WO2017204362A1 - 化粧材 - Google Patents

化粧材 Download PDF

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Publication number
WO2017204362A1
WO2017204362A1 PCT/JP2017/019816 JP2017019816W WO2017204362A1 WO 2017204362 A1 WO2017204362 A1 WO 2017204362A1 JP 2017019816 W JP2017019816 W JP 2017019816W WO 2017204362 A1 WO2017204362 A1 WO 2017204362A1
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WO
WIPO (PCT)
Prior art keywords
layer
gloss
matting agent
pattern
added
Prior art date
Application number
PCT/JP2017/019816
Other languages
English (en)
French (fr)
Inventor
栄一 東川
Original Assignee
凸版印刷株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=60411412&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2017204362(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by 凸版印刷株式会社 filed Critical 凸版印刷株式会社
Priority to KR1020187033821A priority Critical patent/KR102444750B1/ko
Priority to CN201780031642.XA priority patent/CN109153240B/zh
Priority to JP2018519657A priority patent/JP6958551B2/ja
Priority to EP17802948.4A priority patent/EP3466678A4/en
Publication of WO2017204362A1 publication Critical patent/WO2017204362A1/ja
Priority to US16/194,583 priority patent/US10640916B2/en

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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0002—Wallpaper or wall covering on textile basis
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    • D—TEXTILES; PAPER
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    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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    • E04F13/002—Coverings or linings, e.g. for walls or ceilings made of webs, e.g. of fabrics, or wallpaper, used as coverings or linings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
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    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24851—Intermediate layer is discontinuous or differential
    • Y10T428/24868—Translucent outer layer
    • Y10T428/24876—Intermediate layer contains particulate material [e.g., pigment, etc.]

Definitions

  • the present invention relates to a cosmetic material for use in surface makeup of a building interior / exterior, joinery, furniture, and the like. More specifically, the present invention relates to a cosmetic material that can express a three-dimensional impression obtained by a difference in surface gloss and can express a pattern that can be seen only from a specific observation angle.
  • a desired pattern such as a wood grain pattern or a stone grain pattern is usually applied to a cosmetic material used for surface makeup of a building interior / exterior, joinery, furniture, or the like.
  • a decorative material that expresses the unevenness of the surface of natural wood and stone materials in a three-dimensional manner is desirable. It is widely used mainly for applications.
  • the surface of the formed synthetic paint layer A glossy transparent or translucent synthetic coating layer is formed on the portion excluding the portion corresponding to the dent pattern.
  • the formation of synthetic paint layers with different luster can be performed by conventional printing methods such as gravure printing methods following the formation of pattern patterns (pattern ink layers), so no special equipment is required and production efficiency is high. Synchronization with the pattern is easy.
  • the thickness of the synthetic paint layer is much thinner than the height difference of the unevenness to be expressed, so the amount of resin used can be reduced, and it is advantageous in terms of flexibility, and has excellent bending processability. It is easy to realize a decorative material. Moreover, since there is no large unevenness
  • a method for adjusting the gloss of the gloss adjusting layer a method of adding a gloss adjusting agent (matting agent) to a transparent resin as a binder is generally used.
  • the gloss adjusting agent fine particles of inorganic material or organic material are mainly used.
  • fine particles of inorganic material especially silica fine particles
  • the gloss adjusting agent imparts unevenness to the surface of the gloss adjusting layer, and the unevenness scatters light to provide a matting effect.
  • the type and amount of the gloss adjusting agent the required gloss can be freely created.
  • the unevenness provided by the gloss adjusting agent is small with respect to the thickness of the gloss adjusting layer, and is very small compared to the unevenness provided by the mechanical embossing method. For this reason, a phenomenon occurs in which the unevenness obtained by the difference in gloss is changed between when the surface of the decorative material is observed from the front and when observed from an oblique direction. This is because, when viewed from an oblique direction, the gloss (glossiness) of the portion with relatively low gloss increases, so the portion with relatively high gloss (glossiness) and the portion with low gloss (glossiness) This is because the difference in gloss (difference in gloss) becomes smaller. On the other hand, such a phenomenon is an important effect in some cases for design expression. That is, it is possible to change the appearance depending on the angle at which the pattern expressed by the difference in gloss is observed, and the design that can be seen when viewed from the front becomes invisible when viewed from an oblique direction.
  • an object of the present invention is to provide a cosmetic material capable of expressing a picture that can be seen only from a specific observation angle.
  • the inventors have adjusted the gloss when observed from an oblique angle by adjusting the layer thickness of the gloss adjustment layer having a relatively low gloss and the particle size of the matting agent to be added. It was found that the luster of the layer was positively increased, and the pattern (design) expressed by the difference in luster was made invisible.
  • a decorative material includes a first gloss adjustment layer provided on a base material, and a first gloss adjustment layer partially provided on the first gloss adjustment layer.
  • a second gloss adjustment layer having a gloss different from that of the adjustment layer, and the particle size of the first gloss adjustment layer and the second gloss adjustment layer is relatively low. It is characterized in that a matting agent less than 1.0 times the layer thickness is added.
  • the cosmetic material of one aspect of the present invention when the layer thickness of the gloss adjustment layer with low gloss and the particle size of the matting agent to be added are in the optimum range, The matte effect can be reduced, and the picture expressed by the difference in gloss can be made invisible. Thereby, the cosmetics which can express the picture which can be seen only from a specific observation angle can be provided.
  • a decorative material 1 according to an embodiment of the present invention will be described with reference to the drawings.
  • the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones.
  • the embodiment described below exemplifies a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention describes the material, shape, structure, and the like of component parts as follows. It is not something specific.
  • the technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.
  • the decorative material 1 of the present embodiment is provided with a first gloss adjustment layer 5 provided on a base material 2 and a part of the first gloss adjustment layer 5. And a second gloss adjusting layer 6 having a gloss different from the gloss of the gloss adjusting layer 5. And among these 1st, 2nd glossiness adjustment layers 5 and 6, in the glossiness adjustment layer with relatively low glossiness, the particle size is less than 1.0 times the layer thickness, more preferably 0.9 times or less. It is important that a matting agent is added. As a result, the matting agent can be exposed on the surface in a state of floating on the gloss adjusting layer.
  • the unevenness imparted to the surface can be reduced while obtaining a sufficient matting effect by observation from the front, the effect of scattering light incident from an angle is weakened, and when observed from an angle The matte effect can be lowered. For this reason, when observed from an oblique direction, the design expressed by the difference in gloss, that is, the design can be made invisible.
  • the base ink layer 3 may be a layer formed by, for example, applying solid ink to the base material 2.
  • the layer thickness is the thickness of the resin portion that fills between the matting agents when observing the cross section of the gloss adjustment layer having a relatively low gloss.
  • the particle size of the matting agent is less than 1.0 times the layer thickness, more preferably 0.9 times or less, the matting agent is floating in the gloss adjusting layer, or A plurality of matting agents are overlapped to be exposed on the surface of the gloss adjusting layer. Therefore, the measurement of the layer thickness can be obtained by measuring a plurality of resin portions where the matting agent is not exposed or between the matting agents and averaging the obtained values.
  • the particle size when the particle shape is not spherical, the cross section of the particle may be elliptical and the average value of the major axis and minor axis may be used as the particle size. That is, in this embodiment, the particle size is an average particle size when the cross-sectional shape of the particles is assumed to be circular or elliptical.
  • the lower limit of the particle size of the matting agent is that if the particle size becomes too small, the matting effect is reduced even from the front view, and the required design expression cannot be obtained.
  • the layer thickness is preferably 0.2 times the thickness of the gloss adjusting layer having a relatively low gloss.
  • the particle size of the matting agent is less than 1.0 times the layer thickness, more preferably 0.9 times or less,
  • the specific size is preferably 2 ⁇ m or more and 15 ⁇ m or less. Any particle size can be selected within this numerical range. For example, when the layer thickness is set to 5 ⁇ m, the particle size of the matting agent may be less than 5 ⁇ m, more preferably 4.5 ⁇ m or less.
  • the matting agent a known matting agent that is commercially available can be used.
  • examples thereof include fine particles made of an inorganic material such as silica, glass, alumina, calcium carbonate, barium sulfate, and acrylic. Since the first and second gloss adjusting layers 5 and 6 are required to have high transparency, it is desirable to use fine particles such as silica, glass, and acrylic having high transparency.
