JP7155509B2 - decorative material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a decorative material, and more particularly to a decorative material having texture different from conventional ones.

There are a wide variety of design expressions in decorative materials, but for example, as described in Patent Document 1 and Patent Document 2, by providing a large number of parallel line-shaped uneven patterns, the intensity of the light reflected on the surface, that is, the glossiness However, there is a technique for giving a unique appearance texture that changes according to the combination of the incident angle of the illumination light and the viewing direction of the observer.

Japanese Patent Publication No. 7-22989 JP-A-4-125199

By forming a multiplicity of parallel line-shaped uneven patterns as described in Patent Documents 1 and 2, it is possible to express, for example, the luster of the surface (wood grain) of the wood.
However, in recent years, there has been a demand for further diversification of design expressions, and it is necessary to provide expressions that give new textures to meet these demands.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a decorative material having a structure capable of realizing a different texture.

The present invention will be described below.

One aspect of the present invention is a decorative material having a pattern formed on the surface, the pattern being a form in which a plurality of convex filaments and a plurality of concave filaments are alternately arranged, and the plurality of convex When a virtual surface including the apex of the filament portion is assumed to be a pattern top enveloping surface, the pattern top enveloping surface has unevenness.

The decorative material includes a substrate and a pattern forming layer disposed on one surface of the substrate to form a pattern, and the surface of the substrate has unevenness to form unevenness on the envelope surface of the top of the pattern. It may be configured as

In the above-described decorative material, unevenness may be formed on the pattern top enveloping surface by varying the heights of the plurality of ridges.

A relationship in which the duty ratio is constant regardless of the height H of the protruding filament portion, where W _{a is the width of the protruding filament portion, W b is the width of the concave filament portion, and W a /W b is the duty} ratio. may be configured to include a pattern having

When W a is the width of the ridge portion, W _b is the width of the ridge portion, and W _a /W _b is the duty ratio, the higher the height H of the _ridge portion, the smaller the duty ratio. It may be configured to include a pattern having

The width of the ridge portion may be less than 30 μm, and H/W _a is greater than 1, where W _a is the width of the ridge portion and H is the height of the ridge portion. It may be configured to include a site.

According to the decorative material of the present invention, according to the combination of the incident angle of the illumination light and the line-of-sight direction of the observer, due to the unique structure of the form of the convex filament portion, the concave filament portion, and the pattern top virtual envelope surface, In the varying degree of gloss, it has a more varied texture different from the conventional one. Furthermore, when the pattern portion on the surface of the decorative material is touched with a hand, due to the shape of the projected line portion, the recessed line portion, and the virtual envelope surface of the top of the pattern, compared to the conventional decorative material composed of the projected line portion, It also has a more varied texture in terms of tactile sensation.

3 is a plan view showing an enlarged part of the surface of the decorative material 10. FIG. 1 is a diagram showing a cross section of a decorative material 10; FIG. 2 is a diagram showing a cross section of a decorative material 20; FIG. It is the figure which expanded and represented a part of surface of the decorative material 30. FIG. 5 is a diagram focusing on one unit area 33 in FIG. 4. FIG. 6(a) to 6(c) are cross-sectional views of the decorative material 30. FIG. It is the figure which expanded and represented a part of surface of the decorative material 50. FIG. It is a figure explaining a net|network area. It is a figure explaining the scene which forms unevenness|corrugation in a type|mold with a laser. 10(a) to 10(c) are diagrams illustrating another example of the layer structure of the decorative material 10. FIG.

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below based on the embodiments shown in the drawings. However, the present invention is not limited to these forms. Note that in the drawings shown below, the sizes and ratios of members may be changed or exaggerated for clarity. In addition, for the sake of visibility, parts that are not required for explanation and repetitive symbols may be omitted.

FIG. 1 is a plan view (plan view) of a part of the decorative material 10 according to the first embodiment, which is enlarged and viewed from the pattern forming layer 12 side. Directional arrows (x, y, z) are also shown as necessary in FIG. 1 and the following figures for convenience. Here, the xy direction is the in-plane direction of the decorative material 10, and the z direction is the thickness direction. FIG. 1 is a diagram of the decorative material 10 viewed from the pattern layer forming layer 12 side, particularly from the z direction.
2 shows the cross-sectional shape of the decorative material 10. As shown in FIG. This cross section is a cross section in the thickness direction (z direction) orthogonal to the direction in which the ridgeline of the protruding linear portion 13, which will be described later, extends.
As can be seen from FIGS. 1 and 2, the decorative material 10 comprises a substrate 11 and a pattern forming layer 12 laminated on one surface of the substrate 11 .

The base material 11 is a sheet-like member having a function of supporting the pattern forming layer 12 and imparting strength to the decorative material 10 . Further, the substrate 11 of this embodiment has an uneven substrate surface S _k having unevenness on the surface on which the pattern forming layer 12 is arranged. In this embodiment, unevenness is also formed on the imaginary surface of the pattern forming layer 12, i.e., the imaginary _enveloping surface St at the top of the pattern.
Dotted lines in FIG. 2 are imaginary lines.

