Covering materials

Abstract

To provide a surface material having good noncombustibility and scratch resistance and a manufacturing method thereof.SOLUTION: Disclosed is a surface material 1 to be applied to a surface of an underlying material, wherein the surface material 1 is a sheet material 2 including a synthetic resin, an aggregate, and an endothermic substance as the main elements, with the rate of the synthetic resin being 6-12 wt.% and the aggregate and the endothermic substance being 80-90 wt.%, and is assembled with a hardened material layer 4 of a coating composition laminated on one surface side of the sheet material 2 and including a condensation hardening type silicone composition. The coating composition includes a silane coupling agent bearing an amino group, or, a thickness of the sheet material is in a range of 1.3-2.2 mm, or the endothermic substance may include at least one of metal hydroxide. Moreover, a coating sheet layer including an organic resin laminated on a side opposite to the sheet material of the hardened material layer may further be provided, or, a mass per unit area of the whole layer of the hardened material layer and the coating sheet layer may be in a range of 3.0 g / m2 or over and 20.0 g / m2 or under.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This invention provides a surface covering with good fire resistance and scratch resistance. Material To relate to. [Background technology]

[0002] Conventionally, the technology described in Patent Document 1 has been proposed as a finishing method for joining sheet-like covering materials to walls and the like (see paragraph

[0005] and Figures 3 and 4 of Patent Document 1). Furthermore, the technology described in Patent Document 2 has been proposed as a flame-retardant covering material, as well as a usable base material and aggregate (see paragraphs

[0004] and

[0005] of Patent Document 2). [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Patent No. 3140680 [Patent Document 2] Patent No. 2542992 [Overview of the project] [Problems that the invention aims to solve]

[0004] However, the conventional technologies described above were insufficient in terms of fire resistance. One aspect of the present invention aims to provide a covering material that has better non-flammability and scratch resistance compared to conventional flame-retardant covering materials. In other words, one aspect of the present invention aims to provide a surface covering material that is both non-flammable and scratch-resistant by increasing the ratio of aggregate and heat-absorbing substances compared to existing surface covering materials, while forming a hardened layer of a specific material. Furthermore, one aspect of the present invention aims to provide a surface covering material with good adhesion by specifying a coating composition. One aspect of the present invention aims to achieve both non-combustibility and ease of installation by specifying the thickness of the sheet material. One aspect of the present invention aims to provide a sheet material with reliable non-flammability by selecting an endothermic substance. One aspect of the present invention aims to improve the productivity of sheet materials by processing them by extrusion molding. One aspect of the present invention aims to impart a natural three-dimensional feel and texture to a sheet material by processing it with spray painting. [Means for solving the problem]

[0005] A surface covering material according to one aspect of the present invention is a surface covering material for application to the surface of a substrate material in order to achieve the above objective, wherein the surface covering material is a sheet material mainly composed of synthetic resins, aggregates, and a heat-absorbing substance, with synthetic resins making up 6 to 12% by weight and aggregates and the heat-absorbing substance making up 80 to 90% by weight, and is characterized by comprising a cured layer of a coating composition containing a condensation-curing type silicone composition laminated on one side of the sheet material. A surface covering material according to one aspect of the present invention is characterized in that the coating composition contains a silane coupling agent containing an amino group. A covering material according to one aspect of the present invention is characterized in that the thickness of the sheet material is in the range of 1.3 to 2.2 mm. A covering material according to one aspect of the present invention is characterized in that the endothermic substance contains at least one metal hydroxide. A method for manufacturing a covering material according to one aspect of the present invention is characterized by processing a sheet material by extrusion molding. A method for manufacturing a covering material according to one aspect of the present invention is characterized by processing a sheet material by spray painting. [Effects of the Invention]

[0006] According to one aspect of the present invention, a surface covering material with good fire resistance and scratch resistance can be provided. In other words, according to one aspect of the present invention, by increasing the ratio of aggregate and heat-absorbing substance compared to existing covering materials, and by forming a hardened layer of a specific material, it is possible to provide a covering material that is both non-flammable and scratch-resistant. Also, according to one aspect of the present invention, by specifying the coating composition, it is possible to provide a facing material with good adhesion. According to one aspect of the present invention, by defining the thickness of the sheet material, it is possible to achieve both nonflammability and easy workability. According to one aspect of the present invention, by selecting a heat-absorbing substance, reliable nonflammability can be imparted to the sheet material. According to one aspect of the present invention, by processing the sheet material by extrusion molding, the productivity of the sheet material can be improved. According to one aspect of the present invention, by processing the sheet material by spray coating, a natural three-dimensional effect and texture can be imparted to the sheet material.

