WO2020203737A1 - 化粧材及びその製造方法 - Google Patents
化粧材及びその製造方法 Download PDFInfo
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- WO2020203737A1 WO2020203737A1 PCT/JP2020/013945 JP2020013945W WO2020203737A1 WO 2020203737 A1 WO2020203737 A1 WO 2020203737A1 JP 2020013945 W JP2020013945 W JP 2020013945W WO 2020203737 A1 WO2020203737 A1 WO 2020203737A1
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- decorative material
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- E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
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Definitions
- the present invention relates to a decorative material and a method for producing the same.
- Decorative materials are widely used for decorating interior materials and exterior materials such as furniture and fittings, and in recent years, there has been a demand for materials that can give a three-dimensional effect in order to enhance the decorative effect.
- a material that forms regions having different glossiness in the surface of the decorative material and imparts a three-dimensional effect by the contrast of the glossiness has been proposed.
- a means for imparting a three-dimensional effect by contrasting glossiness a means for partially exposing the matte layer, a means for partially forming unevenness by embossing, a means for partially forming a brilliant ink layer, and a means for forming a brilliant ink layer.
- Examples thereof include a combination of the above-mentioned means (Patent Documents 1 to 3).
- the decorative material of Patent Document 1 a glossy layer is partially formed on the matte layer formed on the entire surface, and a portion where the matte layer is exposed (low glossy portion) and a portion having a glossy layer (high glossy portion) It is possible to give a three-dimensional effect with the contrast of.
- the decorative material of Patent Document 1 has a problem that the three-dimensional effect is insufficient and the exposed mat layer portion is easily soiled. Further, since the decorative material of Patent Document 1 does not have anisotropy of glossiness, it has a strong artificial impression, and the design is insufficient when it is desired to express a natural object such as wood grain.
- the decorative material of Patent Document 2 can partially form unevenness by embossing to give a three-dimensional effect by the contrast between the concave portion (low gloss portion) and the flat portion (high gloss portion).
- the decorative material of Patent Document 2 has a problem that the design is insufficient when it is desired to express a natural object.
- the decorative material of Patent Document 3 can give a three-dimensional effect by contrasting a region having a matte layer (low gloss portion) and a region having a pearl pigment adjacent to the region (high gloss portion) in the plane. Is.
- the decorative material of Patent Document 3 also has insufficient three-dimensional effect, the matte layer portion is easily soiled, and the design is insufficient when it is desired to express a natural object. There was a problem. Further, as the decorative material of Patent Document 3, it is necessary to use a relatively costly material such as a pearl pigment and metal scales.
- An object of the present invention is to provide a decorative material capable of imparting an excellent three-dimensional effect and having a good expression of natural objects, and a method for producing the decorative material.
- a decorative material which is arranged on at least a part of a plurality of independent recesses (A) and a portion where the plurality of independent recesses (A) do not exist on the first main surface side of the decorative material. It is and a groove-like parallel uneven pattern group (B) comprising, the average depth of the recess of the mean depth X a of a plurality of independent recesses (a), the groove-like parallel uneven pattern group (B) the upon defined as X B, satisfy the relation of X B ⁇ X a, the decorative material.
- a method for producing a decorative material which comprises the following steps (1) and (2).
- a single layer of a base material selected from a plastic film or a composite of a plastic film and paper, or a laminate containing the base material is embossed with an embossed plate to form the above [1] to [8].
- the decorative material of the present invention can give an excellent three-dimensional effect and has good expressiveness of natural objects, so that the design can be made extremely good.
- the method for producing a decorative material of the present invention can easily produce a decorative material having the above-mentioned effects.
- FIG. 1 It is a top view of the 1st main surface side which shows one Embodiment of the decorative material of this invention. It is an enlarged plan view of the circular part surrounded by the alternate long and short dash line in FIG. It is an image which measured the altitude of the decorative material of Example 1 from the first main surface side, and expressed the measured altitude by shading. It is sectional drawing which includes the AA' line of FIG. 1 and consists of the cut plane parallel to the z-axis of FIG. It is a top view explaining one step which calculates the average depth (X A ) of a plurality of independent recesses (A). It is a figure which shows the flow of one Embodiment of the step which forms the uneven shape of the 1st main surface of the decorative material of this invention. It is a figure which shows one scene of the process of making a plate by a laser which is an example of the process S14 of FIG.
- the decorative material of the present invention is a group of groove-shaped parallel uneven patterns arranged on the first main surface side at least in a plurality of independent recesses (A) and at least a part of a portion where the plurality of recesses (A) do not exist. (B) and has an average depth X a of the plurality of independent recesses (a), when the average depth of the concave portion of the groove-like parallel uneven pattern group (B) is defined as X B, It satisfies the relationship of X B ⁇ X A.
- FIG. 1 is a plan view of the first main surface side showing one embodiment of the decorative material 100 of the present invention.
- the decorative material 100 of the present invention is arranged on the surface on the first main surface side in a place where a plurality of independent recesses (A) 10 and the plurality of recesses (A) 10 do not exist. It has a groove-shaped parallel uneven pattern group (B) 20.
- the groove-shaped parallel uneven pattern group (B) 20 is composed of groove-shaped uneven patterns 20a, 20b, ..., And 20l, and each groove-shaped uneven pattern is parallel.
- FIG. 2 is an enlarged plan view of a circular portion surrounded by the alternate long and short dash line in FIG. As shown in FIG.
- the groove-shaped parallel uneven pattern group (B) 20 is composed of a concave portion 21 and a convex portion 22 surrounded by the concave portion 21.
- "parallel" of a group of groove-like parallel concavo-convex patterns means that adjacent recesses are parallel when the decorative material is viewed in a plan view.
- the "parallel" of the groove-shaped parallel uneven pattern group is not limited to being completely parallel, but includes being substantially parallel.
- Approximately parallel means that a tangent line is drawn on the edge of a set of adjacent recesses, and the angle formed by the two tangent lines is within 7.0 degrees, preferably within 5.0 degrees, more preferably. Is within 3.0 degrees.
- FIG. 3 is a plan view in which the altitude of the decorative material of Example 1 is measured from the first main surface side and the measured altitude is represented by shading.
- the elongated high-concentration portion extending in the vertical direction is the recess (A).
- a plurality of the recesses (A) are independently present in the plane of the decorative material of FIG.
- the low-concentration portion extending diagonally downward to the right is the groove-shaped parallel uneven pattern group (B).
- the groove-shaped parallel uneven pattern group (B) is arranged in a place where a plurality of independent recesses (A) do not exist.
- FIG. 4 is a cross-sectional view including the AA'line of FIG. 1 and consisting of a cut surface parallel to the z-axis of FIG.
- parts having a recess (A) since the average depth X A deep, light incident on the relevant section is likely to be scattered and attenuated by multiple reflections. Therefore, the portion having the recess (A) is visually recognized as dark. Meanwhile, parts having a groove-like parallel uneven pattern group (B) causes no multiple reflection in the convex portions, since fewer multiple reflections shallow average depth X B in the recess, brighter than the recess (A) visible Will be done. Further, the brightness of the portion having the groove-shaped parallel uneven pattern group (B) differs depending on whether the portion is visually recognized from the extending direction of the groove or the direction orthogonal to the extending direction of the groove.
- the decorative material of the present invention has a plurality of independent recesses (A) and a groove-shaped parallel uneven pattern group (B), and satisfies the relationship of X B ⁇ X A.
- the portion having the concave portion (A) the portion having the groove-shaped parallel uneven pattern group (B) can be visually recognized relatively brightly, and a three-dimensional effect can be imparted by the contrast of brightness.
- the brightness of the groove-shaped parallel uneven pattern group (B) can be imparted with anisotropy, a natural object can be expressed well.
- the ratio of the area occupied by the recess (A) (the total area of the plurality of independent recesses (A)) to the total area of the first main surface is preferably 20 to 50%, and preferably 30 to 40%. More preferred.
- the plan view shape of the concave portion (A) is an elongated shape elongated in an arbitrary direction
- the height data is measured in a direction orthogonal to the extending direction of the concave portion (A). For example, when the plan view shape is the recess (A) in FIG.
- the average depth of the concave portion (A) on the left side is defined as XA -1, and the average depth of the concave portion (A) on the right side (maximum depth of the five locations).
- the average depth of the recesses of the groove-shaped parallel uneven pattern group (B) can be calculated by X B as the following B1 to B3.
- B1 With respect to the individual recesses of the groove-shaped parallel uneven pattern group (B) existing in the surface of the decorative sheet, the height data in the direction across the individual recesses was measured at five randomly selected points, and the height was measured. Obtain 5 cross-section curves with data. The measurement direction at each measurement point is a direction orthogonal to the extension direction of the recess. Since the width of the convex portion of the groove-shaped parallel uneven pattern group (B) is measured at the same time, it is preferable to make a cross-sectional curve that crosses the convex portion.
- B2 The maximum depth of each measurement point is extracted from the height data measured in B1, and the average value of the maximum depths of the five points is taken as the average depth of each recess.
- the average depth of the plurality of independent recesses (A) (X A) is preferably from 40 ⁇ 150 [mu] m, more preferably 45 ⁇ 120 [mu] m, further preferably 50 ⁇ 100 [mu] m.
- X A or more 40 [mu] m it can be easily lowered the brightness of a portion having a recess (A).
- X A and 150 ⁇ m or less it is possible to reproduce the darkness of the recess (A), the gloss and is well harmonized realistic design of the groove-like parallel uneven pattern group (B).
- the average depth (X B ) of the recesses of the groove-shaped parallel uneven pattern group (B) is preferably 5 to 100 ⁇ m, more preferably 10 to 70 ⁇ m, and even more preferably 15 to 60 ⁇ m.
- X B is preferably 5 ⁇ m or more, it is possible to easily impart anisotropy of lightness.
- X B is 60 ⁇ m or less from the viewpoint of making it difficult to fill the concave portion of the groove-shaped parallel uneven pattern (B) with the colorant when performing the wiping step described later.
- the X A -X B is 20 ⁇ m or more, more preferably 30 ⁇ m or more, more preferably 40 ⁇ m or more.
- the X A -X B and above 20 [mu] m can be a separate plurality of recesses (A), it tends to increase the contrast of the lightness of the groove-like parallel uneven pattern group (B).
- the X A -X B and above 20 [mu] m when performing wiping step described later, while the colorant in the recess (A) is a large amount of filling, a groove-like parallel uneven pattern of (B) The amount of colorant filled in the recesses can be reduced to improve the contrast.
