WO2020196377A1

WO2020196377A1 - Decorative material

Info

Publication number: WO2020196377A1
Application number: PCT/JP2020/012643
Authority: WO
Inventors: 小笠原　健; 玲子桜井; 祥太西根
Original assignee: 大日本印刷株式会社
Priority date: 2019-03-28
Filing date: 2020-03-23
Publication date: 2020-10-01
Also published as: JP7409371B2; JPWO2020196377A1

Abstract

The present invention provides a decorative material that has high tactility expressed by a physical uneven shape, has exceptional design properties through a visual sense of irregularity accompanying the physical uneven shape, and has exceptional soiling resistance and abrasion resistance.　This decorative material has a substrate, a pattern layer that covers a portion of one surface of the substrate, a raised printing layer, and a surface-protective layer, wherein the decorative material is such that: the raised printing layer is provided so as to cover at least a part of a region where the pattern layer is not formed in plan view, and so as to cover at least 30% of the total surface of the decorative material; the surface-protective layer is provided to the entire surface of the decorative material so as to cover the substrate, the pattern layer, and the raised printing layer; and protrusions that correspond to the raised printing layer are formed in the outermost surface of the decorative material at portions above the raised printing layer.

Description

Cosmetic material

The present invention relates to a decorative material.

Interior members of buildings such as walls, ceilings and floors or exterior members such as exterior walls, roofs, eaves ceilings, fences and gates, various doors such as window frames and entrance doors, handrails, skirting boards, surrounding edges and window frames. , Door frames, fittings such as moldings or building members, kitchen equipment or kitchen furniture, furniture or home appliances, cabinet surface veneers such as OA equipment, vehicle interior members or exterior members, etc. are generally used. , Resin members, wood members, metal members, and other various members are used as adherends, and decorative materials are attached to these adherends.

As the decorative material used for the above-mentioned applications, for example, a pattern composed of a low-gloss pattern ink layer, a surface protective layer, and the like are provided on a base material, and a gloss difference is provided between the pattern area and its peripheral area. A decorative material composed of ink is proposed. In this decorative material, due to the visual effect (also referred to as "gloss matte effect") caused by such a gloss difference, the actual recess is not formed and the surface is substantially flat, but the surface is embossed. Even if there is no (molding) processing, the pattern region having a relatively low gloss with respect to the surroundings is recognized as a recess only in the printing and coating steps (for example, Patent Documents 1 and 2).
Further, a decorative sheet having a liquid-repellent pattern layer on a base material sheet and an uneven pattern layer having the liquid-repellent pattern layer as a concave portion, and a top coat layer formed on the upper surface of the convex portion of the uneven pattern layer has been proposed. (For example, Patent Document 3).

Japanese Unexamined Patent Publication No. 49-39166 Japanese Unexamined Patent Publication No. 2005-125780 Japanese Unexamined Patent Publication No. 10-166540

By the way, with the recent increase in consumers' preference for luxury goods or the diversification of their preference, the demand for designability required for the above-mentioned interior members, exterior members, etc. has become more complicated and stricter. .. The decorative materials described in

Patent Documents

1 and 2 have a feeling of unevenness due to the difference in luster, and although they have an excellent design property, the feeling of unevenness has two stages (or two gradations) of a concave portion and a convex portion. ) Is monotonous, and there are few steps in the visual unevenness. Therefore, there are cases where it is not possible to meet the increasingly complicated and strict demand for design.

A decorative sheet described in Patent Document 3 has been proposed as a decorative sheet corresponding to such a request. However, since the top coat layer is partially provided on the upper surface of the convex portion of the uneven pattern layer, the top coat layer selectively disappears due to wear when used, and it is not possible to meet the demand for wear resistance. In addition, the design is also deteriorated.

The present invention has been made under such circumstances, and has a high tactile sensation developed by a physical uneven shape, an excellent design property due to a physical uneven shape and a visual uneven shape, and stain resistance. It is an object of the present invention to provide a decorative material having excellent wear resistance.

As a result of diligent research to solve the above-mentioned problems, the present inventors have found that the above-mentioned problems can be solved by an invention relating to a cosmetic material having the following constitution.

[1] A decorative material having a base material, a pattern layer covering a part of one surface of the base material, a raised printing layer, and a surface protective layer.
The raised printing layer is provided so as to cover at least a part of the non-formed region of the pattern layer and 30% or more of the entire surface of the decorative material in a plan view.
The surface protective layer is provided on the entire surface of the decorative material so as to cover the base material, the pattern layer, and the raised printing layer.
A convex portion corresponding to the raised printing layer is provided on the outermost surface of the decorative material immediately above the raised printing layer.
Cosmetic material.
[2] The decorative material according to the above [1], which has a wide-area decorative layer having a covering area wider than that of the pattern layer in a plan view between the base material and the pattern layer.
[3] The decorative material according to the above [1] or [2], which has a primer layer so as to cover at least the pattern layer in a plan view.
[4] The decorative material according to any one of [1] to [3] above, wherein the raised printing layer has a fine convex portion corresponding to the raised auxiliary agent on the surface thereof.
[5] The cosmetic according to any one of [1] to [4] above, wherein the base material has an adherend on a surface opposite to the surface having the pattern layer, via an adhesive layer. Material.

According to the present invention, a decorative material having a high tactile sensation developed by a physical uneven shape and an excellent design property due to a physical uneven shape and a visual uneven shape, and also having excellent stain resistance and abrasion resistance. Can be provided.

It is a schematic perspective view which shows the appearance of an example of the decorative material of this invention. It is a schematic sectional view which shows the layer structure of an example of the decorative material of this invention. It is a schematic perspective view which shows the appearance of an example of the decorative material of this invention. It is a schematic sectional view which shows the layer structure of an example of the decorative material of this invention.

[Cosmetic material]
Hereinafter, the decorative material of the present invention will be described. In addition, in this specification, the numerical values relating to "greater than or equal to", "less than or equal to" and "to" relating to the description of the numerical range are numerical values that can be arbitrarily combined, and the numerical values of 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 having a base material, a pattern layer covering a part of one surface of the base material, a raised printing layer and a surface protection layer, and the raised printing layer is viewed in a plan view. It is provided so as to cover at least a part of the non-formed region of the pattern layer and cover 30% or more of the entire surface of the decorative material, and the surface protective layer is provided on the base material, the pattern layer and the pattern layer. It is provided on the entire surface of the decorative material so as to cover the raised printing layer, and has a convex portion corresponding to the raised printing layer on the outermost surface of the decorative material immediately above the raised printing layer. is there.

In the present invention, "planar view" means the appearance of the decorative material looking down from the surface on the surface protective layer side, that is, the angle formed by the thickness direction and the line-of-sight direction of the decorative material is 0 ° or more and 90 ° or less. It refers to the appearance that is looked down on. Explaining a typical example of "planar view" with reference to FIGS. 1 and (2-a), the line-of-sight direction is made to coincide with the normal direction N of the surface of the decorative material 10 on the surface protective layer 6 side. In this case, the angle between the thickness direction of the decorative material and the line-of-sight direction is 0 °.

Hereinafter, the constitution of the decorative material of the present invention will be described with reference to FIGS. 1 to 4.
FIG. 1 is a schematic perspective view showing the appearance of the decorative material 10 of the present invention. The decorative material 10 of the present invention contains a base material 1, a pattern layer 2, a raised printing layer 4, a surface protective layer 5, and a convex portion 6. It is shown to have. In FIG. 1, the primer layer 3 is provided so as to cover at least the pattern layer 2, but is not shown in this figure. Further, FIG. 3 is a schematic perspective view showing the appearance of the decorative material 10 of the present invention, wherein the decorative material 10 of the present invention has a base material 1, a large area decorative layer 7, a pattern layer 2, a raised printing layer 4, and a surface. It is shown to have a protective layer 5 and a convex portion 6.
More specifically, the surface protective layer 5 is provided on the surface thereof, and the raised printing layer 4 is provided on the outermost surface of the decorative material 10 (on the surface of the surface protective layer 5) immediately above the raised printing layer 4. The raised printing layer 4 covers at least a part of the non-formed region of the pattern layer 2 in a plan view, and 30% or more of the entire surface of the decorative material is covered. It can be seen that it is provided so as to cover it.