  • a matting agent having a low bulk density formed by secondary aggregation of fine primary particles, not solid true spherical particles has a high matting effect with respect to the added amount. Therefore, by using such a matting agent, it is possible to form a gloss adjusting layer having a lower gloss. Thereby, the difference of the glossiness of the 1st glossiness adjustment layer 5 and the 2nd glossiness adjustment layer 6 can be enlarged, and the uneven
  • an arbitrary numerical value can be selected as the particle size of the matting agent, but when a known matting agent is used, it is preferably 2 ⁇ m or more and 15 ⁇ m or less. More preferably, it is 4 ⁇ m or more and 12 ⁇ m or less.
  • a matting agent having a particle size of less than 2 ⁇ m has a low matting effect, so that the unevenness characteristic of the present embodiment cannot be sufficiently obtained.
  • a matting agent having a particle size of more than 15 ⁇ m results in increased light scattering, leading to white turbidity of the first and second gloss adjusting layers 5 and 6 and an increase in visual feeling of particles. And the unevenness
  • the matting agent may be smaller or larger in specific gravity than the resin composition, for example, if the matting agent floats in the resin composition constituting the gloss adjusting layer to which the matting agent is added. Also good.
  • the gloss adjusting layer to which the matting agent is added is divided into two equal parts in the layer thickness direction of the gloss adjusting layer, the layer located on the substrate 2 side is set as the lower layer, and is located on the side opposite to the substrate 2 side.
  • the layer is an upper layer, 50% or more of the matting agent added to the gloss adjusting layer may be present in the upper layer.
  • the abundance ratio of the matting agent added to the gloss adjusting layer is defined by the ratio calculated by the area ratio between the matting agent and the resin part constituting the other gloss adjusting layer when the cross section is observed. It is what is done. That is, the upper layer of the gloss adjusting layer may contain the same amount of matting agent or more matting agent as the lower layer of the gloss adjusting layer in terms of area ratio. If it is the said structure, the frequency with which a several matting agent overlaps will increase, and the state in which the matting agent is exposed to the surface of a glossiness adjustment layer will be formed easily.
  • the resin part (resin composition) constituting the first and second gloss adjusting layers 5 and 6 examples include polyurethane, acrylic silicon, fluorine, epoxy, vinyl, polyester, melamine, amino Alkyd, urea and the like can be used.
  • the form of the resin composition is not particularly limited, such as aqueous, emulsion, solvent type.
  • a curing method for the resin composition for example, a one-component type, a two-component type, an ultraviolet curing method, or the like can be used.
  • urethane-based materials using isocyanate as the resin composition are suitable from the viewpoints of workability, cost, cohesive strength of the resin itself, and the like.
  • the isocyanate include tolylene diisocyanate (TDI), xylylene diisocyanate (XDI), hexamethylene diisocyanate (HMDI), diphenylmethane diisocyanate (MDI), lysine diisocyanate (LDI), isophorone diisocyanate (IPDI), methylhexane diisocyanate (HTDI). ), Bis (isocyanatemethyl) cyclohexane (HXDI), trimethylhexamethylene diisocyanate (TMDI) and other derivatives such as adducts, burettes and isocyanurates can be used.
  • HMDI hexamethylene diisocyanate
  • IPDI isophorone diisocyanate
  • a resin that is cured by active energy rays such as ultraviolet rays and electron beams.
  • functional additives such as antibacterial agents and fungicides may be added to the first and second gloss adjusting layers 5 and 6 in order to impart various functions.
  • the ultraviolet absorber for example, benzotriazole, benzoate, benzophenone, and triazine can be used.
  • group can be used as a light stabilizer.
  • a release agent having a silicone skeleton can be added when anti-contamination performance and Sellotape (registered trademark) releasability are required.
  • the type of the release agent is not particularly limited, but by using a silicone release agent having a terminal functional group that has reactivity with the resin composition, antifouling performance and durability of cello tape release properties can be achieved. It can be improved.
  • the first and second gloss adjusting layers 5 and 6 have different gloss.
  • the first gloss adjustment layer 5 covers the entire surface of the substrate 2 on the first gloss adjustment layer 5 side
  • the second gloss adjustment layer 6 is on the first gloss adjustment layer 5.
  • the surface on the second gloss adjusting layer 6 side is partially covered.
  • a design (design) is expressed by the difference in gloss between the first and second gloss adjustment layers 5 and 6.
  • the first gloss adjustment layer 5 covers the entire surface of the substrate 2 on the first gloss adjustment layer 5 side, but other configurations may be employed. .
  • the first gloss adjusting layer 5 may partially cover the surface of the base 2 on the first gloss adjusting layer 5 side.
  • a matting agent is added to the gloss adjustment layer having a relatively low gloss among the first and second gloss adjustment layers 5 and 6.
  • the addition amount of the matting agent is preferably 5 parts by mass or more and 40 parts by mass or less with respect to 100 parts by mass of the resin composition. More preferably, it is 10 to 30 mass parts.
  • the amount is less than 5 parts by mass, the matte effect is insufficient, so that the difference in gloss with the relatively glossy gloss adjustment layer is small, the impression of unevenness is insufficient, and the pattern expressed by the difference in gloss Becomes difficult to see. As a result, the design feeling that is desired to be expressed is insufficient.
  • the resin composition when it is larger than 40 parts by mass, the resin composition is relatively insufficient with respect to the matting agent, which causes the matting agent to drop off or the scratch resistance to be reduced due to the dropping. The required durability is greatly impaired.
  • any matting agent can be added to the gloss adjustment layer having a relatively high gloss. These should be appropriately adjusted according to the final unevenness and design. Further, the matting agent and the resin composition used for the first and second gloss adjusting layers 5 and 6 may be the same or different. These can be freely selected from the feeling of unevenness and various required characteristics.
  • the layer thicknesses of the first and second gloss adjusting layers 5 and 6 can be selected from arbitrary numerical values.
  • the particle size of the matting agent is preferably 2 ⁇ m or more and 15 ⁇ m or less. Among them, it is more preferable that the thickness is 2.3 ⁇ m or more and 16.7 ⁇ m or less.
  • the first and second gloss adjusting layers 5 and 6 are the outermost layers of the decorative material 1, and therefore wear resistance, scratch resistance, solvent resistance, stain resistance, and the like necessary for the decorative material 1. Surface properties are required. Among these, the wear resistance and scratch resistance are affected by the layer thickness, and a thicker layer is advantageous.
  • a more preferable layer thickness of the first and second gloss adjusting layers 5 and 6 is 2.3 ⁇ m or more and 12 ⁇ m or less.
  • the thickness is less than 2.3 ⁇ m, the wear resistance and the scratch resistance are greatly deteriorated, so that the use as the decorative material 1 may be limited.
  • the workability as the decorative material 1 may deteriorate.
  • the base material 2 is not particularly limited as long as it is used as a base paper for the decorative material 1.
  • paper such as thin paper, resin-mixed paper, titanium paper, resin-impregnated paper, flame-retardant paper, inorganic paper, woven or non-woven fabric made of natural fiber or synthetic fiber, homo- or random polypropylene resin, polyolefin resin such as polyethylene resin Synthetic resin systems such as copolyester resins, amorphous crystalline polyester resins, polyethylene naphthalate resins, polybutylene resins, acrylic resins, polyamide resins, polycarbonate resins, polyvinyl chloride resins, polyvinylidene chloride resins, fluorine resins Substrate, wood veneer, veneer, plywood, laminated wood, particle board, medium density fiber board, etc., wood base material, gypsum board, cement board, calcium silicate board, ceramic board, inorganic base material, iron, copper , Metal base materials such as aluminum and stainless steel, or composite materials and
  • a pattern ink layer 4 for adding a pattern to the decorative material 1 can be provided between the base material 2 and the first gloss adjustment layer 5.
  • the pattern pattern for example, a grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, or the like can be used.
  • the pattern ink layer 4 is formed immediately below the second gloss adjusting layer 6.
  • the pattern of the pattern ink layer 4 is not synchronized with the gloss of the second gloss adjustment layer 6 and expresses a pattern that is completely different from the gloss of the second gloss adjustment layer 6.
  • the design expressed by the difference in gloss of the second gloss adjustment layer 6 expresses a design that is completely different from the design of the pattern ink layer 4 as a design.
  • a base ink layer 3 is provided between the base material 2 and the pattern ink layer 4 so as to cover the entire surface of the base material 2 on the first gloss adjustment layer 5 side according to the required design. May be.
  • the base ink layer 3 may be a multilayer of two or more layers as necessary, such as concealment.
  • the pattern ink layer 4 may be formed by laminating as many as the number of color separations necessary for expressing a desired design. As described above, the pattern ink layer 4 and the base ink layer 3 are variously combined depending on a required design, that is, a design to be expressed, but are not particularly limited.