- the convex portion of the groove-shaped parallel uneven pattern group (B) means that it is located between the concave portions of the groove-shaped parallel uneven pattern group (B).
- Y A is preferably 0.99 ⁇ 500 [mu] m, more preferably from 170 ⁇ 450 [mu] m, further preferably 200 ⁇ 400 [mu] m.
- the Y A and above 150 [mu] m it can be easily recognized as a separate area of the individual recess (A). Note that by the Y A and above 150 [mu] m, may be when performing wiping step described later, it tends to fill a large amount of colorant in the recess (A). Further, by setting the Y A and 500 ⁇ m or less, will light incident on the recess (A) is likely to be multiple reflection, it easy to visually recognize darken recess (A).
- Y B1 is preferably 10 to 200 ⁇ m, more preferably 15 to 150 ⁇ m, and even more preferably 20 to 100 ⁇ m.
- Y B1 is preferably 10 to 200 ⁇ m, more preferably 15 to 150 ⁇ m, and even more preferably 20 to 100 ⁇ m.
- Y B2 is preferably 10 to 250 ⁇ m, more preferably 20 to 200 ⁇ m, and even more preferably 40 to 180 ⁇ m.
- Y B2 is preferably 10 to 250 ⁇ m, more preferably 20 to 200 ⁇ m, and even more preferably 40 to 180 ⁇ m.
- Y A, Y B1 and Y B2 preferably satisfies any one of the following formulas (1) and (2), the following equation (1) and (2 ) Is more preferable. Further, when any of the following formulas (1) and (2) is satisfied, it is more preferable to further satisfy any of the following formulas (3) and (4). Further, when the following formulas (1) and (2) are satisfied, it is more preferable to further satisfy the following formulas (3) and (4). More preferably the Y B1 / Y A in the formula (3) is 0.20 to 0.40. More preferably the Y B2 / Y A in the formula (4) is 0.20 to 0.60. Y B1 ⁇ Y A (1) Y B2 ⁇ Y A (2) 0.06 ⁇ Y B1 / Y A ⁇ 0.40 (3) 0.10 ⁇ Y B2 / Y A ⁇ 1.00 (4)
- Average width Y A separate plurality of recesses (A) can be calculated by the following C1 ⁇ C2.
- C1 From the five cross-sectional curves measured in A1, the widths of the recesses (A) at the individual measurement points are calculated, and the average value of the widths at the five points is taken as the average width of the individual recesses (A).
- C2 on average the average width of the individual recesses calculated at C1 (A), and calculates the Y A.
- the average width of the left recess (A) (Y A- 1 + Y A-2) / 2
- the average width Y B1 of the recesses of the groove-shaped parallel uneven pattern group (B) can be calculated by the following D1 to D2.
- D1 From the five cross-sectional curves measured in B1 above, the widths of the recesses of the individual measurement points are calculated, and the average value of the widths of the five points is taken as the average width of the individual recesses.
- D2 Y B1 is calculated by averaging the average widths of the individual recesses calculated in D1 above.
- the average width of the concave portion located nth from the left is defined as Y B1-n . Since there are nine recesses of the groove-shaped parallel uneven pattern group (B) in FIG. 4 (20d to 20l in FIG. 4), the average width Y B1 of the recesses of the groove-shaped parallel uneven pattern group (B) is expressed by the following formula. Can be calculated with.
- the average width Y B2 of the convex portion of the groove-shaped parallel uneven pattern group (B) can be calculated by the following E1 to E2.
- the convex portion of the groove-shaped parallel uneven pattern group (B) means that it is located between the concave portions of the groove-shaped parallel uneven pattern group (B).
- E1 From the five cross-sectional curves measured in B1, the width of the convex portion of each measurement point is calculated, and the average value of the widths of the five points is taken as the average width of the individual convex portion.
- the lengths of the plurality of independent recesses (A) are not particularly limited, and the range of preferable lengths varies depending on the design to be expressed, and therefore cannot be unconditionally stated. For example, if a design to represent the entire decorative sheet pattern of wood, it is preferable that the average length of the recess (A) (L A) is 2 ⁇ 50 mm, more preferably 5 ⁇ 30 mm.
- the average length of the recesses (A) can be calculated as an average value obtained by measuring the lengths of the individual recesses (A).
- the length of each recess (A) means the maximum value of the distance between any two points in each recess (A).
- each groove-shaped uneven pattern constituting the groove-shaped parallel uneven pattern group (B) is not particularly limited, but as shown in FIG. 1, generally from an arbitrary end to another end of the decorative sheet. It is preferable that the length is crossed (however, the portion where the concave portion (A) is present is excluded. If necessary, the vicinity of the concave portion (A) is also excluded).
- plan view shape of the concave portion (A) is not particularly limited, and various patterns can be mentioned.
- the plan view shape of the recess (A) preferably forms one or more patterns selected from conduits, autumn materials, and knots.
- a conduit is a cylindrical cell that serves as a passage for water, and the arrangement of minute conduits makes it appear to the human eye that a dark pattern is formed along the arrangement.
- Autumn wood is a part with narrow eyes and dark color that is formed from summer to autumn.
- the part with a large mesh width made from spring to summer is called spring wood, and the annual rings of wood are formed by alternately repeating spring wood and autumn wood.
- a node is a trace of a branch incorporated into the trunk, has a shape close to a circle or an ellipse, and has a darker color than the surrounding tissue.
- the plan view shape of the concave portion (A) is preferably a concave portion.
- the plan view shape of the concave portion (A) is preferably a joint pattern.
- the plan view shape of the recess (A) is preferably a recess of the cloth.
- the plan view shape of the recess (A) is preferably a wrinkle pattern.
- the plan view shape of the individual groove-shaped uneven patterns constituting the groove-shaped parallel uneven pattern group (B) is not particularly limited, and various patterns can be mentioned, but it is preferably wavy as shown in FIG.
- the brightness of the portion having the groove-shaped parallel uneven pattern group (B) changes along the wave shape. Therefore, the contrast between the concave portion (A) and the groove-shaped parallel uneven pattern group (B) is not uniform at each place in the surface of the decorative sheet, and the expressiveness of a natural object can be improved. Further, since the above-mentioned distribution of light-dark contrast changes as the incident direction of light changes or the observer moves, the design can be made extremely good.
- the wavelength (period) and wave height of the wavy pattern are not particularly limited, and the wavelength (period) can be appropriately adjusted in the range of about 1 to 100 mm and the wave height can be appropriately adjusted in the range of about 1 to 20 mm.
- D A and D B and, by performing the ink scraping direction of the wiping process described later in a direction parallel to the D A, in the recess (A) while the colorant is heavily filled , The amount of the colorant filled in the concave portion of the groove-shaped parallel uneven pattern (B) can be reduced to improve the contrast.
- Stretching direction of a plurality of independent recesses (A) refers to the average direction of the extending direction of each recess (A).
- the stretching direction of the individual recesses (A) means the direction in which the distance between any two points in the individual recesses (A) is maximized. For example, if the recess of FIG. 5 (A), the direction connecting the two points of the points A and B becomes the stretching direction D A.
- Extending direction of the groove-like parallel uneven pattern group (B) (D B) means in a direction obtained by averaging the extending direction of each recess. Further, the extending direction of each recess means the direction of a straight line connecting the start point and the end point of each recess.
- the angle between D A and D B is 5 to 70 degrees, more preferably from 7 to 50 degrees, more preferably 10 to 40 degrees.
- the said angle between 5 degrees or more by performing the ink scraping direction of the wiping process described later in a direction parallel to the D A, in the recess (A) while the colorant is heavily filled, grooves
- the amount of the colorant filled in the recesses of the parallel uneven pattern (B) can be reduced to improve the contrast. Further, it by less 70 degrees the angle, when the wiping direction parallel to the D A, blades for scraping is easily suppressed from being caught in a groove-like parallel uneven pattern group (B).
- the decorative material of the present invention is preferably filled with the colorant 30 in at least a part of the plurality of independent recesses (A) in the depth direction.
- the design of the decorative material can be improved.
- the concave portion (A) can be made darker, and the contrast of lightness in the surface of the decorative material can be made higher. Dark colors are dark gray, dark green, dark blue, black, dark purple, enji, brown, and other low-brightness, low-colored dark colors.
- the means for filling at least a part of the recess (A) in the depth direction is to apply a filling ink containing a colorant and a binder resin to the first main surface side of the decorative material, and scratch a doctor blade or the like.
- Examples thereof include means for scraping the ink with a removing blade.
- the amount of the colorant filled in the recess (A) can be adjusted by adjusting the material of the blade, the angle at which the blade is applied, the viscosity of the ink, and the like.
- colorant examples include carbon black (black), iron black, titanium white, antimony white, chrome yellow, titanium yellow, petal handle, cadmium red, ultramarine blue, cobalt blue and other inorganic pigments, quinacridone red, and isoindolinone yellow.
- Organic pigments such as phthalocyanine blue, dyes and the like.
- Binder resins for filling inks include acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer, polyvinyl butyral, alkyd resin, petroleum resin, ketone resin, and epoxy resin. , Melamine resin, fluororesin, silicone resin, rubber resin and the like.
- the decorative material of the present invention is configured such that at least a part of a plurality of independent recesses (A) in the depth direction is filled with a colorant, and further, any of the following conditions (i) and (ii) is satisfied. It is preferable to satisfy. (I) At least a part of the groove-shaped parallel uneven pattern group (B) in the depth direction of the recess is not filled with the colorant.
- the groove-like parallel uneven pattern group have been colorant filling at least a portion of the depth of the recess (B), the filling amount per unit area of the colorant W B, the multiple independent the filling amount per unit area of the colorant becomes filled to at least a portion of the depth direction of the recess (a) when the defined as W a of satisfy the relationship of W B ⁇ W a.
- W A is individually means an average filling amount of the coloring agent per unit area of the individual recess (A)
- W B is constituting the groove-like parallel uneven pattern group (B) It means the average filling amount of the colorant per unit area of the recess.
- X A, X B, X A -X B, the range of Y A, Y B1 and Y B2, and, D A and D It is preferable that at least one or more embodiments selected from the relationship with B are the preferred embodiments described above.
- the shape of the surface (second main surface) opposite to the first main surface of the decorative material is not particularly limited, and may be smooth or may be provided with irregularities.
