JP7392352B2 - Decorative material - Google Patents

Description

The present invention relates to decorative materials.

Interior parts of buildings such as walls, ceilings, and floors, or exterior parts such as external walls, roofs, eaves, fences, gates, window frames, various doors such as entrance doors, handrails, baseboards, edges, and window frames. In addition to fittings and fixtures such as door frames and moldings, kitchen equipment or kitchen furniture, furniture or home appliances, decorative surface panels for cabinets such as OA equipment, interior and exterior components of vehicles, etc. Various members such as resin members, wooden members, and metal members are used as adherends, and decorative materials are bonded to these adherends.

A decorative material used for the above purpose, for example, has a pattern made of a low-gloss pattern ink layer, a surface protective layer, etc. on a base material, and has a gloss difference between the pattern area and the surrounding area. A decorative material having the following structure has been proposed. In this decorative material, due to the visual effect caused by the difference in gloss (also referred to as the "gloss matte effect"), the embossed material has no actual recesses formed and the surface is essentially flat. Even without (forming) processing, the pattern area, which has a relatively low gloss compared to the surrounding area, can be recognized as a recess just by the printing and coating process (for example, Patent Documents 1 and 2).

Japanese Unexamined Patent Publication No. 49-39166 Japanese Patent Application Publication No. 2005-125780

By the way, with the recent increase in consumers' preference for luxury goods or the diversification of their preferences, the demands for design in the above-mentioned interior materials, exterior materials, etc. are becoming more complex and stricter. . The decorative materials described in Patent Documents 1 and 2 have an uneven feel due to the difference in gloss, and although they have excellent design properties, the uneven feel has two levels (or two gradations) of concave parts and convex parts. ), which is monotonous, and there are few visual unevenness levels. As a result, there are cases where it is not possible to meet the demands for design, which are becoming more complex and strict.

The present invention has been made under these circumstances, and provides a decorative material that has a high tactile sensation due to its physically uneven shape and an excellent design due to its physical uneven shape and visual unevenness. The purpose is to

As a result of intensive research to solve the above problems, the present inventors have found that the above problems can be solved by an invention related to a decorative material having the following configuration.

[1] A decorative material comprising a base material, a pattern layer covering a part of one side of the base material, and a raised printing layer,
The raised printing layer covers at least a part of the non-forming area of the pattern layer in plan view,
having a convex portion corresponding to the raised print layer on the outermost surface of the decorative material directly above the raised print layer;
The maximum height (Sz) measured in accordance with ISO 25178-6:2010 is 15 μm or more,
Decorative materials.
[2] The decorative material according to [1] above, further comprising a surface protective layer provided on the entire surface of the decorative material so as to cover the base material, the pattern layer, and the raised print layer.
[3] The decorative material according to [1] or [2] above, which has a wide-area decorative layer between the base material and the pattern layer, the covering area of which is larger in plan view than the pattern layer.
[4] The decorative material according to any one of [1] to [3] above, wherein the raised printing layer has fine convex portions corresponding to the raised auxiliary agent on its surface.
[5] The makeup according to any one of [1] to [4] above, further comprising an adherend on the surface of the base material opposite to the surface having the pattern layer, with an adhesive layer interposed therebetween. Material.

According to the present invention, it is possible to provide a decorative material that has a high tactile sensation due to the physical unevenness and excellent design properties due to the physical unevenness and visual unevenness.

FIG. 1 is a schematic perspective view showing the appearance of an example of the decorative material of the present invention. FIG. 1 is a schematic cross-sectional view showing the layer structure of an example of the decorative material of the present invention. FIG. 1 is a schematic perspective view showing the appearance of an example of the decorative material of the present invention. FIG. 1 is a schematic cross-sectional view showing the layer structure of an example of the decorative material of the present invention. 1 is a SEM image of the surface of the decorative material obtained in Example 1.

[Decorative materials]
The decorative material of the present invention will be explained below. In addition, in this specification, numerical values related to "more than", "less than", and "~" in the description of numerical ranges are numerical values that can be combined arbitrarily, and the numerical values in the examples can be used as the upper and lower limits of the numerical range.

The decorative material of the present invention is a decorative material comprising a base material, a pattern layer covering a part of one surface of the base material, and a raised print layer, wherein the raised print layer is larger than the pattern layer in plan view. Covers at least a portion of the non-forming area, has a convex portion corresponding to the raised print layer on the outermost surface of the decorative material directly above the raised print layer, and complies with ISO 25178-6:2010. The maximum height (Sz) measured by the method is 15 μm or more.

In the present invention, "planar view" refers to the appearance of the decorative material when looking down on the surface of the decorative material on the raised print layer (or surface protective layer if it has a surface protective layer) side, that is, the thickness direction and line of sight of the decorative material. It refers to the appearance when looking down at an angle between 0° and 90°. A typical example of "planar view" will be explained with reference to FIG. 1 and FIG. In this case, the angle between the thickness direction of the decorative material and the viewing direction is 0°.

The structure of the decorative material of the present invention will be explained below using FIGS. 1 to 4.
FIG. 1 is a schematic perspective view showing an example of a preferable appearance of the decorative material 10 of the present invention. It is shown that it has a shaped part 6. In FIG. 1, the primer layer 3 is provided to at least cover the pattern layer 2, but is not shown in this figure. Further, FIG. 3 is a schematic perspective view showing an example of a preferable appearance of the decorative material 10 of the present invention. 4, a surface protective layer 5 and a convex portion 6 are shown.
More specifically, a surface protective layer 5 is provided on the surface of the decorative material 10, and the raised printed layer 4 is provided on the outermost surface of the decorative material 10 (on the surface of the surface protective layer 5) directly above the raised printed layer 4. The raised print layer 4 covers at least a part of the non-forming area of the pattern layer 2 in plan view, and covers 30% or more of the entire surface of the decorative material. It can be seen that it is provided so as to cover it.

FIG. 2-a, which is a schematic cross-sectional view showing an example of a preferable cross-section of the decorative material 10 of the present invention, shows a pattern layer 2 covering a part of one surface 1F of the base material 1, at least the pattern layer 2. A primer layer 3 is provided so as to cover (in the form of Figure (2-a), cover the entire surface including the area where the pattern layer 2 is formed and the area where the pattern layer 2 is not formed). A raised print layer 4 is provided so as to cover at least a part of the area where the layer 2 is not provided (non-forming area), and a surface protective layer 5 is formed of the base material 1, the pattern layer 2, the primer layer 3, and the raised print layer 4. The surface of the surface protective layer 5, which is the outermost surface of the decorative material 10 and directly above the raised printed layer 4, is provided on the entire surface of the decorative material so as to cover the raised printed layer 4, and has a convex portion corresponding to the raised printed layer 4. 6.

As shown in Figure (2-a), the primer layer 3 may be provided to cover at least the pattern layer 2, or may be provided to cover the entire surface of the decorative material. It does not have to be provided to cover the entire surface as shown in Figure (2-c). As shown in Figure (2-c), when the primer layer 3 is provided in a part, the raised printing layer 4 is provided on one side 1F of the base material 1, and the raised printing layer 4 is provided on one side 1F of the base material 1. In a region where none of the pattern layer 2, the primer layer 3, and the raised printing layer 4 are provided, the surface protection layer 5 may be provided on and in contact with the base material 2.

As shown in FIG. 2-b, the decorative material 10 of the present invention may have a wide-area decorative layer 7 between the base material 1 and the pattern layer 2, and the wide-area decorative layer 7 may be provided so as to cover the entire surface of the decorative material 10 (so-called "solid layer"), or may be a layer forming a pattern. When the wide-area decorative layer 7 is a layer forming a pattern, the pattern layer 2 and the wide-area decorative layer 7 exist complementary to each other in plan view, and together they cover one surface 1F of the base material 1. Cover the entire surface. In the case of a designed appearance expressed by a normal decorative material, the large-area decorative layer 7 is often a layer provided with a relatively larger covered area than the pattern layer 2 in plan view.
Furthermore, if necessary, the difference between the pattern layer 2 and the wide-area decorative layer 7 can be changed by, for example, changing the amount of the matting agent added, the particle size, or both of these. A desired difference in glossiness (difference in gloss) can be provided between the two.