The uneven surface _Sk of the base material is an uneven surface in which the surface height is not constant in the xy-direction positions, and the surface height position changes depending on the xy-direction positions. More specifically, it has one or more maximal portions, ie, maximal points or maximal lines (ridge lines or ridge lines), and the distance between the maximal portions is in the range of about 3 mm or more and 300 mm or less, which is visually or tactilely recognizable. , more preferably about 10 mm or more and 100 mm or less.
The height may be changed only in one direction, for example, the height may be changed only in the x direction, and the height may be constant in the y direction. Specifically, the shape obtained by cutting the substrate uneven surface Sk along a virtual cutting plane parallel to the _zx plane is
z=A sin(kx+φ)
y=B
(A, k, B, and φ are appropriate constants)
is a sinusoidal curve represented by, while the shape cut by a virtual cutting plane parallel to the yz plane is
Z=C
x=D
(C and D are constants as appropriate)
An uneven shape is exemplified.

Alternatively, the uneven surface may have a height that changes in both the x-direction and the y-direction. Specifically, the shape obtained by cutting the substrate uneven surface Sk along a virtual cutting plane parallel to the _zx plane is
z=A sin(kx+φ)
y=B
(A, k, φ, B are appropriate constants)
is a sinusoidal curve represented by, while the shape cut by a virtual cutting plane parallel to the yz plane is
z = E sin (my + ξ)
x=F
(E, m, ξ, and F are constants as appropriate)
An uneven shape is exemplified.

In addition to the above, various uneven surface shapes can be adopted as the uneven shape of the base material uneven surface _Sk according to the desired surface appearance design and tactile feel of the decorative material.
In addition, the difference in height of the uneven surface _Sk of the base material is preferably about 0.1 mm or more and 10 mm or less, more preferably 0.5 mm or more and 1 mm, which is visually recognizable or tactile. It is about the following. In particular, when mass production is carried out by adopting a manufacturing method in which a sheet-like base material is embossed with an embossing plate in the form of a metal roll to form unevenness, the height of the base material uneven surface _Sk is high or low due to processing suitability. The upper limit of the difference is 1 mm or less, preferably 0.7 mm or less.

As the base material 11, the same material as conventionally known decorative material can be applied, and the material is not particularly limited. For example, the material of the substrate is generally polyolefin resin such as polyethylene, polypropylene, olefin thermoplastic elastomer, ionomer, etc., acrylic resin such as polymethyl methacrylate, polybutyl methacrylate, etc., thermoplastic resin such as polyethylene terephthalate, polybutylene terephthalate, etc. Thermoplastic resins such as polyester resins, thermoplastic urethane resins, vinyl chloride resins, ABS resins (acrylonitrile-butadiene-styrene copolymer), styrene resins, melamine resins, unsaturated polyester resins, two-component curable urethane resins, etc. A curable resin, or an ionizing radiation curable resin such as a radical polymerization type acrylate type or a cationic polymerization type epoxy type which is cured by ionizing radiation (ultraviolet rays, electron beams, etc.) is used. In addition, when the material of the base material is a resin, it may be colored with a known coloring agent. In addition, paper, non-woven fabric, metal, wood, ceramics such as porcelain and glass, cement, stone, etc. can also be used in the form of sheets, plates, three-dimensional objects, etc., and can be appropriately laminated with the above resin material.

The thickness of the substrate is not particularly limited, but in the case of a sheet-like substrate or a film-like substrate, for example, the thickness of the thinnest portion is about 20 μm or more and 1000 μm or less, and in the case of a plate-like substrate, for example, The thinnest portion can be about 1 mm or more and 20 mm or less.

The pattern forming layer 12 is a layer laminated on the uneven surface _Sk of the base material 11 and forms a pattern in the decorative material 10 . In this embodiment, the pattern forming layer 12 has the following configuration.

As can be seen from FIGS. 1 and 2, in the pattern forming layer 12 in this embodiment, the convex line portions 13 and the concave line portions 14 are alternately arranged to form a pattern.
The protruding linear portion 13 has a substantially rectangular shape with a height H ₁₃ and a width W ₁₃ in the cross section shown in FIG. The protruding linear portion 13 has this cross section, and its ridgeline is configured to extend in a direction different from the arrangement direction (for example, a direction orthogonal to the arrangement direction). The length by which the protruding filamentary portion 13 extends is not particularly limited and can be appropriately determined according to need. Here, the height of one protruding filamentary portion 13 may vary in its width direction, but in that case, the height of the protruding filamentous portion 13 is the highest portion. Further, the width of the protruding filamentary portion 13 is defined as the width at the center in the height direction.
On the other hand, the recessed line portions 14 are formed between the adjacent projected line portions 13 as shown in FIG. Therefore, the width W ₁₄ of the concave filamentary portion 14 is a value obtained by subtracting the width W ₁₃ of the convex filamentary portion 13 from the pitch P ₁₃ of the convex filamentary portion 13 .

Here, the sizes of W ₁₃ , W ₁₄ , and H ₁₄ are not particularly limited, but from the viewpoint of forming the pattern of the decorative material, they are preferably fine. ₁₃ ≤ 1000 µm, 1 µm ≤ W ₁₄ ≤ 1000 µm, and 3 µm ≤ H ₁₃ ≤ 3000 µm.

