WO2021192881A1

WO2021192881A1 - Decorative material and method for producing decorative material

Info

Publication number: WO2021192881A1
Application number: PCT/JP2021/008343
Authority: WO
Inventors: 美幸飯原; 小笠原　健; 祥太西根
Original assignee: 大日本印刷株式会社
Priority date: 2020-03-23
Filing date: 2021-03-04
Publication date: 2021-09-30

Abstract

Provided is a decorative material having a visually three-dimensional feel and excellent wear resistance.　This decorative material includes a first region and a second region in a plane, wherein: the surface of the first region has a lower altitude than the surface of the second region; the decorative material in a portion corresponding to the first region has, on one surface of a base material A, a first cured product layer having a releasable surface; the decorative material in a portion corresponding to the second region has a second cured product layer on the one surface of the base material A; the first cured product layer and the second cured product layer are formed on the same surface side of the base material A; a decorative layer is provided on at least a part of a side opposite to the side, of the base material A, having the first cured product layer and the second cured product layer; and the base material A is a resin-impregnated paper capable of light transmission.

Description

Cosmetic material and manufacturing method of decorative material

The present invention relates to a decorative material and a method for producing the decorative material.

Conventionally, the surface of a table, counter, wall, floor, etc. is a decorative material obtained by impregnating a porous base material such as titanium paper with an uncured resin solution of melamine resin and curing the resin impregnated by a hot press. Is used. The decorative material may be further laminated with phenol core paper or the like, if necessary. A decorative material impregnated and cured with such a melamine resin exhibits physical properties such as strength, hardness, and heat resistance.

The decorative material as described above is required to have a design showing a high-class feeling, and a visual three-dimensional effect is imparted by forming an uneven shape on the surface.
As a decorative material having an uneven shape on the surface, an embossed decorative material using an embossed plate (mirror surface plate with a texture) having an uneven shape has been proposed (see, for example, Patent Documents 1 and 2). ).

However, in the case of imparting a desired uneven pattern design feeling to the surface of the decorative material described in Patent Documents 1 and 2, there is a problem that an embossed plate is required for each pattern, which is costly and difficult to manufacture. be. Further, this decorative material has a problem that it is difficult to synchronize the uneven shape with the pattern of the base, and it is difficult to impart a high degree of design.

On the other hand, the decorative material of Patent Document 3 has been proposed as a decorative material having a surface uneven shape without using an embossed plate.

Japanese Unexamined Patent Publication No. 2015-193209 JP-A-2017-87544 International Publication No. 2016/148091

The decorative material of Patent Document 3 is provided on a paper base material, a release layer provided on a part of the surface of the paper base material and containing a cured product of an ionizing thermosetting resin, and the rest of the surface of the paper material base material. It is provided with a surface layer containing a cured product of the melamine resin. The decorative board of Patent Document 3 is a step of providing a release layer on a part of the surface of a paper substrate, impregnating the paper substrate with an uncured melamine resin, and covering the release layer with the uncured melamine resin. After that, it is produced by a method including a step of thermosetting the uncured melamine resin by heating and a step of peeling off the cured resin film covering the release layer. As a result, in the decorative material of Patent Document 3, an elevation difference is formed between the portion having the release layer and the portion not having the release layer, and the surface uneven shape is formed.
Since the decorative material of Patent Document 3 does not use an embossed plate, the problems of Patent Documents 1 and 2 can be solved. However, when the decorative material of Patent Document 3 is used in a place where a high level of abrasion resistance is required, such as a table, there are many cases where the design property deteriorates with time.

As a result of diligent research by the present inventors, the decorative material of Patent Document 3 has a decorative layer after the release layer containing the cured product of the ionizing radiation curable resin and the surface layer containing the cured product of the melamine resin are worn. It has been found that the design property is deteriorated due to the inability to suppress the wear of the resin.
As a result of further diligent research, the present inventors have completed a decorative material having a visual three-dimensional effect and capable of dramatically improving wear resistance.

An object of the present invention is to provide the following [1] to [3].
[1] A decorative material, wherein the decorative material has a first region and a second region in a plane, and the surface of the first region has a lower altitude than the surface of the second region. The decorative material in the portion corresponding to the first region has a first cured product layer having a releasable surface on one surface of the base material A, and the decorative material in the portion corresponding to the second region. Has a second cured product layer on one surface of the base material A, and the first cured product layer and the second cured product layer are formed on the same surface side of the base material A. A resin having a decorative layer on at least a part of the base material A opposite to the side having the first cured product layer and the second cured product layer, and the base material A has light transmittance. A decorative material that is impregnated paper.

[2] A method for producing a decorative material, which comprises the following steps (A1) to (A7).
(A1) A step of preparing a paper to be a base of a base material A.
(A2) A step of forming a first cured product layer having a releasable surface on at least a part of one surface of paper, and forming a laminate A having a decorative layer on the other surface.
(A3) The laminate A is impregnated with a curable resin composition, and the paper is impregnated with the curable resin composition to obtain a base material A, which is a resin-impregnated paper having light transmission, and the laminate A is obtained. A step of obtaining a laminate B formed by forming an uncured curable resin composition layer on the entire surface of the side having the first cured product layer.
(A4) A step of obtaining a laminate C, which comprises arranging a release film on the uncured curable resin composition layer side of the laminate B.
(A5) A step of hot-pressing the laminated body C with both sides sandwiched between mirror plates to form a second cured product layer obtained by curing the uncured curable resin composition layer.
(A6) A step of taking out the laminated body C from between the mirror surface plates.
(A7) When the release film is peeled off from the laminate C, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. A step of forming a second region in which a second cured product layer formed in a portion having no first region forming layer remains.

[3] A method for producing a decorative material, which comprises the following steps (B1) to (B9).
(B1) A step of preparing a paper to be a base of the base material A.
(B2) A step of obtaining a laminate D formed by forming a first cured product layer having a releasable surface on at least a part of one surface of paper.
(B3) A step of obtaining a laminated body E formed by forming a decorative layer on at least a part of one surface of the base material B.
(B4) A step of obtaining a laminated body F formed by laminating a surface of the laminated body D opposite to the first cured product layer and a surface of the laminated body E on the decorative layer side.
(B5) The laminate F is impregnated with a curable resin composition, and the paper is impregnated with the curable resin composition to obtain a base material A, which is a resin-impregnated paper having light transmission, and the laminate F is obtained. A step of obtaining a laminate G formed by forming an uncured curable resin composition layer on the entire surface of the side having the first cured product layer.
(B6) A step of obtaining a laminate H, which comprises arranging a release film on the uncured curable resin composition layer side of the laminate G.
(B7) A step of heat-pressing the laminated body H with both sides sandwiched between mirror plates to form a second cured product layer obtained by curing the uncured curable resin composition layer.
(B8) A step of taking out the laminated body H from between the mirror surface plates.
(B9) When the release film is peeled off from the laminate H, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. A step of forming a second region in which a second cured product layer formed in a portion having no first region forming layer remains.

According to the present invention, it is possible to provide a decorative material having a visual three-dimensional effect and excellent wear resistance.

It is sectional drawing which shows one Embodiment of the decorative material of this invention. It is sectional drawing which shows the other embodiment of the decorative material of this invention. It is sectional drawing which shows one step of the manufacturing method of the decorative material of this invention. It is sectional drawing which shows one step of the manufacturing method of the decorative material of this invention. It is sectional drawing which shows one step of the manufacturing method of the decorative material of this invention. It is sectional drawing which shows one step of the manufacturing method of the decorative material of this invention. It is sectional drawing which shows one step of the manufacturing method of the decorative material of this invention. It is sectional drawing which shows one step of the manufacturing method of the decorative material of this invention.

[Cosmetic material]
The decorative material of the present invention has a first region and a second region in a plane, and the surface of the first region has a lower altitude than the surface of the second region and corresponds to the first region. The decorative material of the above has a first cured product layer having a releasable surface on one surface of the base material A, and the decorative material at a portion corresponding to the second region is the base material A. A second cured product layer is provided on one surface, and the first cured product layer and the second cured product layer are formed on the same surface side of the base material A, and the first cured product layer of the base material A is formed. A resin-impregnated paper having a decorative layer on at least a part of the side opposite to the side having the one cured product layer and the second cured product layer, and the base material A having light transmittance. be.