FIG. 4-a, which is a schematic cross-sectional view showing an example of a preferable cross-section of the decorative material 10 of the present invention, shows a pattern layer 2 covering a part of one surface 1F of the base material 1, and a pattern layer 2 provided thereon. The raised print layer 4 is provided so as to cover at least a part of the non-formed area (non-formed area), and the decorative material is provided so that the surface protection layer 5 covers the base material 1, the pattern layer 2, and the raised print layer 4. It is shown that the surface of the surface protective layer 5, which is provided on the entire surface of the decorative material 10 and is the outermost surface of the decorative material 10, directly above the raised printed layer 4 has a convex portion 6 corresponding to the raised printed layer 4. . In this way, the decorative material 10 of the present invention also has an aspect in which the primer layer 3 is not included.
Figure (4-b), which is a cross-sectional schematic diagram showing an example of a preferable cross-section of the decorative material 10 of the present invention, shows a large area decoration between the base material 1 and the pattern layer 2 in the above figure (4-a). A layer 7 is shown provided. Further, in Figure (4-c), which is a cross-sectional schematic diagram showing an example of a preferable cross-section of the decorative material 10 of the present invention, there is a wide area between the base material 1 and the pattern layer 2 in the above figure (4-a). An area decoration layer 71 is provided as a solid layer covering the entire surface, and furthermore, the pattern layer 2 and a wide area decoration layer 72 provided in a pattern on the wide area decoration layer 71 are arranged complementary to each other in a plan view. A case is shown in which both of them are provided so as to cover the entire surface of one side 1F of the base material.

(About surface shape properties)
The decorative material 10 of the present invention has a surface shape in which the maximum height (Sz) measured in accordance with ISO 25178-6:2010 is 15.0 μm or more. If the maximum height (Sz) is less than 15.0 μm, a high tactile sensation cannot be obtained, and an excellent design due to the physical unevenness shape and visual unevenness cannot be obtained. The maximum height (Sz) is a numerical value representing the distance from the highest point to the lowest point on the surface. When a protective layer is provided, this is an index indicating the height difference from the surface protective layer (the portion corresponding to the pattern layer).
From the viewpoint of improving tactility and design, the maximum height (Sz) is preferably 20.0 μm or more, more preferably 25.0 μm or more, and still more preferably 40.0 μm or more. The upper limit of the maximum height (Sz) is not particularly limited because the larger the height, the better the tactile feel and design, but it is subject to surface characteristics such as stain resistance and abrasion resistance, stability as a decorative sheet, and manufacturing. Considering ease of application, etc., the thickness is 100.0 μm or less, preferably 85.0 μm or less.
In this specification, numerical values regarding surface shape characteristics are the average values of numerical values measured at arbitrary 10 points on the decorative sheet using a method compliant with ISO 25178-6:2010.

The decorative material 10 of the present invention preferably has a surface shape in which the height of the protruding peaks (Spk) measured in accordance with ISO 25178-6:2010 is 4.1 μm or more. . The protruding peak height (Spk) is a numerical value representing the average height of the protruding peaks, and specifically, it is an index indicating the state of local swelling of the convex portions and preferably fine convex portions in the decorative material. Therefore, when the protruding peak height (Spk) is 4.1 μm or more, the tactile sensation is mainly improved.
From the viewpoint of improving the tactile sensation, the height of the protruding peak (Spk) is more preferably 5.0 μm or more, still more preferably 6.0 μm or more, and even more preferably 7.0 μm or more. There is no particular limit to the upper limit of the height of the protruding peaks (Spk), as the tactile sensation tends to improve as the height increases, but it is subject to surface characteristics such as stain resistance and abrasion resistance, stability as a decorative sheet, and manufacturing Considering ease of fabrication, etc., the thickness is 30.0 μm or less, preferably 25.0 μm or less.

The decorative material 10 of the present invention preferably has a surface shape in which the maximum peak height (Sp) measured in accordance with ISO 25178-6:2010 is 1.0 μm or more. The maximum peak height (Sp) is a numerical value representing the maximum height from the average surface of the surface, and specifically, the height of a convex part from the surface of a decorative material, or a fine convex part that is preferably provided. When the maximum peak height (Sp) is 1.0 μm or more, the tactile sensation is mainly improved.
From the viewpoint of improving the tactile sensation, the maximum peak height (Sp) is more preferably 5.0 μm or more, still more preferably 10.0 μm or more, even more preferably 15.0 μm or more. The upper limit of the maximum peak height (Sp) is not particularly limited because the larger the height, the better the tactility, but it is subject to surface properties such as stain resistance and abrasion resistance, stability as a decorative sheet, and ease of manufacturing. Considering the height, it is 60.0 μm or less, preferably 45.0 μm or less.

The decorative material 10 of the present invention preferably has a surface shape in which the arithmetic mean height (Sa) measured in accordance with ISO 25178-6:2010 is 2.0 μm or more. The arithmetic mean height (Sa) is a numerical value representing the average of the absolute values of the heights of concave portions and convex portions from the average plane of the surface, specifically, the convex portions, and the fine convex portions that are preferably provided. The height of the portion forming the convex portion relative to the average surface of the material, and the pattern layer forming the concave portion relative to the overall surface of the decorative material (or the pattern layer in the surface protective layer if a surface protective layer is provided) It is the average value of the depth of the part forming a recess relative to the average surface of a decorative material such as the area corresponding to When the thickness (Sa) is 2.0 μm or more, the design property is improved mainly due to the physical unevenness shape and the visual unevenness.
From the viewpoint of improving the tactile sensation, the arithmetic mean height (Sa) is more preferably 2.3 μm or more, still more preferably 2.5 μm or more, and even more preferably 3.0 μm or more. The upper limit of the maximum peak height (Sp) is not particularly limited as the design tends to improve as the height increases, but it is subject to surface properties such as stain resistance and abrasion resistance, stability as a decorative sheet, and manufacturing efficiency. Considering ease of use, the thickness is 15.0 μm or less, preferably 10.0 μm or less, and more preferably 5.0 μm or less.

As described above, the decorative material of the present invention has specific surface shape characteristics, and as a result, the decorative material of the present invention has a high tactile sensation, and also has physical unevenness and visual unevenness. It also has an excellent design due to its tactile feel. In order for the decorative material of the present invention to have the above-mentioned surface shape characteristics, it is necessary to have a specific layer structure.
Next, each layer constituting the decorative material of the present invention will be explained in more detail.

(Base material 1)
The base material 1 can be any material that is normally used as a base material for decorative materials without any limitation, and representative examples include base materials made of paper, non-woven fabric or woven fabric, resin, wood, metal, non-metallic inorganic materials, etc. It can be mentioned. There is no particular limit to the thickness of the base material, and a film, sheet, or plate-like material can be used as desired, but it is usually about 20 to 300 μm for a film or sheet, and 500 μm to 500 μm for a plate. A length of about 10 cm is used.

Examples of the paper base material include kraft paper, titanium paper, linter paper, parchment paper, glassine paper, parchment paper, resin-impregnated paper, thin paper, and Japanese paper. Examples of base materials for nonwoven or woven fabrics include inorganic fibers made of inorganic materials such as glass, alumina, silica, and carbon, and organic fibers made of various synthetic resins such as polyester resin, acrylic resin, polyethylene, and polypropylene. Examples include base materials such as nonwoven fabrics or woven fabrics, and composites thereof.

Examples of resins include polypropylene, polyethylene, polyolefin thermoplastic elastomers, polyolefin resins such as ionomers, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and ethylene glycol-terephthalic acid-isophthalic acid. Copolymers, polyester resins such as polyester thermoplastic elastomers, acrylic resins such as polymethyl (meth)acrylate, polybutyl (meth)acrylate, methyl (meth)acrylate-butyl (meth)acrylate copolymers, polyester resins, polycarbonate resins Examples include resin base materials made of thermoplastic resins such as , acrylonitrile-butadiene-styrene resin (hereinafter also referred to as "ABS resin"), and vinyl chloride resin.

Examples of the wood include wood base materials made of wood of various tree species such as cedar, cypress, pine, oak, lauan, teak, and rubber wood. The wood base material can be in the form of a film or sheet called veneer, or in the form of a board such as veneer, plywood, laminated wood, particle board, or fiberboard.
Examples of the metal include metal substrates made of iron, aluminum, copper, tin, titanium, alloys containing at least one of these metals (eg, carbon steel, stainless steel, duralumin, brass, bronze, etc.).
Furthermore, examples of nonmetallic inorganic materials include cement, gypsum, calcium silicate, ceramics, glass, and various ceramics.

The base material may be colored or uncolored (may be transparent), and if it is colored, there is no particular restriction on the manner of coloring, and it may be transparently colored, Opaque coloring (concealing coloring) may be used, and these can be selected arbitrarily.

