Stock material or miscellaneous articles – Structurally defined web or sheet – Continuous and nonuniform or irregular surface on layer or...
Patent
1995-03-17
1997-04-15
Watkins, William
Stock material or miscellaneous articles
Structurally defined web or sheet
Continuous and nonuniform or irregular surface on layer or...
428141, 428215, 428331, 428328, 4284244, 428483, 4289133, 427561, 427565, 427568, 427204, 427199, 427257, 4273722, 427387, 427280, B05D 506
Patent
active
056207727
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to a decorative sheet having a "hammer tone" texture. Hammer tone texture has been used in various fields, because it gives a beautiful finishing effect even when the surface of the backing is rough to some degree.
BACKGROUND OF THE INVENTION
Usually decorative sheets have been made using by the following processes: (a) a resin film is formed on a paper surface by coating a polyvinyl chloride resin sol on the paper surface, (b) a vinyl chloride sheet as a backing is subjected to printing, embossing, or other working, (c) a foaming agent is used to produce a three dimensional appearance, or (d) flake-like or pellet-like chips are sprayed and adhered at random in order to provide a stereoscopic appearance. See, for example, Interior Encyclopedia published by the Trade Association for Wall-Covering Materials of Tokyo, Japan in 1988 at pages 697 and 698.
If a stereoscopic texture called "hammer tone" (i.e., as if hammered at random to form a three dimensional or other stereoscopic appearance) is attempted to be produced by the printing or embossing processes as described above, a poor stereoscopic appearance results because the same pattern appears repeatedly according to the circumference of the printing roll or embossing roll. No random texture is formed.
If a foaming agent is used, the expression of stereoscopic appearance is reduced. If a decorative sheet is adhered using chips, flaking of the chips is troublesome.
Usually in order to obtain a hammer tone texture, paint containing silicone resin is used. Japanese Unexamined Patent Publication (Kokai) No. 63-91168 discloses a coating composition containing a powdered silicone resin to form a hammer tone texture to form on a painted surface. Such a coating composition causes a hammer tone texture to appear because the silicone resin repels the coating composition components on the surface of the coating composition due to the low surface tension of the silicone resin. This is a non-wetting phenomenon. However, since a silicone resin has a low surface tension and is poor in compatibility with other coating composition components, it must be constantly immersed in a solvent. Thus, it has been difficult to coat a silicone resin by a method substantially other than spray coating.
However, application by spray coating has involved the following problems or restrictions: so-called "sagging" of the coating often occurs. effect spray coating over a large area at one time without refilling or using a new spraying can. prevent clogging at the nozzle portion. A diluent or injection gas become indispensable for use in spraying. without heat or under strict drying conditions of about 180.degree. C. and about 20 minutes if crosslinking of coating is required.
Accordingly, it has been difficult to use the conventional silicone resin coating composition as decorative film, especially a decorative film that can be stored on a roll.
SUMMARY OF THE INVENTION
One aspect of the present invention recognizes the following preferred features in a decorative sheet having a hammer tone texture, especially a long sheet having a hammer tone texture that can be stored in a roll form until use: from repetition of the same pattern, hammer tone texture, diluent nor injection gas is necessary, and that production cost is low. lower than that used for spraying techniques.
Another aspect of the invention relates to a decorative sheet having a hammer tone texture, containing a backing sheet, primer layer, and decorative layer, the decorative layer having a surface roughness of 6 .mu.m or more.
The decorative sheet having a hammer tone texture of the present invention comprises a backing sheet, a primer layer on the backing sheet, and a decorative layer on the primer layer, the decorative layer formed by applying the decorative layer in the form of a hammer tone coating composition using a controlled means of delivery of the composition to the primer layer at a sufficient thickness after mixing with sufficient agitation and then drying
REFERENCES:
patent: 3935147 (1976-01-01), Godshalk et al.
patent: 4686261 (1987-08-01), Naito
patent: 4812336 (1989-03-01), Okamoto et al.
Trade Association for Wall-Covering Material of Tokyo, Interior Encyclopedia, Tokyo, Japan, pp. 697-698, (1988).
Japanese Industrial Standard, "Float and Polished Plate Glasses, JIS R 3203", Edition 4, Tokyo, Japan (Mar. 1, 1991).
Japanese Industrial Standard, "Surface roughness--Definitions and designation, JIS B 0601", Edition, 1, Tokyo, Japan (Feb. 1, 1994).
ALEXIT-Hammerschlaglack 2:1 (ALEXIT-Hammer-Metal-Finish) product data sheet, Mankiewicz Egbr. & Co., Hamburg, Germany (May 1990).
Griswold Gary L.
Hornickel John H.
Kirn Walter N.
Minnesota Mining and Manufacturing Company
Watkins William
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