JPH05125814A - Decorative material and its manufacture - Google Patents

Abstract

PURPOSE:To express texture different from conventional ones by leaving a pattern derived from irregularity formed by embossing finish as a pattern design and having fine irregularity on the surface. CONSTITUTION:A colored synthetic resin layer 21 with fine particulates 23 fastened on its surface is embossing finished, and the particulates 23 are buried in the resin layer 21 at its recessed part. Thereafter, hardening type synthetic resin is applied on the surface and hardened, and a protruded part 25 with fine irregularity derived from the particulates 23 and an overcoat layer 29 with a flat recessed part 27 are formed. Thereafter, the surface is leveled by plate pressing and a decorative material with an irregular part 31 and a flat part 33 is manufactured.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material such as a floor material and a wall material and a method for manufacturing the same, and more particularly to a decorative material having a fine uneven pattern having a texture different from conventional textures and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, flooring materials based on synthetic resins,
Decorative materials such as wall materials are known, and in order to improve their design, various techniques such as printing, flow pattern, use of chips, particles, embossing, etc. have been studied to add patterns and improve texture. ing.

[0003] For example, in Japanese Patent Laid-Open No. Hei 2-132265, a floor layer having an unprecedented texture while improving cigarette resistance by forming a surface layer of a curable resin layer containing heat-resistant transparent beads is disclosed. Wood has been proposed.

Further, in Japanese Patent Application Laid-Open No. 2-132267, in a synthetic resin flooring material having a surface layer made of synthetic resin and inorganic particles having different color tones and having irregularities, the surface of the convex portion is an inorganic particle layer. It has been shown that a flooring material having a ceramic-like appearance and texture can be obtained by embedding the inorganic particles in a synthetic resin in the concave portions by forming the floor material.

Further, in Japanese Patent Application Laid-Open No. 2-157357, particles are dispersed on a printed layer to form irregularities by embossing and the particles are embedded in a synthetic resin layer by penetrating the printed layer in the concave portions. It is described that the effect similar to that of Tani Dyeing Embossing can be obtained, and a unique design effect similar to glaze applied to a baked product can be obtained.

[0006]

DISCLOSURE OF THE INVENTION The present invention provides a decorative material in which fine irregularities are left and formed on the surface by a delicate touch, and a design effect having a unique texture can be obtained, and a manufacturing method thereof. is there.

[0007]

The decorative material of the present invention comprises a colored synthetic resin layer, exposed fine particles at least a part of which protrudes from a part of the colored synthetic resin layer, and the colored synthetic resin layer. The embedded fine particles embedded in the layer in the other part, and the overcoat layer laminated on the colored synthetic resin layer and reflecting the fine irregularities derived from the exposed fine particles at the site where the exposed fine particles are present. And having.

The method for producing a decorative material of the present invention is characterized by sequentially performing the following steps (a) to (c). (A) The colored synthetic resin layer having fine particles adhered to the surface thereof is subjected to unevenness processing, leaving the fine particles in the convex portions in a state where at least a part thereof protrudes from the colored synthetic resin, and coloring the fine particles in the concave portions. Step of embedding in a synthetic resin layer. (B) The surface is coated with a transparent or semi-transparent cross-linking or curing type synthetic resin, and the cross-linking or curing type synthetic resin is cured while leaving the plastic deformability of the colored synthetic resin layer, and this is derived from the protruding fine particles. A step of forming an overcoat layer made of a cured product of a crosslinked or curable resin having a fine uneven pattern formed on the surface. (C) A step of selectively plastically deforming the colored synthetic resin layer to flatten the surface or to give unevenness to the surface different from the step (a).

[0009]

EXAMPLE FIG. 1 is an explanatory sectional view showing an example of a method for manufacturing a decorative material of the present invention, and FIG. 1 (D) is a decorative material of the example of the present invention. Hereinafter, the manufacturing process will be sequentially described with reference to the drawings.

First, as shown in FIG. 1A, a backing layer 11 made of vinyl chloride resin or the like is formed on a nonwoven fabric 13 of glass fiber.
The colored synthetic resin layer 21 is provided on the base material sheet provided with
Further, the fine particles 23 are dispersed and fixed thereon.