When the base material is colored, examples of colorants include white pigments such as titanium white, inorganic pigments such as iron black, yellow lead, titanium yellow, Bengara, cadmium red, ultramarine blue, and cobalt blue; quinacridone red. , isoindolinone yellow, phthalocyanine blue, nickel-azo complex, azomethine azo black pigment, perylene black pigment, and other organic pigments or dyes; metal pigments made of flaky foil pieces of aluminum, brass, etc.; titanium dioxide-coated mica, bases Examples include coloring agents such as pearlescent pigments made of scaly foil pieces such as lead carbonate. For example, if the surface hue of the adherend material to which the decorative sheet is attached varies, and you want to hide the surface hue and improve the stability of the color tone of the pattern layer and the wide-area decorative layer provided as desired. An inorganic pigment such as a white pigment may be used.

In the case of coloring the resin, any of the following methods can be used: adding a coloring agent into the resin (kneading, kneading), forming a coating film containing a resin and a coloring agent, etc. In the case of coloring paper, nonwoven fabrics, or woven fabrics, it can be carried out by any means such as mixing with pulp or fiber materials, or by forming a coating film, or by a combination of these methods.
In the case of coloring wood, it can be carried out by dyeing with a dye, forming a coating film, or a combination thereof. In the case of metal coloring, in addition to coating film formation, an electrolytic coloring method in which a metal oxide film is formed on the surface using an anodic oxidation method can be employed. In the case of non-metallic inorganic materials, it can be carried out by forming a coating film, adding it to the base material, or a combination thereof.

Additives may be added to the base material, if necessary. Additives are mainly used for resins, such as inorganic materials such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, antioxidants, ultraviolet absorbers, and light stabilizers. etc. The blending amount of the additive is not particularly limited as long as it does not impede the processing properties, and can be set as appropriate depending on the required properties.

From the viewpoint of improving the weather resistance of the decorative material of the present invention, among the above additives, it is preferable to use weathering agents such as ultraviolet absorbers and light stabilizers.
As the UV absorber, UV absorbers commonly used in cosmetic materials can be used without any particular restrictions, such as benzotriazole UV absorbers, benzophenone UV absorbers, triazine UV absorbers, and hydroxyphenyltriazine UV absorbers. agents, etc. As the light stabilizer, any light stabilizer commonly used in cosmetic materials can be used without particular limitation, and examples thereof include hindered amine light stabilizers such as piperidinyl sebacate light stabilizers. Further, these ultraviolet absorbers and light stabilizers may have a reactive functional group having an ethylenic double bond such as a (meth)acryloyl group, vinyl group, or allyl group in the molecule.
These UV absorbers, weathering agents such as light stabilizers, and other various additives can be used alone or in combination.

In the present invention, the above-mentioned base materials can be used alone or in combination. It may be a combination of multiple paper base materials, a paper base material and a fiber base material, a paper base material and a resin base material, a fiber base material and a resin base material, a paper base material, a fiber base material and a resin base material. It may also be a combination of materials. Furthermore, the resin base material may have either a single layer of the above resin or a multilayer structure of the same or different resins.

The shape of the base material is not particularly limited and may be selected as desired.For example, it may be flat, it may have a curved surface, or it may have a non-flat shape such as one with corners. It may be of. Although FIGS. 1 and 2 show a flat plate-shaped (also referred to as "sheet-shaped") decorative material, the shape of the decorative material of the present invention is not limited to this. Considering the ease of manufacturing the decorative material, its uses, ease of processing, etc., it is preferable to have a flat plate shape.
The thickness of the base material is preferably 20 μm or more, more preferably 30 μm or more, and even more preferably 40 μm or more, considering surface properties such as abrasion resistance, weather resistance, and scratch resistance, processing characteristics, and ease of handling. The upper limit is preferably 200 μm or less, more preferably 160 μm or less, and even more preferably 100 μm or less.

In order to improve interlayer adhesion between the base material and other layers, strengthen adhesion to various adherends, etc., the base material is subjected to physical treatments such as oxidation or roughening on one or both sides. A surface treatment such as a surface treatment or a chemical surface treatment can be performed.
Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone-ultraviolet treatment, etc., and examples of the roughening method include sandblasting, solvent treatment, and the like. These surface treatments are appropriately selected depending on the type of substrate, but corona discharge treatment is generally preferably used in terms of surface treatment effects and operability.
In addition, in order to improve interlayer adhesion between the base material and other layers, strengthen adhesion to various adherends, etc., treatments such as forming an easy-to-adhesion layer on at least one surface of the base material are performed. It may be applied.

(Picture layer 2)
The pattern layer 2 is provided so as to cover a part of one side of the base material, and is a layer that imparts design to the decorative material of the present invention, and in particular provides a visual unevenness due to the difference in gloss with the raised print layer. This is an effective layer when applying. In addition, by combining the pattern layer with the raised print layer and convex portions described below, the decorative material of the present invention has a physical uneven shape as well as a visual uneven feeling, and has an extremely high tactile feel and design quality. Become what you have.
In the decorative material of the present invention, the design may be imparted by the pattern layer alone, or may be imparted by the pattern layer consisting of the pattern layer and a wide-area decorative layer to be described later. It is preferable to impart design properties as a pattern layer consisting of a pattern layer and a large-area decorative layer.
To give a specific example of a preferred embodiment, the pattern layer is formed with a relatively low-gloss ink, the raised print layer is formed with a relatively high-gloss ink, and the pattern layer is formed with a relatively high-gloss ink, so that the pattern layer is formed with a relatively low-gloss ink, so that the pattern layer is By configuring it to have relatively low gloss (that is, low gloss), it is possible to effectively create a visual appearance in which the pattern layer is recessed relative to the raised print layer. .

The pattern imparted by the pattern layer or the pattern layer consisting of the pattern layer and the large-area decorative layer may be selected as desired without any particular restriction. (patterns), stone grain patterns that imitate rock surfaces such as cleavage planes of granite plates, fabric patterns that imitate the grain or cloth-like patterns, and leather (including artificial or synthetic leather) that expresses the grain of leather (including artificial or synthetic leather). Patterns such as grain patterns, tiling patterns, brickwork patterns, hair lines, parallel grooves, satin finishes, sand grains, letters, symbols, geometric patterns, and patterns such as marquetry and patchwork that combine these patterns are included. In addition, examples of patterns that are a combination of these include, for example, patterns that resemble the surface of artificial stone, which is made by mixing crushed stones such as marble with white cement, solidifying it, and polishing it to give it a marble-like finish.
Among the above, wood grain patterns are preferred from the viewpoint of making full use of the characteristics of the decorative material of the present invention, which is that it has an extremely high tactile feel and design due to its uneven shape. The wood grain pattern includes a straight grain pattern, a board grain pattern, a heather grain pattern, a wood grain pattern, etc., and any of them may be used.

The pattern layer preferably has lower gloss (matte or low gloss) than the surrounding area from the viewpoint of improving the visual unevenness caused by the difference in gloss.
When the wood grain pattern exemplified as a preferable pattern is adopted as the pattern of the decorative material of the present invention, the wood grain pattern has a lower gloss (matte or low gloss) and concave conduit portion, a higher gloss (glossy) There is also a spring wood portion that is highly glossy and has convex portions, and an autumn wood portion that is highly glossy and has convex portions (shiny portion). In the decorative material of the present invention, the lower gloss (matte or low gloss) conduit portion is formed with a relatively low gloss pattern layer, and the higher gloss (glossy or high gloss) wood surface portion is formed with a relatively low gloss pattern layer. The spring wood part, the fall wood part, or both the spring wood part and the autumn wood part are formed with a wide-area decorative layer, and the direct area of the wide-area decorative layer is further covered with a relatively high-gloss raised printing layer. , and it is preferable that the thickness of the raised printing layer is thicker than that of the pattern layer. With this configuration, the outermost surface of the decorative material directly above the pattern layer that expresses the conduit portion has a relatively physical shape compared to the outermost surface of the raised print layer that expresses the wood grain portion that becomes the convex portion. By creating concavities and visually low gloss, the visual unevenness can be improved, resulting in an extremely high tactile feel and visual design that resembles the grain pattern on the surface of natural wood boards. .