- Examples of the decorative material of the present invention include the following laminated configurations (1) to (8).
- "/" indicates the interface of the layer, and the surface of the layer located on the left side indicates the first main surface of the decorative material.
- (1) Single layer of base material (2) Decorative layer / base material (3)
- Surface protective layer / decorative layer / base material (4) Transparent resin layer / decorative layer / base material (5)
- Surface protective layer / transparency Resin layer / decorative layer / base material surface protective layer / primer layer / transparent resin layer / decorative layer / base material (7) surface protective layer / base material / decorative layer (8) surface protective layer / primer layer / Base material / decorative layer
- the decorative material preferably contains a base material.
- the material of the base material is not particularly limited, but in consideration of the ease of forming a plurality of independent recesses (A) and groove-shaped parallel uneven patterns (B) by embossing, a plastic film or a plastic film and paper A complex with is preferred.
- the resin constituting the plastic film include polyolefin resins such as polyethylene and polypropylene, vinyl chloride resins, vinylidene chloride resins, polyvinyl alcohols, vinyl resins such as ethylene-vinyl alcohol copolymers, polyethylene terephthalates, and polybutylene.
- polyester resins such as terephthalate, acrylic resins such as polymethylmethacrylate, methylpolyacrylate and ethylpolymethacrylate, polystyrene, acrylonitrile-butadiene-styrene copolymer (ABS resin), cellulose triacetate and polycarbonate.
- polyolefin resins, vinyl chloride resins, polyester resins, or acrylic resins are preferable from the viewpoints of various physical properties such as weather resistance and water resistance, printability, molding processability, and price.
- the base material may be a transparent base material or a colored base material. Further, the base material may be a laminated base material in which a plurality of base materials are laminated. When the laminated structure of the decorative material is (7) and (8) above, a transparent base material is used as the base material in order to visually recognize the decorative layer through the base material.
- the thickness of the base material is not particularly limited, but is preferably 20 to 200 ⁇ m, more preferably 40 to 160 ⁇ m, and even more preferably 40 to 100 ⁇ m.
- one side or both sides may be subjected to an easy adhesion treatment such as a physical treatment or a chemical surface treatment.
- the decorative sheet preferably has a decorative layer at any position on the decorative sheet.
- the portion where the decorative layer is formed is preferably on the side close to the base material from the viewpoint of enhancing the weather resistance of the decorative layer.
- the decorative layer may be located on the inner layer side (opposite to the first main surface) of the base material as in the laminated configurations (7) and (8).
- the decorative layer may be, for example, a colored layer that covers the entire surface (so-called solid colored layer), or may be a pattern layer formed by printing various patterns using ink and a printing machine. It may be a combination of these.
- the pattern given by the decorative layer is not particularly limited, and examples thereof include a wood pattern, a stone pattern, a tile pattern, a brick pattern, a fabric pattern, and a leather pattern.
- the wood pattern is preferably formed by combining the wood surface portion with one or more patterns selected from conduits, autumn wood and knots.
- the stone pattern is preferably formed by combining the stone surface portion and the concave portion.
- the tile pattern or brick pattern is preferably formed by combining the background portion of the tile or brick and the joint pattern.
- the fabric pattern is preferably formed by combining the background portion of the fabric and the concave portion of the fabric.
- the leather pattern is preferably formed by combining a leather background portion and a wrinkled pattern.
- the decorative layer can be formed by applying and drying an ink for a decorative layer containing, for example, a colorant such as a pigment or a dye and a binder resin.
- a colorant such as a pigment or a dye and a binder resin.
- Additives such as extender pigments, antioxidants, plasticizers, catalysts, curing agents, ultraviolet absorbers and light stabilizers can be mixed with the ink, if necessary.
- the colorant and the binder resin of the decorative layer are not particularly limited, and for example, the same as those exemplified for the filling ink can be used.
- the thickness of the decorative layer may be appropriately selected according to the desired pattern, but from the viewpoint of hiding the ground color of the adherend and improving the design, it is preferably 0.1 ⁇ m or more and 20 ⁇ m or less, preferably 0.5 ⁇ m. More than 10 ⁇ m is more preferable, and 1.0 ⁇ m or more and 5.0 ⁇ m or less is further preferable.
- the decorative material may have a surface protective layer in order to improve scratch resistance.
- the surface protective layer preferably contains a cured product of the curable resin composition from the viewpoint of improving the scratch resistance of the decorative sheet.
- the curable resin composition examples include a thermosetting resin composition containing a thermosetting resin, an ionizing radiation curable resin composition containing an ionizing radiation curable resin, and a mixture thereof.
- an ionizing radiation curable resin composition is preferable from the viewpoint of increasing the crosslink density of the surface protective layer and improving the surface characteristics such as scratch resistance.
- the electron beam curable resin composition is more preferable among the ionizing radiation curable resin compositions from the viewpoint that it can be applied without a solvent and is easy to handle.
- the thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that is cured by heating.
- the thermosetting resin include acrylic resin, urethane resin, phenol resin, urea melamine resin, epoxy resin, unsaturated polyester resin, and silicone resin.
- a curing agent is added to these curable resins as needed.
- the ionizing radiation curable resin composition is a composition containing a compound having an ionizing radiation curable functional group (hereinafter, also referred to as “ionizing radiation curable compound”).
- 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 preferable.
- a (meth) acryloyl group means an acryloyl group or a metachloroyl group.
- (meth) acrylate means acrylate or methacrylate.
- 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 ⁇ -rays, and charged particle beams such as ⁇ -rays and ion rays are also included.
- the ionizing radiation curable compound can be appropriately selected and used from the polymerizable monomers and polymerizable oligomers conventionally used as ionizing radiation curable resins.
- 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.
- “(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.
- polymerizable oligomer examples include (meth) acrylate oligomers having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth) acryloyl group as the functional groups.
- urethane (meth) acrylate oligomer, epoxy (meth) acrylate oligomer, polyester (meth) acrylate oligomer, polyether (meth) acrylate oligomer, polycarbonate (meth) acrylate oligomer, acrylic (meth) acrylate oligomer and the like can be mentioned.
- polymerizable oligomer a highly hydrophobic polybutadiene (meth) acrylate-based oligomer having a (meth) acrylate group on the side chain of the polybutadiene oligomer, and a silicone (meth) acrylate-based oligomer having a polysiloxane bond on the main chain.
- aminoplast resin (meth) acrylate-based oligomers modified from aminoplast resins having many reactive groups in small molecules, novolak type epoxy resins, bisphenol type epoxy resins, aliphatic vinyl ethers, aromatic vinyl ethers, etc.
- oligomers and the like having cationically polymerizable functional groups.
- polymerizable oligomers may be used alone or in combination of two or more. From the viewpoint of improving processing properties, scratch resistance and weather resistance, urethane (meth) acrylate oligomer, epoxy (meth) acrylate oligomer, polyester (meth) acrylate oligomer, polyether (meth) acrylate oligomer, polycarbonate (meth) acrylate One or more selected from oligomers and acrylic (meth) acrylate oligomers is preferable, one or more selected from urethane (meth) acrylate oligomers and polycarbonate (meth) acrylate oligomers is more preferable, and urethane (meth) acrylate oligomers are even more preferable. ..
- a monofunctional (meth) acrylate can be used in combination with the ionizing radiation curable resin composition for the purpose of reducing the viscosity of the ionizing radiation curable resin composition.
- These monofunctional (meth) acrylates may be used alone or in combination of two or more.
- the ionizing radiation curable resin composition preferably contains an additive such as a photopolymerization initiator or a photopolymerization accelerator.
- a photopolymerization initiator include one or more selected from acetophenone, benzophenone, ⁇ -hydroxyalkylphenone, Michler ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, ⁇ -acyl oxime ester, thioxanthones and the like.
- the photopolymerization accelerator can reduce the polymerization inhibition by air at the time of curing and accelerate the curing rate. For example, from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester and the like. One or more selected species can be mentioned.
- the surface protective layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant, if necessary.
- the thickness of the surface protective layer is preferably 1.5 ⁇ m or more and 30 ⁇ m or less, more preferably 2 ⁇ m or more and 15 ⁇ m or less, and further preferably 3 ⁇ m or more and 10 ⁇ m or less from the viewpoint of the balance between processing characteristics, scratch resistance and weather resistance.
- the decorative sheet may have a transparent resin layer from the viewpoint of increasing the strength.
- the transparent resin layer is preferably located between the base material and the surface protective layer.
- the transparent resin layer is preferably located between the base material and the primer layer.
- the transparent resin layer is preferably located between the decorative layer and the surface protective layer from the viewpoint of protecting the decorative layer.
- the resin constituting the transparent resin layer examples include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylic resins, vinyl chloride resins and the like, and among these, processability From the viewpoint of the above, a polyolefin resin is preferable. Further, the transparent resin layer may be a mixture of these exemplified resins, or may be a laminate of one or more layers of these exemplified resins.
- the polyolefin-based resin of the transparent resin layer includes polyethylene (low density, medium density, high density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, and ethylene-vinyl acetate.
- examples thereof include polymers, ethylene-acrylic acid copolymers, and ethylene-propylene-butene copolymers.
- polyethylene (low density, medium density, high density), polypropylene, ethylene-propylene copolymer, and propylene-butene copolymer are preferable, and polypropylene is more preferable.
- the transparent resin layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant.
- the ultraviolet absorber is preferably a triazine-based compound, and more preferably a hydroxyphenyltriazine-based compound.
- the thickness of the transparent resin layer is preferably 20 ⁇ m or more and 150 ⁇ m or less, more preferably 40 ⁇ m or more and 120 ⁇ m or less, and further preferably 60 ⁇ m or more and 100 ⁇ m or less, from the viewpoint of the balance between scratch resistance, processing suitability and weather resistance.
- Primer layer When the decorative sheet has a surface protective layer, it is preferable to have a primer layer in contact with the surface of the surface protective layer on the substrate side.
- the primer layer improves the adhesion between the base material and the surface protective layer (adhesion between the transparent resin layer and the surface protective layer when it has a transparent resin layer), and is a long-term interlayer when exposed outdoors. Adhesion can be ensured (so-called weather resistance) and scratch resistance can be easily improved.
- the primer layer is mainly composed of a binder resin, and may contain additives such as an ultraviolet absorber and a light stabilizer, if necessary.
- urethane resin acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, polycarbonate-based urethane-acrylic copolymer (in the polymer main chain).
