Method for manufacturing a facing material

Abstract

To provide a method for manufacturing a surface material having excellent scuff resistance and having beauty.SOLUTION: The invention is a method for manufacturing a surface material with concave parts. The surface material includes a colored layer and a transparent film on a surface thereof. The colored layer is formed by a composition containing granular inorganic particles, and includes the concave parts on a surface of the colored layer. The transparent film is unevenly located on edge portions of the concave parts in the colored layer.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a novel facing material. Manufacturing method 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 to 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, pattern finishing imitating natural stones, soil, plants, etc. has attracted attention.

[0003] As such a pattern finishing material, for example, a mixed material prepared by mixing an aggregate in the form of fine aggregate obtained by pulverizing natural stone or the like with a synthetic resin as a binder is used, and a decorative sheet or the like expressing the texture of natural stone is used (for example, Patent Document 1, Patent Document 2). In such a decorative sheet, the aggregate is fixed with a small amount of resin to exhibit an appearance similar to natural stone.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the case of the above-described decorative sheet, when the amount of resin in the mixed material is set to be small, the surface strength is insufficient, and there is a risk of becoming brittle and defective. In particular, in the case of a decorative sheet having an uneven pattern, the concave and convex portions (such as corners) are liable to be damaged by scratches or abrasions.

[0006] The present invention has been made to solve the above problems, and an object thereof is to provide a surface material having excellent scratch resistance.

Means for Solving the Problems

[0007] As a result of intensive studies, the present inventor has conceived of a surface material having recesses and having a specific transparent film on its outermost surface, and has completed the present invention.

[0008] That is, the surface material of the present invention has the following characteristics. 1. A surface material having recesses Manufacturing method which is the above surface material has a colored layer and a transparent film on its surface 、 the above colored layer 、 has recesses on its surface, the above transparent film is unevenly distributed at the edge of the recesses of the above colored layer, The colored layer is formed from a composition for a colored layer containing granular inorganic particles and a resin, and the transparent coating is formed by a transparent coating material. The method includes a step of applying the transparent coating material to the inner surface of a mold, drying and curing it, filling the composition for the colored layer after curing, and demolding after curing. The mold is a mold having a flat portion and a plurality of convex portions on the inner surface. A surface material characterized by this Manufacturing method. 2. The transparent The coating material is The surface material according to 1., characterized by containing a silicone resin and a synthetic resin other than the silicone resin Manufacturing method .

Effects of the Invention

[0009] According to the present invention, a surface material having excellent scratch resistance can be obtained.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Explanation of Symbols

[0011] A. Face Material A1: Concave Portion A2: Convex Portion A3: Edge of Concave Portion 1: Coloring Layer 11: Concave Portion (11’: Flat Portion of Concave Portion) 12: Convex Portion (12’: Flat Portion of Convex Portion) 13: Edge of Concave Portion 2: Transparent Coating Layer

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments for carrying out the present invention will be described.

[0013] FIG. 1 is a schematic cross-sectional view showing an example of the face material of the present invention.

[0014] (Face Material) The face material A of the present invention has a coloring layer 1 and a transparent coating 2. As shown in FIG. 1, when viewed from the front direction, it has a concave portion A1 on its surface. In the present invention, the portion protruding more than the concave portion A1 is defined as the convex portion A2. A cross-sectional view of the X-X’ portion of FIG. 1 is shown in FIG. 2. As shown in FIG. 2, when viewed in the cross-sectional direction, the coloring layer 1 of the face material A of the present invention has a concave portion 11 on its surface. Further, the transparent coating 2 is characterized by being unevenly distributed at the edge 13 of the concave portion 11 of the coloring layer (hereinafter also referred to as the “edge of the concave portion 13”). As shown in FIG. 3 (an enlarged schematic view of the Y portion of FIG. 2), the transparent coating 2 is provided on the surface of the coloring layer 1 and is unevenly distributed so as to form a thicker film in the vicinity of the edge 13 of the concave portion 11 of the coloring layer than in other portions.

[0015] In the face material A of the present invention having such characteristics, the strength of the edge A3 of the concave portion can be efficiently increased, defects such as scratches and abrasion marks can be suppressed, and excellent abrasion resistance can be exhibited. In the present invention, the edge of the concave portion refers to a region including at least a portion straddling between the concave portion and the convex portion, as shown in FIG. 3.