FIG. (2-a), which is a schematic cross-sectional view of the decorative material 10 of the present invention, covers a pattern layer 2 that covers a part of one surface 1F of the base material 1, and at least the pattern layer 2 (FIG. (2). In the form of −a), the primer layer 3 is provided so as to cover the entire surface covering the formed region of the pattern layer 2 and the non-formed region of the pattern layer 2), and the pattern layer 2 on the primer layer 3 is not provided. The raised print layer 4 is provided so as to cover at least a part of the region (non-formed region), and the surface protective layer 5 is cosmetic so as to cover the base material 1, the pattern layer 2, the primer layer 3, 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 material and is the outermost surface of the decorative material 10 immediately above the raised printing layer 4 has a convex portion 6 corresponding to the raised printing layer 4. Is done.

As shown in FIG. (2-a), the primer layer 3 may be provided so as to cover at least the entire surface of the decorative material as long as it is provided so as to cover the pattern layer 2. It does not have to be provided so as to cover the entire surface as shown in FIG. (2-c). As shown in FIG. (2-c), when the primer layer 3 is partially provided, the raised printing layer 4 is provided on one surface 1F of the base material 1 and is provided on one surface 1F of the base material 1. In the region where none of the pattern layer 2, the primer layer 3, and the raised printing layer 4 is provided, the surface protective layer 5 may be provided so as to be 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. 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 handle. When the wide-area decorative layer 7 is a layer forming a pattern, the pattern layer 2 and the wide-area decorative layer 7 are complementary to each other in a plan view, and both are combined to form one surface 1F of the base material 1. Cover the entire surface. In the case of the design appearance expressed by ordinary decorative materials, the wide area decorative layer 7 is often a layer in which the covering area in a plan view is relatively wider than that of the pattern layer 2.
Further, if necessary, the pattern layer 2 and the wide area decorative layer 7 can be combined with the pattern layer 2 and the wide area decorative layer 7 by changing, for example, the amount of the matting agent added, the particle size, or both of them. A desired difference in glossiness (gloss difference) can be provided between them.

In FIG. (4-a), which is a schematic cross-sectional view of the decorative material 10 of the present invention, a pattern layer 2 covering a part of one surface 1F of the base material 1 and a region (non-existent) in which the pattern layer 2 is not provided. A raised printing layer 4 is provided so as to cover at least a part of the formed region), and a surface protective layer 5 is provided on the entire surface of the decorative material so as to cover the base material 1, the pattern layer 2, and the raised printing layer 4. It is shown that the surface of the surface protective layer 5 which is the outermost surface of the decorative material 10 immediately above the raised printing layer 4 has a convex portion 6 corresponding to the raised printing layer 4. As described above, the decorative material 10 of the present invention also has an aspect of not having the primer layer 3.
In FIG. (4-b), which is a schematic cross-sectional view of the decorative material 10 of the present invention, a wide-area decorative layer 7 is provided between the base material 1 and the pattern layer 2 in the above figure (4-a). Things are shown. Further, in FIG. (4-c), which is a schematic cross-sectional view of the decorative material 10 of the present invention, in the above figure (4-a), the wide area decorative layer 71 is entirely between the base material 1 and the pattern layer 2. The pattern layer 2 and the wide area decorative layer 72 provided in a pattern pattern are arranged complementary to each other in a plan view on the wide area decorative layer 71, which is provided as a solid layer of the coating. The one provided so as to cover the entire surface of one surface 1F is shown.
Hereinafter, each layer constituting the decorative material of the present invention will be described in more detail.

(Base material 1)
As the base material 1, those usually used as a base material for decorative materials can be adopted without limitation, and for example, a base material made of paper, non-woven fabric or woven fabric, resin, wood, metal, non-metal inorganic material or the like is represented. Can be mentioned. The thickness of the base material is also not particularly limited, and a film, sheet, or plate-like form can be appropriately used as desired, but usually, the film or sheet is about 20 to 300 μm, and the plate is 500 μm or more. A film of about 10 cm is used.

Examples of the paper base material include kraft paper, titanium paper, linter paper, parchment paper, glassin paper, parchment paper, resin impregnated paper, thin leaf paper, Japanese paper and the like. The base material of the non-woven fabric or woven fabric is, for example, an inorganic fiber composed of an inorganic material such as glass, alumina, silica, or carbon, or an organic fiber composed of various synthetic resins such as polyester resin, acrylic resin, polyethylene, and polypropylene. Examples thereof include a non-woven fabric or woven fabric to be constructed, and a base material such as a composite thereof.

Examples of the resin include polypropylene, polyethylene, polyolefin-based thermoplastic elastomers, polyolefin resins such as ionomer, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), ethylene glycol-terephthalic acid-isophthalic acid. Polypolymers, polyester resins such as polyester thermoplastic elastomers, polymethyl (meth) acrylates, polybutyl (meth) acrylates, methyl (meth) acrylate-butyl (meth) acrylate copolymers and other acrylic resins, polyester resins, polycarbonate resins , Acrylonitrile-butadiene-styrene resin (hereinafter, also referred to as "ABS resin"), a resin base material made of a thermoplastic resin such as a vinyl chloride resin can be mentioned.

Examples of wood include wood base materials made of wood of various tree species such as cedar, cypress, pine, oak, rawang, teak, and rubber tree. The wood base material may be in the form of a film or sheet called a veneer, or in the form of a single plate, plywood, laminated wood, particle board, fiberboard or the like.
Examples of the metal include a metal base material made of iron, aluminum, copper, tin, titanium, an alloy containing at least one of these metals (for example, carbon steel, stainless steel, duralumin, brass, bronze, etc.).
Examples of non-metallic inorganic materials include cement, gypsum, calcium silicate, ceramics, glass, and various ceramics.

The base material may be colored or uncolored (transparent), and when it is colored, the mode of coloring is not particularly limited and may be transparently colored. It may be opaque coloring (concealed coloring), and these may be arbitrarily selected.

When the base material is colored, the colorant includes, for example, white pigments such as titanium white, and inorganic pigments such as iron black, yellow lead, titanium yellow, petals, cadmium red, ultramarine blue, and cobalt blue; quinacridone red. Organic pigments or dyes such as isoindolinone yellow, phthalocyanine blue, nickel-azo complex, azomethine azo black pigment, perylene black pigment; metal pigment consisting of scaly foil pieces such as aluminum and brass; titanium dioxide coated mica, base Examples thereof include colorants such as pearl pigments made of scaly foil pieces such as lead carbonate. For example, when the surface hue of the adherend to which the decorative sheet is attached varies, it is desired to conceal the surface hue and improve the color tone stability of the pattern layer and the wide area decorative layer provided as desired. May use an inorganic pigment such as a white pigment.

In the case of coloring the resin, any means such as addition of a colorant to the resin (kneading, kneading), formation by applying a coating film of a paint containing the resin and the colorant, and the like can be adopted. In the case of coloring paper, non-woven fabric, or woven fabric, it can be carried out by any means such as mixed extraction with pulp or fiber material, formation of a coating film, or a combination thereof.
In the case of coloring wood, it can be carried out by either dyeing with a dye, forming a coating film, or a combination thereof. In the case of coloring a metal, in addition to forming a coating film, an electrolytic coloring method or the like in which a metal oxide film is formed on the surface by using an anodic oxidation method can be adopted. Further, in the case of a non-metallic inorganic material, it can be carried out by either means of forming a coating film or adding it to a base material, or a combination thereof.

Additives may be added to the base material, if necessary. As additives, mainly in the case of resins, for example, inorganics such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, antioxidants, ultraviolet absorbers, and light stabilizers. And so on. The blending amount of the additive is not particularly limited as long as it does not impair the processing characteristics and the like, and can be appropriately set according to the required characteristics and the like.