  • the colorant examples include inorganic pigments such as carbon black, titanium white, zinc white, petal, yellow lead, bitumen, cadmium red, azo pigments, lake pigments, anthraquinone pigments, phthalocyanine pigments, isoindolinone pigments.
  • Organic pigments such as dioxazine pigments, or mixtures thereof can be used.
  • the solvent for example, toluene, xylene, ethyl acetate, butyl acetate, methyl alcohol, ethyl alcohol, isopropyl alcohol, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, water, or a mixture thereof can be used.
  • Functional additives such as a curing accelerator and a curing retarder may be added.
  • Each of the base ink layer 3, the pattern ink layer 4, and the first and second gloss adjustment layers 5 and 6 is, for example, a gravure printing method, an offset printing method, a screen printing method, an electrostatic printing method, an inkjet printing method, or the like. It can be formed by various printing methods. In addition, since the base ink layer 3 and the first gloss adjustment layer 5 cover the entire surface of the substrate 2 on the first gloss adjustment layer 5 side, for example, a roll coating method, a knife coating method, a micro coating method, and the like. It can also be formed by various coating methods such as a gravure coating method and a die coating method. These printing methods and coating methods may be selected separately depending on the layer to be formed, or the same method may be selected and collectively processed.
  • the coating amount may be adjusted in the above-described printing method and coating method.
  • the coating amount can be calculated from the difference in mass between various printing methods and coating methods in which the gloss adjusting layer is formed on the base material 2 and not.
  • the relationship between the coating amount and the layer thickness can be obtained by cross-sectional observation.
  • a transparent resin layer (not shown) can be provided between the pattern ink layer 4 and the first gloss adjusting layer 5.
  • the transparent resin layer for example, it is preferable to use a resin composition containing an olefin resin as a main component.
  • olefin resin examples include, in addition to polypropylene, polyethylene, polybutene and the like, ⁇ -olefin (eg, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1 -Decene, 1-undecene, 1-dodecene, tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-eicosene, 3-methyl-1-butene, 3 -Methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, 4-methyl-1-hexene, 4,4-dimethyl-1-pentene, 4-ethyl-1-hexene, 3 -Ethyl-1-hexene
  • additives such as a heat stabilizer, an ultraviolet absorber, a light stabilizer, an antiblocking agent, a catalyst scavenger and a colorant may be added to the transparent resin layer.
  • additives can be appropriately selected from known ones and used.
  • the transparent resin layer can be formed by various lamination methods such as a method using hot pressure, an extrusion laminating method, and a dry laminating method.
  • the particle size of the first gloss adjustment layer 5 and the second gloss adjustment layer 6 is relatively low.
  • the pattern seen when observing from the front becomes invisible when viewed from an oblique direction.
  • the cosmetic material 1 capable of expressing a picture that can be seen only from a specific observation angle.
  • the decorative material 1 that enables design expression with high message property so that the pattern expressed by the difference in gloss depending on the observation angle becomes invisible.
  • the decorative material 1 of the present embodiment uses a matting agent made of an inorganic material having a high matting effect. Therefore, the gloss of the added gloss adjusting layer can be greatly reduced. Therefore, the difference between the gloss of the first gloss adjustment layer 5 and the gloss of the second gloss adjustment layer 6 can be increased. Thereby, the picture expressed by the difference in gloss can be visually recognized more clearly by observation from the front.
  • the particle size of the matting agent is in the range of 2 ⁇ m or more and 15 ⁇ m or less, and the surface strength and design properties required for the cosmetic material 1 are obtained by setting the particle size to an optimal range. Can be compatible.
  • a matting agent is 5 mass parts or more and 40 mass parts or less with respect to 100 mass parts of resin compositions which comprise a gloss adjustment layer with relatively low gloss. It was made to add in. Therefore, the gloss of the added gloss adjusting layer can be surely lowered, so that the pattern expressed by the difference in gloss can be clearly and reliably visually recognized from the front.
  • the gloss adjusting layer to which the matting agent is added is divided into two equal parts in the layer thickness direction of the gloss adjusting layer, and the layer located on the substrate 2 side is set as the lower layer.
  • the layer located on the side opposite to the substrate 2 side is the upper layer, 50% or more of the matting agent added to the gloss adjusting layer is present in the upper layer. Therefore, the matting agent can be sufficiently exposed on the surface of the gloss adjusting layer. By doing this, it is possible to reduce the unevenness imparted to the surface while obtaining a sufficient matte effect by observation from the front, so the effect of scattering light incident from an angle becomes weaker, and observed from an angle The matte effect at the time can be lowered. For this reason, when observed from an oblique direction, the design expressed by the difference in gloss, that is, the design can be made invisible.
  • the matting agent was added also to the gloss adjustment layer with relatively high gloss. Even if it is such a form, the effect which scatters the light which injects from diagonal will become weak, and the matting effect at the time of observing from diagonal can be made low. For this reason, when observed from an oblique direction, the design expressed by the difference in gloss, that is, the design can be made invisible. As a result, the pattern that can be seen when viewed from the front becomes invisible when viewed from an oblique direction. As a result, it is possible to provide the cosmetic material 1 capable of expressing a picture that can be seen only from a specific observation angle.
  • the particle size of the matting agent was 0.2 times or more the layer thickness of the gloss adjusting layer to which the matting agent was added. Therefore, a sufficient matting effect can be reliably obtained even when viewed from the front, and the required design expression can be achieved.
  • Example 1 the impregnated paper having a basis weight 50g / m 2 (GFR-506 : Kohjin Ltd. Co.) was used as the base material 2. Then, on one surface of the base material 2, using the oil-based nitrified cotton resin-based gravure printing ink (PCNT (PCRNT), each color: manufactured by Toyo Ink Co., Ltd.), the base ink layer 3 and the pattern ink layer 4 are provided. They were formed in this order. The pattern of the pattern ink layer 4 was a wood grain pattern.
  • PCNT oil-based nitrified cotton resin-based gravure printing ink
  • an ink for the first gloss adjustment layer 5 is applied on the base 2 on which the pattern ink layer 4 is formed so as to cover the entire surface of one side of the base 2, and the first gloss adjustment layer 5 was formed.
  • Ink is 100 parts by weight of acrylic polyol (6KW-700: manufactured by Taisei Fine Chemical Co., Ltd.), 8 parts by weight of silica matting agent (Mizukasil 310P: manufactured by Fuji Silysia Chemical Co., Ltd.), polyisocyanate (cured by UR190B) Agent: Toyo Ink Co., Ltd.) 10 parts by mass.
  • the amount of ink applied was 3.5 g / m 2 .
  • the layer thickness was 3.2 ⁇ m.
  • the average particle size of the silica-based matting agent was 2.7 ⁇ m.
  • the second gloss adjusting layer 6 was formed by applying the ink for the second gloss adjusting layer 6 to a portion of the first gloss adjusting layer 5 immediately above the pattern ink layer 4.
  • Ink is 100 parts by mass of acrylic polyol (6KW-700: manufactured by Taisei Fine Chemical Co., Ltd.), 3 parts by mass of silica-based matting agent (Mizukasil 310P: manufactured by Fuji Silysia Chemical Co., Ltd.), polyisocyanate (cured by UR190B) Agent: Toyo Ink Co., Ltd.) 10 parts by mass.
  • the average particle size of the silica-based matting agent was 2.7 ⁇ m.
  • Example 2 the ink for the first gloss adjusting layer 5 is applied on the base 2 on which the pattern ink layer 4 is formed so as to cover the entire surface of one side of the base 2, and the first gloss The adjustment layer 5 was formed.
  • Ink is 100 parts by mass of acrylic polyol (6KW-700: manufactured by Taisei Fine Chemical Co., Ltd.), 8 parts by mass of silica-based matting agent (ACEMATT OK900: manufactured by Evonik), polyisocyanate (UR190B curing agent: Toyo Ink) It was composed of 10 parts by mass.
  • the average particle size of the silica-based matting agent was 7.5 ⁇ m.
  • the amount of ink applied was 9 g / m 2 .
  • the layer thickness was 8.6 ⁇ m.
  • the ink for the second gloss adjustment layer 6 is applied only to the portion on the first gloss adjustment layer 5 that is directly above the pattern ink layer 4, so that the second gloss adjustment layer 6 is applied.