Moreover, it is preferable that H ₁₃ /W ₁₃ (also referred to as aspect ratio), which is the ratio of the height to the width of the protruding linear portion 13, be greater than one. According to this, the texture of the decorative material can be further improved. However, if the aspect ratio is too large, the difficulty of manufacturing the mold increases, and when an external force is applied to the mold and the decorative material, stress concentrates on the ridges 13, making them susceptible to damage. Therefore, the aspect ratio is usually 5 or less, preferably 3 or less.

In addition, although the cross-sectional shape of the protruding line portion 13 of this embodiment is substantially rectangular, it is not limited thereto and may be of another form. For example, a trapezoidal shape, a shape with a semicircular tip, and a shape with an outward corner formed with an R can be mentioned, and it is possible to change them as appropriate. At this time, as for the width of the protruding linear portion, the width at the center in the height direction is defined as the width of the protruding linear portion as described above. The same applies to each form described later.

Here, the pattern forming layer 12 has unevenness as a whole on the side (top side) opposite to the substrate side (base end side). The unevenness of this embodiment is as follows.
An imaginary enveloping surface that includes the ridgeline of the top of the ridge portion 13 is assumed to be a pattern top _enveloping surface St, as indicated by the dotted line _St in FIG. In this embodiment, the imaginary envelope surface _St is formed to have unevenness. The irregularities are selected from irregularities similar to the irregularities exemplified in the explanation of the substrate irregular surface _Sk .
In particular, since the pattern top enveloping surface St forms the shape of the outermost surface of the decorative material, it greatly contributes to the appearance design and tactile feel of the decorative material more than the _uneven surface _Sk of the base material. Therefore, especially for the pattern top envelope surface St, it is necessary to select the optimum shape for reproducing the desired appearance design and _tactile sensation.
For example, the decorative material surface reproduces the appearance design and feel of the wood board surface (wood grain), and the appearance design and feel of the wood board surface (wood grain) of the so-called "floating style" in which the autumn wood part of the annual rings protrudes above the relief. When reproducing , the shape of the pattern top envelope surface St should be an uneven shape in which the autumn wood part is relatively projected and the spring wood part is relatively recessed, corresponding to the uneven shape of the annual rings on the surface of the _ukizukuri wood board. . In this case, the line-like uneven shape in which a plurality of protruding filaments and a plurality of concave filamentary portions are alternately arranged extends in a direction that roughly coincides with the average running direction of the autumn wood portion of annual rings. are arranged as follows.

Further, for example, when the decorative material surface reproduces the appearance design and feel of a granite plate, the shape of the pattern top _enveloping surface St corresponds to the surface irregularity shape of the micro single crystal group arranged on the cleavage plane of the granite plate surface. An uneven shape corresponding to each single crystal portion is formed. In this case, the line-shaped irregularities in which the protruding line portions and the plurality of recessed line portions are alternately arranged are arranged in parallel lines for each closed region defined by the outline of each single crystal on the cleavage plane. The closed areas that fit the uneven shape and are adjacent to each other via the boundary line are the extending directions of the protruding filament portion and the concave filament portion, the width of the protruding filament portion, and the width of the concave filament portion. Any one or more are arranged differently.

Incidentally, as a specific example of the arrangement of such parallel lines, the arrangement disclosed in Japanese Patent Application Laid-Open No. 8-52849 (in particular, FIGS. 2, 3, and 10) can be mentioned.

In this embodiment, since the heights of the plurality of ridges 13 of the pattern forming layer 12 are all the same, the uneven shape of the imaginary enveloping surface St at the top of the pattern is the same as that of the substrate _uneven surface _Sk of the substrate 11. It follows the unevenness of the However, the present invention is not limited to this, and as will be described later, the unevenness of the imaginary _enveloping surface St at the top of the pattern may be formed independently of the unevenness of the base material, or the unevenness of the base material and other The _unevenness of the pattern top imaginary envelope surface St may be determined by combining with the unevenness. That is, the shape of the pattern top enveloping surface _St and the shape of the substrate irregular surface _Sk do not need to be the same shape, and both may be of the same shape depending on the desired appearance design or tactile sensation. Both may have different shapes.

In this way, by having the protruding filaments and having unevenness in the imaginary enveloping surface of the top of the pattern formed by the protruding filaments, it is possible to give a unique texture different from the conventional ones in terms of appearance design and tactile sensation.

As a material for forming the pattern forming layer 12, a normal material used for decorative materials can be appropriately used. The pattern forming layer 12 is made of the same material as the base material 11 if the base material is heated and softened to press the mold (embossing plate). In addition, if the pattern forming layer 12 is laminated on the base material 11 as a separate layer from the base material 11, from the viewpoint of curing the melted composition after molding, the same as the base material 11 prepared separately from the base material 11. can be used.

In addition, although the ridge line shown here has a form in which the ridge line extends linearly, the ridge line is not limited to this, and in a plan view, the ridge line portion has a parabolic, hyperbolic, or curved shape in the direction in which the ridge extends. Other shapes such as sinusoidal curves, hyperbolic sinusoidal curves, elliptical function curves, cycloidal curves, or other curvilinear or wavy shapes are also possible. The same applies to each form described later.