1 and 2 are cross-sectional views showing an embodiment of the decorative material 100 of the present invention.
The decorative material 100 of FIGS. 1 and 2 has a first region R1 and a second region R2 in a plane (in the XY plane in the same figure). Further, the surface of the first region R1 has a lower altitude than the surface of the second region R2. Further, in the decorative material 100 of FIGS. 1 and 2, the first region R1 and the second region R2 are in a complementary set relationship with each other when the entire surface of the decorative material 100 in the plane is set as the entire set. ..
Further, the decorative material 100 of FIGS. 1 and 2 has a first cured product layer 21 having a releasable surface on the base material A (10) at a portion corresponding to the first region R1. .. Further, the decorative material 100 of FIGS. 1 and 2 has a second cured product layer 22 on the base material A (10) at a portion corresponding to the second region R2. Further, in the decorative material 100 of FIGS. 1 and 2, the first cured product layer 21 and the second cured product layer 22 are on the same surface side of the base material A (10) (in the figure, the z-axis direction of the base material A). Is formed on the plus side of).
Further, the decorative material 100 of FIGS. 1 and 2 is on the side opposite to the side of the base material A (10) having the first cured product layer 21 and the second cured product layer 22 (in the figure, z of the base material A). The decorative layer 30 is provided on the minus side in the axial direction). Further, the decorative layer 30 of FIGS. 1 and 2 has a first decorative layer 31 synchronized with the first region R1 and a second decorative layer 32 synchronized with the second region R2. As shown in FIGS. 1 and 2, the first decorative layer 31 and the second decorative layer 32 are preferably synchronized with the first region R1 and the second region R2, respectively, but may not be synchronized.
Further, the decorative material 100 of FIG. 2 has a base material B (50) and a reinforcing layer 60 on the surface of the decorative layer 30 opposite to the base material A (10).
In FIGS. 1 and 2, t1 indicates the thickness of the first cured product layer 32, and t2 indicates the thickness of the second cured product layer 22. Further, in FIG. 2, t0 indicates the thickness of the permeation prevention layer 41.

In the present specification, the "flat surface" refers to a surface of the base material A that is visually recognized in the vertical direction from the side having the first cured product layer and the second cured product layer when the base material A of the decorative material is used as a reference. , Means the xy plane of FIGS. 1 and 2.
Further, in the present specification, the “elevation” means the thickness direction of the decorative material, and means the z direction of FIGS. 1 and 2. The high (or low) altitude of a specific location (specific surface, specific position, etc.) means that the value of the z coordinate in the thickness direction of the specific location is relatively large (or small). do. In FIG. 1, it means that the higher the specific part is in the upper part of the figure, the higher the altitude is, and the lower the specific part is in the lower part of the figure, the lower the altitude is.
Further, in the present specification, "synchronization" includes, of course, a form in which two target patterns completely match and overlap each other when the decorative material is viewed in a plan view. Strictly limited to this form, the concept is to allow deviation of the shape and position as long as there is no discomfort in the appearance design and the quality is not hindered. Examples of the two target patterns include a combination of the first decorative layer 31 and the first region R1 and a combination of the second decorative layer 31 and the second region R2.

In the present specification, the term "curable resin" simply means a cured product obtained by curing an uncured product of a curable resin. Similarly, when simply referred to as "thermosetting resin", it means a cured product obtained by curing an uncured product of a thermosetting resin, and when it is referred to as "ionizing radiation curable resin", it means ionizing radiation curable. It means a cured product obtained by curing an uncured product of a resin.
Further, in the present specification, the terms curable resin composition, thermosetting resin composition, and ionizing radiation curable resin composition mean that they are uncured unless otherwise specified.

<Base material A>
The base material A is a resin-impregnated paper having light transmittance. Further, the base material A is located between the first cured product layer and the second cured product layer and the decorative layer.
In the decorative material of the present invention, even if the first cured product layer and the second cured product layer are worn, the decorative layer is protected by the base material A, so that the abrasion resistance can be dramatically improved.

The base material A may have light transmittance to such an extent that the decorative layer can be visually recognized.
As for the base material A, the total light transmittance of JIS K7361-1: 1997 is preferably 40% or more, and more preferably 50% or more.
Further, the haze of the base material A itself may generally differ depending on the location in the plane of the decorative material 100. The haze of the base material A can be 10% or more and 96% or less. The haze of the base material A is preferably 20% or more, more preferably 30% or more as the lower limit value. The upper limit of the haze of the base material A is more preferably 90% or less, and more preferably 60% or less. As used herein, haze means the haze of JIS K7136: 2000.

The base material A may have the same total light transmittance or haze in the plane of the base material A, or may be different. For example, the total light transmittance or haze may be the same or different between the portion of the base material A having the first cured product layer and the portion of the base material A having the second cured product layer. good.

In order to impart contrast between the first region R1 which has the first cured product layer and the second region R2 which has the second cured product layer and enhance the design of the decorative material, the base material A It is preferable that the total light transmittance or the haze value is different between the portion having the first cured product layer and the portion having the second cured product layer of the base material A.

Further, when the haze of the portion of the base material A having the first cured product layer is defined as Hz1 and the haze of the portion of the base material A having the second cured product layer is defined as Hz2, the relationship of Hz2 <Hz1 can be satisfied. preferable. With such a configuration, a glossy contrast is imparted to the first region, which is the portion having the first cured product layer, and the second region, which is the portion having the second cured product layer, and the design of the decorative material is provided. You can improve your sex. Further, by satisfying the relationship of Hz2 <Hz1, the first region can be more dented and more easily seen, and the visual three-dimensional effect can be more easily enhanced. In particular, in a configuration that satisfies the relationship of Hz2 <Hz1, by configuring the base material A to contain a colorant, a color tone is added to the glossiness, so that the contrast between the two regions becomes clearer, so that the pattern is displayed. Can be clarified and the design can be further enhanced.
Hz1-Hz2 is preferably 1% or more and 30% or less, and more preferably 5% or more and 20% or less.

Further, a visual contrast is imparted between the first region R1 which is the portion having the first cured product layer and the second region R2 which is the portion having the second cured product layer, and the design of the decorative material is enhanced. When the decorative material 100 is observed from the side of the first cured product layer 21 in order to enhance the color tone, it is preferable that the color tone of the first region R1 is more cloudy than the color tone of the second region R2. More cloudy means higher brightness. Specifically, when defined by the brightness of the Munsell color system, the difference (V1-V2) between the brightness V1 in the first region R1 and the brightness V2 in the second region R2 is preferably 2 or more. 4 or more is more preferable.
In addition to this, the saturation of the first region R1 is preferably lower than the saturation of the second region R2. In this case, the difference (C2-C1) between the saturation C1 in the first region R1 and the saturation C2 in the second region R2 is preferably 2 or more and 6 or less, and more preferably 2 or more and 4 or less.
That is, the relationship between the color tone of the first region R1 and the color tone of the second region R2 includes the following forms (1) to (3). The form (1) or (2) is preferable, and the form (2) is more preferable, in order to impart a visual contrast between the regions R1 and R2 and enhance the design of the decorative material.
(1) V1> V2 and C1 = C2
(2) V1> V2 and C1 <C2
(3) V1> V2 and C1> C2
When the decorative material 100 is observed from the side of the first cured product layer 21, the color tone of the first region R1 is more cloudy than that of the second region R2, so that it can be visually recognized as described in (4) below. It is preferable to satisfy the relationship of (4) and (5) below, and it is more preferable to satisfy the relationship of (4) and (5) below. When the following relationship (4) is satisfied, the difference between the haze of the first region R1 of the laminated body B and the haze of the second region R2 of the laminated body B is preferably 1% or more and 30% or less. More preferably, it is 5% or more and 20% or less. The layer structure of the laminated body B is described in the method for producing a decorative material described later.
(4) Haze of the first region R1 of the laminate B> Haze of the second region R2 of the laminate B (5) Total light transmittance of the first region R1 of the laminate B ≠ the second region R2 of the laminate B Total light transmittance

The base material A (resin-impregnated paper having light transmittance) can be obtained, for example, by impregnating the base paper with a resin. At this time, by bringing the refractive index of the fibers constituting the paper close to the refractive index of the resin and sufficiently filling the gaps between the fibers with the resin, the light transmittance of the base material A can be increased and the haze can be lowered. .. That is, even if the base paper itself is opaque, a resin-impregnated paper (base material A) having light transmittance can be obtained by sufficiently impregnating the paper with a resin having a similar refractive index. Further, the light transmittance and the haze can be adjusted by controlling the amount of the resin impregnated in the base paper. Further, by imparting regions having different amounts of impregnated resin in the plane of the base paper, regions having different light transmittance and haze values can be imparted in the plane of the base material A.
The base material A may be a laminate of resin-impregnated paper having light transmittance. A laminated body of resin-impregnated paper having light transparency can be obtained by impregnating a resin in a state where a plurality of base papers are stacked.

