid content 50% by weight, medium: water], 0.3 parts by mass of crosslinking agent (epoxy group-containing crosslinking agent), and 25 parts by mass of additives [antifoaming agent, film-forming aid, water, etc.] by a conventional method. The viscosity (at 25°C) of the prepared base composition 3 was 11.0 Pa·s, and the solid content at the time of filling was 73% by mass.

[0074] (Example 1) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 40) with a flat inner surface was used as the formwork. Inorganic particles (3) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 After that, base composition 1 is applied (weight per unit area: 5.0 kg / m²). 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material was flat, and in a front view, the inorganic particles (3) formed striped exposed areas (X), while the inorganic particles (1) formed covered areas (Y), giving it a natural appearance. Furthermore, it had excellent texture and clarity, and overall, it had a matte finish (gloss level 2-3 at 60 degrees) with a natural gloss contrast near the striped areas of the inorganic particles (3).

[0075] (Example 2) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 40) with a flat inner surface was used as the formwork. Inorganic particles (4) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 After that, base composition 1 is applied (weight per unit area: 5.0 kg / m²). 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material was flat, and in a front view, the inorganic particles (3) formed striped exposed areas (X), while the inorganic particles (1) formed covered areas (Y), giving it a natural-looking design. Compared to Example 1, the vividness of the striped pattern was slightly lower, but overall it had excellent texture and vividness, and within the matte finish (glossiness 2-3 at 60 degrees), there was a natural gloss contrast near the striped areas of the inorganic particles (4).

[0076] (Example 3) As the formwork, a rectangular silicone resin formwork (300mm x 600mm, durometer A hardness 40) capable of forming a travertine pattern with flat areas and multiple protrusions (protrusion height 0.2-2mm, major axis of protrusion 0.2-10mm) on the inner surface of the formwork was used. Inorganic particles (3) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 After distributing it unevenly at the base of the protruding parts of the formwork, the base composition 1 is then applied (weight per unit area: 5.0 kg / m²). 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material had a flat surface with a recessed pattern. When viewed from the front, the inorganic particles (3) formed striped exposed areas (X), and the inorganic particles (1) formed covered areas (Y), resulting in a natural-looking design. It also had excellent texture and clarity, and overall, it had a matte finish (gloss level 2-3 at 60 degrees) with a natural gloss contrast near the striped areas of the inorganic particles (3). Furthermore, the recessed pattern emphasized depth, resulting in excellent three-dimensionality.

[0077] (Example 4) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 40) with a flat inner surface was used as the formwork. Inorganic particles (5) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 ) After that, base composition 2 is applied (weight per unit area 5.0 kg / m 2 After curing (at 65°C for 24 hours), the mold was removed to produce the patterned layer. The resulting surface material was flat, and in a front view, the inorganic particles (5) formed striped exposed areas (X), while the inorganic particles (2) formed covered areas (Y), giving it a natural appearance. Furthermore, it had excellent texture and clarity, and overall, it had a matte finish (gloss level 2-3 at 60 degrees) with a natural gloss contrast near the striped areas of the inorganic particles (5).

[0078] (Example 5) As the formwork, a rectangular silicone resin formwork (300mm x 600mm, durometer A hardness 40) capable of forming a travertine pattern with flat areas and multiple protrusions (protrusion height 0.2-2mm, major axis of protrusion 0.2-10mm) on the inner surface of the formwork was used. Inorganic particles (5) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 ) and distribute it unevenly at the base of the protruding parts of the formwork, and then apply base composition 2 (weight per unit area: 5.0 kg / m 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material had a flat surface with a recessed pattern. When viewed from the front, the inorganic particles (5) formed striped exposed areas (X), and the inorganic particles (2) formed covered areas (Y), resulting in a natural-looking design. It also had excellent texture and clarity, and overall, it had a matte finish (gloss level 2-3 at 60 degrees) with a natural gloss contrast near the striped areas of the inorganic particles (5). Furthermore, the recessed pattern emphasized depth, resulting in excellent three-dimensionality.

[0079] (Comparative Example 1) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 40) with a flat inner surface was used as the formwork. Apply base composition 1 to the above formwork (weight per unit area: 5.0 kg / m²) 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material was flat and, in a front view, consisted only of a coating (Y) of inorganic particles (1). The resulting surface material was inferior to the example in terms of texture, clarity, and gloss contrast.

[0080] (Comparative Example 2) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 40) with a flat inner surface was used as the formwork. Apply the base composition 3 in a striped pattern to the above mold (mass per unit area: 100 g / m²). 2 After that, apply base composition 1 (weight per unit area: 5.0 kg / m²). 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material was flat and, when viewed from the front, formed a striped pattern, but this was formed only in the covered portion (Y). The resulting surface material was inferior to the example in terms of texture, clarity, and gloss contrast.

[0081] (Comparative Example 3) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 40) with a flat inner surface was used as the formwork. Apply base composition 2 to the above formwork (weight per unit area: 5.0 kg / m²) 2 After curing (at 65°C for 24 hours), the mold was removed and the patterned layer (surface material) was manufactured. The resulting surface material was flat and, in a front view, consisted only of a coating portion (Y) of inorganic particles (2). The resulting surface material was inferior to the example in terms of texture, clarity, and gloss contrast. Furthermore, compared to Examples 4 and 5, the clarity of the black color was inferior.

Claims

1. A surface material having a patterned layer, The above patterned layer is formed by immobilizing inorganic particles (P) with a resin component. The surface of the patterned layer is characterized by having an exposed portion (X) where the inorganic particles (P) are exposed and a covered portion (Y) where the inorganic particles (P) are covered with a resin component.

2. The surface of the patterned layer has an exposed portion (X) where the first inorganic particles (P1) are exposed and a covered portion (Y) where the second inorganic particles (P2) are covered with a resin component. The surface material according to claim 1, characterized in that the particle diameter D80 of the first inorganic particle (P1) is smaller than the particle diameter D80 of the second inorganic particle (P2).

3. The surface material according to claim 1, characterized in that the exposed portion (X) has a pattern.

4. The surface material according to claim 1, characterized in that the surface of the patterned layer is flat.

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