Brief Description of the Drawings

[0007] [Figure 1] It is a cross-sectional view of the facing material according to the first embodiment of the present invention. [Figure 2] It is a cross-sectional view of the facing material according to the second embodiment of the present invention. [Figure 3] It is a cross-sectional view of the facing material according to the third embodiment of the present invention.

Modes for Carrying Out the Invention

[0008] (Facing Material 1 According to the First Embodiment) The facing material according to the first embodiment will be described with reference to FIG. 1. In FIG. 1, "1" is the facing material. The facing material 1 is composed of three layers: a sheet material 2, a base fabric 3 located on the back side of the sheet material 2, and a cured product layer 4 located on the front side of the sheet material 2. Note that the ratio of the thicknesses of the three layers of the facing material 1 is not limited to FIG. 1.

[0009] (Sheet Material 2) The sheet material 2 mainly consists of synthetic resins, aggregates, and heat-absorbing substances. In addition to synthetic resins, aggregates, and heat-absorbing substances, the sheet material 2 may contain, for example, wetting agents, dispersants, thickeners, light stabilizers, and cross-linking agents. As sheet material 2, for example, a sheet can be used which is formed from aggregates and fillers selected from natural stone or its crushed stone, colored aggregates, cold water sand, and ceramic granules, in addition to an "endothermic substance" such as aluminum hydroxide used as aggregate or filler, with a synthetic resin component as a binder.

[0010] (Synthetic resins) Examples of synthetic resins include polyolefin resins such as polyethylene, polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, ethylene-α-olefin copolymer, and propylene-α-olefin copolymer; olefin copolymer resins such as ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ethylene-(meth)acrylic acid (ester) copolymer, and ethylene-unsaturated carboxylic acid copolymer metal neutralized products (ionomers); polyethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, polyethylene naphthalate, polyethylene terephthalate-isophthalate copolymer, 1,4-cyclohexanedimethanol copolymer polyethylene terephthalate, and polyaryl esters. Polyester resins such as polycarbonate, acrylic resins such as poly(meth)acrylonitrile, polymethyl(meth)acrylate, polyethyl(meth)acrylate, polybutyl(meth)acrylate, and polyacrylamide, polyamide resins such as 6-nylon, 6,6-nylon, and 6,10-nylon, styrene resins such as polystyrene, AS resin, and ABS resin, vinyl resins such as polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetal, and polyvinyl butyral, fluorine resins such as polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, and ethylene-perfluoroalkyl vinyl ether copolymer, or mixtures, copolymers, composites, and laminates of two or more of these can be used.

[0011] (aggregate) As explained earlier, the aggregate used will be selected from, for example, natural stone or its crushed form, colored aggregate, crushed sand, or ceramic granules. In the first embodiment, colored fine aggregate was used as the aggregate, but the invention is not limited to this.

[0012] (endothermic substance) The endothermic substance only needs to contain at least one metal hydroxide. Endothermic substances include, for example, aluminum fluoride, aluminum hydroxide, dicalcium phosphate, calcium oxalate, cobalt hydroxide, borax, magnesium hydroxide, sodium bicarbonate, and cobalt ammonia chloride complex, and are substances that absorb heat when they decompose. Aluminum hydroxide also exists as a natural mineral, such as boehmite, gibbsite, and diasbore. In the first embodiment, aluminum hydroxide was used as the endothermic substance, but the invention is not limited to this. Considering the texture, processability, handling properties, and non-flammability of the sheet substrate 2, it is desirable that the ratio of the synthetic resin component as a binder to the aggregate, filler, and heat-absorbing substance components be approximately 6-12% by weight for the former and 80-90% by weight for the latter. In particular, the amount of heat-absorbing substance must be sufficient to achieve non-flammability as a sheet material. There are no particular restrictions on the thickness of sheet material 2. However, considering the processability and non-combustibility of the sheet, it is preferable that the thickness of sheet material 2 be approximately 1.3 mm to 2.2 mm, and more preferably 1.5 mm to 2.0 mm.

[0013] (Base fabric 3) The base fabric 3 consists of a woven or nonwoven fabric. There are no particular restrictions on the material of the base fabric 3, but considering the non-flammability of the sheet, it is preferable to use heat-resistant fibers such as glass fibers or silica fibers. In the first embodiment, a glass nonwoven fabric was used as the base fabric 3, but the embodiment is not limited to this.

