JPH0651379B2 - Surface material for decoration and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention relates to a floor material, a wall material, a ceiling material, by bonding to the surface of a base material such as synthetic resin, metal, wood, gypsum board, and concrete. System bath, system kitchen,
The present invention relates to a novel film-shaped decorative surface material that can be used for furniture exteriors, vehicle interiors, home appliance exteriors, and the like, and a method for producing the same.

[Prior Art] Conventional flooring materials, wall materials, ceiling materials, etc. are generally used by laminating a print-printed vinyl chloride film or sheet on a substrate, but the print-printed pattern is flat. There was no sense of transparency or volume, and the image was thin and cheesy compared to natural materials.

Recently, vinyl chloride plastisol was applied on a vinyl chloride sheet, and color chips of vinyl chloride were sprayed on it, then heated and compressed to gel the vinyl chloride plastisol and roll the chips to remove crushed stone patterns. The way to put out is becoming popular.

[Problems to be Solved by the Invention]

However, the above method has a problem that the production cost becomes high because extremely large heat energy and a long time are required to gel the vinyl chloride plastisol.

In addition, the rolling pattern of vinyl chloride color chips is characterized by the fact that it has a deeper and heavier thickness than the printing method, but it has subtle color tones such as natural stones and bleeding, blurring, and dust. There is a limit that you can only show a monotonous and uniform pattern without changing.

The present invention focuses on such problems and limitations of the prior art, and provides a decorative surface material that can be manufactured at low cost and that can easily create a color tone like natural stone such as granite and marble, and a method for manufacturing the same. The purpose is to do.

[Means for Solving the Problems]

The decorative surface material of the present invention in accordance with this object is a transparent film, a colored adhesive layer provided on one surface of the film, a colored adhesive layer, and a partial adhesive in the colored adhesive layer. And a plastic chip scattered so as to be embedded in the plastic chip, wherein the film thickness of the colored adhesive layer around the plastic chip is formed to be thicker than the film thickness of other parts. , Mainly the non-embedded portion of the colored adhesive layer is rolled onto the colored adhesive layer around the plastic chip.

Further, the method for producing a decorative surface material of the present invention comprises applying a colored adhesive with a uniform film thickness on a transparent film, and forming a plastic chip on the colored adhesive layer, and the plastic chip forming a colored adhesive. It is sprayed so as to be partially embedded in the layer, and due to the surface tension of the colored adhesive layer in the peripheral portion of the plastic chip, the thickness of the colored adhesive layer in the peripheral portion of the plastic chip is made larger than that in other portions. After thickening and drying the colored adhesive layer, the method comprises rolling the plastic chip, mainly the non-embedded portion of the colored adhesive layer, onto the colored adhesive layer around the plastic chip.

In the method of the present invention, a colored adhesive layer having substantially transparency is provided on one surface of a transparent film substrate with a uniform thickness. The film substrate may be substantially transparent, and may be colorless and transparent or colored and transparent. In the case of a colored transparent film, its color may be different from the color of the colored adhesive, in which case the color of the film layer and the color of the adhesive layer are mixed to give a complex shade. Is also possible. The material of the film is not particularly limited as long as it can carry the colored adhesive layer.

The resin component of the colored adhesive used here is a resin composed of polyurethane, vinyl urethane, polystyrene, polyester, polyamide, polyacrylic ester, ethylene vinyl acetate, modified vinyl, vinyl acetate acrylic, epoxy, melamine, isocyanate, compound, etc. Then, as a functional group, a hydroxyl group, a carboxyl group, a primary amine group,
Containing a secondary amine group, a tertiary amine group, a methoxy group, a methylol group, a double bond, a triple bond, etc., and self-curing or cross-linking with a curing agent such as epoxy, amine, isocyanate, melamine Is appropriate.

When spraying plastic chips on the colored adhesive layer,
The settling of the chip onto the adhesive layer due to the gravity of the chip,
Due to the surface tension of the adhesive, the adhesive rises on the contact surface around the chip.

In this state, the plastic chip is partially embedded in the colored adhesive layer, the thickness of the colored adhesive layer on the bottom surface side of the embedded chip is reduced, and the colored adhesive layer around the chip is Since the adhesive swells along the peripheral surface of the chip due to its surface tension, the film thickness of the colored adhesive layer in the peripheral portion becomes thicker than the film thickness in other portions.

In this state, the colored adhesive layer is dried, for example, hot air dried. At the time of hot air drying, the portion exposed from the adhesive layer of the sprayed tip is most likely to receive the heat energy, so the heat transfer from this heated tip causes the adhesive around the tip to adhere to other parts. It receives more dry heat energy than the agent. Also, the colored adhesive around the chip is
As described above, the surface tension raises along the peripheral surface of the chip, so that the surface area of the portion increases, and the portion is more easily dried than the other adhesive portions. Therefore,
In the colored adhesive layer, the peripheral part of the chip has the highest drying speed.

