Manufacturing method of facing material

Abstract

The present invention provides a method for manufacturing a surface material that offers excellent texture and clarity, and can express a natural-looking design. [Solution] The present invention relates to a method for manufacturing a surface material, wherein the surface material has a patterned layer in which inorganic particles (P) are fixed with a resin component, and the patterned layer is (1) A step of scattering first inorganic particles (P1) onto the formwork, (2) A step of applying a base composition containing a resin component and a second inorganic particle (P2) to a mold on which the first inorganic particles (P1) have been scattered. (3) A step of integrating the first inorganic particles (P1) and the base composition and curing them together. (4) The process of demolding, Obtained by, The above formwork is characterized by having a durometer A hardness of 60 or less.

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 the above Patent Document 1 tends to have a monotonous pattern and texture 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 texture and vividness and can express a natural design.

Means for Solving the Problems

[0006] As a result of diligent research, the inventors conceived a method for manufacturing a surface material using a specific formwork, and thus completed the present invention.

[0007] In other words, the method for manufacturing the surface material of the present invention has the following characteristics. 1. A method for manufacturing a surface material, The above surface material has a patterned layer in which inorganic particles (P) are fixed with a resin component. The above pattern layer is (1) A step of scattering first inorganic particles (P1) onto the formwork, (2) A step of applying a base composition containing a resin component and a second inorganic particle (P2) to a mold on which the first inorganic particles (P1) have been scattered. (3) A step of integrating the first inorganic particles (P1) and the base composition and curing them together. (4) The process of demolding, Obtained by, A method for manufacturing a surface material, characterized in that the durometer A hardness of the above-mentioned formwork is 60 or less. 2. The method for manufacturing a surface material according to 1, characterized in that, in step (1) above, first inorganic particles (P1) are scattered in a desired pattern. [Effects of the Invention]

[0008] According to the manufacturing method of the present invention, a surface material can be manufactured that has excellent texture and clarity, and has a pattern layer that gives a natural appearance. [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 is a method for manufacturing a surface material, The above-mentioned surface material has a patterned layer in which inorganic particles (P) are fixed with a resin component. The above pattern layer is (1) A step of scattering first inorganic particles (P1) onto the formwork, (2) A step of applying a base composition containing a resin component and a second inorganic particle (P2) to a mold on which the first inorganic particles (P1) have been scattered. (3) A step of integrating the first inorganic particles (P1) and the base composition and curing them together. (4) The process of demolding, It is characterized by being obtained by the following method. In the manufacturing method of the present invention, in steps (1) and (2) above, the mold may be in a stationary state or in a state that has been transported by a transport means such as a manufacturing line. Furthermore, step (3) above can also be performed while the product is stationary or while it is being transported by a transfer means such as a manufacturing line.

[0013] The surface of the patterned layer obtained by the above manufacturing method can form 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.

[0014] In the present invention, as described above, by having exposed portions (X) on the surface of a patterned layer in which inorganic particles (P) are immobilized with a resin component, it is possible to manufacture a surface material having a natural-looking patterned layer that takes advantage of the texture and vividness derived from the inorganic particles (P).

[0015] The formwork used in step (1) above is characterized by having a durometer A hardness of 60 or less (more preferably 5 to 60, even more preferably 10 to 55, and particularly preferably 15 to 50). In such a case, when the first inorganic particles (P1) scattered in step (1) above fall onto the formwork, they diffuse appropriately, forming sparse and dense areas, and can then be stably placed on the inner surface of the formwork. As a result, the first inorganic particles (P1) can be scattered to form a desired pattern (a pattern with natural gradations of light and dark). Furthermore, in step (1) and / or step (2) above, even when the mold is being transported by a transport means such as a manufacturing line, the scattered first inorganic particles (P1) can be stably placed on the mold without being significantly disturbed by vibrations caused by transport, so that 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).

[0016] 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.

[0017] The material of the formwork is not particularly limited as long as it satisfies the above requirements, but for example, formwork made of silicone resin, urethane resin, etc., can be used. In the present invention, a formwork made of silicone resin that satisfies the above-mentioned durometer A hardness is preferred.

[0018] Furthermore, 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).

[0019] In step (1) above, when scattering the first inorganic particles (P1), it is preferable to scatter the first inorganic particles (P1) in a desired pattern (to create a desired pattern). The desired pattern is not particularly limited, but examples include island patterns, striped patterns, linear patterns, grid patterns, spotted (dot) patterns, and various motif patterns. In the present invention, scattering in striped or linear patterns is preferable.

