JP6913299B2 - Decorative board and its manufacturing method - Google Patents

Description

The present invention relates to a decorative board and a method for producing the same.

Conventionally, the surfaces of tables, counters, walls, floors, etc. are impregnated with an uncured resin solution of melamine resin on a porous base material such as titanium paper, laminated on phenol core paper or the like as necessary, and then impregnated resin. A decorative board is used in which the liquid is hardened by a hot press. A decorative board impregnated and cured with such a melamine resin exhibits physical properties such as strength, hardness, and heat resistance.

The decorative board as described above is required to have a design showing a high-class feeling, and the surface is given a concavo-convex appearance. Various shapes can be adopted as such uneven shapes, but among them, the groove-shaped uneven shape of the wood grain conduit portion, the gloss matte-like uneven shape, and the like are typical and are frequently used. The "gloss matte uneven shape" means an uneven shape in which a high gloss region and a low gloss region are mixed in a pattern on the surface of the article. The surface of the article having such a structure is characterized in that the low-gloss region visually looks recessed as compared with the high-gloss region, regardless of the physical unevenness, and thus the three-dimensional design appearance can be reproduced. The "gloss matte uneven shape" itself is well known as disclosed in Patent Document 1 and Patent Document 2.

In Patent Document 3, as a decorative plate having a gloss matte-like uneven shape on the surface, an embossed plate (textured mirror plate) having a desired uneven shape formed on the surface is used for thermal pressure. Pressed veneers have been proposed.

However, in the case of imparting a desired uneven pattern design feeling to the surface of the decorative plate described in Patent Document 3, a mirror surface plate surface-treated for only the type of design is required, which increases the cost. Further, in this decorative board, it is difficult to synchronize the uneven shape with the pattern of the base, and it is difficult to enhance the design.

In Patent Document 4, as a method for manufacturing a decorative board in which a concave portion or the like synchronized with a pattern is formed, a thermosetting resin is impregnated by providing a permeation prevention layer and a liquid-repellent pattern layer on the surface of the base paper. A manufacturing method has been proposed to prevent a phenomenon in which a liquid-repellent pattern is covered with a film of a thermosetting resin during thermosetting.

However, it is difficult to completely prevent the coating of the thermosetting resin by the manufacturing method described in Patent Document 4, and the decorative board manufactured by such a manufacturing method has a clear uneven shape design feeling. It is difficult to express.

In Patent Document 5, a porous base material is used as a method for producing a decorative plate having a release layer in a part of the surface and a thermosetting resin layer in the remaining region of the surface without the release layer. In the first step of providing a release layer on a part of the upper part, the porous base material is impregnated with a thermosetting resin, the release layer is coated with the thermosetting resin, and then the thermosetting resin is heated. A manufacturing method including a second step of curing and a third step of peeling the thermosetting resin film in the region covering the top of the release layer has been proposed.

The decorative board described in Patent Document 5 can express a clear gloss matte design feeling by showing a different design feeling between the thermosetting resin layer and the release layer.

Special Publication No. 49-39166 Special Fair 1-20065 Gazette Japanese Unexamined Patent Publication No. 47-14273 JP-A-2002-166501 International Publication No. 2016/148091

However, in the decorative board described in Patent Document 5, when the width of the release layer is narrow (for example, when the release layer is aligned with the wood grain-patterned conduit portion), the thermosetting resin film covering the release layer The peelability may decrease and become unstable, and the peeling of the thermosetting resin film from the release layer may be insufficient. Therefore, it is difficult for the decorative board described in Patent Document 5 to express a design feeling based on a clear uneven shape when the width of the release layer is narrow.

Therefore, an object of the present invention is to provide a decorative board capable of expressing a design feeling based on a clear uneven shape even when the width of the release layer is narrow, and a method for manufacturing the decorative board.

In order to solve the above problems, the present invention provides the following decorative board and a method for manufacturing the same.
[1] It has a first direction, a second direction, and a thickness direction that are orthogonal to each other, and also
A support sheet having a first main surface and a second main surface located on the opposite side of the first main surface, and
A first layer provided so as to extend along the first direction on a part of the first main surface, and
A second layer provided so as to surround the first layer on the rest of the first main surface, and
It is a decorative board equipped with
The first layer has a wide portion having a width of 20 μm or more and 100 μm or less.
The second layer has an opening that exposes at least a portion of the wide portion.
In a cut surface formed by cutting the decorative plate on a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outer line in the plan view of the wide portion. When the width of the wide portion is WB, the height of the wide portion is HB, and the height of the second layer is H, H> HB and WB ≧ (H-HB).
The decorative board in which at least a part of the wide portion is exposed from the opening of the second layer on the cut surface.
[2] The decorative board according to [1], wherein the difference (H-HB) between the height of the second layer and the height of the first layer on the cut surface is 1 μm or more.
[3] The decorative board according to [1] or [2], wherein the area of the wide portion exposed from the opening of the second layer is 80% or more of the area of the wide portion.
[4] The decorative board according to any one of [1] to [3], wherein the first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin.
[5] The decorative board according to any one of [1] to [4], wherein the second layer is a cured resin layer containing a cured product of a thermosetting resin.
[6] The decorative board according to [5], wherein the thermosetting resin contains a water-soluble thermosetting resin.
[7] The decorative board according to [6], wherein the water-soluble thermosetting resin contains a melamine resin.
[8] The decorative board according to any one of [1] to [7], wherein the first layer and / or the second layer contains a silicone-based release agent.
[9] The support sheet has a base sheet, and the base sheet has a first main surface located on the first main surface side of the support sheet and the second main surface side of the support sheet. The decorative board according to any one of [1] to [8], which has a second main surface located at.
[10] The decorative board according to [9], wherein the support sheet further has a decorative layer provided on the first main surface of the base material sheet.
[11] The decorative board according to [9] or [10], wherein the base material sheet is a porous sheet.
[12] The decorative board according to [11], wherein the support sheet further has a cured product of a thermosetting resin filled in the voids of the porous sheet.
[13] The method for producing a decorative board according to any one of [1] to [12].
The above method
(1) Step of preparing the support sheet,
(2) A step of forming the first layer on a part of the first main surface of the support sheet.
(3) A step of forming a coating layer that surrounds the first layer and covers at least a part of the first layer on the rest of the first main surface of the support sheet.
(4) The step including a step of peeling a portion of the coating layer covering the first layer along the first direction to form a second layer on the rest of the first main surface of the support sheet is included.
The intermediate body obtained in the step (3) is cut on a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outer line in the plan view of the wide portion. The method, wherein the width of the wide portion of the cut surface to be formed is WB, and WB ≧ TB when the thickness of the portion of the coating layer that covers the wide portion is TB.
[14] The method according to [13], wherein the thickness (TB) of the portion of the coating layer that covers the wide portion of the cut surface is 1 μm or more.
[15] The first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin.
The step (2) is
(2-1) Using the ionizing radiation curable resin composition containing the ionizing radiation curable resin, an ionizing radiation curable resin composition layer covering a part of the first main surface of the support sheet is formed. Process and
(2-2) The method according to [13] or [14], which comprises a step of curing the ionizing radiation curable resin composition layer to form the cured resin layer as the first layer.
[16] The method according to [15], wherein the ionizing radiation curable resin composition contains a silicone-based mold release agent.
[17] The coating layer is a cured resin layer containing a cured product of a thermosetting resin.
The step (3) is
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the rest of the first main surface of the support sheet, and the first layer is formed. A step of forming a thermosetting resin composition layer that covers at least a part of the above, and
(3-2) The method according to any one of [13] to [16], which comprises a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer.
[18] The method according to [17], wherein the thermosetting resin contains a water-soluble thermosetting resin.
[19] The method according to [18], wherein the water-soluble thermosetting resin contains a melamine resin.
[20] The method according to any one of [17] to [19], wherein the thermosetting resin composition contains a silicone-based mold release agent.
[21] The support sheet has a base sheet, and the base sheet has a first main surface located on the first main surface side of the support sheet and the second main surface side of the support sheet. The method according to any one of [13] to [20], which has a second main surface located at.
[22] The method according to [21], wherein the support sheet further has a decorative layer provided on the first main surface of the base material sheet.
[23] The method according to [21] or [22], wherein the base material sheet is a porous sheet.
[24] The coating layer is a cured resin layer containing a cured product of a thermosetting resin.
The step (3) is
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the rest of the first main surface of the support sheet, and the first layer is formed. A step of forming a thermosetting resin composition layer that covers at least a part of
(3-2) Including a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer.
In the step (3-1), the porous sheet is impregnated with the thermosetting resin composition.
The method according to [23], wherein in the step (3-2), the thermosetting resin composition impregnated in the porous sheet is cured.

According to the present invention, there is provided a decorative board capable of expressing a design feeling based on a clear uneven shape and a method for manufacturing the decorative board.

FIG. 1 is a plan view of a decorative board according to an embodiment of the present invention. FIG. 2 is an enlarged view of a region represented by reference numeral R in FIG. FIG. 3 is a cross-sectional view taken along the line AA of FIG. FIG. 4 is a cross-sectional view taken along the line BB of FIG. FIG. 5 is a cross-sectional view taken along the line CC of FIG. FIG. 6 is a plan view showing an embodiment in which the angle formed by the extending direction of the first layer and the first direction of the decorative board is + 30 °. FIG. 7 is a plan view showing an embodiment in which the angle formed by the extending direction of the first layer and the first direction of the decorative board is −30 °. FIG. 8 is an explanatory diagram for explaining an embodiment of the method for manufacturing a decorative board shown in FIG. FIG. 9 is an explanatory diagram (continuation of FIG. 8) for explaining one embodiment of the method for manufacturing a decorative board shown in FIG. FIG. 10 is a cross-sectional view of the intermediate obtained in step (3). FIG. 11 is a cross-sectional view of the intermediate obtained in step (3). FIG. 12 is an explanatory diagram for explaining a method of measuring the peeling weight.

Decorative board Hereinafter, embodiments of the decorative board according to the present invention will be described with reference to the drawings. FIG. 1 is a plan view of a decorative board according to an embodiment of the present invention, FIG. 2 is an enlarged view of a region represented by reference numeral R in FIG. 1, and FIG. 3 is an enlarged view of AA of FIG. It is a cross-sectional view, FIG. 4 is a cross-sectional view taken along the line BB of FIG. 2, and FIG. 5 is a cross-sectional view taken along the line CC of FIG.

As shown in FIGS. 1 to 5, the decorative board 1 according to the embodiment of the present invention has a first direction X, a second direction Y, and a thickness direction Z that are orthogonal to each other. In the present embodiment, the first direction X corresponds to the longitudinal direction of the decorative plate 1, the second direction Y corresponds to the lateral direction of the decorative plate 1, but the first direction X corresponds to the lateral direction of the decorative plate 1. The second direction Y may correspond to the longitudinal direction of the decorative plate 1.

As shown in FIGS. 2 to 5, the decorative plate 1 includes a support sheet 2 having a second main surface S2 located on the opposite side of the first main surface S1 and the first main surface S1, and a first support sheet 2. The first layer 3 is provided so as to extend along the first direction X on a part of the main surface S1, and the first layer 3 is surrounded by the rest of the first main surface S1 of the support sheet 2. The second layer 4 provided in the above is provided.

As shown in FIG. 2, the plan view shape of the first layer 3 in the present embodiment is a pattern having an elongated outer line (contour line) extending in the extending direction D1 and orthogonal to the extending direction D1. The dimension in the width direction gradually expands from the lower end to the upper end of FIG. 2, reaches the maximum width at the substantially central portion of the extending direction D1, and then gradually decreases.

As shown in FIGS. 2 to 4, the first layer 3 has a wide portion 31 having a width of 20 μm or more, and the second layer 4 has an opening 40 that exposes at least a part of the wide portion 31. .. That is, the wide portion 31 in the present embodiment is a region having a width of 20 μm or more including the central portion of the first layer 3 having an elongated shape whose width changes continuously in a plan view. Both ends of the first layer 3 form narrow portions 32, which will be described later.

As shown in FIGS. 2 to 4, the opening 40 of the second layer 4 has a recess 5 formed on the surface of the decorative plate 1, and at least a part of the bottom portion of the recess 5 is formed by the wide portion 31. ing.

As shown in FIG. 3, the decorative plate 1 is cut at a plane extending in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outer line in the plan view of the wide portion 31. The following conditions are satisfied in the cut surface formed in the above.
[Characteristic 1] When the width of the wide portion 31 is WB, the height of the wide portion 31 is HB, and the height of the second layer 4 is H, H> HB and WB ≧ (H-HB).
[Feature 2] At least a part of the wide portion 31 is exposed from the opening 40 of the second layer 4.

It can be confirmed that the conditions 1 and 2 are satisfied by observing the cut surface with a scanning microscope (SEM). In the present invention, "planar view" means observing a target member or portion from the normal direction of the first main surface of the support sheet (corresponding to the thickness direction Z in FIGS. 1 to 5). Means. For example, in FIGS. 3 to 5, it means looking down from above toward the figure. Further, "planar view" is a virtual concept that treats a target member or part as being observable even when it is hidden by another member or part and cannot be actually observed. That is, "plan view" corresponds to projecting the target member or portion onto a virtual plane perpendicular to the thickness direction Z of the decorative board.

In the present embodiment, the height of the wide portion 31 on the cut surface is constant. When the height of the wide portion 31 on the cut surface is not constant, the minimum value of the height of the wide portion 31 is defined as the height HB of the wide portion 31 on the cut surface. In the present embodiment, the height of the second layer 4 on the cut surface is constant. When the height of the second layer 4 on the cut surface is not constant, the maximum height of the second layer 4 is defined as the height H of the second layer 4 on the cut surface.

The heights H and HB may be measured by uniquely determining a reference (reference point or reference plane) having a height of 0 with respect to the decorative plate 1, and the reference is arbitrary. In the present embodiment, as shown in FIG. 3, the heights H and HB are measured with the surface of the decorative layer 22 on the first main surface S1 side as a reference (height = 0).