As a result, in the peripheral portion of the chip, due to swelling due to surface tension, the thickness of the adhesive layer increases as it approaches the peripheral surface of the chip, and as the thickness increases, the hue as the colored adhesive layer becomes darker. Further, by preferentially drying from the chip peripheral part, the pigment in the colored adhesive is pulled from the other part to the chip peripheral part in the middle of drying, the pigment concentration becomes locally high, and further The hue around the chip becomes darker.

In this way, by spraying the plastic chips on the colored adhesive layer and drying with hot air at, for example, 50 to 120 ° C. to fix the adhesive layer, a remarkable difference in shade of the colored adhesive layer is provided around the chip. You can

The film to which this chip is adhered is, for example, 80 to 25
It is heated at 0 ° C. for 5 to 20 minutes and compression-rolled at a pressure of 3 to 100 kg / cm ² .

What is important here is that if the adhesive is a thermoplastic resin,
Since the adhesive will flow with the chips by heating and rolling,
It is necessary to select a curable resin as the adhesive. By the film rolling, the plastic chip, which is protruding from the colored adhesive layer, mainly the non-embedded colored adhesive layer is to be rolled, and this rolled chip portion has a hue of the peripheral portion of the chip. It covers the thickened colored adhesive layer portion. As a result, there is a difference in shade around the first chip-spraying portion, and also a subtle hue difference in which the difference in shade gradually changes, a pattern like a natural stone is deposited, and the decorative surface material of the present invention is obtained. To be

In the present invention, the light and shade pattern of the adhesive layer changes its pattern due to changes in the size, specific gravity, shape and softening point of the plastic chip. The transparent colored adhesive used here has a surface tension of 50 to 75 dyn / cm and a nonvolatile content of 10 to 70.
%, Viscosity of 5 to 20,000 cps, preferably 50 to
It is important to choose an aqueous emulsion of 3,000 cps. When the viscosity is 20,000 cps or more, the chips are less likely to settle in the adhesive layer, the action due to the above-mentioned surface tension becomes slow, and even if the drying locally progresses,
Since the fluidity of the adhesive layer is poor, the gathering of the adhesive from the peripheral adhesive layer (pulling of the pigment, etc.) becomes poor. In addition, solvent-based adhesives and solvent-dispersed emulsions such as vinyl chloride plastisol have a low surface tension of 20 to 50 dyn / cm, making it difficult to increase the thickness of the adhesive layer around the chip. It becomes difficult for the difference in shade of the adhesive layer to appear.

The thickness of the adhesive that is first applied uniformly is 10 to 300 μm.
Is appropriate. If it is less than 10μ, the adhesive strength of the chip becomes too low, and if it is more than 300μ, the absolute value of the film thickness is too large. Therefore, even if the adhesive rises due to surface tension and the concentration of the adhesive increases due to local drying, there is a difference in hue. The impact will be relatively small.

Coloring occurs due to the difference in the thickness of the colored adhesive layer after drying or rolling, but the thickness of this adhesive layer is preferably about 1/10 to 5 times the initial uniform coating thickness. That is, at the periphery of the spray tip, the initial coating thickness of 5
It is preferable to adjust it so that it is not more than twice, and about 1/10 or more of the initial coating thickness on the bottom surface side of the spraying tip where the layer thickness becomes the smallest.

In addition, the plastic chip has its size, shape, color,
When 2 to 20 types of products with different specific gravities and softening points are mixed and used, the degree of sedimentation in the adhesive layer and the shape of the adhesive swelling due to surface tension will differ, so there will be variations in light and shade. The handle will be deposited and become closer to natural stone. As the size of the chip, particles or beads having a particle diameter of 0.5 to 10 mm are suitable. If a fine powder with a thickness not more than 3 times the thickness of the adhesive layer is used,
Most of it is contained in the adhesive layer, which makes it difficult to roll the chips.

The film-shaped decorative surface material, in which natural stone patterns with subtle hue differences are deposited, created as described above, by bonding to the surface of a base material such as synthetic resin, metal, wood, gypsum board, or concrete. It is used for indoor and outdoor floor materials, wall materials, ceiling materials, system baths, system kitchens, furniture, vehicle interiors, home appliances exteriors, etc.

〔Example〕

1 to 4 schematically show the manufacturing process of the decorative surface material according to the present invention.