[0020] 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 areas of density. This makes it possible to impart a natural gradation pattern. The means for scattering the first inorganic particles (P1) is not particularly limited and can be scattered using known scattering devices.

[0021] In step (1) above, the scattering of the first inorganic particles (P1) can be carried out by any means as long as it can be scattered in a desired pattern. For example, this can be done by letting the first inorganic particles (P1) supplied from a hopper or the like flow down, or by spraying them. Furthermore, it is preferable to scatter the first inorganic particles (P1) from above the formwork, preferably from a height of 10 to 1000 mm, more preferably 15 to 800 mm, and even more preferably 20 to 500 mm.

[0022] 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.

[0023] In step (2) above, the solid content of the base composition when applied (filled) 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 application 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 applied at room temperature (preferably 15-30°C). Known tools such as sprayers, rollers, trowels, brushes, reciprocators, and coaters can be used for application.

[0024] 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. Furthermore, step (4) above may be performed as appropriate after step (3).

[0025] The thickness of the patterned layer obtained by the above steps (1) to (4) is preferably 0.5 to 10 mm, more preferably 0.8 to 5 mm. Even with such a thin patterned layer, the above effects make it possible to express aesthetically pleasing and natural-looking patterns with a sense of three-dimensionality.

[0026] Furthermore, the surface material of the present invention may be provided with reinforcing materials inside and / or on the back surface of the pattern layer, if necessary. When introducing reinforcing materials to the surface material, for example, as in step (2) above, (2-1) A step of applying a base composition containing a resin component and a second inorganic particle (P2) to a mold on which the first inorganic particle (P1) has been scattered. (2-2) A step of embedding / laminating a reinforcing material before the base composition above hardens, Methods including, and / or, After step (4) above, (5) 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].

[0027] Furthermore, a transparent coating layer can be provided on the surface of the patterned layer, to the extent that the effects of the present invention are not significantly hindered. When providing a transparent coating layer, after step (4) above, for example, the transparent coating material can be applied and dried on the surface (preferably the entire surface) of the patterned layer after demolding to provide the transparent coating layer. Also, when performing step (5) above, the transparent coating material can be applied before or after step (5). The amount of transparent coating material applied is preferably 10 to 300 g / m². 2 , comfortably 20~200g / m 2 That is the case.

[0028] <Components of the facing material> In the method for manufacturing the facing material of the present invention, preferred components of the facing material will be described. • Pattern layer The inorganic particles (P) constituting the pattern layer are inorganic particles (preferably granular particles) made from 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.

[0029] 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.

[0030] 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".

[0031] 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 excellent aesthetic appeal can be formed.

[0032] 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.

[0033] 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.

[0034] 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, 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 alcohols, cellulose derivatives, or composites thereof. These can be used individually or in combination of two or more.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] • Reinforcement Examples of reinforcing materials include woven fabrics, non-woven fabrics, ceramic paper, synthetic paper, mesh, cloth, gypsum board, plywood, slate boards, and metal plates. The reinforcing material may consist of two or more of the above materials. By using such reinforcing materials, the strength of the surface material can be increased.

[0042] 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.

[0043] <Embodiment> The present invention will describe specific embodiments of the manufacturing method for the surface material and the resulting surface material. The present invention is not limited to these embodiments.

[0044] (Method of manufacturing the facing material of Embodiment 1) (1) A step of scattering first inorganic particles (P1) in a striped pattern on the inner surface of a silicone mold (durometer A hardness 60 or less) with a flat inner surface. (2) A step of applying a base composition containing second inorganic particles (P2) and resin components. (3) A step of integrating the first inorganic particles (P1) and the base composition and curing them together. (4) The process of demolding, This allows for the formation of a patterned layer and the manufacture of a surface material.

[0045] Figure 1 shows an example of a front view of a surface material obtained by the above manufacturing method. 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.

[0046] In Embodiment 1 of the present invention, the surface of the patterned layer, when viewed from the front, has an exposed portion (X) [Figure 1:11] where first inorganic particles (P1) are exposed, and a covered portion (Y) [Figure 1:12] where second inorganic particles (P2) are covered with a resin component. Furthermore, when viewed from a cross-sectional direction, the patterned layer [Figure 2:10] has second inorganic particles (P2) fixed with a resin component, and its surface forms an exposed portion (X) [Figure 2:11] where the first inorganic particles (P1) are exposed, and a covered portion (Y) [Figure 2:12] where the inorganic particles (P) are covered with a resin component.

