JP7553254B2 - Tiles, tile application methods and architectural structures - Google Patents

Description

This disclosure relates to tiles, tile installation methods, and architectural structures.

Tiles are widely used to decorate the walls of buildings. Wall restoration, which involves removing damaged or soiled tiles and installing new tiles, is also common.

Patent Document 1 (JP Patent Publication 2018-184737A) describes a "tile wall repair method for repairing a tile wall formed by attaching a large number of tiles by replacing a defective tile that is damaged or deteriorated with a repair tile, the method comprising: a printing step of determining printing conditions for printing a pattern corresponding to the pattern on the tile surface of the defective tile based on the pattern on the tile surface of the defective tile or a tile that is not missing, printing a pattern on the surface of a base tile using a printer according to the printing conditions to form the repair tile; and a repair step of removing the defective tile from the tile wall and attaching the repair tile."

JP 2018-184737 A

Tile surfaces often consist of fine, irregular patterns and base colors. This makes it difficult to match the appearance of new tiles to be installed in wall repairs with that of existing tiles. Furthermore, manufacturing tiles for repairs to match existing tiles requires a lead time of about three months and a large lot size of over 1,000 tiles. For this reason, there is a demand for on-demand tiles for wall repairs.

Joint material is often filled between tiles to create decorative joints. Decorative joints add a design to buildings, and can accommodate errors in the shape and dimensions of tiles to align them and prevent them from moving. Examples of decorative joints include flat joints, sunken joints, cover joints, inverted cover joints, and shinoki joints. With decorative joints other than flat joints, the tile and the decorative joint are not flush, and part of the side of the tile is exposed to the outside. For this reason, it is desirable for repair tiles to be able to reproduce the appearance of the existing tiles, including their sides.

The present disclosure provides tiles that can be manufactured on demand in small lot sizes with short lead times, and that can nearly reproduce the appearance of the repaired area when used to repair the wall surface of a building. The present disclosure also provides a tile installation method and a building structure that use such tiles.

According to one embodiment, a tile is provided that includes a tile substrate having a main surface and at least one side surface, and a decorative film attached to the tile substrate so as to cover the main surface of the tile substrate and extend from at least a portion of the periphery of the main surface of the tile substrate to at least a portion of the at least one side surface of the tile substrate.

According to another embodiment, a method for installing tiles is provided, which includes attaching the tiles to a wall surface and filling a gap between the tiles adjacent to the tiles with a joint material, the joint material being filled so that a portion of the decorative film extending to at least a portion of the at least one side surface of the tile substrate is visible and at least a portion of the at least one side surface of the tile substrate is exposed.

According to another embodiment, a method for installing tiles is provided, which includes attaching the tiles to a wall surface and filling a gap between the tiles adjacent to the tiles with a joint material, the joint material being filled such that a portion of the decorative film extending to at least a portion of the at least one side surface of the tile substrate is visible and the at least one side surface of the tile substrate is covered with the joint material.

According to another embodiment, there is provided an architectural structure to which the above-mentioned tiles are applied, in which a grout material is filled between the tiles adjacent to the tile so that a portion of the decorative film extending to at least a portion of the at least one side surface of the tile substrate is visible and at least a portion of the at least one side surface of the tile substrate is exposed.

According to another embodiment, there is provided an architectural structure to which the above-mentioned tiles are applied, in which the joint material filled between the tile adjacent to the tile and the tile is filled such that the portion of the decorative film extending to at least a portion of the at least one side surface of the tile substrate is visible, and the at least one side surface of the tile substrate is covered with the joint material.

The tiles disclosed herein can be manufactured on-demand in small lot sizes with short lead times, and when used to repair building walls, can nearly reproduce the appearance of the repaired area.

The above description should not be construed as disclosing all embodiments of the present invention and all advantages associated with the present invention.

FIG. 2 is a schematic cross-sectional view of a tile according to one embodiment. FIG. 2 is a schematic cross-sectional view of a tile according to another embodiment. FIG. 2 is a schematic cross-sectional view of a tile according to another embodiment. FIG. 1 is a schematic cross-sectional view of a decorative laminate film according to a first embodiment. FIG. 1 is a schematic cross-sectional view of a decorative laminate film according to a first embodiment. FIG. 1 is a schematic cross-sectional view of a decorative laminate film according to a first embodiment. FIG. 1 is a schematic cross-sectional view of a decorative laminate film according to a first embodiment. FIG. 1 is a schematic cross-sectional view of a decorative laminate film according to a first embodiment. 2 is a flow chart illustrating an example of a method for manufacturing a decorative laminate film according to the first embodiment. FIG. 4 is a schematic cross-sectional view of a decorative laminate film according to a second embodiment. 4 is a flow chart illustrating an example of a method for producing a decorative laminate film according to a second embodiment. FIG. 4 is a schematic cross-sectional view of a decorative laminate film according to a third embodiment. FIG. 4 is a schematic cross-sectional view of a decorative laminate film according to a third embodiment. 10 is a flow chart illustrating an example of a method for manufacturing a decorative laminate film according to a third embodiment. 1 is a schematic cross-sectional view of a portion of an architectural structure according to one embodiment. 1 is a schematic cross-sectional view of a portion of an architectural structure according to another embodiment. 1 is a photograph of a ceramic tile before application of a decorative laminate film. 1 is a photograph of the tile of Example 1 to which the decorative laminate film is attached.

The present invention will be described in more detail below with reference to the drawings for the purpose of illustrating representative embodiments of the present invention, but the present invention is not limited to these embodiments. Regarding the reference numbers of the drawings, elements with similar numbers in different drawings indicate similar or corresponding elements.

In this disclosure, "film" also includes articles called "sheets."

In this disclosure, "pressure-sensitive adhesion" refers to the property of a material or composition that has initial tack over a range of temperatures of use, e.g., from 0°C to 50°C, adheres to a variety of surfaces with light pressure, and does not exhibit a phase change (liquid to solid).

In one embodiment, the tile includes a tile substrate having a main surface and at least one side surface, and a decorative film attached to the tile substrate so as to cover the main surface of the tile substrate and extend from at least a portion of the periphery of the main surface of the tile substrate to at least a portion of at least one side surface of the tile substrate.

The tile substrate may be made of tiles of various materials, shapes, and sizes. In one embodiment, the tile substrate is a ceramic tile. The tile substrate may or may not be permeable to air or water. A glaze may or may not be applied to the surface of the tile substrate. The main surface, side, or back surface of the tile substrate may have a three-dimensional shape such as a groove, ridge, protrusion, or recess. The shape of the tile substrate is generally rectangular or square (four sides), but may also be circular (one side), elliptical (one side), triangular (three sides), hexagonal (six sides), or other geometric shapes. The dimensions of the tile substrate are generally about 40 mm or more and about 1000 mm or less on one side or diameter of the tile substrate.

The decorative film is attached to the tile substrate so as to cover the main surface of the tile substrate and extend from at least a portion of the periphery of the main surface of the tile substrate to at least a portion of at least one side surface of the tile substrate. This prevents the decorative film from peeling off the tile substrate, increasing the durability of the tile, and allows the tile to match its appearance with existing tiles even when viewed from a direction tilted from the normal to the surface on which the tile is installed.

Figure 1 shows a schematic cross-sectional view of one embodiment of a tile. The tile 10 includes a tile substrate 12 and a decorative film 16. The decorative film 16 is attached to the tile substrate 12 so as to cover the main surface 13 of the tile substrate 12 and extend from at least a portion of the periphery of the main surface 13 of the tile substrate 12 to at least a portion of the side surface 14 of the tile substrate 12.

Figure 2 shows a schematic cross-sectional view of a tile in another embodiment. In Figure 2, the decorative film 16 is attached so as to extend beyond the side surface 14 of the tile substrate 12 and further to a portion of the back surface 15 of the tile substrate 12. By extending the decorative film 16 to the back surface 15 of the tile substrate 12, the decorative film 16 can be attached to the tile substrate 12 more firmly.

Figure 3 shows a schematic cross-sectional view of a tile in another embodiment. In Figure 3, the decorative film 16 is attached beyond the side 14 of the tile substrate 12 and further covers the back surface 15 of the tile substrate 12. As with the embodiment shown in Figure 2, this embodiment also allows the decorative film 16 to be more firmly attached to the tile substrate 12.

It is desirable for the decorative film to extend from the entire periphery of the main surface of the tile substrate to at least a portion of all of the side surfaces of the tile substrate. This more effectively prevents the decorative film from peeling off the tile substrate, and allows the appearance to match that of existing tiles even when the tile is observed in a direction inclined from the normal to the tile installation surface and from various angles with the normal as the central axis. In this embodiment, as shown in FIG. 3, when the decorative film is attached so as to extend beyond the side surfaces of the tile substrate and further cover the back surface of the tile substrate, the entire surface of the tile substrate can be covered with the decorative film, reducing or preventing the intrusion of moisture, acid, etc. into the tile substrate and suppressing deterioration of the tile substrate.

It is desirable for the decorative film to conceal the surface of the tile substrate. The "surface" of the tile substrate includes both the main surface of the tile substrate and the side surface portion that is covered with the decorative film. For example, the surface of the tile substrate can be concealed by including a colorant such as a white pigment in one or more of the layers that make up the decorative film.

The decorative film of the first embodiment has a transparent gray layer and a base solid color layer, and at least one of the transparent gray layer and the base solid color layer is a printed layer. The decorative laminate film also optionally has a pattern layer. The observer visually recognizes the base solid color layer through the transparent gray layer. Without being bound by any theory, it is believed that in a laminate structure in which at least one of the transparent gray layer and the base solid color layer is a printed layer, by allowing the observer to view the base solid color layer with adjusted brightness through a separately provided transparent gray layer, the observer can be given the impression that the appearance of the repaired part is more accurately reproduced.

In general, the print layer is formed by converting RGB image data obtained by photographing the repaired part with a digital camera or the like into CMYK image data, and then printing process inks (cyan (C), magenta (M), yellow (Y), and black (K), and optionally light inks) as ink dots or tint dots on the substrate using printing techniques such as inkjet printing, offset printing, and gravure printing. In the print layer, colors other than the process inks are expressed by subtractive color mixing of these process inks. A white base is usually exposed between the ink dots or tint dots, and the observer perceives colors of various hues, lightnesses, and saturations due to the juxtaposition (additive) mixing of reflected light from this white base and reflected light from the ink dots or tint dots.