[0016] (Coloring Layer) The colored layer 1 of the present invention can be formed by curing a composition (such as a composition for a colored layer) containing granular inorganic particles and a resin. Thereby, the granular inorganic particles are fixed by the resin, and a colored layer exhibiting a color tone based on the granular inorganic particles is obtained. That is, the color tone of the colored layer is based on the color tone of the granular inorganic particles. Further, the colored layer 1 may have a plurality of colored regions having different color tones. In this case, the colored layer can be formed by curing a plurality of compositions for colored layers having different color tones.

[0017] As the granular inorganic particles, any of natural products and artificial products can be used as long as the material of the matrix is inorganic. As the granular inorganic particles, an embodiment including at least granular colored inorganic particles is preferable. As such granular colored inorganic particles, particularly, opaque ones with a light transmittance of less than 3% are preferable, and those with a light transmittance of 2% or less are more preferable. Specific examples of such granular colored inorganic particles include, for example, marble, granite, serpentine, granite, sandstone, slate, basalt, porphyry, diorite, andesite, limestone, and their pulverized products, ceramic pulverized products, ceramic pulverized products, metal grains, etc. Further, fluorite, gypsum, feldspar, silica stone, silica sand, and their pulverized products, glass pulverized products, glass beads, etc. colored so as to satisfy the above conditions can also be used.

[0018] The above light transmittance is the value of the total light transmittance measured by a turbidimeter. In this measurement, a sample of granular inorganic particles is filled in a transparent glass cell with an inner thickness of 5 mm, and then gradually filled with water, and then the bubbles in the cell are removed by vibration and used.

[0019] In addition to the above-mentioned granular colored inorganic particles, it is also possible to adopt a form containing granular transparent inorganic particles. The use of such granular transparent inorganic particles is suitable in terms of improving aesthetics. As the granular transparent inorganic particles, those having a light transmittance of 3% or more (more preferably 3 to 50%, still more preferably 10 to 30%) are suitable. Examples of the granular transparent inorganic particles include silica, gypsum, feldspar, silica stone, etc. and their pulverized products, glass pulverized products, glass beads, etc. Any colorless or colored type can be used as long as it satisfies the above light transmittance. In the present invention, "α~β" is synonymous with "α or more and β or less".

[0020] The particle size of the granular inorganic particles is preferably 0.01 mm to 5 mm, more preferably 0.02 mm to 2 mm, still more preferably 0.03 to 0.8 mm. By variously combining granular inorganic particles with different particle sizes, the range of design properties can also be widened. The particle size of the granular inorganic particles is measured by sieving using a metal mesh sieve specified in JIS Z8801-1:2000.

[0021] The resin for immobilizing the granular inorganic particles is preferably one having a transparent coating. Examples of such resin forms include solvent-soluble resins, non-aqueous dispersion resins, solvent-free resins, water-dispersion resins, water-soluble resins, etc. Examples of the resin types include acrylic resins, urethane resins, epoxy resins, vinyl chloride resins, vinyl acetate resins, acrylic silicone resins, fluorine resins, silicone resins, polyvinyl alcohol, cellulose derivatives, etc., or composites thereof. Such resins may have the property of causing a cross-linking reaction.

[0022] The ratio of the above resin, in terms of solid content, is preferably 1 to 50 parts by weight, more preferably 2 to 30 parts by weight, and still more preferably 3 to 20 parts by weight with respect to 100 parts by weight of the total amount of granular inorganic particles. With such a ratio, it is easy to impart a design property that makes use of the aesthetic appearance due to the connection (aggregation) of the granular inorganic particles. That is, it is easy to obtain a colored layer composed of a connected body (aggregate) of granular inorganic particles. Also, the gloss is suppressed and a matte appearance is likely to be exhibited. Further, even when viewed through the transparent coating described later, an aggregated pattern (for example, a stone texture pattern, etc.) having a fine uneven shape derived from the granular inorganic particles can be visually recognized.

[0023] The composition for the colored layer may contain components (additives) other than the above, if necessary, as long as the effects of the present invention are not significantly impaired. Examples of such components include plasticizers, algicides, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoamers, crosslinking agents, film-forming aids, antifreezing agents, coloring pigments, extender pigments, pearlescent pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, and the like.