FIG. 3 shows a diagram for explaining the second embodiment. FIG. 3 is a cross-sectional view of the decorative material 20 from the same viewpoint as in FIG. As can be seen from FIG. 3, in the decorative material 20, the surface of the base material 21 on which the pattern forming layer 22 is arranged is also a smooth flat surface, and does not have unevenness. The material and thickness of the base material 21 can be considered in the same manner as the base material 11 .

On the other hand, in the convex filamentary portions 23 and the concave filamentary portions 24 provided in the pattern forming layer 22, the height H23 of the convex filamentary portions ₂₃ is formed so that the plurality of convex filamentary portions 23 are different. . As a result, even if the substrate uneven surface _Sk is a flat plane, the pattern top imaginary envelope surface _St is configured to have unevenness.
Such a decorative material 20 can also give a unique texture different from the conventional ones.

The concept of the uneven shape of the pattern top _enveloping surface St is the same as that of the pattern top _enveloping surface St described for the decorative material 10 .

Further, the width W ₂₃ of the protruding filamentary portion 23, the width W ₂₄ of the concave filamentary portion 24, and the height H ₂₃ of the protruding filamentary portion 23 are not particularly limited, but the pattern of the decorative material is not limited. In the present embodiment, it is preferable that 1 μm≦W ₂₃ ≦1000 μm, 1 μm≦W ₂₄ ≦1000 μm, and 3 μm≦H ₂₃ ≦3000 μm.

FIG. 4 is an enlarged view of a part of the decorative material 30 according to the third embodiment, viewed from the pattern forming layer 32 side. In the decorative material 30 of the present embodiment, unit regions 33, which are regular hexagonal regions, are arranged two-dimensionally in the xy directions in a plan view. For the sake of clarity, FIG. 4 shows one unit region 33 bordered by a thick line.
The unit area referred to here is a repeating unit, that is, in a plane (xy plane), a plane is formed by repeatedly arranging adjacent in a direction having translational symmetry (a direction orthogonal to three pairs of opposite sides). It means a unit area that can be covered without gaps.

FIG. 5 shows an enlarged view of one unit area 33 extracted from FIG. As can be seen from FIG. 5, the unit area 33 is further divided into 10 individual areas 34 to 43, and each of the individual areas 34 to 43 is provided with a pattern forming layer.
In the decorative material 30 of this embodiment, unit regions 33 are arranged as repeating units, and in this unit region 33, individual regions 34 to 43 having respective patterns are formed. However, a plurality of individual regions may be formed in the whole without the unit region as such a repeating unit. Since there are two types of regions in this embodiment, they are distinguished by calling them "unit regions" and "individual regions" for ease of understanding, but they can also be collectively expressed as "regions."

Although dotted lines are partially shown in FIGS. 4 and 5, these dotted lines do not actually exist, but are imaginary lines added to facilitate understanding of the boundaries between the unit regions and the individual regions. . As can be seen from FIGS. 4 and 5, in this embodiment, the unit area 33 is a regular hexagon, and the individual areas 34 to 43 within the unit area 33 are triangular.

6A to 6C show cross-sectional shapes of three individual regions 34, 35, and 36 among the individual regions 34 to 43. FIG. All of these cross sections are cross sections in the thickness direction (z direction) orthogonal to the direction in which the ridge lines of the protruding linear portions formed in the individual regions extend.
As can be seen from FIGS. 6(a) to 6(c), the decorative material 30 includes a substrate 21 and a pattern forming layer 32 laminated on one surface of the substrate 21. As shown in FIG. The pattern forming layer 32 forms the shapes of the unit regions 33 and the individual regions 34 to 43 .

The base material 21 of this embodiment is the same as the base material 21 of the decorative material 20 described above. Therefore, the surface of the substrate 21 on which the pattern forming layer 32 is laminated is also formed as a smooth flat surface.

The pattern forming layer 32 is a layer that forms a pattern laminated on one surface of the base material 21, and the pattern has a predetermined shape such as the unit region 33 and the individual regions 34 to 43. constitutes In this embodiment, the pattern forming layer 32 has the following configuration.

As described above, in the present embodiment, the pattern forming layer 32 has the regular hexagonal unit regions 33 in plan view of the decorative material 30, and the plurality of unit regions 33 are two-dimensionally arranged in the xy plane to form the entire plane. is covered. Each unit area 33 is divided into a plurality of individual areas 34 to 43, and a pattern is formed for each individual area. The individual regions 34, 35, and 36 will be described below as an example.

As can be seen from FIGS. 5 and 6(a), the individual regions 34 are formed by alternately arranging protruding linear portions 34a and concave linear portions 34b.
The protruding linear portion 34a has a substantially rectangular shape with a height H _34a and a width W _34a in the cross section shown in FIG. 6(a). The protruding linear portion 34a has this cross section, and its ridgeline is configured to extend in a direction different from the arrangement direction (for example, a direction orthogonal to the arrangement direction). The length by which the protruding linear portion 34 a extends is determined by the contour shape of the individual region 34 .
On the other hand, the recessed line portions 34b are formed between the adjacent projected line portions 34a as shown in FIG. 6(a), and the shape thereof is determined by the shape of the projected line portions 34a. Therefore, the width W _34b of the concave filamentary portion 34b is a value obtained by subtracting the width W _34a of the convex filamentary portion 34a from the pitch P _34a of the convex filamentary portion 34a.