When mixing process inks that include black (K) ink, matching the brightness may result in a mismatch in saturation. For example, it is common to use achromatic black (K) ink to adjust brightness, but this can also reduce saturation to an unacceptable level. The same occurs when adjusting brightness by mixing cyan (C), magenta (M), and yellow (Y) inks without using black (K), which can also result in a shift in hue. These phenomena are more pronounced in inkjet printing and offset printing, which express gradation by combining a white background with ink dots or halftone dots, as well as in some gravure printing methods, and may not be solved by image processing algorithms alone when converting image data.

Architectural tiles use pigments with relatively low saturation, whereas process inks, which require a wide range of colors to be expressed by combining a limited number of inks, generally use pigments with high saturation. These differences in pigment types can also have a detrimental effect on color reproduction.

In one embodiment, the base solid color layer is a printed layer formed using a printing technique such as inkjet printing, offset printing, or gravure printing, particularly inkjet printing. The decorative laminate film of this embodiment can be advantageously used for repair surfaces having colors that are particularly difficult to reproduce with conventional decorative films.

4 shows a schematic cross-sectional view of a decorative laminate film 110 according to a first embodiment. The decorative laminate film 110 includes a pattern layer 112, a transparent gray layer 114, and a substrate solid color layer 116, which are optional components. The pattern layer 112 is disposed on the transparent receptor layer 122, the transparent gray layer 114 is disposed on the transparent receptor layer 124, and the substrate solid color layer 116 is disposed on the receptor layer 126, respectively. The decorative laminate film 110 in FIG. 4 further includes, as optional components, a surface protection layer 128 as the outermost layer, a pressure-sensitive adhesive layer 136 for attaching the decorative laminate film 110 to the tile substrate, and a liner 140 for protecting the pressure-sensitive adhesive layer 136. The liner 140 is peeled off before the decorative laminate film 110 is attached to the tile substrate. These layers are laminated via bonding layers 132, 134, and 138 to form the decorative laminate film 110. In FIG. 4, the transparent gray layer 114 is disposed between the pattern layer 112 and the base solid color layer 116, and the base solid color layer 116 is visible to an observer from above through the transparent gray layer 114.

Figure 5 shows a schematic cross-sectional view of a decorative laminate film 110 according to another embodiment of the present disclosure. Unlike Figure 4, the decorative laminate film 110 in Figure 5 is arranged in the order of transparent gray layer 114, optional pattern layer 112, and base solid color layer 116 from the top. In this embodiment, the base solid color layer 116 and pattern layer 112 are visible to an observer from above through the transparent gray layer 114.

As shown in FIG. 4, the transparent gray layer 114 may be disposed between the pattern layer 112 and the base solid color layer 116, and as shown in FIG. 5, the pattern layer 112 may be disposed between the transparent gray layer 114 and the base solid color layer 116.

The transparent gray layer may be a receptor layer. In the embodiment shown in FIG. 6, the pattern layer 112 is disposed directly on the transparent gray layer 114, and the transparent gray layer 114 also functions as a receptor layer for the pattern layer 112. In this embodiment, the pattern layer can be formed directly on the transparent gray layer by printing, transferring, etc., resulting in a thin decorative laminate film with a simpler structure. Therefore, the film manufacturing process can be further simplified, and the thin decorative laminate film is highly flexible and has the advantage of being able to conform to the uneven surface of the tile substrate.

The transparent gray layer may be an adhesive layer or a pressure-sensitive adhesive layer. In the embodiment shown in FIG. 7, the transparent gray layer 114 also functions as a bonding layer between the transparent receptor layer 122 and the substrate solid color layer 116. In the embodiment shown in FIG. 8, the transparent gray layer 114 also functions as a bonding layer for laminating the surface protection layer 128. In these embodiments, other layers, such as a receptor layer, a surface protection layer, etc., can be laminated on the transparent gray layer without using a separate bonding layer, resulting in a thin decorative laminate film with a simpler structure. Therefore, the film manufacturing process can be simplified, and the thin decorative laminate film has the advantage of being highly flexible and conformable to the uneven surface of the tile substrate.

The pattern layer can be formed on the transparent receptor layer or on the transparent grey layer that also functions as the receptor layer by printing such as inkjet printing, offset printing, gravure printing, screen printing, electrostatic printing, etc. using toner, solvent-based ink, UV-curable ink, water-based ink, latex ink, etc. In one embodiment, the pattern layer is an inkjet printed layer. The pattern layer may also be a metal vapor deposition layer or a metal sputter layer of indium, tin, chromium, etc., formed using a screen mask, etc.

The pattern layer may be monochromatic or multicolored. In one embodiment, the pattern layer may be formed in a neutral color using an image that approximates the pattern of the repair surface.

The thickness of the handle layer may vary, and generally can be about 1 μm or more, about 5 μm or more, or about 10 μm or more, and about 100 μm or less, about 50 μm or less, about 40 μm or less, or about 30 μm or less.

In one embodiment, the transparent gray layer is a printed layer formed on the transparent receptor layer by printing such as inkjet printing, offset printing, gravure printing, screen printing, electrostatic printing, etc. using toner, solvent-based ink, UV-curable ink, water-based ink, latex ink, etc. In one embodiment, the transparent gray layer is an inkjet printed layer.

In another embodiment, the transparent gray layer is a film formed by mixing various resins, for example, acrylic resins including polymethyl methacrylate (PMMA), polyolefins such as polyurethane (PU), polyvinyl chloride (PVC), polycarbonate (PC), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate, fluororesins, copolymers such as ethylene-vinyl acetate copolymer (EVA), ethylene-acrylic acid copolymer, ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, acrylonitrile-butadiene rubber (NBR), and acrylonitrile-butadiene-styrene copolymer (ABS), or mixtures thereof, with a black pigment or black dye. These films may have a surface treatment such as a primer treatment or a corona treatment on the bonding surface with other layers.

The transparent gray layer may function as a receptor layer for the pattern layer. In this embodiment, either the above-mentioned printed layer or the above-mentioned resin film can be used as the transparent gray layer. By using the printed layer as a transparent gray layer and a receptor layer, the printing and lamination process can be simplified, and a thinner decorative laminate film with excellent surface conformability can be obtained. From the standpoints of strength, printability, solvent resistance (e.g., alcohol resistance), etc., a film containing polyvinyl chloride, polyurethane, acrylic resin, or acrylic-urethane resin can be advantageously used as the transparent gray layer that also functions as a receptor layer. A transparent gray layer containing polyvinyl chloride is also advantageous in making the decorative laminate film flame retardant.

The transparent gray layer may function as a bonding layer for other layers constituting the decorative laminate film. In this embodiment, the transparent gray layer can be formed using a composition in which a black pigment or a black dye is mixed with various types of adhesives, such as acrylic, polyolefin, polyurethane, polyester, rubber, and other solvent-based, emulsion-based, pressure-sensitive, heat-sensitive, heat-curable, or UV-curable adhesives. In one embodiment, the transparent gray layer includes an acrylic adhesive, a polyurethane adhesive, or a rubber adhesive.

The transparent gray layer is generally achromatic, but may be chromatic. In one embodiment, the transparent gray layer contains only black pigment or black dye. In another embodiment, the transparent gray layer contains a combination of black pigment or black dye and white pigment or white dye. In another embodiment, the transparent gray layer contains chromatic pigment or dye, such as red, blue, yellow, etc., in addition to black pigment or black dye. In this embodiment, the color of the transparent gray layer can be appropriately shifted to match the hue and saturation of the base solid color layer.

The transparent gray layer may contain resin beads colored black. The black resin beads may be transparent resin particles kneaded with a black pigment or black dye. By using the black resin beads, the black pigment or black dye can be more uniformly dispersed in the transparent gray layer.

The visible light transmittance of the transparent gray layer, when measured in accordance with JIS A 5759:2008, is generally about 40% or more, about 50% or more, or about 60% or more, and about 95% or less, about 90% or less, or about 85% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm. By setting the average visible light transmittance of the transparent gray layer within the above range, the brightness of the base solid color layer can be effectively adjusted. The entire surface of the transparent gray layer may have the above average visible light transmittance, or a part or a plurality of parts may have the above average visible light transmittance.

The thickness of the transparent gray layer may vary, and generally can be about 1 μm or more, about 5 μm or more, or about 10 μm or more, and about 300 μm or less, about 100 μm or less, about 50 μm or less, or about 30 μm or less.

In one embodiment, the substrate solid color layer is a printed layer formed on the receptor layer by printing such as inkjet printing, offset printing, gravure printing, screen printing, electrostatic printing, etc. using toner, solvent-based ink, UV-curable ink, water-based ink, latex ink, etc. In one embodiment, the substrate solid color layer is an inkjet printed layer.

In another embodiment, the base solid color layer is a colored film formed by mixing various resins, for example, acrylic resins including polymethyl methacrylate (PMMA), polyolefins such as polyurethane (PU), polyvinyl chloride (PVC), polycarbonate (PC), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate, fluororesins, copolymers such as ethylene-vinyl acetate copolymer (EVA), ethylene-acrylic acid copolymer, ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, acrylonitrile-butadiene rubber (NBR), and acrylonitrile-butadiene-styrene copolymer (ABS), or mixtures thereof, with pigments or dyes. In this embodiment, decorative laminated films with different colors can be produced from one type of colored film by selecting an appropriate one from transparent gray layers having different visible light transmittances.

The solid color layer of the substrate is a chromatic color, and its hue, brightness, and chroma may vary. In one embodiment, based on the L ^* a ^* b ^* color system, the L ^* value of the solid color layer of the substrate is in the range of about 30 or more and about 99 or less, a ^* is in the range of about -10 or more and about 20 or less, and b ^* is in the range of about -10 or more and about 30 or less. When the L ^* , a ^* , and b ^* of the solid color layer of the substrate are in the above ranges, the effect of brightness adjustment by the transparent gray layer becomes greater.

The thickness of the substrate solid color layer may vary, and generally can be about 1 μm or more, about 5 μm or more, or about 10 μm or more, and about 300 μm or less, about 100 μm or less, about 50 μm or less, or about 30 μm or less.