From the viewpoint of improving the weather resistance of the decorative material of the present invention, it is preferable to use a weather resistant agent such as an ultraviolet absorber and a light stabilizer among the above additives.
As the ultraviolet absorber, an ultraviolet absorber generally used for cosmetic materials can be used without particular limitation. For example, a benzotriazole-based ultraviolet absorber, a benzophenone-based ultraviolet absorber, a triazine-based ultraviolet absorber, and a hydroxyphenyltriazine-based ultraviolet absorber can be used. Examples include agents. As the light stabilizer, a light stabilizer generally used for cosmetic materials can be used without particular limitation, and examples thereof include hindered amine-based light stabilizers such as piperidinyl sebacate-based 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, a vinyl group or an allyl group in the molecule.
These ultraviolet absorbers, weather resistant agents such as light stabilizers, and various other additives can be used alone or in combination of two or more.

In the present invention, the above-mentioned base materials can be used alone or in combination of two or more. It may be a combination of a plurality of 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, and a paper base material and a fiber base material and a resin base material. It may be a combination with a material. Further, the resin base material may be composed of either a single layer of the above resin or a plurality of layers made of the same or different resins.

The shape of the base material is not particularly limited and may be appropriately selected as desired. For example, a flat plate shape, a curved surface shape, or a non-flat plate shape having corners or the like may be used. It may be. Although the decorative material in the form of a flat plate (also referred to as “sheet-like”) is shown in FIGS. 1 and 2, the shape of the decorative material of the present invention is not limited to this. Considering the ease of manufacturing, use, and processing of the decorative material, the flat plate shape is preferable.
The thickness of the base material is preferably 20 μm or more, more preferably 30 μm or more, still more preferably 40 μm or more, in consideration of surface characteristics 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.

The base material is physically prepared on one or both sides of the base material, such as an oxidation method or an unevenness method, in order to improve the interlayer adhesion between the base material and the other layers and to strengthen the adhesiveness with various adherends. Surface treatment such as surface treatment or chemical surface treatment can be applied.
Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone-ultraviolet treatment method and the like, and examples of the unevenness method include sandblasting method and solvent treatment method. These surface treatments are appropriately selected depending on the type of the base material, but in general, the corona discharge treatment method is preferably used from the viewpoint of the effect and operability of the surface treatment.
In addition, in order to improve the interlayer adhesion between the base material and other layers, strengthen the adhesiveness with various adherends, etc., a treatment such as forming an easy-adhesion layer on at least one surface of the base material is performed. May be given.

(Picture layer 2)
The pattern layer 2 is provided so as to cover a part of one surface of the base material and is a layer that imparts design to the decorative material of the present invention, and in particular, a visual unevenness due to a gloss difference from the raised printing layer. It is an effective layer when giving. Further, by combining the pattern layer with the raised printing layer and the convex portion described later, the decorative material of the present invention has a physical uneven shape and a visual unevenness, and has an extremely high tactile sensation and design. Will have.
In the decorative material of the present invention, the design property may be imparted only by the pattern layer, or the design property may be imparted as a pattern layer composed of the pattern layer and the wide area decorative layer described later, from the viewpoint of the design property. , It is preferable to impart designability as a pattern layer composed of a pattern layer and a wide area decorative layer.
To give a specific example of a preferred embodiment, the pattern layer is formed of a relatively low-gloss ink, the raised printing layer is formed of a relatively high-gloss ink, and the pattern layer is formed with respect to the raised printing layer. By configuring the pattern layer to have a relatively low gloss (that is, a low gloss), it is possible to effectively express the visual appearance in which the pattern layer is recessed relative to the raised printing layer. ..

The pattern imparted by the pattern layer or the pattern layer composed of the pattern layer and the wide area decorative layer may be selected as desired without particular limitation. For example, a wood grain pattern or a pattern on the surface of a marble plate (for example, travertin marble) may be selected. Patterns), stone patterns that imitate the surface of rocks such as the open surface of granite plates, fabric patterns that imitate textures and cloth-like patterns, and leather (leather) that expresses the grain of leather (including artificial or synthetic leather). There are patterns such as grain) patterns, tiled patterns, brickwork patterns, hairlines, perforated grooves, satin finish, grain, letters, symbols, geometric patterns, etc., and parquet, patchwork, etc. that combine these patterns. Further, as a pattern in which these are combined, for example, an artificial stone obtained by mixing crushed stone of a stone material such as marble with white cement, hardening it, and polishing it to finish it like marble, that is, a pattern like the surface of artificial marble can be mentioned.
Among the above, the wood grain pattern is preferable from the viewpoint of further utilizing the characteristics of the decorative material of the present invention, which has an extremely high tactile sensation and design due to the uneven shape. The wood grain pattern includes a grain pattern, a board pattern, a heather pattern, a wood grain pattern, and the like, but any of them may be used.

The pattern layer preferably has a lower gloss (matte or low gloss) than its surroundings from the viewpoint of improving the visual unevenness due to the gloss difference.
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 a concave conduit portion, and a higher gloss (glossy). Alternatively, there is a spring material portion (high gloss and convex portion), and an autumn material portion (shining portion) that is further glossy and convex portion. In the decorative material of the present invention, a lower gloss (matte or low gloss) conduit portion is formed by a relatively low gloss pattern layer, and a higher gloss (glossy or high gloss) bark portion, specifically. The spring material part, the autumn material part, or both the spring material part and the autumn material part are formed with a wide area decorative layer, and the direct part of the wide area decorative layer is covered with a relatively high gloss raised printing layer. Moreover, it is preferable that the thickness of the raised printing layer is thicker than that of the pattern layer. With such a configuration, the outermost surface of the decorative material immediately above the pattern layer expressing the conduit portion is relatively physical as compared with the outermost surface of the raised printing layer expressing the wood surface portion which is the convex portion. By forming recesses and visually reducing gloss, it is possible to improve the visual unevenness, and it is possible to obtain an extremely high tactile sensation and visual design that are similar to the grain pattern on the surface of a natural wood board. ..

Further, when the tiled pattern or the brickwork pattern exemplified as the preferred embodiment of the decorative material of the present invention is adopted, the tiled pattern or the brickwork pattern has a lower gloss and a recessed joint groove portion and a higher gloss. In addition, there is a tile or brick portion that becomes a convex portion. In the decorative material of the present invention, the joint groove portion having a lower gloss and a concave portion is formed by a relatively low gloss pattern layer, and the tile or brick portion having a higher gloss and a convex portion is formed by a wide area decorative layer. Further, it is preferable that the immediate upper portion of the wide area decorative layer is covered with a relatively high-gloss raised printing layer, and 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 immediately above the pattern layer expressing the joint groove portion is a convex portion, which is relatively physical compared to the outermost surface of the raised printing layer representing the tile or brick portion. It is possible to improve the visual unevenness by making the concave part and visually low gloss, and it is possible to obtain an extremely high tactile sensation and visual design property similar to the actual tiled or brickwork. It becomes.

Other than the above, as an application example of the pattern layer, for example, in the case of a pattern on the open surface of a granite plate, the lowest gloss biotite, higher gloss feldspars, and higher gloss quartz are mixed around it. The lowest glossy biotite, and the boundary between biotite, feldspar and quartz can be formed by a pattern layer, and higher glossy feldspar and quartz can be formed by a wide area decorative layer. Further, in the veneer pattern in which the board and the board are combined, the lower glossy boundary between the boards can be formed by the pattern layer, and the other part can be formed by the wide area decorative layer.
As described above, the pattern layer is physically related to the formation of a lower gloss (matte or low gloss) portion, and the pattern imparted by the pattern layer or the pattern layer composed of the pattern layer and the wide area decorative layer. It is preferably used for forming a portion that becomes a recess.

A resin composition containing at least a binder resin and, if necessary, a matting agent is preferably used for forming the pattern layer, and other components used as desired, such as colorants such as pigments and dyes, and extender pigments. , Stabilizer, ultraviolet absorber, light stabilizer, solvent and the like can be appropriately mixed. That is, the pattern layer is a layer containing at least a binder resin and a matting agent, and is a layer capable of containing other components used as desired.
When a matting agent is added to the primer layer, the addition of the matting agent to the pattern layer may be omitted if the desired low gloss can be sufficiently expressed in the pattern layer by the primer layer. ..