The difference (H-HB) between the height H of the second layer 4 and the height HB of the wide portion 31 on the cut surface is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 5 μm or more. The upper limit of the difference (H-HB) between the height H of the second layer 4 and the height HB of the wide portion 31 on the cut surface is not particularly limited, but usually, the design appearance reproducibility of the decorative plate 1 is recessed. When the depth of 5, that is, the difference (H-HB) exceeds a certain level, it tends to saturate, and when the depth of the recess 5 increases above a certain level, the difficulty in manufacturing technology also tends to increase. Therefore, from a practical point of view, it is preferable that the upper limit of the difference (H-HB) between the height H of the second layer 4 and the height HB of the wide portion 31 is kept below a certain level. Specifically, when the decorative layer 22 forms a wood grain pattern and the first layer 3 is position-synchronized with the conduit portion of the wood grain pattern, the height H of the second layer 4 and the height of the wide portion 31 on the cut surface. The upper limit of the difference from HB (H-HB) is preferably 50 μm, more preferably 30 μm, and even more preferably 15 μm.

The decorative board 1 is manufactured by a manufacturing method including steps (1) to (4), as will be described later. The intermediate body obtained in the step (3) is cut along a plane extending in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outer line in the plan view of the wide portion 31. The following conditions are satisfied in the cut surface formed in the above.
[Condition 3] When the width of the wide portion 31 is WB and the thickness of the portion CL11 covering the wide portion 31 of the coating layer CL is TB, WB ≧ TB.

As a result of the manufacturing method of the decorative board 1 satisfying the condition 3, the decorative board 1 satisfies the condition 1. Further, when the manufacturing method of the decorative plate 1 satisfies the condition 3, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off along the first direction X, a wide portion is formed. The peelability of the portion CL11 covering 31 is improved and stabilized. As a result, the decorative board 1 satisfies the condition 2. When the decorative plate 1 satisfies the condition 2, as shown in FIG. 4, a portion of the wide portion 31 exposed from the opening 40 of the second layer 4 exists over the entire area of the wide portion 31. Therefore, the concave portion 5 has a depth reaching the wide portion 31 over the entire area thereof, and the difference in surface height between the concave portion 5 and the region other than the concave portion 5 becomes significant.

On the other hand, as shown in FIG. 5, the decorative plate is a plane extending in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outer line in the plan view of the narrow portion 32. In the cut surface formed by cutting 1, when the width of the narrow portion 32 is WN, the height of the narrow portion 32 is HN, and the height of the second layer 4 is H, WN <(H-HN). ). Therefore, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off along the first direction X, the peelability of the portion CL12 covering the narrow portion 32 is lowered. Destabilize. Therefore, as shown in FIGS. 2, 4 and 5, the narrow portion 32 is covered with the second layer 4 and is not exposed from the opening 40 of the second layer 4. A part of the narrow portion 32 may be exposed from the opening 40 of the second layer 4, but the portion of the narrow portion 32 exposed from the opening 40 of the second layer 4 is the narrow portion 32. It does not exist over the entire area.

As shown in FIGS. 2 to 4, the portion of the surface of the decorative plate 1 adjacent to the concave portion 5 is a relatively convex portion, and the surface of the decorative plate 1 is formed with an uneven shape. .. The decorative plate 1, which is the result of the manufacturing method including the steps (1) to (4) described later, has a relative surface of the recess 5 (including the surface of the wide portion 31 exposed from the opening 40 of the second layer 4). The surface of the region other than the concave portion 5 including the convex portion is relatively mirror-finished, and the surface of the region other than the concave portion 5 including the convex portion is relatively mirror-finished. It has the characteristic of forming a highly glossy region having reflectivity. Therefore, the decorative board 1 can express a gloss matte-like design feeling based on the uneven shape. In particular, by aligning the uneven shape of the decorative board 1 (that is, the high gloss area and the low gloss area) with the pattern of the decorative layer 22 described later, the decorative board 1 has an excellent gloss matte design feeling. Can be expressed. For example, when the decorative layer 22 forms a wood grain pattern, the recess 5 is referred to as a conduit portion in the wood grain pattern (that is, a groove portion of a line formed by an opening of a cut surface of the conduit, also referred to as a conduit groove). The position is synchronized so that the positions in the plan view of both are the same, and the area other than the concave portion 5 including the convex portion is the region other than the conduit portion in the wood grain pattern (also referred to as the bark portion or the like) and both. By synchronizing the positions so that the positions in the plan view match, the conduit portion in the wood grain pattern has a relatively concave appearance, whereby the decorative board 1 has a surface uneven shape similar to that of a real wood grain pattern. It is possible to express the design feeling (texture) of.

Since the concave portion 5 has a depth reaching the wide portion 31 over the entire area and the surface height difference between the concave portion 5 and the region other than the concave portion 5 is significant, the decorative plate 1 is based on a clear uneven shape. , A gloss matte design feeling and a surface uneven shape design feeling (texture) can be expressed.

In the decorative board 1, the entire wide portion 31 may be exposed from the opening 40 of the second layer 4 to form the bottom portion of the recess 5, but this is not always necessary. A part of the wide portion 31 may be covered with the second layer 4. In particular, when the wide portion 31 is position-synchronized with the wood grain-patterned conduit portion formed by the decorative layer 22, the portion of the wide portion 31 corresponding to the peripheral edge portion of the conduit portion may be covered with the second layer. .. It should be noted that the height difference of the concave-convex shape composed of the concave portion 5 and the convex portion (second layer 4) is sufficiently secured in terms of visual appearance, and within a range in which there is no practical problem in terms of surface physical properties such as wear resistance. The second layer may remain in a trace amount as a residue or a trace over the entire surface of the wide portion 31. When one wide portion 31 is viewed in a plan view, the area (S _31P ) of the portion of the wide portion 31 _{exposed from the opening 40 of the second layer 4 is the total area (S 31T} ) of the wide portion 31. It is preferably 80% or more, more preferably 90% or more, and even more preferably 95% or more. The area ratio S _31P / S _31T can be adjusted by appropriately selecting the formation material composition and heat molding conditions of the first layer 3 and the second layer 4, the material of the release film, the release rate, and the like. When the area ratio S _31P / S _31T is in the above range, the difference in surface height between the recess 5 and the region other than the recess 5 becomes significant, and the decorative plate 1 has a gloss matte design based on a clear uneven shape. It is possible to express the feeling and the design feeling (texture) of the surface uneven shape. For each wide portion 31, the area ratio S _31P / S _31T is preferably in the above range.

Further, in a plan view, the ratio (S _31T / S _{3 ) of the total area (S 31T} ) of the wide portion 31 in the first layer 3 to the total area (S ₃ ) of one first layer 3 is determined. Since it depends on the type of pattern expressed by the first layer 3 and the formation ratio of the recess 5 in the wide portion 31 described above, it cannot be unconditionally specified. As a design guideline for this ratio, when the first layer 3 expresses a wood grain pattern conduit portion, (S _31T / S ₃ ) is 80% in consideration of the formation ratio of the recess 5 in the wide portion 31 described above. The above is preferable, 90% or more is more preferable, and 95% or more is even more preferable. For each first layer 3, the area ratio S _31T / S ₃ is preferably in the above range.

As shown in FIGS. 3 to 5, the decorative plate 1 further includes a reinforcing layer 6 provided on the second main surface S2 of the support sheet 2. The present invention also includes an embodiment in which the reinforcing layer 6 is not provided on the second main surface S2 of the support sheet 2.

Support sheet The support sheet 2 is a sheet that supports the first layer 3 and the second layer 4.
As shown in FIGS. 3 to 5, the support sheet 2 is a base sheet 21 having a second main surface T2 located on the opposite side of the first main surface T1 and the first main surface T1, and the base sheet 21. It has a decorative layer 22 provided on the first main surface T1.

Base sheet As shown in FIGS. 3 to 5, in the base sheet 21, the first main surface T1 is located on the first main surface S1 side of the support sheet 2, and the second main surface T2 is the second main surface T2 of the support sheet 2. 2 It is arranged so as to be located on the main surface S2 side. In this embodiment, the second main surface T2 of the base sheet 21 forms the second main surface S2 of the support sheet 2.

The base sheet 21 is not particularly limited, but is preferably a porous sheet. The porous sheet is not particularly limited as long as it has liquid permeability. When the base sheet 21 has liquid permeability, for example, the base sheet 21 can be impregnated with a resin composition used as a raw material for forming the second layer 4. Examples of the porous sheet include a fiber sheet and the like. Examples of the fiber sheet include paper, non-woven fabric, and woven fabric. Examples of the paper include thin paper, kraft paper, titanium paper, linter paper, paperboard, woodfree paper, coated paper, parchment paper, Japanese paper and the like. Examples of other fiber sheets include sheets composed of inorganic fibers such as glass fiber, asbestos, potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber. From the viewpoint of liquid impregnation, the porous sheet is preferably titanium paper, thin paper, kraft paper, Japanese paper or the like, and more preferably titanium paper. The basis weight of the base sheet 21 can be appropriately adjusted depending on the intended use, usage method, etc. of the final product, and is, for example, 40 to 150 g / m ² . The thickness of the base sheet 21 can be appropriately adjusted depending on the intended use, usage method, etc. of the final product, and is, for example, 50 to 170 μm. In the present specification, the numerical range expressed as "numerical value A to numerical value B" has a numerical value A as an upper limit value and a numerical value B as a lower limit value (that is, a numerical value) unless otherwise specified. (Numerical range including A and numerical value B).

When the base sheet 21 is a porous sheet, it is preferable that the voids of the porous sheet are filled with a cured product of a curable resin. Thereby, the strength of the decorative board 1 can be improved. When the second layer 4 contains a cured product of the curable resin, the cured product of the curable resin filled in the voids of the porous sheet is integrated with the cured product of the curable resin contained in the second layer 4. It is preferable to have. Thereby, the bonding strength between the support sheet 2 and the second layer 4 can be improved. For example, when forming the second layer 4, a curable resin filled in the voids of the porous sheet is formed by impregnating the porous sheet with a curable resin composition which is a raw material for forming the second layer 4 and curing the porous sheet. And the cured product of the curable resin contained in the second layer 4 can be integrated.

In the present invention, there is an embodiment in which the voids of the porous sheet used as the base sheet 21 are not filled with the cured product of the curable resin, and the voids of the porous sheet as the base sheet 21 are made of the curable resin. Also includes embodiments in which the cured product is filled, but the cured product of the curable resin filled in the voids of the porous sheet is not integrated with the cured product of the curable resin contained in the second layer 4. Will be done.

The base sheet 21 may be colored. In the manufacturing stage of the base sheet 21 (for example, if the base sheet 21 is paper, the papermaking stage), the base sheet 21 can be colored by blending a colorant (pigment or dye) with the forming raw material. can. Further, when the second layer 4 is formed, a resin composition containing a colorant is used as a raw material for forming the second layer 4, and the base sheet 21 is impregnated with the resin composition to color the base sheet 21. be able to. Colorants include, for example, carbon black, iron black, titanium white, antimony white, yellow lead, titanium yellow, petals, cadmium red, ultramarine, cobalt blue and other inorganic pigments; quinacridone red, isoindolinone yellow. , Organic pigments or dyes composed of particles such as phthalocyanine blue; metal pigments composed of scaly foil pieces such as aluminum and brass; pearl luster (pearl) pigments composed of scaly foil pieces such as titanium dioxide-coated mica and basic lead carbonate. And so on. As the colorant, one type may be used alone, or two or more types may be used in combination. The blending amount of the colorant can be appropriately adjusted according to the desired color and the like.

The base sheet 21 may contain additives such as a filler, a matting agent, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, and a light stabilizer, if necessary. ..

Decorative Layer As shown in FIGS. 3 to 5, the decorative layer 22 is provided on the first main surface T1 of the base sheet 21. The decorative layer 22 may be formed on the entire first main surface T1 of the base sheet 21, or may be formed on a part of the first main surface T1 of the base sheet 21. When the decorative layer 22 is formed on the entire first main surface T1 of the base sheet 21, the first main surface S1 of the support sheet 2 is formed by the surface of the decorative layer 22. When the decorative layer 22 is formed on a part of the first main surface T1 of the base sheet 21, the first main surface S1 of the support sheet 2 is a part of the first main surface T1 of the base sheet 21 (decorative layer). 22 is not provided) and the surface of the decorative layer 22.

The present invention also includes an embodiment in which the decorative layer 22 is not formed on the first main surface T1 of the base sheet 21. In the embodiment in which the decorative layer 22 is not formed on the first main surface T1 of the base sheet 21, the first main surface S1 of the support sheet 2 is formed by the first main surface T1 of the base sheet 21.

The decorative layer 22 imparts decorativeness (design) to the decorative board 1. The decorative layer 22 is, for example, a colored layer, a pattern layer, or a combination thereof.

The colored layer imparts a desired color to the decorative board 1. The colored layer is, for example, a solid layer formed on the entire first main surface T1 of the base sheet 21. The color of the colored layer is usually an opaque color, but it may be a transparent color when the base color or pattern of the base sheet 21 or the like is utilized. Further, when the color or pattern of the base material such as the base material sheet 21 is utilized, it is not necessary to form the colored layer.

The pattern layer imparts a desired pattern to the decorative board 1. The pattern layer is, for example, a printing layer formed on a part or the whole of the first main surface T1 of the base sheet 21 or a part or the whole of the surface of the colored layer. The patterns constituting the pattern layer include, for example, wood grain patterns composed of spring and autumn wood regions of annual ring cross sections, conduits, leather (skin grain) patterns, and stones on the surface of stone materials such as marble, granite, and sand rock. Examples include eye patterns, grain patterns, tiled patterns, brickwork patterns, cloth patterns, geometric figures, characters, symbols, and abstract patterns.