In one embodiment, both the pattern layer and the transparent gray layer are inkjet printed layers. In another embodiment, the pattern layer, the transparent gray layer, and the base solid color layer are inkjet printed layers.

As the transparent receptor layer that receives the pattern layer and the transparent gray layer, various resins, for example, acrylic resins such as polymethyl methacrylate (PMMA), polyurethane (PU), acrylic-urethane resins, polyolefins such as polyvinyl chloride (PVC), polycarbonate (PC), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate, copolymers such as ethylene-vinyl acetate copolymer (EVA), ethylene-acrylic acid copolymer, ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, acrylonitrile-butadiene rubber (NBR), and acrylonitrile-butadiene-styrene copolymer (ABS), or films containing these copolymers or mixtures thereof can be used. These films may have a surface treatment such as a primer treatment or a corona treatment on the bonding surface with other layers. From the viewpoints of strength, printability, and solvent resistance (e.g., alcohol resistance), films containing polyvinyl chloride, polyurethane, acrylic resin, and acrylic-urethane resin can be advantageously used as the transparent receptor layer. A transparent receptor layer containing polyvinyl chloride is also advantageous in making the decorative laminate film flame retardant.

The visible light transmittance of the transparent receptor layer is generally about 80% or more, about 85% or more, or about 90% or more, and 100% or less, about 98% or less, or about 95% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm, when measured in accordance with JIS A 5759:2008. The entire surface of the transparent receptor layer may have the above average visible light transmittance, or a portion or a plurality of portions may have the above average visible light transmittance.

The thickness of the transparent receptor layer may vary, and is generally about 10 μm or more, about 20 μm or more, or about 50 μm or more, and about 500 μm or less, about 200 μm or less, or about 100 μm or less.

As the receptor layer that receives the solid color layer of the substrate, a film containing the same resin as the transparent receptor layer can be used. These films may have a surface treatment such as a primer treatment or a corona treatment on the bonding surface with other layers. From the standpoints of strength, printability, and solvent resistance (e.g., alcohol resistance), films containing polyvinyl chloride, polyurethane, acrylic resin, and acrylic-urethane resin can be advantageously used as the receptor layer. A receptor layer containing polyvinyl chloride is also advantageous in making the decorative laminate film flame retardant.

The receptor layer may be the transparent receptor layer described above, may be an opaque layer, or may be colored. In one embodiment, the receptor layer contains a white pigment. As the white pigment, conventionally known white pigments such as zinc carbonate, zinc oxide, zinc sulfide, titanium oxide (titanium dioxide), etc. may be used. Talc, kaolin, and calcium carbonate may be included as additives. The white pigment may be used alone or in a mixture of two or more types. The white pigment may be in any form, and may be one that has been subjected to various dispersion treatments by conventionally known methods. In this embodiment, the receptor layer also functions as a concealing layer that conceals the surface (base) of the tile substrate. It is advantageous to use titanium dioxide as the white pigment because of its high whiteness.

The thickness of the receptor layer may vary, and typically may be about 10 μm or more, about 20 μm or more, or about 50 μm or more, and about 500 μm or less, about 200 μm or less, or about 100 μm or less.

As the transparent receptor layer and the receptor layer, films formed by various molding methods, such as extrusion films, extrusion-stretched films, calendared films, and cast films, or laminates thereof, can be used. In one embodiment, the film layer is a cast film. According to this embodiment, it is easy to obtain a thin film layer, and the residual internal stress is relatively low, so that the conformability of the decorative laminate film to the surface of the tile substrate can be advantageously improved.

In one embodiment, the decorative laminate film is attached to the tile substrate by applying an adhesive to the tile substrate surface and then applying the decorative laminate film thereover. In another embodiment, as shown in Figures 4-8, the decorative laminate film has a pressure-sensitive adhesive layer disposed on the opposite side of the transparent gray layer from the substrate solid color layer, and is attached to the tile substrate via the pressure-sensitive adhesive layer.

The pressure-sensitive adhesive layer can be formed using various types of adhesives, such as acrylic, polyolefin, polyurethane, polyester, rubber, and the like, including solvent-based, emulsion-based, pressure-sensitive, heat-sensitive, heat-curable, or UV-curable adhesives. In one embodiment, the adhesive layer includes an acrylic adhesive, a polyurethane adhesive, or a rubber adhesive.

In one embodiment, the pressure-sensitive adhesive layer includes a white pigment. The white pigment is as described for the receptor layer. In this embodiment, the pressure-sensitive adhesive layer also functions as a concealing layer that conceals the tile substrate surface (base). Titanium dioxide is advantageously used as the white pigment because of its high whiteness.

The pressure-sensitive adhesive layer can be formed on the base solid color layer or the receptor layer that receives it by a known method. For example, a pressure-sensitive adhesive composition that contains the components of the pressure-sensitive adhesive layer and, if necessary, an organic solvent is applied to a liner by knife coating, bar coating, or the like, and then dried to form a pressure-sensitive adhesive layer. The base solid color layer or receptor layer can be laminated on the obtained pressure-sensitive adhesive layer by dry lamination, or the like, to impart the pressure-sensitive adhesive layer to the decorative laminate film.

The thickness of the pressure-sensitive adhesive layer is generally about 5 μm or more, about 10 μm or more, or about 20 μm or more, and about 100 μm or less, about 80 μm or less, or about 50 μm or less.

In one embodiment, the decorative laminate film may have a liner to protect the pressure-sensitive adhesive layer. Examples of liners include paper, plastic materials such as polyethylene, polypropylene, polyester, cellulose acetate, and paper coated with such plastic materials. These liners may have a release-treated surface, such as with silicone. The thickness of the liner is generally about 5 μm or more, about 15 μm or more, or about 25 μm or more, and about 300 μm or less, about 200 μm or less, or about 150 μm or less.

The pressure-sensitive adhesive layer generally forms a flat adhesive surface, but may also form an uneven adhesive surface. This uneven adhesive surface includes an adhesive surface in which convex portions containing adhesive and concave portions surrounding the convex portions are formed on the adhesive surface of the pressure-sensitive adhesive layer, and when the adhesive surface is adhered to the tile substrate, a communication path is formed between the tile substrate surface and the adhesive surface, which is defined by the concave portions and communicates with the outside. An example of a method for forming an uneven adhesive surface is described below.

A liner is prepared with a release surface having a predetermined uneven structure. A pressure-sensitive adhesive composition is applied to the release surface of the liner and heated as necessary to form a pressure-sensitive adhesive layer. This transfers the uneven structure (negative structure) of the liner to the surface of the pressure-sensitive adhesive layer that comes into contact with the liner (this becomes the adhesive surface of the decorative laminate film), forming an uneven adhesive surface with a predetermined structure (positive structure) on the adhesive surface. As described above, the unevenness of the adhesive surface is designed in advance to include grooves that can form communication paths when the convex portions are adhered to the tile substrate.

As long as air bubbles can be prevented from remaining when the decorative laminate film is applied, the grooves in the pressure-sensitive adhesive layer may be arranged on the adhesive surface along a regular pattern to form a regular pattern of grooves, or may be arranged in an irregular pattern to form grooves of indefinite shape. When multiple grooves are arranged approximately parallel to each other, the arrangement interval of the grooves is preferably 10 to 2000 μm. The depth of the groove (the distance from the adhesive surface to the bottom of the groove measured in the direction of the film layer) is usually about 10 μm or more and about 100 μm or less. The shape of the groove is not particularly limited as long as it does not impair the effects of the present invention. For example, the shape of the groove can be approximately rectangular (including trapezoidal), approximately semicircular, or approximately semielliptical in the cross section of the groove perpendicular to the adhesive surface.

The decorative laminate film may further include a surface protective layer. The surface protective layer may be an overlaminate film, a clear coating, or an overlaminate film having a clear coating. The surface of the decorative laminate film can be protected by the surface protective layer. The surface protective layer can be formed by laminating a resin film such as polyester such as polyethylene terephthalate (PET), polyvinyl chloride, polyimide, polyurethane, acrylic resin, epoxy resin, or fluororesin directly or through a bonding layer on the layer constituting the decorative laminate film, or by applying a resin composition to the surface of the layer constituting the decorative laminate film and drying it. The overlaminate film having a clear coating can be formed by applying a resin composition to the surface of the resin film and drying the coating film obtained, and laminating the coating film directly or through a bonding layer on the layer constituting the decorative laminate film.

The surface protective layer is generally transparent in the visible light region. The visible light transmittance of the surface protective layer is generally about 80% or more, about 85% or more, or about 90% or more, and 100% or less, about 98% or less, or about 95% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm, when measured in accordance with JIS A 5759:2008. The entire surface protective layer may have the above average visible light transmittance, or a part or a plurality of parts may have the above average visible light transmittance.

The exposed surface of the surface protective layer may have irregularities. In one embodiment, an overlaminate film is used as the surface protective layer, and the exposed surface of the overlaminate film is embossed. In another embodiment, a coating containing a filler such as resin beads or inorganic particles is used as the surface protective layer, and the filler protrudes from the coating, forming irregularities on the exposed surface of the surface protective layer. By providing irregularities on the exposed surface of the surface protective layer by embossing or the like, glare due to reflected light when observed from various angles can be suppressed, and the reproducibility of the appearance of the repaired surface can be improved. In one embodiment, the gloss (gloss) of the overlaminate layer is, when measured in accordance with JIS Z 8741:1997, a Gs (60°) value of about 1 or more, about 2 or more, or about 3 or more, about 40 or less, about 30 or less, or about 20 or less.

The thickness of the surface protection layer is generally about 1 μm or more, about 5 μm or more, or about 10 μm or more, and about 100 μm or less, about 50 μm or less, or about 30 μm or less.

As a bonding layer that bonds the layers that make up the decorative laminate film, commonly used adhesives such as acrylic, polyolefin, polyurethane, polyester, and rubber-based adhesives of the solvent type, emulsion type, pressure-sensitive type, heat-sensitive type, heat-curing type, or UV-curing type can be used. The bonding layer may be formed of the same material as the pressure-sensitive adhesive layer.

The bonding layer is generally transparent, and its visible light transmittance, when measured in accordance with JIS A 5759:2008, is generally about 80% or more, about 85% or more, or about 90% or more, and 100% or less, about 98% or less, or about 95% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm. The entire surface of the bonding layer may have the above average visible light transmittance, or a portion or a plurality of portions may have the above average visible light transmittance.