The binder resin is not particularly limited, and for example, urethane resin, acrylic polyol resin, acrylic resin, polyester resin, alkyd resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate common weight. Resins such as coalescence, vinyl chloride-vinyl acetate-acrylic copolymer, nitrocellulose (nitrified cotton), and cellulose acetate are preferable. Further, for example, a curable resin such as a two-component curable urethane resin using a polyol as a main agent and an isocyanate as a curing agent may be used. These can be used alone or in combination of two or more.

Matters include inorganic fillers such as silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, synthetic silicate, and fine silicate powder; acrylic resin, urethane resin, nylon. Examples thereof include organic fillers such as resins, polypropylenes, and urea-based resins. When the pattern layer contains a matting agent, the pattern layer has a lower gloss, so that it is possible to improve the visual unevenness due to 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.
The content of the matting agent in the pattern layer with respect to 100 parts by mass of the binder resin 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 It is usually 100 parts by mass or less, preferably 50 parts by mass or less, more preferably 20 parts by mass or less, and further preferably 10 parts by mass or less. When the content of the matting agent is within the above range, the pattern layer can be visually recognized as a lower gloss layer, so that it is possible to improve the visual unevenness due to the gloss difference, and the resin composition. The thixotropic property is not extremely high and the coating performance is improved, and as a result, the design property is improved.

In the present invention, various methods can be adopted as a method for expressing a visual unevenness due to the appearance of gloss difference.
For example, it is possible to express a more delicate visual unevenness by providing a low-gloss pattern layer directly above or directly below a non-low-gloss pattern layer, and the pattern layer and a large area decoration. It is also possible to express a visual unevenness by the gloss difference between these layers and the raised printing layer without using any of the layers as low gloss layers. Here, the gloss difference is caused by the relative difference in gloss of each layer, and the non-low gloss pattern layer can also be referred to as a high gloss pattern layer with respect to the low gloss pattern layer. However, these layers can be formed, for example, by adjusting the content of the matting agent contained in these pattern layers, the lightness and darkness of the hue, and the like.
Further, when the primer layer is provided, it is possible to express a visual unevenness by the gloss difference between the primer layer provided so as to cover the pattern layer and the raised printing layer, and the pattern layer is not low gloss. By providing a primer layer so as to cover the pattern layer and providing a low-gloss pattern layer directly above the pattern layer and on the surface of the primer layer, it is possible to express a visual unevenness by the gloss difference. is there. In this case, the low gloss pattern layer may be formed by using the resin composition used for forming the pattern layer.
As described above, in the present invention, the gloss difference can be freely expressed by combining the high and low gloss of the pattern layer, the wide area decorative layer, the pattern layer composed of these, and the various layers such as the raised printing layer and the primer layer described later. It is possible to express a visual unevenness and to express an extremely high tactile sensation and design by combining with the physical unevenness composed of these layers.

Examples of the colorants such as pigments and dyes that can be used in the pattern layer include the same colorants as the pigments and dyes that can be used in the above-mentioned base material, and among these, depending on the desired pattern. It may be selected as appropriate.
The pattern layer may contain a weather resistant agent such as an ultraviolet absorber and a light stabilizer from the viewpoint of improving the weather resistance. Examples of the ultraviolet absorber and the light stabilizer include those that can be contained in the base material, and the ultraviolet absorber and the light stabilizer may be appropriately selected from these according to a desired pattern.

The thickness of the pattern layer may be appropriately selected according to the desired pattern, preferably 0.5 μm or more, more preferably 1 μm or more, still 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 designability by decoration is improved, and the characteristics of the surface shape of the decorative material, for example, the maximum height (Sz) described later, 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, is preferably provided first to protect the pattern layer, and may have a lower gloss if necessary. It is a layer that has a function and can improve the interlayer adhesion between the base material, the pattern layer, the raised printing layer, and the surface protection layer.

A resin composition containing at least a binder resin and a matting agent is preferably used for forming the primer layer, and other components used as desired, such as extender pigments, stabilizers, ultraviolet absorbers, and light stabilizers, A mixture of a solvent or the like can be used. That is, the primer layer is a layer containing at least a binder resin and a matting agent, and is also a layer capable of containing the above-mentioned components used as desired. By including the matting agent, the pattern layer can be visually recognized as a lower gloss layer, so that the visual unevenness due to the gloss difference is improved.
However, if the pattern layer itself can sufficiently express the desired low gloss, the addition of the matting agent to the primer layer can be omitted.

When the primer layer is provided, it may be provided so as to cover at least the above-mentioned pattern layer, and as shown in FIGS. (2-a) and (2-b), the pattern layer is covered and the entire surface of the decorative material is provided. It may be provided so as to cover only the upper part of the picture layer, or just the upper part of the picture layer and its vicinity as shown in FIG. (2-c). You may. From the viewpoint of improving the interlayer adhesion between the base material, the pattern layer, the raised printing layer, and the surface protection layer, as shown in FIGS. (2-a) and (2-b), the pattern layer is covered and the decorative material is used. It is preferable that it is provided so as to cover the entire surface of the above.

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 can be appropriately selected from these. Just do it. 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 the pattern layer at least, and from the viewpoint of efficiently protecting the pattern layer, making the pattern layer less glossy, and improving interlayer adhesion, there is no particular limitation. Further, from the viewpoint of the characteristics of the surface shape of the decorative material, for example, the ease of adjusting the maximum height (Sz) described later, the height is preferably 0.1 μm or more with respect to the upper surface of the pattern layer. It is preferably 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, still more preferably 5 μm or less.

(Large print layer 4)
In plan view, the raised printing layer 4 covers at least a part of the non-formed region of the pattern layer 2, that is, the region where the pattern layer 2 is not provided, and 30% or more of the entire surface of the decorative material. (Hereinafter, the area ratio covered by the raised printing layer may be referred to as "covering ratio of the raised printing layer"). By providing the raised printing layer, a convex portion corresponding to the raised printing layer can be formed on the outermost surface of the decorative material immediately above the raised printing layer, so that a physically uneven shape is formed on the decorative material of the present invention. However, an extremely high tactile sensation can be obtained. Further, due to the synergistic effect of this physical uneven shape and the visual unevenness of the above-mentioned pattern layer, the design becomes extremely high.

The coverage of the raised print layer on the entire surface of the decorative material is preferably 40% or more, more preferably 50% or more, still more preferably 50% or more, from the viewpoint of improving the tactile sensation and designability by the physical uneven shape and the visual unevenness. Is 70% or more. The upper limit is not particularly limited, but is preferably 95% or less, more preferably 90% or less, from the viewpoint of improving the tactile sensation and design.
In the present invention, the coverage of the raised printing layer is obtained by cutting out three 30 cm × 30 cm test pieces from an arbitrary portion with respect to a decorative material having a size of 1 m × 1 m, and performing image analysis on each of these test pieces. Is performed, the coverage of the raised printing layer is calculated, and the average value is used. When the size of the decorative material is not 1 m × 1 m, the ratio of the test piece size 30 cm × 30 cm to the above 1 m × 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 shown only in a mode in which it is provided only in the non-forming region of the pattern layer. However, the raised printing layer may be provided on the pattern layer or a part thereof so as to overlap with each other.
In the present invention, the raised printing layer is preferably provided so as to cover 50% or more of the non-formed region of the pattern layer, that is, the area where the pattern layer is not provided. When the coverage of the raised print layer with respect to the non-formed region of the pattern layer is 50% or more, the tactile sensation and designability can be improved more efficiently by the physical uneven shape and the visual unevenness. From the same viewpoint as this, the coverage of the raised print layer with respect to the non-formed region of the pattern layer is preferably 60% or more, more preferably 65% or more, further preferably 70% or more, and the upper limit is preferably 95%. Below, it is more preferably 90% or less.