As shown in FIG. 1, the decorative layer 22 in the present embodiment imparts a wood grain pattern to the decorative board 1.

The thickness of the decorative layer 22 can be appropriately adjusted according to the product characteristics and the like, and is, for example, 0.1 to 20 μm.

First layer The first layer 3 corresponds to the release layer described in Patent Document 5 (International Publication No. 2016/148091).

As shown in FIG. 2, the first layer 3 extends along the first direction X in a plan view. "The first layer 3 extends along the first direction X" means that the angle formed by the extending direction D1 of the first layer 3 and the first direction X of the decorative board 1 is ± 30 ° or less. It means that there is. The extending direction D1 of the first layer 3 corresponds to the longitudinal direction of the rectangle circumscribing the outer line of the first layer 3 in a plan view. In the present embodiment, the extending direction D1 of the first layer 3 coincides with the first direction X of the decorative board 1. FIG. 6 shows an embodiment in which the angle between the extending direction D1 of the first layer 3 and the first direction X of the decorative plate 1 is + 30 °, and the extending direction D1 of the first layer 3 and the decorative plate 1 FIG. 7 shows an embodiment in which the angle formed by the first direction X is −30 °.

When the decorative board 1 is manufactured by the manufacturing method including the steps (1) to (4) described later, in the step (4), the portion CL1 covering the first layer 3 of the coating layer CL is along the first direction X. Is peeled off. When the angle formed by the extending direction D1 of the first layer 3 and the first direction X of the decorative plate 1 is ± 30 ° or less, the extending direction D1 of the first layer 3 is the decorative plate 1. Similar to the case corresponding to the first direction X, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off along the first direction X, the portion covering the wide portion 31. The peelability of CL11 is improved and stabilized.

As shown in FIG. 2, the first layer 3 has a wide portion 31 having a width of 20 μm or more and 100 μm or less, and a narrow portion 32 having a width of less than 20 μm. The maximum width of the wide portion 31 is not particularly limited as long as it is 20 μm or more and 100 μm or less. Significantly, it is preferably 30 μm or more and 100 μm or less. The minimum width of the narrow portion 32 is zero. In the present embodiment, the minimum width of the wide portion 31 is 20 μm, but the minimum width of the wide portion 31 may exceed 20 μm. In the present embodiment, the first layer 3 is composed of the wide portion 31 and the narrow portion 32, but the first layer 3 may be composed of only the wide portion 31. In the present embodiment, the wide portion 31 has a minimum width and a maximum width, but the width of the wide portion 31 may be constant.

The width of the first layer 3 is defined as follows. As shown in FIGS. 2, 6 and 7, in a plan view, an arbitrary point located on the outline of the first layer 3 is defined as P, and the first layer 3 passes through the outline of the first layer 3 and the point P. When the intersection with the straight line extending in the direction perpendicular to the extending direction D1 of the layer 3 is taken as Q, the distance between the point P and the point Q is the width W of the first layer 3. When the arbitrary point P is located on the outline of the wide portion 31, the distance (width W) between the point P and the point Q is 20 μm or more, and the arbitrary point P is located on the outline of the narrow portion 32. The distance (width W) between the point P and the point Q is less than 20 μm.

As shown in FIGS. 3 to 5, the first layer 3 is provided on a part of the first main surface S1 of the support sheet 2, for example, in a desired pattern. The first layer 3 has a portion having a thickness smaller than that of the adjacent second layer 4, and at least a part of this portion is exposed from the opening 40 of the adjacent second layer 4 to be a decorative plate. The bottom of the recess 5 on the surface of 1 is formed.

Of the first main surface S1 of the support sheet 2, the region where the first layer 3 is provided may be one continuous region or a plurality of discontinuous regions. The first layer 3 may be composed of one continuous layer or may be composed of a plurality of discontinuous layers. When the first layer 3 is composed of one continuous layer, the thickness of the first layer 3 may be constant or may be partially different. When the first layer 3 is composed of a plurality of discontinuous layers, the thickness of each layer may be constant or may be partially different. When the first layer 3 is composed of a plurality of discontinuous layers, the thickness of one layer and the thickness of another layer may be the same or different. The thickness of the first layer 3 is not particularly limited, but is preferably 0.1 to 100 μm, and more preferably 1 to 20 μm.

The first layer 3 is, for example, a resin layer. Examples of the resin layer include a cured resin layer and a thermoplastic resin layer. The first layer 3 may include two or more layers made of different materials.

The curable resin layer is a layer formed by curing the curable resin composition, and contains a cured product of the curable resin. Examples of the curable resin contained in the curable resin composition include a thermosetting resin and an ionizing radiation curable resin. From the viewpoint of surface hardness (scratch resistance), convex shape retention, productivity, etc., it is preferable that at least a part of the curable resin contained in the curable resin composition is an ionizing radiation curable resin, and the curable resin composition. It is more preferable that all of the curable resins contained in the product are ionizing radiation curable resins.

The first layer 3 is preferably formed on the first main surface S1 of the support sheet 2 in a predetermined pattern, and is visually recessed or has low gloss (erasure) among the patterns formed by the decorative layer 22. It is more preferable that the pattern is aligned with the desired region. As a pattern formed by the first layer 3, for example, when the decorative layer 22 has a wood grain pattern, a conduit portion of the wood grain board, a recess such as a spring wood area or a low gloss area, and when the decorative layer 22 has a stone grain pattern, a recess of a travertin marble plate. Part, stone plate surface unevenness such as recesses on the open surface of the granite board, cloth surface texture in the case of cloth pattern, wrinkle shape of leather grain in the case of leather pattern, joint recess in the case of tiled pattern or brickwork pattern, etc. In addition, patterns such as satin finish, grain, hairline, brick groove, letters, symbols, and geometric patterns can be mentioned.

The first layer 3 may contain a silicone-based release agent. The silicone-based mold release agent contained in the first layer 3 is derived from the silicone-based mold release agent (silicone oil) added to the forming raw material of the first layer 3. The silicone-based mold release agent added to the forming raw material of the first layer 3 may be a reactive silicone-based mold release agent or a non-reactive silicone-based mold release agent. When the silicone-based release agent added to the forming raw material of the first layer 3 is a reactive silicone-based release agent, the silicone-based release agent is the other component of the first layer 3 (for example, a curable resin). It can be contained in the first layer 3 in a state of being bound to a cured product or the like). One type of silicone release agent may be used alone, or two or more types may be used in combination.

Second Layer As shown in FIGS. 3 to 5, the second layer 4 is provided so as to surround a part or the whole of the first layer 3 in the rest of the first main surface S1 of the support sheet 2. .. The “remaining portion of the first main surface S1” means a region of the first main surface S1 of the support sheet 2 in which the first layer 3 is not provided. Of the first main surface S1 of the support sheet 2, the region where the second layer 4 is provided may be the entire remaining portion of the first main surface S1 or a part of the remaining portion of the first main surface S1. You may. For example, when a layer other than the first layer 3 (for example, a layer composed of only a narrow portion having a width of less than 20 μm) is provided on a part of the first main surface S1 of the support sheet 2, the second layer is provided. The area where the layer 4 is provided is a part of the rest of the first main surface. In the first main surface S1 of the support sheet 2, the region where the second layer 4 is provided may be one continuous region or a plurality of discontinuous regions. The second layer 4 may be composed of one continuous layer or may be composed of a plurality of discontinuous layers. When the second layer 4 is composed of one continuous layer, the thickness of the second layer 4 may be constant or may be partially different. When the second layer 4 is composed of a plurality of discontinuous layers, the thickness of each layer may be constant or may be partially different. When the second layer 4 is composed of a plurality of discontinuous layers, the thickness of one layer and the thickness of another layer may be the same or different. From the viewpoint of clarifying the contour shape of the uneven shape that appears on the surface of the decorative board 1 and ensuring the difference in surface height between the first layer 3 and the second layer 4, the second layer is directly above the first layer 3. It is preferable that 4 does not remain at all. However, it may be difficult to completely peel off and remove the precursor layer (coating layer CL) of the second layer 4 once formed on the first layer 3 without any traces or residues. In that case, within a range in which the height difference of the concave-convex shape composed of the concave portion 5 and the convex portion (second layer 4) is sufficiently secured in terms of visual appearance and there is no practical problem in terms of surface physical properties such as wear resistance. It is acceptable that the second layer remains in a trace amount as a residue or a trace over the entire surface of the first layer 3.

The area (Sa) of the region of the first main surface S1 of the support sheet 2 where the second layer 4 is provided, and the area of the first main surface S1 of the support sheet 2 where the first layer 3 is provided (Sa). The ratio (Sa: Sb) to Sb) is preferably 3: 7 to 9: 1, and more preferably 5: 5 to 8: 2. When the area ratio is within the above range, the design feeling of the uneven shape expressed by the decorative board 1 becomes clearer.

As shown in FIGS. 2 to 4, the second layer 4 is formed with an opening 40 that exposes at least a part of the wide portion 31. As shown in FIG. 4, the portion of the wide portion 31 exposed from the opening 40 of the second layer 4 exists over the entire area of the wide portion 31. As shown in FIG. 2, the opening 40 of the second layer 4 is positioned and synchronized with the wide portion 31 in a plan view. In the present invention, "position tuning" means that the entire wide portion 31 overlaps with at least a part of the opening 40 in a plan view. The opening 40 may have a portion that does not overlap with the wide portion 31 in a plan view. For example, the opening 40 may have a portion that overlaps with the narrow portion 32 in a plan view.

As shown in FIGS. 2 to 4, the opening 40 of the second layer 4 has a recess 5 formed on the surface of the decorative plate 1. At least a part of the bottom of the recess 5 is formed by the wide portion 31.

The depth of the recess 5 is preferably 1 to 50 μm, more preferably 2 to 30 μm. When the depth of the concave portion 5 is within the above range, the design feeling of the uneven shape expressed by the decorative plate 1 becomes clearer.

The depth of the recess 5 is a region on the surface of the decorative board 1 in which the first layer 3 is not formed (a region in which the second layer 4 is formed) and a region in which the first layer 3 is formed (a region in which the first layer 3 is formed). It is measured as a height difference from the portion of the coating layer CL that covers the wide portion 31 (the portion where the portion CL11 is peeled off). The measurement is carried out using a three-dimensional surface roughness measuring instrument SE-30K manufactured by Kosaka Laboratory Co., Ltd. according to the method specified in JIS B 0601: 2013. The maximum height roughness (Rz) of the surface is used as a parameter of the height difference, and the average value of 10 points is defined as the "height difference".

The second layer 4 is, for example, a resin layer. Examples of the resin layer include a cured resin layer and a thermoplastic resin layer. The second layer 4 may include two or more layers made of different materials.

The curable resin layer is a layer formed by curing the curable resin composition, and contains a cured product of the curable resin. Examples of the curable resin contained in the curable resin composition include a thermosetting resin and an ionizing radiation curable resin. When the first layer 3 is a cured resin layer formed by curing the ionizing radiation curable resin composition, the second layer 4 is a cured resin layer formed by curing the thermosetting resin composition. Is preferable.

The thickness of the second layer 4 is not particularly limited, but is preferably 2 to 250 μm, more preferably 2 to 50 μm.

The second layer may contain a silicone-based release agent. The silicone-based mold release agent contained in the second layer 4 is derived from the silicone-based mold release agent (silicone oil) added to the forming raw material of the second layer 4. The silicone-based mold release agent added to the forming raw material of the second layer 4 may be a reactive silicone-based mold release agent or a non-reactive silicone-based mold release agent, but is preferable. It is a non-reactive silicone-based mold release agent. When the silicone-based mold release agent added to the forming raw material of the second layer 4 is a reactive silicone-based mold release agent, the silicone-based mold release agent is the other component of the second layer 4 (for example, a curable resin). It can be contained in the second layer 4 in a state of being bound to a cured product or the like). One type of silicone release agent may be used alone, or two or more types may be used in combination.

A water-soluble thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.), it is preferable to use polyether-modified silicone as the silicone-based release agent. Since the polyether-modified silicone has properties such as water solubility and water dispersibility, when the silicone-based mold release agent is polyether-modified silicone, the silicone-based mold release agent is mixed with the water-soluble thermosetting resin composition. This facilitates the process, and while preventing the localization of the silicone-based mold release agent, the releasability of the silicone-based mold release agent can be effectively exhibited. The second layer 4 may contain a non-reactive silicone other than the polyether-modified silicone. As the non-reactive silicone other than the polyether-modified silicone, one kind may be used alone, or two or more kinds may be used in combination.

A water-soluble thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.), as a silicone-based mold release agent, a silicone-based mold release agent having an HLB value of 6 or more and 16 or less (particularly, a polyether-modified silicone having an HLB value of 6 or more and 16 or less). It is preferable to use. The HLB value of the silicone release agent is more preferably 10 or more and 15 or less, and even more preferably 12 or more and 14 or less. The higher the HLB value, the easier it is for the silicone release agent to mix with the water-soluble thermoplastic resin, and the localization of the silicone release agent can be prevented. However, if the HLB value is too high, the silicone release agent is released. The mold releasability may decrease. When the HLB value of the silicone-based mold release agent is within the above range, the releasability of the silicone-based mold release agent can be effectively exhibited while preventing the localization of the silicone-based mold release agent. The HLB (Hydrophile-Lypophile Balance) value is a value indicating the affinity of the surfactant for water and oil, and can be obtained from the following formula by the Griffin method.
HLB = 20 × [(Molecular weight of hydrophilic group contained in surfactant) / (Molecular weight of surfactant)]

As a raw material for forming the first layer 3 and / or the second layer 4 of the thermosetting resin composition, a thermosetting resin composition can be used. In particular, it is preferable to use a thermosetting resin composition as a raw material for forming the second layer 4. Examples of the heat-curable resin contained in the heat-curable resin composition include unsaturated polyester resin, polyurethane resin (including two-component curable polyurethane), epoxy resin, aminoalkyd resin, phenol resin, urea resin, and diallyl phthalate. Examples thereof include resins, melamine resins, guanamine resins, melamine-urea cocondensate resins, silicon resins, polysiloxane resins and the like. The thermosetting resin composition used as the raw material for forming the second layer 4 preferably contains a melamine resin. The melamine resin is preferable because it has heat resistance, stain resistance, and high hardness.