  • Ink is 100 parts by weight of acrylic polyol (6KW-700: manufactured by Taisei Fine Chemical Co., Ltd.), 3 parts by weight of a silica matting agent (ACEMATT OK900: manufactured by Evonik) with an average particle size of 7.5 ⁇ m, polyisocyanate (UR190B curing agent: manufactured by Toyo Ink Co., Ltd.) 10 parts by mass. Otherwise, the configuration was the same as in Example 1.
  • Example 3 the ink for the first gloss adjusting layer 5 is applied on the base 2 on which the pattern ink layer 4 is formed so as to cover the entire surface of one side of the base 2, and the first gloss The adjustment layer 5 was formed.
  • Ink is 100 parts by weight of acrylic polyol (6KW-700: manufactured by Taisei Fine Chemical Co., Ltd.), 8 parts by weight of silica-based matting agent (ACEMATT 810: manufactured by Evonik), polyisocyanate (UR190B curing agent: Toyo Ink) It was composed of 10 parts by mass.
  • the average particle size of the silica-based matting agent was 10.5 ⁇ m.
  • the amount of ink applied was 12.5 g / m 2 .
  • the layer thickness was 12.2 ⁇ m.
  • the ink for the second gloss adjustment layer 6 is applied only to the portion on the first gloss adjustment layer 5 that is directly above the pattern ink layer 4, so that the second gloss adjustment layer 6 is applied. 6 was formed.
  • Ink is 100 parts by weight of acrylic polyol (6KW-700: manufactured by Taisei Fine Chemical Co., Ltd.), 3 parts by weight of a silica matting agent (ACEMATT 810: manufactured by Evonik) with an average particle size of 10.5 ⁇ m, polyisocyanate (UR190B curing agent: manufactured by Toyo Ink Co., Ltd.) 10 parts by mass. Otherwise, the configuration was the same as in Example 1.
  • Comparative Example 1 In Comparative Example 1, the base material 2 having the pattern ink layer 4 formed thereon was coated with the ink for the first gloss adjusting layer 5 having the same composition as that of Example 1 so that the application amount was 2.5 g / m 2. It applied so that the whole surface of one side of 2 might be covered. Other than that, the 1st glossiness adjustment layer 5 and the 2nd glossiness adjustment layer 6 were formed similarly to Example 1, and the decorative material 1 was obtained. In addition, the layer thickness of the 1st glossiness adjustment layer 5 at this time was 2.3 micrometers as a result of cross-sectional observation.
  • Comparative example 2 In Comparative Example 2, the base material 2 having the pattern ink layer 4 formed thereon was coated with the ink for the first gloss adjusting layer 5 having the same composition as that of Example 2 so that the coating amount was 7.0 g / m 2. It applied so that the whole surface of one side of 2 might be covered. Other than that, the 1st glossiness adjustment layer 5 and the 2nd glossiness adjustment layer 6 were formed similarly to Example 2, and the decorative material 1 was obtained. In addition, the layer thickness of the 1st glossiness adjustment layer 5 at this time was 6.8 micrometers as a result of cross-sectional observation.
  • the cosmetic material 1 of Examples 1 to 3 as shown in Table 1, it is expressed by the difference between the gloss of the first gloss adjustment layer 5 and the gloss of the second gloss adjustment layer 6 when observed obliquely. It can be seen that the design (design) disappears. That is, it can be seen that a picture that can be seen only from a specific observation angle can be expressed. On the other hand, the decorative materials of Comparative Examples 1 to 3 show no change in the design (design) expressed by the difference in gloss even when observed obliquely. These observation results also appear in the measurement results of the glossiness.
  • the 85 ° glossiness corresponding to the oblique observation can be increased, so that the first gloss adjustment layer 5 and the first glossiness adjustment layer 5
  • the gloss difference (gloss difference) with the gloss adjustment layer 6 of 2 can be reduced.
  • the design expressed by the difference in gloss is considered to be invisible.