Further, as shown in FIGS. 1 and 3, the raised print layer may have a shape like a net-dot-like protrusion group in a plan view in which small protrusions are gathered, or an ellipsoid in a plan view larger than the protrusions. It may have a shape (a part of a spheroid or a three-dimensional shape similar thereto in a three-dimensional shape). An elliptical shape larger than a protrusion is formed by printing the resin composition into an elliptical shape from the beginning when the resin composition for forming a raised printing layer is printed to form a raised printing layer. Also, when printing so that small protrusions are assembled, the resin composition flows and is leveled and drips (so-called "dripping"), resulting in a connection rather than the protrusions. It may have a large oval shape. Therefore, although only the elliptical shape is shown in FIGS. 1 and 3, it may have an irregular shape such that a plurality of protrusions are connected by hanging.

In the present invention, it is preferable that the raised printing layer includes a portion composed of a group of protrusions in terms of obtaining a more delicate tactile sensation and also in terms of design. Further, 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 in which the resin composition is connected by dripping, for example, wood grain. When a pattern of a natural object such as a pattern is used, a more realistic texture can be obtained and a high degree of design can be obtained.

A resin composition containing at least a binder resin is preferably used for forming the raised printing layer, and other components used as desired, such as an extender pigment, a stabilizer, an ultraviolet absorber, a light stabilizer, and a solvent, are used. An appropriately mixed product can be used. That is, the raised printing layer is a layer containing at least a binder resin, and is also a layer that can contain the above-mentioned components that can be used as desired.

As the binder resin used for forming the raised printing layer, it is preferable to use a curable resin from the viewpoint of improving the tactile sensation and designability by the physical uneven shape and the visual unevenness.
As the curable resin, a curable resin such as a thermosetting resin, a two-component curable resin, or an ionizing radiation curable resin can be used, and the tactile sensation and design can be improved by the physical uneven shape and the visual unevenness. An ionizing radiation curable resin is preferable from the viewpoint of facilitating improvement and further improving the stain resistance and abrasion resistance of the decorative material of the present invention.

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

The 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 a functional group having an ethylenic double bond such as a (meth) acryloyl group, a vinyl group, or an allyl group is preferably mentioned. Be done. Further, ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or cross-linking a molecule, and usually, ultraviolet rays (UV) or electron beams (EB) are used. Electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion rays are also included.
Specifically, the ionizing radiation curable resin can be appropriately selected and used from the polymerizable monomers and polymerizable oligomers conventionally used as ionizing radiation curable resins.

As the polymerizable monomer, a (meth) acrylate-based monomer having a radically polymerizable unsaturated group in the molecule is preferable, and a polyfunctional (meth) acrylate monomer is particularly preferable. Here, "(meth) acrylate" means "acrylate or methacrylate".
Examples of the polyfunctional (meth) acrylate monomer include a (meth) acrylate monomer 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 preferable from the viewpoint of improving the tactile sensation and designability due to the physical uneven shape and the visual unevenness, and further improving the 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 sensation and design due to the physical uneven shape and the visual unevenness, and further improving the stain resistance and abrasion resistance. , More preferably 6 or less, still more preferably 4 or less, and particularly preferably 3 or less. These polyfunctional (meth) acrylates may be used alone or in combination of two or more.

Examples of such polymerizable monomers include bifunctional (meth) acrylates such as ethylene glycol di (meth) acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate; trimethylol. Propanetri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, Trifunctional or higher (meth) acrylates such as isocyanuric acid-modified tri (meth) acrylates; are preferred.

Examples of the polymerizable oligomer include a (meth) acrylate oligomer having two or more ionizing radiation curable functional groups in the molecule and having 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 oligomers, polycaprolactone diol urethane (meth) acrylate and the like.

The number of functional groups of these polymerizable oligomers is preferably 2 or more from the viewpoint of improving the tactile sensation and design by the physical uneven shape and the visual unevenness, and further improving the stain resistance and abrasion resistance. The upper limit is preferably 8 or less, more preferably 6 or less, still more preferably 4 or less, and 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 tactile sensation and design due to the physical uneven shape and the visual unevenness, and further improving the stain resistance and abrasion resistance. It is more preferably 1,000 or more, and the upper limit is preferably 80,000 or less, more preferably 50,000 or less. As used herein, the weight average molecular weight is the average molecular weight measured by GPC analysis and converted to standard polystyrene.

The raised print layer is preferably more glossy than the pattern layer from the viewpoint of enhancing the synergistic effect with the visual unevenness of the pattern layer and improving the design. To make the gloss higher than that of the pattern layer, it is possible to adjust the amount of additives that can adjust the gloss, such as a matting agent and an extender pigment.

Further, the swelling printing layer preferably contains a swelling aid in order to secure the thickness. Resin beads and inorganic particles are preferably used as the raising aid.
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. Beads made of a resin such as a thing are preferably mentioned.
Examples of the inorganic particles include particles composed of silica, alumina, kaolinite, antimony oxide, calcium carbonate, barium sulfate, glass, zirconia, titania and the like, and silica is preferable from the viewpoint of cost and the like. The silica particles may be spherical or amorphous, and amorphous silica particles are preferable in consideration of improvement in tactile sensation and the like.

When the build-up printing layer contains a build-up auxiliary agent, a fine convex shape appears on the surface of the build-up print layer corresponding to the shape of the build-up auxiliary agent, and the surface of the convex portion corresponds to the fine convex shape. Further, a fine convex portion (not shown) appears. As a result, as a secondary effect, an effect of improving the matte effect by visually matting due to light scattering and an effect of improving the tactile sensation of rough surface, grain, or wood surface can be obtained. In the decorative material of the present invention, the convex portion has a fine convex portion corresponding to the fine convex shape on the surface of the raised printing layer, which is expressed corresponding to the shape of the raising auxiliary agent contained in the raised printing layer. The fine convex portion corresponds to each surface of the above-mentioned small protrusions forming a raised printing layer, and each surface having an elliptical shape in a plan view larger than the above-mentioned protrusions. It develops in the shape. The fine convex portion does not directly reflect the shape of the heaping aid due to the surface protective layer provided on the heaping printing layer, but is caused by the heaping aid and exhibits a shape corresponding to the heaping aid. It is a thing.

The average particle size of the heaping aid is preferably 0.1 to 40 μm, more preferably 5 to 30 μm, and further preferably 10 to 25 μm from the viewpoint of ensuring the thickness of the heaping printing layer. Further, when it is within the above range, it is easy to adjust the properties of the surface shape such as the maximum height (Sz) described later, and it is easy to improve the tactile sensation and design due to the physical uneven shape and the visual unevenness. Become.

The content of the swelling aid is preferably 5 to 70 parts by mass, more preferably 10 to 60 parts by mass, and further preferably 20 to 50 parts by mass with respect to 100 parts by mass of the resin content forming the swelling printing layer. is there.

It is preferable that the raised print layer has a portion provided along the end portion of the pattern layer, for example, as shown in FIG. By having such a portion, the pattern layer is more physically emphasized as a concave portion by comparison with the raised printing layer, and the visual unevenness due to the gloss difference is also emphasized, and the design is emphasized as well as the tactile sensation. Improves sex.

The thickness of the raised printing layer is preferably 3 μm or more, more preferably 5 μm or more, and further, based on the upper surface of the pattern layer when it does not have a primer layer and based on the upper surface of the primer layer when it has a primer layer. It is preferably 10 μm or more, 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 designability are improved by the physical uneven shape and the visual unevenness, and the convex portion described later is hard to be scraped, so that the deterioration of stain resistance and abrasion resistance is suppressed. Can be done.

(Surface protection layer 5)
The surface protective layer 5 is a layer 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 printing layer 4, and constitutes the decorative material of the present invention. It is a layer that protects each layer and, as a result, protects the decorative material of the present invention.
The surface protective layer may be made of either a thermoplastic resin or a curable resin, and is made of a curable resin from the viewpoint of protecting the decorative material of the present invention and obtaining better stain resistance and abrasion resistance. It is preferable that the layer is composed of a cured product of a curable resin. Further, the layer may be formed by using 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, and thermoplastic (non-crosslinked) urethane resin.

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 for forming the raised printing layer. Of these, an ionizing radiation curable resin is preferable from the viewpoint of improving stain resistance and abrasion 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 raised printing layer.