In addition, when adopting the tiling pattern or the brickwork pattern exemplified as a preferred embodiment of the decorative material of the present invention, the tiling pattern or the brickwork pattern has a lower gloss and a concave joint groove portion, a higher gloss Also, there is a tile or brick part that becomes a convex part. In the decorative material of the present invention, the joint groove portions with lower gloss and concave portions are formed with a relatively low gloss pattern layer, and the tile or brick portions with higher gloss and convex portions are formed with a wide area decorative layer. Furthermore, it is preferable that the area directly above the wide-area decorative layer be covered with a relatively high-gloss printed embossed layer, and that the printed embossed layer is thicker than the pattern layer. With such a configuration, the outermost surface of the decorative material directly above the pattern layer that expresses the joint groove portion has a relatively physical shape compared to the outermost surface of the raised printing layer that expresses the tile or brick portion that becomes the convex portion. By forming concave areas and visually having low gloss, the visual unevenness can be improved, and an extremely high tactile feel and visual design similar to actual tiling or brickwork can be obtained. becomes.

Furthermore, in the present invention, it is also possible to express a more delicate visual unevenness by, for example, providing a low-gloss pattern layer directly above or below a non-low-gloss pattern layer. Neither the pattern layer nor the large-area decorative layer has low gloss, and there is a difference in gloss between the pattern layer and the raised print layer, and a difference in gloss between the primer layer and the raised print layer, which are provided to cover at least the pattern layer, which will be described later. It is also possible to express designs with low gloss and high gloss. That is, in the present invention, a visual unevenness can be freely expressed by combining the gloss levels of various layers such as a pattern layer, a wide-area decorative layer, a pattern layer made of these, a raised print layer, and a primer layer. In addition, by combining these layers with physical irregularities, it is possible to express extremely high tactile sensation and design.

As an example of the application of the pattern layer other than the above, for example, in the case of a pattern on the cleavage plane of a granite plate, the lowest gloss biotite is surrounded by higher gloss feldspars, and even higher gloss quartz is mixed. Biotite, which has the lowest gloss, or the boundary between biotite, feldspars, and quartz can be formed with a pattern layer, and higher gloss feldspars and quartz can be formed with a wide-area decorative layer. In addition, in a veneer pattern in which boards are combined, a lower-gloss boundary between boards can be formed by a pattern layer, and the rest can be formed by a wide-area decorative layer.
In this way, the pattern layer can be used to form low-gloss (matte or low-gloss) portions, and also to improve the physical appearance of the pattern imparted by the pattern layer or the pattern layer consisting of the pattern layer and the large-area decorative layer. It is preferably used for forming a portion that will become a concave portion.

For forming the pattern layer, it is preferable to use a resin composition containing at least a binder resin and, if necessary, a matting agent, and other components used as desired, such as coloring agents such as pigments and dyes, and extender pigments. , a stabilizer, an ultraviolet absorber, a light stabilizer, a solvent, etc. can be used. That is, the pattern layer is a layer containing at least a binder resin and a matting agent, and may also contain other components as desired.
In addition, in the case where a matting agent is added to the primer layer, if the desired low gloss can be sufficiently expressed in the pattern layer by the primer layer, the addition of the matting agent to the pattern layer can be omitted. .

There are no particular restrictions on the binder resin, and examples include urethane resin, acrylic polyol resin, acrylic resin, polyester resin, alkyd resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate copolymer. Preferred examples include resins such as vinyl chloride-vinyl acetate-acrylic copolymer, nitrocellulose (nitrified cotton), and cellulose acetate. Furthermore, a curable resin such as a two-component curable urethane resin containing polyol as a main ingredient and isocyanate as a curing agent may also be used. These can be used alone or in combination.

As matting agents, inorganic fillers such as silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, synthetic silicate, and silicate fine powder; acrylic resin, urethane resin, nylon Examples include organic fillers such as resins, polypropylene, and urea resins. By including the matting agent in the pattern layer, the pattern layer has lower gloss, so that it is possible to improve the visual unevenness caused by the difference in gloss.

The volume average particle diameter of these matting agents is preferably 0.5 to 25 μm, more preferably 1 to 15 μm, and even more preferably 3 to 10 μm.
Further, the content of the matting agent relative to 100 parts by mass of the binder resin in the pattern layer is preferably 0.5 parts by mass or more, more preferably 1 part by mass or more, still more preferably 2 parts by mass or more, and the upper limit is The amount is usually 100 parts by mass or less, preferably 50 parts by mass or less, more preferably 20 parts by mass or less, even more preferably 10 parts by mass or less. When the content of the matting agent is within the above range, the pattern layer becomes visible as a layer with lower gloss, so it is possible to improve the visual unevenness caused by the difference in gloss, and the resin composition Since the coating performance is improved without the thixotropic properties of the coating becoming extremely high, the design quality is improved as a result.

Examples of coloring agents such as pigments and dyes that can be used in the pattern layer include the same coloring agents such as pigments and dyes that can be used in the above-mentioned base material. You can select it as appropriate.
The pattern layer may contain weathering agents such as ultraviolet absorbers and light stabilizers from the viewpoint of improving weather resistance. Examples of the ultraviolet absorber and light stabilizer include those that can be included in the base material, and they may be appropriately selected from these depending on the desired pattern.

The thickness of the pattern layer may be appropriately selected depending on the desired pattern, and is preferably 0.5 μm or more, more preferably 1 μm or more, even more preferably 2 μm or more, and the upper limit is preferably 15 μm or less, more preferably It is 10 μm or less, more preferably 8 μm or less. By setting the thickness of the pattern layer within the above range, the decorative design is improved, and the characteristics of the surface shape of the decorative material, such as the above-mentioned maximum height (Sz), can be easily adjusted.

(Primer layer 3)
The primer layer 3 is provided so as to cover at least the above-mentioned pattern layer in a plan view, and is preferably provided first to protect the pattern layer, and can also make the pattern layer lower in gloss if necessary. It is a layer that has a function and can also improve the interlayer adhesion between the base material, the pattern layer, the raised print layer, and the preferably provided surface protective layer.

For forming the primer layer, it is preferable to use a resin composition containing at least a binder resin and a matting agent, and other components used as desired, such as extender pigments, stabilizers, ultraviolet absorbers, light stabilizers, An appropriate mixture of solvents and the like can be used. That is, the primer layer is a layer containing at least a binder resin and a matting agent, and may also contain other components used as desired. By including the matting agent, the pattern layer becomes visible as a layer with lower gloss, thereby improving the visual unevenness caused by the difference in gloss.
However, if the pattern layer itself can sufficiently exhibit the desired low gloss, addition of the matting agent to the primer layer may be omitted.

When a primer layer is provided, it is sufficient that it is provided so as to cover at least the above-mentioned pattern layer, and as shown in Figures (2-a) and (2-b), it covers the pattern layer and covers the entire surface of the decorative material. It may be provided so as to cover the area, or it may be provided partially so as to cover only the area directly above the pattern layer, or the area directly above the pattern layer and its vicinity, as shown in Figure (2-c). It's okay. From the viewpoint of improving the interlayer adhesion between the base material, the pattern layer, the raised printing layer, and the preferably provided surface protective layer, the pattern layer is coated as shown in Figures (2-a) and (2-b), In addition, it is preferable that the decorative material be provided so as to cover the entire surface of the decorative material.

Examples of the binder resin and matting agent used for forming the primer layer include the same binder resin and matting agent that can be used for forming the above-mentioned pattern layer, and the binder resin and matting agent may be appropriately selected from these as desired. Bye. Further, the content of the matting agent is also the same as the content of the matting agent in the above-mentioned pattern layer.

The thickness of the primer layer is not particularly limited as long as it can cover at least the pattern layer, and from the viewpoint of efficiently protecting the pattern layer, making the pattern layer lower in gloss, and improving interlayer adhesion, Furthermore, from the viewpoint of ease of adjustment of the surface shape characteristics of the decorative material, such as the maximum height (Sz) mentioned above, the height based on the top surface of the pattern layer is preferably 0.1 μm or more, and more preferably 0.1 μm or more. Preferably it is 1 μm or more, more preferably 2 μm or more, and the upper limit is preferably 10 μm or less, more preferably 8 μm or less, and still more preferably 5 μm or less.

(raised printing layer 4)
The raised print layer 4 is a layer that covers at least a part of the area where the pattern layer 2 is not formed, that is, the area where the pattern layer 2 is not provided (hereinafter, the layer covered by the raised print layer) in plan view. The area ratio is sometimes referred to as the "coverage of the raised printing layer"). By providing the raised print layer, it is possible to develop a convex portion corresponding to the raised print layer on the outermost surface of the decorative material directly above the raised print layer, so that a physically uneven shape is formed in the decorative material of the present invention. It provides an extremely high tactile sensation. Further, due to the synergistic effect of this physical unevenness and the visual unevenness created by the above-mentioned pattern layer, it has an extremely high design quality.