Further, in order to facilitate the form in which the color tone of the first region R1 is cloudier than the color tone of the second region R2, the curable resin is formed from the side of the first cured product layer 21 of the paper in step A3 described later. It is preferable to impregnate the composition. As a result, regarding the inside of the paper, in the paper immediately below the first cured product layer 21 corresponding to the first region R1, the resin impregnation is inhibited by the first cured product layer 21, and air is provided between the constituent fibers of the paper. Is likely to remain. Then, due to the difference in refractive index between the paper constituent fibers and the air, the light incident on the first region R1 is scattered, and the first region R1 becomes more likely to become cloudy than the second region R2. Further, in the paper immediately below the first cured product layer 21 corresponding to the first region R1, the resin forming the first cured product layer and the fibers are contained, and further, a small amount of impregnated resin is contained. The difference in refractive index between these three types of materials can also cause cloudiness.
On the other hand, in the second region R2 (non-formed region of the first cured product layer 21), the impregnated resin fills the constituent fibers of the paper without being hindered. The difference in refractive index between the impregnated resin and the paper constituent fiber is smaller than the difference in refractive index between air and the paper constituent fiber. As a result, the amount of scattered light incident on the second region R2 is smaller than that of the first region R1, so that the degree of cloudiness of the second region R2 is smaller than that of the first region R1.

The base paper of the base material A preferably has a basis weight of 20 g / m ² or more and 100 g / m ² or less, and more preferably 25 g / m ² or more and 80 g / m ² or less, and 30 g / m. and more preferably ² or more 60 g / ^{m 2} or less. When the base material A is a laminate of resin-impregnated paper having light transmittance, it is preferable that the basis weights of the plurality of base papers are in the above range.
By setting the basis weight of the base paper to 20 g / m ² or more, the impregnated resin can be easily bound by the fibers of the paper. Further, by setting the basis weight of the base paper to 100 g / m ² or less, it is possible to easily impregnate the paper with the resin.
When a plurality of papers are used as the base and the paper of the base material A, the total basis weight of the plurality of papers is preferably ^{200 g / m 2 or less from the viewpoint of visibility of the decorative layer.}

Examples of the paper that is the base of the base material A include wood pulp fiber papers having a large amount of α-cellrose component, Manila hemp valve fiber papers, linter papers, cotton fiber papers, and other papers made from cellulose pulps. If necessary, non-cellulosic resin fibers such as vinylon and acrylic resin may be mixed with these papers. In addition, in order to ensure sufficient light transmission after resin impregnation, the base paper should be free of hiding pigments such as titanium white and carbon black, or even if they are added, the amount should be small. Is preferable.

The paper that is the base of the base material A may contain a colorant. That is, the base material A may contain a colorant. When the base material A contains a colorant, the design of the decorative material can be further enhanced. In particular, as described above, it is preferable that the base material A contains a colorant in a configuration that satisfies the relationship of Hz2 <Hz1.

Examples of the colorant include inorganic pigments such as chrome yellow, titanium yellow, petals, cadmium red, ultramarine blue, and cobalt blue, organic pigments such as quinacridone red, isoindolinone yellow, nickel-azo complex, and phthalocyanine blue, or dyes. And so on.

Examples of the resin impregnated in the base material A include a thermoplastic resin and a curable resin, and a curable resin is preferable from the viewpoint of abrasion resistance. In the present specification, the "resin impregnated in the base material A" and the "resin impregnated in the base material B" are referred to as "impregnated resin of the base material A" and "impregnated resin of the base material B". Sometimes referred to.
The curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 90% by mass or more, and 100% by mass, based on the total amount of the impregnated resin of the base material A. % Is even more preferable.
Examples of the curable resin include a thermosetting resin and an ionizing radiation curable resin, and a thermosetting resin is preferable from the viewpoint of handleability.

The impregnated resin of the base material A is preferably the same type as the resin of the second cured product layer from the viewpoint of adhesion between the base material A and the second cured product layer and production efficiency. When the base material B described later is impregnated with a resin, the resin impregnated in the paper is preferably the same type as the impregnated resin of the base material B from the viewpoint of production efficiency. When the first cured product layer is formed on the base material A, a small amount of the resin component constituting the first cured product layer or a small amount of the resin component constituting the permeation prevention layer invades the base material A. That is, the impregnated resin of the base material A contains a resin component constituting a small amount of the first cured product layer or a resin component constituting a small amount of the permeation prevention layer.

As the thermosetting resin which is a preferred embodiment of the impregnated resin of the base material A, melamine resin, urea resin, melamine-from the viewpoint of further enhancing the texture of the decorative material and improving the mechanical strength of the decorative material. Urea resin, guanamine resin, diallyl phthalate resin, polyester resin, phenol resin, epoxy resin, aminoalkyd resin, silicon resin, polysiloxane resin and the like are preferable, among which melamine resin, urea resin, melamine-urea resin, guanamine resin and sulfonamide are preferable. A thermocurable resin such as a resin is preferable. Further, among the thermosetting resins, melamine resin, melamine-urea resin and phenol resin are preferable, and melamine resin is particularly preferable.

Examples of the means for impregnating the paper with the resin include a means for preparing a composition containing a resin (in the case of a curable resin, an uncured curable resin) and impregnating the fat composition into the base paper. (For example, steps (A3) and (B5) described later.).
Of the resin compositions impregnated in paper, the thermosetting resin composition becomes a cured product of the thermosetting resin by heating at an appropriate time point and curing the resin composition by a reaction such as a cross-linking reaction or a polymerization reaction (for example). , Steps (A5) and (B7) described later.
In the steps (A2) and (B2) described later, the resin constituting the first cured product layer is cured in the steps (A2) and (B2). Then, the region having the first cured product layer of the base material A is less likely to be impregnated with the resin in the steps (A3) and (B5) than the other regions of the base material A. Therefore, the degree of resin impregnation differs between the portion of the base material A having the first cured product layer and the portion of the base material A having the second cured product layer, and the total light transmittance or haze of the two locations is different. You can easily change the value to a different value.

The thickness of the base material A is preferably 80 μm or more and 360 μm or less, and more preferably 80 μm or more and 200 μm or less.
By setting the thickness of the base material A to 80 μm or more, it is possible to easily improve the wear resistance. Further, by setting the thickness of the base material A to 360 μm or less, it is possible to easily secure the visibility of the decorative layer.

<Decorative layer>
The decorative material of the present invention has a decorative layer on at least a part of the base material A on the side opposite to the side having the first cured product layer and the second cured product layer.
Since the decorative material of the present invention has the decorative layer at the position, the decorative layer is less likely to be worn, and the wear resistance of the decorative material can be dramatically improved.

The decorative layer can be formed, for example, by printing with an ink for a decorative layer containing a colorant and a binder resin. The pattern of the decorative layer is not particularly limited.

The decorative layer is at least one of a first decorative layer formed on at least a part of a portion corresponding to the first region and a second decorative layer formed on at least a part of a portion corresponding to the second region. It is preferable to have, and it is more preferable to have both. The first decorative layer is preferably synchronized with the first region, and the second decorative layer is preferably synchronized with the second region.
Details of the first decorative layer and the second decorative layer will be described later.

Examples of embodiments of the decorative layer are shown in A to K below.
A) A configuration in which the first decorative layer is synchronized in all the first regions.
B) A configuration in which the first decorative layer is provided in all the first regions, but the first region and the first decorative layer are not synchronized and the printing is misaligned.
C) Of the plurality of first regions, a configuration in which a first decorative layer is provided in a part of the first regions but no first decorative layer is provided in the other first regions.
D) A configuration in which the second decorative layer is synchronized in all the second regions.
E) A configuration in which a second decorative layer is provided in all the second regions, but the second region and the second decorative layer are not synchronized and printing is misaligned.
F) Of the plurality of existing second regions, a configuration in which a second decorative layer is provided in a part of the second region but no second decorative layer is provided in the other second region.
G) A configuration that has only the first decorative layer and no second decorative layer.
C) A structure having only a second decorative layer.
K) A configuration having a first decorative layer and a second decorative layer.

<Area>
The decorative material of the present invention has a first region R1 and a second region R2 in a plane.
Further, in the decorative material of the present invention, the elevation of the surface of the first region is formed lower than the elevation of the surface of the second region. Therefore, in the decorative material of the present invention, the first region is recessed and visually recognized as compared with the second region, and a three-dimensional effect can be imparted.
The elevation of the surface of the first region can be adjusted by the total thickness of the layers formed on the first region of the base material A. Further, the elevation of the surface of the second region can be adjusted by the total thickness of the layers formed on the second region of the base material A.