  • the cosmetic material of this invention is not limited to said embodiment and Example, A various change is possible in the range which does not impair the characteristic of invention.

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Abstract

本発明は、特定の観察角からだけ見ることのできる絵柄を表現可能な化粧材を提供することを目的とする。本実施形態に係る化粧材（１）では、第１の艶調整層（５）と第２の艶調整層（６）とのうち、相対的に艶の低い艶調整層に、粒径が層厚の１．０倍未満の艶消し剤を添加するようにした。それゆえ、艶消し剤を、艶調整層に浮いている状態で表面に露出させることができる。それゆえ、正面からの観察で十分な艶消し効果を得つつ、表面に付与される凹凸を小さくすることができるため、斜めから入射する光を散乱させる効果が弱くなり、斜めから観察した際の艶消し効果を低くすることができる。そのため、斜めから観察した際に、艶の差により表現された絵柄、つまり、意匠を見えなくすることができる。

Description

化粧材
　本発明は、建築物の内外装、建具、家具等の表面化粧等に使用するための化粧材に関する。さらに詳しくは、表面の艶の差により得られる凹凸感を立体的に表現するとともに、特定の観察角からだけ見ることのできる絵柄を表現可能な化粧材に関する。
　従来、例えば、建築物の内外装、建具、家具等の表面化粧等に用いられる化粧材には、木目柄や石目柄等の所望の柄模様が施されるのが通例である。また、単に木目柄や石目柄等の柄模様を平面的に表現するだけでなく、天然の木材や石材が持つ表面の凹凸感を併せて立体的に表現した化粧材も、高級感が所望される用途を中心に広く用いられている。
　化粧材の表面に平面的な柄模様と併せて立体的な凹凸感を表現する手法としては、従来、様々な方法が考案され、目的に応じて使い分けられている。なかでも、化粧材の表面に実際に凹凸を形成するのではなく、凹部または凸部として表現したい部分の表面の艶状態（具体的には光沢度）を異ならせることにより、人間の目の錯覚を利用して視覚的に凹凸の立体感を表現する手法がある。この手法によれば、実際には凹凸形状が存在しなくても、人間の目には、相対的に艶の高い部分は凸部、艶の低い部分は凹部として認識される。
　具体的には、例えば、凹み模様を含む適宜模様が印刷された基材の印刷面の全面に、艶の低い透明または半透明の合成塗料層を形成した後、形成した合成塗料層の表面の凹み模様に対応する部分を除く部分に艶の高い透明または半透明の合成塗料層を形成する。勿論、艶の高低の関係を逆転させれば、凹凸の関係を逆転させた化粧材を得ることができる。
　このような手法によれば、特殊な薬剤等を必要とすることなく、艶の異なる２種類の塗料を用意するだけで、いかなる基材に対しても、容易に立体的な凹凸感を付与することができる。しかも、艶の異なる合成塗料層の形成は、柄模様（柄インキ層）の形成に引き続きグラビア印刷法等の慣用の印刷法で行うことができるので、特殊設備は一切不要で生産能率も高く、柄模様との同調も容易である。また、合成塗料層の厚みは表現しようとする凹凸の高低差と比較すれば遥かに薄く済むので、樹脂の使用量を削減できるほか、可撓性の面でも有利であり、折り曲げ加工適性に優れた化粧材を容易に実現できる。また、化粧材の表面に大きな凹凸が無いので、凹部に汚染物が留まることも無いという利点もある。
　かかる多くの利点に鑑み、この手法を採用した化粧材は、既に大量に使用されているが、高級感の点ではまだ実際に凹凸を形成する手法を凌ぐには至っていないのが実情である。その理由を考察するに、例えば、機械式エンボス法によれば、天然木の導管等の凹凸形状を、導管等の断面形状まで含めて忠実に再現することが可能である。これに対し、艶の異なる２種類の塗料を使用したこの手法では、表面の艶の段階は２種類であるから、表現できる凹凸の段階も２種類となる。したがって、天然木の導管等の様に、深さ（高さ）が連続的に変化した斜面部を有する凹凸形状を表現することが難しいという問題点がある。
　そこで、近年、深さが連続的に変化した斜面部を有する凹凸形状を表現する合成塗料層（以下、「艶調整層」とも呼ぶ）を設けることによって、天然木の導管等のように、斜面部を有する凹凸形状を表現可能な化粧材が提案されている（例えば、特許文献１参照）。
特許第３６２９９６４号公報
　ところで、化粧材に求められる意匠としては、前述の通り、古くから天然物（木目や石目等）を再現することが好まれてきたが、昨今では、人工的な絵柄（幾何学模様や文字等）を表現することが求められている。これらは、印刷によって表現されることもあるが、前述した艶の差により得られる凹凸感を利用して表現することもできる。艶の差により絵柄を表現する場合、下地の柄は透過して見えるため、天然物のように柄と一致させて凹凸感を付与するだけでなく、全く異なる絵柄をデザインとして表現することも可能である。
　ここで、艶調整層の艶の調整方法としては、バインダーとしての透明樹脂中に艶調整剤（艶消し剤）を添加する方法が一般的である。艶調整剤としては、無機材料または有機材料の微粒子が主に用いられており、特に、無機材料の微粒子（特にシリカ微粒子）は艶消し能が高く、広く用いられている。艶調整剤を添加することにより、艶調整剤が艶調整層の表面に凹凸を付与し、この凹凸が光を散乱することで艶消し効果が得られる。これら艶調整剤の種類や添加量を調整することで、求められる艶を自在に作り出すことができる。
　しかしながら、艶調整剤により付与される凹凸は、艶調整層の厚さに対して小さく、さらに、機械式エンボス法により付与される凹凸に比較すると非常に小さい。そのため、化粧材表面を正面から観察した場合と、斜めから観察した場合とで、艶の差により得られる凹凸感が変化してしまう現象が発生する。これは、斜めからの観察においては、相対的に艶の低い部分の艶（光沢度）が上昇してしまうため、相対的に艶（光沢度）の高い部分と艶（光沢度）の低い部分との艶の差（光沢度の差）が小さくなってしまうためである。
　一方、このような現象は、意匠表現にとって、場合によっては重要な効果となる。すなわち、艶の差により表現した絵柄を観察する角度によって見え方を変化させ、正面から観察した際に見える絵柄が、斜めからの観察では見えなくなるという設計が可能となる。
　本発明は、上記課題を解決するために、特定の観察角からだけ見ることのできる絵柄を表現可能な化粧材を提供することを目的とする。
　本発明者らは、鋭意検討の結果、相対的に艶の低い艶調整層の層厚と添加される艶消し剤の粒径を最適な範囲とすることで、斜めから観察した際に艶調整層の艶が積極的に上昇されるようにし、艶の差により表現された絵柄（意匠）を見えなくすることを見出した。
　上記課題を達成するべく、本発明の一態様の化粧材は、基材上に設けられた第１の艶調整層と、第１の艶調整層上に部分的に設けられ、第１の艶調整層の艶と異なる艶を有する第２の艶調整層とを備え、第１の艶調整層と第２の艶調整層とのうち、相対的に艶の低い艶調整層に、粒径が層厚の１．０倍未満の艶消し剤が添加されていることを特徴とする。
　本発明の一態様の化粧材によれば、艶の低い艶調整層の層厚と添加される艶消し剤の粒径を最適な範囲とすることで、斜めから観察した際に艶調整層の艶消し効果が低下されるようにし、艶の差により表現された絵柄を見えなくすることができる。これにより、特定の観察角からだけ見ることのできる絵柄を表現可能な化粧材を提供することができる。
本発明に係る実施形態の化粧材を示す断面図である。
　本発明の実施形態に係る化粧材１について、図面を参照して説明する。
　ここで、図面は模式的なものであり、厚みと平面寸法との関係、各層の厚みの比率等は現実のものとは異なる。また、以下に示す実施形態は、本発明の技術的思想を具体化するための構成を例示するものであって、本発明の技術的思想は、構成部品の材質、形状および構造等を下記のものに特定するものでない。本発明の技術的思想は、特許請求の範囲に記載された請求項が規定する技術的範囲内において、種々の変更を加えることができる。
（構成）
　図１に示すように、本実施形態の化粧材１は、基材２上に設けられた第１の艶調整層５と、第１の艶調整層５上に部分的に設けられ、第１の艶調整層５の艶と異なる艶を有する第２の艶調整層６とを備えている。そして、これら第１、第２の艶調整層５、６のうち、相対的に艶の低い艶調整層に、粒径が層厚の１．０倍未満、より好ましくは０．９倍以下の艶消し剤が添加されていることが重要である。これにより、艶消し剤を、艶調整層に浮いている状態で表面に露出させることができる。それゆえ、正面からの観察で十分な艶消し効果を得つつ、表面に付与される凹凸を小さくすることができるため、斜めから入射する光を散乱させる効果が弱くなり、斜めから観察した際の艶消し効果を低くすることができる。そのため、斜めから観察した際に、艶の差により表現された絵柄、つまり、意匠を見えなくすることができる。