Here, the sizes of W _34a , W _34b , and H _34a are not particularly limited, but from the viewpoint of forming the pattern of the decorative material, they are preferably fine. _34a ≤ 1000 µm, 1 µm ≤ W _34b ≤ 1000 µm, and 3 µm ≤ H _34a ≤ 3000 µm.

Moreover, it is preferable that H _34a /W _34a (also referred to as an aspect ratio), which is the ratio of the height to the width of the protruding linear portion 34a, be greater than one. According to this, the texture of the decorative material can be further improved. However, if the aspect ratio is too large, the difficulty of manufacturing the mold increases, and when an external force is applied to the mold and the decorative material, stress concentrates on the protruding filaments 34a, making them susceptible to damage. Therefore, the aspect ratio is usually 5 or less, preferably 3 or less.

Here, the plurality of ridges 34a belonging to the individual region 34 have unevenness as a whole on the side (top side) opposite to the substrate side (base end side). The unevenness of this embodiment can also be considered in the same manner as the pattern top _enveloping surface St described above. That is, also in this embodiment, the imaginary envelope surface St at the top of the pattern is formed to have _unevenness . The unevenness may have the same shape as the pattern top _enveloping surface St.

The material forming the pattern forming layer 32 can be considered in the same manner as the pattern forming layer 12 described above.

The individual region 35 is an individual region adjacent to the individual region 34, and as can be seen from FIGS. It becomes
The protruding linear portion _35a has a rectangular shape with a height _H35a and a width W35a in the cross section shown in FIG. 6(b). The protruding linear portion 35a has this cross section, and the ridge line thereof is in a direction different from the arrangement direction (for example, a direction orthogonal to the arrangement direction) and in a direction different from the direction in which the protruding linear portion 34a of the individual region 34 extends. is configured to extend to The length by which the protruding linear portion 35 a extends is determined by the contour shape of the individual region 35 .
On the other hand, as shown in FIG. 6(b), the recessed filamentary portions 35b are formed between adjacent protruding filamentary portions 35a, and the shape thereof is determined by the shape of the protruding filamentary portions 35a. Therefore, the width W35b of the recessed filamentary portion _35b is a value obtained by subtracting the width _W35a of the protruding filamentary portion _35a from the pitch P35a of the protruding filamentary portion 35a.

Here, the preferred size ranges of the height H _35a , width W _35a , and width W _35b in the individual region 35 can be considered in the same manner as in the individual region 34 . In addition, in the individual region 35, in relation to the individual region 34, it is preferable that H _34a >H _35a . Furthermore, in the present embodiment, the individual regions 35 are W _34a =W _35a , W _34b <W _35b , and P ₃₄ <P ₃₅ .
Here, H _34a >H _35a means that the average height of the ridges 34a belonging to the individual region 34 is greater than the average height of the ridges 35a belonging to the individual region 35. .

Also in this case, the plurality of ridges 35a belonging to the individual region 35 have unevenness as a whole on the side (top side) opposite to the substrate side (base end side). This can also be considered in the same manner as the pattern top _enveloping surface St described above.

The individual region 36 is an individual region adjacent to the individual region 34, and as can be seen from FIGS. It becomes
The protruding filament portion 36a has a rectangular shape with a height H _36a and a width W _36a in the cross section shown in FIG. 6(c). The protruding linear portions 36a have this cross section, and the ridgeline thereof is in a direction different from the arrangement direction (for example, a direction perpendicular to the arrangement direction) and in a direction different from the direction in which the protruding linear portions 36a of the individual regions 36 extend. is configured to extend to The length by which the protruding linear portion 36 a extends is determined by the contour shape of the individual region 36 .
On the other hand, as shown in FIG. 6(c), the recessed filamentary portions 36b are formed between adjacent protruding filamentary portions 36a, and the shape thereof is determined by the shape of the protruding filamentary portions 36a. Therefore, the width W _36b of the concave filamentary portion 36b is a value obtained by subtracting the width W _36a of the convex filamentary portion 36a from the pitch P _36a of the convex filamentary portion 36a.

Here, the preferred size ranges of the height H _36a , width W _36a , and width W _36b in the individual region 36 can be considered in the same manner as in the individual region 34 . In addition, in the individual region 36, in relation to the individual region 34, it is preferable that H _34a >H _36a . Furthermore, in the present embodiment, the individual regions 36 are W _34a <W _36a , W _34b <W _36b , and P _35a =P _36a .
Here, H _34a >H _36a means that the average height of the ridges 34a belonging to the individual region 34 is greater than the average height of the ridges 36a belonging to the individual region 36. .

Also in this case, the plurality of ridges 36a belonging to the individual region 36 have unevenness as a whole on the side (top side) opposite to the substrate side (base end side). This can also be considered in the same manner as the pattern top _enveloping surface St described above.

The other individual areas 37 to 43 can be similarly considered.
Each individual region has a unique uneven shape of the imaginary _enveloping surface St at the top of the pattern, and is different from the adjacent individual region in at least one of the height, width, and extending direction of the protruding filaments. preferably.
Even with such a pattern forming layer 12, it is possible to express a unique texture different from that of the past.

