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 and a transparent layer on the surface side of the 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 stone, 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, by applying a plurality of compositions having different color tones in a strip or streak shape on a base sheet, a pattern imitating sedimentary rock or marble is formed, and in order to impart properties such as weather resistance and maintain the design property over a long period, a decorative material provided with a top coat layer on the entire surface side is disclosed.

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 the above Patent Document 1 may easily become monotonous in terms of pattern, texture, and glossiness, and may lack the 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, can express a natural design, and can maintain the design property over a long period. [Means for solving the problem]

[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 and a transparent layer on the surface side of the 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 can express a natural-looking design with excellent texture and vividness, and gloss contrast, and that can maintain its design characteristics over a long period of time. [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(a) is an example of an enlarged schematic cross-section of the pattern layer A-A' in Figure 1. Figure 3(b) is an example of an enlarged schematic cross-section of the area near section Z in (a). [Figure 4] Figure 4 is an example of an enlarged schematic diagram of the area around section Z in Figure 2. [Figure 5] Figure 5 is an example of a front view of the surface material of the present invention. [Figure 6] Figure 6 is an example of a schematic diagram of an enlarged section of A-A', B-B', and C-C' in Figure 5. [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 20: Transparent layer [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 and a transparent layer on the surface side of the 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 patterned layer of the present invention is formed by immobilizing inorganic particles (P) with a resin component. 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] Next, we will explain the components that make up the transparent layer. The transparent layer of the present invention is laminated on the surface side of the patterned layer (preferably covering the entire surface of the patterned layer). The surface side of the patterned layer is the surface 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.

[0027] The transparent layer of the present invention can be formed by a transparent coating material containing at least a resin component. The above resin component includes at least a synthetic resin, and the synthetic resin is preferably one whose coating 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, acrylic silicone resins, fluororesins, silicon resins, 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.

[0028] In the transparent 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, making it possible to improve physical properties such as weather resistance, durability, and stain resistance. 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.

[0029] 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.

[0030] In particular, the transparent 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.

[0031] Examples of crosslinking agents having carbodiimide groups 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.

[0032] Furthermore, the crosslinking agent for the transparent layer of the present invention preferably includes a crosslinking agent that can also react with the synthetic resin having reactive functional groups in the patterned layer. This forms a film with a three-dimensional crosslinked structure between the patterned layer and the transparent layer, further enhancing physical properties such as weather resistance, durability, and stain resistance.

[0033] The transparent coating material that forms the transparent layer may include, in addition to the resin components mentioned above, extender pigments, coloring pigments, water repellents, stain-resistant agents, and the like.

[0034] In this invention, it is preferable that the transparent coating material contains an extender pigment. This makes it possible to form a matte transparent layer. Examples of extender pigments include heavy calcium carbonate, granite, light calcium carbonate, white carbon, talc, kaolin, clay, pottery clay, china clay, diatomaceous earth, barite powder, barium sulfate, precipitated barium sulfate, silica sand, silica powder, quartz powder, resin beads, glass beads, and hollow balloons. These can be used individually or in combination of two or more. Among these, resin beads are preferred. Examples of resin beads include urethane beads, acrylic beads, polyethylene beads, polypropylene beads, polymethyl methacrylate beads, polystyrene beads, nylon beads, styrene-acrylic beads, silicone beads, fluorine beads, cellulose beads, vinyl chloride beads, and EVA beads. These can be used individually or in combination of two or more types. In this invention, urethane beads, acrylic beads, polyethylene beads, polypropylene beads, polymethyl methacrylate beads, and the like are particularly preferred.

[0035] The refractive index of the extender pigment is preferably 1.4 to 1.7. By using such an extender pigment, a transparent layer can be formed that further enhances the texture and clarity of the patterned layer. The mechanism of action is not limited to this, but when the transparent layer contains a resin component and an extender pigment that satisfies the above refractive index, the difference between the refractive index of the film formed by the resin component (for example, about 1 to 2) and the refractive index of the extender pigment is small, so a film with transparency can be formed while suppressing gloss. As a result, it is considered that the texture and clarity of the patterned layer are less likely to be impaired, and a finish that further enhances the design of the patterned layer can be obtained. The refractive index in this invention can be measured using an Abbe refractometer.