[0024] The colored layer 1 of the present invention is characterized in that it has recesses 11 on its surface. The recesses 11 form at least a recessed pattern in the colored layer 1. Such a pattern of the colored layer 1 is not particularly limited and includes various shapes, such as a stone-like pattern, a wood grain pattern, a joint pattern, etc. Among them, it is suitable when it has a recessed pattern in a shape such as a nest-like shape, a worm-eaten shape, a bark pattern, etc., which is formed in natural stones, soil, plants, etc.

[0025] The size of the recesses 11 depends on the shape of the uneven pattern, but the maximum diameter (major axis) is preferably 0.2 to 50 mm (more preferably 0.5 to 30 mm). Also, the depth of the recesses 11 depends on the thickness of the colored layer 1, but is preferably 0.1 to 5 mm (more preferably 0.2 to 3 mm).

[0026] In addition, in the present invention, it is preferable that the colored layer 1 has a plurality of recesses 11, and their shapes may be constant (identical) or different. Furthermore, the arrangement of the plurality of recesses 11 may be regular or random, but in the present invention, it is preferable that a linear pattern, a striped pattern, etc. are formed. In such a case, it is easy to express a pattern imitating natural stone, soil, plants, etc., and a surface material with excellent aesthetic properties can be obtained. In particular, in the present invention, it is suitable for expressing a pattern of natural stone (especially travertine-like, etc.).

[0027] Specifically, as the colored layer 1 expressing the above pattern, it has an uneven pattern formed by the recesses 11 and the protrusions 12 when viewed from the cross-sectional direction of the colored layer 1. For example, as shown in FIG. 4, (a) having random recesses 11 and protrusions 12 on its surface, (b) having a recess 11 and a flat protrusion part 12' where the protrusion 12 is flat on its surface, (c) having a flat recess part 11' where the recess 11 is flat and a protrusion 12 on its surface, and those obtained by combining the above (a) to (c), etc. are exemplified. In the present invention, it is particularly effective when including the uneven pattern in the aspect of the above (b) and / or the above (c).

[0028] In addition, in the above (a) to (c), the recess edge part 13 is a region including at least a part straddling between the recess 11 and the protrusion 12.

[0029] (Transparent coating) The transparent coating 2 is formed of a transparent coating material and is formed unevenly on the recess edge part of the colored layer. The transparent coating material of the present invention is not particularly limited as long as it contains a synthetic resin. As the medium of the transparent coating material, either a solvent-based or a water-based one may be used, but in the present invention, it is preferable that the medium contains water. Thereby, the transparent coating material is likely to be unevenly distributed on the recess edge part 13 of the colored layer 1. Thereby, the effect of scratch resistance can be enhanced.

[0030] Furthermore, in the present invention, it is preferable that the transparent film contains, as synthetic resins, a silicone resin and a synthetic resin other than the silicone resin. By using these in combination, the transparent coating material tends to be unevenly distributed at the edge of the recess of the colored layer, enhancing the effect of scratch resistance, suppressing gloss, and obtaining a surface material with excellent and calm aesthetics.

[0031] Examples of the silicone resin include silicone oils and silicone resins composed of dialkylpolysiloxanes such as dimethylpolysiloxane, polyarylsiloxanes such as polydiphenylsiloxane, and polyalkylarylsiloxanes such as methylphenylpolysiloxane, or modified silicone oils and modified silicone resins such as amino-modified silicone, epoxy-modified silicone, carboxyl-modified silicone, alcohol-modified silicone, and polyether-modified silicone. As the form of the silicone resin, any of a water-soluble resin, a water-dispersible resin, a solvent-soluble resin, a solvent-free resin, and a non-aqueous dispersion resin may be used. In the present invention, a water-dispersible resin (resin emulsion) is preferable.

[0032] Examples of the synthetic resin other than the silicone resin include organic resins such as ethylene resin, vinyl acetate resin, vinyl chloride resin, acrylic resin, acrylic styrene resin, polyester resin, polyether resin, polyolefin resin, ethylene resin, fluororesin, butadiene resin, urethane resin, acrylic-vinyl acetate resin, acrylic-urethane resin, phenol resin, epoxy resin, melamine resin, alkyd resin, acrylic-silicone resin, polyvinyl alcohol resin, cellulose resin and its derivatives, and inorganic resins such as water glass-based and other metal alkoxide compounds. As the form of the synthetic resin, any of a water-soluble resin, a water-dispersible resin, a solvent-soluble resin, a solvent-free resin, and a non-aqueous dispersion resin may be used. In the present invention, a water-dispersible resin (resin emulsion) is preferable.