- the binder resin may be one obtained by cross-linking and curing these resins by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent.
- a polyol resin such as an acrylic polyol resin is preferably crosslinked and cured with an isocyanate-based curing agent, and a acrylic polyol resin is more preferably crosslinked and cured with an isocyanate-based curing agent.
- the thickness of the primer layer is preferably 0.5 ⁇ m or more and 10 ⁇ m or less, more preferably 0.7 ⁇ m or more and 8 ⁇ m or less, and further preferably 1 ⁇ m or more and 6 ⁇ m or less.
- the decorative material of the present invention may have other layers such as an adhesive layer and a back surface primer layer.
- the decorative sheet has a transparent resin layer
- a decorative layer is further provided between the base material and the transparent resin layer
- the positional relationship between the adhesive layer and the decorative layer is not particularly limited.
- the decorative layer, the adhesive layer and the transparent resin layer may be provided in this order from the side closer to the base material, or the adhesive layer, the decorative layer and the transparent resin layer may be provided from the side closer to the base material. May have in this order.
- the adhesive layer can be composed of, for example, a general-purpose adhesive such as a urethane-based adhesive, an acrylic-based adhesive, an epoxy-based adhesive, or a rubber-based adhesive.
- a general-purpose adhesive such as a urethane-based adhesive, an acrylic-based adhesive, an epoxy-based adhesive, or a rubber-based adhesive.
- urethane-based adhesives are preferable in terms of adhesive strength.
- the urethane-based adhesive include an adhesive using a two-component curable urethane resin containing various polyol compounds such as a polyether polyol, a polyester polyol, and an acrylic polyol, and a curing agent such as an isocyanate compound.
- the thickness of the adhesive layer is preferably 0.1 ⁇ m or more and 30 ⁇ m or less, more preferably 1 ⁇ m or more and 15 ⁇ m or less, and further preferably 2 ⁇ m or more and 10 ⁇ m or less.
- the back surface primer layer is a layer formed on the surface opposite to the first main surface of the decorative material for the purpose of improving the adhesiveness between the decorative material and various adherends.
- the material used for forming the back surface primer layer is not particularly limited, and examples thereof include urethane resin, acrylic resin, polyester resin, vinyl chloride / vinyl acetate copolymer, chlorinated polypropylene resin, chlorinated polyethylene resin, and the like. It may be appropriately selected depending on the material of the material.
- the thickness of the back surface primer layer is preferably 0.5 to 5.0 ⁇ m, and more preferably 1 to 3 ⁇ m.
- the above-mentioned decorative layer, front surface protective layer, primer layer, adhesive layer and back surface primer layer are made of ink containing the composition forming each layer by gravure printing method, bar coating method, roll coating method, reverse roll coating method, comma. It can be formed by applying it by a known method such as a coating method, and if necessary, drying and curing it. Further, the transparent resin layer can be formed by, for example, heat melt extrusion.
- the decorative material of the present invention can be used as it is, as a laminated body bonded to an adherend, or by subjecting the decorative material or the laminated body to a predetermined molding process or the like for various purposes.
- Examples of various uses include interior materials for buildings such as walls, ceilings, and floors; fittings such as window frames, doors, and handrails; furniture; housings for home appliances and OA equipment; exterior materials such as entrance doors. ..
- adherend examples include wood boards such as single wood boards, wood plywood boards, perchle boards, MDF (medium density fiber boards), and laminated materials; plaster boards such as plaster boards and plaster slag boards; calcium silicate boards and asbestos slate.
- Cement boards such as boards, lightweight foamed concrete boards, hollow extruded cement boards; fiber cement boards such as pulp cement boards, asbestos cement boards, and wood piece cement boards; ceramic boards such as pottery, porcelain, earthenware, glass, and amber; iron plates, zinc Metal plates such as plated steel plates, polyvinyl chloride sol coated steel plates, aluminum plates and copper plates; thermoplastic resin plates such as polyolefin resin plates, acrylic resin plates, ABS resin plates and polycarbonate plates; phenol resin plates, urea resin plates and unsaturated polyesters.
- Thermo-curable resin plates such as resin plates, polyurethane resin plates, epoxy resin plates, melamine resin plates; resins such as phenol resin, urea resin, unsaturated polyester resin, polyurethane resin, epoxy resin, melamine resin, diallyl phthalate resin, etc.
- resins such as phenol resin, urea resin, unsaturated polyester resin, polyurethane resin, epoxy resin, melamine resin, diallyl phthalate resin, etc.
- FRP plate obtained by impregnating and curing a glass fiber non-woven fabric, cloth, paper, and other various fibrous base materials to form a composite, and these may be used alone or a composite substrate in which two or more of these are laminated. It may be used as.
- the plurality of independent recesses (A) and the groove-shaped parallel uneven pattern group (B) of the first main surface can be formed, for example, by molding with an embossed plate engraved with a laser.
- Molding with an embossed plate engraved with a laser can be performed, for example, in the steps (S11 to S15) of FIG. Hereinafter, each step will be described.
- ⁇ S11 Concentration distribution data creation of recess (A) >>
- a density distribution image that is the basis of the patterns of the plurality of independent recesses (A) expressed on the surface of the decorative material is acquired, and this is used as the density distribution data.
- the density distribution image there is an image in which only the conduit pattern of wood grain is expressed.
- the density distribution image acquired in step S11 is preferably a two-dimensional density pattern that does not have height information.
- Examples of such a density pattern include photographs, pictures and printed matter.
- a three-dimensional image having height information may be used, but in that case, it is preferable to exclude the height information and use only the information based on the density in two dimensions in a plan view.
- the density value D (x, y) is obtained for each two-dimensional coordinate (x, y) of the obtained density distribution image and used as the density distribution data.
- the two-dimensional coordinates (x, y) are not particularly limited, but it is preferable to correspond to the coordinates of the surface of the plate (metal roll-shaped embossed plate in this embodiment) described later.
- the specific expression of the density value D is not particularly limited, but for example, the darkest part of the density distribution image is set to 255, the lightest part is set to 0, and the interval is evenly allocated by an integer to obtain 256 gradations.
- the concentration value can be expressed. As described above, a set of data having a density value D expressed in 256 gradations at each coordinate (x, y) is obtained, and this is used as density distribution data.
- the concentration distribution data is preferably digital data. Therefore, when the original density distribution image is not digital data, it is converted into digital data by using a method of reading the original or a two-dimensional image such as a photograph of the original with a scanner and performing AD conversion. Further, when the pattern is designed by using digital data using CAD or the like from the beginning, the digital data can be used.
- the means for creating the density distribution data is not particularly limited, but for example, using the graphic design drawing software "photoshop” manufactured by Adobe Systems Incorporated, the density gradation (256 gradations) of 8 bits in TIF format is 2540 dpi. It is possible to create concentration distribution data of resolution.
- ⁇ S12 Conversion of concentration distribution data to depth data
- the density value D (x, y) of the density distribution data of the recess (A) obtained in the step S11 is set to the depth F (x) for each coordinate (x, y). , Y) to obtain depth data.
- This depth data is depth data corresponding to the unevenness of a plurality of independent recesses (A). Therefore, the shape of the plurality of independent recesses (A) is determined by this step.
- the conversion of the density value D (x, y) to the depth F (x, y) is performed based on a predetermined rule. As a result, the density distribution and the depth distribution are associated with each other, and it is possible to obtain a unique texture based on the density distribution image in the surface pattern of the decorative material.
- step S11 the darkest portion of the density distribution image is set to gradation 255, and in step S12, this is set to a depth of 300 ⁇ m.
- step S11 the lightest portion of the density distribution image is set to gradation 0, and in step S12, this is set as a reference (depth 0 ⁇ m).
- 0 ⁇ m to 300 ⁇ m is proportionally distributed and assigned to the depth in step S12. Therefore, according to this example, the thinnest portion of the density distribution image serves as a reference (depth 0 ⁇ m), the darker the depth, the deeper the depth, and the darkest portion has a depth of 300 ⁇ m.
- ⁇ S13 Conversion to height data and superposition of data of groove-shaped uneven pattern group (B) >>
- the depths F (x, y) of the plurality of independent recesses (A) obtained in step S12 are set to the height for producing a plate corresponding to the depths F (x, y).
- Depth data is obtained by converting to H1 (x1, y1). That is, a height H1 (x1, y1) for forming an uneven pattern on the surface of the plate, which is a complementary shape of the concave portion (A) having a depth F (x, y), is created.
- the height H2 (x2, y2) for forming the unevenness having a shape complementary to the unevenness of the groove-shaped uneven pattern group (B) having the predetermined depth data is set to the height H1.
- the height H1 (x1, y1) superimposed on the height H2 (x2, y2) is defined as the height H3 (x3, y3). If unevenness is formed on the surface of the plate by the height data H3 (x3, y3), the unevenness on the surface of the decorative material formed by this plate is based on the height data of the first main surface. ..
- ⁇ may be positive or negative. According to this, it is possible to manufacture a plurality of types of decorative materials that give different impressions from the same height data simply by changing ⁇ .
- the metal roll 50 which will finally be the embossed plate 50 as shown in FIG. 7.
- the metal roll 50 include a metal roll 50 in which a copper layer is plated on the surface of a hollow iron cylinder having rotary drive shafts (shafts) 51 at both ends in the axial direction. It is preferable that the surface of the metal roll 50 is polished with a grindstone or the like to roughen the surface to suppress a decrease in engraving efficiency due to specular reflection of laser light for engraving.
- the surface of the prepared metal roll 50 is engraved based on the height data for each coordinate created in step S13 by using a laser light direct engraving machine.
- the metal roll 50 is driven by an electric motor via the rotation drive shaft 51, and rotates around the rotation drive shaft 51 as a central axis.
- the surface of the metal roll 50 is scanned by the light L emitted from the laser head 52.
- An example of the laser light L is a fiber laser light having an oscillation wavelength of 1024 nm, a spot diameter of 10 ⁇ m, and an output of 360 W.
- the laser beam is switched ON-OFF for each coordinate (x, y) according to the height of the height H3 (x3, y3) created in step S13. (Irradiation or non-irradiation switching) is performed, and a recess is formed at the irradiation position by evaporation of metal by one laser irradiation (the recess of the plate corresponds to the convex portion of the decorative material. Therefore, the height The higher the coordinates, the less the number of laser irradiations should be.) Under the laser conditions exemplified above, a recess having a depth of 10 ⁇ m is formed by one laser irradiation.