[0047] In this invention, as shown in Figure 3, the portion of the surface of the first inorganic particle (P1) [Figure 3:13] that is exposed without being covered with the resin component is called the exposed portion (X), and the portion of the surface of the second inorganic particle (P2) [Figure 3:14] that is covered with the resin component [Figure 3:15] is called the covered portion (Y). As described above, the surface material obtained by the manufacturing method of the present invention has exposed portions (X) on the surface of the patterned layer in which inorganic particles (P) are exposed, thereby making it possible to obtain a patterned layer with a natural feel that takes advantage of the texture and vividness derived from the inorganic particles (P).

[0048] The patterned layer of Embodiment 1 is flat on its surface, and is also flat at the boundary between the exposed portion (X) and the covered portion (Y). "Flat" means that it is substantially flat (the surface of the patterned layer is substantially on the same plane).

[0049] 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 texture and vividness derived from inorganic particles (P).

[0050] 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 of the exposed portion (X) and the covered portion (Y) further enhances the clarity of the exposed portion (X) and allows for the formation of an excellent pattern. In Embodiment 1, a striped pattern as shown in Figure 1 is formed, and a striped pattern with excellent vividness can be formed due to the contrast created by the texture.

[0051] 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.

[0052] 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 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.

[0053] 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, so the color tone of the first inorganic particles (P1) can be strongly visualized, and excellent clarity can be obtained. As a result, in addition to contrast due to texture, 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.

[0054] 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 the present invention, the particle sizes of the first inorganic particles (P1) and the second inorganic particles (P2) can be adjusted, for example, using a metal mesh sieve defined in JIS Z8801-1:2019.

[0055] Furthermore, in the present invention, it is preferable to use the first inorganic particles (P1) and the second inorganic particles (P2) with different colors. In such a case, the second inorganic particles (P2) are prepared using one or more, preferably two or more, selected from the inorganic particles (P) so as to be the base color of the facing material. In the present invention, as the second inorganic particles (P2), it is preferable to include a form containing transparent inorganic particles in addition to colored inorganic particles. Also, the first inorganic particles (P1) can be those with a different color from the second inorganic particles (P2) so as to be an accent color for imparting a pattern (design) to the facing material. The first inorganic particles (P1) are prepared using one or more, preferably two or more, selected from the inorganic particles (P). In the present invention, it is preferable to include a form containing colored inorganic particles as the first inorganic particles (P1).

[0056] Note that different colors may be any color tones 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.

[0057] 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}0.5 In the formula, L *1 a *1 , b *1 These are the L values ​​of the first inorganic particle (P1), respectively. * a * , b * L *2 a *2 , b *2 These are the L values ​​of the second inorganic particle (P1), respectively. * a * , b * The L*, a*, and b* values ​​of the inorganic particles can be calculated from the L*, a*, and b* values ​​(average values ​​of three randomly selected points) of the film after applying a composition of 100 parts by mass of inorganic particles to 36 parts by mass of acrylic resin emulsion (50% solids by mass) on a standard white sheet of paper to a dry film thickness of 2 mm, and drying for 48 hours under standard conditions (temperature 25°C, relative humidity 50%; the same applies hereafter).

[0058] 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.

[0059] 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 aesthetically pleasing and natural-looking patterns due to the vividness and other effects described above.

[0060] (Method for manufacturing the facing material of Embodiment 2) (1) A step of scattering first inorganic particles (P1) in a striped pattern on the inner surface of a silicone mold (durometer A hardness 60 or less) having protrusions (recesses in the surface material) corresponding to a desired pattern on the inner surface of the mold, (2) A step of applying a base composition containing second inorganic particles (P2) and resin components. (3) A step of integrating the first inorganic particles (P1) and the base composition and curing them together. (4) The process of demolding, This allows for the formation of a patterned layer and the manufacture of a surface material.

[0061] 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 convex portion (the bottom of the recess in the surface material), the recess in the resulting surface material (especially the bottom of the recess) is easily formed by the base composition. In particular, when the convex portion of the formwork has a sloping or rounded shape (for example, a mountain shape, a parabola shape, or a curved shape), the first inorganic particles (P1) tend to be unevenly distributed at the base of the convex portion, and the base composition does not tend to accumulate at the top of the convex portion. As a result, it is possible to fully express aesthetics such as a three-dimensional effect due to the contrast between the exposed portion (X) and the covered portion (Y), and to express a natural-looking pattern.