When the area of the first region R1 of the decorative material is defined as S1 and the area of the second region is defined as S2, S2 / S1 is preferably 0.1 or more and 20 or less, and 0.5 or more and 10 or less. Is more preferable.
By setting S2 / S1 to 0.1 or more, the paper that is the base of the base material A can be easily impregnated with the resin in the post-processing (for example, steps A3 and B5 described later). Further, by setting S2 / S1 to 20 or less, it is possible to easily improve the design by setting the balance of the ratio of the portion that is visually recognized as dented and the portion that is visually recognized as raised as an appropriate range.

《First area》
The first region is a region that is recessed and visually recognized as compared with the second region.
The first region has a first cured product layer having a releasable surface on the base material A. From the viewpoint of facilitating an increase in the elevation difference between the surface of the first region and the surface of the second region, a permeation prevention layer, which will be described later, is provided between the base material A and the first cured product layer. May be good.

The surface of the first region is preferably roughened. By roughening the surface of the first region, the first region is dented and easily visible, and the three-dimensional effect can be improved.

-First cured product layer-
The surface of the first cured product layer has a releasable property.
Since the surface of the first cured product layer has a releasable property, most of the second cured product layer on the first cured product layer is peeled off. The second cured product layer on the first cured product layer is preferably completely peeled off from the viewpoint of improving the three-dimensional appearance due to the surface unevenness, but the second cured product layer is completely peeled off from the first cured product layer. In many cases, it cannot be done. Therefore, a small amount of the second cured product layer may remain on the first cured product layer as long as the effect of the present invention is not impaired.

The first cured product layer is a layer formed of a curable resin, more specifically, a layer formed of a cured product of an uncured curable resin composition.
Examples of the curable resin are thermosetting resins and ionizing radiation curable resins from the viewpoint of obtaining higher texture design and better surface characteristics, and ionizing radiation curable resins are preferable from the viewpoint of wear resistance. More preferable. That is, the first cured product layer preferably contains an ionizing radiation curable resin.

The first cured product layer may contain a thermoplastic resin, but it is preferable that the first cured product layer contains a curable resin as a main component.
The curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 90% by mass or more, and 100% by mass, based on the total amount of the resin in the first cured product layer. It is even more preferably mass%.

Examples of the thermosetting resin of the first cured product layer include those exemplified as a thermosetting resin that can be impregnated in the base material A.

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 rays such as α-rays and ion rays are also included.
Specifically, the ionizing radiation curable resin can be appropriately selected 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 obtaining a higher quality design and better surface properties.
The number of functional groups of the (meth) acrylate monomer is preferably 2 or more, more preferably 3 or more, still more preferably 4 or more, and the upper limit is preferably 8 from the viewpoint of obtaining a higher quality design and better surface characteristics. Below, it is more preferably 6 or less. These polyfunctional (meth) acrylate monomers may be used alone or in combination of two or more.
The ionizing radiation curable resin of the first cured product layer is preferably a polyfunctional (meth) acrylate monomer from the viewpoint of increasing the crosslink density and improving the scratch resistance.

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. Among them, dipentaerythritol such as dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, and dipentaerythritol hexa (meth) acrylate from the viewpoint of obtaining higher texture design and better surface characteristics. A system-polymerizable monomer is preferable, dipentaerythritol penta (meth) acrylate and dipentaerythritol hexa (meth) acrylate are more preferable, and dipentaerythritol penta (meth) acrylate and dipentaerythritol hexa (meth) acrylate are used in combination. Is particularly preferable.

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 oligomer, polycaprolactone diol urethane (meth) acrylate and the like can be mentioned.

From the viewpoint of obtaining a higher quality design and better surface properties, the number of functional groups of these polymerizable oligomers is preferably 2 or more, more preferably 3 or more, and the upper limit is preferably 8 or less, more preferably. It is 6 or less.

The weight average molecular weight of the polymerizable oligomer is preferably 500 or more, 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 first cured product layer preferably contains a release agent. By including the release agent, it can be peeled off even if another resin is laminated on the surface of the first cured product layer, but the other resin adheres to the second region and is not peeled off, so that the surface of the first region is not peeled off. It is possible to easily give an elevation difference between the surface and the surface of the second region (see steps (A7) and (B9) described later).

Examples of the release agent include a fluorine-based release agent, a silicone-based release agent, and the like, and a silicone-based release agent is preferable from the viewpoint of obtaining a design with a higher texture.
Examples of the silicone-based mold release agent include those having a polysiloxane structure as a basic structure, and among them, modified silicone oil in which an organic group is introduced into at least one of the side chain and the terminal of the polysiloxane skeleton is preferable, and both ends are preferable. A modified silicone oil having an organic group introduced therein is more preferable. As the organic group, from the viewpoint of obtaining a design with a higher texture, a reactive functional group such as a (meth) acrylic group, an amino group, an epoxy group, a mercapto group, a carbinol group, a phenol group or a carboxyl group, or a polyether group , Non-reactive group functional groups such as aralkyl group, fluoroalkyl group, alkyl group, fatty acid amide group and phenyl group are preferably mentioned. Among them, a reactive functional group is preferable, and a (meth) acrylic group is particularly preferable, that is, a (meth) acrylic-modified silicone oil is particularly preferable. Further, these organic groups may have substituents such as a nitrogen atom, a sulfur atom, a hydroxyl group and an alkyl group.

The content of the release agent is preferably 0.1 part by mass or more and 5 parts by mass or less, and more preferably 0.5 parts by mass or more and 3 parts by mass with respect to 100 parts by mass of the curable resin forming the first cured product layer. Parts or less, more preferably 1 part by mass or more and 2 parts by mass or less. When the content of the release agent is within the above range, the effect of adding the release agent can be efficiently obtained.

The first cured product layer preferably contains a filler such as an inorganic filler and an organic filler, and the inorganic filler is more preferable from the viewpoint of wear resistance. When the first cured product layer contains a filler, the reflected light in the first region is diffused so that the first region is dented and easily visible, and the three-dimensional appearance of the decorative material can be easily improved.
Examples of the inorganic filler include oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide, zinc oxide and zirconia oxide; hydroxides such as aluminum hydroxide, magnesium hydroxide and calcium hydroxide; magnesium carbonate and carbon dioxide. Carbonates such as calcium; sulfates such as calcium sulfate and barium sulfate; particles made of inorganic materials such as silicates such as magnesium silicate, aluminum silicate, calcium silicate and aluminosilicate. Of these, oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide and zinc oxide are preferable, and silica is particularly preferable.
Examples of the organic filler include particles such as acrylic, styrene and silicone.
The first cured product layer preferably does not contain brilliant fillers such as pearl pigments, metal particles and metal scales.

The average particle size of the filler is preferably 0.3 μm or more and 20 μm or less, and more preferably 0.5 μm or more and 10 μm or less, from the viewpoint of facilitating Ra1 in the range described later. In the present specification, the average particle size of the filler is a value measured as a mass average value d50 in the particle size distribution measurement by the laser diffraction scattering method.

The content of the filler is preferably 1 part by mass or more and 50 parts by mass or less, more preferably 10 parts by mass with respect to 100 parts by mass of the curable resin forming the first cured product layer, from the viewpoint of facilitating Ra1 in the range described later. It is 10 parts by mass or more and 40 parts by mass or less, more preferably 20 parts by mass or more and 35 parts by mass or less. When the content of the filler is within the above range, the effect of adding the filler can be efficiently obtained.

The thickness t1 of the first cured product layer is not particularly limited, but is usually about 0.1 μm or more and 20.0 μm or less, and is preferably 0.5 μm or more and 10.0 μm from the viewpoint of more easily obtaining a high-quality design. Hereinafter, it is more preferably 1.0 μm or more and 5.0 μm or less.

When the thickness of the first cured product layer is defined as t1 and the thickness of the second cured product layer is defined as t2, it is preferable to satisfy the relationship of t1 <t2. By satisfying such a relationship, it is possible to easily give a three-dimensional effect to the decorative material.
t2-t1 is preferably 1.0 μm or more and 45.0 μm or less, more preferably 2.0 μm or more and 35.0 μm or less, and further preferably 3.0 μm or more and 30.0 μm or less.
By setting t2-t1 to 1.0 μm or more, it is possible to easily improve the three-dimensional effect. Further, by setting t2-t1 to 45.0 μm or less, the first region and the second region can be stably produced easily.

It is preferable to calculate t1 and t2 and t0 (thickness of the permeation prevention layer) described later as an average value of the thicknesses at 20 points. The thickness can be calculated from, for example, a cross-sectional photograph of the decorative material. It is preferable that the 20 locations for calculating the average value are picked up so that there is no bias in the locations.

The first cured product layer can be formed, for example, by applying an ink for the first cured product layer containing components constituting the first cured product layer to a part of the base material A, drying, and curing. can. The region in which the first cured product layer is formed on the base material A is the first region R1.