[0036] The average particle size of the extender pigment is preferably 20 μm or less, more preferably 0.1 to 15 μm. By using an extender pigment with such an average particle size, the above effects can be further enhanced. The average particle size referred to here means the 50% cumulative particle size D50 measured by a centrifugal sedimentation particle size distribution analyzer.

[0037] The ratio of the extender pigment in the transparent coating material is preferably 5 to 100 parts by mass, more preferably 10 to 50 parts by mass, per 100 parts by mass of the solid content of the resin component. With such a ratio, a transparent layer can be formed that maintains the vividness of the pattern layer.

[0038] <Surface material> The surface material of the present invention has a patterned layer and a transparent 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.

[0039] (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 surface 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(a) shows a schematic cross-sectional view (enlarged cross-section) of only the patterned layer in section A-A' of Figure 1, and Figure 3(b) shows an example of an enlarged schematic view of the area near section Z in (a). This is shown. Furthermore, Figure 4 shows an example of an enlarged schematic diagram of the area around section Z in Figure 2.

[0040] 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 surface material has exposed portions (X) [Figure 1:11] where inorganic particles (P) on the surface of the pattern layer are exposed and covered portions (Y) [Figure 1:12] where the inorganic particles (P) are covered with a resin component, both of which are visible through the transparent layer, and when viewed from the cross-sectional direction, the transparent layer [Figure 2:20] is laminated on the surface of the pattern layer [Figure 2:10].

[0041] As shown in Figure 3(a), the patterned layer has inorganic particles (P) fixed with a resin component, and its surface forms an exposed portion (X) [Figure 3(a):11] where the inorganic particles (P) are exposed and a covered portion (Y) [Figure 3(a):12] where the inorganic particles (P) are covered with the resin component. In this invention, as shown in Figure 3(b), in the patterned layer, the portion where at least a part of the surface of the inorganic particles (P) [Figure 3(b):13] is exposed without being covered with the resin component is called the exposed portion (X), and the portion where the surface of the inorganic particles (P) [Figure 3(b):14] is covered with the resin component [Figure 3(b):15] is called the covered portion (Y). Furthermore, the inorganic particles (P) [Figure 3(b):13] constituting the exposed portion (X) are also referred to as the first inorganic particles (P1), and the inorganic particles (P) [Figure 3(b):14] constituting the covered portion (Y) are also referred to as the second inorganic particles (P2).

[0042] 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). In this invention, by laminating a transparent layer on the surface side of such a patterned layer, as shown in Figure 4, the surface of the first inorganic particle (P1) [Figure 4:13] is covered only by the transparent layer [Figure 4:20], while the surface of the second inorganic particle (P2) [Figure 4:14] is covered by the resin component of the patterned layer [Figure 4:15] and the transparent layer [Figure 4:20]. In this case, the first inorganic particle (P1) and the second inorganic particle (P2) have different surface coating characteristics, resulting in a contrast in texture and gloss. This contrast in texture and gloss allows for the expression of a design with excellent clarity and natural feel, and a surface material can be obtained that maintains its design characteristics over a long period of time.

[0043] In Embodiment 1, the surface material is preferably flat. "Flat" means that it is substantially flat (the surface of the surface material is substantially on the same plane). Furthermore, in Embodiment 1, the boundary between the exposed portion (X) and the covered portion (Y) of the patterned layer is also flat.

[0044] In this invention, even if the surface of the surface material is flat, by having exposed portions (X) on the surface of the pattern layer, it is possible to obtain a surface material that has a natural feel by taking advantage of the contrast of texture, clarity, and gloss derived from inorganic particles (P).

[0045] 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 patterns and linear patterns with excellent visual appeal.

[0046] 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.

[0047] 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 in texture and gloss between 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.

[0048] 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 in the pattern layer increases, so the color tone of the first inorganic particles (P1) can be strongly visualized, and excellent vividness can be obtained. 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, an even more excellent pattern can be exhibited due to the vividness. 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.

[0049] 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.

[0050] 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.

[0051] Note that the different colors only need to be colors that can be visually recognized as different colors. For example, the color difference (ΔE) between the first inorganic particles (P1) and the second inorganic particles (P2) is preferably 0.5 or more (more preferably 0.5 to 25, still more preferably 1 to 20).) In such a case, a pattern (design) with excellent visibility can be imparted.