The thermosetting resin composition may contain components involved in the curing reaction of the thermosetting resin, for example, a catalyst, a curing agent (including a cross-linking agent, a polymerization initiator, a polymerization accelerator, etc.) and the like, if necessary. good. For example, examples of curing agents for unsaturated polyester resins and polyurethane resins include isocyanates and organic sulfonates, and examples of curing agents for epoxy resins include organic amines, which start radicals of unsaturated polyester resins. Examples of the agent include peroxides such as methyl ethyl ketone peroxide and azoisobutylnitrile.

As a raw material for forming the first layer 3 and / or the second layer 4 of the ionizing radiation curable resin composition, an ionizing radiation curable resin composition can be used. In particular, it is preferable to use an ionizing radiation curable resin composition as a raw material for forming the first layer 3. The ionizing radiation curable resin contained in the ionizing radiation curable resin composition is a resin that undergoes a cross-linking polymerization reaction by irradiation with ionizing radiation and changes into a three-dimensional polymer structure. Examples of the ionizing radiation include visible light, ultraviolet rays (near ultraviolet rays, vacuum ultraviolet rays, etc.), X-rays, electron beams, ionizing rays, etc., but ultraviolet rays, electron beams, etc. are preferable.

Examples of the ionizing radiation curable resin contained in the ionizing radiation curable resin composition include monomers, oligomers, prepolymers and the like having a polymerizable unsaturated bond, an epoxy group or the like in the molecule that can be crosslinked by irradiation with ionizing radiation. One or more types can be used. In particular, it is preferable to use one or more of the polyfunctional monomer and the oligomer. Examples of the ionizing radiation curable resin include acrylate resins such as urethane acrylate, polyester acrylate and epoxy acrylate, silicon resins such as siloxane, polyester resins and epoxy resins.

Examples of the polymerizable monomer include (meth) acrylate-based monomers having a radically polymerizable unsaturated group in the molecule. In particular, polyfunctional (meth) acrylates are preferred. In addition, "(meth) acrylate" means acrylate or methacrylate. The polyfunctional (meth) acrylate may be any (meth) acrylate having two or more ethylenically unsaturated bonds in the molecule, and is not particularly limited. One type of polyfunctional (meth) acrylate may be used alone, or two or more types may be used in combination. A monofunctional (meth) acrylate may be used in combination with the polyfunctional (meth) acrylate for the purpose of lowering the viscosity thereof.

Examples of the polymerizable oligomer include oligomers having a radically polymerizable unsaturated group in the molecule, such as epoxy (meth) acrylate-based, urethane (meth) acrylate-based, polyester (meth) acrylate-based, and polyether (meth) acrylate-based. Can be mentioned. Further, as the polymerizable oligomer, a highly hydrophobic polybutadiene (meth) acrylate-based oligomer having a (meth) acrylate group in the side chain of the polybutadiene oligomer, a silicone (meth) acrylate-based oligomer having a polysiloxane bond in the main chain, and a small one. Examples thereof include aminoplast resin (meth) acrylate-based oligomers obtained by modifying an aminoplast resin having many reactive groups in the molecule. Examples of the oligomer having a cationically polymerizable functional group in the molecule include novolak type epoxy resin, bisphenol type epoxy resin, aliphatic vinyl ether, aromatic vinyl ether and the like.

The weight average molecular weight of the ionizing radiation curable resin is preferably 500 or more, more preferably 1000 or more. When the weight average molecular weight of the ionizing radiation curable resin is in the above range, the curable resin composition used as a forming raw material when forming the first layer 3 and / or the second layer 4 is transferred to the base sheet 21. Since it is difficult to penetrate, it is easy to form the first layer 3 and / or the second layer 4. This effect is large when the base sheet 21 is a porous sheet.

The weight average molecular weight of the ionizing radiation curable resin is preferably 80,000 or less, more preferably 50,000 or less. When the weight average molecular weight of the ionizing radiation curable resin is in the above range, it is easy to adjust the viscosity of the resin composition to a viscosity suitable for coating.

The "weight average molecular weight" is a value measured by gel permeation chromatography (GPC) using polystyrene as a standard substance.

The ionizing radiation curable resin is preferably at least one selected from polyfunctional monomers and oligomers having a weight average molecular weight of 500 or more. Examples of such a polyfunctional monomer or oligomer include acrylate resins such as dipentaerythritol hexaacrylate, dipentaerythritol pentaacrylate, urethane acrylate, polyester acrylate, and epoxy acrylate.

If necessary, the ionizing radiation curable resin composition may contain a component involved in the curing reaction of the ionizing radiation curable resin, for example, a photopolymerization initiator (sensitizer). For example, when the ionizing radiation curable resin composition is cured by irradiation with ultraviolet rays, the ionizing radiation curable resin composition preferably contains a photopolymerization initiator (sensitizer). Since the ionizing radiation curable resin is sufficiently cured by irradiating with an electron beam, when the ionizing radiation curable resin composition is cured by irradiating with an electron beam, the ionizing radiation curable resin composition is a photopolymerization initiator ( It does not have to contain a sensitizer).

When the ionizing radiation curable resin has a radically polymerizable unsaturated group, the photopolymerization initiator includes, for example, acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler benzoyl benzoate, Michler ketone, diphenyl sulfide, etc. At least one of dibenzyldisulfide, diethyl oxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate and the like can be used. When the ionizing radiation curable resin composition has a cationically polymerizable functional group, the photopolymerization initiator may be, for example, an aromatic diazonium salt, an aromatic sulfonium salt, a metallocene compound, a benzoin sulfonic acid ester, or a freeleoxysulfone. At least one kind such as xonium diallyl iodosyl salt can be used.

The amount of the photopolymerization initiator added is not particularly limited, but is usually 0.1 to 10 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin.

The ionizing radiation curable resin composition preferably contains a polyfunctional polymerizable monomer in order to improve heat resistance and crosslink density.

As the raw material for forming the first layer 3 and / or the second layer 4 of the thermoplastic resin composition, the thermoplastic resin composition can be used. Examples of the thermoplastic resin contained in the thermoplastic resin composition include polyester resin (for example, polyethylene terephthalate, polybutylene terephthalate, etc.), (meth) acrylic resin, and polyolefin resin (for example, polyethylene (high density, medium density, or). Low density), polypropylene (isotactic type or syndiotactic type), polybutene, ethylene-propylene copolymer, ethylene-propylene-butene copolymer, etc.), polyvinyl chloride resin, polystyrene, ABS resin, polycarbonate resin, Examples include polyamide resin.

Silicone-based mold release agent The silicone-based mold release agent may be contained in the first layer 3 and / or the second layer 4. The silicone release agent is a modified silicone having an organopolysiloxane structure as a basic structure and having an organic group introduced into a side chain and / or a terminal. The end into which the organic machine is introduced may be one end or both ends.

The reactive silicone-based release agent refers to a modified silicone having an organic group introduced into the side chain and / or the terminal, which is reactive depending on the nature of the organic group to be introduced. Examples of the reactive silicone-based release agent include amino-modified silicone, epoxy-modified silicone, mercapto-modified silicone, carboxyl-modified silicone, carbinol-modified silicone, phenol-modified silicone, methacryl-modified silicone, and heterogeneous functional group-modified silicone. .. More specifically, amino-modified polydimethylsiloxane, epoxy-modified polydimethylsiloxane, mercapto-modified polydimethylsiloxane, carboxyl-modified polydimethylsiloxane, carbinol-modified polydimethylsiloxane, phenol-modified polydimethylsiloxane, methacryl-modified polydimethylsiloxane, heterologous. Examples thereof include functional group-modified polydimethylsiloxane. As the reactive silicone-based release agent, one type may be used alone, or two or more types may be used in combination.

The non-reactive silicone-based release agent is not particularly limited as long as it is a silicone having no reactive functional group such as an amino group, an epoxy group, a mercapto group, a carboxy group, a hydroxy group, a (meth) acryloyl group and an allyl group. Examples of the non-reactive silicone-based release agent include silicone composed of polysiloxane, polyether-modified silicone, aralkyl-modified silicone, fluoroalkyl-modified silicone, long-chain alkyl-modified silicone, higher fatty acid ester-modified silicone, and higher fatty acid amide. Examples thereof include modified silicone and phenyl-modified silicone. More specifically, polyether-modified polydimethylsiloxane, aralkyl-modified polydimethylsiloxane, fluoroalkyl-modified polydimethylsiloxane, long-chain alkyl-modified polydimethylsiloxane, higher fatty acid ester-modified polydimethylsiloxane, higher fatty acid amide-modified polydimethylsiloxane, Examples thereof include phenyl-modified polydimethylsiloxane. One type of non-reactive silicone-based release agent may be used alone, or two or more types may be used in combination.

A thermosetting resin composition is used as a raw material for forming the polyether-modified silicone second layer 4, and the thermosetting resin composition is a water-soluble thermoplastic resin composition (for example, melamine resin, urea resin, sulfonamide resin, glioxal). When a resin, a guanamine resin, etc.) is contained, it is preferable to use polyether-modified silicone as the silicone-based mold release agent contained in the second layer 4. The polyether-modified silicone has a polysiloxane main chain and has one or more polyoxyalkylene groups as substituents. The main chain may form a ring.

The bonding position of the polyoxyalkylene group in the polyether-modified silicone can be any suitable bonding position. For example, the polyoxyalkylene group may be attached to both ends of the main chain, to one end of the main chain, or to the side chain. The polyether-modified silicone is preferably a side-chain type polyether-modified silicone in which a polyoxyalkylene group is bonded to a side chain.

The side chain type polyether-modified silicone is represented by, for example, the general formula (1).

In the general formula (1), R independently represents an alkyl group having 1 to 3 carbon atoms, R ¹ represents an alkylene group having 1 to 4 ^{carbon atoms, and R 2} represents a hydrogen atom or 1 to 15 carbon atoms. Representing an alkyl group, R ³ _{is a} polyoxyalkylene group represented by − (C ₂ H ₄ O) a − (C ₃ H ₆ O) _b −, a is 1 to 50, and b is 0 to 0. It is 30, m is 1 to 7000, and n is 1 to 50.

In the general formula (1), R is preferably a methyl group.

Examples of the polyether-modified silicone include trade names "KF-6011" (HLB: 14.5), "KF-6011P" (HLB: 14.5), and "KF-6012" manufactured by Shin-Etsu Silicone Co., Ltd. HLB: 7.0), "KF-6013" (HLB: 10.0), "KF-6015" (HLB: 4.5), "KF-6016" (HLB: 4.5), "KF-6017" (HLB: 4.5), "KF-6017P" (HLB: 4.5), "KF-6043" (HLB: 14.5), "KF-6004" (HLB: 9.0), "KF351A" (HLB: 12), "KF352A" (HLB: 7), "KF353" (HLB: 10), "KF354L" (HLB: 16), "KF355A" (HLB: 12), "KF615A" (HLB: 10) ), "KF945" (HLB: 4), "KF-640" (HLB: 14), "KF-642" (HLB: 12), "KF-643" (HLB: 14), "KF-644" ( Side-chain type (linear type) polyether modification such as HLB: 11), "KF-6020" (HLB: 4), "KF-6204" (HLB: 10), "X22-4515" (HLB: 5) Silicone oil; side chain type (branched chain type) polyether modification such as trade name "KF-6028" (HLB: 4.0), "KF-6028P" (HLB: 4.0) manufactured by Shin-Etsu Silicone Co., Ltd. Silicone oil; side chain type (branched chain type, alkyl co-modified type) polyether-modified silicone oil such as trade name "KF-6038" (HLB: 3.0) manufactured by Shin-Etsu Silicone Co., Ltd. can be mentioned.

Reinforcing layer The reinforcing layer 6 is a layer that reinforces the decorative plate 1. As shown in FIGS. 3 to 5, the reinforcing layer 6 is laminated on the main surface of the support sheet 2 opposite to the first layer 3 and the second layer 4, that is, the second main surface S2. There is. The reinforcing layer 6 has, for example, a porous sheet and a cured product of a thermosetting resin existing in the voids of the porous sheet. The reinforcing layer 6 can be formed, for example, by heating a thermosetting resin impregnated sheet to cure the thermosetting resin. Examples of the thermosetting resin include unsaturated polyester resin, polyurethane resin (including two-component curable polyurethane), epoxy resin, aminoalkyd resin, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, and melamine. -Urea cocondensation resin, silicon resin, polysiloxane resin and the like can be mentioned. Examples of the thermosetting resin impregnated sheet include phenol resin impregnated paper which is widely used as a core paper such as a melamine resin decorative board.

Phenol resin impregnated paper is usually a paper produced by impregnating ^{kraft paper having a basis weight of 150 to 250 g / m 2} with phenol resin so as to have an impregnation rate of 45 to 60% and drying at 100 to 140 ° C. be. Commercially available products can be used for the phenol resin impregnated paper. When laminating the phenol resin impregnated paper, if necessary, the second main surface S2 of the support sheet 2 may be subjected to a corona discharge treatment or a primer layer may be formed.

The decorative board 1 may have another reinforcing layer laminated on one or both of both sides of the reinforcing layer 6, if necessary. For example, when the decorative board 1 is a melamine resin decorative board, so-called titanium mixed with a titanium white pigment is mixed in order to hide the blackish brown color tone of the core paper used as the reinforcing layer 6 from being seen through from the surface of the decorative board. A barrier paper made of paper can be laminated between the core paper and the support sheet 2. Further, in order to offset the warp of the decorative plate 1 that occurs during thermal pressure molding, a balance paper or the like made of titanium paper is placed on the back surface of the reinforcing layer 6 (the surface of the support sheet 2 opposite to the second main surface S2). ) Can be laminated. These other reinforcing layers are impregnated with an uncured resin composition containing a thermosetting resin such as a melamine resin, and then hot-press molded together with the other layers (for example, the support sheet 2). Can be integrated with the layer of.

