Method for manufacturing a facing material

Abstract

To provide a method for manufacturing a surface material having beauty owing to appearance of solidity, etc.SOLUTION: The invention is a method for manufacturing a surface material with concave parts. The surface material includes a colored layer and a colored transparent film. 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 colored 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 finishes imitating natural stones, soil, plants, etc. have 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 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. Further, although an uneven pattern can be formed, it lacks variation and it is difficult to express a three-dimensional effect.

[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 and excellent aesthetic properties such as three-dimensional appearance.

Means for Solving the Problems

[0007] As a result of intensive studies, the present inventor has conceived a surface material having recesses, in which a colored transparent film is unevenly distributed at the edges of the recesses, and further 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 said surface material has a colored layer and a colored transparent film on its surface 、 said colored layer 、 has recesses on its surface, said colored transparent film is unevenly distributed at the edges of the recesses of said colored layer, The colored layer is formed from a composition for a colored layer containing granular inorganic particles and a resin, and the colored transparent film is formed by a colored transparent coating material. The method includes a step of applying the colored 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. characterized surface material Manufacturing method. 2. The surface material according to 1., characterized by containing a silicone resin and a synthetic resin other than said silicone resin The coating material is in said colored transparent Manufacturing method . 3. The surface material according to 1. or 2., characterized in that the color tone is different between the edges of the recesses and other parts in a front view. Manufacturing method . 4. After demolding, a transparent coating material is further applied and dried on the surface of the facing material. The surface material according to any one of 1. to 3., characterized in that a transparent film is provided on the outermost surface Form thereof. Manufacturing method .

Effects of the Invention

[0009] According to the present invention, a surface material having excellent scratch resistance and excellent aesthetic properties due to three-dimensional appearance or the like can be obtained.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Explanation of Reference Numerals

[0011] A. Surface material A1: Concave portion A2: Convex portion A3: Edge of concave portion 1: Colored 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: Colored 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 surface material of the present invention.

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

[0015] In the present surface material A having such characteristics, the strength of the recess edge A3 can be efficiently increased, defects such as scratches and abrasions can be suppressed, excellent scratch resistance can be exhibited, and a three-dimensional effect can be imparted. In the present invention, the recess edge means, as shown in FIG. 3, a region including at least a portion straddling between the recess and the convex portion.

[0016] Further, in the present surface material A, when viewed from the front, the color tone of the recess edge A3 and other portions (the recess A1, the convex portion A2) can be made different. Thereby, the unevenness and three-dimensional effect can be further enhanced.

[0017] The difference in color tone only needs to be visible to the naked eye, and can be adjusted, for example, by the color tone of the colored transparent film 2. Specifically, for example, when the colored layer and the colored transparent film 2 are of the same color system, a dark-colored portion (or a light-colored portion) is formed at the recess edge A3, and a calm design property can be imparted. On the other hand, when the colored layer 1 and the colored transparent film 2 are not of the same color system, an accent pattern is formed at the recess edge A3, and a design property with contrast can be imparted. Further, in addition to the different color tones, as long as the characteristics of the present invention are not impaired, the three-dimensional effect can be enhanced by differences in glossiness, texture, etc.

[0018] (Colored 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.

[0019] 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 containing 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, pulverized ceramic products, pulverized ceramic products, metal grains, etc. Further, fluorite, gypsum, feldspar, silica, silica sand, and their pulverized products, pulverized glass products, glass beads, etc., colored so as to satisfy the above conditions can also be used.

[0020] 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, then gradually filled with water, and then the air bubbles in the cell are removed by vibration before use.

[0021] 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 type, colorless or colored, can be used as long as it satisfies the above light transmittance. In the present invention, "α to β" is synonymous with "α or more and β or less".

[0022] The particle size of the granular inorganic particles is preferably 0.01 mm to 5 mm, more preferably 0.02 mm to 2 mm, and 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.

[0023] The resin for immobilizing the granular inorganic particles preferably has a transparent coating. Examples of such resin forms include solvent-soluble resins, non-aqueous dispersion resins, solventless 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.

[0024] 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 even 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 takes advantage 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 an 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.

[0025] 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, anti-algal agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, defoamers, crosslinking agents, film-forming aids, antifreezing agents, coloring pigments, extender pigments, lustrous pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, and the like.

[0026] 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 are formed in natural stones, soils, plants, etc.

[0027] 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).

[0028] In the present invention, it is preferable that the colored layer 1 has a plurality of recesses 11, and the shapes thereof may be the same or different. Further, 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 facing material excellent in aesthetic appearance can be obtained. In particular, the present invention is suitable for expressing a pattern of natural stone (especially, travertine-like, etc.).