The thickness of the bonding layer can generally be about 1 μm or more, about 2 μm or more, or about 5 μm or more, and about 50 μm or less, about 40 μm or less, or about 30 μm or less.

Depending on the application of the decorative laminate film, conventional additives such as antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers such as talc, kaolin, calcium carbonate, aluminum flakes, fumed silica, alumina, and nanoparticles may be added to one or more of the above layers.

The total thickness of the decorative laminate film, excluding the liner, is generally about 50 μm or more, about 80 μm or more, or about 100 μm or more, and about 1 mm or less, about 500 μm or less, or about 200 μm or less.

The decorative laminated film is, for example,
(1) acquiring image data by photographing a surface having a pattern to be replicated;
(2) creating pattern data by binarizing the image data;
(3) creating base material solid color data by subtracting the pattern data from the image data;
(4) creating transparent gray color data;
(5) forming a pattern layer based on the pattern data;
(6) forming a base material solid color layer based on the base material solid color data;
(7) forming a transparent gray layer based on the transparent gray color data;
(8) laminating the pattern layer, the base solid color layer, and the transparent gray layer to form a decorative laminate film having the appearance of a replicated surface having the pattern.

An example of the above method is described below with reference to Figure 9, but is not limited to the following.

In step (1), a digital camera or the like is used to take a photograph of the tile to be replaced on the wall of the building. The photographed image is obtained as RGB image data in a format such as JPEG.

In step (2), the obtained RGB image data (JPEG format in FIG. 9) is binarized using a predetermined threshold value on image processing software to create pattern data. The pattern data is obtained by image conversion from RGB image data to CMYK image data. The pattern data may be in grayscale, or may be data in which only the pattern portion has been restored to full color data after binarization.

In step (3), the pattern data obtained by binarization is subtracted from the RGB image data of the captured image to create base material solid color data. The base material solid color data is obtained by image conversion from RGB image data to CMYK image data.

In step (4), transparent gray data is created as CMYK image data. Multiple transparent gray data sets with different gradations may be prepared, and the brightness may be adjusted using these multiple transparent gray data sets while checking the appearance of the decorative laminate film.

In steps (5) to (7), a pattern layer, a base material solid color layer, and a transparent gray layer are formed based on the pattern data, base material solid color data, and transparent gray color data. In one embodiment, as shown in FIG. 9, the pattern layer, base material solid color layer, and transparent gray layer are all formed by inkjet printing. In the example shown in FIG. 9, these layers are formed on a receptor film, but the base material solid color layer may be formed as a resin film, and the transparent gray layer may be formed as a receptor layer or a bonding layer.

In step (8), the films are laminated together to produce a decorative laminate film. A bonding layer may be used for lamination, or the layers may be laminated directly by thermocompression.

If the surface to be replicated does not have a pattern, the process of creating pattern data (2) and the process of forming a pattern layer based on the pattern data (5) can be omitted, and the process of creating base material solid color data (3) can create the base material solid color data directly from the image data.

The decorative film of the second embodiment includes an image film including a transparent receptor layer having a first surface and a second surface opposite the first surface, an inkjet printed pattern layer disposed on the first surface of the transparent receptor layer, and a colored opaque pressure-sensitive adhesive layer disposed on the second surface of the transparent receptor layer.

According to the second embodiment, by using an image film in which an inkjet-printed pattern layer is arranged on the first surface of a transparent receptor layer and a colored opaque pressure-sensitive adhesive layer is arranged on the second surface, the combination of the pattern formed by inkjet printing and the coloring of the pressure-sensitive adhesive layer can reproduce the appearance of a repaired surface with various patterns and colors that cannot be achieved by inkjet printing alone. With this structure, by coloring the pressure-sensitive adhesive layer itself, a simple structure can be achieved without additionally laminating a colored layer. The simple laminate structure of the decorative laminate film can simplify the manufacturing process of the decorative laminate film, and can make the decorative laminate film thinner to further improve its ability to follow the uneven tile substrate surface. Making the decorative laminate film thinner is also advantageous in terms of non-flammability, since it can reduce flammable organic components.

10 shows a schematic cross-sectional view of a decorative laminate film 210 according to one embodiment. The decorative laminate film 210 includes an image film 212 including a transparent receptor layer 214, an inkjet printing pattern layer 216, and a colored opaque pressure-sensitive adhesive layer 218. The decorative laminate film 210 of FIG. 10 further includes, as optional components, a surface protective layer 222 as the outermost layer, and a liner 230 that protects the colored opaque pressure-sensitive adhesive layer 218. The liner 230 is peeled off before the decorative laminate film 210 is attached to the tile substrate. The surface protective layer 222 may be laminated via a bonding layer 224. The surface protective layer 222 may be an overlaminate film or a clear coating. When the decorative laminate film 210 is applied to a tile substrate, the pattern formed by the inkjet printed pattern layer 216 is combined with the solid substrate color (background color excluding the pattern from the image) formed by the colored opaque pressure-sensitive adhesive layer 218 or the combination of the colored opaque pressure-sensitive adhesive layer 218 and the transparent receptor layer 214, and is perceived by the observer as an image.

The transparent receptor layer receives the ink composition that forms the inkjet printed pattern layer, and has a transparency that allows the colored opaque pressure-sensitive adhesive layer to be seen through the transparent receptor layer. Due to the transparency of the transparent receptor layer, even if a portion of the ink composition penetrates the transparent receptor layer, the penetrated portion can be seen. Therefore, it is possible to provide a decorative laminate film having an image that exhibits high clarity even when the inkjet printed pattern layer is made thin.

As the transparent receptor layer, a film or laminate as described for the decorative laminate film of the first embodiment can be used.

In one embodiment, the transparent receptor layer is an acrylic resin film containing a polymer blend of a carboxyl group-containing (meth)acrylic polymer and an amino group-containing (meth)acrylic polymer. Such an acrylic resin film containing a polymer blend can have high strength even when it is relatively thin, and can effectively improve the conformability of the decorative laminate film to the uneven surface of a tile substrate, or can impart flame resistance to the decorative laminate film.

In one embodiment, the transparent receptor layer is colorless. In this embodiment, the solid color of the substrate is represented by a colored opaque pressure-sensitive adhesive layer. The colorless transparent receptor layer does not suffer from a decrease in elongation properties due to the inclusion of a colorant such as a pigment. Therefore, decorative laminate films containing a colorless transparent receptor layer are particularly excellent in conforming to the uneven surface of a tile substrate.

The transparent receptor layer may be colored as necessary. In this embodiment, the solid color of the substrate is expressed by a combination of the colored opaque pressure-sensitive adhesive layer and the transparent receptor layer. Examples of colorants include inorganic pigments such as titanium oxide, carbon black, yellow lead, yellow iron oxide, red iron oxide, and red iron oxide, phthalocyanine pigments such as phthalocyanine blue and phthalocyanine green, organic pigments such as azo lake pigments, indigo pigments, perinone pigments, perylene pigments, quinophthalone pigments, dioxazine pigments, and quinacridone pigments such as quinacridone red. The content of the colorant in this embodiment varies depending on the thickness of the transparent receptor layer, the elongation properties required for the transparent receptor layer, and the like, but is generally about 1% by weight or more, about 2% by weight or more, or about 3% by weight or more, about 30% by weight or less, about 25% by weight or less, or about 20% by weight or less of the transparent receptor layer.

The thickness of the transparent receptor layer may vary, and is generally about 10 μm or more, about 20 μm or more, or about 50 μm or more, and about 500 μm or less, about 200 μm or less, or about 100 μm or less. In embodiments in which the transparent receptor layer is colored, the thickness of the transparent receptor layer is desirably about 200 μm or less, about 100 μm or less, or about 80 μm or less, thereby ensuring the transparency of the transparent receptor layer. In applications in which the decorative laminate film is required to be non-flammable, the thickness of the transparent receptor layer varies depending on its material, and for example, when the transparent receptor layer is a polyvinyl chloride film, it is desirably about 200 μm or less, about 150 μm or less, or about 100 μm or less, and when the transparent receptor layer is an acrylic resin film, it is desirably about 80 μm or less, about 60 μm or less, or about 40 μm or less.

The visible light transmittance of the transparent receptor layer is generally about 70% or more, about 80% or more, or about 90% or more, and 100% or less, about 98% or less, or about 95% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm, when measured in accordance with JIS A 5759:2008. The entire surface of the transparent receptor layer may have the above average visible light transmittance, or a portion or a plurality of portions may have the above average visible light transmittance.

Depending on the application of the decorative laminate film, additives such as antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers may be added to the transparent receptor layer.

In one embodiment, the transparent receptor layer does not contain a flame retardant. In this embodiment, the decorative laminate film can be made non-flammable without the use of a flame retardant by making the total thickness of the decorative laminate film thin (e.g., about 100 μm or less).

The inkjet-printed pattern layer can be formed on the transparent receptor layer by inkjet printing using a solvent-based ink or a UV-curable ink. The inkjet-printed pattern layer can be monochromatic or multicolored. The inkjet-printed pattern layer can be formed in achromatic or chromatic colors based on the pattern of the repair surface.

The thickness of the inkjet print pattern layer may vary, and generally, when using solvent-based inks, it can be about 0.1 μm or more, or about 0.5 μm or more, and about 10 μm or less, or about 5 μm or less. When using UV-curable inks, it can be about 0.5 μm or more, or about 1 μm or more, and about 30 μm or less, or about 20 μm or less.

The colored opaque pressure-sensitive adhesive layer adheres the decorative laminate film to the tile substrate surface and also functions as a concealing layer that conceals the tile substrate surface (base). The colored opaque pressure-sensitive adhesive layer expresses the solid color of the substrate alone (when the transparent receptor layer is colorless) or in combination with the transparent receptor layer (when the transparent receptor layer is colored). The colored opaque pressure-sensitive adhesive layer contains, as a colorant, inorganic pigments such as titanium oxide, carbon black, yellow lead, yellow iron oxide, red iron oxide, and red iron oxide, phthalocyanine pigments such as phthalocyanine blue and phthalocyanine green, azo lake pigments, indigo pigments, perinone pigments, perylene pigments, quinophthalone pigments, dioxazine pigments, and quinacridone pigments such as quinacridone red, and other organic pigments. The colored opaque pressure-sensitive adhesive layer may express an achromatic color such as white, gray, or black, or may express a chromatic color. The colored opaque pressure-sensitive adhesive layer may contain glittering materials such as mica and aluminum powder.

