JPS601183B2 - Decorative material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a chemical paper material, and more specifically to a method for producing a novel decorative material that can form a patterned surface on the surface of the decorative material.

In order to enhance the design effect of building materials, various methods have been devised, such as pasting multicolored printed paper or film on them, or using foaming agents to create irregularities on the surface. However, although the above-mentioned methods can produce delicate and elegant design effects, the current situation is that they are not sufficient to produce rough, so-called powerful design effects.

As a result of intensive research in order to achieve a design effect that cannot be expressed using the above-mentioned conventional method, the present inventor has completed a method for manufacturing decorative materials that can produce an impressive design rich in texture.

That is, in the present invention, when a curable material mixed with a filler is cured and molded, an uncured portion is left on the surface or near the surface of the curable material, and then the hardened portion is cured. This method of producing a decorative material is characterized in that by removing the filler, more filler is exposed in a portion corresponding to the uncured portion of the molded article than in other portions. Hereinafter, the above-mentioned present invention will be explained in detail.

First, the present invention will be explained in detail with reference to the drawings. The reason why it is possible to expose more filler than other hardened parts by removing the hardened part, which is the core of the present invention, is due to a general phenomenon, that is, in FIG. After the curable substance 2 is cured in the formwork 3, the curable substance 2 fills the voids created by the filler 1 without any gaps, and then the formwork 3
When the filler is removed and viewed from the side that was in contact with the formwork, the larger the size of the filler, and the smaller the amount of filler, the smaller the area of the filler exposed. More filler is exposed in the cross section than that exposed on the front surface.

The present invention skillfully utilizes this general phenomenon and has been researched to make the mouth surface appear partially and in a pattern. For example, in FIG. A sheet 5 on which an arbitrary pattern 4 is drawn with ink containing a curing inhibitor of a curable material is spread, and then the curable material 2 containing the filler 1 is poured into the sheet 5 so that the diagonal lined areas 6 corresponding to the pattern are formed. When the other parts are cured, it is removed from the mold,
If the uncured portion is removed by washing out or the like, the filler can be exposed as shown in FIG. 2B.

The example shown in Figure 3 is a case where the size of the filler is two types, and in such a case, more filler is exposed in the part corresponding to the uncured part than in other parts, and moreover, the filler is Since there are two types, the design effect is great. Furthermore, by changing the color of each filler, an even greater design effect can be achieved. According to the gist of the present invention, the color, shape, etc. of the filler to be mixed can be used in a wide variety of ways, not just one type, and furthermore, by using a colored curable substance. It can exhibit excellent design effects. Examples of the curable substances used in the present invention include phenolic resins, amino resins, polyester resins, epoxy resins, furan resins,
Thermosetting resins such as isocyanate resins, lime, gypsum,
Examples include substances that harden by mixing with water, such as cement.

In addition, as the filler to be mixed into the above-mentioned hardening substance, all sorts of materials can be used, such as plastic, metal, wood, glass, minerals, and other organic or inorganic materials, and the shape, color, etc. There are no particular restrictions.

However, it is more preferable to use a material that exhibits adhesion to the applied curable material and is evenly dispersed in the applied curable material. Here, as a method of providing a hardened part and a hardened part in an arbitrary pattern using a hardening material mixed with the filler described above, for example, when unsaturated polyester resin is used as a hardening material, a hardening inhibitor or a hardening material can be used. Ink or paint containing known inhibitors such as hydroquinone, picric acid, nitrosobenzene, etc., and curing accelerators such as penzoyl peroxide, dimethylaniline, methyl ethyl ketone peroxide, etc. can be applied to sheets or molds by various known printing methods or by hand drawing. A cured portion can be provided with an uncured portion by drawing a pattern using a method, a coating method using a mask pattern, etc., and promoting curing after contacting the pattern.

When using a curable substance other than unsaturated polyester resin, this can be done by combining a curing inhibitor, a curing inhibitor, and a curing accelerator for each. For example, using a curable resin that hardens through a polymerization reaction. In this case, hydroquinone acts as an effective hardening inhibitor, and when cement is used as a hardening substance, various acids, sugars, etc. are effective as hardening inhibitors and hardening inhibitors.
When using gypsum hemihydrate as a hardening substance, glue, starch, etc. are effective as hardening inhibitors. Further, as another embodiment of providing a cured portion and an uncured portion, for example, when polyvinyl chloride sol is used as the curable material, it can be achieved by selectively heating in a pattern.