[0033] In particular, in the present invention, an embodiment containing an acrylic resin emulsion and / or an acrylic styrene emulsion as a synthetic resin other than the silicone resin is preferable. The glass transition temperature of the acrylic resin is preferably 5 to 100 °C (more preferably 10 to 80 °C). Thereby, the effects of the present invention can be further enhanced.

[0034] The solid content weight ratio of the above silicone resin to the synthetic resin other than the above silicone resin is preferably 5:95 to 90:10 (more preferably 10:90 to 80:20, still more preferably 15:85 to 60:40). In such a case, the transparent coating material tends to be unevenly distributed at the edge of the recess of the colored layer, and the scratch resistance can be enhanced.

[0035] Furthermore, by satisfying the solid content weight ratio of the above silicone resin and the above synthetic resin, the transparent coating material can obtain a stable matting effect without using a powder component such as a known matting agent, and the formed transparent film, regardless of its film thickness, hardly causes gloss unevenness (mat unevenness) and can form a uniform mat surface. Therefore, a surface material with high aesthetic properties and a stable appearance without gloss unevenness can be obtained without impairing the design properties such as the color tone of the colored layer.

[0036] The solid content of the transparent coating material is preferably 2 to 50% by weight (more preferably 5 to 30% by weight). Also, the transparent coating material can be diluted with various solvents during coating. The dilution ratio of the coating material is preferably 0 to 1000% by weight (more preferably 0 to 800% by weight) with respect to the transparent coating material, and the solid content during coating is preferably 0.1 to 50% by weight (more preferably 0.2 to 30% by weight, still more preferably 0.3 to 20% by weight). In such a case, the transparent coating material tends to be unevenly distributed at the edge of the recess of the colored layer, and the effects of the present invention can be enhanced.

[0037] Also, the coating amount per unit area of the transparent coating material is preferably 10 to 500 g / m 2 (more preferably 20 to 400 g / m 2, more preferably 30 to 300 g / m 2 ), and in terms of solid content, preferably 1 to 150 g / m 2 (more preferably 1.5 to 80 g / m 2 , still more preferably 2 to 40 g / m 2 ). In such a case, the transparent coating material tends to be unevenly distributed at the edge of the recess of the colored layer, and sufficient scratch resistance can be obtained.

[0038] The transparent coating material forms a colorless and transparent film, or may contain some coloring components (such as coloring pigments, dyes, and dispersions thereof) as long as the effects of the present invention are not inhibited, and may form a colored transparent film. Further, these transparent coating materials may contain, for example, plasticizers, anti-algal agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoamers, film-forming aids, antifreezing agents, water repellents, hydrophilic agents, crosslinking agents, matting agents, extender pigments, lustrous pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, etc.

[0039] The transparent film 2 of the present invention is provided on the surface of the colored layer 1 and is characterized by being unevenly distributed at the edge 13 of the recess of the colored layer 1. Thereby, the strength of the recess edge (especially near the corner) of the facing material A of the present invention can be efficiently increased, defects such as scratches and gouges can be suppressed, and excellent scratch resistance can be exhibited. As the mode in which the transparent film 2 is unevenly distributed, for example, the transparent film 2 (I) is not provided on the convex portion 12 (convex flat portion 12') and is provided only on the edge 13 of the recess; (II) is provided on the whole including the recess 11 (recess flat portion 11') and the convex portion 12 (convex flat portion 12'), and forms a thick film at the edge 13 of the recess; (III) is provided discontinuously (dispersed) on the whole including the recess 11 (recess flat portion 11') and the convex portion 12 (convex flat portion 12'), and is provided on the edge 13 of the recess; (IV) is provided discontinuously (dispersed) on the whole including the recess 11 (recess flat portion 11') and the convex portion 12 (convex flat portion 12'), and forms a thick film at the edge 13 of the recess. Examples include the following.

[0040] In the present invention, as described in (I) to (IV) above, the transparent film 2 is unevenly distributed so as to border the edge portion 13 of the recess of the colored layer 1. Thereby, the scratch resistance can be enhanced. Note that when the colored layer 1 has a plurality of recesses, the transparent film 2 may be provided at all the edge portions 13 of the recesses, or may be provided only partially.