The colorant content of the colored opaque pressure-sensitive adhesive layer varies depending on the thickness of the colored opaque pressure-sensitive adhesive layer, the adhesive properties required of the colored opaque pressure-sensitive adhesive layer, the type of coloring, the colorant used, etc., but is generally about 1% by weight or more, about 3% by weight or more, or about 5% by weight or more, about 50% by weight or less, about 40% by weight or less, or about 30% by weight or less of the colored opaque pressure-sensitive adhesive layer.

The colored opaque pressure-sensitive adhesive layer can be formed using a composition in which a colorant is mixed with various types of adhesives, such as acrylic, polyolefin, polyurethane, polyester, rubber, and other solvent-based, emulsion-based, pressure-sensitive, heat-sensitive, heat-curable, or UV-curable adhesives. In one embodiment, the colored opaque pressure-sensitive adhesive layer includes an acrylic adhesive, a polyurethane adhesive, or a rubber adhesive.

In one embodiment, the colored opaque pressure-sensitive adhesive layer is formed from an acrylic adhesive containing a polymer blend of a carboxy group-containing (meth)acrylic polymer and an amino group-containing (meth)acrylic polymer. Such an acrylic adhesive containing a polymer blend can contain a colorant in a high concentration and uniformly dispersed state by utilizing the interaction between the colorant and the carboxy group or amino group. Therefore, in this embodiment, a colored opaque pressure-sensitive adhesive layer having high hiding power and a relatively thin thickness can be formed.

The thickness of the colored opaque pressure-sensitive adhesive layer may vary, and is generally about 5 μm or more, about 10 μm or more, or about 20 μm or more, and about 100 μm or less, about 80 μm or less, or about 50 μm or less. In applications where the decorative laminate film is required to be flame-resistant, it is desirable for the thickness of the colored opaque pressure-sensitive adhesive layer to be about 70 μm or less, about 50 μm or less, or about 30 μm or less.

The visible light transmittance of the colored opaque pressure-sensitive adhesive layer, when measured in accordance with JIS A 5759:2008, is generally about 30% or less, about 20% or less, or about 10% or less as the average visible light transmittance at wavelengths of 380 nm to 780 nm.

Depending on the application of the decorative laminate film, additives such as tackifiers, antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers may be added to the colored opaque pressure-sensitive adhesive layer.

In one embodiment, the colored opaque pressure-sensitive adhesive layer does not contain a flame retardant. In this embodiment, the decorative laminate film can be made non-flammable without the use of a flame retardant by making the total thickness of the decorative laminate film thin (e.g., about 100 μm or less).

The colored opaque pressure-sensitive adhesive layer can be formed on the transparent receptor layer by a known method. For example, a pressure-sensitive adhesive composition containing the components of the colored opaque pressure-sensitive adhesive layer and, if necessary, an organic solvent is applied to a liner by knife coating, bar coating, or the like, and then dried to form a colored opaque pressure-sensitive adhesive layer. A transparent receptor layer can be laminated on the obtained colored opaque pressure-sensitive adhesive layer by dry lamination, or the like, to form a colored opaque pressure-sensitive adhesive layer on the transparent receptor layer.

The decorative laminate film may have a liner that protects the colored opaque pressure-sensitive adhesive layer. The liner may be one that is described for the decorative laminate film of the first embodiment.

The colored opaque pressure-sensitive adhesive layer generally forms a flat adhesive surface, but may also form an uneven adhesive surface. The uneven adhesive surface may be that described for the pressure-sensitive adhesive layer of the decorative laminate film of the first embodiment.

The decorative laminate film may further include a surface protective layer on the inkjet printed pattern layer. The surface protective layer may be the same as that described for the decorative laminate film of the first embodiment.

The bonding layer that bonds the overlaminate film to the decorative laminate film can be the same as that described for the decorative laminate film in the first embodiment.

Depending on the application of the decorative laminate film, additives such as antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers may be added to the surface protective layer or bonding layer.

The total thickness of the decorative laminate film excluding the liner is generally about 30 μm or more, about 40 μm or more, or about 50 μm or more, and about 500 μm or less, about 200 μm or less, or about 100 μm or less. In applications where the decorative laminate film is required to be non-flammable, the total thickness of the decorative laminate film varies depending on the constituent materials; for example, when the transparent receptor layer is a polyvinyl chloride film, it is desirable that the total thickness be about 250 μm or less, about 200 μm or less, or about 150 μm or less, and when the transparent receptor layer is an acrylic resin film, it is desirable that the total thickness be about 100 μm or less, about 90 μm or less, or about 80 μm or less.

In one embodiment, the decorative laminate film, excluding the liner, does not include any components other than the transparent receptor layer, the inkjet printed pattern layer, the colored opaque pressure-sensitive adhesive layer, the surface protective layer, and the bonding layer of the surface protective layer, i.e., it consists of the transparent receptor layer, the inkjet printed pattern layer, the colored opaque pressure-sensitive adhesive layer, the surface protective layer, and, if necessary, the bonding layer of the surface protective layer.

The decorative laminate film of one embodiment is non-flammable in the ISO 5660-1 cone calorimeter test. For example, when the heat release rate (kW/ ^m2 ) and total heat release amount (MJ/ ^m2 ) of the decorative laminate film are measured using a cone calorimeter, the total heat release amount is 8 MJ/m2 or ^less for 20 minutes after the start of heating, and the time during which the film shows a heat release rate exceeding 200 kW/ ^m2 is 10 seconds or less in total. In one embodiment, the decorative laminate film achieves the above non-flammability without containing a flame retardant.

The decorative laminate film is, for example,
(1) providing a transparent receptor layer having a first surface and a second surface opposite the first surface;
(2) acquiring image data by photographing the patterned surface to be replicated;
(3) A step of binarizing the image data to generate pattern data;
(4) creating base material solid color data by subtracting the pattern data from the image data;
(5) forming a colored, opaque pressure-sensitive adhesive layer on the second surface of the transparent receptor layer based on the solid color data of the substrate; and (6) forming an inkjet-printed pattern layer on the first surface of the transparent receptor layer by inkjet printing based on the pattern data.

An example of the above method is described below with reference to Figure 11, but is not limited to the following.

The above can be used as the transparent receptor layer in step (1).

In step (2), a digital camera or the like is used to take a photograph of the tile to be replaced on the wall of the building. The photographed image is obtained as RGB image data in a format such as JPEG.

In step (3), the obtained RGB image data (JPEG format in FIG. 11) is binarized using a predetermined threshold value on image processing software to create pattern data. The pattern data is obtained by image conversion from RGB image data to CMYK image data. The pattern data may be in grayscale, or may be data in which only the pattern portion has been restored to full color data after binarization.

In step (4), the pattern data obtained by binarization is subtracted from the RGB image data of the captured image to create base material solid color data. The base material solid color data is obtained by image conversion from RGB image data to CMYK image data.

In step (5), a colored opaque pressure-sensitive adhesive layer is formed on the second surface of the transparent receptor layer based on the solid substrate color data. The pressure-sensitive adhesive composition for forming the colored opaque pressure-sensitive adhesive layer can be prepared as described above. The colored opaque pressure-sensitive adhesive layer can be formed to express the solid substrate color alone (when the transparent receptor layer is colorless) or in combination with the transparent receptor layer (when the transparent receptor layer is colored). A plurality of colored opaque pressure-sensitive adhesive layers and a plurality of transparent receptor layers each having a different color may be prepared, and the combination of the colored opaque pressure-sensitive adhesive layer and the transparent receptor layer that most closely resembles the solid substrate color data may be selected and laminated.

In step (6), an inkjet printed pattern layer is formed on the first surface of the transparent receptor layer based on the pattern data. Step (6) may be performed after step (5) or before step (5).

For the colored opaque pressure-sensitive adhesive layer in step (5), multiple colored opaque pressure-sensitive adhesive layers of different colors may be prepared, and the colored opaque pressure-sensitive adhesive layer of the color that is closest to the solid color data of the substrate may be selected and used.

To reproduce colors more accurately, complementary colors that make up for differences between the colored opaque pressure-sensitive adhesive layer and the solid color data of the substrate may be added by coloring the transparent receptor layer or by additional inkjet printing onto the transparent receptor layer.

The decorative film of the third embodiment includes a transparent receptor layer having a first surface and a second surface opposite the first surface, a transparent gray layer printed directly on the first surface of the transparent receptor layer, a substrate solid color layer printed directly on the second surface of the transparent receptor layer, and a white opaque pressure-sensitive adhesive layer disposed directly on the substrate solid color layer, the transparent receptor layer having a thickness of about 50 μm or less. The transparent gray layer of the decorative laminate film may further include a pattern.

In the decorative laminate film of the third embodiment, the observer sees the base solid color layer through the transparent gray layer, which may or may not contain a pattern. The white opaque pressure-sensitive adhesive layer disposed directly on the base solid color layer not only adheres the decorative laminate film to the tile base surface, but also functions as a white base that reflects light that is incident on the decorative laminate film and passes between the ink dots or dots. Without being bound by any theory, it is believed that in a laminate structure in which the transparent gray layer and the base solid color layer are disposed directly on the first and second surfaces of the transparent receptor layer, respectively, as printed layers, the observer is allowed to see the base solid color layer, the brightness of which is adjusted, through the separately provided transparent gray layer, thereby giving the observer an impression that the appearance of the repaired surface is more accurately reproduced.

The decorative laminate film of the third embodiment has a simple laminate structure having a transparent gray layer and a solid base layer printed directly on the first and second sides of a thin transparent receptor layer, respectively, and a white opaque pressure-sensitive adhesive layer disposed directly on the solid base layer, so that the manufacturing process of the decorative laminate film can be simplified, and coupled with the transparent receptor layer having a thickness of about 50 μm or less, the decorative laminate film can be made thinner and its conformability to the uneven tile base surface can be improved. Making the decorative laminate film thinner is also advantageous in terms of non-flammability, since it can reduce flammable organic components. In addition, the transparent receptor layer having a thickness of about 50 μm or less reduces the optical effects caused by the transparent receptor layer, and can improve the color reproducibility of the combination of the transparent gray layer and the solid base layer, especially the color and pattern reproducibility when the transparent gray layer has a pattern.