For example, by adding a pattern to a base material that transmits heat rays using ink or paint containing a heat ray absorber, and then irradiating heat rays through this, the patterned areas can be covered with a pattern. It is possible to cure the vinyl chloride sol and leave the portion corresponding to the L-patterned portion uncured. In addition, various means for selectively heating in a pattern can be employed. In the gist of the present invention, the method is not limited to the two embodiments described above, and many other means can be applied in order to provide a hardened material with a hardened portion and an unhardened portion.

After the cured and uncured portions are thus provided, the sheets or molds that have been brought into contact are separated and the uncured portions are removed.

The uncured portion may be removed by washing with water or other liquids, blowing off the uncured portion by blowing compressed air, or other methods may be used. good. By going through this process, the filler is exposed more on the surface where most of the uncured parts have been removed than on other parts, resulting in a decorative material rich in the desired rough and powerful texture. be able to. Further, if necessary, if the uncured portion is not completely removed, it is cured. Furthermore, if necessary, a so-called top coating may be applied by applying a paint containing a curable resin and then curing it. By combining the present invention with a molding method using a mold, the originally intended design effect can be further enhanced, and this method will be explained in detail next.

For example, using a pour molding mold with unevenness,
A paint etc. containing a curing inhibitor of the curable substance to be used is adhered to the convex portion of the mold, and then a curable substance according to the gist of the present invention is poured in to promote curing, and a paint etc. containing a curing inhibitor is applied. By removing the mold when the part that comes into contact with it is uncured and the other parts are hardened, and then removing the hardened part, the convex part of the mold, that is, the concave part of the molded material, exposes a large amount of filler. It is possible to obtain a decorative material rich in texture with a unique texture that is difficult to express in words. Furthermore, according to the gist of the present invention, it is easy to expose a large amount of the filler to the convex portions of the molded material, and various design effects can be imparted by combining it with mold materials. In addition, when using a sheet-like material with a pattern drawn with ink or paint containing a foaming agent and foamed as the uneven mold, a curing retardant, curing inhibitor, or curing accelerator may be printed on it. It is also possible to easily manufacture it in large quantities by installing it with a machine or the like. Hereinafter, the present invention will be explained in more detail with reference to Examples.

Example 1 First, using an ink consisting of 7 parts of cellulose acetate ink and 3 parts of hydroquinone (hardening inhibitor), a floral pattern was applied to a polyethylene terephthalate film with a thickness of 30 cm by gravure printing, and the ink was dried. It was placed in a mold for pouring so that the printed surface was in contact with the poured material.

Next, 5 parts by weight of a green pigment was added to an unsaturated polyester resin having the following composition: 10 parts by weight of an unsaturated polyester resin curable at room temperature, 10 parts by weight of styresomonomer, 1 part by weight of methyl ethyl ketone peroxide, 1 part by weight of cobalt naphthenate, and heated at 100 q○ for 10 minutes. Similarly, 5 parts by weight of brown pigment was added to the unsaturated polyester resin having the above composition and cured in the same manner, and both were crushed and green pigment was added.The size of the resin was such that it passed through a 20-mesh section but did not pass through a 50-mesh section. The green particulate matter ■ and the one containing brown pigment passed through a 50-mesh section and passed through a 1
A brown granular material that did not pass through 00 mesh was used.

Next, the above granules were used as a filler and the unsaturated polyester resin was used as a curable substance, and the two were mixed to obtain the following composition.

Cold-curing unsaturated polyester resin 10 parts by weight Styrene monomer 10'' Red pigment
5 〃Methyl ethyl ketone/gu oxide 1 〃Cobalt naphthenate 1
〃Green particulate matter tBI 150 〃Brown particulate matter tBI 150 〃After that,
It was poured into the mold described above, left for 25 minutes at 80 qo, and then removed from the mold.

Next, most of the hardened portion corresponding to the floral pattern was blown away by blowing compressed air out of the nozzle.

Next, it was left at 100°C for 1 hour to completely cure the remaining uncured portion, and then an unsaturated polyester resin having the following composition: 10 parts by weight of a room-temperature curable unsaturated polyester resin: 20 parts by weight of styrene monomer
Methyl ethyl ketone peroxide 1" cobalt naphthenate 1" was poured onto the pattern surface to coat it, and was left to stand at 80 qo for 30 minutes to harden.

The unsaturated polyester decorative material obtained in this way has a reddish color as a whole, with large green filler-like particles and small brown filler 'B' exposed in the floral pattern, and a glossy surface. It was filled with a certain sense of power.