The constitution of the base sheet is not particularly limited to the above embodiment, and various modifications can be made. In general,
As the base sheet, a synthetic resin or a synthetic resin composition in which an additive is added as necessary is used, and a fiber reinforcing agent is further integrated in order to enhance strength and dimensional stability.

The colored synthetic resin layer 21 can fix and retain the fine particles 23 by the primary solidification, and can be plastically deformed after the overcoat layer 29 is formed by the crosslinking or curing of the curable resin in the subsequent step. Any of them may be used. Specifically, for example, a vinyl chloride resin paste, an acrylic resin, a polyester resin, a polyurethane resin or the like is applied in a liquid form or a paste form to obtain fine particles 2
After spraying 3, the resin composition is solidified to form the colored synthetic resin layer 21, and the fine particles 23 are fixed to the surface. A thermoplastic resin is preferably used as the base material of the colored synthetic resin layer 21.

Prior to or during the solidification of the resin composition, the fine particles 23 may be pressed down so that the fine particles 23 may penetrate into the resin composition to a certain extent to firmly fix the resin composition. However, it is necessary that the fine particles 23 are fixed so that at least a part of the fine particles 23 protrudes in the portion where the fine irregularities are finally formed.

The fine particles have an average particle size of 50 to 10
00 μm is preferable, and 100 to 50 is preferable.
It is 0 μm, more preferably 200 to 400 μm.
As the shape of the fine particles 23, any shape such as a spherical shape, an elliptical shape, a dice shape, or an irregular shape can be selected. Also, fine particles 2
Examples of the material constituting 3 are vinyl chloride resin, acrylic resin, styrene resin, such as synthetic resin particles (eg, beads, chips, granules, etc.), glass (beads, powders, etc.), ceramics, natural stones, metals. Materials and the like can be mentioned. The fine particles 23 may be transparent, semitransparent, or opaque. The fine particles 23 are required to have heat resistance and pressure resistance to the extent that fine irregularities can be formed on the surface thereof even after being subjected to heating or pressure treatment in a later step.

In FIG. 1A, the colored synthetic resin layer 2
Although the fine particles 23 are fixed to the entire surface of No. 1, the fixed region and the non-fixed region of the fine particles 23 may be formed on the colored synthetic resin layer 21 by forming a pattern. Then, as shown in FIG. 1 (B), at least the fine particles 23
Unevenness is formed on the surface by embossing or the like, while leaving a part of the protruding fixing portion.

At this time, in the recess 27, the fine particles 23 are embedded in the colored synthetic resin layer 23. Further, the concave portion 27 becomes a flat surface according to the embossing roll. On the other hand, in the convex portion 25, the fine particles 23 are held in a state in which a part thereof protrudes from the colored synthetic resin layer 21. The degree of the unevenness to be formed is not particularly limited, but it is preferable that the convex portion 25 corresponds to a so-called tile and the concave portion 27 corresponds to a joint portion, for example. The recess 27 usually has a width of about 1 to 8 mm or more, and a depth of about 0.2 to 1.0 mm is preferable.

Further, the colored synthetic resin layer 21 may be formed of two or more layers, or the embossed uneven surface may be formed in multiple steps, whereby the decorative material finally obtained is
A more delicate decorative pattern can be formed.

Then, as shown in FIG. 1C, a coating material mainly composed of a liquid or paste-like cross-linking or curing resin is coated and cured to form an overcoat layer 29. At this time, in the convex portion 25, the fine particles 23 protruding from the colored synthetic resin 21.
The overcoat layer 29 has fine unevenness reflecting the fine unevenness due to the above. On the other hand, in the concave portion 27, the fine particles 23 are embedded, and the substantially smooth overcoat layer 29 is formed.

In order to form the unevenness reflecting the fine particles 23 in the overcoat layer 29, it is preferable to coat a coating material mainly composed of a crosslinkable or curable resin by an air knife method. According to the air knife method, the fine particles 2 on the rough surface portion are pre-coated.
The coating material is filled up to the gaps 3, 23, and then the excess coating material is swept away by the air blown from the air knife, so that the convex portion 25 made of a rough surface and the convex portion 27 made of a smooth surface are almost A coating film of the coating material is formed with a uniform thickness.