Among these, in the present embodiment, there is a relationship in which the average heights of the projected linear portions are different between a plurality of regions (regions as a general term for regions existing in the uneven layer regardless of whether they are unit regions or individual regions). Those that include regions are preferred. Including a plurality of areas having different average heights in this manner can increase the variety of expression of textures different from the conventional one.
Here, when differentiating the heights of the protruding linear portions between the regions in this way, the following may be done. That is, when W _{a is the width of the convex filament portion and W b is the width of the concave filament portion and W a /W b is the duty} ratio, the duty ratio W _a / The duty ratio W _a /W _b can be configured to decrease as W _b is the same or as the height H of the protruding linear portion increases. This makes it possible to express textures that are further different from conventional ones. Incidentally, in the decorative materials disclosed in Patent Document 1 (Japanese Patent Publication No. 7-22989) and Patent Document 2 (Japanese Patent Laid-Open No. 4-125199), as described in the examples, metal plate materials An embossing plate manufactured by etching through a photosensitive resist film patterned by light exposure from a block image is formed on the top. Therefore, due to the so-called side etching phenomenon, the duty ratio W _a /W _b inevitably increases as the height H increases. (See the claims of Japanese Patent No. 4612200 and FIG. 1).

FIG. 7 shows a plan view of the decorative material 50 according to the fourth embodiment. FIG. 7 is a diagram corresponding to FIG. This decorative material 50 is an example in which regions 53 to 57 are arranged in the x-direction in the pattern forming layer 52, and the boundaries between the regions indicated by dotted lines are curved. Each region has a convex linear portion, a concave linear portion, a pattern top enveloping surface S _t , and a substrate uneven surface S _k , following the example of the individual regions described above.
The effects of the present invention can be obtained even with such a decorative material 50 .

Next, an example of a method for manufacturing a decorative material will be described. Here, a method for producing the decorative material 30 is exemplified. However, the method of manufacturing the decorative material is not limited to this.
The manufacturing method described below includes a step of preparing an original image, a step of preparing a block copy image, a step of preparing a plate, and a step of preparing a pattern forming layer.

In the step of preparing the document image, a pattern to be expressed on the pattern forming layer 32 is obtained and used as the document image. Since the document image is preferably digital data, if it is not digital data, it is converted into digital data by using a photograph, a scanner, or the like. Moreover, when the pattern is designed from the beginning using digital data using CAD or the like, the digital data can be used.
Thus, a document image is obtained as digital data.

In the process of creating a block copy image, a line pattern is generated as a binary image on a two-dimensional virtual plane in correspondence with the gradation image of the pattern using a density-line conversion program. Then, the block copy image is obtained as digital data.

Here, lines are generated as a binary image in accordance with preset line generation conditions such as the period of the ridges, the shape of the lines, the direction in which the lines extend, and the variable range of the width of the lines. Generate. The parallel lines generated in this way correspond to the convex linear portions of the decorative material, and the portions between the line segments correspond to the concave linear portions of the decorative material. In this way, a block copy image having a parallel line pattern is obtained.

In the step of making a plate, an embossed plate (molding die for decorative material) having a concave-convex pattern having a plan view shape as shown in FIG.
The concave-convex pattern has an aggregate of individual areas covered by partitioning a plane by connecting individual areas 34 to 43, 34 to 43, 34 to 43, .
Here, as shown in FIG. 8 corresponding to FIG. 4 (partially represented by thick lines for ease of viewing), such an uneven pattern consists only of the contour shape of each region. With respect to the net-like region 32 ′, which is an image that does not have the convex linear portions and the concave linear portions, the parallel convex linear lines are formed in the regions 34 to 43, 34 to 43, . . . It is assumed that the portions 34a, 35a, 36a, .
Specifically, the manufacturing process of the uneven pattern consists of the following procedures (1) to (5).

[(1) Gradation gradation image creation process]
The following image creation steps (1)-1 to (1)-3 are performed using Adobe Systems' graphic design drawing software "Illustrator", TIFF format, 8-bit image gradation (256 gradations), 2540 dpi. image data (reticulated area, parallel lines, and a composite image of both) with a resolution of .

(1)-1
First, an image of the net-like region 32' corresponding to the image shown in FIG. 8, excluding the parallel line image, was created from the plan view image of the uneven pattern in FIG.

(1)-2
, 42, 43 to be fitted into each of the individual regions 34, 35, . . . , 42, 43. Digital grayscale image data corresponding to the shapes of 42b, 43a and 43b (hereinafter also referred to as parallel line shapes) were created.
The grayscale image corresponds to the image density for each coordinate of the surface of the metal roll, which will be described later.

(1)-3
Using the drawing software "Illustrator", the parallel line shape for each individual area obtained above is inserted into each individual area in the net-like area obtained above, and the grayscale image data corresponding to the uneven pattern in FIG. got This grayscale image data is also referred to as uneven pattern image data.

[(2) Metal roll preparation step]
In parallel with the above step (1), a metal roll 60 for embossing plate engraving as shown in FIG. 9 was prepared. The metal roll 60 is formed by plating a copper layer on the surface of a hollow iron cylinder having rotating shafts 61 at both ends in the axial direction. The surface of the metal roll 60 was roughened by polishing with a whetstone to prevent a decrease in engraving efficiency due to specular reflection of engraving laser light.