-Penetration prevention layer-
The permeation prevention layer is arranged between the base material A and the first cured product layer as needed.
By having a permeation prevention layer between the base material A and the first cured product layer, the composition constituting the first cured product layer is suppressed from penetrating into the base material A side, and the first cured product layer The thickness can be secured, and thus the thickness of the second cured product layer can be easily increased, and the wear resistance of the decorative material can be improved.

It is preferable that the permeation prevention layer is formed not entirely on the base material A but on a part of the base material A. By making the portion where the permeation prevention layer is formed not all of the base material A but a part of the base material A, the paper which is the base of the base material A can be easily impregnated with the resin.
Further, the permeation prevention layer is preferably formed in synchronization with the first region.

The permeation prevention layer preferably contains a curable resin. In other words, the permeation prevention layer preferably contains a cured product of an uncured curable resin composition.
The content of the curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, and further preferably 80% by mass or more of the total solid content constituting the permeation prevention layer. It is preferably 90% by mass or more, and more preferably 90% by mass or more.
Since the permeation prevention layer contains the curable resin, the sealing effect of the first cured product layer by the permeation prevention layer can be improved.

The composition forming the permeation prevention layer preferably contains a thermoplastic resin in order to make it difficult for the composition forming the permeation prevention layer to permeate into the base material. The content of the thermoplastic resin is preferably 2 parts by mass or more and 30 parts by mass or less, and more preferably 5 parts by mass or more and 15 parts by mass or less with respect to 100 parts by mass of the curable resin.
Examples of the thermoplastic resin include general-purpose thermoplastic resins such as acrylic resins, polyester resins, and cellulosic resins.

Examples of the curable resin of the permeation prevention layer include a thermosetting resin and an ionizing radiation curable resin, and an ionizing radiation curable resin is more preferable.

Examples of the thermosetting resin of the permeation prevention layer include those similar to those exemplified as the thermosetting resin that can be impregnated in the base material A.

Examples of the ionizing radiation curable resin of the permeation prevention layer include those similar to the ionizing radiation curable resin exemplified in the first cured product layer. The ionizing radiation curable resin of the permeation prevention layer is a polymerization having two or more ionizing radiation curable functional groups in the molecule from the viewpoint of facilitating the suppression of the composition forming the permeation prevention layer from penetrating into the substrate. Sex oligomers are preferred.

The permeation prevention layer preferably contains substantially no release agent from the viewpoint of facilitating the formation of the first cured product layer. The fact that the release agent is substantially not contained means that the content of the release agent is less than 0.1% by mass of the total solid content of the permeation prevention layer, preferably 0.01% by mass or less. Yes, more preferably 0% by mass (does not contain a release agent).

It is preferable that the permeation prevention layer contains substantially no filler. The fact that the filler is substantially not contained means that the content of the filler is less than 0.1% by mass of the total solid content of the permeation prevention layer, and is preferably 0.01% by mass or less, more preferably. Is 0% by mass (does not contain filler).

The thickness t0 of the permeation prevention layer is preferably 0.1 μm or more and 10.0 μm or less, and more preferably 0.5 μm or more and 5.0 μm or less.
By setting t0 to 0.1 μm or more, it is possible to easily suppress the penetration of the uncured curable resin composition contained in the ink for the first cured product layer into the substrate side. Further, by setting t0 to 10.0 μm or less, the permeation prevention layer can be stably formed without affecting other regions.

When the thickness of the permeation prevention layer is defined as t0, the thickness of the first cured product layer is defined as t1, and the thickness of the second cured product layer is defined as t2, it is preferable to satisfy the relationship of t0 + t1 <t2. By satisfying such a relationship, it is possible to easily give a three-dimensional effect to the decorative material.
t2- (t0 + t1) is preferably 1.0 μm or more and 45.0 μm or less, more preferably 2.0 μm or more and 35.0 μm or less, and further preferably 3.0 μm or more and 30.0 μm or less. ..
By setting t2- (t0 + t1) to 1.0 μm or more, it is possible to easily improve the three-dimensional effect. Further, by setting t2- (t0 + t1) to 45.0 μm or less, the first region and the second region can be stably produced easily.

The permeation prevention layer can be formed, for example, by applying an ink for a permeation prevention layer containing a component constituting the permeation prevention layer to a part of the base material A, drying and curing.

-First decorative layer-
The decorative material of the present invention is on the side opposite to the side of the base material A having the first cured product layer and the second cured product layer, and the first decorative layer is formed on at least a part of the portion corresponding to the first region. It is preferable to have. Further, it is preferable that the first decorative layer is synchronized with the first region.

The first decorative layer 31 may be formed in an arbitrary pattern in the first region. The arbitrary pattern depends on the design to be imparted to the entire decorative material.
For example, when the design given to the entire decorative material is a wood pattern, the first decorative layer 31 has one or more patterns selected from conduits, spring woods, and knots, which are portions constituting the recesses in the wood board. It is preferably formed. In other words, the first region preferably forms one or more patterns selected from wood conduits, spring wood and knots. A conduit is a cylindrical cell that serves as a passage for water, and by arranging minute conduits, a groove-like recess is formed along the arrangement by the human eye in a state where wood is sawn on a board. At the same time, it seems that a dark pattern is formed. Spring lumber is a part with wide eyes and light color that is formed from spring to summer. The narrow part of the lumber that is made from summer to autumn is called autumn lumber, and the annual rings of wood are formed by alternately repeating spring lumber and autumn lumber. 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.
Further, when the design given to the entire decorative material is a stone pattern such as travertine, it is preferable that the first decorative layer 31 has a concave pattern. In other words, the first region preferably forms a stone recessed pattern.
Further, when the design to be applied to the entire decorative material is a tile pattern or a brick pattern, the first decorative layer 31 is preferably a joint pattern. In other words, the first region preferably forms a tile or brick joint pattern.
By making the design given by the first decorative layer 31 as described above, the first region R1 is recessed and easily visible, and the visual three-dimensional effect can be improved.

The first decorative layer can be formed, for example, by printing with an ink for the first decorative layer containing a colorant and a binder resin.

Examples of the colorant for the first decorative layer include carbon black (black), iron black, titanium white, antimony white, yellow lead, titanium yellow, valve handle, cadmium red, ultramarine blue, cobalt blue and other inorganic pigments, and quinacridone red. , Isoindolinone yellow, nickel-azo complex, organic pigments such as phthalocyanine blue, dyes and the like. The colorant of the first decorative layer preferably does not contain bright pigments such as pearl pigments, metal particles and metal scales.
The binder resin of the first decorative layer is not particularly limited. For example, acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral. Examples thereof include resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fibrous derivatives, rubber resins and the like.

The thickness of the first decorative layer can be appropriately adjusted in the range of 0.1 μm or more and 20 μm or less in consideration of the desired design.

-Surface shape-
The arithmetic mean roughness Ra (Ra1) of JIS B0601: 1994 at a cutoff value of 0.8 mm on the surface of the first region is preferably 1.0 μm or more and 5.0 μm or less, and 1.0 μm or more and 3.0 μm or less. Is more preferable.
By setting Ra1 to 1.0 μm or more, the first region can be recessed to make it easier to see. Further, by setting Ra1 to 5.0 μm or less, it is possible to suppress the appearance of the first region as whitish and facilitate the improvement of design.

Ra1 can be adjusted by, for example, the surface shape of the base material A, the particle size and the amount of the inorganic filler added in the first cured product layer, and the like.

《Second area》
The second region is a region that is visually recognized higher than the first region.
The second region has a second cured product layer on the base material A.

-Second cured product layer-
The second cured product layer is a layer formed of a curable resin, more specifically, a layer formed of a cured product of an uncured curable resin composition.

As the curable resin of the second cured product layer, a thermosetting resin and an ionizing radiation curable resin are preferably mentioned, and a thermosetting resin is more preferable, from the viewpoint of obtaining a design property with a higher texture. That is, the second cured product layer preferably contains a thermosetting resin. By using the thermosetting resin, a design property with a higher texture can be obtained, the adhesion to the base material A is improved, and more excellent mechanical strength can be obtained.
Examples of the thermosetting resin include the same as those exemplified as the thermosetting resin that can be impregnated in the base material A. Among them, melamine resin, urea resin, melamine-urea resin, diallyl phthalate resin, guanamine resin and sulfone. An amide resin is preferable, a melamine resin, a melamine-urea resin and a phenol resin are more preferable, and a melamine resin is more preferable.
Examples of the ionizing radiation curable resin include those similar to those exemplified in the first cured product layer.