[0014] (cured material layer 4) The cured layer 4 is a coating composition containing a "condensation-curing type silicone composition". A "condensation-curing silicone composition" refers to a composition having hydrolyzable silyl or silanol groups, in which these groups hydrolyze and condense with moisture under a catalyst or heating environment to form a silicone skeleton. Specifically, examples include "silicone oligomers" that can form a cured film by reacting with moisture in the air in the presence of a catalyst, and silicone resins that have silanol groups and can be cured by heat curing. Silicone oligomers that can be cured at room temperature are particularly preferred. In addition, as a "condensation-curing type silicone composition," a "silane coupling agent" that exhibits good adhesion to the surface of an inorganic substrate can also be used.

[0015] Here, "silicone oligomers" refer to silicone oligomers having methyl groups: KC-89S, KR-515, KR-500, X-40-9225, X-40-9246, X-40-9250 (all manufactured by Shin-Etsu Chemical Co., Ltd.); silicone oligomers having both methyl and phenyl groups: KR-401N, X-40-9227, KR-510, KR-9218, KR-213 (all manufactured by Shin-Etsu Chemical Co., Ltd.); and silicone oligomers having epoxy groups: KR-517, X-41-1059A, X Examples include -24-9590 and KR-516 (both manufactured by Shin-Etsu Chemical Co., Ltd.); X-41-1805, X-41-1810, and X-41-1818 (all manufactured by Shin-Etsu Chemical Co., Ltd.), which are silicone oligomers having mercapto groups; KR-513 (manufactured by Shin-Etsu Chemical Co., Ltd.), which is a silicone oligomer having acrylic groups; X-40-9296 (manufactured by Shin-Etsu Chemical Co., Ltd.), which is a silicone oligomer having methacrylic groups; and KR-511 (manufactured by Shin-Etsu Chemical Co., Ltd.), which is a silicone oligomer having vinyl groups.

[0016] In the first embodiment, KR-401N (a silicone oligomer having methyl and phenyl groups, with a methoxy group content of 33% by mass, manufactured by Shin-Etsu Chemical Co., Ltd.) was used as the silicone oligomer, but the embodiment is not limited to this. Examples of "curing catalysts" for curing silicone oligomers include compounds such as aluminum, titanium, zirconium, and tin. Specifically, these include diisopropoxy(ethyl acetate)aluminum, isopropoxybis(ethyl acetate)aluminum, tris(ethyl acetate)aluminum, diisopropoxybis(acetylacetonate)titanium, diisopropoxybis(ethyl acetate)titanium, tetrakis(2-butoxyethyl alcohol)titanium, dibutoxybis(ethyl acetate)zirconium, tetrakis(2-butoxyethyl alcohol)zirconium, dibutyltin dilaurate, and dibutyltinbis(octyloxycarbonylmethylthiolate). Commercially available products of these include D-20, D-25, and DX-9740 (all manufactured by Shin-Etsu Chemical Co., Ltd.).

[0017] In the first embodiment, D-25 (manufactured by Shin-Etsu Chemical Co., Ltd.) was used as the curing catalyst, but the embodiment is not limited to this. Here, known silane coupling agents are preferably used, with examples including (meth)acrylicsilane coupling agents, epoxysilane coupling agents, aminosilane coupling agents, and mercaptosilane coupling agents. Among these, silane coupling agents containing an amino group can be preferably used. Specifically, examples include N-2-(aminoethyl)-3-aminopropylmethyldimethoxysilane, N-2-(aminoethyl)3-aminopropyltrimethoxysilane, N-2-(aminoethyl)-3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N-(1,3-dimethylbutylidene)propylamine, N-phenyl-3-aminopropyltrimethoxysilane, and N,N-bis[3-(trimethoxysilyl)propyl]ethylenediamine, but 3-aminopropyltrimethoxysilane and 3-aminopropyltriethoxysilane are particularly preferred. Furthermore, other alkoxylanes, such as tetramethoxysilane and tetraethoxysilane, may be added as appropriate to these silane coupling agents containing amino groups. Preferably, the "silane coupling agent" is 3-aminopropyltriethoxysilane alone at a concentration of 5 g / m². 2 To form to a certain extent.

[0018] (Nonflammable) Regarding non-combustibility, the technical standards for non-combustible materials stipulated in the Building Standards Act Enforcement Order require that the following requirements be met in a heat generation test using a cone calorimeter testing machine compliant with ISO 5660-1 (Article 108-2, paragraphs 1 and 2 of the Building Standards Act Enforcement Order). For the surface material 1 of this first embodiment to be certified as a non-combustible material, it must meet the following requirements: 50 kW / m 2 The following requirements 1-3 must all be met during a 20-minute heating period using radiant heat. 1. Total heat output is 8 MJ / m³ 2 below 2. The maximum heat generation rate remains at 200 kW / m² for 10 seconds or more. 2 Do not exceed 3. No cracks or holes that penetrate to the back surface, which would be harmful from a fire-retardant standpoint, will occur. According to the covering material 1 of the first embodiment, by forming the sheet material 2 with the above-described composition, it is possible to obtain certification as a non-combustible material.