- Scanning of the metal roll surface with such laser light is repeated, for example, about 10 times.
- the engraving liquid T is sprayed from the engraving liquid discharge port 53 onto the laser irradiation region on the surface of the metal roll. It is preferable to irradiate with laser light.
- the surface of the metal roll 20 is preferably plated with hard chrome plating or the like in order to improve durability.
- the thickness of the plating layer is usually about 10 ⁇ m.
- a plate 50 (molded mold for decorative material, embossed plate in this embodiment) having a shape complementary to the uneven shape of the first main surface of the decorative material can be obtained.
- the plates (embossed plates) produced in steps S11 to S14 are used to emboss the decorative material before forming the first main surface to prepare the decorative material.
- the embossing may be performed by an appropriate known method, and is not particularly limited.
- the temperature and pressure during embossing may be appropriately adjusted depending on the material of the decorative material, and if the base material of the decorative material and the transparent resin layer are polyolefin, the temperature and pressure are about 140 to 180 ° C. and 10 to 50 kg / cm 2. ..
- a typical method of embossing is as follows, for example.
- the embossed plate is pressed against the surface of the softened resin base material to form an uneven pattern on the surface of the embossed plate on the surface of the base material. Then, the resin base material is solidified by cooling or light irradiation to fix the uneven pattern on the resin base material. After that, the resin having the uneven pattern is released from the embossed plate.
- the method for producing a decorative material of the present invention includes the following steps (1) and (2).
- a single layer of a base material selected from a plastic film or a composite of a plastic film and paper, or a laminate containing the base material is embossed with an embossed plate to obtain the above-mentioned decorative material of the present invention.
- Process. (2) A step of applying a filling ink containing a colorant and a binder resin to the surface of the decorative material obtained in (1) on the first main surface side, and then scraping off the filling ink.
- the decorative material obtained through the steps (1) to (2) above is filled with a colorant at least a part of the recess (A) in the depth direction, so that the design of the decorative material is further improved. be able to.
- a colorant at least a part of the recess (A) in the depth direction
- the filling amount of the colorant of the decorative material obtained in the step (2) is the above-mentioned (i) and (ii).
- the contrast of brightness between the concave portion (A) and the concave portion forming the groove-shaped parallel uneven pattern group (B) becomes higher, and a decorative material having a more three-dimensional effect can be obtained. be able to.
- the embossing condition of the step (1) is not particularly limited, and examples thereof include the conditions described in the above step S15.
- the step (2) preferably includes the following steps (2-1) to (2-3).
- (2-1) Along at least a part of the surface of a roll having a circular cross section, the decorative material obtained in the step (1) is placed along the surface so that the first main surface side of the decorative material faces the side opposite to the roll.
- Process. (2-2) A step of applying a filling ink containing a colorant and a binder resin to the surface of the decorative material obtained in the step (1) on the first main surface side.
- (2-3) A step of pressing the blade against the first main surface side of the decorative material and scraping off the filling ink adhering to the first main surface side.
- the material of the roll includes metal, rubber, resin and the like, of which rubber and resin are preferable, and rubber is more preferable.
- the material of the roll have cushioning properties such as rubber and resin, it is possible to easily prevent the colorant from remaining excessively in the recesses. Further, by making the material of the roll have cushioning properties such as rubber and resin, it is possible to easily satisfy any of the above conditions (i) and (ii).
- the filling ink in the step (2-2) contains a colorant and a binder resin, and preferably contains a solvent if necessary.
- the colorant of the filling ink is preferably a dark color.
- the direction of scraping ink ( ⁇ 10 degrees relative to D A, preferably within 5 degrees ⁇ , more preferably within 3 degrees ⁇ ) D A substantially coincides it is preferable to.
- the angle of the blade with respect to the first main surface of the decorative material is preferably substantially vertical. Approximately vertical means a range of 90 ⁇ 10 degrees, preferably 90 ⁇ 5 degrees, more preferably 90 ⁇ 3 degrees.
- the material of the blade includes metal, rubber, resin and the like, and among these, metal is preferable.
- step (2-3) the pressure at which the blade is applied to the decorative material can be appropriately adjusted within a range in which ink streaks and unevenness do not occur.
- embossed plate A whose surface was hard chrome-plated was produced according to steps S11 to S14 in the main text of the specification. Further, the embossed plates B to C were produced in the same manner as the plate A except that the shapes of the concave portion (A) and the groove-shaped parallel uneven pattern group (B) were changed as shown in Table 1. Further, the embossed plates D to E were produced in the same manner as the plate A except that the groove-shaped parallel uneven pattern group (B) was not formed and the shape of the concave portion (A) was changed as shown in Table 1.