　なお、基材２と第１の艶調整層５との間には、後述するように下地インキ層３、柄インキ層４および透明樹脂層（不図示）等、他の層を配置する構成としてもよい。また、下地インキ層３は、例えば、基材２上にインキをベタ塗りして形成した層であってもよい。
　ここで、層厚とは、相対的に艶の低い艶調整層の断面を観察した際に艶消し剤同士の間を満たす樹脂部分の厚さである。本実施形態では、艶消し剤の粒径が層厚の１．０倍未満、より好ましくは０．９倍以下となっているため、艶消し剤は艶調整層内で浮いている状態、もしくは複数の艶消し剤が重なり合うことで艶調整層の表面に露出している状態となっている。そのため、層厚の測定は艶消し剤の露出していない樹脂部分、もしくは艶消し剤の間の樹脂部分を複数箇所測長し、得られた値を平均化することで求めることができる。また、粒径については、粒子形状が球状で無い場合には、粒子の断面を楕円形状としてその長径と短径との平均値を粒径とすればよい。つまり、本実施形態において粒径とは、粒子の断面形状を円状又は楕円形状と仮定した場合の平均粒径である。
　また、艶消し剤の粒径の下限値は、粒径が小さくなり過ぎると正面からの観察でも艶消し効果が小さくなってしまい、要求される意匠表現ができなくなってしまうことを考慮すれば、相対的に艶の低い艶調整層の層厚の０．２倍とするのが好ましい。
　なお、層厚と艶消し剤の粒径との関係としては、艶消し剤の粒径は、層厚の１．０倍未満、より好ましくは０．９倍以下であることが重要であり、具体的な大きさとしては、２μｍ以上１５μｍ以下であることが好ましい。この数値範囲内であれば、任意の粒径を選択することができる。例えば、層厚を５μｍに設定した場合、艶消し剤の粒径は５μｍ未満、より好ましくは４．５μｍ以下とすればよい。
　艶消し剤としては、市販されている公知の艶消し剤等を用いることができる。例えば、シリカ、ガラス、アルミナ、炭酸カルシウム、硫酸バリウム、アクリル等の無機材料からなる微粒子が挙げられる。第１、第２の艶調整層５、６は、透明性が高いことが要求されるため、なかでも、透明性の高いシリカ、ガラス、アクリル等の微粒子を用いることが望ましい。特に、シリカ微粒子のなかでも、中実の真球状粒子ではなく、微細な１次粒子が２次凝集してなる嵩密度の低い艶消し剤は添加量に対する艶消し効果が高い。それゆえ、このような艶消し剤を用いることで、より艶の低い艶調整層を形成できる。これにより、第１の艶調整層５と第２の艶調整層６の艶の差を大きくすることができ、得られる凹凸感を大きくすることができる。これにより、より深みのある優れた意匠表現が可能となる。
　艶消し剤の粒径は、前述の通り、任意の数値を選択できるが、公知の艶消し剤を使用する場合には、２μｍ以上１５μｍ以下とすることが好ましい。さらに好ましくは、４μｍ以上１２μｍ以下とする。粒径が２μｍ未満の艶消し剤は、艶消し効果が低いため、本実施形態の特徴である凹凸感が十分に得られない。また、粒径が１５μｍより大きい艶消し剤は、光の散乱が大きくなってしまうため、第１、第２の艶調整層５、６の白濁を招いたり、目視での粒子感が大きくなったりし、本実施形態の特徴である凹凸感が損なわれてしまう。
　なお、艶消し剤は、例えば、その艶消し剤が添加された艶調整層を構成する樹脂組成物内に浮くのであれば、その比重は当該樹脂組成物よりも小さくてもよいし、大きくてもよい。
　また、艶消し剤が添加された艶調整層を当該艶調整層の層厚方向に２等分し、基材２側に位置する層を下層とし、基材２側とは反対側に位置する層を上層とした場合に、当該上層には、艶調整層に添加された艶消し剤の５０％以上が存在していてもよい。ここで、艶調整層に添加された艶消し剤の存在比は、断面観察をした場合に艶消し剤とそれ以外の艶調整層を構成する樹脂部分との面積比によって算出される比率によって定義されるものである。つまり、艶調整層の上層は、面積比に換算して、艶調整層の下層と同量の艶消し剤又はそれ以上の艶消し剤を含んでいればよい。
　上記構成であれば、複数の艶消し剤が重なり合う頻度が高まり艶調整層の表面に艶消し剤が露出している状態が容易に形成される。
　第１、第２の艶調整層５、６を構成する樹脂部分（樹脂組成物）としては、例えば、ポリウレタン系、アクリルシリコン系、フッ素系、エポキシ系、ビニル系、ポリエステル系、メラミン系、アミノアルキッド系、尿素系等を用いることができる。また、樹脂組成物の形態は、水性、エマルジョン、溶剤系等、特に限定されるものではない。さらに、樹脂組成物の硬化法としては、例えば、一液タイプ、二液タイプ、紫外線硬化法等を用いることができる。
　本実施形態では、特に、樹脂組成物としてイソシアネートを用いたウレタン系のものが、作業性、価格、樹脂自体の凝集力等の観点から好適である。イソシアネートとしては、例えば、トリレンジイソシアネート（ＴＤＩ）、キシリレンジイソシアネート（ＸＤＩ）、ヘキサメチレンジイソシアネート（ＨＭＤＩ）、ジフェニルメタンジイソシアネート（ＭＤＩ）、リジンジイソシアネート（ＬＤＩ）、イソホロンジイソシアネート（ＩＰＤＩ）、メチルヘキサンジイソシアネート（ＨＴＤＩ）、ビス（イソシアネートメチル）シクロヘキサン（ＨＸＤＩ）、トリメチルヘキサメチレンジイソシアネート（ＴＭＤＩ）等の誘導体であるアダクト体、ビュレット体およびイソシアヌレート体等の硬化剤を用いることができる。
　これらのうち、耐候性が求められる用途では、直鎖状の分子構造を有するヘキサメチレンジイソシアネート（ＨＭＤＩ）を用いることが好ましい。また、表面硬度が求められる用途では、イソホロンジイソシアネート（ＩＰＤＩ）を用いることが好ましい。さらに、ヘキサメチレンジイソシアネート（ＨＭＤＩ）とイソホロンジイソシアネート（ＩＰＤＩ）との利点を組み合わせるべく、混合して用いることも有効である。この他にも、表面硬度の向上を図る場合には、紫外線や電子線等の活性エネルギー線で硬化する樹脂を用いることが好ましい。なお、これらの樹脂は、相互に組み合わせて用いることが可能である。
　また、第１、第２の艶調整層５、６には、各種機能を付与するために、例えば、抗菌剤、防カビ剤等の機能性添加剤を添加してもよい。また、必要に応じて紫外線吸収剤、光安定化剤を添加してもよい。紫外線吸収剤としては、例えば、ベンゾトリアゾール系、ベンゾエート系、ベンゾフェノン系、トリアジン系を用いることができる。また、光安定化剤としては、ヒンダードアミン系を用いることができる。さらに、汚染防止性能やセロテープ（登録商標）離型性が求められる場合には、シリコーン骨格を持つ離型剤を添加することができる。この場合、離型剤の種類は特に限定されないが、樹脂組成物に対して反応性を有する末端官能基を持つシリコーン離型剤を用いることで、汚染防止性能やセロテープ離型性の耐久性を向上できる。
　本実施形態では、第１、第２の艶調整層５、６は、互いに異なる艶を有している。また、第１の艶調整層５は、基材２の第１の艶調整層５側の面の全面を被覆しており、第２の艶調整層６は、第１の艶調整層５上の第２の艶調整層６側の面を部分的に被覆している。そして、第１、第２の艶調整層５、６の艶の差により絵柄（意匠）が表現されている。
　なお、本実施形態では、第１の艶調整層５が、基材２の第１の艶調整層５側の面の全面を被覆する例を示したが、他の構成を採用することもできる。例えば、第１の艶調整層５が、基材２の第１の艶調整層５側の面を部分的に被覆する構成としてもよい。
　また、第１、第２の艶調整層５、６のうち、相対的に艶の低い艶調整層には、艶消し剤が添加されている。艶消し剤の添加量は、樹脂組成物１００質量部に対して５質量部以上４０質量部以下が好ましい。さらに好ましくは、１０質量部以上３０質量部以下とする。５質量部未満である場合には、艶消し効果が不足するため、相対的に艶の高い艶調整層との艶の差が小さくなり、凹凸感が不足し、艶の差により表現された絵柄が見え難くなる。その結果、表現したい意匠感が不足してしまう。また、４０質量部より大きい場合には、艶消し剤に対して樹脂組成物が相対的に不足するため、艶消し剤の脱落や、脱落による耐傷性の低下を招いてしまい、化粧材１に求められる耐久性が大きく損なわれてしまう。
　なお、相対的に艶の高い艶調整層においても、任意の艶消し剤を添加することが可能である。これらは最終的な凹凸感や意匠性に応じて適宜調整されるべきものである。また、第１、第２の艶調整層５、６に用いられる艶消し剤および樹脂組成物は、同じでも異なっていてもよい。これらは凹凸感および各種要求特性から自由に選択することができる。
　また、第１、第２の艶調整層５、６の層厚は、任意の数値を選択できるが、前述の通り、艶消し剤の粒径は２μｍ以上１５μｍ以下が好ましいため、同等程度の範囲内、より好ましくは２．３μｍ以上１６．７μｍ以下とすることが好ましい。また、第１、第２の艶調整層５、６は、化粧材１の最表面となる層のため、化粧材１として必要な耐摩耗性、耐擦傷性、耐溶剤性、耐汚染性等の表面物性が求められる。なかでも、耐摩耗性や耐擦傷性は層厚による影響があり、層厚が厚い方が有利となる。したがって、第１、第２の艶調整層５、６のさらに好ましい層厚は２．３μｍ以上１２μｍ以下となる。２．３μｍ未満の場合、耐摩耗性および耐擦傷性が大幅に悪くなるため、化粧材１としての用途が限られることがある。また、１６．７μｍより大きい場合、第１、第２の艶調整層５、６自体の可撓性が悪くなるため、化粧材１としての加工性が悪化することがある。