[0019] (Manufacturing method for cover material 1) As a method for manufacturing the covering material 1, a glass nonwoven fabric is used as the base fabric 3, and a sheet material 2 containing 10% by weight of a synthetic resin component as a binder, 10% by weight of colored fine aggregate, and 80% by weight of aluminum hydroxide is formed on this glass nonwoven fabric by extrusion molding. On one side of this sheet material 2, apply the following coating composition: Dry 5.0 g / m 2 The mixture is applied and left to cure for one day under conditions of 23°C and 55% RH to form a hardened layer 4. Note • Silicone oligomer: KR-401N (silicone oligomer having methyl and phenyl groups, methoxy group content 33% by mass, manufactured by Shin-Etsu Chemical Co., Ltd.) 98 parts by mass • Curing catalyst: D-25 (manufactured by Shin-Etsu Chemical Co., Ltd.) 2 parts by mass

[0020] According to the covering material 1 of the first embodiment, the productivity of the sheet material can be improved by processing the sheet material by extrusion molding. Although the manufacturing method of the covering material 1 is exemplified by the extrusion molding of the sheet material 2, it is not limited to this method, and it may also be processed by spray painting or die molding. When sheet materials are processed by spray painting, a natural three-dimensional effect and texture can be imparted to the sheet material. When sheet materials are processed by embossing, various surface shapes, including three-dimensional shapes, can be imparted to the sheet material.

[0021] (Covering material 1 according to the second embodiment) The covering material according to the second embodiment will be explained using Figure 2. A coating layer 5 containing another organic resin is formed on the surface of the cured material layer 4. Note that the thickness ratio of the four layers, including the coating layer 5, is not limited to that shown in Figure 2. The coating layer 5 is intended to improve the surface properties of the sheet material 2. The total mass per unit area of ​​the entire layer, including the coating layer 5 and the cured material layer 4, is 3.0 g / m². 2 More than 20.0g / m 2 It is within the following range. For the coating layer 5, any known material containing an organic resin can be used, provided that it can provide surface protection. The coating layer 5 can be appropriately selected from, for example, polyurethane-based, acrylic-based, acrylic-silicone-based, polyester-based materials, etc. The coating layer 5 can also be in the form of aqueous, emulsion, or solvent-based. It is also possible to use a two-component type coating layer 5 that is crosslinked by adding isocyanate. If you want to further improve the surface hardness of the decorative sheet, you can also use resins that harden with ultraviolet light or electron beam irradiation. Furthermore, UV absorbers and light stabilizers may be added as appropriate to improve weather resistance. In addition, alumina, silica, silicon nitride, silicon carbide, glass beads, etc. may be added as desired to improve surface appearance, adjust gloss, or provide wear resistance. Flame retardants, anti-blocking agents, antistatic agents, etc. may also be added as appropriate.

[0022] (Covering material 1 according to the third embodiment) The covering material according to the third embodiment will be explained using Figure 3. A pattern layer 6 is formed on the surface of the sheet material 2 between it and the cured material layer 4. Additionally, a primer layer may be provided between the sheet material 2 and the pattern layer 6, although this is not shown in the diagram, to improve ink adhesion. Note that the thickness ratio of the five layers, including the pattern layer 6, is not limited to Figure 3. Here, the pattern layer 6 can be created by various known printing methods such as gravure printing, offset printing, screen printing, and inkjet printing, depending on the type and surface shape of the sheet material to be printed on. In particular, if the surface of the sheet material has an uneven shape, it is desirable to use the inkjet printing method, which is a non-contact printing method.

[0023] The ink used can be any conventionally known material. In particular, when using inkjet printing, various conventionally known inks such as water-based, solvent-based, and UV-based inks can be used and can be appropriately selected depending on the type of sheet material to be printed on. The ink components include pigments or dyes as colorants, and conventionally known pigments and dyes can be used according to the color of the ink to be used. For example, some inorganic pigments that can be suitably used as pigments include titanium dioxide, zinc oxide, zinc sulfide, lead white, calcium carbonate, precipitated barium sulfate, white carbon, alumina white, kaolin gray, talc, bentonite, black iron oxide, cadmium red, red iron oxide, molybdenum red, molybdate orange, chromium vermilion, lead yellow, cadmium yellow, yellow iron oxide, titanium yellow, chromium oxide, viridian, titanium cobalt green, cobalt green, cobalt chromium green, Victoria green, ultramarine, dark blue, cobalt blue, cerulean blue, cobalt silica blue, cobalt zinc silica blue, manganese violet, and cobalt violet.