- the transparent resin layer is heated to a softened state, and embossing is performed from the surface on the transparent resin layer side using the embossed plate A prepared in the above "2", and the surface on the transparent resin layer side (first).
- An uneven shape was formed on the surface on the main surface side).
- Table 1 shows the measured values of the uneven shape.
- the doctor blade is pressed so as to be perpendicular to the first main surface for filling. The ink was scraped off to obtain the decorative material of Example 1.
- Direction for scraping the filling ink was the same direction as D A.
- Example 2 to 3 The decorative materials of Examples 2 to 3 were obtained in the same manner as in Example 1 except that the embossed plate A was changed to the embossed plates B to C.
- Comparative Examples 1 and 2 The decorative materials of Comparative Examples 1 and 2 were obtained in the same manner as in Example 1 except that the embossed version A was changed to the embossed versions D to E.
- the decorative material of the example can give an excellent three-dimensional effect and has good expressiveness of natural objects, so that it can be confirmed that the design is extremely good.
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Abstract
Description
[1]化粧材であって、前記化粧材の第1主面側には、独立した複数の凹部(A)と、前記独立した複数の凹部(A)が存在しない箇所の少なくとも一部に配置されてなる溝状平行凹凸模様群(B)とを有し、前記独立した複数の凹部(A)の平均深さをXA、前記溝状平行凹凸模様群(B)の凹部の平均深さをXBと定義した際に、XB<XAの関係を満たす、化粧材。
[2]前記XAが40~150μmであり、前記XBが5~100μmである、上記[1]に記載の化粧材。
[3]前記XA-XBが20μm以上である、上記[1]又は[2]に記載の化粧材。
[4]前記独立した複数の凹部(A)の平均幅をYA、前記溝状平行凹凸模様群(B)の凹部の平均幅をYB1、前記溝状平行凹凸模様群(B)の凸部の平均幅をYB2と定義した際に、YAが150~500μmであり、前記YB1が10~200μmであり、前記YB2が10~250μmである、上記[1]~[3]の何れかに記載の化粧材。
[5]前記独立した複数の凹部(A)の延伸方向をDA、前記溝状平行凹凸模様群(B)の延伸方向をDBと定義した際に、DAとDBとが非平行である、上記[1]~[4]の何れかに記載の化粧材。
[6]前記DAと前記DBとの成す角度が5~70度である、上記[5]に記載の化粧材。
[7]前記溝状平行凹凸模様群(B)を構成する個々の溝状平行凹凸模様は、平面視形状が波状である、上記[1]~[6]の何れかに記載の化粧材。
[8]前記凹部(A)の平面視形状が、木材の導管、秋材及び節から選ばれる1種以上である、上記[1]~[7]の何れかに記載の化粧材。
[9]前記独立した複数の凹部(A)の深さ方向の少なくとも一部に着色剤が充填されてなる、上記[1]~[8]の何れかに記載の化粧材。
[10]下記(i)及び(ii)の何れかの条件を満たす、上記[9]に記載の化粧材。
(i)前記溝状平行凹凸模様群(B)の凹部の深さ方向の少なくとも一部に着色剤が充填されてない。
(ii)前記溝状平行凹凸模様群(B)の凹部の深さ方向の少なくとも一部に着色剤が充填されてなり、該着色剤の単位面積当たりの充填量をWB、前記独立した複数の凹部(A)の深さ方向の少なくとも一部に充填されてなる着色剤の単位面積当たりの充填量をWAと定義した際に、WB<WAの関係を満たす。
[11]下記(1)~(2)の工程を含む、化粧材の製造方法。
(1)プラスチックフィルム又はプラスチックフィルムと紙との複合体から選ばれる基材の単層、あるいは、前記基材を含む積層体をエンボス版で賦型して、上記[1]~[8]の何れかに記載の化粧材を得る工程。
(2)前記(1)で得られた化粧材の第1主面側の面に、着色剤及びバインダー樹脂を含む充填用インキを塗布した後、前記充填用インキを掻き取る工程。
本発明の化粧材は、第1主面側に、独立した複数の凹部(A)と、前記複数の凹部(A)が存在しない箇所の少なくとも一部に配置されてなる溝状平行凹凸模様群(B)とを有し、前記独立した複数の凹部(A)の平均深さをXA、前記溝状平行凹凸模様群(B)の凹部の平均深さをXBと定義した際に、XB<XAの関係を満たすものである。
図1は、本発明の化粧材100の一実施形態を示す第1主面側の平面図である。図1に示すように、本発明の化粧材100は、第1主面側の面に、独立した複数の凹部(A)10と、前記複数の凹部(A)10が存在しない箇所に配置されてなる溝状平行凹凸模様群(B)20を有するものである。なお、図1において、溝状平行凹凸模様群(B)20は、溝状凹凸模様20a、20b、・・・、及び20lから構成されており、各溝状凹凸模様は平行である。
図2は、図1の一点鎖線で囲まれた円形部分を拡大した平面図である。図2に示すように、溝状平行凹凸模様群(B)20は、凹部21と、凹部21に囲まれた凸部22とから構成されている。
なお、本明細書において、溝状平行凹凸模様群の「平行」とは、化粧材を平面視した際に、隣接する凹部が平行であることを意味する。さらに、溝状平行凹凸模様群の「平行」とは、完全に平行であることに限定されず、略平行であることを含むものとする。略平行とは、隣接する一組の凹部の縁に接線を引き、2本の接線が成す角度が7.0度以内であることを意味し、好ましくは5.0度以内であり、より好ましくは3.0度以内である。
図4は、図1のA-A’線を含み、図1のz軸に平行な切断面からなる断面図である。
以上のように、本発明の化粧材は、独立した複数の凹部(A)と、溝状平行凹凸模様群(B)とを有し、かつ、XB<XAの関係を満たすことから、凹部(A)を有する箇所に比べて、溝状平行凹凸模様群(B)を有する箇所を相対的に明るく視認させることができ、明度のコントラストにより立体感を付与することができる。さらには、溝状平行凹凸模様群(B)による明度に異方性を付与できるため、自然物を良好に表現することができる。
独立した複数の凹部(A)の平均深さXAは、例えば、下記A1~A3のステップで算出できる。
A1:個々の凹部(A)に関して、個々の凹部(A)を横断する方向の高さデータを、ランダムに抽出した5箇所で測定し、高さデータを備えた5つの断面曲線を得る。凹部(A)の平面視形状が任意の方向に延伸してなる細長い形状である場合、凹部(A)の延伸方向に直交する方向で高さデータを測定する。例えば、平面視形状が図5の凹部(A)の場合、a~eの5箇所において、凹部(A)の延伸方向(図5の上下方向)と直交する方向である点線方向の高さデータを測定する。
A2:A1で測定した高さデータから、各測定箇所の最大深さを抽出し、5箇所の最大深さの平均値を、個々の凹部(A)の平均深さとする。
A3:A2で算出した個々の凹部(A)の平均深さを平均して、XAを算出する。
凹部(A)の平均深さXA=(XA-1+XA-2)/2
B1:化粧シートの面内に存在する溝状平行凹凸模様群(B)の個々の凹部に関して、個々の凹部を横断する方向の高さデータを、ランダムに抽出した5箇所で測定し、高さデータを備えた5つの断面曲線を得る。各測定箇所における測定方向は、凹部の延伸方向に直交する方向とする。なお、同時に溝状平行凹凸模様群(B)の凸部の幅を測定するため、凸部を横断する断面曲線とすることが好ましい。
B2:B1で測定した高さデータから、各測定箇所の最大深さを抽出し、5箇所の最大深さの平均値を、個々の凹部の平均深さとする。
B3:B2で算出した個々の凹部の平均深さを平均して、XBを算出する。
溝状平行凹凸模様群(B)の凹部の平均深さXB=(XB1-1+XB1-2+XB1-3+XB1-4+XB1-5+XB1-6+XB1-7+XB1-8+XB1-9)/9
溝状平行凹凸模様群(B)の凹部の平均深さ(XB)は、5~100μmであることが好ましく、10~70μmであることがより好ましく、15~60μmであることがさらに好ましい。XBを5μm以上とすることにより、明度の異方性を付与しやすくできる。また、XBを100μm以下とすることにより、独立した複数の凹部(A)と、溝状平行凹凸模様群(B)との明度のコントラストを高くしやすくできる。なお、後述するワイピング工程を行う際に、溝状平行凹凸模様(B)の凹部に着色剤を充填させにくくする観点からは、XBは60μm以下とすることが好ましい。
また、本発明の化粧材は、凹部(A)の平均幅をYA、溝状平行凹凸模様群(B)の凹部の平均幅をYB1、溝状平行凹凸模様群(B)の凸部の平均幅をYB2と定義した際に、YA、YB1及びYB2が下記の範囲であることが好ましい。なお、溝状平行凹凸模様群(B)の凸部は、溝状平行凹凸模様群(B)の凹部の間に位置するものを意味する。
YAを150μm以上とすることにより、個々の凹部(A)を独立した領域として認識しやすくできる。なお、YAを150μm以上とすることにより、後述するワイピング工程を行う際に、凹部(A)に多量の着色剤を充填させやすくすることができる。また、YAを500μm以下とすることにより、凹部(A)内に入射した光が多重反射されやすくなり、凹部(A)を暗く視認させやすくできる。
YB1<YA (1)
YB2<YA (2)
0.06≦YB1/YA≦0.40 (3)
0.10≦YB2/YA≦1.00 (4)
C1:上記A1で測定した5つの断面曲線から、個々の測定箇所の凹部(A)の幅を算出し、5箇所の幅の平均値を個々の凹部(A)の平均幅とする。
C2:上記C1で算出した個々の凹部(A)の平均幅を平均して、YAを算出する。
凹部(A)の平均幅YA=(YA-1+YA-2)/2
D1:上記B1で測定した5つの断面曲線から、個々の測定箇所の凹部の幅を算出し、5箇所の幅の平均値を個々の凹部の平均幅とする。
D2:上記D1で算出した個々の凹部の平均幅を平均して、YB1を算出する。
溝状平行凹凸模様群(B)の凹部の平均幅YB1=(YB1-1+YB1-2+YB1-3+YB1-4+YB1-5+YB1-6+YB1-7+YB1-8+YB1-9)/9
E1:上記B1で測定した5つの断面曲線から、個々の測定箇所の凸部の幅を算出し、5箇所の幅の平均値を個々の凸部の平均幅とする。
E2:上記E1で算出した個々の凸部の平均幅を平均して、YB2を算出する。
溝状平行凹凸模様群(B)の凸部の平均幅YB2=(YB2-1+YB2-2+YB2-3+YB2-4+YB2-5+YB2-6)/6
凹部(A)の平均長さは、個々の凹部(A)の長さを測定し、その平均値として算出できる。なお、個々の凹部(A)の長さは、個々の凹部(A)内の任意の2点間距離の最大値を意味する。
凹部(A)の平面視形状は特に限定されず、各種の模様が挙げられる。
化粧シート全体で表現する意匠が木材の模様の場合、凹部(A)の平面視形状は、導管、秋材及び節から選ばれる1種以上の模様を形成することが好ましい。
導管とは、水分の通路となる円筒形の細胞であり、微小な導管が配列することにより、人の目には該配列に沿って濃色の絵柄が形成されているようにみえる。秋材とは、夏から秋にかけて形成される目幅が狭く色の濃い部分のことである。なお、春から夏にかけてつくられる目幅の大きな部分は春材と称し、春材と秋材とが交互に繰り返されることで木材の年輪が形成される。節とは、幹に取り込まれた枝の痕跡であり、円形又は楕円形に近い形状をしており、周辺組織よりも濃い色を有している。