[0052] The above color difference (ΔE) is a value measured using a color difference meter for colors, and can be calculated by the following formula from the respective L * value, a * value, b * value. <Formula> ΔE = { (L *1 - L *2 ) 2 + (a *1 - a *2 ) 2 + (b *1 - b *2 ) 2 0]} 0.5 In the formula, L *1 , a *1 , b *1 are the L * , a * , b * of the first inorganic particles (P1) respectively, and L *2 , a *2 , b *2 are the L * , a * , b * Note that the L * , a * , b * of the above inorganic particles are the L * value, a * value, b * value (average value of three randomly selected points) of the film when a composition in which 36 parts by mass of an acrylic resin emulsion (solid content 50% by mass) is mixed with 100 parts by mass of inorganic particles is applied so as to have a dry film thickness of 2 mm and dried for 48 hours under standard conditions (temperature 25 °C, relative humidity 50%. The same applies hereinafter). can be calculated from

[0053] The hues of the first inorganic particles (P1) and the second inorganic particles (P2) are not particularly limited and can be set to any desired hue. However, in this invention, the L of the first inorganic particles (P1) and / or the second inorganic particles (P2) * Even when setting a dark hue with a value of 60 or less, by having an exposed area (X), it is possible to provide a surface material with a natural-looking pattern layer that utilizes the color tone derived from inorganic particles (P). * The value (brightness) represents the color; a higher value indicates a brighter color, while a lower value indicates a darker (more intense) color.

[0054] 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.

[0055] The thickness of the transparent layer of the present invention is preferably 5 to 300 μm, more preferably 10 to 100 μm. In this case, the design qualities such as the texture, clarity, and gloss contrast of the patterned layer can be further enhanced, and the design quality can be maintained over a long period of time without impairing the natural appearance of the design.

[0056] The surface material of the present invention allows for adjustment to desired gloss levels, etc., while preserving the contrast between the texture, clarity, and gloss of the patterned layer through the use of a transparent layer. For example, to give a calm and elegant aesthetic, the gloss at 60 degrees is preferably 8 or less, more preferably 1 to 7, and even more preferably 1.5 to 6. Similarly, 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 between 60 degrees and 85 degrees is preferably 2 or less, more preferably 1.5 or less, and even more preferably 1 or less. By satisfying the above ranges for gloss at 60 degrees and 85 degrees, unevenness in gloss depending on the viewing angle (direction) is suppressed, further enhancing the sense of calmness and aesthetic appeal. On the other hand, by setting the gloss level 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, high gloss finish, or mirror finish. In this invention, the gloss level is a value measured in accordance with JIS K5600-4-7 "Specular Gloss." Specifically, it is the 60-degree or 85-degree specular gloss level measured by a gloss meter, and is the average value obtained by measuring at 10 arbitrary locations on the surface of the material.

[0057] The surface material of the present invention may have a reinforcing material in addition to the pattern layer and the transparent layer described above. Such a reinforcing material can be provided inside and / or on the back surface of the pattern 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.

[0058] 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.

[0059] (Embodiment 2) Embodiment 2 of the present invention of the facing material will be described below. Figure 5 shows an example of a front view of the facing material of the present invention. Figure 6 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 5. The surface material of the present invention may have an uneven pattern on its surface. 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 5.

[0060] In Embodiment 2 of the present invention, when viewed from the front, the surface of the surface material has an exposed portion (X) [Figure 5:11] where inorganic particles (P) on the surface of the pattern layer are exposed, and a covered portion (Y) [Figure 5:12] where the inorganic particles (P) are covered with a resin component, both of which are visible through the transparent layer, and the surface of the surface material has a recessed pattern [Figure 5:16]. Furthermore, when viewed from the cross-sectional direction, a transparent layer [Figure 6:20] is laminated on the surface of the patterned layer [Figure 6:10]. In addition, the patterned layer has inorganic particles (P) fixed with a resin component, and its surface forms exposed portions (X) [Figure 6:11] where the inorganic particles (P) are exposed and covered portions (Y) [Figure 6:12] where the inorganic particles (P) are covered with the resin component, resulting in a discontinuous recessed pattern [Figure 6:16].