[0024] Examples of organic pigments include azo pigments, phthalocyanine pigments, anthraquinone pigments, quinacridone pigments, isoindolinone pigments, quinophthalone pigments, dye lake pigments, and fluorescent pigments. Examples of black pigments include carbon black produced by the furnace process and the channel process. In addition to carbon black, other black pigments that can be used in this third embodiment include, for example, aniline black, lumogen black, and azomethine azoblack. Furthermore, a black pigment can also be created by using multiple chromatic pigments such as cyan, magenta, yellow, brown, and orange pigments.

[0025] There are no particular limitations on the dyes that can be used in the third embodiment, and examples include oil-based dyes, disperse dyes, direct dyes, acid dyes, and basic dyes. Preferred hues include yellow, magenta, cyan, black, blue, green, and red, with yellow, magenta, cyan, and black dyes being particularly preferred. Among the oil-soluble dyes, some are oil-soluble dyes obtained by salting water-soluble dyes with long-chain bases. Disperse dyes such as CI Disperse Yellow, CI Disperse Red, and CI Disperse Blue can also be used. In particular, if long-term weather resistance is desired, it is desirable to use an ink containing inorganic pigments for formation.

[0026] (Method of manufacturing the pattern layer 6) A sheet material 2 is formed in the same manner as the first embodiment described with reference to Figure 1, and a pattern layer 6 is formed on one side of this sheet material 2. The pattern layer 6 is formed by printing a granite-like design using an inkjet printing method with a cationic curable UV inkjet ink. Only inorganic pigments were used as colorants in the cationic curable UV inkjet ink. The printed substrate sheet was stored at room temperature for more than 24 hours to allow the reaction to proceed. On top of this pattern layer 6, apply the following coating composition at a rate of 5.0 g / m². 2 The mixture was applied and left to cure for one day under conditions of 23°C and 55% RH to form a cured layer 4. Note • Silicone oligomer: KR-401N (silicone oligomer having methyl and phenyl groups, methoxy group content 33% by mass, manufactured by Shin-Etsu Chemical Co., Ltd.) 96 parts by mass · Hardening catalyst: 2 parts by mass of D-25 (manufactured by Shin-Etsu Chemical Co., Ltd.) · Aminosilane: 2 parts by mass of 3-aminopropyltriethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) According to the third embodiment, by forming the pattern layer 6 by the inkjet printing method, various patterns can be expressed regardless of the surface shape of the sheet material 2.

[0027] (Other characteristic points of the present invention) In the present invention, in addition to the characteristic points described in the claims, it has the following characteristic points and effects. As a first characteristic point, it is a facing material, further comprising a coating layer containing an organic resin laminated on the surface of the cured product layer opposite to the sheet material. As a second characteristic point, it is a facing material, and the mass per unit area of the entire layer including the cured product layer and the coating layer is 3.0 g / m 2 or more and 20.0 g / m 2 within the following range. As a third characteristic point, it is a facing material, and a base fabric made of a woven fabric or a non-woven fabric is laminated on the other surface side of the sheet material.

[0028] As a fourth characteristic point, it is a facing material, and the base fabric is made of glass fiber. As a fifth characteristic point, it is a facing material, and the facing material is a non-combustible material that satisfies the requirements described in Article 108-2, No. 1 and No. 2 of the Building Standards Law Construction Order in the heat generation test by a cone calorimeter tester conforming to ISO5660-1. As a sixth characteristic point, it is a facing material, and a pattern layer is laminated on the surface of the sheet material opposite to the base fabric. As a seventh characteristic point, it is a method for manufacturing a facing material, characterized by processing a sheet material by mold pressing. As an eighth characteristic point, it is a method for manufacturing a facing material, characterized by forming a pattern layer by the inkjet printing method.

[0029] (Effects due to other features of the present invention) According to the first characteristic, by further providing a coating layer on the surface, it is possible to provide a surface covering material with various surface properties. According to the second characteristic, by defining the mass of the hardened material layer and coating layer laminated on the surface, it is possible to provide the sheet material with reliable non-flammability while possessing various surface properties. According to the third characteristic, the productivity of sheet material can be improved by constructing a base fabric. According to the fourth characteristic, by selecting the material of the base fabric, more reliable non-combustibility can be achieved.