[0041] (Reinforcing material) The surface material of the present invention may have a reinforcing material. Such a reinforcing material can be provided inside and / or on the back surface of the colored layer. Examples of the reinforcing material include woven fabric, non-woven fabric, ceramic paper, synthetic paper, mesh, cloth, gypsum board, plywood, slate board, metal plate, and the like. The reinforcing material may be composed of two or more of the above materials. By using such a reinforcing material, the strength of the surface material can be enhanced.

[0042] (Manufacturing method) The manufacturing method of the surface material of the present invention is not particularly limited, and various methods can be adopted. As an example, a method using a mold can be mentioned. In this method, first, a mold having recesses and protrusions (recesses of the colored layer) corresponding to a desired pattern is prepared. The mold is not particularly limited, but for example, a mold made of silicone resin, urethane resin, or a mold provided with release paper can be used. When manufacturing using a mold, since the inner surface of the mold becomes the surface of the surface material, a desired uneven pattern can be imparted to the surface of the surface material by adjusting the shape of the inner surface of the mold.

[0043] Using the above mold, for example, · A method in which the composition for the colored layer is filled on the inner surface of the mold, demolded after curing, a transparent coating material is applied to the surface of the colored layer, and dried and cured. · A method in which a transparent coating material is applied to the inner surface of the mold, after drying and curing, the composition for the colored layer is filled, and demolded after curing. The surface material can be manufactured by the like.

[0044] In the application and filling of the composition for the colored layer and the transparent coating material, known instruments such as sprayers, rollers, spatulas, brushes, reciprocators, coaters, etc. can be used. When introducing a reinforcing material, for example, before the composition for the colored layer cures, the reinforcing material may be embedded inside the colored layer or laminated on the back surface of the colored layer.

[0045] Specifically, the facing material shown in FIGS. 1 to 3 is preferably manufactured by, for example, the following method. (1) A transparent coating material is manufactured by mixing and stirring a synthetic resin (preferably a silicone resin and a synthetic resin other than the silicone resin) and, if necessary, an additive by a conventional method. Also, a composition for the colored layer is manufactured by mixing and stirring granular inorganic particles, a resin, and, if necessary, an additive by a conventional method. (2) A mold having desired concave and convex portions (forming the concave portions of the colored layer) on the inner surface (a mold with a desired concavo-convex pattern transferred) is prepared, and the transparent coating material is applied to the inner surface of the mold and dried and cured. (3) Next, the mold is filled with the composition for the colored layer and demolded after curing.

[0046] The facing material obtained by the above method is such that the convex portions on the inner surface of the mold are inverted to form the concave portions of the colored layer. Also, a transparent film is provided on the surface of the colored layer, and the transparent film is unevenly distributed at the edges of the concave portions. Thereby, scratch resistance can be exhibited. When the transparent coating material is applied to a mold having concave and convex portions, the above-mentioned transparent coating material tends to be unevenly distributed at the foot of the convex portions. In particular, when the above-mentioned transparent coating material is applied to a mold having a flat portion and a convex portion, and further having a shape in which the convex portion has an inclination or a roundness (for example, mountain-shaped, parabolic-shaped, curved-shaped), the transparent coating material can be more unevenly distributed at the foot of the convex portion. Thereby, a facing material capable of sufficiently exhibiting the effects of the present invention can be efficiently manufactured.

[0047] In the above (2), it is preferable to dry and cure the transparent coating material after coating. During the drying and curing process, the transparent coating material is more likely to be unevenly distributed due to the foot of the convex portion on the inner surface of the mold. Therefore, when the transparent coating material is in a cured state rather than an uncured state and the composition for the colored layer in the above (3) is filled, the effects of the present invention can be fully exerted. Note that the curing in the above (2) may be finger-touch dry or more (preferably semi-cured, more preferably cured and dried). Further, in the present invention, by using a colored transparent coating material in which a coloring pigment is added to the transparent coating material in the step (2), it is possible to impart an aesthetic appearance having contrast, three-dimensional effect (depth effect), etc.

[0048] In the present invention, after the above (1) to (3), for example, as the step (4), a transparent coating material can be further applied and dried on the surface of the face material after demolding (preferably on the whole) to provide a transparent film. Thereby, since a transparent film can be further unevenly distributed (laminated) on the edge portion of the recess where the transparent film of the face material manufactured in the above (1) to (3) is unevenly distributed, the scratch resistance can be further enhanced. Also, by using a colored transparent coating material in which a coloring pigment is added to the transparent coating agent in the step (4), it is also possible to impart an aesthetic appearance having contrast, three-dimensional effect (depth effect), etc.