The curable resin of the second cured product layer is preferably the same type as the impregnated resin of the base material A from the viewpoint of adhesion between the base material A and the second cured product layer and manufacturing efficiency. When the base material B, which will be described later, is impregnated with a curable resin, the curable resin of the second cured product layer is the same type as the impregnated resin of the base material B from the viewpoint of production efficiency. preferable.

The second cured product layer may contain a thermoplastic resin, but it is preferable that the second cured product layer contains a curable resin as a main component.
The curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 90% by mass or more, and 100% by mass, based on the total amount of the resin in the second cured product layer. It is even more preferably mass%.

The second cured product layer preferably contains substantially no filler from the viewpoint of reducing diffusion. The term "substantially free" means that the total solid content of the second cured product layer is 0.1% by mass or less, preferably 0.01% by mass or less, and more preferably 0% by mass.

The thickness t2 of the second cured product layer is usually about 1 μm or more and 50 μm or less, preferably 3 μm or more and 40 μm or less, and more preferably 5 μm or more and 30 μm or less.

-Second decorative layer-
The second decorative layer can be formed, for example, by printing with an ink for the second decorative layer containing a colorant and a binder resin.
Examples of the colorant and binder resin of the second decorative layer include those exemplified by the colorant and binder resin of the first decorative layer described later.

The second decorative layer may be formed on the base material in an arbitrary pattern, for example.
The arbitrary pattern depends on the design to be imparted. For example, the arbitrary pattern is a wood surface pattern (a part other than the conduit groove pattern and / or the knot pattern) which is a relatively convex portion on the wood board when the wood grain pattern is given to the entire decorative material, especially autumn. It is preferable to use a lumber, and when a stone pattern such as travertin is applied to the entire decorative material, a pattern other than the recessed portion is preferable, and when a tile pattern or a brick pattern is applied to the entire decorative material, a tile is used. It is preferably a part or a brick part.

The thickness of the second decorative layer can be appropriately adjusted in the range of 0.1 μm or more and 20 μm or less in consideration of the desired design.

-Surface shape-
The arithmetic mean roughness Ra (Ra2) of JIS B0601: 1994 at a cutoff value of 0.8 mm on the surface of the second region is preferably 2.0 μm or less, and preferably 0.5 μm or more and 1.5 μm or less. More preferred.

<Base material B>
The decorative material of the present invention may have a base material B on the surface of the decorative layer opposite to the base material A.
The base material B is preferably selected from a paper base material and a fiber base material, and a paper base material is more preferable. By impregnating the paper base material and the fiber base material with a curable resin, it is possible to easily improve the adhesion between the base material A and the reinforcing layer described later.
Further, if a base material B having a concealing property is used, it is possible to prevent the color of the reinforcing layer, which will be described later, from being transparent.
Further, by using a paper base material or a fiber base material impregnated with a curable resin as the base material B, improvement in mechanical strength of the decorative material and improvement in scratch resistance of the decorative material can be expected.
As the base material B, a metal plate such as an aluminum plate and an iron plate, a non-metal inorganic plate such as a calcium silicate plate, a ceramic plate and a sentment plate, a wood plate, a resin plate and the like can also be used.

Examples of the paper base material include kraft paper, titanium paper, linter paper, resin impregnated paper, thin paper and Japanese paper.
The fiber base material is composed of a fiber base material composed of inorganic fibers such as glass fiber, alumina fiber, silica fiber, and carbon fiber, and organic fiber of various synthetic resins such as polyester resin, acrylic resin, polyethylene resin, and polypropylene resin. Examples thereof include a fiber base material to be used, and a base material such as a composite thereof. Further, the fiber base material may be a non-woven fabric or a woven fabric.
The base material B may be a laminate of two or more types selected from the paper base material and the fiber base material.

The thickness of the base material B is not particularly limited and may be appropriately selected according to the desired performance. From the viewpoint of ensuring mechanical characteristics and handleability, the thickness of the base material B is usually about 10 μm or more and 150 μm or less, preferably 20 μm or more and 120 μm or less. More preferably, it is 30 μm or more and 100 μm or less. When a paper base material is used as the base material B, the basis weight thereof is usually about 20 g / m ² or more and 150 g / m ² or less, preferably 30 g / m ² or more and 100 g / m ² or less from the same viewpoint. Is.

The base material B is preferably impregnated with a curable resin. With such a configuration, the mechanical strength of the decorative material can be improved, and thus the pencil hardness of the surface of the decorative material can be increased, and the surface of the decorative material can be easily scratched.
As the curable resin, a curable resin such as a thermosetting resin or an ionizing radiation curable resin can be used, and the thermosetting resin is preferable from the viewpoint of handleability. That is, the base material B preferably contains a curable resin, and more preferably contains a thermosetting resin.

Examples of the thermosetting resin to be impregnated in the base material B include the same as those exemplified as the impregnated resin of the base material A, and among them, a melamine resin, a urea resin, a melamine-urea resin, a guanamine resin and a sulfonamide resin. Is preferable, melamine resin, melamine-urea resin and phenol resin are more preferable, and phenol resin and melamine resin are more preferable.

Examples of the means for impregnating the base material B with the thermosetting resin include means for preparing an uncured thermosetting resin composition and impregnating the base material with the fat composition (for example, described later). Steps (A3) and (B5).
The impregnated composition becomes a cured product of a thermosetting resin by heating at an appropriate time point and curing it by a reaction such as a crosslinking reaction or a polymerization reaction (for example, steps (A5) and (B7) described later. ).).

The impregnated resin of the base material B may contain a thermoplastic resin, but it is preferable that the base material B contains a curable resin as a main component.
The curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 90% by mass or more, and 100% by mass, based on the total amount of the impregnated resin of the base material B. % Is even more preferable.

As for the base material B, the total light transmittance of JIS K7361-1: 1997 is preferably 20% or less, more preferably 15% or less, further preferably 12% or less, and 10% or less. It is even more preferable to have. By setting the total light transmittance of the base material B within this range, the base material B serves as a base, and the visibility of the decorative layer can be improved. Further, by setting the total light transmittance of the base material B to the above range, the hiding property of the base material B is enhanced, and it is possible to easily suppress the color of the reinforcing layer, which will be described later, from being transparent.

<Reinforcing layer>
The decorative material may have a reinforcing layer on the surface of the decorative layer opposite to the base material A for the purpose of enhancing mechanical properties and the like. When the decorative material has the base material B, the reinforcing layer is preferably arranged on the side opposite to the decorative layer of the base material B.

Examples of the reinforcing layer include a thermosetting resin impregnated sheet.
The types of the fiber base material and the paper base material used in the thermosetting resin impregnated sheet are not particularly limited as long as they are exemplified as the fiber base material and the paper base material of the base material B, and the basis weight is preferably 100 g. / M ² or more and 300 g / m ² or less, more preferably 150 g / m ² or more and 250 g / m ² or less. Further, the thermosetting resin can be used without particular limitation as long as it can be impregnated in the base material in the state of the thermosetting resin composition, and a phenol resin is preferable. That is, a phenol resin impregnated paper is preferable as the reinforcing layer.
As the phenol resin impregnated paper, for example ^{, kraft paper having a basis weight of 150 g / m 2} or more and 250 g / m ² or less is impregnated with phenol resin so as to have an impregnation rate of 20% or more and 60% or less, and 100 ° C. or more and 140 ° C. Those produced by drying to the following extent are preferably used.
As the reinforcing layer, a metal plate such as an aluminum plate and an iron plate, a non-metal inorganic plate such as a calcium silicate plate, a ceramic plate and a sentment plate, a wood plate, a resin plate and the like can also be used.

In the reinforcing layer, the total light transmittance of JIS K7361-1: 1997 is preferably 20% or less, more preferably 15% or less, further preferably 12% or less, and 10% or less. Is even more preferable. By setting the total light transmittance of the reinforcing layer within this range, the reinforcing layer serves as a base, and the visibility of the decorative layer can be enhanced.

<Primer layer, adhesive layer>
In the decorative material of the present invention, a primer layer or an adhesive layer can be provided between each layer in order to improve the adhesion of each layer.
Examples of the resin material forming the primer layer include urethane resin, polyester resin, acrylic resin, acrylic urethane resin, vinyl chloride-vinyl acetate copolymer resin and the like.
As the adhesive constituting the adhesive layer, a general-purpose pressure-sensitive adhesive, a heat-sensitive adhesive, and a curable adhesive (heat-curable adhesive, photo-curable adhesive, two-component curable adhesive, etc.) can be used.
The thickness of the primer layer and the adhesive layer is usually about 0.1 μm or more and 15 μm or less, preferably 1 μm or more and 10 μm or less, from the viewpoint of efficiently obtaining excellent adhesion.