[0061] 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. In this invention, by laminating a transparent layer on the surface side of such a patterned layer, as shown in Figure 4, the surface of the first inorganic particle (P1) [Figure 4:13] is covered only by the transparent layer [Figure 4:20], while the surface of the second inorganic particle (P2) [Figure 4:14] is covered by the resin component of the patterned layer [Figure 4:15] and the transparent layer [Figure 4:20]. This makes it possible to obtain a surface material that has excellent contrast in texture, clarity, and gloss, can express a natural-looking design, and can maintain its design characteristics over a long period of time.

[0062] The surface material 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, the surface of the pattern layer has a flat region [Figure 6: A-A'] at least at the boundary between the exposed portion (X) and the covered portion (Y), and optionally recessed patterns are formed in the exposed portion (X) and the covered portion (Y) [Figure 6: B-B', C-C']. In this invention, it is preferable that the bottom portion of the recessed pattern [Figure 6: 16] forms the covered portion (Y). This enhances the three-dimensional design, such as a sense of depth.

[0063] In this invention, even when the surface of the surface material is flat, by having exposed portions (X) on the surface of the pattern layer, a natural-looking pattern 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.

[0064] 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 5 are preferred. In such cases, the contrast between texture and gloss can create striped and linear patterns with excellent visual appeal.

[0065] 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.

[0066] 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.

[0067] The thickness of the transparent layer of the present invention is preferably 5 to 300 μm, more preferably 10 to 100 μm. In this case, the design qualities such as the texture, clarity, and gloss contrast of the patterned layer can be further enhanced, and the design quality can be maintained over a long period of time without impairing the natural appearance of the design.

[0068] The surface material of the present invention allows for adjustment to desired gloss levels, etc., while preserving the contrast between the texture, clarity, and gloss of the patterned layer through the use of a transparent layer. For example, to give a calm and elegant aesthetic, the gloss at 60 degrees is preferably 8 or less, more preferably 1 to 7, and even more preferably 1.5 to 6. Similarly, 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 between 60 degrees and 85 degrees is preferably 2 or less, more preferably 1.5 or less, and even more preferably 1 or less. By satisfying the above ranges for gloss at 60 degrees and 85 degrees, unevenness in gloss depending on the viewing angle (direction) is suppressed, further enhancing the sense of calmness and aesthetic appeal. On the other hand, by setting the gloss level 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, high gloss finish, or mirror finish. In this invention, the gloss level is a value measured in accordance with JIS K5600-4-7 "Specular Gloss." Specifically, it is the 60-degree or 85-degree specular gloss level measured by a gloss meter, and is the average value obtained by measuring at 10 arbitrary locations on the surface of the material.

[0069] The surface material of the present invention may have a reinforcing material in addition to the pattern layer and the transparent layer described above. Such a reinforcing material can be the same as that used in Embodiment 1 and laminated.

[0070] <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. (4) A step of applying and drying a transparent coating material to the surface (preferably the entire surface) of the patterned layer after demolding to form a transparent layer. It can be manufactured by a method that includes [a specific component]. In the surface material obtained by the above method, first inorganic particles (P1) form exposed portions (X) on the surface of the patterned layer, a covering portion (Y) is formed by the base composition, and a transparent layer is laminated on the surface side of the patterned layer.

[0071] 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.

[0072] 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).

[0073] 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.

[0074] 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.

[0075] 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 2In 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.

[0076] 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.

[0077] 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.

[0078] 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].

[0079] In step (4) above, the amount of transparent coating material applied is preferably 10 to 300 g / m². 2 , comfortably 20~200g / m 2 The amount of transparent coating material applied, calculated based on its solid content, is preferably 2.5 to 75.0 g / m². 2 , more preferably 5.0~50.0 g / m² 2 Furthermore, the drying and curing temperature is preferably 30 to 150°C, and the curing time is preferably 1 minute to 24 hours.

[0080] (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. (4) A step of applying and drying a transparent coating material to the surface (preferably the entire surface) of the patterned layer after demolding to form a transparent layer. It can be manufactured by [method]. In the surface material obtained by the above method, the surface of the patterned layer is flat, the first inorganic particles (P1) form an exposed portion (X), a base composition forms a covered portion (Y), and a transparent layer is laminated on the surface side of the patterned layer.

[0081] 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.

