JPS6366982B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a painted flooring material that is rich in three-dimensional effect and has wear resistance.

Painted wood flooring materials have been proposed in which a transparent topcoat film layer containing an abrasive material is formed on the entire surface of a substrate that has undergone arbitrary decoration such as surface printing or pasting with decorative paper.

However, although this coated flooring material can impart a certain degree of abrasion resistance to the coating film, the following problems still remain.

That is, if the thickness of the topcoat film containing the abrasive is increased, the topcoat film cannot follow the expansion and contraction due to moisture absorption or heat release of the wood base material, and the topcoat film is likely to crack.

Furthermore, shrinkage cracks in the coating film due to drying expansion and contraction of the top coat film are likely to occur.

Therefore, the topcoat film thickness is generally adjusted to 10 to 30μ, and at most 70μ or less.

Therefore, the particle size of the mineral powder added to the paint should be 15μ or less in proportion to the coating thickness, and the maximum is 45μ. However, as the particle size of the powder particles becomes smaller, the abrasion resistance decreases, so in order to improve the abrasion resistance, the amount added must be increased. However, if the amount of powder particles added is increased, the coating film becomes matte and the pattern previously printed on the substrate surface becomes unclear.

Also, if the particle size of the powder particles is made larger than the coating thickness,
Although the abrasion resistance is improved, it becomes matte and the pattern becomes unclear, as described above. Furthermore, the surface of these coatings is smooth and lacks a three-dimensional effect and lacks a sense of design.

In order to give a three-dimensional effect to the painted flooring material in which mineral powder particles are added to the top coat, a three-dimensional uneven pattern is formed by screen printing, and then a transparent top coat is formed with the addition of a shaping material. Flooring materials are also proposed.

However, since an abrasive is added to the top coat, the same drawbacks as mentioned above remain, such as cracking and matte state of the top coat.

In addition, since the top coat is applied on the uneven pattern, the paint on the protrusions flows down towards the recesses, and the coating film thickness on the protrusions becomes thinner, making it difficult to apply the paint on the protrusions where wear resistance is most important. The wear resistance of the material will be reduced.

On the other hand, in order to improve the abrasion resistance on the convex parts, it is possible to increase the amount of top coat applied, but if this is done, the concave parts will be filled with paint,
As a result, the three-dimensional effect is diminished. The present invention aims to solve the problems of the prior art as described above.

That is, in the present invention, as described below, a convex pattern 4 is formed on the surface of the substrate 1 using a paint with a non-volatile content of 50% or more, and then a top coat transparent paint 5 to which mineral powder particles S having a particle size of 20 to 150 μm are added is applied. The mineral powder particles S in the top coat film 5 are partly buried in the paint film of the convex pattern 4, and some are exposed from the top coat film 5, so that the mineral powder particles S are coated. It does not fall off from the film, imparts wear resistance, and prevents the surface from becoming cloudy due to wear of the top coat film 5. Embodiments of the present invention illustrated in the drawings will be described below.

First, an example of the method for manufacturing the flooring material of the present invention will be explained.

(Description of Examples) 1 is a substrate of the flooring material of the present invention, and the surface is subjected to surface treatment by sealing coating, sanding, sealer coating, thin paper coating, etc. as necessary.

The substrate 1 is an organic or inorganic plate such as plywood, fiberboard, wood chip board, gypsum board, cement board, metal plate, synthetic resin board, or a mixed or composite plate of organic and inorganic materials. Paper, cloth, synthetic resin sheets,
Any type of material, such as one pasted with a sheet-like material such as metal foil, may be used.

As mentioned above, the substrate 1 has been subjected to surface treatment.
Apply optionally colored primer paint to the entire surface of the
Dry to form an undercoat film 2.

As the undercoat, synthetic resins such as alkyd resins, amino alkyd resins, acrylic resins, urethane resins, and vinyl acetate resins, lacquers, etc., to which commonly used optional colorants and fillers are added, are used.

Next, a pattern layer 3 is formed by printing an arbitrary pattern such as a woodgrain pattern or an abstract pattern on the surface of the undercoat film 2 using a printing device using ordinary gravure printing ink, offset printing ink, or the like.

The pattern layer 3 is not limited to one color printing, but may be printed in multiple colors.

Next, a convex pattern 4 is formed on the undercoat film 2 pattern layer 3 using a paint having a non-volatile content of 50% or more.The convex pattern 4 may or may not be synchronized with the pattern pattern 3. The paint forming the convex pattern 4 is an alkyd resin to which optional colorants, fillers, etc. are added.
The main ingredients are synthetic resins such as aminoalkyd resin, acrylic resin, urethane resin, vinyl acetate resin, vinyl chloride resin, and epoxy resin.
It is desirable to use an emulsion type or solvent type paint with a non-volatile content of 50% or more and a clay content of 20 to 30 poise.

The raised pattern 4 is formed using a gravure printing machine, a silk screen printing machine, etc. to a coating thickness of about 50 to 500 microns.

Furthermore, in order to reduce the wear of the convex portions after the paint for the convex patterns 4 dries, it is necessary to keep the nonvolatile content of the paint for the convex patterns 4 at 50% or more. Further, the viscosity of the paint for the convex pattern 4 is determined in the range of 20 to 300 poise, taking into consideration the mechanical suitability of the printing device.

For example, when forming the convex pattern 4 using a gravure printing machine, the paint is adjusted to 20 to 130 poise before use. If the viscosity is adjusted to less than 20 poise, the paint will scatter from the plate roll, and the convex pattern will run after the paint is transferred, making it impossible to form a sharp convex pattern. Also, if the viscosity is adjusted to over 130 poise, the plate roll will become clogged and the paint will not circulate smoothly.