The coverage rate of the raised printing layer over the entire surface of the decorative material is preferably 30% or more, more preferably 40% or more, and even more preferably is 50% or more, more preferably 70% or more. The upper limit is not particularly limited, but from the viewpoint of improving the feel and design, it is preferably 95% or less, more preferably 90% or less.
In the present invention, the coverage of the raised printed layer is determined by cutting out three test pieces of 30 cm x 30 cm from arbitrary locations on a decorative material measuring 1 m x 1 m, and performing image analysis on each of these test pieces. The coverage of the raised print layer is calculated and taken as the average value. In addition, if the size of the decorative material is not 1 m x 1 m, the ratio of the test piece size 30 cm x 30 cm to the above 1 m x 1 m size is the same, and three pieces are cut out to calculate the coverage.

For example, in FIGS. (2-a) to (2-c) and (4-a) to (4-c), the raised printing layer is only shown in the form where it is provided only in the area where the pattern layer is not formed. However, the raised printing layer may be provided on the pattern layer or partially overlapping the pattern layer.
In the present invention, the raised printing layer is preferably provided so as to cover 50% or more of the area where the pattern layer is not formed, that is, the area where the pattern layer is not provided. When the coverage rate of the raised print layer to the area where the pattern layer is not formed is 50% or more, the tactile sensation and design can be more efficiently improved by the physical unevenness shape and visual unevenness. From the same point of view, the coverage rate of the raised printing layer to the non-formation area of the pattern layer is preferably 60% or more, more preferably 65% or more, still more preferably 70% or more, and the upper limit is preferably 95%. It is preferably 90% or less.

Further, as shown in FIGS. 1 and 3, the raised printing layer may have a shape like a group of dot-like protrusions in a plan view where small protrusions are gathered, or an elliptical shape in a plan view that is larger than the protrusions. (In terms of three-dimensional shape, it may be a part of a spheroid or a three-dimensional shape similar to this). Those with an elliptical shape larger than the protrusions are formed by printing the resin composition in an elliptical shape from the beginning when printing the resin composition for forming the raised print layer to form the raised print layer. Alternatively, when printing small protrusions in clusters, the resin composition flows, levels, and hangs down (so-called "sagging") to connect, and as a result, the resin composition becomes smaller than the protrusions. It may also have a large elliptical shape. Therefore, although only an elliptical shape is shown in FIGS. 1 and 3, an irregular shape such as a plurality of protrusions connected with each other may be used.

In the present invention, it is preferable that the raised print layer includes a portion constituted by a group of protrusions, since a more delicate tactile sensation can be obtained, and it is also preferable from the point of view of design. In addition, in the present invention, the raised printing layer has not only a group of protrusions but also an elliptical or irregular shape in a plan view that is connected by sagging resin composition, so that, for example, wood grain In the case of using a pattern of a natural object such as a pattern, a more realistic texture can be obtained, and a high design quality can be obtained.

It is preferable to use a resin composition containing at least a binder resin to form the raised print layer, and other components used as desired, such as extender pigments, stabilizers, ultraviolet absorbers, light stabilizers, solvents, etc. An appropriate mixture can be used. That is, the built-up printing layer is a layer containing at least a binder resin, and may also contain other components that are used as desired according to the above-mentioned wishes.

As the binder resin used to form the raised print layer, it is preferable to use a curable resin from the viewpoint of improving the tactile sensation and design through the physical unevenness shape and visual unevenness.
As the curable resin, curable resins such as thermosetting resins, two-component curable resins, and ionizing radiation curable resins can be used, and the physical unevenness and visual unevenness improve tactility and design. Ionizing radiation-curable resins are preferred from the viewpoint of improving the stain resistance and wear resistance of the decorative material of the present invention.

Examples of thermosetting resins include acrylic resins, urethane resins, phenol resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. A curing agent is added to the thermosetting resin as necessary.
Two-component curable resins include two-component urethane resins containing a polyol compound as a main ingredient and an isocyanate compound as a curing agent, two-component epoxy resins, two-component urethane-modified acrylic resins, and two-component polyester resins. Can be mentioned.

An ionizing radiation-curable resin is a resin that is crosslinked and cured by irradiation with ionizing radiation, and has an ionizing radiation-curable functional group. Here, the ionizing radiation-curable functional group is a group that is crosslinked and cured by irradiation with ionizing radiation, and preferably includes functional groups having an ethylenic double bond such as a (meth)acryloyl group, a vinyl group, and an allyl group. It will be done. In addition, ionizing radiation refers to electromagnetic waves or charged particle beams that have energy quantum that can polymerize or crosslink molecules, and ultraviolet rays (UV) or electron beams (EB) are usually used, but other It also includes electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion beams.
Specifically, the ionizing radiation-curable resin can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation-curable resins.

As the polymerizable monomer, (meth)acrylate monomers having a radically polymerizable unsaturated group in the molecule are preferred, and polyfunctional (meth)acrylate monomers are particularly preferred. Here, "(meth)acrylate" means "acrylate or methacrylate."
Examples of polyfunctional (meth)acrylate monomers include (meth)acrylate monomers having two or more ionizing radiation-curable functional groups in the molecule and having at least a (meth)acryloyl group as the functional group, An acrylate monomer having an acryloyl group is preferred from the viewpoint of improving the tactile feel and design due to the physical unevenness shape and visual unevenness, as well as improving stain resistance and abrasion resistance.
The number of functional groups is preferably 2 or more, and the upper limit is preferably 8 or less, from the viewpoint of improving the tactile feel and design due to the physical unevenness shape and visual unevenness, and further improving stain resistance and abrasion resistance. , more preferably 6 or less, still more preferably 4 or less, particularly preferably 3 or less. These polyfunctional (meth)acrylates may be used alone or in combination.

Such polymerizable monomers include bifunctional (meth)acrylates such as ethylene glycol di(meth)acrylate, bisphenol A tetraethoxy diacrylate, bisphenol A tetrapropoxy diacrylate, and 1,6-hexanediol diacrylate; trimethylol; Propane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, Preferred examples include trifunctional or higher functional (meth)acrylates such as isocyanuric acid-modified tri(meth)acrylates.

Examples of the polymerizable oligomer include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule and at least a (meth)acryloyl group as the functional group. For example, urethane (meth)acrylate oligomer, epoxy (meth)acrylate oligomer, polyester (meth)acrylate oligomer, polyether (meth)acrylate oligomer, polycarbonate (meth)acrylate oligomer, acrylic (meth)acrylate oligomer, polycaprolactone urethane (meth)acrylate oligomer, ) acrylate oligomer, polycaprolactone diol urethane (meth)acrylate, etc.

The number of functional groups in these polymerizable oligomers is preferably 2 or more from the viewpoint of improving the tactile feel and design due to the physical unevenness shape and visual unevenness, as well as improving stain resistance and abrasion resistance. The upper limit is preferably 8 or less, more preferably 6 or less, still more preferably 4 or less, particularly preferably 3 or less.

The weight average molecular weight of these polymerizable oligomers is preferably 500 or more from the viewpoint of improving the tactility and design due to the physical unevenness shape and visual unevenness, and further improving stain resistance and abrasion resistance. More preferably, it is 1,000 or more, and the upper limit is preferably 80,000 or less, and more preferably 50,000 or less. In this specification, the weight average molecular weight is an average molecular weight measured by GPC analysis and converted to standard polystyrene.

The raised print layer preferably has higher gloss than the pattern layer from the viewpoint of enhancing the synergistic effect with the visual unevenness caused by the pattern layer and improving the design. A higher gloss than the pattern layer can be achieved by adjusting the amount of additives that can adjust the gloss, such as matting agents and extender pigments.

Further, the printed build-up layer preferably contains a build-up aid in order to ensure the thickness. Preferred examples of the build-up aid include resin beads and inorganic particles.
Examples of resin beads include acrylic resin, styrene resin, polyamide resin (nylon), urethane resin, acrylic-styrene resin, urethane-acrylic resin, polyester resin, melamine resin, polycarbonate resin, polyvinyl chloride resin, benzoguanamine resin, and benzoguanamine-formaldehyde condensation resin. Preferable examples include beads made of resin such as.
Examples of the inorganic particles include particles made of silica, alumina, kaolinite, antimony oxide, calcium carbonate, barium sulfate, glass, zirconia, titania, etc. From the viewpoint of cost etc., silica is preferable. The silica particles may be spherical or amorphous, and amorphous silica particles are preferred from the viewpoint of improving tactile sensation.