The surface protective layer may contain, if desired, a weather resistant agent such as an ultraviolet absorber or a light stabilizer, an ultraviolet shielding agent, an abrasion resistance improver, a polymerization inhibitor, a cross-linking agent, as long as the object of the present invention is not impaired. Infrared absorbers, antistatic agents, adhesive improvers, leveling agents, thixotropic properties, coupling agents, plasticizers, defoamers, fillers, blocking inhibitors, lubricants, solvents, etc. can be added. .. Above all, it is preferable to contain a weather resistant agent such as an ultraviolet absorber and a light stabilizer.
The ultraviolet absorber and the light stabilizer may be appropriately selected from the ultraviolet absorbers and the light stabilizer exemplified as those that can be used for the base material.

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

(Convex portion 6)
The convex portion 6 is formed on the outermost surface of the decorative material of the present invention immediately above the raised printing layer, that is, on the outermost surface of the raised printing layer on the side where the surface protective layer of the base material is provided. It is a convex portion corresponding to the raised printing layer. Further, the convex portion can be said to be a portion in which the surface protection layer is coated on the raised print layer, and this is referred to as a “convex portion corresponding to the raised print layer”.
The decorative material of the present invention has an extremely high tactile sensation by having a physically uneven shape due to the convex portion. Further, due to the synergistic effect of this physical uneven shape and the visual unevenness of the above-mentioned pattern layer, the design becomes extremely high. Further, as described above, the convex portion has a fine convex portion corresponding to the fine convex shape on the surface of the raised printing layer, which is expressed corresponding to the shape of the raising aid included in the raised printing layer. Is preferable. By having such a fine convex portion, a higher tactile sensation can be obtained and a visual unevenness can be improved, so that a higher design property can be obtained.

The height of the convex part (when based on the outermost surface) is approximately the same as the thickness of the raised print 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, further preferably 10 μm or more, still more preferably 20 μm or more, and is preferably an upper limit. It is 50 μm or less.

Further, since the convex portion corresponds to the raised printing layer, it is preferable to have a portion composed of a group of protrusions, and the preferred embodiment of the shape is the same as that of the raised printing layer.

(Wide area decorative layer 7)
The wide-area decorative layer 7 is a layer in which the covering area in a plan view is wider than that of the pattern layer between the base material and the pattern layer or on the same surface as the pattern layer, and the decorative material of the present invention has a pattern. It is a layer that imparts design as a pattern layer together with the layer. In the present invention, from the viewpoint of improving the design, it is preferable that the present invention is composed of a plurality of layers having a pattern layer and a wide area decorative layer.

The wide-area decorative layer may be in the form of a colored layer (so-called “solid layer”) uniformly provided so as to cover the entire surface, or the covering area in a plan view is larger than that of the pattern layer. If it is wider than that, it may be in the form of a stalk layer provided so as to partially cover it, or it may be in the form of having the colored layer and the stalk 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 in which a part thereof is formed by the pattern layer. Therefore, even if the wide-area decorative layer is provided on the same surface as the pattern layer, such as the wide-area decorative layer 72 shown in FIG. (4-c), so as to coexist with the pattern layer. Good. Further, the wide area decorative layer may be a layer composed of one layer as shown in FIGS. (2-b) and (4-b), or two or more layers as shown in FIG. (4-c). It may be a layer composed of a plurality of layers of.

For example, in the case of a wood grain pattern, on a colored layer such as brown or white, a large area decorative layer expressing a high gloss (glossy or high gloss) spring material part, and a high gloss autumn material part (shining part). It can be formed by combining a wide area decorative layer expressing the above and a pattern layer expressing a low gloss (matte or low gloss) conduit portion. Further, specific examples of proper use of the pattern layer and the wide area decorative layer in other patterns are as described above.

For the formation of the wide area decorative layer, the resin composition described as being usable for forming the above-mentioned 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.

(Manufacturing method of decorative material)
Regarding the method for producing a decorative material of the present invention, which is one of the preferred embodiments of the decorative material of the present invention, the base material, the wide area decorative layer, the pattern layer, the primer layer, and the raised printing shown in FIG. The manufacturing method thereof will be described by taking a decorative material having a layer and a surface protective layer as an example.

The decorative material of the present invention is, 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 at least a primer layer so as to cover the pattern layer, the pattern. A step of providing a raised printing layer so as to cover at least a part of the non-formed region of the layer and covering the entire surface of the decorative material with 30% or more, and a base material, a pattern layer, a primer layer and a raised printing layer. It can be manufactured by sequentially going through the steps of providing a surface protective layer on the entire surface so as to cover it.

In the step of providing the wide-area decorative layer and the pattern layer, first, the resin composition used for forming the wide-area decorative layer is applied onto the base material, and the desired colored layer and the pattern layer are provided to form the wide-area decorative layer. Then, the 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 a gravure printing method.

Further, when the surface treatment is applied to the base material, it may be performed before the wide area decorative layer is formed, and when the easy adhesive layer is provided, it may be performed before the wide area decorative layer is formed. Further, when the back surface easy-adhesion layer is provided on the surface (back surface) opposite to the surface on which the pattern layer of the base material is provided, it may be provided before or after the formation of the wide-area decorative layer.

Next, it is a step of providing a primer layer so as to cover at least the pattern layer. The resin composition used for forming the primer layer may be applied to form the primer layer, and the coating method may be appropriately selected from the method for applying the resin composition for forming the wide area decorative layer.
In the step of providing the raised printing layer, the raised printing layer may be formed by applying the resin composition used for forming the raised printing layer, and the coating method is the coating of the resin composition for forming the wide area decorative layer. It may be adopted by appropriately selecting from the method of.

To form the surface protective layer, a curable resin composition containing a liquid uncured product of a curable resin, which is used for forming the surface protective layer, is applied to the entire surface of the decorative material and cured if necessary. To do.
As a method for applying the uncured resin composition containing the liquid uncured product, any of the known methods exemplified as the method for applying the resin composition for the wide area decorative layer may be adopted.
Further, the curing method of the uncured resin composition containing the liquid uncured product of the curable resin may be selected according to the type of the curable resin contained in the uncured resin composition. For example, when the uncured resin composition is a resin composition containing a liquid uncured product of a thermosetting resin, it may be cured by performing a heat treatment according to the thermosetting resin to be used.

When an uncured resin composition containing a liquid uncured product of an ionizing radiation resin is used, the uncured resin layer formed by coating the uncured resin composition is irradiated with ionizing radiation such as an electron beam or ultraviolet rays. It may be a cured product. Here, when an electron beam is used as the ionizing radiation, the accelerating voltage can be appropriately selected according to the resin to be used and the thickness of the layer, but the uncured resin layer can usually be cured at an accelerating voltage of about 70 to 300 kV. preferable. The irradiation dose is preferably an amount at which the crosslink density of the ionizing radiation curable resin is saturated, 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).
The electron beam source is not particularly limited, and for example, a cockloft Walton type, a bandegraft type, a resonance transformer type, an insulated core transformer type, or various electron beam accelerators such as a linear type, a dynamitron type, and a high frequency type are used. be able to.
When ultraviolet rays are used as ionizing radiation, those containing ultraviolet rays having a wavelength of 190 to 380 nm are emitted. The ultraviolet source is not particularly limited, and for example, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, a carbon arc lamp, or the like is used.

Further, after the surface protective layer is formed, a concave-convex shape can be imparted by heat-press molding with an embossed plate, if necessary.
The conditions for heat and pressure molding may be appropriately adjusted according to the type of the curable resin to be used, and are not particularly limited, but usually under temperature conditions of 100 to 200 ° C., the pressure is 0.1 to 9.8 MPa. The time is from 10 seconds to 120 minutes.