溝状凹凸模様の平面視形状を波状とすることにより、溝状平行凹凸模様群(B)を有する箇所の明るさが波の形状に沿って変化する。このため、化粧シートの面内の場所ごとで、凹部(A)と溝状平行凹凸模様群(B)との明暗コントラストが均一ではなくなり、自然物の表現性を良好にすることができる。また、光の入射方向が変化したり、観察者が移動したりすることにより、前述の明暗コントラストの分布は変化することから、意匠性を極めて良好にすることができる。
波状模様の波長(周期)及び波高は特に限定されず、波長(周期)は1~100mm程度、波高は1~20mm程度の範囲で適宜調整することができる。
本発明の化粧材は、独立した複数の凹部(A)の延伸方向をDA、溝状平行凹凸模様群(B)の延伸方向をDBと定義した際に、DAとDBとが非平行であることが好ましい。DAとDBとを非平行として、かつ、後述するワイピング工程のインキ掻き取り方向をDAと平行な方向で行うことにより、凹部(A)には着色剤が多量に充填される一方で、溝状平行凹凸模様(B)の凹部に充填される着色剤の量を少なくして、コントラストをより良好にすることができる。
溝状平行凹凸模様群(B)の延伸方向(DB)は、個々の凹部の延伸方向を平均した方向を意味する。また、個々の凹部の延伸方向は、個々の凹部の始点と終点とを結んだ直線の方向を意味する。
該角度を5度以上とすることにより、後述するワイピング工程のインキ掻き取り方向をDAと平行な方向で行うことにより、凹部(A)には着色剤が多量に充填される一方で、溝状平行凹凸模様(B)の凹部に充填される着色剤の量を少なくして、コントラストをより良好にすることができる。また、該角度を70度以下とすることにより、DAと平行な方向でワイピングする際に、掻き取り用の刃が溝状平行凹凸模様群(B)に引っ掛かることを抑制しやすくできる。
本発明の化粧材は、図4に示すように、独立した複数の凹部(A)の深さ方向の少なくとも一部に着色剤30が充填されてなることが好ましい。当該構成とすることにより、化粧材の意匠性をより良好にすることができる。また、着色剤として暗色系の着色剤を用いることにより、凹部(A)をより暗くすることができ、化粧材面内の明度のコントラストをより高くすることができる。暗色とは、濃灰色、深緑色、紺色、黒色、濃紫色、臙脂(えんじ)色、茶色等の低明度、低彩色の暗い感じのする色のことをいう。
充填用インキのバインダー樹脂としては、アクリル樹脂、スチレン樹脂、ポリエステル樹脂、ウレタン樹脂、塩素化ポリオレフィン樹脂、塩化ビニル-酢酸ビニル共重合体、ポリビニルブチラール、アルキド樹脂、石油系樹脂、ケトン樹脂、エポキシ樹脂、メラミン樹脂、フッ素樹脂、シリコーン樹脂及びゴム系樹脂等が挙げられる。
(i)前記溝状平行凹凸模様群(B)の凹部の深さ方向の少なくとも一部に着色剤が充填されてない。
(ii)前記溝状平行凹凸模様群(B)の凹部の深さ方向の少なくとも一部に着色剤が充填されており、該着色剤の単位面積当たりの充填量をWB、前記独立した複数の凹部(A)の深さ方向の少なくとも一部に充填されてなる着色剤の単位面積当たりの充填量をWAと定義した際に、WB<WAの関係を満たす。
なお、本明細書において、WAは、個々の凹部(A)の単位面積当たりの着色剤の充填量の平均を意味し、WBは、溝状平行凹凸模様群(B)を構成する個々の凹部の単位面積当たりの着色剤の充填量の平均を意味する。
化粧材の第1主面とは反対側の面(第2主面)の形状は特に限定されず、平滑であってもよいし、凹凸が付与されていてもよい。
本発明の化粧材は、下記(1)~(8)の積層構成が挙げられる。なお、「/」は層の界面を示し、左側に位置する層の表面が化粧材の第1主面を示す。
(1)基材の単層
(2)装飾層/基材
(3)表面保護層/装飾層/基材
(4)透明性樹脂層/装飾層/基材
(5)表面保護層/透明性樹脂層/装飾層/基材
(6)表面保護層/プライマー層/透明性樹脂層/装飾層/基材
(7)表面保護層/基材/装飾層
(8)表面保護層/プライマー層/基材/装飾層
化粧材は基材を含むことが好ましい。基材の材質は特に制限されないが、エンボス加工により、独立した複数の凹部(A)及び溝状平行凹凸模様群(B)の形成のしやすさを考慮して、プラスチックフィルム又はプラスチックフィルムと紙との複合体が好ましい。
化粧シートは、意匠性を向上させる観点から、化粧シートの任意の箇所に装飾層を有することが好ましい。
装飾層を形成する箇所は、装飾層の耐候性を高める観点から基材に近い側であることが好ましい。なお、基材が透明であれば,上記積層構成(7)及び(8)のように、装飾層が基材よりも内層側(第1主面とは反対側)に位置してもよい。
石の模様は、石肌部分と、凹陥部とを組み合わせて形成することが好ましい。
タイル模様又はレンガ模様は、タイル又はレンガの地肌部分と、目地模様とを組み合わせて形成することが好ましい。
布地模様は、布の地肌部分と、布地の凹部とを組み合わせて形成することが好ましい。
レザー模様は、レザーの地肌部分と、皺状模様とを組み合わせて形成することが好ましい。
装飾層の着色剤及びバインダー樹脂は特に限定されず、例えば、充填用インキで例示したものと同様にものを用いることができる。
化粧材は、耐擦傷性を向上するために、表面保護層を有していてもよい。
表面保護層は、化粧シートの耐擦傷性を良好にする観点から、硬化性樹脂組成物の硬化物を含むことが好ましい。
また、電離放射線とは、電磁波又は荷電粒子線のうち、分子を重合あるいは架橋し得るエネルギー量子を有するものを意味し、通常、紫外線(UV)又は電子線(EB)が用いられるが、その他、X線、γ線などの電磁波、α線、イオン線などの荷電粒子線も含まれる。
電離放射線硬化性化合物は、具体的には、従来電離放射線硬化性樹脂として慣用されている重合性モノマー、重合性オリゴマーの中から適宜選択して用いることができる。
多官能性(メタ)アクリレートモノマーとしては、分子中に2つ以上の電離放射線硬化性官能基を有し、かつ該官能基として少なくとも(メタ)アクリロイル基を有する(メタ)アクリレートモノマーが挙げられる。
さらに、重合性オリゴマーとしては、他にポリブタジエンオリゴマーの側鎖に(メタ)アクリレート基をもつ疎水性の高いポリブタジエン(メタ)アクリレート系オリゴマー、主鎖にポリシロキサン結合をもつシリコーン(メタ)アクリレート系オリゴマー、小さな分子内に多くの反応性基をもつアミノプラスト樹脂を変性したアミノプラスト樹脂(メタ)アクリレート系オリゴマー、あるいはノボラック型エポキシ樹脂、ビスフェノール型エポキシ樹脂、脂肪族ビニルエーテル、芳香族ビニルエーテル等の分子中にカチオン重合性官能基を有するオリゴマー等がある。
光重合開始剤としては、アセトフェノン、ベンゾフェノン、α-ヒドロキシアルキルフェノン、ミヒラーケトン、ベンゾイン、ベンジルジメチルケタール、ベンゾイルベンゾエート、α-アシルオキシムエステル、チオキサントン類等から選ばれる1種以上が挙げられる。
また、光重合促進剤は、硬化時の空気による重合阻害を軽減させ硬化速度を速めることができるものであり、例えば、p-ジメチルアミノ安息香酸イソアミルエステル、p-ジメチルアミノ安息香酸エチルエステル等から選ばれる1種以上が挙げられる。
化粧シートは、強度を高めるなどの観点から透明性樹脂層を有していてもよい。化粧シートが表面保護層を有する場合、透明性樹脂層は、基材と表面保護層との間に位置することが好ましい。化粧シートがプライマー層を有する場合、透明性樹脂層は、基材とプライマー層との間に位置することが好ましい。また、化粧シートが装飾層を有する場合、装飾層の保護の観点から、透明性樹脂層は、装飾層と表面保護層との間に位置することが好ましい。
化粧シートが表面保護層を有する場合、表面保護層の基材側の面に接してプライマー層を有することが好ましい。プライマー層によって、基材と表面保護層との密着性(透明性樹脂層を有する場合は、透明性樹脂層と表面保護層との密着性)が向上し、屋外暴露した際の長期的な層間密着性の確保(いわゆる耐候密着性)及び耐擦傷性を良好にしやすくできる。
本発明の化粧材は、接着剤層及び裏面プライマー層等のその他の層を有していてもよい。
なお、基材と透明性樹脂層との間に、さらに装飾層を有する場合、接着剤層と装飾層との位置関係は特に限定されない。具体的には、基材に近い側から装飾層、接着剤層及び透明性樹脂層をこの順に有していてもよいし、基材に近い側から接着剤層、装飾層及び透明性樹脂層をこの順に有していてもよい。
ウレタン系接着剤としては、例えば、ポリエーテルポリオール、ポリエステルポリオール、アクリルポリオール等の各種ポリオール化合物と、イソシアネート化合物等の硬化剤とを含む2液硬化型ウレタン樹脂を利用した接着剤が挙げられる。
裏面プライマー層の厚さは、0.5~5.0μmであることが好ましく、1~3μmであることがより好ましい。
また、透明性樹脂層は、例えば、加熱溶融押出しにより形成することができる。
本発明の化粧材は、そのままで、あるいは被着材に貼り合わせた積層体として、あるいは化粧材又は積層体に所定の成形加工等を施して各種用途に用いることができる。
各種用途としては、壁、天井、床等の建築物の内装材;窓枠、扉、手すり等の建具;家具;家電製品、OA機器等の筐体;玄関ドア等の外装材等が挙げられる。
第1主面が有する、独立した複数の凹部(A)、及び溝状平行凹凸模様群(B)は、例えば、レーザーで彫刻したエンボス版で賦型することにより形成することができる。
濃度分布データ作成工程(工程S11)では、化粧材の表面に表現する独立した複数の凹部(A)の模様の元になる濃度分布画像を取得し、これを濃度分布データとする。濃度分布画像の一例としては、木目の導管模様のみが表現された画像が挙げられる。
該2次元座標(x,y)は特に限定されることはないが、後述する版(本実施形態では金属ロール状のエンボス版)表面の座標に対応させることが好ましい。また、濃度値Dの具体的な表現は特に限定されることはないが、例えば濃度分布画像のうち最も濃い部分を255、最も薄い部分を0としてその間を整数で均等に割り付けて256階調で濃度値を表現することができる。
以上により各座標(x,y)において256階調で表現された濃度値Dのデータの集合が得られ、これを濃度分布データとする。
深さデータへの変換工程(工程S12)では、工程S11で得た凹部(A)の濃度分布データの濃度値D(x,y)を、座標(x,y)ごとに深さF(x,y)に変換して深さデータを得る。この深さデータは、独立した複数の凹部(A)の凹凸に対応した深さデータである。したがって、この工程により、独立した複数の凹部(A)の形状が決められる。
ここで、濃度値D(x,y)の深さF(x,y)への変換は、所定の規則に基づいて行われる。これにより濃度分布と深さ分布とが対応付けられ、化粧材の表面模様において、濃度分布画像を基調とする特有の質感を得ることができる。
したがって、この例によれば、濃度分布画像で最も薄い部分が基準(深さ0μm)となり、濃くなるほど深くなり、最も濃い部分で深さが300μmとなる。
高さデータへの変換工程(工程S13)では、工程S12で得られた、独立した複数の凹部(A)の深さF(x,y)を、これに対応する版を作製するための高さH1(x1,y1)に変換して深さデータを得る。すなわち、深さF(x,y)を備えた凹部(A)の相補的形状となる凹凸模様を版の表面に形成するための高さH1(x1,y1)を作成する。
ここで、所定の深さデータを備えた溝状凹凸模様群(B)の凹凸と相補的形状となる凹凸を版の表面に形成するための高さH2(x2,y2)を、高さH1(x1,y1)に対して重畳する。高さH1(x1,y1)に高さH2(x2,y2)を重畳したものを、高さH3(x3,y3)とする。
この高さデータH3(x3,y3)により版の表面に凹凸を形成すれば、この版により賦型される化粧材の表面の凹凸は、第1主面の高さデータに準じたものとなる。
これによれば、αを変更するだけで同じ高さデータから異なる印象を与える複数種類の化粧材を製造することができる。
版作製工程(S14)では、工程S13で得た高さH3(x3,y3)による高さデータを用いて表面に凹凸を有する版を作製する。ここでは1つの例として金属ロールによるエンボス版を例示する。より具体的には以下のようにエンボス版を作製する。
金属ロール50は、その回転駆動軸51を介して電動機で駆動し、回転駆動軸51を中心軸として回転する。その際、レーザーヘッド52から出射した光Lにより、金属ロール50の表面を走査する。レーザー光Lの一例としては、発振波長1024nm、スポット径10μm、出力360Wのファイバーレーザー光が挙げられる。
レーザー光Lで金属ロールの表面を走査する際には、工程S13で作成した高さH3(x3,y3)の高さに応じて、座標(x,y)ごとにレーザー光をON-OFF切換(照射又は非照射の切換)を行い、照射位置には1回のレーザー光照射による金属の蒸発で凹部が形成される(版の凹部は化粧材の凸部に対応する。このため、高さが高い座標ほど、レーザーの照射回数を少なくすればよい。)。上記に例示したレーザーの条件では、1回のレーザー光照射により、深さ10μmの凹部が形成される。