The adhesive layer decorative board 1 may have an adhesive layer, if necessary. The adhesive layer can be formed, for example, between the support sheet 2 and the first layer 3 and / or between the support sheet 2 and the second layer 4 in order to enhance the adhesion between these layers. .. The adhesive layer is preferably a transparent adhesive layer. "Transparency" includes all of colorless transparent, colored transparent, translucent and the like.

The adhesive is not particularly limited, and an adhesive known in the field of decorative boards can be appropriately selected and used. Examples of the adhesive include thermoplastic resins such as polyamide resins, acrylic resins and vinyl acetate resins, and thermosetting resins such as urethane resins. One type of adhesive may be used alone, or two or more types may be used in combination. A two-component curable polyurethane resin or polyester resin using isocyanate as a curing agent can also be used.

The thickness of the adhesive layer is not particularly limited, but the thickness after drying is, for example, 0.1 to 30 μm, preferably 1 to 20 μm.

The primer layer decorative plate 1 has a primer layer on the second main surface S2 of the support sheet 2, the back surface of the reinforcing layer 6 (the surface opposite to the second main surface S2 of the support sheet 2), and the like, if necessary. You may be doing it. Providing the primer layer is useful, for example, when the decorative board 1 and the adherend are laminated to manufacture a decorative member. Examples of the adherend include flat plates of various materials, plate materials such as curved plates, three-dimensional articles, sheets (or films), and the like. Specifically, wood members such as wood single board, wood plywood, particle board, MDF (medium density fiber board) and other wood fiber boards and wood members used as three-dimensional articles; , Three-dimensional shaped articles, metal members used as sheets, etc .; ceramics such as glass and ceramics, non-cement ceramic materials such as plaster, non-ceramic ceramic materials such as ALC (lightweight cellular concrete) plates and solids Ceramic members used as shape articles, etc .; polyolefin resins such as acrylic resin, polyester resin, polystyrene resin, polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) resin, phenol resin, vinyl chloride resin, cellulose resin, Examples thereof include plate materials such as rubber, three-dimensional articles, resin members used as sheets and the like. In addition, these members may be used alone or in combination of two or more.

The adherend may be appropriately selected according to the intended use, and is used for interior / exterior members of buildings such as walls, ceilings, and floors, and fittings such as window frames, doors, handrails, skirting boards, peripheral edges, and moldings. In this case, a wood member, a metal member, a resin member, and a member in which these are combined are preferable. The thickness of the adherend may be appropriately selected depending on the application and the material, and is usually 0.1 to 5 mm, preferably 0.1 to 3 mm.

The primer layer can be formed by applying a known primer agent to the second main surface S2 of the support sheet 2, the back surface of the reinforcing layer 6 (the surface opposite to the second main surface S2 of the support sheet 2), and the like. Examples of the primer include a urethane resin-based primer made of an acrylic-modified urethane resin (acrylic urethane-based resin) and the like, and a urethane-cellulose-based resin (for example, a resin obtained by adding hexamethylene diisocyanate to a mixture of urethane and nitrified cotton. ), A resin-based primer made of a block copolymer of acrylic and urethane, and the like. Additives may be added to the primer, if necessary. Examples of the additive include a filler such as calcium carbonate and clay, a flame retardant such as magnesium hydroxide, an antioxidant, a lubricant, a foaming agent, an ultraviolet absorber, a light stabilizer and the like. The blending amount of the additive can be appropriately adjusted according to the product characteristics.

The amount of the primer applied is not particularly limited, but is usually 0.1 to 100 g / m ² , preferably 0.1 to 50 g / m ² . The thickness of the primer layer is not particularly limited, but is usually 0.01 to 10 μm, preferably 0.1 to 1 μm.

The veneer 1 is a veneer with a high degree of design because a clear concavo-convex shape is formed and a concavo-convex shape including a gloss matte-like concavo-convex shape can be expressed. The decorative board 1 can be used for various purposes by subjecting it to a predetermined molding process or the like. For example, the decorative board 1 is laminated on a base material such as a wood base material, a gold base material, a non-gold base material, a resin base material, etc. It can be used for interiors, furniture, light electric appliances, cabinets of OA equipment, etc. Specific examples of wood base materials include veneer, veneer, wood plywood, particle board, and medium density fiberboard made from various materials such as cedar, cypress, pine, pine, oak, lauan, teak, and melamy. MDF), laminated lumber, chipboard, composite base material on which chipboard is laminated, and the like can be mentioned. Examples of the metal base material include a single metal material such as iron, copper, aluminum, and titanium, or a base material made of an alloy containing one or more of these metal materials. Examples of the non-gold inorganic material base material include ceramic materials such as calcium silicate, gypsum, cement and earthenware, and base materials made of stone materials such as granite and limestone. Examples of the resin base material include a base material made of polyvinyl chloride, polystyrene, polyester resin, acrylic resin, polyolefin resin, phenol resin, urea resin and the like.

The wear-resistant layer decorative board 1 may further include a wear-resistant layer. The wear-resistant layer can be provided, for example, on the second layer 4 or between the support sheet 2 and the second layer 4.

The thickness of the abrasion-resistant layer is not particularly limited, but the thickness of the abrasion-resistant ink at the time of coating is, for example, 10 to 100 μm, and the thickness after drying is, for example, 2 to 20 μm.

For the formation of the abrasion resistant layer, for example, abrasion resistant ink can be used. As the resin contained in the abrasion resistant ink, a thermosetting resin, a curable resin such as an ionizing radiation curable resin, and a thermoplastic resin can be used. The description of these resins is the same as above and will be omitted. As the resin contained in the abrasion-resistant ink, a polyurethane resin (including a two-component curable polyurethane) is preferable because an abrasion-resistant layer can be easily formed. A cross-linking agent, a curing agent, a polymerization accelerator and the like can be added to the abrasion-resistant ink.

The abrasion-resistant ink preferably contains a filler for the purpose of imparting abrasion resistance. The filler is not particularly limited, and an inorganic filler or an organic filler can be used.

Examples of the inorganic filler include calcium carbonate, magnesium carbonate, silica, kaolin, clay, calcium oxide, magnesium oxide, titanium oxide, zinc oxide, barium sulfate, calcium hydroxide, aluminum hydroxide, alumina, magnesium hydroxide, and talc. Examples thereof include mica, hydrotalcite, aluminum silicate, magnesium silicate, calcium silicate, calcined talc, wollastonite, potassium titanate, magnesium sulfate, calcium sulfate, magnesium phosphate and the like.

Examples of the organic filler include polyolefin resins such as polyethylene and polypropylene; fluororesins; styrene resins; epoxy resins; melamine resins; urea resins; acrylic resins; phenol resins; polyimide resins; polyamide resins; Examples include polyester resins. Moreover, a copolymer of these resins can also be used.

As the filler, it is preferable to use an inorganic filler from the viewpoint of excellent wear resistance, and it is more preferable to use alumina, silica, and zirconia. One type of filler may be used alone, or two or more types may be used in combination.

The shape of the filler is not particularly limited, and may be any shape such as a polyhedral spherical shape, a spherical shape, and a polyhedral shape.

The average particle size of the filler is preferably 3 to 50 μm, more preferably 5 to 30 μm. By setting the average particle size of the filler in the above range, the wear resistance of the wear-resistant layer becomes more excellent. The average particle size of the filler is a value measured by the laser diffraction / scattering method.

The preferred lower limit of the Mohs hardness of the filler is 4, and the preferred upper limit is 9. A more preferable lower limit is 7. By using a filler having a Mohs hardness in the above range, the decorative plate 1 can exhibit more excellent wear resistance.

The Mohs hardness of the filler is a value measured by a Mohs hardness meter. Specifically, the Mohs hardness is a box containing 10 types of minerals ranging from soft minerals to hard minerals, and the hardness ranks are shown as 1 degree, 2 degrees, ... 10 degrees from the soft ones. be. The standard minerals are as follows (numbers indicate hardness). 1: Gypsum stone 2: Gypsum 3: Gypsum stone 4: Fluorite stone 5: Linkai stone 6: Seicho stone 7: Sekiei 8: Topaz 9: Corundum 10: Diamond

When the surface of a mineral sample for which hardness is to be determined is scratched with these minerals, the hardness is compared by the force that resists it (whether it is scratched or not). For example, when the Hokai stone is scratched, the hardness of the sample is greater than 3 degrees. If the fluorite is scratched and conversely the fluorite is not scratched, the hardness of this sample is less than 4 degrees. At this time, the hardness of the sample is indicated as 3 to 4 or 3.5. When they are slightly scratched, the hardness of the sample shows the same hardness as the standard mineral used.

The content of the filler in the abrasion-resistant ink is preferably 5 to 50% by mass, more preferably 10 to 30% by mass, with the abrasion-resistant ink as 100% by mass. By adjusting the content of the filler in the abrasion-resistant ink to the above range, the abrasion resistance of the abrasion-resistant layer is more excellent and the smoothness of the surface of the second layer 4 is not impaired. Makes it easier to express the glossy design.

The abrasion resistant ink may be colorless or colored. In the case of coloring, the same colorant as that used in the pattern layer described later can be used.

The abrasion resistant ink may contain a solvent for the purpose of adjusting the viscosity. As the solvent, water; hydrocarbon compounds such as toluene and xylene; alcohol compounds such as methanol, ethanol and methyl glycol; ketone compounds such as acetone and methyl ethyl ketone; ester compounds such as methyl formate and ethyl acetate; N-methylpyrrolidone and N. , Nitrogen-containing compounds such as N-dimethylformamide; ether compounds such as terrorahydrofuran and dioxane; halogenated hydrocarbon compounds such as methylene chloride and chloroform; dimethyl sulfoxide and the like. These solvents can be used alone or in admixture of two or more. The amount of the solvent in the abrasion-resistant ink can be appropriately set according to the viscosity of the ink.

Known additives can be added to the abrasion-resistant ink depending on the desired physical properties to be obtained. As additives, for example, ultraviolet absorbers, infrared absorbers, light stabilizers, polymerization inhibitors, cross-linking agents, antistatic agents, antioxidants, leveling agents, coupling agents, plasticizers, defoamers, fillers, Examples include thermal radical generators and aluminum chelating agents.

The abrasion-resistant layer can be formed, for example, by applying an abrasion-resistant ink to a predetermined surface and drying and / or curing the resin contained in the abrasion-resistant ink. Examples of the method for applying the abrasion-resistant ink include a roll coating method, a comma coating method, a curtain coating method, a squeeze coating method, a blade coating method, and a gravure coating method.

Method for Manufacturing Decorative Board Hereinafter, embodiments of the method for manufacturing a decorative board according to the present invention will be described with reference to the drawings. 8 and 9 are explanatory views for explaining an embodiment of the method for manufacturing a decorative board according to the present invention. Note that FIG. 9 is a continuation of FIG.

The method for manufacturing the decorative board 1 according to the present embodiment is as follows.
(1) A step of preparing a support sheet 2 having a second main surface S2 located on the opposite side of the first main surface S1 and the first main surface S1.
(2) A step of forming the first layer 3 on a part of the first main surface S1 of the support sheet 2.
(3) A step of forming a coating layer CL that surrounds the first layer 3 and covers at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2.
(4) The step of peeling the portion CL1 covering the first layer 3 of the coating layer CL along the first direction X to form the second layer 4 on the remaining portion of the first main surface S1 of the support sheet 2 is included. ..
Hereinafter, each step will be described.

Process (1)
In the step (1), as shown in FIG. 8A, a support sheet 2 having a second main surface S2 located on the opposite side of the first main surface S1 and the first main surface S1 is prepared.

As shown in FIG. 8A, the support sheet 2 has a first main surface T1 located on the first main surface S1 side of the support sheet 2 and a second main surface located on the second main surface S2 side of the support sheet 2. It has a base sheet 21 having a surface T2 and a decorative layer 22 provided on the first main surface T1 of the base sheet 21.

The support sheet 2 can be manufactured by forming the decorative layer 22 on the first main surface T1 of the base sheet 21. Before forming the decorative layer 22 on the first main surface T1 of the base sheet 21, the first main surface T1 of the base sheet 21 may be subjected to treatments such as corona discharge treatment, plasma treatment, and ozone treatment. Thereby, the adhesion of the decorative layer 22 can be improved.

The decorative layer 22 is, for example, a colored layer, a pattern layer, or a combination thereof. As shown in FIG. 1, the decorative layer 22 in the present embodiment imparts a wood grain pattern to the decorative board 1.

The colored layer is, for example, a solid layer formed on the entire surface of the first main surface T1 of the base sheet 21. Examples of the solid layer forming method include coating methods such as roll coating method, knife coating method, air knife coating method, die coating method, lip coating method, comma coating method, kiss coating method, flow coating method, and dip coating method. Be done.

The pattern layer is, for example, a printing layer formed on a part or the whole of the first main surface T1 of the base sheet 21 or a part or the whole of the surface of the colored layer by a printing method. Examples of the printing method used for forming the pattern layer include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method.

The ink used to form the decorative layer 22 is, for example, a mixture of a solvent or a dispersion medium and components such as a colorant and a binder resin. The ink may contain a colorant, an extender pigment, a stabilizer, a plasticizer, a catalyst, a curing agent and the like as other components. The ink may be an aqueous composition from the viewpoint of reducing VOC (volatile organic compound) of the sheet.

Colorants contained in the ink include, for example, inorganic pigments such as carbon black, iron black, titanium white, antimony white, yellow lead, titanium yellow, petal handle, cadmium red, ultramarine blue, cobalt blue; quinacridone red, isoindolinone. Organic pigments or dyes such as yellow and phthalocyanine blue; metal pigments made of scaly foil pieces such as aluminum and brass; pearl gloss pigments made of scaly foil pieces such as titanium dioxide-coated mica and basic lead carbonate. Can be mentioned. One type of colorant may be used alone, or two or more types may be used in combination.