[(3) Laser beam engraving step]
As schematically shown in FIG. 9, a laser direct engraving machine is used to engrave the surface of the metal roll 60 prepared in step (2) based on the pattern image data created in step (1). As a result, a shape having the same planar shape as the pattern on the surface of the decorative material and a reverse pattern (the portions corresponding to the convex portions of the decorative material become concave on the embossed plate surface) was formed on the surface as shown in FIG.
Therefore, the shape that the pattern on the embossed plate should have is a mode in which the concave-convex relationship of the pattern on the decorative material is reversed, and can be considered in the same way.

The metal roll 60 is driven by an electric motor via its rotary drive shaft 61 and rotates around the rotary drive shaft 61 as its central axis. The entire surface of the metal roll 60 is scanned with a fiber laser beam L emitted from a laser head 62 having an oscillation wavelength of 1024 nm, a laser spot diameter of 10 μm, and an output of 600 W. At that time, the laser light is switched ON-OFF (switching between irradiation and non-irradiation) according to the density value of the uneven pattern image data created in step (1), and the irradiation position is irradiated with the laser light once. Evaporation of the metal forms recesses with a depth of 10 μm. The scanning of the metal roll surface with such laser light was repeated 10 times. In order to prevent the evaporated metal from remaining or adhering to the surface of the metal roll 60 in the form of powder, the engraving liquid T was sprayed from the engraving liquid discharge head 63 onto the laser beam irradiated area of the surface of the metal roll 60. Laser light irradiation was performed in this state.
At that time, for example, at the position coordinates of the image density corresponding to the plate depth of 50 μm on the uneven pattern image data, the laser light is irradiated (ON) only for the first five scans out of a total of ten scans, and the remaining five scans are performed. The batch is controlled so that the laser light is not irradiated (OFF).
The scanning of the laser beam was completed, and the desired uneven shape was formed on the surface of the metal roll 60 .

[(4) Electropolishing step]
After washing the engraving liquid, electropolishing was performed to remove metal residue adhering to the surface of the metal roll 60 .

[(5) Chrome plating step]
After step (4), a chromium layer having a thickness of 10 μm was formed on the surface of the metal roll by plating.

As described above, it is possible to obtain a plate (molding die for decorative material, embossed plate in the present embodiment) having a surface in which the unevenness of the pattern formed on the surface of the pattern forming layer 32 is reversed.

Next, in the step of producing the pattern forming layer, the decorative material 30 is obtained by embossing the substrate 21 using the produced plate (embossing plate). Embossing may be performed by any suitable known method, and is not particularly limited. A representative method of embossing is, for example, as follows.
A resin sheet made of a thermoplastic resin such as a polyolefin resin is used as a base material. This base material is heated and softened, and an embossing plate is pressed against the surface of the base material to shape the uneven pattern of the embossing plate surface on the surface of the resin sheet. Then, the resin sheet is cooled and solidified to fix the uneven pattern on the resin sheet. After that, the resin sheet on which the uneven pattern is formed is released from the embossing plate.
Here, various embossing methods will be further explained, for example, the following methods (A) to (E).

(A) A resin sheet serving as a base material is heated and softened, and an embossing plate is pressed to perform embossing.
(B) Embossing and lamination by heat-sealing a resin sheet (base material) that serves as a surface sheet and a resin sheet (second base material) that serves as a base sheet by heat and pressure when the embossing plate is pressed. and are simultaneously embossed by a doubling embossing method.
(C) A resin sheet (base material) to be used as a surface sheet is melt-extruded from a T-die, brought into contact with a cylindrical embossing plate that also serves as a cooling roller, and embossed at the same time as forming the surface sheet. At this time, a resin sheet (second base material) inserted into the back side of the top sheet and used as a base sheet is heat-sealed to perform doubling embossing at the same time as film formation.
(D) As disclosed in JP-A-57-87318, JP-A-7-32476, etc., the surface of a cylindrical embossing plate is coated with an uncured liquid of an ionizing radiation curable resin. Further, a base sheet made of a resin sheet or the like is superimposed thereon, and ionizing radiation is irradiated to cure the uncured liquid material to obtain a cured material. At that time, after the cured product is adhered to the base sheet, the mold is released from the embossing plate to form a substrate comprising the base sheet and the cured product on the base sheet, thereby embossing the substrate.
(E) Impregnated paper obtained by impregnating paper such as titanium paper with uncured thermosetting resin such as melamine resin is placed on a backing material such as core paper or wood plywood, and a plurality of these are placed A thermosetting resin decorative material is produced by laminating and integrating each layer by hot-press molding the layers. At that time, by inserting an embossing plate on the surface side of the impregnated paper, the thermosetting resin is impregnated and hardened to form a decorative material, and the surface is embossed simultaneously with the hot press.

In addition, thermoplastic resins are typically used as the material of the substrate used in the embossing methods (A) to (C), and the material of the substrate used in the embossing method (D) is typically In (E), an ionizing radiation-curable resin is used, and in the embossing method (E), a thermosetting resin is typically used as the material of the base material.