FIG. 1 shows a colored adhesive layer 2 on one side of a transparent film 1.
It shows a state in which is applied with a uniform thickness. When the plastic chips (for example, color chips) 3a and 3b are sprayed on the colored adhesive layer 2 as shown in FIG.
The chips 3a and 3b are partially settled and buried in the adhesive layer 2 due to their own weight, and the protrusions 2a are generated in the adhesive layer due to surface tension in the peripheral portion of the chip. When drying (for example, hot air drying) is performed in this state, the thickness of the adhesive layer becomes about half as a whole, as shown in FIG. At this time, as described above, the drying speed of the peripheral portion 2a of the chip is high, so that the pigment in the adhesive layer is removed from the peripheral portion 2a.
, The density of this portion 2a is further increased, and the hue difference is further increased. After the adhesive layer 2 has been dried and fixed, rolling is performed as shown in FIG. 4 to mainly roll the non-embedded portions of the adhesive layers of the chips 3a and 3b, and the rolled portions 3c and 3d are the adhesive around the chips. Cover the layers. The surface material shown in FIG. 4 is the decorative surface material 4 according to the present invention. The exposed surface side 4a of the film 1 is the decorative surface side, and the rolled surface 4b is the synthetic resin or metal. It is used for exterior decoration of various building materials, various devices, appliances, furniture, etc. as a side to be attached to the base material. If the decorative surface is intentionally provided with irregularities, for example, to have a function such as slip resistance, the rolling side 4b having irregularities can be used as the outer surface side.

Next, more specific examples will be described.

Example 1 To a transparent vinyl chloride film having a thickness of 300 µ, 1 part of an acramin pigment toning with 3 parts of Denaseol EX614 manufactured by Nagase Kasei Co., Ltd. was added to 100 parts of Nikasol FX922A manufactured by Nippon Carbide Industries Co., Ltd. and well stirred. , Viscosity 2
Colored adhesive adjusted to 00-800 cps, 50-80
It was coated to a thickness of μ.

From above, a polyethylene semi-transparent chip with a softening point of 110 ° C (1.5 mm square), a vinyl chloride color chip with a softening point of 130-140 ° C (3 mm granules), a softening point of 150-170 ° C.
1,000 vinyl chloride color chips (1 mm granules)
It was sprayed so as to have a density of 100,000 particles / m ² . 8
After drying at 0 ° C. for 3 minutes, it was heated at 140 to 150 ° C. for 10 minutes, pressed at a pressure of 20 kg / cm ² , and rolled.

The film-like decorative surface material produced in this manner provided a color tone very close to that of natural stone.

Example 2 To a transparent vinyl chloride film having a thickness of 300 μm, 1 part of an acramin pigment prepared by toning 100 parts of Cotax 730 manufactured by Toray Industries, Inc. and 3 parts of Denacol EX614 manufactured by Nagase Kasei Co., Ltd. was well stirred. The viscosity to 20-100
The colored adhesive adjusted to cps was coated in a thickness of 50 to 80 μ.

From above, a polyethylene semi-transparent chip with a softening point of 110 ° C (1.5 mm square), a vinyl chloride color chip with a softening point of 130-140 ° C (3 mm granules), a softening point of 150-170 ° C.
1,000 vinyl chloride color chips (1 mm granules)
It was sprayed so as to have a density of 100,000 particles / m ² . 8
After drying at 0 ° C. for 3 minutes, it was heated at 140 to 150 ° C. for 10 minutes, pressed at a pressure of 20 kg / cm ² , and rolled.

The film-like decorative surface material produced in this manner provided a color tone very close to that of natural stone.

〔The invention's effect〕

As described above, according to the present invention, as compared with the conventional method using vinyl chloride plastisol, it is possible to obtain a decorative surface material at a low cost with an extremely small amount of heat energy, and an extremely deep surface like natural stone. In addition, it is possible to easily bring out the light and shade unevenness with a taste, and it is possible to make these subtle changes with various color tones and patterns.

Therefore, by applying the decorative surface material according to the present invention to the interior and exterior of various building materials, various devices, appliances, furniture, etc., the value of these interior and exterior materials can be greatly increased.

[Brief description of drawings]

1 to 4 are schematic partial cross-sectional views schematically showing the manufacturing process of the decorative surface material of the present invention. 1 ... film 2 ... colored adhesive layer 3a, 3b ... plastic chip 4 ... decorative surface material

Claims (2)

[Claims] 1. A transparent film, a colored adhesive layer provided on one surface of the film, and a colored adhesive layer which is dispersed so as to be partially embedded in the colored adhesive layer. And a plastic chip, wherein the film thickness of the colored adhesive layer around the plastic chip is formed to be thicker than the film thickness of other parts, and the colored adhesive layer mainly of the colored adhesive layer is not formed. The decorative surface material, wherein the buried portion is rolled onto the colored adhesive layer around the plastic chip. 2. A transparent film is coated with a colored adhesive in a uniform film thickness, and a plastic chip is formed on the colored adhesive layer so that the plastic chip is partially embedded in the colored adhesive layer. The colored adhesive layer around the plastic chip is made thicker than the other parts by the surface tension of the colored adhesive layer around the plastic chip. After being dried, the plastic chip, mainly the non-embedded portion of the colored adhesive layer, is rolled onto the colored adhesive layer of the peripheral portion of the plastic chip, the method for producing a decorative surface material.