Examples of the binder resin contained in the ink include urethane resin, acrylic urethane resin, vinyl chloride / vinyl acetate copolymer resin, vinyl chloride / vinyl acetate / acrylic copolymer resin, chlorinated polypropylene resin, acrylic resin, and polyester resin. , Polylamin resin, butyral resin, polystyrene resin, nitrocellulose resin (nitrated cotton), cellulose acetate resin and the like. As the binder resin, one type may be used alone, or two or more types may be used in combination.

Examples of the solvent or dispersion medium contained in the ink include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, -2-methoxyethyl acetate, and acetate. Ester-based organic solvents such as -2-ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, etc. Ketone-based organic solvent; ether-based organic solvent such as diethyl ether, dioxane, tetrahydrofuran; chlorine-based organic solvent such as dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene; inorganic solvent such as water and the like. As the solvent or dispersion medium, one type may be used alone, or two or more types may be used in combination.

The decorative layer 22 may be formed by a method such as a hand-drawing method, a suminagashi method, a photographic method, a transfer method, a laser beam drawing method, or an electron beam drawing method. When the decorative layer 22 is a metal layer (metal thin film) such as aluminum, chromium, gold, silver, or copper, the decorative layer 22 can be formed by a method such as a vapor deposition method, a sputtering method, or an etching method.

The thickness of the decorative layer 22 can be appropriately adjusted according to the product characteristics, but the thickness at the time of ink coating is, for example, 1 to 200 μm, and the thickness after drying is, for example, 0.1 to 20 μm. Is.

Process (2)
In the step (2), as shown in FIG. 8 (b), the first layer 3 is formed on a part of the first main surface S1 of the support sheet 2. As a result, an intermediate M1 including the support sheet 2 and the first layer 3 formed on a part of the first main surface S1 of the support sheet 2 is formed. The first layer 3 is formed so as to extend along the first direction X on a part of the first main surface S1 of the support sheet 2.

As the resin composition (coating liquid) for forming the first layer 3, for example, a thermosetting resin composition, an ionizing radiation curable resin composition, a thermoplastic resin composition, or the like can be used. When a thermosetting resin composition is used, for example, the thermosetting resin composition is printed on a part of the first main surface S1 of the support sheet 2 in a predetermined pattern and heated to cure. One layer 3 can be formed. When an ionizing radiation curable resin composition is used, for example, the ionizing radiation curable resin composition is printed on a part of the first main surface S1 of the support sheet 2 in a predetermined pattern and cured by irradiating with ionizing radiation. By doing so, the first layer 3 can be formed. When the thermoplastic resin composition is used, for example, the first layer 3 is formed by printing the thermoplastic resin composition on a part of the first main surface S1 of the support sheet 2 in a predetermined pattern and drying it. can do. Examples of the printing method used for forming the first layer 3 include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method. The resin composition for forming the first layer 3 may be applied to a part of the first main surface S1 of the support sheet 2 by a method other than the printing method. As a method of applying the resin composition, for example, Examples include a coating method such as a roll coating method and a gravure coating method.

When the resin composition for forming the first layer 3 contains a silicone-based mold release agent (silicone oil), the silicone-based mold release agent is oriented toward the surface of the first layer 3 when the resin composition is cured. , The first layer 3 is imparted with releasability. Thereby, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off, the peelability of the portion CL1 covering the first layer 3 can be improved.

The amount of the silicone release agent (silicone oil) used is usually 0.1 to 50 parts by mass, preferably 0.5 to 50 parts by mass, per 100 parts by mass of the resin contained in the resin composition for forming the first layer 3. It is 20 parts by mass, more preferably 3 to 20 parts by mass, and even more preferably 3 to 10 parts by mass. When the amount of the silicone release agent (silicone oil) used is within the above range, the first layer 3 is coated when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off in the step (4). The peelability of the portion CL1 to be formed can be improved.

It is preferable to use an ionizing radiation curable resin as the resin composition (coating liquid) for forming the first layer 3. In this case, the first layer 3 is a cured resin layer containing a cured product of the ionizing radiation curable resin, and the step (2) is an ionizing radiation curable resin composition containing (2-1) an ionizing radiation curable resin. To form an ionizing radiation curable resin composition layer covering a part of the first main surface S1 of the support sheet 2 and (2-2) curing the ionizing radiation curable resin composition layer. The step of forming the cured resin layer as the first layer 3 is included.

When ultraviolet rays are used as the ionizing radiation for curing the ionizing radiation curable resin composition layer, the ultraviolet sources include, for example, ultra-high pressure mercury lamp, high pressure mercury lamp, low pressure mercury lamp, carbon arc lamp, black light fluorescent lamp, and metal halide. A light source such as a lamp lamp can be used. The wavelength of ultraviolet rays is, for example, 190 to 380 nm. When an electron beam is used as the ionizing radiation for curing the ionizing radiation curable resin composition layer, the electron beam source may be, for example, a cockcroftwald type, a bandegraft type, a resonance transformer type, or an insulated core transformer type. , Linear type, Dynamitron type, High frequency type and other electron beam accelerators can be used. The energy of the electron beam is preferably 100 to 1000 keV, more preferably 100 to 300 keV. The irradiation amount of the electron beam is preferably 2 to 15 Mrad.

The coating liquid for forming the first layer 3 preferably contains an extender pigment. As a result, thixotropy can be imparted to the coating liquid, and the pattern shape of the coating liquid can be maintained when the coating liquid is printed using the plate. Examples of the extender pigment include silica, talc, clay, barium sulfate, barium carbonate, calcium sulfate, calcium carbonate, magnesium carbonate and the like. Of these, silica, which has a high degree of freedom in material design and is excellent in designability, whiteness, and coating stability as an ink, is preferable, and fine powder silica is particularly preferable.

The content of the extender pigment in the coating liquid is usually 0.1 to 20 parts by mass, preferably 0.5 to 15 parts by mass, and more preferably 2 to 15 parts by mass per 100 parts by mass of the resin contained in the coating liquid. It is even more preferably 5 to 15 parts by mass. By setting the content of the extender pigment in the above range, it is possible to impart sufficient thixotropy to the coating liquid, and it is possible to obtain the effect of imparting a raised shape and the appearance of fine uneven surfaces.

The coating liquid may be colorless or colored. In the case of coloring, the same colorant as that used in the decorative layer can be used.

The coating liquid may contain a solvent for the purpose of adjusting the viscosity. As the solvent, water; hydrocarbon compounds such as toluene and xylene; alcohol compounds such as methanol, ethanol and methyl glycol; ketone compounds such as acetone and methyl ethyl ketone; ester compounds such as methyl formate and ethyl acetate; N-methylpyrrolidone and N. , Nitrogen-containing compounds such as N-dimethylformamide; ether compounds such as terrorahydrofuran and dioxane; halogenated hydrocarbon compounds such as methylene chloride and chloroform; dimethyl sulfoxide and the like. These solvents can be used alone or in admixture of two or more. The amount of the solvent in the coating liquid can be appropriately set according to the viscosity of the coating liquid.

Known additives can be appropriately added to the coating liquid according to the desired physical characteristics. As additives, for example, ultraviolet absorbers, infrared absorbers, light stabilizers, polymerization inhibitors, cross-linking agents, antistatic agents, antioxidants, leveling agents, coupling agents, plasticizers, defoamers, fillers, Examples include thermal radical generators and aluminum chelating agents.

The first layer 3 is preferably formed on the first main surface S1 of the support sheet 2 in a predetermined pattern. The pattern of the first layer 3 preferably corresponds to a recessed region or a low gloss (erasing) region on the surface of the decorative plate 1. Examples of the pattern of the first layer 3 include a conduit portion of a wood grain board, an uneven surface of a stone board, a cloth surface texturer, a satin finish, a grain of sand, a hairline, a striped groove, characters, symbols, and a geometric pattern. In the present embodiment, the first layer 3 is formed on the first main surface S1 of the support sheet 2 in the pattern of the conduit portion having a wood grain pattern.
Pattern is

The thickness of the first layer 3 is not particularly limited, and the thickness at the time of coating is, for example, 1 to 200 μm, and the thickness after drying is, for example, 0.1 to 20 μm.

Process (3)
For example, when the coating layer CL is a curable resin layer containing a cured product of a thermosetting resin, step (3) uses a thermosetting resin composition containing (3-1) a thermosetting resin. A step of forming a thermosetting resin composition layer that surrounds the first layer 3 and covers at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2. 3-2) The step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer CL is included.

For example, when the base sheet 21 is a porous sheet and the coating layer CL is a cured resin layer containing a cured product of a thermosetting resin, the step (3) is performed by using (3-1) the thermosetting resin. A thermosetting resin that surrounds the first layer 3 and covers at least a part of the first layer 3 on the rest of the first main surface S1 of the support sheet 2 by using the thermosetting resin composition containing the same. In the step (3-1), the step (3-1) includes a step of forming the composition layer and a step of (3-2) curing the thermosetting resin composition layer to form the cured resin layer as a coating layer CL. The sheet is impregnated with the thermosetting resin composition, and in the step (3-2), the thermosetting resin composition impregnated in the porous sheet can be cured.

In the step (3), first, as shown in FIG. 8 (c), the remaining portion of the first main surface S1 of the support sheet 2 (that is, the first layer 3 of the first main surface S1 of the support sheet 2 is formed. The non-existing region) and at least a part of the first layer 3 are covered with a resin composition (coating liquid) for forming the second layer 4, and dried if necessary. As a result, the support sheet 2, the first layer 3 formed on a part of the first main surface S1 of the support sheet 2, and the remaining portion of the first main surface S1 of the support sheet 2 surround the first layer 3. In addition, an intermediate M2 including a resin composition layer PC formed so as to cover at least a part of the first layer 3 is formed.

As the resin composition (coating liquid) for forming the second layer 4, for example, a thermosetting resin composition, an ionizing radiation curable resin, a thermoplastic resin composition, or the like can be used. When an ionizing radiation curable resin is used as the resin composition for forming the first layer 3, it is preferable to use a thermosetting resin composition as the resin composition for forming the second layer 4.

When forming the resin composition layer PC so as to surround the first layer 3 and cover at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2, the resin composition Is supplied from, for example, the first main surface S1 side of the support sheet 2. When a porous sheet is used as the base sheet 21, a part of the supplied resin composition is impregnated in the base sheet 21, and the rest not impregnated in the porous sheet is the first main component of the support sheet 2. It covers the rest of the surface S1 and at least a part of the first layer 3. The resin composition does not impregnate the first layer 3 and covers the first layer 3. In order to promote the impregnation of the resin composition into the base material sheet 21, in addition to the supply of the resin composition from the first main surface S1 side of the support sheet 2, in addition to the supply of the resin composition from the second main surface S2 side of the support sheet 2. The resin composition may be supplied. When a porous sheet is used as the base sheet 21, only the resin composition may be supplied from the second main surface S2 side of the support sheet 2. Similarly, when the resin composition is only supplied from the second main surface S2 side of the support sheet 2, a part of the supplied resin composition is impregnated into the base sheet 21 to be a porous sheet. The rest not impregnated with the resin covers at least a part of the first main surface S1 of the support sheet 2 and the first layer 3. Examples of the method for supplying the resin composition include immersion in the resin composition; coating with a coater such as a kiss coater or a comma coater; and spraying with a spray device, a shower device or the like.

The resin composition may cover at least a part of the first layer 3, for example, the entire area occupied by the first layer 3 (the first layer 3 of the first main surface S1 of the support sheet 2 is provided). It is sufficient that 30% or more of the area covered by the resin composition is covered with the resin composition. The coating ratio of the resin composition in the entire area of the first layer 3 is preferably 50 to 100%.

The thickness of the resin composition layer PC is not particularly limited, but is, for example, 2 to 250 μm at the time of coating and, for example, 2 to 50 μm after drying.

The filling rate of the resin composition filled in the voids of the porous sheet can be appropriately adjusted according to the performance required for the decorative plate 1, the porosity of the porous sheet, and the like. The filling rate of the resin composition is preferably 30 to 200%, more preferably 50 to 150%. The filling rate of the resin composition is calculated by the following formula.
Filling rate (%) = [(Weight of porous sheet after impregnation with resin composition-Weight of porous sheet before impregnation with resin composition) / Porous sheet before impregnation with resin composition Weight] x 100

After forming the resin composition layer PC and before curing, if necessary, the gloss of the surface of the resin composition layer PC may be adjusted. For example, a method of curing in a state where a gloss-adjusted shaping sheet is laminated on a resin composition layer PC, a method of installing an embossed template (textured mirror plate) on a resin composition layer PC and curing, etc. Therefore, the gloss of the surface of the resin composition layer PC can be adjusted. After that, in the step (4), the portion CL1 that covers the first layer 3 of the coating layer CL is peeled off to adjust the gloss on the surface of the decorative plate 1 by fine irregularities due to shaping, and the coating layer. It is possible to obtain a decorative plate 1 having a three-dimensional and deep design having a deep matte design portion obtained by peeling the portion CL1 covering the first layer 3 of the CL from the remaining portion CL2 of the coating layer CL. ..

When a thermosetting resin composition is used, the cured resin layer is formed as a coating layer CL by heating and curing the resin composition layer PC. When an ionizing radiation curable resin composition is used, the cured resin layer is formed as a coating layer CL by irradiating the resin composition layer PC with ionizing radiation to cure it.

When the resin composition for forming the second layer 4 contains a silicone-based mold release agent (silicone oil), it is oriented on the surface of the second layer 4 when the resin composition is cured, so that the second layer 4 has a second layer. Releasability from 1 layer 3 is imparted. Thereby, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off, the peelability of the portion CL1 covering the first layer 3 can be improved. When the silicone-based mold release agent is a non-reactive silicone oil, the silicone-based mold release agent tends to be oriented on the surface of the second layer 4.