かかるレーザー光による金属ロール表面に対する走査を、例えば10回程度繰り返す。また、蒸発した金属が粉体となって金属ロール50の表面に残留又は付着することを防止するため、彫刻液吐出口53から彫刻液Tを金属ロールの表面のレーザー光照射領域に吹き付けた状態でレーザー光照射を行うことが好ましい。
このように、金属ロール50の表面をレーザーで微細に彫刻することにより、第1主面の表面形状を形成し得る形状を備えた金属ロールを得ることができる。
賦形工程(S15)は、工程S11~S14で作製した版(エンボス版)を用いて、第1主面を形成する前の化粧材にエンボス加工を行って化粧材を作製する。
エンボス加工は、適宜な公知の方法によれば良く、特に制限はない。エンボス加工時の温度及び圧力は、化粧材の材質によって適宜調整すればよく、化粧材の基材及び透明性樹脂層がポリオレフィンであれば、140~180℃、10~50kg/cm2程度である。
エンボス加工の代表的な方法は例えば次のようなものである。
まず、軟化した樹脂基材の表面にエンボス版を押圧して該基材表面にエンボス版表面の凹凸模様を賦形する。そして樹脂基材を冷却や光照射により固化して、樹脂基材上の凹凸模様を固定する。その後に凹凸模様が賦形された樹脂をエンボス版から離型する。
本発明の化粧材の製造方法は、下記(1)~(2)の工程を含むものである。
(1)プラスチックフィルム又はプラスチックフィルムと紙との複合体から選ばれる基材の単層、あるいは、前記基材を含む積層体をエンボス版で賦型して、上述した本発明の化粧材を得る工程。
(2)前記(1)で得られた化粧材の第1主面側の面に、着色剤及びバインダー樹脂を含む充填用インキを塗布した後、前記充填用インキを掻き取る工程。
特に、工程(1)で得られた化粧材の第1主面に関する、XA、XB、XA-XB、YA、YB1及びYB2の範囲、並びに、DAとDBとの関係から選ばれる少なくとも一以上の実施形態を、上述した好適な実施形態とすることにより、工程(2)で得られた化粧材の着色剤の充填量が上述した(i)及び(ii)の何れかの条件を満たし、凹部(A)と、溝状平行凹凸模様群(B)を構成する凹部との間の明度のコントラストがより高くなり、立体感をより際立たせた化粧材を得ることができる。
(2-1)断面円形のロールの表面の少なくとも一部に、工程(1)で得られた化粧材を該化粧材の第1主面側が前記ロールとは反対側を向くようにして沿わせる工程。
(2-2)工程(1)で得られた化粧材の第1主面側の面に、着色剤及びバインダー樹脂を含む充填用インキを塗布する工程。
(2-3)化粧材の第1主面側に刃を押し当て、第1主面側に付着した充填用インキを掻き取る工程。
なお、充填用インキの着色剤は暗色系のものであることが好ましい。
化粧材の第1主面に対する刃の角度は略垂直であることが好ましい。略垂直とは、90±10度の範囲を意味し、好ましくは90±5度、より好ましくは90±3度である。なお、化粧材の進行方向側に傾いた場合をプラス、化粧材の進行方向とは反対側に傾いた場合をマイナスと表記している。
また、刃の材質は、金属、ゴム及び樹脂等が挙げられ、この中でも金属が好ましい。
1-1.立体感
実施例及び比較例で得られた化粧材について、蛍光灯の照明下で、任意の成人20人に、立体感を感じるか否かについて目視評価させた。
AA:立体感が良好と答えた人が18人以上であった。
A:立体感が良好と答えた人が15~17人であった。
B:立体感が良好と答えた人が11~14人であった。
C:立体感が良好と答えた人が10人以下であった。
実施例及び比較例で得られた化粧材について、蛍光灯の照明下で、任意の成人20人に、天然の質感の有無を目視評価させた。
AA:天然の質感があると答えた人が18人以上であった。
A:天然の質感があると答えた人が15~17人であった。
B:天然の質感があると答えた人が11~14人であった。
C:天然の質感があると答えた人が10人以下であった。
明細書本文の工程S11~S14に準じて、表面が硬質クロムメッキ処理されたエンボス版Aを作製した。また、凹部(A)及び溝状平行凹凸模様群(B)の形状を表1のように変更した以外は、版Aと同様にして、エンボス版B~Cを作製した。また、溝状平行凹凸模様群(B)を形成せず、凹部(A)の形状を表1のように変更した以外は、版Aと同様にして、エンボス版D~Eを作製した。
[実施例1]
着色基材(厚さ60μmの白色ポリプロピレンフィルム)上に、グラビア多色印刷により、黒色系インキによる導管溝模様の絵柄層、及び、茶褐色系インキによる導管部以外の木肌模様からなる絵柄層を形成し、合計厚み1μmの木材模様の装飾層を形成した。
次いで、装飾層上に接着剤層(ポリエステル樹脂、厚さ:5μm)を形成した。次いで、接着剤層上に、透明性樹脂層(透明ポリプロピレン樹脂シート、厚さ:80μm)を押出しラミネート方式で積層した。
次いで、透明性樹脂層を加熱して軟化状態にし、上記「2」で作製したエンボス版Aを用いて透明性樹脂層側の面からエンボス処理を施し、透明性樹脂層側の面(第1主面側の面)に凹凸形状を形成した。凹凸形状の測定値を表1に示す。
さらに、透明性樹脂層側の面(第1主面側の面)に、黒褐色の充填用インキを塗布した後、第1主面に対して垂直となるようにドクター刃を押し当て、充填用インキを掻き取り、実施例1の化粧材を得た。充填用インキを掻き取る方向は、DAと同一方向とした。
エンボス版Aをエンボス版B~Cに変更した以外は、実施例1と同様にして、実施例2~3の化粧材を得た。
エンボス版Aをエンボス版D~Eに変更した以外は、実施例1と同様にして、比較例1~2の化粧材を得た。
20:溝状凹凸模様群(B)
20a、20b、20c、20d、20e、20f、20g、20h、20i、20j、20k、20l:溝状凹凸模様
30:着色剤
100:化粧材
50:版(エンボス版、金属ロール)
51:回転駆動軸
52:レーザーヘッド
53:彫刻液吐出口
Claims (11)
- 化粧材であって、前記化粧材の第1主面側には、独立した複数の凹部(A)と、前記独立した複数の凹部(A)が存在しない箇所の少なくとも一部に配置されてなる溝状平行凹凸模様群(B)とを有し、前記独立した複数の凹部(A)の平均深さをXA、前記溝状平行凹凸模様群(B)の凹部の平均深さをXBと定義した際に、XB<XAの関係を満たす、化粧材。
- 前記XAが40~150μmであり、前記XBが5~100μmである、請求項1に記載の化粧材。
- 前記XA-XBが20μm以上である、請求項1又は2に記載の化粧材。
- 前記独立した複数の凹部(A)の平均幅をYA、前記溝状平行凹凸模様群(B)の凹部の平均幅をYB1、前記溝状平行凹凸模様群(B)の凸部の平均幅をYB2と定義した際に、YAが150~500μmであり、前記YB1が10~200μmであり、前記YB2が10~250μmである、請求項1~3の何れか1項に記載の化粧材。
- 前記独立した複数の凹部(A)の延伸方向をDA、前記溝状平行凹凸模様群(B)の延伸方向をDBと定義した際に、DAとDBとが非平行である、請求項1~4の何れか1項に記載の化粧材。
- 前記DAと前記DBとの成す角度が5~70度である、請求項5に記載の化粧材。
- 前記溝状平行凹凸模様群(B)を構成する個々の溝状平行凹凸模様は、平面視形状が波状である、請求項1~6の何れか1項に記載の化粧材。
- 前記凹部(A)の平面視形状が、木材の導管、秋材及び節から選ばれる1種以上である、請求項1~7の何れか1項に記載の化粧材。
- 前記独立した複数の凹部(A)の深さ方向の少なくとも一部に着色剤が充填されてなる、請求項1~8の何れか1項に記載の化粧材。
- 下記(i)及び(ii)の何れかの条件を満たす、請求項9に記載の化粧材。
(i)前記溝状平行凹凸模様群(B)の凹部の深さ方向の少なくとも一部に着色剤が充填されてない。
(ii)前記溝状平行凹凸模様群(B)の凹部の深さ方向の少なくとも一部に着色剤が充填されてなり、該着色剤の単位面積当たりの充填量をWB、前記独立した複数の凹部(A)の深さ方向の少なくとも一部に充填されてなる着色剤の単位面積当たりの充填量をWAと定義した際に、WB<WAの関係を満たす。 - 下記(1)~(2)の工程を含む、化粧材の製造方法。
(1)プラスチックフィルム又はプラスチックフィルムと紙との複合体から選ばれる基材の単層、あるいは、前記基材を含む積層体をエンボス版で賦型して、請求項1~8の何れか1項に記載の化粧材を得る工程。
(2)前記(1)で得られた化粧材の第1主面側の面に、着色剤及びバインダー樹脂を含む充填用インキを塗布した後、前記充填用インキを掻き取る工程。
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CN202080024701.2A CN113710476A (zh) | 2019-03-29 | 2020-03-27 | 装饰材料及其制造方法 |
JP2021511978A JPWO2020203737A1 (ja) | 2019-03-29 | 2020-03-27 | |
AU2020251379A AU2020251379B2 (en) | 2019-03-29 | 2020-03-27 | Decorative material and method for producing same |
US17/442,375 US20220168992A1 (en) | 2019-03-29 | 2020-03-27 | Decorative material and method for producing same |
EP20783871.5A EP3950329A4 (en) | 2019-03-29 | 2020-03-27 | DECORATIVE MATERIAL AND METHOD OF PRODUCTION THEREOF |
JP2024015885A JP2024040257A (ja) | 2019-03-29 | 2024-02-05 | 化粧材及びその製造方法 |
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JPH05131800A (ja) * | 1991-10-09 | 1993-05-28 | Dainippon Printing Co Ltd | 化粧材及びその製造方法 |
JPH11268500A (ja) * | 1998-03-19 | 1999-10-05 | Dainippon Printing Co Ltd | 万線状凹凸模様を有する化粧材 |
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JP3069153B2 (ja) * | 1991-06-05 | 2000-07-24 | 大日本印刷株式会社 | 木目調化粧シート |
US6988342B2 (en) * | 2003-01-17 | 2006-01-24 | Masonite Corporation | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
BE1018753A3 (nl) * | 2009-05-11 | 2011-08-02 | Flooring Ind Ltd Sarl | Laminaatpaneel en werkwijzen voor het vervaardigen van laminaatpanelen. |
JP6742075B2 (ja) * | 2015-03-31 | 2020-08-19 | ニチハ株式会社 | 建築板及びその製造方法 |
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JPH05131800A (ja) * | 1991-10-09 | 1993-05-28 | Dainippon Printing Co Ltd | 化粧材及びその製造方法 |
JPH11268500A (ja) * | 1998-03-19 | 1999-10-05 | Dainippon Printing Co Ltd | 万線状凹凸模様を有する化粧材 |
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EP3950329A4 (en) | 2023-01-04 |
AU2020251379B2 (en) | 2023-04-20 |
JPWO2020203737A1 (ja) | 2020-10-08 |
AU2020251379A1 (en) | 2021-11-18 |
CN113710476A (zh) | 2021-11-26 |
EP3950329A1 (en) | 2022-02-09 |
JP2024040257A (ja) | 2024-03-25 |
US20220168992A1 (en) | 2022-06-02 |
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