[0029] 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 the colored layer 1 is viewed from the cross-sectional direction. 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 portion 12' where the protrusion 12 is flat on its surface, (c) having a flat recess portion 11' where the recess 11 is flat and a protrusion 12 on its surface, and those combining the above (a) to (c) etc. can be mentioned. 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).

[0030] In the above (a) to (c), the recess edge portion 13 is a region including at least a portion straddling between the recess 11 and the protrusion 12.

[0031] (Colored transparent film) The colored transparent film 2 is provided on the surface of the colored layer 1, and is characterized by being unevenly distributed on the recess edge portion 13 of the colored layer 1. Thereby, when the facing material A of the present invention is viewed from the front, the appearance (for example, color tone, etc.) is different between the recess edge portion A3 and other portions (recess A1, protrusion A2), and a facing material with high aesthetic appearance due to unevenness, three-dimensionality, etc. can be obtained.

[0032] Such a colored transparent film 2 is preferably formed by uneven distribution of a colored transparent coating material. The colored transparent coating material may be a composition containing a resin component and a coloring component as long as the film has transparency. As the medium of the colored transparent coating material, either a solvent-based or water-based system may be used, but in the present invention, it is preferable that the medium contains water. Thereby, the colored transparent coating material is likely to be unevenly distributed at the concave edge portion 13 of the colored layer 1, and a surface material excellent in scratch resistance and three-dimensional effect can be obtained.

[0033] The resin component is not particularly limited, and examples thereof include ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, acrylic styrene resin, acrylic silicone resin, urethane resin, fluororesin, silicone resin, etc., or composite resins thereof. As the form of the resin component, any of water-soluble resin, water-dispersible resin, solvent-soluble resin, solvent-free resin, non-aqueous dispersion resin, etc. may be used, but in the present invention, a water-dispersible resin (resin emulsion) is preferable.

[0034] In the present invention, an embodiment in which the resin component includes a silicone resin and a synthetic resin other than the silicone resin is preferable. By using these resin components in combination, the colored transparent coating material is likely to be unevenly distributed at the concave edge portion of the colored layer, the effect of scratch resistance is enhanced, and a surface material with suppressed gloss and excellent aesthetic appearance with a calm feeling can be obtained. Furthermore, the color tone of the concave edge portion becomes distinct, and the aesthetic appearance such as three-dimensional effect can be further enhanced.

[0035] Specifically, 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 for the form of the silicone resin, it can be any of water-soluble resin, water-dispersible resin, solvent-soluble resin, solvent-free resin, non-aqueous dispersion resin, etc. In the present invention, a water-dispersible resin (resin emulsion) is preferred.

[0036] In addition, as a synthetic resin other than the silicone resin, an embodiment containing an acrylic resin emulsion and / or an acrylic styrene emulsion is preferred. 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.

[0037] 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 scratch resistance can be enhanced, and a surface material with an unevenly distributed colored transparent film and excellent three-dimensional effect can be obtained.

[0038] As the coloring component, known coloring components (coloring pigments, dyes, etc.) can be used, and preferably, coloring pigments such as organic coloring pigments and inorganic coloring pigments are mentioned. The mixing ratio is preferably 0.01 to 30 parts by weight (more preferably 0.02 to 20 parts by weight, still more preferably 0.05 to 10 parts by weight) of the coloring component with respect to 100 parts by weight of the above resin component (solid content). When mixing the coloring pigment with the resin component, it can be mixed in the form of a dispersion of each pigment.

[0039] The colored transparent coating material can be diluted with various solvents during application. The solid content during the application of the colored transparent coating material 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), and the coating amount per unit area is preferably 10 to 500 g / m 2 (more preferably 20 to 400 g / m 2 , still more preferably 30 to 300 g / m 2 ). In such a case, it is likely to be unevenly distributed at the edge of the recess of the colored layer, the effects of the present invention can be easily obtained, and the aesthetic property can be enhanced.

[0040] Furthermore, the colored transparent coating material may contain, for example, a plasticizer, an algicide, an antibacterial agent, a deodorant, an adsorbent, a flame retardant, a thickener, an antifoaming agent, a film-forming aid, an antifreezing agent, a water repellent, a hydrophilic agent, a crosslinking agent, a matting agent, an extender pigment, a glitter pigment, a phosphorescent pigment, a fluorescent pigment, an aggregate, a fiber, an ultraviolet absorber, a light stabilizer, an antioxidant, a catalyst, etc.