A water-soluble thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.), it is preferable to use polyether-modified silicone oil as the silicone-based mold release agent. Since the polyether-modified silicone oil has properties such as water solubility and water dispersibility, if the silicone-based mold release agent is a polyether-modified silicone oil, the silicone-based mold release agent is easily mixed with the water-soluble thermoplastic resin. Therefore, the releasability of the silicone-based mold release agent can be effectively exhibited while preventing the localization of the silicone-based mold release agent. Further, the silicone-based mold release agent mixed with the uncured water-soluble thermosetting resin composition inhibits the curing of the water-soluble thermosetting resin and reduces the strength of the cured product of the thermosetting resin. Is expected. The decrease in the strength of the cured product of the thermosetting resin is due to the peelability of the portion CL1 covering the first layer 3 when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off in the step (4). It is thought that it will contribute to the improvement of. The thermosetting resin composition may contain a non-reactive silicone oil other than the polyether-modified silicone oil. As the non-reactive silicone other than the polyether-modified silicone oil, one kind may be used alone, or two or more kinds may be used in combination.

A water-soluble thermocurable resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermocurable resin composition is used as a raw material for forming the second layer 4 and the thermocurable resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.), as a silicone-based mold release agent, a silicone-based mold release agent having an HLB value of 6 or more and 16 or less (particularly, a polyether-modified silicone oil having an HLB value of 6 or more and 16 or less). ) Is preferably used. The HLB value of the silicone release agent is more preferably 10 or more and 15 or less, and even more preferably 12 or more and 14 or less. The higher the HLB value, the easier it is for the silicone oil-based mold release agent to mix with the uncured water-soluble thermosetting resin composition, and the localization of the silicone-based mold release agent can be prevented. If the value is too high, the releasability of the silicone-based mold release agent may decrease. When the HLB value of the silicone-based mold release agent is within the above range, the releasability of the silicone-based mold release agent can be effectively exhibited while preventing the localization of the silicone-based mold release agent. Further, the silicone-based mold release agent mixed with the uncured water-soluble thermosetting resin composition inhibits the curing of the uncured water-soluble thermosetting resin composition, thereby curing the thermosetting resin. It is expected to reduce the strength of objects. The decrease in the strength of the cured product of the thermosetting resin is due to the peelability of the portion CL1 covering the first layer 3 when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off in the step (4). It is thought that it will contribute to the improvement of.

The amount of the silicone release agent (silicone oil) used is usually 0.1 to 50 parts by mass, preferably 0.5 to 50 parts by mass, per 100 parts by mass of the resin contained in the resin composition for forming the second layer 4. It is 20 parts by mass, more preferably 3 to 20 parts by mass, and even more preferably 3 to 10 parts by mass. When the amount of the silicone release agent (silicone oil) used is within the above range, the first layer 3 is coated when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off in the step (4). The peelability of the portion CL1 to be formed can be improved.

When a thermosetting resin composition is used as the resin composition for forming the second layer 4, the resin composition layer PC can be cured as follows.

First, as shown in FIG. 8D, the release film PF is laminated on the resin composition layer PC, and the reinforcing sheet PP is laminated on the second main surface S2 of the support sheet 2. As a result, the support sheet 2, the first layer 3 formed on a part of the first main surface S1 of the support sheet 2, the rest of the first main surface S1 of the support sheet 2, and at least a part of the first layer 3. An intermediate M3 including a resin composition layer PC laminated to cover the resin composition layer PC, a peeling film PF laminated on the resin composition layer PC, and a reinforcing sheet PP laminated on the second main surface S2 of the support sheet 2 is formed. NS. The peeling film PF may be laminated on the resin composition layer PC at any time before, after, or at the same time as the lamination of the reinforcing sheet PP on the second main surface S2 of the support sheet 2.

As the peeling film PF, for example, an easily adhesive resin film can be used. Examples of the easily adhesive resin film include a thermoplastic resin film, and examples of the thermoplastic resin include polyolefin resins such as polyethylene, polypropylene, and polymethylpentene; vinyl chloride-vinyl acetate copolymer, ethylene-. Vinyl resins such as vinyl acetate copolymers and ethylene-vinyl alcohol copolymers; polyester resins such as polyethylene terephthalate and polybutylene terephthalate; methyl polymethacrylate, ethyl polymethacrylate, ethyl polyacrylate, butyl polyacrylate and the like Acrylic resin; Examples thereof include a single film such as a synthetic resin such as polystyrene, polycarbonate, polyarylate, and polyimide, or a laminate of these films.

An easy-adhesive layer may be formed on the surface of the easy-adhesive resin film by applying the easy-adhesive resin. Before forming the easy-adhesive layer, in order to improve the adhesiveness of the easy-adhesive layer, the surface of the easy-adhesive resin film may be subjected to a treatment such as a corona discharge treatment, a plasma treatment, or an ozone treatment.

Examples of the resin contained in the easy-adhesion layer (sometimes called a primer layer or an anchor layer) include acrylic resin, vinyl chloride-vinyl acetate copolymer, polyester resin, urethane resin, chlorinated polypropylene, and chlorinated polyethylene. Be done.

As the peeling film PF, it is preferable to use a peeling film whose peeling weight is adjusted with the resin film to be peeled (the portion CL1 of the coating layer CL that covers the first layer 3). For example, in the case of a thermosetting film of melamine resin, it is preferable to adjust the peeling weight to 0.1 to 10 N / inch. If the peeling weight is less than 0.1, it is difficult to peel off the thermosetting film of the melamine resin, and if the peeling weight exceeds 10 N / inch, the peeling film may break or a resin film other than the resin film to be peeled off. (The portion of the coating layer CL other than the portion CL1 that covers the first layer 3) may also be peeled off. By using a peeling film whose peeling weight is adjusted to 0.1 to 10 N / inch, the resin film to be peeled off (the portion CL1 of the coating layer CL that covers the first layer 3) can be easily removed. can do.

The peeling weight is a value measured using the Tencilon universal material testing machine RTB-1250A manufactured by Orientec Co., Ltd., and the specific measuring method is as follows. In the intermediate M4 described later, a cut is made in the peeling film PF to a width of 1 inch, a part of the peeling film PF is peeled off with a width of 1 inch, and a part of the peeling film PF is peeled off as shown in FIG. One end (lower part) of the intermediate body M4 is fixed to the testing machine. The weight when the peeling film PF peeled off by 180 ° is peeled off at a speed of 100 mm / min in the upper direction (arrow direction) is measured, and this is referred to as "peeling weight".

As the peeling film whose peeling weight is adjusted to 0.1 to 10 N / inch, for example, a film having a base film and a cured resin layer formed on the base film can be used. .. This film is preferably used so that the surface on the cured resin layer side is in contact with the resin composition layer PC. The base film is not particularly limited, and examples thereof include paper, non-woven fabric, and thermoplastic resin sheet. The substrate film is preferably a thermoplastic resin sheet, and from the viewpoint of heat resistance, a polyester resin sheet such as polyethylene terephthalate is particularly preferable. The thickness of the base film is not particularly limited, and is usually 10 to 200 μm. Further, the cured resin layer is preferably a cured resin layer formed by curing the ionizing radiation curable resin composition. This makes it easy to adjust the peeling weight of the melamine resin from the thermosetting film to 0.1 to 10 N / inch. The above description applies to the ionizing radiation curable resin composition. The ionizing radiation curable resin composition may appropriately contain components such as extender pigments for the purpose of adjusting the peeling weight and the like. The thickness of the curable resin layer is usually 1 to 30 μm.

As the reinforcing sheet PP, for example, a thermosetting resin impregnated sheet can be used. The thermosetting resin impregnated sheet has a porous sheet and a thermosetting resin impregnated in the porous sheet. Examples of the thermosetting resin include unsaturated polyester resin, polyurethane resin (including two-component curable polyurethane), epoxy resin, aminoalkyd resin, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, and melamine. -Urea cocondensation resin, silicon resin, polysiloxane resin and the like can be mentioned. Examples of the thermosetting resin-impregnated sheet include phenol resin-impregnated paper, which is widely used as the core paper for decorative boards. Phenol resin impregnated paper is generally produced by impregnating kraft paper having a basis weight of 150 to 250 g / m ² as core paper with phenol resin so as to have an impregnation rate of 45 to 60% and drying at 100 to 140 ° C. It is a paper that has been made. Commercially available products can be used for the phenol resin impregnated paper. When laminating the phenol resin impregnated paper, if necessary, the second main surface S2 of the support sheet 2 may be subjected to a corona discharge treatment or a primer layer may be formed.

Next, as shown in FIG. 8E, the intermediate M3 is sandwiched between the two mirror-finished metal plates P1 and P2, pressurized and heated to cure the resin composition layer PC. As a result, the cured resin layer is formed as the coating layer CL. When a porous sheet is used as the base sheet 21, the resin composition impregnated in the voids of the porous sheet is also cured at this stage. When a thermosetting resin impregnated sheet is used as the reinforcing sheet PP, the thermosetting resin of the thermosetting resin impregnated sheet is also cured at this stage to form the reinforcing layer 6. The peeling film PF adheres to the coating layer CL at this stage.

The heating temperature and heating time can be appropriately adjusted depending on the type of thermosetting resin used and the like. For example, in the case of isocyanate-curable unsaturated polyester resin or urethane-curable polyurethane resin, it takes 1 to 5 days at 40 to 60 ° C., and in the case of polysiloxane resin, it takes 1 to 30 minutes at 80 to 150 ° C., and the melamine resin. In the case of, it is 90 to 160 ° C. for 30 seconds to 30 minutes.

The pressure applied by the mirror-finished metal plates P1 and P2 is, for example, 5 to 100 kg / cm ² .

As a result, as shown in FIG. 9 (f), the support sheet 2, the first layer 3 formed on a part of the first main surface S1 of the support sheet 2, and the first main surface S1 of the support sheet 2 In the remaining portion, a coating layer CL formed so as to surround the first layer 3 and cover at least a part of the first layer 3, a peeling film PF laminated on the coating layer CL, and a support sheet. An intermediate M4 including a reinforcing layer 6 laminated on the second main surface S2 of 2 is formed.

As shown in FIG. 9 (f), the coating layer CL has a portion CL1 that covers the first layer 3 and a portion CL2 that does not cover the first layer 3. The portion CL1 that covers the first layer 3 is formed on the surface of the first layer 3 so as to cover the first layer 3. The portion CL2 that does not cover the first layer 3 is formed on the surface of the first main surface S1 of the support sheet 2 so as to surround the first layer 3.

As shown in FIG. 9 (f), the portion CL1 covering the first layer 3 has a portion CL11 covering the wide portion 31 and a portion CL12 covering the narrow portion 32.

As shown in FIG. 10, a plane extending in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outer line in the plan view of the wide portion 31, in step (3). The following conditions are satisfied in the cut surface formed by cutting the obtained intermediate.
[Condition 3] When the width of the wide portion 31 is WB and the thickness of the portion CL11 covering the wide portion 31 of the coating layer CL is TB, WB ≧ TB.

As a result of the manufacturing method of the decorative board 1 satisfying the condition 3, the decorative board 1 satisfies the above condition 1. Further, when the manufacturing method of the decorative plate 1 satisfies the condition 3, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off along the first direction X, a wide portion is formed. The peelability of the portion CL11 covering 31 is improved and stabilized. As a result, the decorative board 1 satisfies the above condition 2. When the decorative board 1 satisfies the above condition 2, as shown in FIG. 4, a portion of the wide portion 31 exposed from the opening 40 of the second layer 4 exists over the entire area of the wide portion 31. Therefore, the concave portion 5 has a depth reaching the wide portion 31 over the entire area thereof, and the difference in surface height between the concave portion 5 and the region other than the concave portion 5 becomes significant.

On the other hand, as shown in FIG. 11, the process (1) is a plane extending in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outer line in the plan view of the narrow portion 32. In the cut surface formed by cutting the intermediate obtained in 3), when the width of the narrow portion 32 is WN and the thickness of the portion CL12 covering the narrow portion 32 of the coating layer CL is TN. WN <TN. Therefore, in the step (4), when the portion CL1 covering the first layer 3 of the coating layer CL is peeled off along the first direction X, the peelability of the portion CL12 covering the narrow portion 32 is lowered. Destabilize. Therefore, as shown in FIGS. 2, 4 and 5, the narrow portion 32 is covered with the second layer 4 and is not exposed from the opening 40 of the second layer 4. A part of the narrow portion 32 may be exposed from the opening 40 of the second layer 4, but the portion of the narrow portion 32 exposed from the opening 40 of the second layer 4 is the narrow portion 32. It does not exist over the entire area.

Process (4)
In the step (4), as shown in FIG. 9 (g), the portion CL1 covering the first layer 3 of the coating layer CL is peeled off along the first direction X, and the first main surface of the support sheet 2 is peeled off. The second layer 4 is formed on the rest of S1. "Peeling along the first direction X" means that the peeling direction coincides with the first direction X in a plan view. In a plan view, as long as the peeling direction coincides with the first direction X, the peeling direction may be a direction parallel to the first direction X or a direction intersecting the first direction X. The portion CL1 of the coating layer CL that covers the first layer 3 is more easily peeled off than the remaining CL2 of the coating layer CL. However, of the portion CL1 that covers the first layer 3, the portion CL12 that covers the narrow portion 32 is less likely to be peeled off than the portion CL11 that covers the wide portion 31. Therefore, the portion CL11 that covers the wide portion 31 is peeled off together with the peeling film PF while being adhered to the peeling film PF, while the portion CL12 that covers the narrow portion 32 and the remaining portion CL2 of the coating layer CL are supported. It remains on the rest of the first main surface S1 of the sheet 2 and forms the second layer 4. By removing the portion CL11 of the coating layer CL that covers the wide portion 31 of the first layer 3, the opening 40 of the second layer 4 is formed, and at least a part of the wide portion 31 is the second. It is exposed through the opening 40 of the layer 4 to form a recess 5 on the surface of the decorative plate 1. As a result, as shown in FIG. 9H, the decorative board 1 is manufactured.