12 shows a schematic cross-sectional view of a decorative laminate film 310 according to one embodiment. The decorative laminate film 310 includes a transparent receptor layer 312, a transparent gray layer 314 printed directly on the first surface (upper surface) of the transparent receptor layer 312, and a substrate solid color layer 316 printed directly on the second surface (lower surface) of the transparent receptor layer 312. A white opaque pressure-sensitive adhesive layer 318 is disposed directly on the substrate solid color layer 316. The decorative laminate film 310 of FIG. 12 further includes, as optional components, a surface protective layer 320 as the outermost layer, and a liner 330 that protects the white opaque pressure-sensitive adhesive layer 318. The liner 330 is peeled off before the decorative laminate film 310 is attached to the tile substrate surface. The surface protective layer 320 may be laminated via a bonding layer 322. The surface protective layer 322 may be an overlaminate film, a clear coating, or an overlaminate film having a clear coating. In FIG. 12, the substrate solid color layer 316 is viewed by an observer from above through the transparent gray layer 314.

Figure 13 shows a schematic cross-sectional view of a decorative laminate film 310 according to another embodiment. The transparent gray layer 314 of the decorative laminate film 310 further includes a pattern 315. In Figure 13, the base solid color layer 316 is viewed by an observer from above through the transparent gray layer 314 including the pattern 315, and is viewed by the observer as an image having a pattern as a whole.

The transparent receptor layer receives the ink composition that forms the transparent gray layer with or without a pattern, and the base material solid color layer, and has a transparency that allows the base material solid color layer to be seen through the transparent receptor layer. Due to the transparency of the transparent receptor layer, even if a part of the ink composition permeates the transparent receptor layer, the permeated part can be seen. Therefore, it is possible to provide a decorative laminate film having an image that shows high clarity even when the transparent gray layer, especially the transparent gray layer with a pattern, is thinned.

As the transparent receptor layer, various resins, for example, films containing acrylic resins such as polymethyl methacrylate (PMMA), polyolefins such as polyvinyl chloride (PVC), polycarbonate (PC), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate, copolymers such as ethylene-vinyl acetate copolymer (EVA), ethylene-acrylic acid copolymer, ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, acrylonitrile-butadiene rubber (NBR), and acrylonitrile-butadiene-styrene copolymer (ABS), or mixtures thereof, can be used. These films may have a surface treatment such as a primer treatment or a corona treatment on the bonding surface with other layers. From the viewpoints of strength, printability, and solvent resistance (e.g., alcohol resistance), films containing polyvinyl chloride or acrylic resins can be advantageously used as the transparent receptor layer, and it is preferable to use an acrylic resin film.

In one embodiment, the transparent receptor layer is an acrylic resin film containing a polymer blend of a carboxy group-containing (meth)acrylic polymer and an amino group-containing (meth)acrylic polymer. An acrylic resin film containing such a polymer blend has excellent printability, allowing a printed layer to be formed on both the first and second sides. In addition, an acrylic resin film containing such a polymer blend can have high strength even if it is relatively thin, and can effectively increase the conformability of the decorative laminate film to the uneven surface of a tile substrate, or can impart non-flammability to the decorative laminate film.

As the transparent receptor layer, films formed by various molding methods, such as extruded films, extrusion-stretched films, calendared films, cast films, etc., or laminates thereof can be used. In one embodiment, the film layer is a cast film. According to this embodiment, it is easy to obtain a thin film layer, and the residual internal stress is relatively low, so that the conformability of the decorative laminate film to the surface of the tile substrate can be advantageously improved.

In one embodiment, the transparent receptor layer is colorless. In this embodiment, the solid color of the substrate is expressed only by the solid substrate color layer. The colorless transparent receptor layer does not suffer from a decrease in elongation properties due to the inclusion of a colorant such as a pigment. Therefore, a decorative laminate film including a colorless transparent receptor layer has particularly excellent conformability to the uneven surface of a tile substrate.

The transparent receptor layer may be colored if necessary. In this embodiment, the solid color of the substrate is expressed by a combination of the solid color substrate layer and the transparent receptor layer. The colorant and its content can be those described for the decorative laminate film of the second embodiment.

The thickness of the transparent receptor layer is about 50 μm or less. The thickness of the transparent receptor layer can be, for example, about 5 μm or more, about 10 μm or more, or about 15 μm or more, and about 44 μm or less, about 40 μm or less, or about 36 μm or less. By using such a thin transparent receptor layer, the conformability of the decorative laminate film to the tile substrate surface can be advantageously increased, and it is also advantageous in obtaining non-flammability.

The visible light transmittance of the transparent receptor layer is generally about 70% or more, about 80% or more, or about 90% or more, and 100% or less, about 98% or less, or about 95% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm, when measured in accordance with JIS A 5759:2008. The entire surface of the transparent receptor layer may have the above average visible light transmittance, or a portion or a plurality of portions may have the above average visible light transmittance.

Depending on the application of the decorative laminate film, additives such as antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers may be added to the transparent receptor layer.

In one embodiment, the transparent receptor layer does not contain a flame retardant. In this embodiment, the decorative laminate film can be made non-flammable without the use of a flame retardant by making the total thickness of the decorative laminate film thin (e.g., about 100 μm or less).

The transparent gray layer is formed directly on the first surface of the transparent receptor layer by printing, such as inkjet printing, offset printing, gravure printing, screen printing, electrostatic printing, etc., using toner, solvent-based ink, UV-curable ink, water-based ink, latex ink, etc. In one embodiment, the transparent gray layer is an inkjet printed layer.

The transparent gray layer is generally achromatic, but may be chromatic. In one embodiment, the transparent gray layer contains only black pigment or black dye. In another embodiment, the transparent gray layer contains a combination of black pigment or black dye and white pigment or white dye. In another embodiment, the transparent gray layer contains chromatic pigment or dye, such as red, blue, yellow, etc., in addition to black pigment or black dye. In this embodiment, the color of the transparent gray layer can be appropriately shifted to match the hue and saturation of the base solid color layer.

The transparent grey layer may further include a pattern. The transparent grey layer including the pattern may be formed by a multi-colour printing technique in printing such as inkjet printing, offset printing, gravure printing, screen printing, electrostatic printing, etc. The pattern may be monochromatic or multi-coloured. The pattern may be formed in achromatic colours using an image that approximates the pattern of the repaired surface.

The visible light transmittance of the pattern-free portion of the transparent gray layer, when measured in accordance with JIS A 5759:2008, is generally about 40% or more, about 50% or more, or about 60% or more, and about 95% or less, about 90% or less, or about 85% or less, as the average visible light transmittance at wavelengths of 380 nm to 780 nm. By setting the average visible light transmittance of the pattern-free portion of the transparent gray layer within the above range, the brightness of the base solid color layer can be effectively adjusted.

The thickness of the transparent gray layer may vary, and generally, when a solvent-based ink is used, it may be about 0.1 μm or more, or about 0.5 μm or more, and about 10 μm or less, or about 5 μm or less. When a UV-curable ink is used, it may be about 0.5 μm or more, or about 1 μm or more, and about 30 μm or less, or about 20 μm or less.

The substrate solid color layer is formed directly on the second surface of the transparent receptor layer by printing, such as inkjet printing, offset printing, gravure printing, screen printing, electrostatic printing, etc., using toner, solvent-based ink, UV-curable ink, water-based ink, latex ink, etc. In one embodiment, the substrate solid color layer is an inkjet printed layer.

The solid color layer of the substrate is a chromatic color, and its hue, brightness, and chroma may vary. In one embodiment, based on the L ^* a ^* b ^* color system, the L ^* value of the solid color layer of the substrate is in the range of about 30 or more and about 99 or less, a ^* is in the range of about -10 or more and about 20 or less, and b ^* is in the range of about -10 or more and about 30 or less. When the L ^* , a ^* , and b ^* of the solid color layer of the substrate are in the above ranges, the effect of brightness adjustment by the transparent gray layer becomes greater.

The thickness of the substrate solid color layer may vary, and generally, when a solvent-based ink is used, it can be about 0.1 μm or more, or about 0.5 μm or more, and about 10 μm or less, or about 5 μm or less. When a UV-curable ink is used, it can be about 0.5 μm or more, or about 1 μm or more, and about 30 μm or less, or about 20 μm or less.

In one embodiment, both the transparent gray layer and the substrate solid color layer are inkjet printed layers.

The white opaque pressure-sensitive adhesive layer, which is placed directly on the base solid color layer, adheres the decorative laminate film to the tile base surface and also functions as a concealing layer that conceals the tile base surface (base). The white opaque pressure-sensitive adhesive layer contains a white pigment such as titanium oxide (titanium dioxide), barium sulfate, or zinc oxide as a colorant. It is advantageous to use titanium oxide as the white pigment because of its high whiteness. Aluminum paste may be added to the white opaque pressure-sensitive adhesive layer to increase the concealing properties of the white opaque pressure-sensitive adhesive layer. Aluminum paste has little effect on the brightness and can be used advantageously.

The colorant content of the white opaque pressure-sensitive adhesive layer varies depending on the thickness of the white opaque pressure-sensitive adhesive layer, the adhesive properties required of the white opaque pressure-sensitive adhesive layer, the type of coloring, the colorant used, etc., but is generally about 1% by weight or more, about 3% by weight or more, or about 5% by weight or more, about 50% by weight or less, about 40% by weight or less, or about 30% by weight or less of the white opaque pressure-sensitive adhesive layer.

The white opaque pressure-sensitive adhesive layer can be formed using a composition in which a colorant is mixed with various types of adhesives, such as acrylic, polyolefin, polyurethane, polyester, rubber, and other solvent-based, emulsion-based, pressure-sensitive, heat-sensitive, heat-curable, or UV-curable adhesives. In one embodiment, the white opaque pressure-sensitive adhesive layer includes an acrylic adhesive, a polyurethane adhesive, or a rubber adhesive.

In one embodiment, the white opaque pressure-sensitive adhesive layer is formed from an acrylic adhesive containing a polymer blend of a carboxy group-containing (meth)acrylic polymer and an amino group-containing (meth)acrylic polymer. Such an acrylic adhesive containing a polymer blend can contain a colorant, such as titanium oxide, in a high concentration and uniformly dispersed state by utilizing the interaction between the colorant and the carboxy group or amino group. Therefore, in this embodiment, a white opaque pressure-sensitive adhesive layer having high hiding power and a relatively thin thickness can be formed.