[0041] The colored 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 edge of the recess (especially near the corner) of the facing material A of the present invention can be efficiently increased, defects such as scratches and abrasions can be suppressed, excellent scratch resistance can be exhibited, and the depth feeling (depth) is emphasized more than the actual dent, enhancing the three-dimensional effect.

[0042] In the present invention, as the mode in which the colored transparent film 2 is unevenly distributed, for example, the colored transparent film 2 (I) is not provided on the convex portion 12 (convex flat portion 12'), but 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 is 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) Discontinuously (sporadically) provided over the whole including the concave portion 11 (concave flat portion 11') and the convex portion 12 (convex flat portion 12'), and being a thick film at the concave edge portion 13. etc. can be mentioned.

[0043] In the present invention, as in the above (I) to (IV), the colored transparent film 2 is unevenly distributed so as to border the concave edge portion 13 of the colored layer 1. Thereby, the scratch resistance can be enhanced, and the sense of depth (depth) is emphasized more than the actual dent, enhancing the three-dimensional effect. Note that the colored transparent film 2 may be provided at all the concave edge portions 13 or may be provided at a part thereof when the colored layer 1 has a plurality of concave portions.

[0044] (Transparent film) The facing material of the present invention can also be provided with a transparent film 3 on the outermost surface. The transparent film 3 is formed of a transparent coating material. The transparent coating material of the present invention is not particularly limited as long as it contains a resin component. As the medium of the transparent coating material, either a solvent-based or an aqueous-based one may be used, but in the present invention, it is preferable that the medium contains water. Thereby, the scratch resistance can be further enhanced.

[0045] Furthermore, in the present invention, it is preferable that the transparent film 3 contains a silicone resin and a synthetic resin other than the silicone resin as resin components. The solid content weight ratio of the above silicone resin and the synthetic resin other than the above silicone resin is preferably 5:95 to 95:5 (more preferably 10:90 to 80:20, still more preferably 15:85 to 60:40). In such a case, the scratch resistance can be enhanced. Furthermore, without using a powder component such as a known matting agent, a stable matting effect can be obtained, and the formed transparent film is less likely to cause gloss unevenness (mat unevenness) regardless of its film thickness and can form a uniform mat surface. Therefore, a facing material with high aesthetic appearance and a stable appearance without gloss unevenness can be obtained without impairing the design properties such as the color tone of the colored layer and the colored transparent film.

[0046] In the present invention, as the resin component of the transparent coating material, it is preferably of the same type or identical to the resin component of the colored transparent coating material. Thereby, the above-described effects can be further enhanced.

[0047] The solid content of the transparent coating material is preferably 2 to 50% by weight (more preferably 5 to 30% by weight). Further, 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). In such a case, the effects of the present invention can be enhanced.

[0048] Also, 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, is preferably 1 to 200 g / m 2 (more preferably 1.5 to 100 g / m 2 , even more preferably 2 to 80 g / m 2 ). In such a case, sufficient scratch resistance can be obtained.

[0049] The transparent coating material may form a colorless and transparent film, or may contain some coloring components (coloring pigments, dyes, dispersions thereof, etc.) 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, bright pigments, phosphorescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, etc.

[0050] The transparent film 3 of the present invention is provided on the surface having the colored layer 1 and the colored transparent film 2, and may be provided over the entire surface or discontinuously (dispersed). Further, in the present invention, it is preferable that the transparent film 3 is provided at least at the edge of the recess (particularly near the corner) (more preferably, the entire part including the edge of the recess) of the face material A, whereby the strength of the edge of the recess can be further increased, defects such as scratches and gouges can be suppressed, and excellent scratch resistance can be exhibited.

[0051] (Reinforcing material) The face material of the present invention may have a reinforcing material. Such a reinforcing material can be provided inside and / or on the back surface of the 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, etc. The reinforcing material may be composed of two or more of the above materials. By using such a reinforcing material, the strength of the face material can be increased.

[0052] (Manufacturing method) The manufacturing method of the face 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 face material, a desired concavo-convex pattern can be imparted to the face material surface by adjusting the shape of the inner surface of the mold.

[0053] 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, and a colored transparent coating material is applied to the surface of the colored layer and dried and cured. · A method in which a colored 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. etc., the face material can be manufactured.

[0054] In the application and filling of the composition for the coloring layer and the colored transparent coating material, known instruments such as sprayers, rollers, trowels, brushes, reciprocators, coaters, etc. can be used. When introducing a reinforcing material, for example, before the composition for the coloring layer cures, the reinforcing material can be embedded inside the coloring layer or laminated on the back surface of the coloring layer.