<Adhesion material>
The decorative material of the present invention may be one in which an adherend is laminated and integrated.
The adherend is preferably arranged on the outermost layer on the side having the decorative layer with reference to the base material A.

The adherend is, for example, a single wood board, a wood plywood board, a particle board, an MDF (medium density fiber board), a wood board such as an laminated material; a plaster board such as a plaster board or a plaster slag board; a calcium silicate board, an asbestos slate board. , Lightweight foamed concrete board, hollow extruded cement board, etc.; fiber cement board, pulp cement board, asbestos cement board, wood piece cement board, etc .; ceramic board, pottery, porcelain, earthenware, glass, amber, etc. Metal plates such as 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 plates and polycarbonate plates; phenol resin plates, urea resin plates and unsaturated polyester resin plates , Thermo-curable resin plate such as polyurethane resin plate, epoxy resin plate, melamine resin plate; resin such as phenol resin, urea resin, unsaturated polyester resin, polyurethane resin, epoxy resin, melamine resin, diallyl phthalate resin, glass fiber Examples thereof include a so-called FRP board which is made by impregnating and curing a non-woven fabric, a cloth, a paper, and various other fibrous base materials to form a composite. The adherend may be used alone or as a composite substrate in which two or more of these are laminated.

The method of laminating the base material and various adherends is not particularly limited, and for example, a method of adhering a sheet to the adherend with an adhesive or the like can be adopted. The adhesive may be appropriately selected from known adhesives according to the type of adherend and the like. For example, polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ionomer and the like, as well as butadiene-acrylic nitrile rubber, neoprene rubber, natural rubber and the like can be mentioned.

<Use>
The decorative material of the present invention is used, for example, as a top plate for various counters and desks; furniture; cabinets for kitchen products; residential building materials such as doors; and the like. Among these, members including a horizontal surface such as a top plate used for counters and desks are required to have a visual three-dimensional effect, and are rubbed by various objects such as clothes, cleaning supplies, and watches, so that they have abrasion resistance. Therefore, it is preferable in that the effect of the decorative board of the present invention can be easily exhibited.

[Manufacturing method of decorative material]
The decorative material of the present invention can be produced, for example, by a process including the following (A1) to (A7).
(A1) A step of preparing a paper to be a base of a base material A.
(A2) A step of forming a first cured product layer having a releasable surface on at least a part of one surface of paper, and forming a laminate A having a decorative layer on the other surface.
(A3) The laminate A is impregnated with a curable resin composition, and the paper is impregnated with the curable resin composition to obtain a base material A, which is a resin-impregnated paper having light transmission, and the laminate A is obtained. A step of obtaining a laminate B formed by forming an uncured curable resin composition layer on the entire surface of the side having the first cured product layer.
(A4) A step of obtaining a laminate C, which comprises arranging a release film on the uncured curable resin composition layer side of the laminate B.
(A5) A step of hot-pressing the laminated body C with both sides sandwiched between mirror plates to form a second cured product layer obtained by curing the uncured curable resin composition layer.
(A6) A step of taking out the laminated body C from between the mirror surface plates.
(A7) When the release film is peeled off from the laminate C, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. A step of forming a second region in which a second cured product layer formed in a portion having no first region forming layer remains.

Although not shown, when removing the second cured product layer 22 directly above the first cured product layer 21 in the first region R1, only the second cured product layer 22 near the surface of the first cured product layer 21 is removed. , It may be left so that the surface becomes a thin film with a rough surface. By doing so, the surface of the concave portion of the first region R1 becomes a rough surface, and the gloss is lower than the surface of the surrounding second region, so that the three-dimensional effect formed by both regions R1 and R2 is emphasized. You can also do it.

The process (A1) is a process of preparing the paper that is the base of the base material A.

In the step (A2), a laminate A (71) having a first cured product layer 21 having a releasable surface and a decorative layer 30 on the other surface is formed on at least a part of one surface of the paper 10a. This is a process (Fig. 3).
Either the first cured product layer 21 or the decorative layer 30 may be formed first.
The portion where the first cured product layer 21 is formed becomes the first region R1 of the decorative material. The curable resin composition used for forming the first cured product layer is preferably cured at this stage.

When the decorative material has the base material B, it is preferable to arrange the base material B on the surface of the decorative layer opposite to the base material A in the step (A2). That is, when the decorative material has the base material B, it is preferable that the laminate A1 contains the base material B.

When the decorative material 100 has the permeation prevention layer 41, it is preferable to have a step of forming the permeation prevention layer between the step (A1) and the step (A2). When the penetration prevention layer forming ink contains a curable resin composition, it is preferable to cure at this stage.

In the step (A3), the laminate A is impregnated with the curable resin composition, the paper is impregnated with the curable resin composition, and the base material A (10), which is a resin-impregnated paper having light transmission property, is obtained. This is a step of obtaining a laminate B (72) formed by forming an uncured curable resin composition layer (22a) on the entire surface of the laminate A on the side having the first cured product layer (FIG. 4).

In the step (A3), it is preferable that the curable resin composition contained in the laminate B (72) is dried.

The step (A4) is a step of obtaining a laminate C (73) formed by arranging the release film 80 on the uncured curable resin composition layer 22a side of the laminate B (FIG. 5).

The release film 80 is a first cured product layer having a releasable surface among the second cured product layers obtained by curing the uncured curable resin composition layer 22a in the steps (A7) and (B9) described later. It has a role of removing the upper second cured product layer. That is, the adhesive force between the release film and the second cured product layer is x1, the second cured product layer and the layer located on the base material A side of the cured product layer (in the case of the first region, the first cured product layer, In the case of the second region, when the adhesive force with the base material A) is x2, if the relationship of x1> x2 in the first region and x1 <x2 in the second region is satisfied, the release film 80 The material and the like are not particularly limited.

The release film 80 is a single layer of a polyester resin such as polyethylene terephthalate or polybutylene terephthalate; a polyolefin resin such as polyethylene or polypropylene; an acrylic resin; or a resin layer formed on these resin sheets. Things can be mentioned.

When the decorative material has a reinforcing layer, it is preferable to arrange the reinforcing layer on the surface of the decorative layer opposite to the base material A in the step (A4). That is, when the decorative material has a reinforcing layer, it is preferable that the laminated body C includes the reinforcing layer.

In the step (A5), the laminated body C (73) is hot-pressed with both sides of the laminated body C (73) sandwiched between mirror plates to cure the uncured curable resin composition layer 22a. This is a step of forming the bi-cured product layer 22.
During the step (A5), the curable resin composition impregnated in the base material A and the base material B can also be cured.

The conditions of the hot press may be appropriately adjusted according to the type of the thermosetting resin used, and are not particularly limited. However, the pressure is usually 0.1 MPa or more and 9.8 MPa under the temperature conditions of 100 ° C. or higher and 200 ° C. or lower. Hereinafter, the time is 10 seconds to 120 minutes.

The step (A6) is a step of taking out the laminated body C from between the mirror face plates.
In the step (A7), when the release film is peeled off from the laminate C, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. At the same time, it is a step of forming a second region in which the second cured product layer formed in a portion having no first region forming layer remains (FIG. 1).
In the step (A7), the second cured product layer on the first cured product layer is removed, while the second cured product layer remains on the second region, so that after the step (A7). Then, the surface of the first region is lower in altitude than the surface of the second region.

Further, the decorative material of the present invention can be produced, for example, by a process including the following (B1) to (B9).
(B1) A step of preparing a paper to be a base of the base material A.
(B2) A step of obtaining a laminate D formed by forming a first cured product layer having a releasable surface on at least a part of one surface of paper.
(B3) A step of obtaining a laminated body E formed by forming a decorative layer on at least a part of one surface of the base material B.
(B4) A step of obtaining a laminated body F formed by laminating a surface of the laminated body D opposite to the first cured product layer and a surface of the laminated body E on the decorative layer side.
(B5) The laminate F is impregnated with a curable resin composition, and the paper is impregnated with the curable resin composition to obtain a base material A, which is a resin-impregnated paper having light transmission, and the laminate F is obtained. A step of obtaining a laminate G formed by forming an uncured curable resin composition layer on the entire surface of the side having the first cured product layer.
(B6) A step of obtaining a laminate H, which comprises arranging a release film on the uncured curable resin composition layer side of the laminate G.
(B7) A step of heat-pressing the laminated body H with both sides sandwiched between mirror plates to form a second cured product layer obtained by curing the uncured curable resin composition layer.
(B8) A step of taking out the laminated body H from between the mirror surface plates.
(B9) When the release film is peeled off from the laminate H, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. A step of forming a second region in which a second cured product layer formed in a portion having no first region forming layer remains.