(About the properties of the surface shape)
The decorative material 10 of the present invention preferably has a surface shape such that the maximum height (Sz) measured in accordance with ISO 25178-6: 2010 is 15.0 μm or more. When the maximum height (Sz) is 15.0 μm or more, a higher tactile sensation can be obtained due to the physical uneven shape, and it is more excellent due to the physical uneven shape and the visual uneven shape. You can get the design. The maximum height (Sz) is a numerical value representing the distance from the highest point to the lowest point on the surface, and specifically, a convex portion in a decorative material, a preferably fine convex portion, and a pattern layer (or surface). When a protective layer is provided, it is an index showing the height difference from the surface protective layer corresponding to the pattern layer).
From the viewpoint of improving the tactile sensation and design, the maximum height (Sz) is preferably 20.0 μm or more, more preferably 25.0 μm or more, still more preferably 40.0 μm or more. The upper limit of the maximum height (Sz) is not particularly limited because the larger the upper limit, the better the tactile sensation and design, but the surface characteristics such as stain resistance and abrasion resistance, stability as a decorative sheet, and manufacturing Considering ease of use and the like, it is 100.0 μm or less, preferably 85.0 μm or less.
In addition, in this specification, the numerical value concerning the characteristic of a surface shape is an average value of the numerical value measured by the method conforming to ISO 25178-6: 2010 at arbitrary 10 points of a decorative sheet.

The decorative material 10 of the present invention preferably has a surface shape such that the protruding peak height (Spk) measured in accordance with ISO 25178-6: 2010 is 4.1 μm or more. .. The protruding peak height (Spk) is a numerical value indicating the average height of the protruding peak, and specifically, is an index indicating a state of local swelling of a convex portion and a preferably fine convex portion in a decorative material. When the height of the protruding mountain portion (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 ridge (Spk) is more preferably 5.0 μm or more, further preferably 6.0 μm or more, and even more preferably 7.0 μm or more. The upper limit of the height of the protruding ridge (Spk) tends to improve the tactile sensation as it increases, so there is no particular limitation, but surface characteristics such as stain resistance and abrasion resistance, stability as a decorative sheet, and manufacturing Considering ease of use and the like, it 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 such that the maximum mountain height (Sp) measured in accordance with ISO 25178-6: 2010 is 1.0 μm or more. The maximum mountain height (Sp) is a numerical value representing the maximum value of the height from the average surface of the surface, and specifically, the height of the convex portion from the surface of the decorative material and the height of the fine convex portion preferably provided. When the maximum mountain height (Sp) is 1.0 μm or more, the tactile sensation is mainly improved.
From the viewpoint of improving the tactile sensation, the maximum mountain height (Sp) is more preferably 5.0 μm or more, further preferably 10.0 μm or more, and even more preferably 15.0 μm or more. The upper limit of the maximum mountain height (Sp) tends to improve the tactile sensation as it increases, so there is no particular limitation, but surface characteristics such as stain resistance and abrasion resistance, stability as a decorative sheet, and ease of manufacture Considering the above, 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 such that 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 the concave and convex portions from the average surface of the surface, specifically, the convex portion and the preferably provided fine convex portion. The height of the portion of the material that forms a convex portion relative to the average surface of the surface, and the pattern layer that forms a relative concave portion of the decorative material as a whole (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 that forms the recess relative to the average surface of the surface of the decorative material such as), and is an index showing the state of undulations on the entire surface of the decorative material, and is the arithmetic mean height. When the Sa (Sa) is 2.0 μm or more, the designability is improved mainly due to the physical uneven 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, further preferably 2.5 μm or more, and even more preferably 3.0 μm or more. The upper limit of the maximum mountain height (Sp) tends to improve the design as it increases, so there is no particular limitation, but surface characteristics such as stain resistance and abrasion resistance, stability as a decorative sheet, and manufacturing Considering ease of use and the like, it is 15.0 μm or less, preferably 10.0 μm or less, and more preferably 5.0 μm or less.

In this specification, the above-mentioned maximum height (Sz), protruding peak height (Spk), maximum peak height (Sp), and arithmetic mean height (Sa) are based on ISO 25178-6: 2010. Then, using a non-contact shape analysis laser microscope (for example, "VK-X1000 (model number)", manufactured by KEYENCE CORPORATION), it is measured as the average value of any 10 points on the surface of the decorative material 10 under the following conditions. To.
・ Magnification: 400 times ・ Measurement range: 500 μm x 700 μm at 10 locations ・ S-filter, L-filter: None

As described above, the decorative material of the present invention preferably has the characteristics of a specific surface shape, which makes it easier for the decorative material of the present invention to have a higher tactile sensation, and also has a physical uneven shape and visual sense. It is easy to have excellent design due to the unevenness. In order for the decorative material of the present invention to have the above-mentioned surface shape properties, it is preferable to have a specific layer structure.

(Use of decorative material)
The decorative material of the present invention has a high tactile sensation developed by the physical uneven shape, and has excellent design properties due to the physical uneven shape and the visual uneven shape, and is also excellent in stain resistance and abrasion resistance. Is. Therefore, the decorative material of the present invention can be used as it is, laminated on the adherend via an adhesive layer, or subjected to a predetermined molding process or the like for various purposes.
For example, flat plates of various materials, plates such as curved plates, sheets (or films) and other adherends are laminated, and interior members of buildings such as walls, ceilings and floors or outer walls, roofs, eaves ceilings, fences, etc. Exterior materials such as gates, window frames, various doors such as entrance doors, handrails, skirts, surrounding edges, window frames, door frames, fittings or construction members such as malls, kitchen or kitchen furniture, furniture or home appliances , Can be used for surface decorative boards of cabinets of OA equipment, vehicle interior members, exterior members, and the like.

Examples of the adherend include wood single boards made of various woods such as cedar, cypress, pine, and lauan, wood plywood, particle boards, MDF (medium density fiberboard), and wood fiber boards such as laminated wood. Wood members used as three-dimensional articles, etc .; Plates and steel plates such as iron and aluminum, three-dimensional articles, metal members used as sheets, etc .; Ceramics such as glass and ceramics, non-cement ceramic materials such as gypsum, ALC ( Ceramic members used as plate materials such as non-ceramic ceramic materials such as (lightweight cellular concrete) plates and three-dimensional articles; polyolefin resins such as acrylic resin, polyester resin, polystyrene, polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) ) Resin, phenol resin, vinyl chloride resin, cellulose resin, plate materials such as rubber, three-dimensional shaped articles, resin members used as sheets and the like can be mentioned. In addition, these members can be used alone or in combination of two or more.

The adhesive used for the adhesive layer is not particularly limited, and known adhesives can be used. For example, adhesives such as heat-sensitive adhesives and pressure-sensitive adhesives are preferable. Examples of the resin used for the adhesive constituting the 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. , Polycarbonate resin and the like, and these can be used alone or in combination of two or more. Further, a two-component curing type polyurethane-based adhesive or polyester-based adhesive using an isocyanate compound or the like as a curing agent can also be applied.
An adhesive may also be used for the adhesive layer. As the pressure-sensitive adhesive, acrylic-based, urethane-based, silicone-based, rubber-based and other pressure-sensitive adhesives can be appropriately selected and used.

The adhesive layer is formed by applying and drying the above resin in a form that can be applied such as a solution or an emulsion by a means such as a gravure printing method, a screen printing method, or a reverse coating method using a gravure plate. 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 further preferably 10 μm or more and 30 μm or less.

Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to this example.
(Evaluation and observation method)
(1) Evaluation of tactile sensation With respect to the cosmetic materials obtained in each Example and Comparative Example, 20 adults were allowed to evaluate whether or not the tactile sensation (unevenness) when touched by hand was excellent. Table 1 shows the results of classifying the aggregated tactile sensation evaluations according to the following criteria.
A: More than 18 out of 20 people answered that they had a good tactile sensation.
B: Of the 20 people, 15 or more and 17 or less answered that the tactile sensation was excellent.
C: The number of people who answered that the tactile sensation was excellent was 11 to 14 out of 20.
D: Less than 10 out of 20 responded that the tactile sensation was excellent.
(2) Evaluation of Gloss Matte Feeling With respect to the cosmetic materials obtained in each Example and Comparative Example, 20 adults were allowed to visually evaluate whether or not the glossy matte feeling (unevenness feeling) was excellent. Table 1 shows the results of classifying the aggregated gloss matte feeling evaluations according to the following criteria.
A: More than 18 out of 20 people answered that they had an excellent design with unevenness.
B: Of the 20 people, 15 or more and 17 or less answered that they had an excellent design with unevenness.
C: 11 out of 20 people answered that they had an excellent design with unevenness, and 14 people or less.
D: Less than 10 out of 20 people answered that they had an excellent design with unevenness.
(3) Evaluation of stain resistance The cosmetic materials obtained in each Example and Comparative Example were evaluated according to the following criteria in accordance with the provisions of the JAS Contamination A Test.
A: There was no or little change in appearance.
B: The change in appearance was slight.
C: The change in appearance was noticeable.
D: The appearance change was remarkable.
(4) Evaluation of Abrasion Resistance The decorative materials obtained in each Example and Comparative Example were evaluated in accordance with the provisions of the JAS plywood abrasion A test. Specifically, the decorative material is horizontally fixed to the rotating disk of the test device, two rubber disks wrapped with abrasive paper (S-42) are attached, and the decorative material is rotated while applying a total load of 500 gf. Then, the number of rotations at which the residual rate of the pattern of the decorative material became 50% was confirmed, and the evaluation was made according to the following evaluation criteria. The device was stopped every 5 rotations, and the state of the pattern of the decorative material was visually confirmed.
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 (5) Measurement of coverage of raised print layer 2 m × 2 m obtained in each Example and Comparative Example Three 30 cm x 30 cm test pieces were cut out from an arbitrary location on a decorative material of the size of the above, and image analysis was performed on each of these test pieces using a microscope to cover the entire surface of the decorative material and the pattern layer. The coverage of the raised print layer with respect to the non-formed region was calculated, and the average value was calculated.

(Example 1)
A colored single-layer PET sheet for building materials (manufactured by Toyo Boseki Co., Ltd., "A4100 (model number)", thickness: 50 μm) that has been easily adhered is used as a base material, and an acrylic resin is applied to the surface of the base material that has been easily adhered. A resin composition containing titanium white, a valve handle, and yellow lead as a colorant was applied by a gravure printing method using a mixed resin with a urethane resin as a binder to form a colored layer having a thickness of 5 μm. Next, a wide-area decorative layer constituting a wood surface portion composed of a spring material portion and an autumn material portion by using a resin composition containing a nitrocellulose as a binder and a colorant containing a valve handle as a main component on the colored layer. A wood grain pattern having the above was formed, and a conduit portion was further formed as a pattern layer on the wide area decorative layer. Next, a resin composition for forming a primer layer containing a two-component curable resin (main agent: acrylic polyol, curing agent; hexamethylene diisocyanate) and a filler so as to cover the entire surface of the decorative material (filler average particle size: 1). .3 μm, filler content: 40 parts by mass of silica particles with respect to 100 parts by mass of resin content) was applied to form a primer layer having a thickness of 5 μm.
Next, gravure printing is performed using a resin composition containing acrylic resin as a main component and 65 parts by mass of silica particles having an average particle diameter of 15 μm added to 100 parts by mass of the resin content as a raising aid for forming a raised printing layer. On the non-formed region of the pattern layer of the conduit portion (the region where the wood surface portion is exposed in a plan view), 80% of the entire surface of the decorative material is covered with the raised printing layer (referenced to the upper surface of the primer layer). Maximum height: 20 μm) was formed. Further, an ionizing radiation curable resin composition for forming a surface protective layer (ionizing radiation curable resin: electron beam curable acrylate resin, other additives: silica, extender pigment) is applied over the entire surface by a roll coating method to the surface. An uncured resin layer to be a protective layer is formed and irradiated with an electron beam (pressurized voltage: 175 KeV, 5Mrad (50 kGy)) to cure the uncured resin layer to form a surface protective layer (thickness: 5 μm). Formed. Then, it was heat-cured at 70 ° C. for 24 hours to obtain the cosmetic material of Example 1. The obtained decorative material was evaluated as described above. The evaluation results are shown in Table 1.

(Examples 2 to 4, Comparative Examples 2 and 3)
In Example 1, a decorative material was produced in the same manner as in Example 1 except that the coverage of the raised print layer on the entire surface of the decorative material and the non-formed region of the pattern layer was set as shown in Table 1. The above evaluation was performed on the obtained decorative board, and the results are shown in Table 1.

(Example 5)
In Example 1, the resin composition used for the swelling printing layer is a resin composition containing acrylic resin as a main component and acrylic beads as a swelling aid (heaping aid average particle size 30 μm, swelling auxiliary content: resin). A decorative material was obtained in the same manner as in Example 1 except that the number of beads made of acrylic resin was 35 parts by mass with respect to 100 parts by mass. The obtained decorative material was evaluated as described above. The evaluation results are shown in Table 1.

(Example 6)
A decorative material was obtained in the same manner as in Example 1 except that the primer layer was not provided in Example 1. The obtained decorative material was evaluated as described above. The evaluation results are shown in Table 1.

(Comparative Example 1)
A decorative material was produced in the same manner as in Example 1 except that the raised print layer was not provided in Example 1. The above evaluation was performed on the obtained decorative board, and the results are shown in Table 1.

1 *, the coverage of the raised print layer on the entire decorative material.
2 *, the coverage of the raised print layer with respect to the non-formed region of the pattern layer.

From the results of Examples 1 to 6, the decorative material of the present invention has a high tactile sensation developed by the physical uneven shape, and excellent designability due to the physical uneven shape and the visual uneven shape, and also has stain resistance. And it was excellent in abrasion resistance.
On the other hand, the decorative material of Comparative Example 1 having no raised printing layer had no tactile sensation and unevenness, and was inferior in design. Further, the decorative materials of Comparative Examples 2 and 3 having a raised printing layer but having a coverage of less than 30% were inferior in tactile sensation and unevenness, and could not be said to have excellent designability.

10. Cosmetic material 1. Base material 1F. One side of the substrate 2. Picture layer 3. Primer layer 4. Raised print layer 5. Surface protective layer 6. Convex part 7. Large area decorative layer 71. Large area decorative layer 72. Large area decorative layer N. Normal direction

Claims

A decorative material having a base material, a pattern layer covering a part of one surface of the base material, a raised printing layer, and a surface protective layer.
The raised printing layer is provided so as to cover at least a part of the non-formed region of the pattern layer and 30% or more of the entire surface of the decorative material in a plan view.
The surface protective layer is provided on the entire surface of the decorative material so as to cover the base material, the pattern layer, and the raised printing layer.
A convex portion corresponding to the raised printing layer is provided on the outermost surface of the decorative material immediately above the raised printing layer.
Cosmetic material.
The decorative material according to claim 1, wherein the raised printing layer covers 50% or more of a non-formed region of the pattern layer.
The decorative material according to claim 1 or 2, which has a wide-area decorative layer having a covering area wider than that of the pattern layer in a plan view between the base material and the pattern layer or on the same surface as the pattern layer. ..
The decorative material according to claim 3, wherein the wide-area decorative layer forms a spring material portion and an autumn material portion.
The decorative material according to any one of claims 1 to 4, wherein the pattern layer forms a conduit pattern.
The decorative material according to any one of claims 1 to 5, which has a primer layer so as to cover at least the pattern layer in a plan view.
The decorative material according to claim 6, wherein the primer layer contains a matting agent.
The decorative material according to claim 6 or 7, wherein the primer layer is provided so as to cover the entire surface.
The decorative material according to any one of claims 1 to 8, wherein the raised printing layer includes a portion composed of a group of protrusions.
The decorative material according to any one of claims 1 to 9, wherein the raised printing layer contains a raised aid.
The cosmetic according to claim 10, wherein the raised printing layer has a fine convex shape corresponding to the raised auxiliary agent on its surface, and the convex portion has a fine convex portion corresponding to the fine convex shape. Material.
The decorative material according to any one of claims 1 to 11, wherein the surface protective layer is a cured product of a curable resin composition.
The decorative material according to any one of claims 1 to 12, further comprising an adherend via an adhesive layer on a surface of the base material opposite to the surface having the pattern layer.