JPH0579499B2 - - Google Patents

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention can be applied to flooring materials, wall materials, ceiling materials, system buses, system kitchens, furniture exteriors, vehicle interiors,
This invention relates to a novel decorative film-like surface material that can be used for the exterior of home appliances, etc., and a method for producing the same.

[Conventional technology]

Conventional floor materials, wall materials, ceiling materials, etc. are generally made by laminating printed vinyl chloride films or sheets onto the base material, but the printed patterns are flat and have a transparent or voluminous feel. There is no
Compared to natural materials, it had a strong impression of being flimsy and cheap.

Recently, vinyl chloride plastisol is applied onto a vinyl chloride sheet, and colored vinyl chips are sprinkled on top of it, then heated and compressed to gel the vinyl chloride plastisol and roll the chips to create crushed stone handles, etc. The method is becoming popular.

[Problem to be solved by the invention]

However, the above method requires an extremely large amount of thermal energy and a long time to gel the vinyl chloride plastisol, resulting in a problem of high production costs.

Furthermore, the pattern produced by rolling PVC color chips is characterized by the ability to produce a deeper and more solid appearance than printing methods, but it also produces subtle color tones such as uneven shading, blurring, blurring, and clouding, similar to natural stone. There is a limit to the fact that there is no variation and only monotonous and uniform patterns can be produced.

The present invention has focused on the problems and limitations of the prior art, and can be manufactured at low cost, and is particularly suitable for use with complex shading such as natural stones such as granite and marble, where the density of the dotted pattern changes non-uniformly. An object of the present invention is to provide a decorative surface material that can easily create a pattern and a method for manufacturing the same.

[Means to solve the problem]

The decorative surface material of the present invention that meets this purpose includes a transparent film, a colored adhesive layer provided on one side of the film, and a large number of chips sprinkled on the colored adhesive layer. , at least a portion of the plurality of chips have locally varied distribution density, and the chips are pressed onto a colored adhesive layer.

Further, in the method for producing a decorative surface material of the present invention, a colored adhesive is coated on a transparent film with a uniform thickness, and a large number of chips are placed on the colored adhesive layer, and at least one of the large number of chips is coated with a colored adhesive on a transparent film. The method consists of dispersing a portion of the adhesive so that the dispersion density varies locally on the colored adhesive layer, drying the colored adhesive layer, and then pressing the chips onto the colored adhesive layer.

In the method of the present invention, a substantially transparent colored adhesive layer is provided with a uniform thickness on one side of a transparent film substrate. The film base material only needs to be substantially transparent, and may be either colorless and transparent or colored and transparent. In the case of colored transparent film,
The color may be different from the color of the colored adhesive;
If they are different, the color of the film layer and the color of the adhesive layer can be mixed to create a complex color shade. The material of the film is not particularly limited as long as it can support the colored adhesive layer.

The resin components of the colored adhesive used here are resins made of polyurethane, vinyl urethane, polystyrene, polyester, polyamide, polyacrylic ester, ethylene vinyl acetate, modified vinyl, vinyl acetate acrylic, epoxy, melamine, isocyanate, compounds, etc. It contains a hydroxyl group, a carboxyl group, a primary amine group, a secondary amine group, a tertiary amine group, a methoxy group, a methylol group, a double bond, a triple bond, etc. as a functional group, and is self-curing. epoxy, amine, isocyanate,
Suitable materials are those that can be crosslinked and cured with a curing agent such as melamine.

In addition, the above transparent colored adhesive has a viscosity of 10
It is preferable to use an aqueous emulsion adjusted to ~10,000 cps, preferably 50 to 2,000 cps. If the viscosity is less than 10 cps, the chip adhesion strength of the colored adhesive layer will be too low, and if it exceeds 10,000 cps, it will be difficult to promote changes in chip dispersion density, which will be described later, when the adhesive layer flows.

A large number of chips are spread on the colored adhesive layer, and at least some of the chips are spread so that the density of the chips varies locally. In other words, all of the chips to be sprayed may be scattered at different densities depending on the spraying area, or when multiple types of chips are sprayed,
Chips of one type may be distributed at a substantially uniform density over which chips of another type are distributed at varying densities. The latter method, in which multiple types of chips are spread, produces a color tone that is closer to that of natural stone.

The material of the chips to be sprayed is not particularly limited. Chips, granules, particles, powders, etc. made of plastic, inorganic materials, or natural materials can be used. Three varieties with different sizes, shapes, colors, specific gravity, softening points, etc.
It is preferable to spray ~20 varieties. Plastics, inorganic materials, and natural materials have different specific gravity, so the way they settle into the adhesive layer will be different. What's more, natural materials have strong water absorption properties, so they can absorb colored adhesives and create deep-colored finishes, creating interesting patterns.

The scattering of chips is carried out, for example, as follows.

First, natural materials such as wood, straw, palm, reed, bud,
Chips of 3 to 10 mm square made of coconut, straw, rattan, paper, cloth, etc. are uniformly scattered to a density of 10,000 to 50,000 grains/m ² . Next, plastics such as nylon, polyester, polyethylene, vinyl chloride, polypropylene, vinylon, celluloid, polystyrene, polyurethane, and polyimide have a softening point of 100.
~180℃, chips with a size of 1~5mm, 10,000 ~
Spread at a density of 50000 pieces/m ² .

Furthermore, inorganic particles such as ceramic, diamond sand, granite, brick, glass, carborangum, mica, etc. with a size of 0.1 to 1 mm are added to the particle size of 0 to 1 million.
Spray in a non-uniformly localized manner with varying density of grains/m ² .

When dispersed in the above manner, the inorganic particles settle and become impregnated into the adhesive layer, a small portion of each plastic chip adheres to the adhesive, and the natural material absorbs the adhesive while floating on the surface of the adhesive layer. Color and glue.