Further, when forming the convex pattern 4 using a screen printing machine, the paint is adjusted to 100 to 300 poise. It can be used by adjusting the viscosity to 100 poise or higher, but when removing the plate, the convex pattern tends to flow,
If the viscosity is 300 poise or more, the paint will not separate easily and it will be difficult to form a convex pattern.

In general, if the coating thickness of the raised pattern 4 is 100μ or less, a gravure printer is suitable; if it is 100μ or more, a screen printer is suitable.

Particle size 20~ on the entire surface where convex pattern 4 is formed
A transparent top coat to which mineral powder particles S of 150 μm are added is applied, and then dried and cured to form a transparent top coat 5.

That is, the mineral powder S used has a considerably large particle size.

The top coat paint is applied to the entire surface including the convex patterns 4, and at the same time, on the convex patterns 4, a portion flows down into the recesses 6 between the convex patterns 4, and the top coat paint is thin and the mineral powder particles S in the paint form a top coat film. 5, the transparent paint becomes thicker in the recess 6, and the mineral powder particles S are buried in the top coat.

After applying the topcoat transparent paint 5, while the paint 5 is in an uncured or semi-cured state, the mineral powder particles S on the surface of the convex pattern 4 are pressed by a roll r to form the topcoat paint 5 within the coating film of the convex pattern 4. A part of the more exposed mineral powder grains S is buried.

In this case, the mineral powder particles S have a considerably large particle size, that is, 20 to 150μ, as described above, while the top coat 5 is applied quite thinly, so when the top coat 5 is applied, the second As shown in the figure, in the convex pattern 4 portions, the mineral powder particles S protrude to a considerable extent from the surface of the top coat 5 and are exposed.

Therefore, if the top coat 5 of the convex pattern 4 is pressed with a roll in the state shown in FIG. 2, a portion of the mineral powder particles S will be buried in the convex pattern 4.

(Figure 2b○) As the transparent top coating 5, a commonly used synthetic resin coating such as an alkyd resin, an aminoalkyd resin, an acrylic resin, or a urethane resin is used, and it is colored if necessary.

The mineral powder particles S to be added and mixed into the transparent top coat 5 include diamond sand, silica stone, garnet, aluminum oxide, silicon carbide, etc., and must have a new Mohs hardness of 5 or more.

The amount of mineral powder added is 0.5 to 70% by weight.
Further, a top coat containing mineral powder S is applied using a roll coater, and at the same time as the top coat is applied, a portion of the mineral powder in the top coat 5 of the convex pattern 4 is buried in the convex pattern 4. There is no harm in doing so.

The particle size of the mineral powder particles S is made larger than the thickness of the top coat 5 of the convex pattern 4 portions, and the amount added is decreased in proportion to the particle size, so that the luster caused by the addition of the mineral powder particles is The eraser is made to such an extent that it does not appear on the top coat film 5 of the convex pattern 4 parts.

Some of the mineral powder particles are exposed from the top coat 5 and fixed, but some are buried in the convex pattern 4 coating, so there is no risk of them falling off and this helps improve wear resistance. There is no difference.

Note that the pattern 3 may be formed by pasting decorative paper on the substrate 1, or may be printed after forming the convex pattern 4.

Effects of the present invention: The flooring material of the present invention has an excellent design with a rich three-dimensional effect, and has significantly improved wear resistance.

That is, the top coat 5 is formed as thin as possible in the convex patterns 4 and thick in the concave parts 6 between the convex patterns 4. On the other hand, the particle size of the mineral powder particles S is as small as possible in the convex patterns 4. The thickness is generally selected to be larger than the thickness of the top coat film 5. Therefore, the mineral powder particles S can reach into the convex pattern 4 from the surface of the top coat 5 in the convex pattern 4 portions. For this reason, in the convex pattern 4 parts that require the most wear resistance, mineral powder particles S with large particle sizes are fixed to the coating film and exposed from the surface of the topcoat film 5, so that it is difficult to apply the topcoat as in the past. The wear resistance is significantly improved compared to the case where small-diameter mineral particles are embedded in the film.

Further, since the thickness of the top coat 5 may be thin compared to the particle size of the mineral powder particles S, the top coat 5 does not fill the recesses 6, and a three-dimensional effect can be sufficiently expressed.

Since the particle size of the mineral powder particles S is large, by reducing the amount added in proportion to the particle size, the matte state of the top coat 5 can be minimized as much as possible.

[Brief explanation of drawings]

Figure 1: Cross-sectional view of the flooring material of the present invention, Figure 2:
Action explanatory diagram of the flooring material of the present invention, 1: Substrate, 2: Undercoat film and undercoat paint,
3: Pattern pattern, 4: Convex pattern, 5: Top coat film and top coat paint, S: Mineral powder.

Claims (1)

[Claims] 1. A convex pattern 4 is formed on the surface of the substrate 1 using a paint with a non-volatile content of 50% or more, and a convex pattern 4 is formed on the surface of the paint with a particle size of 20 to 20%.
In a painted floor material on which a transparent top coat film 5 containing 150μ of mineral powder particles S is formed, the transparent top coat film 5 is thin in the 4 areas of the convex patterns and thicker in the 6 areas of the concave areas between the convex patterns 4. , The particle size of the mineral powder particles S is made larger than the thickness of the top coat transparent coating film 5 of the convex pattern 4 portion, and a part of the mineral powder particles S in the top coat transparent coating film 5 of the convex pattern 4 portion has a convex pattern. A painted flooring material with a rich three-dimensional effect, which is characterized by being buried in a transparent top coating film 5 and partially exposed from the top coat transparent coating film 5.