[0062] Figure 4 shows an example of a front view of the surface material of the present invention obtained by the above manufacturing method. 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 Embodiment 2 of the present invention has 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.

[0063] 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 has 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 a resin component, resulting in a discontinuous recessed pattern [Figure 5:16].

[0064] 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 texture and vividness derived from the inorganic particles (P). Furthermore, by having recessed patterns, a three-dimensional design such as a sense of depth can be added.

[0065] The patterned layer in Embodiment 2 is flat and has arbitrarily discontinuous recessed patterns. In Embodiment 2, the recessed patterns are planar and there are no 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.

[0066] 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 texture and vividness derived from inorganic particles (P). Furthermore, by having recessed patterns, it is possible to add a three-dimensional design such as a sense of depth, in addition to the contrast created by the texture.

[0067] 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 of the exposed portion (X) and the covered portion (Y) further enhances the clarity of the exposed portion (X) and allows for the formation of an excellent pattern. In Embodiment 2, a striped pattern is formed as shown in Figure 4, and a striped pattern with excellent vividness can be formed due to the contrast created by the texture.

[0068] 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. [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 (1) 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, particle size range 45-600 μm, light transmittance 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 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 hue was black (L * Value = 35.0, a * Value = 1.0, b * The value was 1.5. ·Inorganic particles (3) 100 parts by mass of colored inorganic particles [a mixture of yellow silica sand, red silica sand, and white silica sand (mass ratio) = 75:15:10, with a particle size range of 45-425 μm and a light transmittance of less than 1%] were defined as inorganic particles (3). The particle size D80 of these inorganic particles (3) was 150-212 μm, and 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, with a particle size range of 45-425 μm and a light transmittance of less than 1%] were defined as inorganic particles (4). The particle size D80 of these inorganic particles (4) was 250-300 μm, and 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 (4) was 150-212 μm, and 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.

[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 component [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.

[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 component [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.

[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 spraying from a height of 250 mm above the formwork), then 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 (surface material). During the scattering of inorganic particles (3) and the application of base composition 1, the mold was left undisturbed. The scattered inorganic particles (3) diffused appropriately on the mold to form sparse and dense areas, and then remained stably placed in a striped pattern without disturbance, making it possible to carry out the coating process of the base composition 1. The resulting surface material was flat, and in a front view, inorganic particles (3) formed striped exposed areas (X), while inorganic particles (1) formed covered areas (Y). The striped pattern had varying shades, giving it a natural appearance. It also exhibited excellent texture and clarity.

[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 (3) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 (After spraying from a height of 250 mm above the formwork), then 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 (surface material). The inorganic particle (3) scattering step and the base composition 1 application step were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (3) diffused appropriately on the mold to form sparse and dense areas, and then remained stably placed in a striped pattern without disturbance, making it possible to carry out the coating process of the base composition 1. The resulting surface material was flat, and in a front view, inorganic particles (3) formed striped exposed areas (X), while inorganic particles (1) formed covered areas (Y). The striped pattern had varying shades, giving it a natural appearance. It also exhibited excellent texture and clarity.

[0076] (Example 3) 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 spraying from a height of 250 mm above the formwork), then base composition 1 is applied (weight per unit area: 5.0 kg / m²) 2After curing (at 65°C for 24 hours), the mold was removed to produce the patterned layer (surface material). The inorganic particle (4) scattering process and the base composition 1 application process were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (4) diffused appropriately on the mold to form sparse and dense areas, and then remained stably placed in a striped pattern without disturbance, making it possible to carry out the application process of the base composition 1. The resulting surface material was flat, and in a front view, the inorganic particles (4) formed striped exposed areas (X), and the inorganic particles (1) formed covered areas (Y), with varying shades in the striped pattern, giving it a natural appearance. Compared to Examples 1 and 2, the vividness of the striped pattern was slightly lower, but it had superior texture and vividness.

[0077] (Example 4) 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 (The mixture is sprayed from a height of 250 mm above the formwork, and after it is concentrated at the base of the protruding parts of the formwork, then the 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 (surface material). The inorganic particle (3) scattering step and the base composition 1 application step were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (3) diffused appropriately on the mold to form sparse and dense areas, and then remained stably placed in a striped pattern without disturbance, making it possible to carry out the coating process of the base composition 1. The resulting surface material had a concave pattern on a flat surface. In a front view, inorganic particles (3) formed striped exposed areas (X), and inorganic particles (1) formed covered areas (Y). The striped pattern had varying shades, giving it a natural appearance. It also had excellent texture and clarity. Furthermore, the concave pattern emphasized depth, resulting in a superior three-dimensional effect.