The decorative material 30 can be obtained as described above.

Next, decorative materials as modifications of the decorative materials 10, 20, 30, and 50 described above will be described. The layer structure is shown in FIGS. 10(a) to 10(c). Here, FIGS. 10A to 10C are described based on the decorative material 10, but other forms of decorative material can be similarly considered.

The decorative material 10' having the structure shown in FIG. 10(a) is a single-layered decorative material. Such a decorative material 10' can be obtained by, for example, embossing the base material 11 made of a thermoplastic resin sheet by heating and softening it and pressing an embossing plate. As a result, on the surface of the substrate 11, a pattern is formed by the pattern forming layer 12 composed of the convex linear portions 13 and the concave linear portions 14 having desired uneven shapes. In this configuration, there is no additional decorative layer, but even if the base material 11 is transparent, by laminating it on another material, the surface can be decorated by making use of the pattern of the other material. Further, the substrate 11 may be appropriately colored with a coloring agent such as brown or gray. In this case, the substrate itself becomes the decorative layer.

A decorative material 10'' having the structure shown in FIG. 10(b) has a structure in which a decorative layer 11a is formed on the back side of the base material 11 in contrast to the structure shown in FIG. 10(a). In order to produce the decorative material 10'' having such a structure, for example, a transparent resin sheet is used as the base material 11 so that the decorative layer 11a can be seen through, and the back side of the base material 11 is decorated. After the layer 11a is printed and formed, the layer 11a is softened by heating and embossed by pressing it against the surface facing the embossing plate.

The decorative material 10''' having the structure shown in FIG. 10(c) has the structure shown in FIG. 10(b). This is an example in which another base material 11b is laminated as a base sheet. In order to produce the decorative material 10''' having such a structure, the decorative layer 11a is formed by printing on the front side of the base material 11b made of a colored opaque thermoplastic resin sheet as a base sheet. This base sheet and a substrate 11 made of a transparent thermoplastic resin sheet serving as a surface sheet are laminated by thermal fusion using the doubling embossing method, and at the same time a desired pattern is embossed on the surface of the substrate 11 .

Applications of the decorative materials described above are not particularly limited, but examples include interior materials for buildings such as walls, floors, and ceilings; exterior materials for exterior walls, roofs, gates, fences, and fences; Fittings such as frames, doors, and door frames; surface materials for fixtures such as rims, baseboards and handrails; surface materials for housings of home electric appliances such as TV receivers and refrigerators; surface materials for furniture such as chests of drawers; , surface materials for containers such as resin bottles, interior or exterior materials for vehicles, interior or exterior materials for ships, and the like.

Reference Signs List 10, 20, 30, 50 Decorative material 11, 21 Base material 12, 22, 32, 52 Pattern forming layer 13, 23, 34a, 35a, 36a Protruding filamentary portions 14, 24, 34b, 35b, 36b Concave filamentary portions

Claims (6)

A decorative material having a pattern formed on its surface,
The pattern is a form in which a plurality of convex filaments and a plurality of concave filaments are alternately arranged,
When the imaginary surface including the apexes of the plurality of ridges is a pattern apex enveloping surface, the pattern apex enveloping surface has irregularities,
The unevenness of the pattern top enveloping surface is formed by the heights of the plurality of ridges being different.is being,
A substrate, and a pattern forming layer disposed on one surface of the substrate and forming the pattern,
The unevenness of the top enveloping surface of the pattern is formed by having the unevenness on the surface of the base material.
cosmetic material. A decorative material having a pattern formed on its surface,
The pattern is a form in which a plurality of convex filaments and a plurality of concave filaments are alternately arranged,
When the imaginary surface including the apexes of the plurality of ridges is a pattern apex enveloping surface, the pattern apex enveloping surface has irregularities,
W_a, the width of the recessed line portion is W_bas W_a/W_bis a duty ratio, patterns having a relationship that the duty ratio is constant irrespective of the height H of the protruding linear portion are included.fruit,
A substrate, and a pattern forming layer disposed on one surface of the substrate and forming the pattern,
The unevenness of the pattern top enveloping surface is formed by having the unevenness on the surface of the base material.
cosmetic material. A decorative material having a pattern formed on its surface,
The pattern is a form in which a plurality of convex filaments and a plurality of concave filaments are alternately arranged,
When the imaginary surface including the apexes of the plurality of ridges is a pattern apex enveloping surface, the pattern apex enveloping surface has irregularities,
When W _{a is the width of the convex filament portion, W b is the width of the concave filament portion, and W a /W b is the duty} ratio, the higher the height H of the convex filament portion, the higher the duty ratio. Including a pattern with a decreasing relationship,
cosmetic material. A substrate, and a pattern forming layer disposed on one surface of the substrate and forming the pattern,
4. The decorative material according to claim 3 , wherein the unevenness of the top enveloping surface of the pattern is formed by having unevenness on the surface of the base material. 5. The decorative material according to any one of claims 1 to 4, wherein the width of said protruding linear portion is less than 30 µm. The decorative material according to any one of claims 1 to 5, comprising a portion where H/W _a is greater than 1, where W _a is the width of the protruding filament portion and H is the height of the protruding filament portion. .

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