When a build-up aid is included in the build-up printing layer, a fine convex shape appears on the surface of the build-up print layer corresponding to the shape of the build-up aid, and the surface of the convex portion corresponds to the fine convex shape. Furthermore, fine convex portions (not shown) appear on the surface, which improves the matte effect by visual matting due to light scattering as a secondary effect, and also improves the texture of rough surfaces, sand grains, or wood grains. An improvement effect can be obtained. In the decorative material of the present invention, the convex portions have minute convex portions corresponding to the fine convex shapes on the surface of the printed build-up layer that are developed in accordance with the shape of the build-up aid contained in the printed build-up layer. The fine convex portions are formed by forming convex portions corresponding to the surfaces of each of the above-mentioned small protrusions that form the raised printing layer, and each surface of the elliptical shape in plan view that is larger than the above-mentioned protrusions. It is expressed in the cervix. The fine convex portions do not directly reflect the shape of the build-up aid due to the surface protection layer preferably provided on the build-up printing layer, but are caused by the build-up aid and have a shape corresponding to the build-up aid. It is intended to be presented.

The average particle diameter of the build-up aid is preferably 0.1 to 40 μm, more preferably 5 to 30 μm, and even more preferably 10 to 25 μm, from the viewpoint of ensuring the thickness of the built-up printing layer. In addition, within the above range, it is easy to adjust the properties of the surface shape such as the maximum height (Sz), and the tactile sensation and design due to the physical unevenness shape and visual unevenness are improved.

The content of the build-up aid is preferably 5 to 70 parts by weight, more preferably 10 to 60 parts by weight, even more preferably 20 to 50 parts by weight, per 100 parts by weight of the resin forming the built-up printing layer. be.

The raised print layer preferably has a portion provided along the edge of the pattern layer, as shown in FIG. 1, for example. By having such a part, the pattern layer is physically emphasized as a concave part by contrast with the raised printing layer, and the visual unevenness due to the difference in gloss is also emphasized, which improves the design as well as the tactile feel. Improves sex.

The thickness of the raised printing layer is preferably 3 μm or more, more preferably 5 μm or more, and further Preferably it is 10 μm or more, even more preferably 20 μm or more, and the upper limit is preferably 50 μm or less. If it is within the above range, the tactile sensation and design will be improved due to the physical unevenness shape and the visual unevenness, and the convex portion described below will be difficult to scrape, and the deterioration of stain resistance and abrasion resistance will be suppressed. I can do it.

(Surface protective layer 5)
The surface protective layer 5 is a layer preferably provided on the entire surface of the decorative material of the present invention so as to cover the base material 1, the pattern layer 2, the primer layer 3, and the raised print layer 4, and constitutes the decorative material of the present invention. This is a layer that protects each layer of the present invention and, as a result, protects the decorative material of the present invention. As mentioned above, it is possible to improve surface properties such as stain resistance and abrasion resistance by keeping the surface shape within the above range, but by providing a surface protective layer, these properties can be improved. It becomes possible to further improve the surface properties of
The surface protective layer may be composed of either a thermoplastic resin or a curable resin, and from the viewpoint of protecting the decorative material of the present invention and obtaining better stain resistance and abrasion resistance, the surface protective layer may be composed of a thermoplastic resin or a curable resin. It is preferable that the layer is made of a cured product of a curable resin. Alternatively, the layer may be composed of a thermoplastic resin and a curable resin in combination.

Examples of the thermoplastic resin include acrylic resin, polyester resin, unsaturated polyester resin, vinyl chloride-vinyl acetate copolymer resin, polyester urethane resin, thermoplastic (non-crosslinked) urethane resin, and the like.

Examples of the curable resin include curable resins such as thermosetting resins, two-component curable resins, and ionizing radiation curable resins, which are curable resins that can be used to form the printing embossed layer. Among these, ionizing radiation-curable resins are preferred from the viewpoint of improving stain resistance and wear resistance. The ionizing radiation-curable resin may be appropriately selected from the ionizing radiation-curable resins exemplified as those that can be used for forming the printing layer.

The surface protective layer may optionally contain weathering agents such as ultraviolet absorbers and light stabilizers, ultraviolet shielding agents, abrasion resistance improvers, polymerization inhibitors, crosslinking agents, Infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixotropic agents, coupling agents, plasticizers, antifoaming agents, fillers, antiblocking agents, lubricants, solvents, etc. can be added. . Among these, it is preferable to contain weathering agents such as ultraviolet absorbers and light stabilizers.
The ultraviolet absorber and light stabilizer may be appropriately selected from the ultraviolet absorbers and light stabilizers listed as examples that can be used in the base material.

The thickness of the surface protective layer is preferably determined based on the top surface of the primer layer, considering protection of the decorative material, improvement of stain resistance and abrasion resistance, and ease of forming the surface protective layer. It is 1 μm or more, more preferably 2 μm or more, even more preferably 3 μm or more, and the upper limit is preferably 15 μm or less, more preferably 10 μm or less, and still more preferably 7 μm or less.

(Convex portion 6)
The convex portion is the outermost surface of the decorative material of the present invention immediately above the printed embossed layer, that is, directly above the printed embossed layer, on the side of the base material where the printed embossed layer is provided (or where the surface protective layer is provided). If provided, it is a convex portion corresponding to the raised print layer on the outermost surface of the side on which the surface protective layer is provided. In addition, the convex part can be said to be a part where a raised print layer is provided (or, if a surface protective layer is provided, a part where the surface protective layer is coated on the raised print layer), and this is referred to as "corresponding to the raised print layer". This is called a "convex part".
The decorative material of the present invention has an extremely high tactile sensation because it has a physically uneven shape due to the convex portions. Further, due to the synergistic effect of this physical unevenness and the visual unevenness created by the above-mentioned pattern layer, it has an extremely high design quality. In addition, as described above, the convex portion has a fine convex portion that corresponds to the fine convex shape on the surface of the printed build-up layer that is developed in accordance with the shape of the build-up aid included in the printed build-up layer. It is preferable. By having such fine convex portions, a higher tactile sensation can be obtained, and the visual unevenness is improved, so that a higher design quality can also be obtained.

The height of the convex portion (based on the outermost surface) is approximately the same as the thickness of the raised printing layer. Therefore, the height of the convex portion (based on the outermost surface) is preferably 3 μm or more, more preferably 5 μm or more, even more preferably 10 μm or more, even more preferably 20 μm or more, and the upper limit is preferably It is 50 μm or less.

Further, since the convex portion corresponds to the raised print layer, preferable aspects of its shape are the same as those of the raised print layer, such as that it is preferable to have a portion constituted by a group of protrusions.

(Large area decorative layer 7)
The wide-area decorative layer 7 is a layer that is placed between the base material 1 and the pattern layer 2 or on the same surface as the pattern layer 2, and has a covering area larger than that of the pattern layer 2 in a plan view, and is a layer that is provided with the decorative layer 7 of the present invention. This layer, together with the pattern layer 2, imparts design to the material as a pattern layer. In the present invention, from the viewpoint of improving the design, it is preferable to consist of a plurality of layers including a pattern layer and a large-area decorative layer.

The wide-area decorative layer may be in the form of a colored layer (so-called "solid layer") that is uniformly provided so as to cover the entire surface, or the pattern layer has a covered area in plan view that is larger than that of the pattern layer. As long as it is wider than this, it may be in the form of a pattern layer provided so as to partially cover it, or it may be in the form of a pattern layer including the colored layer and the pattern layer.
When the wide-area decorative layer is a pattern layer, the decorative material of the present invention may also have a wide-area decorative layer, a part of which is formed by the pattern layer. Therefore, even if the wide-area decorative layer is a layer provided on the same surface as the pattern layer so as to coexist with the pattern layer, such as the wide-area decorative layer 72 shown in FIG. 4-c, good. Further, the wide-area decorative layer may be a single layer as shown in Figures (2-b) and (4-b), or may be a layer consisting of two or more layers as shown in Figure (4-c). The layer may be composed of a plurality of layers.

For example, in the case of a wood grain pattern, on top of a colored layer such as brown or white, there is a wide-area decorative layer that expresses the high-gloss (glossy or high-gloss) spring wood part, and then a high-gloss autumn wood part (shiny part). It can be formed by combining a wide-area decorative layer that expresses the image and a pattern layer that expresses a low-gloss (matte or low-gloss) conduit portion. Further, specific examples of how to properly use the pattern layer and the wide-area decorative layer in other patterns are as described above.

For forming the wide-area decorative layer, the resin composition described above as one that can be used for forming the pattern layer can be used.
Further, the thickness of the wide-area decorative layer may be appropriately determined as desired, and may be selected from the numerical range described as the thickness of the pattern layer.