[0030] According to the fifth characteristic, by satisfying the standards for non-combustibility testing, it becomes possible to use it as a non-combustible material. According to the sixth characteristic, by adding a patterned layer, it is possible to improve the design, such as by representing valuable stone materials. According to the seventh characteristic, by processing the sheet material through embossing, various surface shapes, including three-dimensional shapes, can be imparted to the sheet material. According to the eighth characteristic feature, by forming the pattern layer using an inkjet printing method, it becomes possible to express various patterns regardless of the surface shape of the sheet material. [Examples]

[0031] Referring to the first to third embodiments, the covering materials of Examples 1 to 6 and Comparative Examples 1 to 5 will be described below. (Example 1) In Example 1, a glass nonwoven fabric was used as the base fabric, and a sheet material containing 10% by weight of a synthetic resin component as a binder, 10% by weight of colored fine aggregate, and 80% by weight of aluminum hydroxide was formed on this glass nonwoven fabric by extrusion molding. The sheet thickness was 2 mm. In addition, the following coating composition was applied to one side of this sheet material at a dry rate of 5.0 g / m². 2 The material was applied and left to cure for one day under conditions of 23°C and 55% RH to form a hardened layer. Note • Silicone oligomer: KR-401N (silicone oligomer having methyl and phenyl groups, methoxy group content 33% by mass, manufactured by Shin-Etsu Chemical Co., Ltd.) 98 parts by mass • Curing catalyst: D-25 (manufactured by Shin-Etsu Chemical Co., Ltd.) 2 parts by mass

[0032] (Example 2) In Example 2, a sheet material was formed in the same manner as in Example 1, and the following coating composition was applied to one side of the sheet material at a dry rate of 5.0 g / m². 2 The material was applied and left to cure for one day under conditions of 23°C and 55% RH to form a hardened layer. Note • Silicone oligomer: KR-401N (silicone oligomer having methyl and phenyl groups, methoxy group content 33% by mass, manufactured by Shin-Etsu Chemical Co., Ltd.) 96 parts by mass • Curing catalyst: D-25 (manufactured by Shin-Etsu Chemical Co., Ltd.) 2 parts by mass • Aminosilane: 3-Aminopropyltriethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) 2 parts by mass

[0033] (Example 3) In Example 3, a sheet material was formed in the same manner as in Example 1, and the following coating composition was applied to one side of the sheet material at a dry rate of 5.0 g / m². 2 The material was applied, dried at 120°C, and then left to cure for one day under conditions of 23°C and 55% RH to form a hardened layer. Note • Aminosilane: 100 parts by mass of a diluted aqueous solution of 3-aminopropyltriethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) (containing dilute hydrochloric acid)

[0034] (Example 4) In Example 4, a sheet material was formed in the same manner as in Example 1, and the following coating composition was applied to one side of the sheet material at a dry rate of 5.0 g / m². 2 The material was applied, dried at 120°C, and then left to cure for one day under conditions of 23°C and 55% RH to form a hardened layer. Note • Aminosilane: 100 parts by mass of a diluted aqueous solution of 3-aminopropyltriethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) (containing dilute hydrochloric acid) Furthermore, a coating layer is applied on top of this cured layer using an acrylic resin material at a density of 10.2 g / m². 2 It was formed in [location / method].

[0035] (Example 5) In Example 5, a sheet material was formed in the same manner as in Example 1, and a pattern layer was formed on one side of this sheet material. The pattern layer was formed by printing a granite-like design using an inkjet printing method with a cationic curable UV inkjet ink. Only inorganic pigments were used as colorants in the cationic curable UV inkjet ink. The printed substrate sheet was stored at room temperature for 24 hours or more to allow the reaction to proceed. On top of this pattern layer, apply the following coating composition at a rate of 5.0 g / m². 2 The material was applied and left to cure for one day under conditions of 23°C and 55% RH to form a hardened layer. Note • Silicone oligomer: KR-401N (silicone oligomer having methyl and phenyl groups, methoxy group content 33% by mass, manufactured by Shin-Etsu Chemical Co., Ltd.) 96 parts by mass • Curing catalyst: D-25 (manufactured by Shin-Etsu Chemical Co., Ltd.) 2 parts by mass • Aminosilane: 3-Aminopropyltriethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) 2 parts by mass

[0036] (Example 6) In Example 6, a glass nonwoven fabric was used as the base fabric, and a sheet material containing 10% by weight of a synthetic resin component as a binder, 10% by weight of colored fine aggregate, and 80% by weight of aluminum hydroxide was formed on this glass nonwoven fabric by embossing. The sheet thickness was 1.5 mm in the thinnest part and 2.0 mm in the thickest part. The surface of the obtained sheet material had a three-dimensional representation of cedar wood grain, creating a design that resembled actual wood. A cured layer was formed on one side of this sheet material in the same manner as in Example 1.