　基材２は、化粧材１の原紙として用いられるものであれば、特に限定されるものではない。例えば、薄葉紙、樹脂混抄紙、チタン紙、樹脂含浸紙、難燃紙、無機質紙等の紙類、天然繊維または合成繊維からなる織布もしくは不織布、ホモまたはランダムポリプロピレン樹脂、ポリエチレン樹脂等のポリオレフィン樹脂、共重合ポリエステル樹脂、アモルファス状態の結晶性ポリエステル樹脂、ポリエチレンナフタレート樹脂、ポリブチレン樹脂、アクリル系樹脂、ポリアミド樹脂、ポリカーボネート樹脂、ポリ塩化ビニル樹脂、ポリ塩化ビニリデン樹脂、フッ素系樹脂等の合成樹脂系基材、木材単板、突板、合板、集成材、パーティクルボード、中密度繊維板等の木質系基材、石膏板、セメント板、珪酸カルシウム板、陶磁器板等の無機系基材、鉄、銅、アルミニウム、ステンレス等の金属系基材、またはこれらの複合材、積層体等、従来公知の材料を用いることができる。また、基材２の形状としては、例えば、フィルム状、シート状、板状、異型成型体等を用いることができる。
　なお、基材２と第１の艶調整層５の間には、化粧材１に柄模様を付加するための柄インキ層４を設けることができる。柄模様としては、例えば、木目模様、石目模様、砂目模様、タイル貼模様、煉瓦積模様、布目模様、皮絞模様、幾何学図形等を用いることができる。図１の例では、柄インキ層４は、第２の艶調整層６の直下の部分に形成されている。また、柄インキ層４の柄模様は、第２の艶調整層６の艶と同調しておらず、第２の艶調整層６の艶と全く異なる柄模様を表現している。言い換えると、第２の艶調整層６の艶の差により表現する絵柄は、柄インキ層４の柄模様と全く異なる絵柄をデザインとして表現している。
　さらに、基材２と柄インキ層４との間には、求められる意匠に応じて、基材２の第１の艶調整層５側の面の全面を被覆する下地インキ層３を設けるようにしてもよい。また、下地インキ層３は、隠蔽性等、必要に応じて２層以上の多層としてもよい。さらに、柄インキ層４は、求められる意匠を表現するために必要な分版の数だけ積層して形成してもよい。このように、柄インキ層４と下地インキ層３とは、求められる意匠、つまり、表現したい意匠に応じて様々な組み合わせとなるが、特に限定されるものではない。
　下地インキ層３および柄インキ層４の構成材料は、特に限定されるものではない。例えば、マトリックスと、染料、顔料等の着色剤とを溶剤中に溶解、分散してなる印刷インキやコーティング剤を用いることができる。マトリックスとしては、例えば、油性の硝化綿樹脂、２液ウレタン樹脂、アクリル系樹脂、スチレン系樹脂、ポリエステル系樹脂、ウレタン系樹脂、ポリビニル系樹脂、アルキド樹脂、エポキシ系樹脂、メラミン系樹脂、フッ素系樹脂、シリコーン系樹脂、ゴム系樹脂等の各種合成樹脂類、またはこれらの混合物、共重合体等を用いることができる。また、着色剤としては、例えば、カーボンブラック、チタン白、亜鉛華、弁柄、黄鉛、紺青、カドミウムレッド等の無機顔料や、アゾ顔料、レーキ顔料、アントラキノン顔料、フタロシアニン顔料、イソインドリノン顔料、ジオキサジン顔料等の有機顔料、またはこれらの混合物を用いることができる。また、溶剤としては、例えば、トルエン、キシレン、酢酸エチル、酢酸ブチル、メチルアルコール、エチルアルコール、イソプロピルアルコール、アセトン、メチルエチルケトン、メチルイソブチルケトン、シクロヘキサノン、水等、もしくはこれらの混合物等を用いることができる。
　また、下地インキ層３および柄インキ層４には、各種機能を付与するために、例えば、体質顔料、可塑剤、分散剤、界面活性剤、粘着付与剤、接着助剤、乾燥剤、硬化剤、硬化促進剤および硬化遅延剤等の機能性添加剤を添加してもよい。
　下地インキ層３、柄インキ層４および第１、第２の艶調整層５、６の各層は、例えば、グラビア印刷法、オフセット印刷法、スクリーン印刷法、静電印刷法、インクジェット印刷法等の各種印刷方法によって形成することができる。また、下地インキ層３および第１の艶調整層５は、基材２の第１の艶調整層５側の面の全面を被覆しているため、例えば、ロールコート法、ナイフコート法、マイクログラビアコート法、ダイコート法等の各種コーティング方法によっても形成することができる。これらの印刷方法、コーティング方法は、形成する層によって別々に選択してもよいし、同じ方法を選択して一括加工してもよい。
　第１、第２の艶調整層５、６の層厚を調整するには、前述の印刷方法およびコーティング方法において塗布量を調整すればよい。塗布量は、各種印刷方法およびコーティング方法において、基材２に艶調整層を形成したものと、しないものとを作製し、質量差から算出することができる。塗布量と層厚との関係は、断面観察により求めることができる。
　また、特に耐摩耗性が要求される場合には、柄インキ層４と第１の艶調整層５の間に透明樹脂層（不図示）を設けることができる。透明樹脂層としては、例えば、オレフィン系樹脂を主成分とした樹脂組成物を用いることが好ましい。オレフィン系樹脂としては、例えば、ポリプロピレン、ポリエチレン、ポリブテン等の他に、αオレフィン（例えば、プロピレン、１－ブテン、１－ペンテン、１－ヘキセン、１－ヘプテン、１－オクテン、１－ノネン、１－デセン、１－ウンデセン、１－ドデセン、トリデセン、１－テトラデセン、１－ペンタデセン、１－ヘキサデセン、１－ヘプタデセン、１－オクタデセン、１－ノナデセン、１－エイコセン、３－メチル－１－ブテン、３－メチル－１－ペンテン、３－エチル－１－ペンテン、４－メチル－１－ペンテン、４－メチル－１－ヘキセン、４，４－ジメチル－１－ペンテン、４－エチル－１－ヘキセン、３－エチル－１－ヘキセン、９－メチル－１－デセン、１１－メチル－１－ドデセン、１２－エチル－１－テトラデセン等）を単独重合あるいは２種類以上共重合させたものや、エチレン・酢酸ビニル共重合体、エチレン・ビニルアルコール共重合体、エチレン・メチルメタクリレート共重合体、エチレン・エチルメタクリレート共重合体、エチレン・ブチルメタクリレート共重合体、エチレン・メチルアクリレート共重合体、エチレン・エチルアクリレート共重合体、エチレン・ブチルアクリレート共重合体等のように、エチレンまたはαオレフィンとそれ以外のモノマーとを共重合させたものを用いることができる。特に、表面強度の更なる向上を図る場合には、高結晶性のポリプロピレンを用いることが好ましい。
　また、透明樹脂層には、例えば、熱安定剤、紫外線吸収剤、光安定化剤、ブロッキング防止剤、触媒捕捉剤および着色剤等の添加剤を添加してもよい。これらの添加剤は、公知のものから適宜選択して使用することができる。また、透明樹脂層は、例えば、熱圧を応用した方法、押出ラミネート方法、ドライラミネート方法等の各種積層方法によって形成することができる。
（作用その他）
（１）以上のように、本実施形態の化粧材１では、第１の艶調整層５と第２の艶調整層６とのうち、相対的に艶の低い艶調整層に、粒径が層厚の１．０倍未満、より好ましくは０．９倍以下の艶消し剤を添加するようにした。それゆえ、艶消し剤を、艶調整層に浮いている状態で表面に露出させることができる。それゆえ、正面からの観察で十分な艶消し効果を得つつ、表面に付与される凹凸を小さくすることができるため、斜めから入射する光を散乱させる効果が弱くなり、斜めから観察した際の艶消し効果を低くすることができる。そのため、斜めから観察した際に、艶の差により表現された絵柄、つまり、意匠を見えなくすることができる。
　これにより、正面から観察した際に見える絵柄が、斜めからの観察では見えなくなる。その結果、特定の観察角からだけ見ることのできる絵柄を表現可能な化粧材１を提供することができる。そして、観察する角度によって艶の差により表現した絵柄が見えなくなるような、メッセージ性の高い意匠表現を可能にした化粧材１を提供することができる。
（２）さらに、本実施形態の化粧材１では、艶消し効果の高い無機材料からなる艶消し剤を用いる。そのため、添加される艶調整層の艶を大きく下げられる。それゆえ、第１の艶調整層５の艶と第２の艶調整層６の艶との差を大きくすることができる。これにより、艶の差により表現された絵柄を、正面からの観察でより明確に視認させることができる。
（３）また、本実施形態の化粧材１では、艶消し剤の粒径を２μｍ以上１５μｍ以下の範囲内とし、最適な範囲にすることで、化粧材１として求められる表面強度、意匠性を両立できる。
（４）また、本実施形態の化粧材１では、相対的に艶の低い艶調整層を構成する樹脂組成物１００質量部に対して、艶消し剤を５質量部以上４０質量部以下の範囲内で添加するようにした。それゆえ、添加される艶調整層の艶を確実に下げられるため、艶の差により表現された絵柄を、正面からの観察でより明確で、且つ確実に視認させることができる。
（５）また、本実施形態の化粧材１では、艶消し剤が添加された艶調整層を当該艶調整層の層厚方向に２等分し、基材２側に位置する層を下層とし、基材２側とは反対側に位置する層を上層とした場合に、当該上層には、艶調整層に添加された艶消し剤の５０％以上が存在するようにした。それゆえ、艶消し剤を艶調整層の表面に十分に露出させることができる。こうすることで、正面からの観察で十分な艶消し効果を得つつ、表面に付与される凹凸を小さくすることができるため、斜めから入射する光を散乱させる効果が弱くなり、斜めから観察した際の艶消し効果を低くすることができる。そのため、斜めから観察した際に、艶の差により表現された絵柄、つまり、意匠を見えなくすることができる。