(Method for manufacturing decorative materials)
Regarding the manufacturing method of the decorative material of the present invention, one of the preferable embodiments of the decorative material of the present invention is shown in Figure (2-b), which includes a base material, a wide area decorative layer, a pattern layer, a primer layer, and a raised print. The manufacturing method will be explained by taking as an example a decorative material having a surface protection layer and a surface protection layer.

The decorative material of the present invention includes, for example, a step of providing a wide-area decorative layer on a base material, a step of providing a pattern layer on the wide-area decorative layer, a step of providing a primer layer so as to cover at least the pattern layer, and a step of providing the pattern. A step of providing a raised print layer so as to cover at least a part of the non-forming area of the layer and to cover 30% or more of the entire surface of the decorative material, and a step of providing a base material, a pattern layer, a primer layer and a raised print layer. It can be manufactured by sequentially providing a surface protective layer over the entire surface so as to cover the surface.

The process of forming a wide-area decorative layer and a pattern layer is to first form a wide-area decorative layer by applying a resin composition used for forming a wide-area decorative layer onto a base material and providing a desired colored layer and pattern layer. Then, a resin composition used for forming the pattern layer is applied to form the pattern layer. The resin composition is applied by a known method such as a gravure printing method, a bar coating method, a roll coating method, a reverse roll coating method, or a comma coating method, preferably by a gravure printing method.

Further, when surface treatment is applied to the base material, it may be carried out before forming the wide-area decorative layer, and when providing an easily bonding layer, it may be carried out before forming the wide-area decorative layer. In addition, when the back easily adhesive layer is provided on the surface (back surface) opposite to the surface on which the pattern layer is provided of the base material, it may be provided either before or after the formation of the wide-area decorative layer.

Next is a step of providing a primer layer so as to cover at least the pattern layer. It may be formed by applying the resin composition used for forming the primer layer, and the application method may be appropriately selected from the methods for applying the resin composition for forming the wide-area decorative layer described above.
In the step of providing a raised print layer, the raised printed layer may be formed by applying a resin composition used for forming the raised printed layer, and the coating method includes applying the resin composition for forming the wide area decorative layer. An appropriate method may be selected and adopted from the following methods.

Formation of the surface protective layer is carried out by applying a curable resin composition, preferably containing a liquid uncured product of a curable resin, to the entire surface of the decorative material and curing it as necessary. I will do it.
As a method for applying the uncured resin composition containing the liquid uncured material, any of the known methods exemplified as the method for applying the resin composition for the wide-area decorative layer may be employed.
Furthermore, the method for curing the uncured resin composition containing the liquid uncured material of the curable resin may be selected depending on the type of curable resin contained in the uncured resin composition. For example, when the uncured resin composition is a resin composition containing a liquid uncured thermosetting resin, it may be cured by performing a heat treatment depending on the thermosetting resin used.

When using an uncured resin composition containing a liquid uncured ionizing radiation resin, the uncured resin layer formed by applying the uncured resin composition is irradiated with ionizing radiation such as electron beams and ultraviolet rays. It may be made into a cured product. When using an electron beam as the ionizing radiation, the accelerating voltage can be appropriately selected depending on the resin used and the thickness of the layer, but it is usually possible to cure the uncured resin layer at an accelerating voltage of about 70 to 300 kV. preferable. The irradiation dose is preferably an amount that saturates the crosslinking density of the ionizing radiation-curable resin, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad).
There are no particular limitations on the electron beam source; for example, various electron beam accelerators such as a Cockroft-Walton type, a Vandegraft type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, and a high frequency type are used. be able to.
Furthermore, when ultraviolet rays are used as ionizing radiation, those containing ultraviolet rays with a wavelength of 190 to 380 nm are emitted. There are no particular restrictions on the ultraviolet light source, and for example, a high pressure mercury lamp, a low pressure mercury lamp, a metal halide lamp, a carbon arc lamp, etc. can be used.

Further, after forming the surface protective layer, if necessary, an uneven shape can be imparted by heating and pressure molding using an embossing plate.
The conditions for heating and pressure molding may be adjusted as appropriate depending on the type of curable resin used, and are not particularly limited, but are usually at a temperature of 100 to 200°C and a pressure of 0.1 to 9.8 MPa. The time is from 10 seconds to 120 minutes.

(Applications for decorative materials)
The decorative material of the present invention has a high tactile sensation due to the physical unevenness, excellent design properties due to the physical unevenness and visual unevenness, and has excellent stain resistance and abrasion resistance. It is. Therefore, the decorative material of the present invention can be used for various purposes as it is, by being laminated onto an adherend via an adhesive layer, or by being subjected to a predetermined molding process.
For example, it can be laminated on adherends such as flat plates, curved plates, etc. of various materials, sheets (or films), etc., and can be used as interior parts of buildings such as walls, ceilings, and floors, or as exterior walls, roofs, soffits, fences, etc. Exterior parts such as gates, window frames, various doors such as entrance doors, handrails, skirting boards, surrounding edges, window frames, door frames, fittings and fixtures such as moldings, as well as kitchen equipment or kitchen furniture, furniture, and home appliances. It can be used for decorative surface panels of products, cabinets of OA equipment, etc., interior parts or exterior parts of vehicles, etc.

Examples of adherends include wood veneers made of various woods such as cedar, cypress, pine, and lauan, wood plywood, particle board, MDF (medium density fiberboard), and wood fiber boards such as laminated wood. Wooden members used as three-dimensional articles, etc.; Metal members used as iron, aluminum plates, steel plates, three-dimensional articles, sheets, etc.; Ceramics such as glass, ceramics, non-cement ceramic materials such as plaster, ALC ( Ceramic members used as plates of non-ceramic ceramic materials such as lightweight cellular concrete plates and three-dimensional articles; Polyolefin resins such as acrylic resins, polyester resins, polystyrene and polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) ) resins, phenolic resins, vinyl chloride resins, cellulose resins, and rubber plates, three-dimensional articles, resin members used as sheets, and the like. Further, these members can be used alone or in combination.

The adhesive used in the adhesive layer is not particularly limited, and any known adhesive can be used, and preferred examples include adhesives such as heat-sensitive adhesives and pressure-sensitive adhesives. Examples of resins used for the adhesive constituting this adhesive layer include acrylic resin, polyurethane resin, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer resin, styrene-acrylic copolymer resin, and polyester resin. , polyamide resin, etc., and these can be used alone or in combination. Furthermore, a two-component curing type polyurethane adhesive or polyester adhesive using an isocyanate compound or the like as a curing agent can also be applied.
Moreover, an adhesive can also be used for the adhesive layer. As the adhesive, an acrylic adhesive, a urethane adhesive, a silicone adhesive, a rubber adhesive, or the like can be appropriately selected and used.

The adhesive layer is formed by applying the above resin in a coatable form such as a solution or emulsion using a gravure printing method, a screen printing method, or a reverse coating method using a gravure plate, and drying it. can do.
The thickness of the adhesive layer is not particularly limited, but from the viewpoint of obtaining excellent adhesiveness, it is preferably 1 μm or more and 100 μm or less, more preferably 5 μm or more and 50 μm or less, and even more preferably 10 μm or more and 30 μm or less.

Next, the present invention will be explained in more detail with reference to examples, but the present invention is not limited to these examples in any way.
(Evaluation and observation method)
(1) Measurement of surface shape properties Regarding the surface of the decorative materials obtained in each example and comparative example, the maximum height (Sz), protruding peak height ( Spk), maximum peak height (Sp), and arithmetic mean height (Sa) were measured. Specifically, using a non-contact shape analysis laser microscope ("VK-X1000 (model number)", manufactured by Keyence Corporation), each of the above properties was measured at arbitrary 10 points under the following conditions, The average value was taken as the numerical value for each property. Table 1 shows the measurement results.
・Magnification: 400x ・Measurement range: 500 μm x 700 μm at 10 locations ・S-filter, L-filter: None