[0082] (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. (4) A step of applying and drying a transparent coating material to the surface (preferably the entire surface) of the patterned layer after demolding to form a transparent layer. 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), the base composition forming covered parts (Y), and a transparent layer being laminated on the surface side of the pattern layer.

[0083] 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.

[0084] The surface material of the present invention can be used as a material for decorating buildings, such as walls (exterior and interior), columns, etc. 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]

[0085] Examples and comparative examples are shown below to further clarify the features of the present invention.

[0086] (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 (III) 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.

[0087] (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.

[0088] (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.

[0089] (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.

[0090] (Manufacturing of transparent coating materials) A transparent coating material was produced by uniformly mixing 44 parts by mass of resin components [carboxyl group acrylic silicone resin emulsion, solids content 45% by mass, medium: water], 1 part by mass of crosslinking agent [carbodiimide group-containing crosslinking agent, solids content 40% by mass], 5 parts by mass of extender pigment [acrylic resin beads, particle size D50 is 10 μm], and 50 parts by mass of additives [antifoaming agent, film-forming aid, ultraviolet absorber, water, etc.] by a conventional method.

[0091] (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 to produce the patterned layer. The resulting patterned layer 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), resulting in a natural-looking design. Furthermore, it exhibited excellent texture and clarity, and overall, it had a matte finish (glossiness 2-3 at 60 degrees) with a natural gloss contrast near the striped pattern areas of the inorganic particles (3). Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material utilized the contrast between the texture, clarity, and gloss of the patterned layer, resulting in a design with a natural feel. Furthermore, the obtained surface materials were exposed to the outdoors for six months, and changes in the appearance of the surface materials were observed. As a result, the degree of deterioration and soiling was minor, and the aesthetic appearance was maintained.

[0092] (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). Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material utilized the contrast between the texture, clarity, and gloss of the patterned layer, resulting in a design with a natural feel. Furthermore, the obtained surface materials were exposed to the outdoors for six months, and changes in the appearance of the surface materials were observed. As a result, the degree of deterioration and soiling was minor, and the aesthetic appearance was maintained.

[0093] (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). 2After 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. Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material utilized the contrast between the texture, clarity, and gloss of the patterned layer, resulting in a design with a natural feel. Furthermore, the obtained surface materials were exposed to the outdoors for six months, and changes in the appearance of the surface materials were observed. As a result, the degree of deterioration and soiling was minor, and the aesthetic appearance was maintained.

[0094] (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). Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material utilized the contrast between the texture, clarity, and gloss of the patterned layer, resulting in a design with a natural feel. Furthermore, the obtained surface materials were exposed to the outdoors for six months, and changes in the appearance of the surface materials were observed. As a result, the degree of deterioration and soiling was minor, and the aesthetic appearance was maintained.

[0095] (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. Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material utilized the contrast between the texture, clarity, and gloss of the patterned layer, resulting in a design with a natural feel. Furthermore, the obtained surface materials were exposed to the outdoors for six months, and changes in the appearance of the surface materials were observed. As a result, the degree of deterioration and soiling was minor, and the aesthetic appearance was maintained.

[0096] (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 solely of a coating (Y) of inorganic particles (1). Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material was inferior to the example in terms of texture, clarity, and gloss contrast of the patterned layer.

[0097] (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, in a front view, formed a striped pattern, but a covering portion (Y) was also formed. Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material was inferior to the example in terms of texture, clarity, and gloss contrast of the patterned layer. Furthermore, the obtained surface material was exposed to the outdoors for six months, and changes in the appearance of the surface material were observed. As a result, the degree of deterioration and soiling was minor.

[0098] (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 solely of a coating (Y) of inorganic particles (2). Furthermore, compared to Examples 4 and 5, it exhibited inferior black color clarity. Furthermore, a transparent coating material is applied to the entire surface of the patterned layer (mass per unit area: 120 g / m²). 2 , based on solid content mass of 30.2 g / m³ 2 The material was then dried and cured (at 80°C for 30 minutes) to produce a surface material (dimensions: 300mm x 600mm, thickness: 3mm). The resulting surface material was inferior to the example in terms of texture, clarity, and gloss contrast of the patterned layer.

Claims

1. A surface material having a patterned layer and a transparent layer on the surface side of the 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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