[0037] (Comparative Example 1) In Comparative Example 1, a covering material according to Comparative Example 1 was prepared in the same manner as in Example 1, except that a sheet containing 30% by weight of a synthetic resin component as a binder and 70% by weight of colored fine aggregate was prepared. (Comparative Example 2) In Comparative Example 2, a covering material was prepared in the same manner as in Example 1, except that the sheet material contained 5% by weight of a synthetic resin component as a binder, 15% by weight of colored fine aggregate, and 80% by weight of aluminum hydroxide. (Comparative Example 3) In Comparative Example 3, the cured layer was made using an acrylic resin material with a dry density of 12.2 g / m². 2 A covering material according to Comparative Example 3 was prepared in the same manner as in Example 1, except that it was formed in the same manner as in Example 1. (Comparative Example 4) In Comparative Example 4, the amount of cured material applied was 30 g / m². 2 Except for the change made to the above, the covering material for Comparative Example 4 was prepared in the same manner as in Example 1. (Comparative Example 5) In Comparative Example 5, the amount of cured material applied was 1 g / m². 2 A covering material for Comparative Example 5 was prepared in the same manner as in Example 1, except for the change made to [specific detail]. (Evaluation method) Examples 1-6 and Comparative Examples 1-5 described above were evaluated based on four criteria: (1) non-flammability, (2) scratch resistance, (3) aesthetic appeal, and (4) ease of installation.

[0038] (Nonflammable) For non-flammability, a heat generation test was conducted using a cone calorimeter testing machine compliant with ISO 5660-1. Specifically, the test was performed at 50 kW / m³. 2 We evaluated whether all of the following requirements 1-3 were met during a 20-minute heating period using radiant heat. Note 1. Total heat output is 8 MJ / m³ 2 below 2. The maximum heat generation rate remains at 200 kW / m² for 10 seconds or more. 2 Do not exceed 3. No cracks or holes that penetrate to the back surface, which would be harmful from a fire-retardant standpoint, will occur.

[0039] (Scratch resistance) Scratch resistance was evaluated using the scratch hardness test (pencil method) in accordance with JIS 5600-5-4. Specifically, a 750g load was applied to a pencil fixed at a 45° angle, and the hardness of the hardened material layer and coating layer was measured. Pencil leads with hardness levels from 2B to 4H were used. Hardness measurements were repeated until indentations appeared in each layer, and the scratch resistance as a surface material was evaluated. A score of HB or higher was marked as a pass ("○"), and anything below HB was marked as a fail ("×").

[0040] (Design) Regarding design aesthetics, printed designs were evaluated visually. A "○" was used to indicate a pass in the visual evaluation, while "×" indicated a fail in all other cases. (Workability) Regarding workability, the sheet was lightly bent to visually check for cracks or other defects. If no cracks or defects were found during the visual inspection, it was marked as a pass ("○"), and if cracks or defects were found, it was marked as a fail ("×"). (Evaluation results) The evaluation results for Examples 1-6 and Comparative Examples 1-5 are shown in Table 1.

[0041] [Table 1]

[0042] (Evaluation from the perspective of non-combustibility) As shown in the evaluation results above, the covering materials for Examples 1 to 6 passed all three evaluation items: non-flammability, scratch resistance, and ease of installation ("○"). In contrast, the surface materials in Comparative Examples 1 to 5 all had a "fail" rating (×) in at least one of the three evaluation items: non-flammability, scratch resistance, and ease of installation. First, from the perspective of non-flammability, Comparative Examples 1, 3, and 4 all have a "fail" rating (×). Comparative Example 1 does not contain aluminum hydroxide, unlike Example 1. Therefore, it was confirmed that the aluminum hydroxide contained in Example 1 has a beneficial effect in terms of non-flammability.

[0043] Comparative Examples 3 and 4 differ from Example 1 in their cured layer. Therefore, it was confirmed that the cured layer is related to the non-combustibility. When Comparative Example 3 is compared with Example 1, the coating compositions of the two are different. Therefore, from the viewpoint of non-flammability, the acrylic resin material used in Comparative Example 3 is undesirable, and it was confirmed that the combination of silicone oligomer and curing catalyst used in Example 1, or the aminosilane used in Examples 2 and 3, is preferable. When Comparative Example 4 is compared with Example 1, the amount of cured material applied is different. Therefore, from the standpoint of non-flammability, it was confirmed that the amount of material applied in Comparative Example 3 was too much.