The chip adhesive film thus obtained is dried with hot air at 50-120°C. When the adhesive layer flows during this dry heating, the dispersion density of the chips with different dispersion densities is encouraged to become more non-uniform, resulting in a more interesting non-uniform pattern. After the adhesive layer is dried and fixed, the temperature is 80~
Heated at 250℃ for 5-20 minutes, pressure 3-100Kg/cm ²
It is compressed and rolled. By compression and rolling, the dispersed chips are pressed (rolled) onto the colored adhesive layer.

In the membrane material manufactured as described above, different types of chips and particles are scattered on a uniform transparent colored adhesive, the plastic chips are rolled and flattened, and the natural material absorbs the colored adhesive. The color changes to a complex hue. Inorganic particles vary in their scattering density, so they are localized non-uniformly and form a shading pattern, resembling a pattern of large and small stars scattered throughout the galaxy. In other words, at least a portion of the scattering tip (inorganic particles in the above embodiment)
It is scattered with its density varying locally, resulting in a pattern and color tone that are extremely similar to natural stone.

The film-like decorative surface material with a delicate natural stone pattern created as described above can be pasted onto the surface of a base material such as synthetic resin, metal, wood, gypsum board, concrete, etc. Used for indoor and outdoor flooring, wall materials, ceiling materials, system baths, system kitchens, furniture, vehicle interiors, and the exteriors of home appliances.

In addition, in the decorative surface material according to the present invention,
The surface on the film base material side is the decorative surface, but if you want the decorative surface to have irregularities, for example to provide a non-slip function, the uneven chip rolling or crimping side should be the outer surface. is also possible. In particular, when inorganic particles or natural materials are selected as the chip, the uneven surface can be used as a non-slip surface.

〔Example〕

Next, specific examples of the present invention will be described.

Example 1 Nikazole FX922A100 manufactured by Nippon Carbide Industries Co., Ltd. was applied to a transparent vinyl chloride film with a thickness of 300μ.
1 part, 3 parts of Denacol EX614 manufactured by Nagase Kasei Co., Ltd. and 1 part of toned acramine pigment were added, stirred well, and coated with a colored adhesive with a thickness of 50 to 80 μm, the viscosity of which was adjusted to 100 to 800 cps. .

Wood chips with a size of 3 to 10 mm square and grasshopper chips were mixed thereon and sprinkled at a substantially constant density of 10,000 to 50,000 pieces/m ² . Next, size 2
~3 mm, three colors of vinyl chloride color chips with a softening point of 120 to 150°C and one type of low melting point translucent chip with a softening point of 120°C are mixed to create a substantially constant density.
It was spread at a density of 10000-50000 pieces/ ^m2 .

Furthermore, by mixing glass powder with a size of 0.1 to 1 mm, brick powder, and mica powder, the scattering density is 0 to 1,000,000.
It was applied non-uniformly and localized, varying in the grain/m ² range.

This film was dried at 80°C for 3 minutes to fix the chips to the adhesive layer, and then heated at a temperature of 140 to 150°C for 10 minutes and pressurized at a pressure of 20 kg/cm ² .

The film-like decorative surface material produced in this way had a deep color tone very similar to natural stone, interspersed with fine patterns with varying density.

Example 2 100 parts of Kotax 730 manufactured by Toray Industries, Inc. was applied to a transparent vinyl chloride film with a thickness of 300μ.
Add 3 parts of Denacol EX614 manufactured by Nagase Kasei Co., Ltd. and 1 part of toned acramine pigment, stir well, and adjust the viscosity to 20 to 100 cps.
Coated with a thickness of .

Wood chips with a size of 3 to 10 mm square and grasshopper chips were mixed thereon and sprinkled at a substantially constant density of 10,000 to 50,000 pieces/m ² . Next, size 2
~3 mm, three colors of vinyl chloride color chips with a softening point of 120 to 150°C and one type of low melting point translucent chip with a softening point of 120°C are mixed to create a substantially constant density.
It was spread at a density of 10000-50000 pieces/ ^m2 .

Furthermore, by mixing glass powder with a size of 0.1 to 1 mm, brick powder, and mica powder, the scattering density is 0 to 1,000,000.
It was applied non-uniformly and localized, varying in the grain/m ² range.

This film was dried at 80° C. for 3 minutes to fix the chips to the adhesive layer, and then heated at a temperature of 140 to 150° C. for 10 minutes and pressurized at a pressure of 20 kg/cm ² .

The film-like decorative surface material produced in this way had a deep color tone very similar to natural stone, interspersed with fine patterns with varying density.

〔Effect of the invention〕

As explained above, according to the present invention, a decorative surface material can be obtained at a low cost with extremely less thermal energy than the conventional method using vinyl chloride plastisol, and the density of the dotted pattern is It is possible to easily create the extremely deep and flavorful shading unevenness of natural stone, where the pattern changes non-uniformly, and it is also possible to create these subtle changes in various 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.

Claims (1)

[Scope of Claims] 1. A transparent film, a colored adhesive layer provided on one surface of the film, and a large number of chips sprinkled on the colored adhesive layer, the film having a plurality of chips. 1. A decorative surface material characterized in that at least some of the chips have a locally varying distribution density and are pressed onto a colored adhesive layer. 2. A colored adhesive is applied to a transparent film with a uniform thickness, and a large number of chips are dispersed onto the colored adhesive layer, with at least some of the chips being locally scattered on the colored adhesive layer. 1. A method for producing a decorative surface material, comprising: dispersing the chips so as to vary their density, drying the colored adhesive layer, and then pressing the chips onto the colored adhesive layer.