（６）また、本実施形態の化粧材１では、相対的に艶の高い艶調整層にも艶消し剤を添加するようにした。このような形態であっても、斜めから入射する光を散乱させる効果が弱くなり、斜めから観察した際の艶消し効果を低くすることができる。そのため、斜めから観察した際に、艶の差により表現された絵柄、つまり、意匠を見えなくすることができる。これにより、正面から観察した際に見える絵柄は、斜めからの観察では見えなくなる。その結果、特定の観察角からだけ見ることのできる絵柄を表現可能な化粧材１を提供することができる。
（７）また、本実施形態の化粧材１では、艶消し剤の粒径を、艶消し剤が添加された艶調整層の層厚の０．２倍以上とした。そのため、正面からの観察でも十分な艶消し効果が確実に得られ、要求される意匠表現が可能となる。
　以下に、本発明の化粧材１の実施例について説明する。
　＜実施例１＞
　実施例１では、坪量５０ｇ／ｍ２の含浸紙（GFR-506：興人(株)製）を基材２として用いた。そして、基材２の一方の面に、油性硝化綿樹脂系グラビア印刷インキ（PCNT（PCRNT）各色：東洋インキ(株)製）を使用して、下地インキ層３と、柄インキ層４とをこの順に形成した。柄インキ層４の柄模様は、木目柄とした。
　続いて、柄インキ層４を形成した基材２上に、第１の艶調整層５用のインキを基材２の一方の面の全面を被覆するように塗布し、第１の艶調整層５を形成した。インキは、アクリルポリオール（6KW-700：大成ファインケミカル(株)製）１００質量部に対して、シリカ系艶消し剤（ミズカシル310P：富士シリシア化学(株)製）８質量部、ポリイソシアネート（UR190B硬化剤：東洋インキ(株)製）１０質量部から構成した。インキの塗布量は３．５ｇ／ｍ２とした。層厚は断面観察の結果、３．２μｍであった。シリカ系艶消し剤の平均粒径は２．７μｍとした。次に、第２の艶調整層６用のインキを、第１の艶調整層５上の、柄インキ層４の直上の部分に塗布することで、第２の艶調整層６を形成した。インキは、アクリルポリオール（6KW-700：大成ファインケミカル(株)製）１００質量部に対して、シリカ系艶消し剤（ミズカシル310P：富士シリシア化学(株)製）３質量部、ポリイソシアネート（UR190B硬化剤：東洋インキ(株)製）１０質量部から構成した。シリカ系艶消し剤の平均粒径は２．７μｍとした。
　＜実施例２＞
　実施例２では、柄インキ層４を形成した基材２上に、第１の艶調整層５用のインキを基材２の一方の面の全面を被覆するように塗布し、第１の艶調整層５を形成した。インキは、アクリルポリオール（6KW-700：大成ファインケミカル(株)製）１００質量部に対して、シリカ系艶消し剤（ACEMATT OK900：エボニック社製）８質量部、ポリイソシアネート（UR190B硬化剤：東洋インキ(株)製）１０質量部から構成した。シリカ系艶消し剤の平均粒径は７．５μｍとした。また、インキの塗布量は９ｇ／ｍ２とした。層厚は断面観察の結果、８．６μｍであった。次に、第２の艶調整層６用のインキを、第１の艶調整層５上であって、柄インキ層４の直上となる部分にのみ塗布することで、第２の艶調整層６を形成した。インキは、アクリルポリオール（6KW-700：大成ファインケミカル(株)製）１００質量部に対して、平均粒径７．５μｍのシリカ系艶消し剤（ACEMATT OK900：エボニック社製）３質量部、ポリイソシアネート（UR190B硬化剤：東洋インキ(株)製）１０質量部から構成した。それ以外は実施例１と同様の構成とした。
　＜実施例３＞
　実施例３では、柄インキ層４を形成した基材２上に、第１の艶調整層５用のインキを基材２の一方の面の全面を被覆するように塗布し、第１の艶調整層５を形成した。インキは、アクリルポリオール（6KW-700：大成ファインケミカル(株)製）１００質量部に対して、シリカ系艶消し剤（ACEMATT 810：エボニック社製）８質量部、ポリイソシアネート（UR190B硬化剤：東洋インキ(株)製）１０質量部から構成した。シリカ系艶消し剤の平均粒径は１０．５μｍとした。また、インキの塗布量は１２．５ｇ／ｍ２とした。層厚は断面観察の結果、１２．２μｍであった。次に、第２の艶調整層６用のインキを、第１の艶調整層５上であって、柄インキ層４の直上となる部分にのみに塗布することで、第２の艶調整層６を形成した。インキは、アクリルポリオール（6KW-700：大成ファインケミカル(株)製）１００質量部に対して、平均粒径１０．５μｍのシリカ系艶消し剤（ACEMATT 810：エボニック社製）３質量部、ポリイソシアネート（UR190B硬化剤：東洋インキ(株)製）１０質量部から構成した。それ以外は実施例１と同様の構成とした。
　＜比較例１＞
　比較例１では、柄インキ層４を形成した基材２上に、実施例１と同じ組成の第１の艶調整層５用のインキを塗布量２．５ｇ／ｍ２となるように基材２の一方の面の全面を被覆するように塗布した。それ以外は実施例１と同様に第１の艶調整層５および第２の艶調整層６を形成し、化粧材１を得た。なお、このときの第１の艶調整層５の層厚は、断面観察の結果、２．３μｍであった。
　＜比較例２＞
　比較例２では、柄インキ層４を形成した基材２上に、実施例２と同じ組成の第１の艶調整層５用のインキを塗布量７．０ｇ／ｍ２となるように基材２の一方の面の全面を被覆するように塗布した。それ以外は実施例２と同様に第１の艶調整層５および第２の艶調整層６を形成し、化粧材１を得た。なお、このときの第１の艶調整層５の層厚は、断面観察の結果、６．８μｍであった。
　＜比較例３＞
　比較例３では、柄インキ層４を形成した基材２上に、実施例３と同じ組成の第１の艶調整層５用のインキを塗布量１０．０ｇ／ｍ２となるように基材２の一方の面の全面を被覆するように塗布した。それ以外は実施例３と同様に第１の艶調整層５および第２の艶調整層６を形成し、化粧材１を得た。なお、このときの第１の艶調整層５の層厚は、断面観察の結果、９．７μｍであった。
　＜評価＞
　以上の実施例１～３、比較例１～３について、意匠性と光沢度の評価を行った。
　＜意匠性＞
　正面および斜めから化粧材１の意匠性を観察した。そして、斜めからの観察で艶の差による絵柄（意匠）が見られなくなる場合を「○」、斜めからの観察で艶の差による絵柄（意匠）がかなり弱くなっている場合を「△」、斜めからの観察で艶の差による絵柄（意匠）が変化せずに見られる場合を「×」とした。
　＜光沢度＞
　第１の艶調整層５、つまり、相対的に艶の低い艶調整層における２０°、６０°、８５°の光沢度を測定した。
　これらの評価結果を表１に示す。
Figure JPOXMLDOC01-appb-T000001
　実施例１～３の化粧材１では、表１に示すように、斜めから観察した際に第１の艶調整層５の艶と第２の艶調整層６の艶との差により表現される絵柄（意匠）が見えなくなることが分かる。すなわち、特定の観察角からだけ見ることのできる絵柄を表現可能であることが分かる。一方、比較例１～３の化粧材では、斜めから観察しても艶の差により表現される絵柄（意匠）に変化が見られない。また、これらの観察結果は光沢度の測定結果にも現れており、実施例１～３では斜め観察に該当する８５°光沢度を高くすることができるため、第１の艶調整層５と第２の艶調整層６との光沢度差（艶の差）を小さくすることができる。その結果、艶の差により表現される意匠が見えなくなっていると考えられる。
　なお、本発明の化粧材は、上記の実施形態および実施例に限定されるものではなく、発明の特徴を損なわない範囲において種々の変更が可能である。
１　化粧材
２　基材
３　下地インキ層
４　柄インキ層
５　第１の艶調整層
６　第２の艶調整層

Claims (7)

  1. 　基材上に設けられた第１の艶調整層と、前記第１の艶調整層上に部分的に設けられ、前記第１の艶調整層の艶と異なる艶を有する第２の艶調整層とを備え、
    　前記第１の艶調整層と前記第２の艶調整層とのうち、相対的に艶の低い艶調整層に、粒径が層厚の１．０倍未満の艶消し剤が添加されていることを特徴とする化粧材。
  2. 　前記艶消し剤は、無機材料からなることを特徴とする請求項１に記載の化粧材。
  3. 　前記艶消し剤の粒径は、２μｍ以上１５μｍ以下の範囲内であることを特徴とする請求項１または２に記載の化粧材。
  4. 　前記艶消し剤は、前記艶消し剤が添加された前記艶調整層を構成する樹脂組成物１００質量部に対して、５質量部以上４０質量部以下の範囲内で添加されていることを特徴とする請求項１から３のいずれか１項に記載の化粧材。
  5. 　前記艶消し剤が添加された前記艶調整層を当該艶調整層の層厚方向に２等分し、前記基材側に位置する層を下層とし、前記基材側とは反対側に位置する層を上層とした場合に、前記上層には、前記艶調整層に添加された前記艶消し剤の５０％以上が存在していることを特徴とする請求項１から４のいずれか１項に記載の化粧材。
  6. 　前記艶消し剤は、相対的に艶の高い艶調整層にも添加されていることを特徴とする請求項１から５のいずれか１項に記載の化粧材。
  7. 　前記艶消し剤の粒径は、前記艶消し剤が添加された前記艶調整層の層厚の０．２倍以上であることを特徴とする請求項１から６のいずれか１項に記載の化粧材。
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