[0049] In the above (4), the coating amount per unit area of the transparent coating material is preferably 5 to 500 g / m 2 (more preferably 10 to 300 g / m 2 ) and, in terms of solid content conversion, preferably 1 to 200 g / m 2 (more preferably 1.5 to 100 g / m 2 , still more preferably 2 to 80 g / m 2 ). The above effects can be exerted.

[0050] In the present invention, in the above (4), even when a transparent coating is provided on the entire surface of the facing material, defects such as gloss unevenness are less likely to occur, and a calm aesthetic appearance can be exhibited. In particular, in the present invention, the coloring layer is one in which inorganic particles are fixed with a small amount of resin, the transparent coating material contains a silicone resin, and by adopting means selected from adjusting the coating amount of the transparent coating material, the above effects can be obtained. The mechanism of this action is not limited to the following, but when the transparent coating material is applied to the coloring layer of the present invention, the transparent coating material forms a film while penetrating the surface of the coloring layer, so that a facing material can be obtained that retains the shape of fine irregularities derived from the inorganic particles forming the coloring layer. It is presumed that the above effects can be obtained thereby.

[0051] The facing material obtained from the above (1) to (3) (and further (4)) preferably has a glossiness at 60 degrees of 8 or less (more preferably 1 to 7, still more preferably 1.5 to 6). If the glossiness is within such a range, it has a calmness and can impart a refined aesthetic appearance. Further, the facing material of the present invention preferably has a glossiness at 85 degrees of 8 or less (more preferably 1 to 7, still more preferably 1.5 to 6). Further, the difference in glossiness between 60 degrees and 85 degrees is preferably 2 or less (more preferably 1.5 or less, still more preferably 1 or less). By satisfying the above range of glossiness at 60 degrees and 85 degrees in this way, unevenness in gloss due to the viewing angle (direction) can be suppressed, and the sense of calmness and aesthetic appearance can be further enhanced. In addition, the glossiness in the present invention is a value measured in accordance with JIS K5600-4-7 "Specular Glossiness". Specifically, it is the value of the 60-degree or 85-degree specular glossiness measured by a gloss meter, and it is the average value obtained by measuring 10 arbitrary places on the surface of the facing material A.

[0052] The surface material of the present invention can be used as a material for decorating building walls and the like. When fixing the surface material of the present invention to a wall or the like, for example, an adhesive, an adhesive tape, a nail, a screw, a bolt, a rail, or the like may be used. Examples of the base material constituting the building wall or the like include concrete, mortar, siding board, extruded board, gypsum board, perlite board, plywood, brick, plastic board, metal plate, glass, porcelain tile, and the like. These base materials may have a film (existing film, undercoat film, etc.) already formed on their surfaces, or may have wallpaper pasted on them, and the like.

Examples

[0053] Examples and comparative examples are shown below to clarify the features of the present invention.

[0054] (Manufacture of the composition for the coloring layer) The raw materials were uniformly mixed by a conventional method at the mixing ratios shown in Table 1 to produce a composition for the coloring layer. The raw materials used are as follows. · Granular colored inorganic particles [mixture of brown silica sand: reddish-brown silica sand: yellow silica sand (weight ratio) = 65:15:20), particle size 0.03 to 0.6 mm, light transmittance less than 1%] · Granular transparent inorganic particles [alunite; particle size 0.1 to 0.4 mm, light transmittance 16%] · Resin component [acrylic resin emulsion, solid content 50% by weight, medium; water] · Additives [defoamer, film-forming aid, water, etc.]

[0055]

Table 1

[0056] (Manufacture of transparent coating materials 1 to 10) The raw materials were uniformly mixed by a conventional method at the mixing ratios shown in Table 2 to produce transparent coating materials. The raw materials used are as follows. · Silicone resin emulsion [polyoxyethylene alkyl ether emulsion of dimethylpolysiloxane, solid content 50% by weight, medium; water] · Acrylic resin emulsion [solid content 50% by weight, glass transition temperature 40°C, medium; water] · Additives [defoaming agent, film-forming aid, etc.] (Manufacture of transparent coating material 1') 20 parts by weight of the above transparent coating material 1, 0.5 part by weight of a colored dispersion liquid (acrylic resin emulsion, pigment paste [a mixed liquid of ocher pigment: red safflower pigment: black pigment (weight ratio) = 25:55:20, solid content 50% by weight, resin solid content 40% by weight, pigment solid content 10% by weight, medium; water]), and 80 parts by weight of water were uniformly mixed to produce transparent coating material 1' (solid content 3.2%).