The thickness of the white opaque pressure-sensitive adhesive layer may vary, and is generally about 5 μm or more, about 10 μm or more, or about 20 μm or more, and about 100 μm or less, about 80 μm or less, or about 50 μm or less. In applications where the decorative laminate film is required to be flame-resistant, it is desirable for the thickness of the white opaque pressure-sensitive adhesive layer to be about 70 μm or less, about 50 μm or less, or about 30 μm or less.

The visible light transmittance of the white opaque pressure-sensitive adhesive layer, when measured in accordance with JIS A 5759:2008, is generally about 30% or less, about 20% or less, or about 10% or less as the average visible light transmittance at wavelengths of 380 nm to 780 nm.

Depending on the application of the decorative laminate film, additives such as tackifiers, antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers may be added to the white opaque pressure-sensitive adhesive layer.

In one embodiment, the white opaque pressure-sensitive adhesive layer does not contain a flame retardant. In this embodiment, the decorative laminate film can be made non-flammable without the use of a flame retardant by making the total thickness of the decorative laminate film thin (e.g., about 100 μm or less).

The white opaque pressure-sensitive adhesive layer can be formed directly on the solid color layer of the substrate by a known method. For example, a pressure-sensitive adhesive composition containing the components of the white opaque pressure-sensitive adhesive layer and, if necessary, an organic solvent is applied to a liner by knife coating, bar coating, or the like, and then dried to form a white opaque pressure-sensitive adhesive layer. The solid color layer of the substrate can be laminated on the obtained white opaque pressure-sensitive adhesive layer by dry lamination, or the like, so that the white opaque pressure-sensitive adhesive layer is disposed directly on the solid color layer of the substrate.

The decorative laminate film may have a liner that protects the white opaque pressure-sensitive adhesive layer. The liner may be the same as that described for the decorative laminate film of the first embodiment.

The white opaque pressure-sensitive adhesive layer generally forms a flat adhesive surface, but may also form an uneven adhesive surface. The uneven adhesive surface may be that described for the pressure-sensitive adhesive layer of the decorative laminate film of the first embodiment.

The decorative laminate film may further include a surface protective layer on the transparent gray layer. As the surface protective layer, the one described for the decorative laminate film of the first embodiment can be used.

The bonding layer that bonds the overlaminate film to the decorative laminate film can be the same as that described for the decorative laminate film in the first embodiment.

Depending on the application of the decorative laminate film, additives such as antioxidants, UV absorbers, light stabilizers, plasticizers, lubricants, antistatic agents, flame retardants, and fillers may be added to the surface protective layer or bonding layer.

The total thickness of the decorative laminate film, excluding the liner, is generally about 30 μm or more, about 40 μm or more, or about 50 μm or more, and about 200 μm or less, about 150 μm or less, or about 100 μm or less. In applications where the decorative laminate film is required to be non-flammable, it is desirable for the total thickness of the decorative laminate film to be about 105 μm or less, about 100 μm or less, or about 95 μm or less.

In one embodiment, the decorative laminate film, excluding the liner, does not include any components other than the transparent receptor layer, the transparent gray layer with or without a pattern, the white opaque pressure-sensitive adhesive layer, the surface protective layer, and the bonding layer of the surface protective layer, i.e., it consists of the transparent receptor layer, the transparent gray layer with or without a pattern, the white opaque pressure-sensitive adhesive layer, the surface protective layer, and optionally the bonding layer of the surface protective layer.

The decorative laminate film of one embodiment is non-flammable in the ISO 5660-1 cone calorimeter test. For example, when the heat release rate (kW/ ^m2 ) and total heat release amount (MJ/ ^m2 ) of the decorative laminate film are measured using a cone calorimeter, the total heat release amount is 8 MJ/m2 or ^less for 20 minutes after the start of heating, and the time during which the film shows a heat release rate exceeding 200 kW/ ^m2 is 10 seconds or less in total. In one embodiment, the decorative laminate film achieves the above non-flammability without containing a flame retardant.

The decorative laminate film in which the transparent gray layer includes a pattern is, for example,
(1) providing a transparent receptor layer having a first surface and a second surface opposite the first surface;
(2) acquiring image data by photographing the patterned surface to be replicated;
(3) A step of binarizing the image data to generate pattern data;
(4) creating base material solid color data by subtracting the pattern data from the image data;
(5) creating transparent gray data;
(6) a step of synthesizing the transparent gray color data and the pattern data to generate transparent gray layer data;
(7) printing a substrate solid color layer on the second surface of the transparent receptor layer based on the substrate solid color data;
(8) printing a transparent gray layer on the first surface of the transparent receptor layer based on the transparent gray layer data, and (9) forming a white opaque pressure-sensitive adhesive layer on the substrate solid color layer.

An example of the above method is described below with reference to Figure 14, but is not limited to the following.

The above can be used as the transparent receptor layer in step (1).

In step (2), a digital camera or the like is used to take a photograph of the tile to be replaced on the wall of the building. The photographed image is obtained as RGB image data in a format such as JPEG.

In step (3), the obtained RGB image data (JPEG format in FIG. 14) is binarized using a predetermined threshold value on image processing software to create pattern data. The pattern data is obtained by image conversion from RGB image data to CMYK image data. The pattern data may be in grayscale, or may be data in which only the pattern portion has been restored to full color data after binarization.

In step (4), the pattern data obtained by binarization is subtracted from the RGB image data of the captured image to create base material solid color data. The base material solid color data is obtained by image conversion from RGB image data to CMYK image data.

In step (5), transparent gray data is created as CMYK image data. Multiple transparent gray data sets with different gradations may be prepared, and the brightness may be adjusted using these multiple transparent gray data sets while checking the appearance of the decorative laminate film.

In step (6), the transparent gray color data and the pattern data are combined to create transparent gray layer data. For example, the transparent gray layer data can be created by selecting, cutting, and copying only the pattern portion of the pattern data obtained in step (3), pasting the copied data into the transparent gray color data obtained in step (5), and then integrating the images.

In steps (7) and (8), a substrate solid color layer is printed on the second surface of the transparent receptor layer based on the substrate solid color data, and a transparent gray layer is printed on the first surface of the transparent receptor layer based on the transparent gray layer data. In one embodiment, both the substrate solid color layer and the transparent gray layer are formed by inkjet printing, as shown in FIG. 14.

In step (9), a white opaque pressure-sensitive adhesive layer is formed on the solid color layer of the substrate. The pressure-sensitive adhesive composition for forming the white opaque pressure-sensitive adhesive layer can be prepared as described above.

Step (8) may be performed before or after step (7). Step (8) may be performed after steps (7) and (9).

As shown in Figure 14, a surface protection layer may be laminated on top of the transparent gray layer if necessary.

If there is no pattern on the repair surface, step (3) can be omitted, and in step (4) the base material solid color data can be created directly from the image data, and in step (6) the transparent gray color data can be used as is as the transparent gray layer data.

The tiles can be manufactured by attaching the decorative film to the tile substrate using an adhesive or pressure-sensitive adhesive, or by attaching the decorative laminate film to the tile substrate via a pressure-sensitive adhesive layer of the decorative laminate film. The decorative film or decorative laminate film can be attached to the substrate by hand, or by using a vacuum/pressure forming method, a water pressure transfer method, or the like.

A tile installation method according to one embodiment includes attaching the above-mentioned tile to a wall surface and filling a gap between the tile and an adjacent tile with a joint material, the joint material being filled so that a portion of the decorative film extending to at least a portion of at least one side surface of the tile substrate is visible and at least a portion of the at least one side surface of the tile substrate is exposed. This ensures that the tile has air permeability or water permeability.

The tiles can be attached to the wall surface and the joints can be filled with a general joint material, such as mortar or a resin-based adhesive. Fixtures such as screws and fasteners, or a three-dimensional shape on the back of the tile base material can be fitted to the three-dimensional shape of the wall surface to attach the tiles to the wall surface.

Another embodiment of the tile installation method includes attaching the above-mentioned tile to a wall surface and filling a gap between the tile and a tile adjacent to the tile, the gap being filled so that a portion of the decorative film extending to at least a portion of at least one side of the tile substrate is visible and at least one side of the tile substrate is covered with the gap. This can prevent moisture from entering the tile substrate or the wall surface. The gap may be filled so that it covers the decorative film covering at least one side of the tile substrate.

In one embodiment of an architectural structure to which the above-mentioned tiles are applied, the grout material filled between adjacent tiles is filled so that the portion of the decorative film extending to at least a portion of at least one side of the tile substrate is visible and at least a portion of at least one side of the tile substrate is exposed. In this embodiment, the air permeability or water permeability of the tile can be ensured through the exposed portion of the side of the tile substrate.

Figure 15 is a schematic cross-sectional view of a portion of an architectural structure in one embodiment. The tile 10 is installed on a wall surface 30, and the gap between the tile 10 and an existing tile 22 adjacent to it is filled with a joint material 20. The joint material 20 is filled so that the portion of the decorative film 16 that extends to a portion of the side surface 14 of the tile substrate 12 is visible, and a portion of the side surface 14 of the tile substrate 12 is exposed.

In another embodiment of the architectural structure to which the above-mentioned tiles are applied, the joint material filled between the tiles adjacent to the tiles is filled so that the portion of the decorative film extending to at least a portion of at least one side of the tile substrate is visible, and at least one side of the tile substrate is covered with the joint material. In this embodiment, it is possible to prevent moisture from entering the tile substrate or the wall surface. The joint material may be filled so as to cover the decorative film covering at least one side of the tile substrate.

Figure 16 is a schematic cross-sectional view of a part of an architectural structure of another embodiment. The tile 10 is installed on a wall surface 30, and the gap between the tile 10 and an existing tile 22 adjacent to the tile 10 is filled with a joint material 20. The joint material 20 is filled so that the portion of the decorative film 16 that extends to a part of the side surface 14 of the tile substrate 12 is visible, and the side surface 14 of the tile substrate 12 is covered with the joint material 20. In Figure 16, the joint material 20 is filled so as to cover the decorative film 16 that extends over the side surface 14 of the tile substrate 12.