Example 2 As shown in FIG. 4A, an abstract pattern 8 was printed on a polyvinyl chloride film 7 with a thickness of 50 mm using acrylic emulsion foam ink (Peacock Foam, manufactured by Moroboshi Ink Co., Ltd.) by screen printing, and then printed at 60 mm. After letting the ink dry,
The pattern was further screen-printed using ink with the following composition: 10 parts by weight of cellulose-based water-soluble resin (Kurucel manufactured by Hercules) 10 parts by weight of sugar (sugar cubes manufactured by Taiyo Seito Co., Ltd.) 10 parts water
Ink layer 4 is provided from 500〃60qo
It was dried.

Next, an abstract pattern was foamed at 13,000 ml and laid in a mold 3 as shown in FIG. 4B. Next, quartz crushed into about 5 pieces was used as the filler 1, ordinary Bortland cement (manufactured by Asano Cement Co., Ltd.) was used as the hardening material 2, and the composition of ordinary Boltland cement 10 parts by weight of quartz was used as the hardening material 2.
40 Water
50° C., poured into the mold 3 described above, left at 25° C. for 3 hours, removed from the mold, and washed out using water to remove uncured portions.

As shown in Figure 4C, the thus obtained cement decorative material has sharp concave areas created by the foamed ink, and furthermore, the quartz filler is exposed in these areas, and combined with the abstract pattern, it is particularly sensitive to directional light rays. When exposed to light, the reflected light from the quartz created a very beautiful design.

Example 3 As shown in FIG. 5A, a base grid pattern 11 was printed on a transparent polyethylene terephthalate film 10 with a thickness of 50 mm using black ink using a gravure printing method.
It was sent to the transparent glass plate 12 of the ribs.

Next, from the cured white epoxy resin, a cube having a length of approximately 1 willow on each side was cut out to serve as the filler 1, and a yellow epoxy resin was poured as the curable material 2 onto the pattern 11.

Next, by uniformly irradiating the black substrate with an infrared lamp 13, the black substrate grating pattern portion was selectively heated and cured, and then the curable substance 2 was separated from the film 10, and then the uncured portion was washed out with water and removed.

As shown in FIG. 5B, the thus obtained epoxy decorative material was entirely yellow with white chip pieces exposed in the shape of a base grain, and was extremely beautiful.

As is clear from the above description, according to the present invention, a pattern can be created by mixing a filler into various curable substances to provide a hardened portion and an unhardened portion, and then through a step of removing the unhardened portion. Since the filler can be exposed in a shape and a powerful design rich in texture can be imparted, it can fully meet the recent demands for sophisticated and complex decorations as well as innovative decorative materials with three-dimensional effects and aesthetic effects. It is something.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram for explaining the gist of the present invention,
FIG. 2 is a schematic cross-sectional view showing a place where a curable substance mixed with a filler is poured into a mold. FIG. 2 is an explanatory diagram for explaining the gist of the present invention,
Figure A is a schematic cross-sectional view showing a sheet with a pattern made of ink containing a hardening inhibitor placed in a mold, and a curable substance containing a filler poured onto it. It is a schematic cross-sectional view after removing an uncured part. Figure 3 shows
FIG. 2 is an explanatory diagram for explaining the gist of the present invention, and is a sectional view showing a case where two types of fillers are used. Figure 4 shows
This figure is for explaining one embodiment of the present invention.
B is a schematic cross-sectional view of a sheet provided with a printed pattern;
is a schematic cross-sectional view showing the sheet placed in a mold and a hardening material mixed with a filler is poured into it, and Figure C is a vague cross-sectional view after the hardened portion has been removed. . Figure 5 is for explaining one embodiment of the present invention, Figure A is a vague cross-sectional view of the part where infrared rays are being irradiated, and Figure B is a diagram showing the completed embodiment of the present invention. FIG. 1... Filler, 2... Curable substance, 3... Formwork, 4... Ink pattern containing hardening inhibitor, 5... Sheet, 6・・・・・・Uncured part. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5

Claims (1)

[Scope of Claims] 1. When a curable material mixed with a filler is cured and molded, an uncured portion is left on the surface or near the surface of the curable material, and then the uncured portion is cured. A method for producing a decorative material, comprising: exposing more filler in a portion corresponding to the uncured portion of a molded article than in other portions by removing the filler. 2. A curable substance containing the above-mentioned filler on the surface containing the pattern layer of a sheet or mold provided with a pattern layer containing a curing inhibitor, curing accelerator, or curing inhibitor, as a means for curing while leaving an uncured portion. 2. The method for producing a decorative material according to item 1 above, which uses a method of bringing the curable material into contact with the curable material, then promoting the curing of the curable material to produce a cured portion and an uncured portion corresponding to the pattern layer, and then releasing the sheet or mold. 3. The method for producing a decorative material according to item 1 above, which uses a curable substance whose curing is accelerated by heat as the means for curing while leaving an uncured portion, and selectively heats it in a pattern.