[0057]

Table 2

[0058] <Manufacture of facing material (I)> As a mold, a rectangular mold (30 cm × 60 cm) with a travertine pattern having a plurality of convex portions (height of convex portion 0.2 to 2 mm, major diameter of convex portion 0.2 to 10 mm) formed on a flat portion was used. The above transparent coating material was applied to the mold (weight per unit area 100 g / m 2 ), and after being unevenly distributed at the foot of the convex portion of the mold, it was dried and cured (at 23°C for 24 hours). Next, a composition for a colored layer was applied onto the above transparent film (weight per unit area 3.3 kg / m 2 ), and after curing (at 65°C for 24 hours), it was demolded to produce facing material (I). Note that the transparent coating material and the colored layer composition were used in the combinations shown in Table 3 (Examples 1 to 11).

[0059] <Manufacture of facing material (II)> The first transparent coating material was applied to the same mold as above (weight per unit area 100 g / m 2 ), and after being unevenly distributed at the foot of the convex portion of the mold, it was dried and cured (at 23°C for 24 hours). Next, a composition for a colored layer was applied onto the above first transparent film (weight per unit area 3.3 kg / m 2 ), and after curing (at 65°C for 24 hours), it was demolded. Furthermore, a second transparent coating material was further applied to the entire surface of the surface having the first transparent film (the surface having the flat portion and the concave portion) (weight per unit area: 140 g / m 2 ), and a facing material (II) provided with a second transparent film layer was produced. The transparent coating material and the coloring layer composition were used in the combinations shown in Table 3 (Examples 12 to 21).

[0060] <Production of facing material (III)> The composition 1 for the coloring layer was applied to the same mold as above (weight per unit area: 3.3 kg / m 2 ), and after curing (at 65°C for 24 hours), it was demolded to produce a facing material (III) (Comparative Example 1).

[0061] (Examples 1 to 21, Comparative Example 1) For each of the facing materials produced by the above method, the following tests were conducted. The results are shown in Table 3. (Scratch resistance) After rubbing the surface of the obtained facing material 1000 times with a deck brush (made of resin), the surface of the facing material was visually evaluated. Those without defects were rated as A, and those with defects were rated as D on a four-point scale (A > B > C > D).

[0062]

Table 3

[0063] Examples 1 to 21 were facing materials with good scratch resistance evaluation. On the other hand, in Comparative Example 1, defects were observed around the edge of the concave portion.

[0064] Furthermore, the following evaluation was conducted on the appearance of the obtained facing material. The results are shown in Table 3. (Gloss) In accordance with JIS K5600-4-7 "Specular Gloss", any 10 locations on the surface of facing material A were measured (measurement angles: 60 degrees, 85 degrees), and the average value was calculated. Also, among the 10 measured locations, the difference (absolute value) between the minimum and maximum values of gloss was calculated, and the gloss (lustre) unevenness was evaluated in four grades (A > B > C > D) (A: 1 or less, B: more than 1 and 2 or less, C: more than 2 and 3 or less, D: more than 3).

[0065] The facing materials obtained in Examples 1 to 21 all had suppressed gloss and a calming feeling. Also, in Examples 20 and 21, the colored transparent coating was unevenly distributed at the edges of the recesses on the surface of the colored layer, and the facing materials were excellent in aesthetic appearance with a three-dimensional effect and the like imparted thereto.

Claims

1. A method for manufacturing a surface material having a recess, comprising the steps of: The surface material has a colored layer and a transparent coating on the surface thereof, The colored layer has a recess on its surface, the transparent coating is unevenly distributed on the edge portion of the recess of the colored layer, The colored layer is formed from a colored layer composition containing granular inorganic particles and a resin, and the transparent coating is formed from a transparent coating material, The method includes a step of applying the transparent coating material to the inner surface of a mold, drying and curing the material, filling the colored layer composition, and removing the colored layer composition from the mold after the material has cured. The method for manufacturing a surface material is characterized in that the formwork has a flat portion and a plurality of convex portions on its inner surface.

2. 2. The method for manufacturing a surface material according to claim 1, wherein the transparent coating material contains a silicone resin and a synthetic resin other than the silicone resin.

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