The tiles and application method of the present disclosure can be suitably used for repairing interior and exterior walls. The tiles and application method of the present disclosure can also be used for decorating interior and exterior walls when constructing new buildings.

The following examples illustrate specific embodiments of the present disclosure, but the invention is not limited thereto. All parts and percentages are by weight unless otherwise specified.

<Example 1>
1. Data Preparation Step 1: A photo of a wall tile (dark brown with a pattern of dots of irregular size and color) was taken with a digital camera.
Step 2: Pattern data was created by binarizing the JPEG data of the wall tile.
Step 3: Base material solid color data was created by subtracting the pattern data from the JPEG data of the wall tile.
Step 4: Transparent gray data for adjusting transmittance was created.
Step 5: The transparent gray color data and the pattern data are combined to create transparent gray layer data.

2. Precursor 1
A 60 μm thick 3M® Scotchcal® Paint Film PF050 (3M Japan Co., Ltd., Shinagawa-ku, Tokyo, Japan) was prepared as a white receptor layer. Based on the substrate solid color data created in step 3, a substrate solid color layer having a thickness of 6 μm was printed on the receptor surface of PF050 with GS3 ink using SC-S80650 (Seiko Epson Corporation, Suwa-shi, Nagano-ken, Japan). The ink concentrations were cyan 13%, magenta 30%, yellow 52%, and black 0%.

3. Precursor 2
A 60 μm thick 3M® Scotchcal® Paint Film PF052 (3M Japan Ltd., Shinagawa-ku, Tokyo, Japan) was prepared as a transparent receptor layer. Based on the transparent gray layer data created in step 5, a 6 μm thick transparent gray layer was printed with GS3 ink on the receptor surface of PF052 using SC-S80650 (Seiko Epson Corporation, Suwa-shi, Nagano-ken, Japan). The binarization threshold was 90%. The transparent gray layer was 5% black. Then, a 23 μm thick 3M® Scotchcal® Paint Film PF953AP (Super Matte Transparent Overlaminate Film, 3M Japan Ltd., Shinagawa-ku, Tokyo, Japan) was laminated on the transparent gray layer.

Precursor 1 and precursor 2 were laminated together to obtain a decorative laminate film. The total thickness of the decorative laminate film was 162 μm. The decorative laminate film was attached to a ceramic tile (95 mm x 95 mm, 6 mm thick) so that it extended from the entire periphery of the main surface of the ceramic tile to all sides and further to a part of the back surface of the ceramic tile, obtaining the tile of Example 1. When the appearance of the tile of Example 1 was visually evaluated, the appearance of a wall tile was reproduced. A photograph of the ceramic tile before the decorative laminate film was attached is shown in Figure 17, and a photograph of the tile of Example 1 with the decorative laminate film attached is shown in Figure 18.

It is obvious to those skilled in the art that the above-mentioned embodiments and examples can be modified in various ways without departing from the basic principles of the present invention. It is also obvious to those skilled in the art that various improvements and modifications of the present invention can be made without departing from the spirit and scope of the present invention. Some aspects of the present invention are described below.
[Aspect 1]
a tile substrate having a major surface and at least one side surface;
a decorative film attached to the tile substrate so as to cover the main surface of the tile substrate and extend from at least a portion of the periphery of the main surface of the tile substrate to at least a portion of the at least one side surface of the tile substrate;
The tile containing.
[Aspect 2]
2. The tile of claim 1, wherein the decorative film extends from the entire periphery of the major surface of the tile substrate to at least a portion of all of the side surfaces of the tile substrate.
[Aspect 3]
3. The tile of any of claims 1 or 2, wherein the decorative film conceals a surface of the tile substrate.
[Aspect 4]
The decorative film is a decorative laminate film having a transparent gray layer and a base material solid color layer, at least one of the transparent gray layer and the base material solid color layer is a printed layer, and the base material solid color layer is visible through the transparent gray layer. A tile according to any one of claims 1 to 3.
[Aspect 5]
A tile according to any one of claims 1 to 3, wherein the decorative film is a decorative laminate film comprising an image film including a transparent receptor layer having a first surface and a second surface opposite to the first surface, an inkjet printed pattern layer disposed on the first surface of the transparent receptor layer, and a colored opaque pressure-sensitive adhesive layer disposed on the second surface of the transparent receptor layer.
[Aspect 6]
A tile according to any one of claims 1 to 3, wherein the decorative film is a decorative laminate film comprising a transparent receptor layer having a first surface and a second surface opposite to the first surface, a transparent gray layer printed directly on the first surface of the transparent receptor layer, a substrate solid color layer printed directly on the second surface of the transparent receptor layer, and a white opaque pressure-sensitive adhesive layer disposed directly on the substrate solid color layer, wherein the transparent receptor layer has a thickness of 50 μm or less.
[Aspect 7]
Attaching the tile according to any one of aspects 1 to 6 to a wall surface; and
Filling the gap between the tile and the tile adjacent to the tile with a joint material.
A tile installation method comprising:
The method of claim 1, wherein the grout is filled such that a portion of the decorative film extending to at least a portion of the at least one side of the tile substrate is visible and at least a portion of the at least one side of the tile substrate is exposed.
[Aspect 8]
Attaching the tile according to any one of aspects 1 to 6 to a wall surface; and
Filling the gap between the tile and the tile adjacent to the tile with a joint material.
A tile installation method comprising:
The method of claim 1, wherein the grout is filled such that a portion of the decorative film extending onto at least a portion of the at least one side of the tile substrate is visible and the at least one side of the tile substrate is covered with the grout.
[Aspect 9]
An architectural structure to which the tile according to any one of aspects 1 to 6 has been applied, wherein the grout material filled between the tile adjacent to the tile and the tile is filled so that the portion of the decorative film extending to at least a portion of the at least one side surface of the tile base material is visible, and at least a portion of the at least one side surface of the tile base material is exposed.
[Aspect 10]
An architectural structure to which the tile according to any one of aspects 1 to 6 has been applied, wherein the joint material filled between the tile adjacent to the tile and the tile is such that a portion of the decorative film extending to at least a portion of the at least one side surface of the tile base material is visible, and the at least one side surface of the tile base material is covered with the joint material.

10 Tile 12 Tile substrate 13 Main surface 14 Side surface 15 Back surface 16 Decorative film 20 Joint material 22 Existing tile 30 Wall surface 110 Decorative laminate film 112 Pattern layer 114 Transparent grey layer 116 Substrate solid colour layer 122, 124 Transparent receptor layer 126 Receptor layer 128 Surface protective layer 132, 134, 138 Bonding layer 136 Pressure-sensitive adhesive layer 140 Liner 210 Decorative laminate film 212 Image film 214 Transparent receptor layer 216 Inkjet printed pattern layer 218 Coloured opaque pressure-sensitive adhesive layer 222 Surface protective layer 224 Bonding layer 230 Liner 310 Decorative laminate film 312 Transparent receptor layer 314 Transparent grey layer 315 Pattern 316 Base material solid color layer 318 White opaque pressure-sensitive adhesive layer 320 Surface protective layer 322 Bonding layer 330 Liner

Claims (8)

a tile substrate having a major surface and at least one side surface;
a decorative film adhered to the tile substrate so as to cover the main surface of the tile substrate and extend from an entire periphery of the main surface of the tile substrate to at least a portion of all of the side surfaces of the tile substrate ,
The decorative film is a decorative laminated film having a transparent gray layer and a base material solid color layer, at least one of the transparent gray layer and the base material solid color layer is a printed layer, and the base material solid color layer is visible through the transparent gray layer . a tile substrate having a major surface and at least one side surface;
a decorative film attached to the tile substrate so as to cover the main surface of the tile substrate and extend from the entire periphery of the main surface of the tile substrate to at least a portion of all of the side surfaces of the tile substrate;
A repair tile comprising:
A repair tile, wherein the decorative film is a decorative laminated film comprising an image film including a transparent receptor layer having a first surface and a second surface opposite to the first surface, an inkjet printed pattern layer disposed on the first surface of the transparent receptor layer, and a colored opaque pressure-sensitive adhesive layer disposed on the second surface of the transparent receptor layer. a tile substrate having a major surface and at least one side surface;
a decorative film attached to the tile substrate so as to cover the main surface of the tile substrate and extend from the entire periphery of the main surface of the tile substrate to at least a portion of all of the side surfaces of the tile substrate;
A repair tile comprising:
A repair tile, wherein the decorative film is a decorative laminate film comprising: a transparent receptor layer having a first surface and a second surface opposite to the first surface; a transparent gray layer printed directly on the first surface of the transparent receptor layer; a substrate solid color layer printed directly on the second surface of the transparent receptor layer; and a white opaque pressure-sensitive adhesive layer disposed directly on the substrate solid color layer, wherein the transparent receptor layer has a thickness of 50 μm or less. The repair tile according to any one of claims 1 to 3 , wherein the decorative film conceals the surface of the tile substrate. A method for installing a repair tile, comprising: attaching the repair tile according to any one of claims 1 to 4 to a wall surface; and filling a gap between the repair tile and a tile adjacent to the repair tile with a joint material,
The method of claim 1, wherein the grout is filled such that a portion of the decorative film extending to at least a portion of all of the sides of the tile substrate is visible and at least a portion of the at least one side of the tile substrate is exposed. A method for installing a repair tile, comprising: attaching the repair tile according to any one of claims 1 to 4 to a wall surface; and filling a gap between the repair tile and a tile adjacent to the repair tile with a joint material,
The method of claim 1, wherein the joint material is filled such that a portion of the decorative film extending to at least a portion of all of the sides of the tile substrate is visible and the at least one side of the tile substrate is covered with the joint material. An architectural structure to which a repair tile as described in any one of claims 1 to 4 has been installed, wherein the grout filled between the tile adjacent to the repair tile and the repair tile is filled so that the portion of the decorative film extending to at least a portion of all of the side surfaces of the tile substrate is visible and at least a portion of the at least one side surface of the tile substrate is exposed. An architectural structure to which a repair tile as described in any one of claims 1 to 4 has been installed, wherein the joint material filled between the tile adjacent to the repair tile and the repair tile is filled so that the portion of the decorative film extending to at least a portion of all of the side surfaces of the tile base material is visible, and at least one side surface of the tile base material is covered with the joint material.

Images