The viscosity of the coating material is preferably 6000 cps (25 ° C.) or less, more preferably 5000 cps (25 ° C.) or less, still more preferably 3000 cps (25 ° C.) or less, and particularly 1000 cps in relation to the air knife. (25 ° C) or less is desirable.

By doing so, the fine particles 23
It is possible to form a coating film having a uniform thin thickness that partially reflects the fine irregularities based on the above. The thickness of the coating film of the coating material is preferably 0.3 mm or less, and preferably 0.1 mm or less.
It is 2 mm or less.

Then, depending on the characteristics of the coating material,
The coating film of the coating material is cured by irradiation with ultraviolet rays, heating, etc. to form an overcoat layer 29 as shown in FIG.

As the coating material, any crosslinkable or curable resin can be used. For example, crosslinkable vinyl chloride resin paste sol, photocurable resin paint such as ultraviolet rays, thermosetting urethane and those. Examples thereof include emulsions, thermosetting or room temperature curing type epoxy resins and polyester resins. As the photocurable resin, for example, various resins described in "Plastic Painting and Printing Handbook", pages 71 to 80, issued by Research Institute of Technology, December 10, 1983, can be used. Can be used. Further, the ultraviolet curable resins described in JP-A Nos. 51-10628 and 54-139223 can also be used. When enumerating specific examples of the photocurable resin, diethylene glycol dimethacrylate, trimethylolpropane trimethacrylate,
1,4-Butane diacrylate, neopentyl glycol diacrylate, an acrylic-urethane resin composition, and the like can be mentioned, but an acrylic-urethane resin composition is preferable in view of the later processability.

The overcoat layer 29 is preferably transparent or translucent. Then, the colored synthetic resin layer 21 is selectively plastically deformed by a continuous press using a molding roll or the like or a flat plate press to flatten the surface.
At this time, the overcoat layer 29 is first formed due to the difference in meltability depending on the temperature between the overcoat layer 29 formed of a photocurable resin or the like and the colored synthetic resin layer 21 formed of a thermoplastic resin or the like. The fine irregularities of the formed convex portions 25 and the smooth surfaces of the concave portions remain as they are. As a result, FIG. 1 (D)
As shown in, the surface is almost flat as a whole, but microscopically, the smooth portion 33 and the fine uneven portion 31 are formed by an arbitrary pattern design, and a decorative material having a delicate touch is obtained. Be done. A more delicate touch can be expressed by providing unevenness in multiple stages during the unevenness processing shown in FIG. Further, the overcoat layer 29 on the surface is
It has heat resistance and cigarette resistance, and also has abrasion resistance and excellent durability, making it suitable as a flooring material.

The pressing pressure is usually 20 to 100 kg / cm.
² is suitable, preferably 25 to 70 kg / cm ^{2 and} particularly preferably 30 to 50 kg / cm ² . The pressing temperature is usually 50 to 200 ° C, preferably 70 to 200 ° C.
170 ° C., particularly preferably 90 to 140 ° C.

Further, in the above description, each layer was sequentially formed and treated on the base material lined with the non-woven fabric 13 with the backing layer 11, but the surface side of the colored synthetic resin layer 21 and the base material were separately prepared. The base material is unrolled or cut into tiles, and the surface layer side of the colored synthetic resin layer 21 of FIG. 1 (C) is superposed on the base material, and the surface is flattened and integrated with the base material at the same time by a pressing process. May be.

Further, instead of flattening the surface as shown in FIG. 1D, unevenness of a pattern different from the uneven pattern shown in FIG. 1C is applied to the decoration material of FIG. 1C. It is also possible to give a more complicated design by giving it to the semi-finished product with an embossing roll or the like.

FIG. 2 is a cross-sectional view showing another embodiment of the decorative material of the present invention, in which the pattern layer 24 is partially formed on the colored synthetic resin layer 21, and the fixing resin layer 22 is interposed therebetween. It is the same as the embodiment shown in FIG. 1 except that the fine particles 23 are fixed.