[0044] (Evaluation from the perspective of scratch resistance) Next, from the perspective of scratch resistance, Comparative Examples 2, 3, and 5 all have a "fail" rating (×). Comparative Example 2 differs from Example 1 in the ratio of synthetic resin component to colored fine aggregate. Therefore, from the viewpoint of scratch resistance, it was confirmed that the ratio of synthetic resin component to colored fine aggregate in Example 1 is appropriate. When Comparative Example 3 is compared with Example 1, the coating compositions of the two are different. Therefore, from the viewpoint of scratch resistance, it was confirmed that the acrylic resin material used in Comparative Example 3 is undesirable. When Comparative Example 5 is compared with Example 1, the amount of cured material applied is different. Therefore, from the standpoint of scratch resistance, it was confirmed that the amount of material applied in Comparative Example 5 was too small.

[0045] (Evaluation from the perspective of constructability) From the perspective of workability, Comparative Example 4 has a failure mark ("×"). Comparative Example 4 differs from Example 1 in the amount of cured material layer applied. Therefore, from the perspective of workability, it was confirmed that the amount of cured material layer applied in Comparative Example 4 was too much. (Evaluation based on design aesthetics) From a design perspective, only Example 5 has a "○" rating. It was confirmed that the "pattern layer" in Example 5 was well-evaluated.

[0046] (Overall evaluation) The covering materials from Examples 1 to 6 were compared with each other. Compared to Example 1, Example 2 differs in the composition and ratio of the coating composition of the cured layer. However, it passed all three evaluation items—non-flammability, scratch resistance, and workability—with a "○" rating, confirming that there were no differences. In Example 3, the coating composition of the cured layer was entirely replaced with aminosilane compared to Example 1, but all three evaluation items—non-flammability, scratch resistance, and workability—received a "○" rating, confirming that there was no difference. Compared to Example 1, Example 4 involves forming a coating layer on top of the cured material layer, but it passed all three evaluation items—non-flammability, scratch resistance, and workability—with a "○" rating, confirming that there were no differences.

[0047] In Example 5, compared to Example 1, a coating layer was formed on the cured material layer using an inkjet printing method. However, all three evaluation items—non-flammability, scratch resistance, and workability—received a "○" rating, confirming that there were no differences. In Example 6, the sheet material was formed by die molding, resulting in a change in sheet thickness. However, all three evaluation items—non-flammability, scratch resistance, and workability—received a "○" rating, confirming that there were no differences. Overall, it was confirmed that the covering materials described in Examples 1 to 6 can provide covering materials that satisfy all three evaluation criteria: non-combustibility, scratch resistance, and ease of installation. [Explanation of symbols]

[0048] 1. Covering material 2 Sheet material 3 Base fabric 4 Cured material layer 5 Coating layer 6 Image Layers

Claims

1. A surface covering material to be applied to the surface of a base material, The aforementioned covering material mainly consists of synthetic resins, aggregates, and heat-absorbing substances, and comprises a sheet material containing 6 to 12% by weight of the synthetic resins and 80 to 90% by weight of the aggregates and heat-absorbing substances. A cured layer of a coating composition containing a condensation-curing type silicone composition is laminated on one side of the sheet material, The sheet material comprises a base fabric laminated on the other side, The aforementioned base fabric consists solely of woven fabric. The amount of the cured layer to be applied is 1 g / m². ２ Super 30g / m ２ A covering material characterized by being less than [amount missing].

2. A surface covering material to be applied to the surface of a base material, The aforementioned covering material mainly consists of synthetic resins, aggregates, and heat-absorbing substances, and comprises a sheet material consisting of one layer containing 6 to 12% by weight of the synthetic resins and 80 to 90% by weight of the aggregates and heat-absorbing substances. A cured layer of a coating composition containing a condensation-curing type silicone composition is laminated on one side of the sheet material, The sheet material comprises a base fabric laminated on the other side, The aforementioned base fabric consists solely of woven fabric. The amount of the cured layer to be applied is 1 g / m². ２ Super 30g / m ２ A covering material characterized by being less than [amount missing].

3. The covering material according to claim 1 or 2, characterized in that the base fabric does not contain fibrous hydrated magnesium silicate.

4. The surface covering material according to claim 3, characterized in that the aggregate consists of one or more materials selected from natural stone or crushed stone thereof, colored aggregate, cold water sand, and ceramic granules.

5. A pattern layer is provided between the sheet material and the cured material layer, The covering material according to claim 4, characterized in that the pattern layer contains an inorganic pigment or an organic pigment.

Images