[0055] Specifically, the facing materials shown in FIGS. 1 to 3 are preferably manufactured by, for example, the following method. (1) Manufacture the composition for the coloring layer and the colored transparent coating material. (1-1) The composition for the coloring layer is manufactured by mixing and stirring granular inorganic particles, a resin, and, if necessary, additives by a conventional method. (1-2) The colored transparent coating material is manufactured by mixing and stirring a resin component and a coloring component by a conventional method. (2) Prepare a mold having desired concave and convex portions (forming the concave portions of the coloring layer) on the inner surface (a mold with a desired concavo-convex pattern transferred), and apply, dry, and cure the colored transparent coating material on the inner surface of the mold. (3) Next, fill the mold with the composition for the coloring layer, and demold after curing.

[0056] 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 coloring layer. Further, it has a colored transparent film on the surface of the coloring layer, and the colored transparent film is unevenly distributed at the edge of the concave portion, and can exhibit an aesthetic property having contrast, three-dimensional feeling (depth feeling), etc.

[0057] In particular, in the above (2), when a colored transparent coating material is applied to a mold having concave and convex portions, the above-mentioned colored transparent coating material tends to be unevenly distributed at the foot of the convex portion. In particular, when the above-mentioned colored 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 roundness (for example, mountain-like, parabolic, curved), the colored transparent coating material can be more unevenly distributed at the foot of the convex portion. The mechanism by which the colored transparent coating material is unevenly distributed at the foot of the convex portion on the inner surface of the mold is not limited to the following, but it is considered that it is likely to be unevenly distributed near the boundary between the flat portion and the convex portion due to the action of the surface tension of the colored transparent coating material, the influence of viscosity, etc. Therefore, in the present invention, as the colored transparent coating material, it is preferable to contain water having a large surface tension as a medium, and further to set the viscosity low as described above.

[0058] Also, in the above (2), it is preferable to cure the colored transparent coating material after application. During the drying and curing process, the colored transparent coating material is more likely to be unevenly distributed by the foot of the convex portion on the inner surface of the mold. Note that the curing in the above (2) may be finger-touch dry or more (preferably semi-cured, more preferably cured and dried).

[0059] In the above (3), after the colored transparent coating material is cured, by filling the composition for the colored layer, a facing material having a desired appearance can be stably manufactured. Note that when the composition for the colored layer is filled in a state where the colored transparent coating material is cured rather than in an uncured state, the effects of the present invention can be sufficiently exhibited.

[0060] In the present invention, after the above (1) to (3), for example, as a step (4), a transparent coating material can be further applied and dried to provide a transparent film on the surface of the facing material after demolding (preferably the whole surface). Thereby, since a transparent film can be further unevenly distributed (laminated) on the edge of the concave portion where the colored transparent film of the facing material manufactured in the above (1) to (3) is unevenly distributed, the scratch resistance can be further enhanced and the three-dimensional effect can be enhanced.

[0061] In the present invention, in the above (4), 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 formed by fixing inorganic particles 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, etc., the above effects can be obtained. Although this mechanism of action is not limited to the following, when the transparent coating material is applied to the coloring layer of the present invention, the transparent coating material penetrates the surface of the coloring layer and forms a film, 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.

[0062] 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, it is preferable that the difference in glossiness between 60 degrees and 85 degrees is 2 or less (more preferably 1.5 or less, still more preferably 1 or less). By thus satisfying the above range of glossiness at 60 degrees and 85 degrees, unevenness in gloss due to the viewing angle (direction) is suppressed, and the sense of calmness and aesthetic appearance can be further enhanced. Note that 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 is the average value obtained by measuring 10 arbitrary locations on the surface of the facing material A.

[0063] 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, nails, screws, bolts, rails, etc. may be used. Examples of the base material constituting the building wall and 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 be those having a film (existing film, undercoat film, etc.) already formed on their surfaces, or those with wallpaper pasted thereon.

Examples

[0064] Examples and comparative examples are shown below to clarify the features of the present invention.

[0065] (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 white silica sand: yellow silica sand: brown silica sand (weight ratio) = 80:10:10), particle size 0.03 - 0.6 mm, light transmittance less than 1%] · Granular transparent inorganic particles [anhydrite; particle size 0.1 - 0.4 mm, light transmittance 16%] · Resin component [acrylic resin emulsion, solid content 50% by weight, medium; water] · Additives [defoaming agent, film-forming aid, water, etc.]