The decorative material shown in FIG. 2 is a colored synthetic resin layer 2
A pattern layer 24 is formed on 1 by printing or the like, and a fixing resin layer 22 is further laminated thereon, and then the fixing resin layer 22 fixes the fine particles 23. The fixing resin layer 22 can be similarly formed by using the same material as the colored synthetic resin layer 21 except that it is transparent or translucent.

When the semi-finished decorative material obtained in the above step is subjected to the unevenness-imparting treatment as described with reference to FIG. 1 (B), fine particles in the recesses are embedded in the colored synthetic resin layer 21. ,
The pattern layer 24 in this portion is destroyed and the colored synthetic resin layer 2
1 can be seen. Thereafter, by performing the same treatment as in FIG. 1, a flooring material having a printed pattern and expressing a more diverse design is obtained.

[0031]

According to the present invention, a decorative material capable of expressing a texture and a touch different from conventional ones by leaving the previously processed arbitrary uneven pattern as a design and having a fine uneven pattern on the surface. Is obtained.

Production Example A vinyl chloride resin paste sol is applied to the back surface of a glass fiber non-woven fabric so that the layer thickness after solidification is 1.0 mm, heated and solidified to produce a base material sheet, which is pre-rolled. Rolled up.

Separately from the above, the vinyl chloride resin paste sol colored in blue on the release sheet has a layer thickness of 1 after solidification.
so that the average particle size is 300 μm.
Disperse the ceramic white fine particles of
After gently pressing and heating to 180 ° C., the vinyl chloride resin paste sol was gelated (primary formation of a colored synthetic resin layer) and the ceramic fine particles were fixed.

Then, using an embossing roll, 180 ° C.
By heating to, unevenness was formed as shown in FIG. 1 (B), and the fine particles 23 were embedded in the recesses 27. Next, an ultraviolet curable resin was uniformly applied to the surface using an air knife, and was irradiated with ultraviolet rays to be cured to form an overcoat layer having a thickness of 0.1 mm.

Further, the colored synthetic resin layer on which the overcoat layer is formed as described above is peeled off from the release sheet, overlapped with the above-mentioned unwound base material sheet, and 12 by flat plate pressing.
Both were integrated by pressing at 0 ° C. and 40 kg / cm ² and the surface was flattened to obtain a decorative material suitable for the floor material shown in FIG. 1 (D).

This decorative material has fine irregularities due to the protrusion of fine particles from the colored synthetic resin layer left and formed on the surface, and has a delicate touch pattern pattern completely different from the conventional one. It was

[Brief description of drawings]

FIG. 1 is an explanatory cross-sectional view showing an embodiment of a decorative material of the present invention and a manufacturing example thereof.

FIG. 2 is an explanatory sectional view showing another embodiment of the decorative material of the present invention.

[Explanation of symbols]

 11 Backing Layer 13 Nonwoven Fabric 21 Colored Synthetic Resin Layer 22 Fixing Resin Layer 23 Fine Particles 24 Printing Layer 25 Convex Part 27 Concave Part 29 Overcoat Layer 31 Uneven Part 33 Smooth Part

Claims (2)

[Claims] 1. A colored synthetic resin layer, exposed fine particles projecting at least a part of the colored synthetic resin layer in a part of the colored synthetic resin layer, and embedded in the layer in another part of the colored synthetic resin layer. A decorative material comprising embedded fine particles and an overcoat layer, which is laminated on a colored synthetic resin layer and reflects fine irregularities derived from the exposed fine particles at a site where the exposed fine particles are present. 2. (a) The colored synthetic resin layer having fine particles adhered to the surface thereof is subjected to a concavo-convex process to leave the fine particles in the convex portion in a state in which at least a part thereof protrudes from the colored synthetic resin, and the concave portion is formed. Embedded in the colored synthetic resin layer in step (b), the surface is coated with a transparent or semitransparent crosslinkable or curable synthetic resin, and the crosslinkable or curable type is left while leaving the plastic deformability of the colored synthetic resin layer. Curing the synthetic resin of, and forming an overcoat layer made of a cured product of a cross-linking or curable resin on the surface of which fine irregularities derived from protruding fine particles are formed, (c) a colored synthetic resin layer A method for manufacturing a decorative material, which comprises sequentially performing a step of selectively plastically deforming to flatten the surface or to give unevenness different from the step (a) to the surface.