[0078] (Example 5) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 30) 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 spraying from a height of 250 mm above the formwork), then base composition 2 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 inorganic particle (5) scattering process and the base composition 2 application process were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (5) diffused appropriately on the mold to form sparse and dense areas, and then remained stably placed in a striped pattern without disturbance, making it possible to carry out the application process of the base composition 2. The resulting surface material was flat, and in a front view, inorganic particles (5) formed striped exposed areas (X), while inorganic particles (2) formed covered areas (Y). The striped pattern had varying shades, giving it a natural appearance. It also exhibited excellent texture and clarity.

[0079] (Example 6) As the formwork, a rectangular silicone resin formwork (300mm x 600mm, durometer A hardness 50) 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(Spray from a height of 250 mm above the formwork) and concentrate it at the base of the protruding parts of the formwork, then apply base composition 2 (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 (surface material). The inorganic particle (5) scattering process and the base composition 2 application process were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (5) diffused appropriately on the mold to form sparse and dense areas, and then remained stably placed in a striped pattern without disturbance, making it possible to carry out the application process of the base composition 2. The resulting surface material was flat, and in a front view, inorganic particles (5) formed striped exposed areas (X), while inorganic particles (2) formed covered areas (Y). The striped pattern had varying shades, giving it a natural appearance. It also exhibited excellent texture and clarity. Furthermore, the recessed patterns emphasized depth, resulting in a superior three-dimensional effect.

[0080] (Example 7) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 10) 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 spraying from a height of 250 mm above the formwork), then 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 inorganic particle (4) scattering process and the base composition 1 application process were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (4) did not diffuse on the mold and remained stably placed in a striped pattern, making it possible to perform the application process of the base composition 1. On the other hand, a small amount of inorganic particles (4) remained on the mold when demolding was performed. The resulting surface material was flat, and in a front view, the inorganic particles (4) formed striped exposed areas (X), while the inorganic particles (1) formed covered areas (Y), resulting in a design with a natural appearance. Compared to Examples 1 and 2, the formation of the striped pattern was slightly inferior, but it had superior texture and clarity.

[0081] (Comparative Example 1) A rectangular silicone resin mold (300mm x 600mm, durometer A hardness 90) 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 spraying from a height of 250 mm above the formwork), then 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 (surface material). The inorganic particle (4) scattering process and the base composition 1 application process were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (4) bounced and became significantly disordered on the mold, making it difficult to maintain the striped pattern. Furthermore, the inorganic particles (4) also became disordered during the application process of the base composition 1. The resulting surface material was flat, and the striped pattern of the inorganic particles (4) was not retained when viewed from the front. Furthermore, no exposed areas (X) of the inorganic particles (4) were formed, resulting in inferior texture and clarity compared to the example.

[0082] (Comparative Example 2) As a formwork, a formwork (300mm x 600mm, durometer A hardness 90 or higher) made of stainless steel plate covered with release paper was used. Inorganic particles (4) are scattered in a striped pattern on the above mold (mass per unit area: 60 g / m²). 2 (After spraying from a height of 250 mm above the formwork), then 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 (surface material). The inorganic particle (4) scattering process and the base composition 1 application process were carried out with the mold being transported by the transport means of the manufacturing line (line speed: 2 m / sec). The scattered inorganic particles (4) bounced and became significantly disordered on the mold, making it difficult to maintain the striped pattern. Furthermore, the inorganic particles (4) also became disordered during the application process of the base composition 1. The resulting surface material was flat, and the striped pattern of the inorganic particles (4) was not retained when viewed from the front. Furthermore, no exposed areas (X) of the inorganic particles (4) were formed, resulting in inferior texture and clarity compared to the example.

Claims

1. A method for manufacturing a surface material, The above surface material has a patterned layer in which inorganic particles (P) are fixed with a resin component. The above pattern layer is (1) A step of scattering first inorganic particles (P1) onto the formwork, (2) A step of applying a base composition containing a resin component and a second inorganic particle (P2) to a mold on which the first inorganic particles (P1) have been scattered. (3) A step of integrating the first inorganic particles (P1) and the base composition and curing them together. (4) The process of demolding, Obtained by, A method for manufacturing a surface material, characterized in that the durometer A hardness of the above-mentioned formwork is 60 or less.

2. The method for manufacturing a surface material according to claim 1, characterized in that, in step (1) above, the first inorganic particles (P1) are scattered in a desired pattern.

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