The silicone-based release agent contained in the first layer 3 and / or the second layer 4 imparts releasability to the first layer 3 and / or the second layer 4, and therefore, in the step (4), the coating layer CL Of these, the portion CL11 that covers the wide portion 31 is easily peeled off. When both the first layer 3 and the second layer 4 contain a silicone-based release agent, this effect is enhanced.

The method of peeling the portion CL1 covering the first layer 3 of the coating layer CL is not limited to the method using the peeling film. For example, a method in which a protective film such as a masking film, an adhesive tape such as a cellophane tape or a gum tape, a shaping sheet or the like is attached to the surface of the coating layer CL, and then the film is peeled off at the same time; the adhesive tape, the adhesive rubber. Method of peeling with a roller, adhesive rubber sheet, etc .; Method of coating the coating layer CL with a resin solution such as a rubber chloride resin, urethane resin, or polyester resin previously dissolved in a solvent, drying, and then peeling; coating A method of applying a hot melt adhesive to the layer CL and then peeling it off at a low temperature; a method of attaching a resin plate or a metal plate to the coating layer CL and then peeling it off, and the like can be mentioned.

When the portion CL1 covering the first layer 3 of the coating layer CL is peeled off by using a peeling film such as an adhesive tape, a masking tape, or a shaping sheet, the resin film to be peeled off (the first of the coating layer CL). It is preferable to use a film whose peeling weight from the portion CL1) covering the 1st layer 3 is adjusted. For example, in the case of a thermosetting film of melamine resin, it is preferable to adjust the peeling weight to 0.1 to 10 N / inch. If the peeling weight is less than 0.1, it is difficult to peel off the thermosetting film of the melamine resin, and if the peeling weight exceeds 10 N / inch, the peeling film is torn off, or a resin film other than the resin film to be peeled off ( Of the coating layer CL, the portion other than the portion CL1 that covers the first layer 3) may also be peeled off. By using a peeling film whose peeling weight is adjusted to 0.1 to 10 N / inch, the resin film to be peeled off (the portion CL1 of the coating layer CL that covers the first layer 3) can be easily removed. can do.

The decorative board 1 manufactured by the above method has an uneven shape on the surface. Therefore, the decorative plate 1 can express the design feeling of the uneven shape based on the uneven shape. In particular, in the decorative board which is the result of the above-mentioned manufacturing method, the surface of the recess 5 (including the surface of the first layer 3 exposed from the opening 40 of the second layer 4) becomes a relatively rough surface, and the surface is exposed to incident light. On the other hand, in addition to the feature of forming a low-gloss region having diffuse reflectivity, the surface of the region other than the concave portion 5 including the convex portion is relatively mirror-finished, and a high-gloss region having specular reflectivity to incident light is formed. It has the characteristic of Therefore, the decorative board 1 can also express a gloss matte-like design feeling based on the uneven shape. For example, the decorative board 1 can exhibit an appearance having a concavo-convex shape including a gloss matte-like concavo-convex shape in which the concave portion gives a matte feeling and the convex portion gives a glossy feeling. In particular, by synchronizing the uneven shape with the pattern of the decorative layer 22 in a plan view, the decorative board 1 can express an excellent design feeling of the uneven shape. For example, when the decorative layer 22 forms a wood grain pattern, the decorative board 1 is made to have a real wood grain pattern by aligning the concave portion with the conduit portion of the wood grain pattern so that the positions of the decorative layer 22 and the conduit portion of the decorative layer 22 are aligned with each other in the plan view. It is possible to express the appearance including the same gloss matte design feeling (texture) as above.

Since the concave portion 5 has a depth reaching the wide portion 31 over the entire area and the surface height difference between the concave portion 5 and the region other than the concave portion 5 is significant, the decorative plate 1 is based on a clear uneven shape. , A gloss matte design feeling and a surface uneven shape design feeling (texture) can be expressed.

[Example 1]
(1) Manufacture of release ink 60 parts by mass of ionizing radiation curable monomer (Toagosei Co., Ltd., Aronix M400), 0.6 parts by mass of reactive silicone (X-22-164B, manufactured by Shin-Etsu Chemical Co., Ltd.), and 40 parts by mass of methyl ethyl ketone (Maruzen Petrochemical Co., Ltd.) was stirred for 1 hour at a rotation speed of 2000 rpm using a process homogenizer PH91 (manufactured by SMT Co., Ltd.) to produce a release ink.

(2) Manufacture of release film On the easy-adhesion surface of a 50 μm-thick PET film (Cosmo Shine (registered trademark) A4100 (50 μm) manufactured by Toyo Boseki Co., Ltd.), an ionizing radiation curable monomer (Aronix (registered trademark) manufactured by Toa Synthetic Co., Ltd.) ) M350) 100 parts by mass, reactive silicone (manufactured by Shin-Etsu Chemical Co., Ltd., X-22-164B) by 2 parts by mass, silica (manufactured by Fuji Silysia Chemical Ltd., Syricia 450) by 8 parts by mass, and ethyl acetate by 50 parts by mass. The coating ink containing ^{the mixture was coated at 5 g / m 2} (when dried), irradiated with an electron beam of 5 Mrad at an acceleration voltage of 165 kV, and cured to produce a release film.

(3) Manufacture of decorative board Using printing ink (DIC Graphics Co., Ltd., Ode SPTI) on white titanium paper (KJ Special Paper Co., Ltd., KW-1002P) with a ^{basis weight of 100 g / m 2 as the base paper.} After forming the print layer, using the release ink produced in (1) above, a pattern having a constant width (10 μm, 20 μm, 30 μm, 40 μm, 50 μm or 60 μm) and a length (1 mm to 60 mm). Was printed, and 5Mrad electron beam irradiation was performed at an acceleration voltage of 165 kV to form a release layer. The thickness of the release layer was 2 μm.

Next, a liquid uncured composition of a thermosetting resin composed of 50 parts by mass of melamine formaldehyde resin, 45 parts by mass of water, and 5 parts by mass of isopropyl alcohol was mixed with 100 g / g of the uncured composition using an impregnating device for impregnation. An impregnated decorative sheet was obtained by impregnating the mixture so as to have a ratio of ^{m 2 (when dried) and drying.} This impregnated decorative sheet is laminated on four phenol resin impregnated core papers (Ota Sangyo Co., Ltd., Ota Core) ^{having a basis weight of 245 g / m 2} obtained by impregnating kraft paper with a resin solution made of phenol resin, and further impregnated. The peeling film produced in (2) above was laminated on the decorative sheet so that the printed surface of the peeling film was in contact with the printed surface of the impregnated decorative sheet. The formed laminate is sandwiched between two mirror plates and heat-molded using a heat press machine at a pressure of 100 kg / cm ² at a molding temperature of 150 ° C. for 10 minutes, and the uncured composition is thermoset. A cured resin layer containing a melamine resin was formed. At this time, a cured resin layer was formed on the release layer. The thickness of the cured resin layer formed on the release layer was 30 μm.

By peeling the release film from the cured resin layer, the cured resin layer formed on the release layer was peeled off.
When the width of the release layer was 10 to 20 μm, most of the cured resin layer was not peeled off and remained on the release layer.
When the width of the release layer was 30 to 60 μm, most of the cured resin layer was peeled off, and the peeled portion of the cured resin layer was present throughout the release layer.

SEM observation was carried out on the release layer having a width of 30 to 50 μm, and the ratio of the area of the portion where the cured resin layer was peeled off to the area of the release layer was measured and found to be 30% or more.

[Example 2]
The same operation as in Example 1 was performed except that the thickness of the cured resin layer formed on the release layer was changed to 40 μm.
When the width of the release layer was 10 to 30 μm, most of the cured resin layer was not peeled off and remained on the release layer.
When the width of the release layer was 40 to 60 μm, most of the cured resin layer was peeled off, and the peeled portion of the cured resin layer was present throughout the release layer.
SEM observation was carried out on the release layer having a width of 40 to 60 μm, and the ratio of the area of the portion where the cured resin layer was peeled off to the area of the release layer was measured and found to be 30% or more.

[Example 3]
The same operation as in Example 1 was performed except that the thickness of the cured resin layer formed on the release layer was changed to 50 μm.
When the width of the release layer was 10 to 40 μm, most of the cured resin layer was not peeled off and remained on the release layer.
When the width of the release layer was 50 to 60 μm, most of the cured resin layer was peeled off, and the peeled portion of the cured resin layer was present throughout the release layer.
SEM observation was carried out on the release layer having a width of 50 to 60 μm, and the ratio of the area of the portion where the cured resin layer was peeled off to the area of the release layer was measured and found to be 30% or more.

1 ... Decorative plate 2 ... Support sheet S1 ... First main surface of the support sheet S2 ... Second main surface of the support sheet 3 ... First layer 31 ... Wide portion 32 ...・ Narrow portion 4 ・ ・ ・ Second layer 40 ・ ・ ・ Opening 5 of the second layer ・ ・ ・ Recessed portion on the surface of the decorative board 6 ・ ・ ・ Reinforcing layer

Claims (20)

It has a first direction, a second direction, and a thickness direction that are orthogonal to each other, and
A support sheet having a first main surface and a second main surface located on the opposite side of the first main surface, and
A first layer provided so as to extend along the first direction on a part of the first main surface, and
A second layer provided so as to surround the first layer on the rest of the first main surface, and
It is a decorative board equipped with
A base material sheet in which the support sheet has a first main surface located on the first main surface side of the support sheet and a second main surface located on the second main surface side of the support sheet, and the above. It has a decorative layer provided on the first main surface of the base sheet, and has.
The decorative layer forms a wood grain pattern including a conduit portion, and the decorative layer forms a wood grain pattern.
The first layer is formed in a pattern that is position-synchronized with the conduit portion in the wood grain pattern.
The first layer has a wide portion having a width of 20 μm or more and 100 μm or less.
The second layer has an opening that exposes at least a portion of the wide portion.
In a cut surface formed by cutting the decorative plate on a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outer line in the plan view of the wide portion. When the width of the wide portion is WB, the height of the wide portion is HB, and the height of the second layer is H, H> HB and WB ≧ (H-HB).
The decorative board in which at least a part of the wide portion is exposed from the opening of the second layer on the cut surface. The decorative board according to claim 1, wherein the difference (H-HB) between the height of the second layer and the height of the wide portion on the cut surface is 1 μm or more. The decorative board according to claim 1 or 2, wherein the area of the wide portion exposed from the opening of the second layer is 80% or more of the area of the wide portion. The decorative board according to any one of claims 1 to 3, wherein the first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin. The decorative board according to any one of claims 1 to 4, wherein the second layer is a cured resin layer containing a cured product of a thermosetting resin. The decorative board according to claim 5, wherein the thermosetting resin contains a water-soluble thermosetting resin. The decorative board according to claim 6, wherein the water-soluble thermosetting resin contains a melamine resin. The decorative board according to any one of claims 1 to 7, wherein the first layer and / or the second layer contains a silicone-based release agent. The decorative board according to any one of claims 1 to 8, wherein the base sheet is a porous sheet. The decorative board according to claim 9 , wherein the support sheet further has a cured product of a thermosetting resin filled in the voids of the porous sheet. The method for manufacturing a decorative board according to any one of claims 1 to 10.
The above method
(1) Step of preparing the support sheet,
(2) A step of forming the first layer on a part of the first main surface of the support sheet in a pattern synchronized with the conduit portion in the wood grain pattern.
(3) A step of forming a coating layer that surrounds the first layer and covers at least a part of the first layer on the rest of the first main surface of the support sheet.
(4) The step including a step of peeling a portion of the coating layer covering the first layer along the first direction to form a second layer on the rest of the first main surface of the support sheet is included.
The intermediate body obtained in the step (3) is cut on a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outer line in the plan view of the wide portion. The method, wherein the width of the wide portion of the cut surface to be formed is WB, and WB ≧ TB when the thickness of the portion of the coating layer that covers the wide portion is TB. The method according to claim 11 , wherein the thickness (TB) of the portion of the coating layer that covers the wide portion of the cut surface is 1 μm or more. The first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin.
The step (2) is
(2-1) the ionizing radiation curable resin using an ionizing radiation curable resin composition comprising, the ionizing radiation curable resin composition layer covering a portion of said first major surface of the support sheet A process of forming a pattern that is position-synchronized with the conduit portion in the wood grain pattern, and
(2-2) The method according to claim 11 or 12 , which comprises a step of curing the ionizing radiation curable resin composition layer to form the cured resin layer as the first layer. 13. The method of claim 13 , wherein the ionizing radiation curable resin composition comprises a silicone-based mold release agent. The coating layer is a cured resin layer containing a cured product of a thermosetting resin.
The step (3) is
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the rest of the first main surface of the support sheet, and the first layer is formed. A step of forming a thermosetting resin composition layer that covers at least a part of the above, and
(3-2) The method according to any one of claims 11 to 14 , comprising a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer. The method according to claim 15 , wherein the thermosetting resin contains a water-soluble thermosetting resin. The method according to claim 16 , wherein the water-soluble thermosetting resin contains a melamine resin. The method according to any one of claims 15 to 17 , wherein the thermosetting resin composition contains a silicone-based mold release agent. The method according to any one of claims 11 to 18, wherein the base material sheet is a porous sheet. The coating layer is a cured resin layer containing a cured product of a thermosetting resin.
The step (3) is
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the rest of the first main surface of the support sheet, and the first layer is formed. A step of forming a thermosetting resin composition layer that covers at least a part of
(3-2) Including a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer.
In the step (3-1), the porous sheet is impregnated with the thermosetting resin composition.
The method according to claim 19 , wherein in the step (3-2), the thermosetting resin composition impregnated in the porous sheet is cured.

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