[0066]

Table 1

[0067] (Manufacture of Colored Transparent Coating Materials 1 - 10 and Transparent Coating Materials 1 - 10) The raw materials were uniformly mixed by a conventional method at the mixing ratios shown in Table 2 and Table 3 to produce colored transparent coating materials and transparent coating materials. The raw materials used are as follows. · Acrylic resin emulsion [solid content 50% by weight, glass transition temperature 40°C, medium; water] · Silicone resin emulsion [Polyoxyethylene alkyl ether emulsion of dimethylpolysiloxane), solid content 50 wt%, medium; water] · Pigment dispersion 1 [Mixture of acrylic resin emulsion and pigments (ochre pigment: red safflower pigment: black pigment (weight ratio) = 25:55:20), solid content 50 wt%, resin solid content 40 wt%, pigment solid content 10 wt%, medium; water] · Additives: Defoamer, film-forming aid, etc.

[0068]

Table 2

[0069]

Table 3

[0070] <Manufacture of facing material (I)> As a mold, a rectangular mold (30 cm × 60 cm) capable of forming 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) on the flat portion was used. On the above mold, a colored transparent coating material was applied (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, on the above colored transparent film, a composition for the colored layer was applied (weight per unit area 3.3 kg / m 2 ), and after curing (at 65°C for 24 hours), it was demolded to produce the facing material (I). The colored transparent coating material and the colored layer composition were used in the combinations shown in Table 4 (Examples 1 to 12). <Manufacture of facing material (I’)> On the same mold as above, Composition 1 for the colored layer was applied (weight per unit area 3.3 kg / m 2 ), and after curing (at 65°C for 24 hours), it was demolded to produce the facing material (I’) (Comparative Example 1).

[0071] (Examples 1 to 12, Comparative Example 1) For each facing material (I)(I’) manufactured by the above method, the following tests were conducted. The results are shown in Table 4. (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 A, and those with defects were rated D on a four-point scale (A > B > C > D). (Three-dimensional effect) The obtained facing material was visually observed, and those with a three-dimensional effect were rated A, and those with a flat finish were rated D on a four-point scale (A > B > C > D).

[0072]

Table 4

[0073] In Examples 1 to 12, the facing materials were good in terms of scratch resistance evaluation and three-dimensional effect. On the other hand, in Comparative Example 1, defects were observed around the edges of the concave portions, and the facing material was also inferior in terms of three-dimensional effect.

[0074] <Manufacture of facing material (II)> A colored transparent coating material was applied to the same mold as above (weight per unit area: 100 g / m 2 ), and after unevenly distributing it 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 the colored layer was applied on the above colored 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 transparent coating material was applied to the entire surface (the surface having a flat portion and a concave portion) having the colored transparent film (weight per unit area: 140 g / m 2 ), and a facing material (II) provided with a transparent film layer was manufactured. The colored transparent coating material, the transparent coating material, and the colored layer composition were used in the combinations shown in Table 5 (Examples 13 to 20). <Manufacture of facing material (II’)> A composition 1 for the colored layer was applied to the same mold as above (weight per unit area: 3.3 kg / m 2) Then, after curing (at 65°C for 24 hours), it was demolded. Next, the transparent coating material 6 was applied (weight per unit area: 140 g / m 2 ), and a facing material (II’) provided with a transparent film layer was manufactured (Comparative Example 2).

[0075] (Examples 13 to 20, Comparative Example 2) Regarding each of the facing materials (II) and (II’) manufactured by the above method, in addition to the above scratch resistance and three-dimensional effect, the following tests were conducted. The results are shown in Table 5. (Gloss) In accordance with JIS K5600-4-7 “Specular gloss,” ten arbitrary 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 ten measured locations, the difference (absolute value) between the minimum value and the maximum value of the 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).

[0076]

Table 5

[0077] All of the facing materials obtained in Examples 13 to 20 were facing materials with suppressed gloss, a sense of calmness, and a three-dimensional effect. In Comparative Example 2, the facing material had slightly uneven gloss and was inferior in three-dimensional effect.

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 colored transparent coating on the surface of the colored layer, The colored layer has a recess on its surface, the colored 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 colored transparent film is formed from a colored transparent coating material, The method includes a step of applying the colored transparent coating material to the inner surface of a mold, drying and curing the material, filling the colored layer composition, and removing the material 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 colored transparent coating material contains a silicone resin and a synthetic resin other than the silicone resin.

3. 3. The method for manufacturing a surface material according to claim 1, wherein the edge of the recess and the remaining portion have different color tones when viewed from the front.

4. A method for manufacturing a surface material described in any one of claims 1 to 3, characterized in that a transparent coating material is further applied to the surface of the surface material after demolding and dried to form a transparent film on the outermost surface.

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