(2) Evaluation of tactile sensation Regarding the decorative materials obtained in each of the Examples and Comparative Examples, 20 arbitrary adults were asked to evaluate whether or not the tactile sensation (unevenness) was high when touched with their hands. Table 1 shows the results of classifying the aggregated tactile evaluations based on the following criteria.
A: More than 18 out of 20 people answered that the tactile sensation was high.
B: The number of people who answered that the tactile sensation was high was 15 or more and 17 or less out of 20 people.
C: The number of people who answered that the tactile sensation was high was 11 or more and 14 or less out of 20 people.
D: Less than 10 out of 20 people answered that the tactile sensation was high.
(3) Evaluation of Gloss Matte Feeling The cosmetic materials obtained in each of the Examples and Comparative Examples were visually evaluated by 20 arbitrary adults as to whether or not they had a high Gloss Matte feel (unevenness). Table 1 shows the results of classifying the aggregated tactile evaluations based on the following criteria.
A: More than 18 out of 20 people answered that the design had a high level of unevenness.
B: Out of 20 people, 15 or more and 17 or less answered that the design had a high level of unevenness.
C: Of the 20 people, 11 or more and 14 or less answered that the design had a high level of unevenness.
D: Less than 10 out of 20 people answered that the design had a high level of unevenness.
(4) Evaluation of stain resistance The decorative materials obtained in Examples 1 and 2 were evaluated according to the following criteria in accordance with the JAS stain A test regulations.
A: There was no or almost no change in appearance.
B: Appearance change was slight.
C: Appearance change was noticeable.
D: There was a significant change in appearance.
(5) Evaluation of abrasion resistance Regarding the decorative materials obtained in Examples 1 and 2, the decorative materials were fixed horizontally on the rotary plate of the testing device in accordance with the regulations of the JAS plywood abrasion A test, and Attach two rubber discs wrapped with S-42) and rotate the decorative material while applying a total load of 500gf.The number of rotations at which the pattern of the decorative material becomes 50% is evaluated according to the following evaluation criteria. evaluated. The device was stopped every 5 rotations and the surface condition was visually checked.
A: 75 rotations or more B: 50 rotations or more and less than 75 rotations C: 25 rotations or more and less than 50 rotations D: Less than 25 rotations (6) Measurement of coverage of raised print layer 2 m x 2 m obtained in each example and comparative example Three test pieces of 30 cm x 30 cm were cut out from arbitrary locations on the decorative material of size , and image analysis was performed on each of these test pieces using a microscope to determine the entire surface of the decorative material and the pattern layer. The coverage of the raised print layer with respect to the non-forming area was calculated, and the average value thereof was calculated. Table 1 shows the results.

Example 1
The base material is colored base paper for building materials ("CHPS45 (model number)", basis weight: 45 g/m ² , manufactured by Tenma Tokushu Paper Co., Ltd.), and acrylic resin and urethane resin are applied to the easily adhesion-treated surface of the base material. A resin composition containing titanium white, Bengara, and yellow lead as a coloring agent is applied as a binder using a mixed resin of Then, a wood grain pattern (walnut pattern) having a wide-area decorative layer constituting a wood skin part consisting of a spring wood part and an autumn wood part is formed using a resin composition containing a coloring agent whose main component is Bengara, A conduit portion is formed as a pattern layer on the wide-area decorative layer, and then a primer containing a two-part curable resin (base ingredient: acrylic polyol, curing agent: hexamethylene diisocyanate) and filler is used to cover the entire surface of the decorative material. A resin composition for layer formation (average particle size of filler: 1.3 μm, filler content: 40 parts by mass of silica particles per 100 parts by mass of resin) was applied to form a primer layer with a thickness of 5 μm. Formed.
Next, gravure printing was carried out using a resin composition for forming a raised print layer, which mainly consisted of an acrylic resin and had 65 parts by mass of silica particles with an average particle diameter of 15 μm added as a build-up aid per 100 parts by mass of resin. 45% of the entire surface of the decorative material is covered on the area where the pattern layer is not formed (the area where the wood surface is exposed in plan view) of the conduit part, and 90% of the area where the pattern layer is not formed is covered. A raised printing layer (maximum height based on the top surface of the primer layer: 20 μm) was formed in such a manner. Furthermore, an ionizing radiation curable resin composition (ionizing radiation curable resin: electron beam curable acrylate resin, other additives: silica, extender pigment) for forming a surface protective layer is applied over the entire surface by a roll coating method. An uncured resin layer is formed as a protective layer, and an electron beam (pressure voltage: 175 KeV, 5 Mrad (50 kGy)) is irradiated to harden the uncured resin layer to form a surface protective layer (thickness: 5 μm). Formed. Thereafter, heat curing was performed at 70° C. for 24 hours to obtain the decorative material of Example 1. The obtained decorative material was evaluated as described above. The evaluation results are shown in Table 1. Further, FIG. 5 shows an SEM photograph of the surface of the obtained decorative material taken using a scanning electron microscope (SEM).

Examples 2 to 5, Comparative Examples 1 and 2
In Example 1, the build-up aid (shape and average particle diameter), the coverage rate of the build-up print layer to the entire decorative material, the coverage rate to the area where the pattern layer is not formed, and the presence or absence of the surface protective layer are shown in Table 1. A decorative material was produced in the same manner as in Example 1, except that it was made into a material. The obtained decorative board was evaluated as described above, and the results are shown in Table 1.

*1. Coverage rate of the raised printing layer over the entire decorative material.
*2. This is the coverage rate of the raised printing layer to the area where the pattern layer is not formed.
*3. The numerical value is the thickness (μm) of the surface protective layer.

From the results of Examples 1 to 5, the decorative materials of the present invention had a high tactile sensation due to the physical unevenness, and excellent design properties due to the physical unevenness and visual unevenness. From the results of Examples 4 and 5, it was confirmed that the tactile sensation was improved by setting the maximum height (Sz) to 40.0 μm or more.
In addition, when the stain resistance and abrasion resistance of Examples 1 and 2 were evaluated, the stain resistance evaluation of Examples 1 and 2 was both A grade, and the abrasion resistance evaluation was both B grade. In addition to the high tactile sensation created by the physical unevenness, and the excellent design due to the physical unevenness and visual unevenness, it also has excellent surface properties such as stain resistance and abrasion resistance. It was confirmed that
On the other hand, the decorative material of Comparative Example 1, which does not have a raised printed layer, has a small maximum height (Sz) of 0.0 μm, almost no unevenness, and has a good texture and design. It was inferior. In addition, regarding the surface shape properties, the decorative material of Comparative Example 2, which has a maximum height (Sz) of 13.2 μm, which is less than 15 μm, has poor tactile sensation and unevenness like the decorative material of Comparative Example 1, and has an excellent design. It could not be said to have a sexual nature.

10. Decorative materials 1. Base material 1F. One side of the base material 2. Picture layer 3. Primer layer 4. Raised printing layer 5. Surface protective layer 6. Convex portion 7. Wide area decorative layer 71. Wide area decorative layer 72. Wide area decorative layer N. Normal direction

Claims (11)

A decorative material comprising a base material, a pattern layer covering a part of one side of the base material, and a raised printing layer,
The raised printing layer covers at least a part of the non-forming area of the pattern layer in plan view,
having a convex portion corresponding to the raised print layer on the outermost surface of the decorative material directly above the raised print layer;
The maximum height (Sz) measured in accordance with ISO 25178-6:2010 is 15 μm or more, and the protruding peak height (Spk) measured in accordance with ISO 25178-6:2010 is 4. It is 1 μm or more ,
Decorative materials. The decorative material according to claim 1, further comprising a surface protection layer provided on the entire surface of the decorative material so as to cover the base material, the pattern layer, and the raised print layer. The decorative material according to claim 1 or 2, wherein the maximum peak height (Sp) measured in accordance with ISO 25178-6:2010 is 1.0 μm or more. The decorative material according to any one of claims 1 to 3 , wherein the arithmetic mean height (Sa) measured in accordance with ISO 25178-6:2010 is 2.0 μm or more. The decorative material according to any one of claims 1 to 4 , wherein the raised printing layer is provided so as to cover 30% or more of the entire surface of the decorative material in plan view. Any one of claims 1 to 5 , further comprising a wide-area decorative layer between the base material and the pattern layer or on the same surface as the pattern layer, the covering area of which is larger in plan view than the pattern layer. Decorative materials listed in . The decorative material according to any one of claims 1 to 6 , wherein the raised printing layer includes a portion constituted by a group of protrusions. The decorative material according to any one of claims 1 to 7 , wherein the printed build-up layer contains a build-up aid. The makeup according to claim 8 , wherein the raised print layer has a fine convex shape corresponding to the raised auxiliary agent on its surface, and the convex part has a fine convex part corresponding to the fine convex shape. Material. The decorative material according to any one of claims 2 to 9 , wherein the surface protective layer is made of a cured product of a curable resin composition. The decorative material according to any one of claims 1 to 10 , further comprising an adherend on a surface of the base material opposite to the surface having the pattern layer, with an adhesive layer interposed therebetween.