The process (B1) is a process of preparing the paper that is the base of the base material A.

The step (B2) is a step of obtaining a laminate D formed by forming a first cured product layer having a releasable surface on at least a part of one surface of the paper.
The step (B3) is a step of obtaining a laminated body E formed by forming a decorative layer on at least a part of one surface of the base material B.

Either step (B2) or step (B3) may be performed first.
The portion where the first cured product layer 21 is formed in the step (B2) becomes the first region R1 of the decorative material. The curable resin composition used for forming the first cured product layer is preferably cured at this stage.

When the decorative material 100 has the permeation prevention layer 41, it is preferable to have a step of forming the permeation prevention layer between the step (B1) and the step (B2). When the penetration prevention layer forming ink contains a curable resin composition, it is preferable to cure at this stage.

In the step (B4), the laminated body F (B4) is formed by laminating the surface of the laminated body D (74) opposite to the first cured product layer 21 and the surface of the laminated body E (75) on the decorative layer 30 side. 76) is a step of obtaining (FIG. 6).

In the step (B5), the laminate F is impregnated with the curable resin composition, the paper is impregnated with the curable resin composition, and the base material A (10), which is a resin-impregnated paper having light transmission property, is obtained. This is a step of obtaining a laminate G (77) formed by forming an uncured curable resin composition layer (22a) on the entire surface of the laminate F on the side having the first cured product layer (FIG. 7).

When the base material B is a paper base material or a fiber base material, the base material B can also be impregnated with the curable resin composition in the step (B5).

The step (B6) is a step of obtaining a laminate H (78) formed by arranging the release film 80 on the uncured curable resin composition layer 22a side of the laminate G (FIG. 8).

Examples of the release film 80 in the step (B6) include those similar to the release film 80 in the step (A4).

When the decorative material has a reinforcing layer, it is preferable to arrange the reinforcing layer on the surface of the base material B opposite to the decorative layer in the step (B6). That is, when the decorative material has a reinforcing layer, it is preferable that the laminated body H includes the reinforcing layer.

In the step (B7), the laminated body H (78) is hot-pressed with both sides of the laminated body H (78) sandwiched between mirror plates to cure the uncured curable resin composition layer 22a. This is a step of forming the bi-cured product layer 22.
During the step (B7), the base material A and the curable resin composition impregnated in the base material B can also be cured.

The step (B8) is a step of taking out the laminated body H from between the mirror face plates.
In the step (B9), when the release film is peeled off from the laminate H, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. At the same time, it is a step of forming a second region in which the second cured product layer formed in a portion having no first region forming layer remains (FIG. 2).
In the step (B9), the second cured product layer on the first cured product layer is removed, while the second cured product layer remains on the second region, so that after the step (B9). Then, the surface of the first region is lower in altitude than the surface of the second region.

Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to this example.

1. 1. Evaluation 1-1. Abrasion resistance Decorative materials obtained in Examples and Comparative Examples using the trade name "Rotary Ablation Tester" manufactured by Toyo Seiki Seisakusho Co., Ltd. in accordance with "6.2 Abrasion Resistance B Method" of JIS K6902: 2008. The wear resistance of was evaluated. As the polishing material, a polishing paper "Product No .: S-42, 3M company" conforming to JIS R6252 was used. Table 1 shows the number of rotations of the turntable when the printed pattern of the decorative material starts to be worn, and the number of rotations of the turntable when the printed pattern of the decorative material is completely worn and disappears. It is shown that the higher the number of rotations, the better the wear resistance.

1-2. Three-dimensional effect The cosmetic materials obtained in the examples and comparative examples were visually evaluated by any 20 adults under the illumination of a fluorescent lamp to see if they had a three-dimensional effect. The results are shown in Table 1.
A: More than 18 people answered that they had a highly three-dimensional design.
B: The number of people who answered that they had a highly three-dimensional design was 11 or more and 17 or less.
C: The number of people who answered that they had a high three-dimensional design was 6 or more and 10 or less.
D: Less than 5 people answered that they had a highly three-dimensional design.

1-3. Clarity of design With respect to the decorative materials obtained in Examples and Comparative Examples, 20 adults were allowed to visually evaluate the clarity of the design under the illumination of fluorescent lamps, using the contrast of color tone as an evaluation point. The results are shown in Table 1.
A +: More than 19 people answered that the design was highly clear.
A-: The number of people who answered that the design was highly clear was 17 or more and 18 or less.
B +: The number of people who answered that the design was highly clear was 14 or more and 16 or less.
B-: The number of people who answered that the design was highly clear was 11 or more and 13 or less.
C: Less than 10 people answered that the design was highly clear.

2. Preparation of decorative material [Example 1]
Use printing ink (DIC Graphics Co., Ltd., "Ode SPTI") on one side of paper that does not contain colorants (KJ Special Paper Co., Ltd., product number: OLP-38, basis weight: 42 g / m ^2). , The first decorative layer (conduit portion of wood grain) and the second decorative layer (bark portion of wood grain) having a thickness of 3 μm were formed by gravure printing.
Next, the curable resin composition for forming the first cured product layer described below was printed on the other surface of the paper, irradiated with an electron beam (pressurized voltage: 165 KeV, 3Mrad (30 kGy)), and cured. A laminated body A formed by forming a first cured product layer having a thickness t1 of 2.0 μm was obtained.
Next, the laminate A is impregnated with the curable resin composition for forming the second cured product layer below and dried to obtain a base material A which is a resin-impregnated paper having light transmission, and the laminate A is the first. A laminate B formed by forming an uncured curable resin composition layer on the entire surface of the side having the one cured product layer was obtained (so that the amount of the cured resin composition at the time of drying was 80 g / m ^2). Impregnation). The total light transmittance of the base material A was 40% or more in the entire plane, and the haze was 96% or less. Further, Hz1-Hz2 in the main text of the specification was about 10%. [Hz1-Hz2 was calculated as follows. First, the haze of the above paper (KJ Special Paper Co., Ltd., product number: OLP-38, basis weight: 42 g / m ² ) was regarded as Hz1. Next, the haze of the resin-impregnated paper obtained by impregnating the same paper with the curable resin composition for forming the second cured product layer and drying it was regarded as Hz2. From the above Hz1 and Hz2, Hz1-Hz2 was calculated. ]
Next, the following release film is laminated on the surface of the laminate B having the uncured curable resin composition layer, and a reinforcing layer (phenol resin on kraft paper) is laminated on the surface of the laminate B on the decorative layer side. Phenol formaldehyde impregnated core paper (manufactured by Ota Sangyo Co., Ltd., Ota core) obtained by impregnating a liquid uncured resin composition composed of ^{3 sheets with a basis weight of 245 g / m 2 is laminated.} A laminate C was obtained.
Next, both sides of the laminate C were sandwiched between mirror plates, and heat and pressure molding was performed at a molding temperature of 150 ° C. and a molding pressure of 100 kg / cm ^{2 for 10 minutes using a hot press.} By the molding, a second cured product layer formed by curing the uncured curable resin composition layer was formed. Further, by the molding, the uncured curable resin composition impregnated in the base material A was cured. After molding, the laminate C was taken out from between the two mirror plates, and the release film was peeled from the laminate C to obtain the decorative plate of Example 1.
When the release film was peeled off from the laminate C, the second cured product layer on the first cured product layer was removed together with the release film, and a concave first region was formed. .. In addition, a second region was formed in which the second cured product layer remained in the portion having no first cured product layer.
The decorative material of Example 1 had a thickness t1 of 2.0 μm and t2 of 5 μm. The ratio (S2 / S1) of the area S1 of the first region to the area S2 of the second region was about 4.0.

<Curable resin composition for forming the first cured product layer>
Each of the following components was stirred with a process homogenizer (manufactured by SMT Co., Ltd., "PH91") at a rotation speed of 2000 rpm for 1 hour to obtain a resin composition.
60 parts by mass of ionizing radiation curable resin (mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate, trade name "Aronix M400" manufactured by Toa Synthetic Co., Ltd.)
-Silicone-based mold release agent 0.9 parts by mass (both-terminal methacryloyloxyalkyl-modified organopolysiloxane, trade name "X-22-164B" manufactured by Shin-Etsu Chemical Co., Ltd.)
・ Silane coupling treated silica 18 parts by mass (average particle size 3.0 μm)
・ Methyl ethyl ketone 40 parts by mass

<Curable resin composition for forming a second cured product layer>
・ Melamine formaldehyde resin 60 parts by mass ・ Water 35 parts by mass ・ Isopropyl alcohol 5 parts by mass

<Making a release film>
The following ionizing thermosetting resin composition is applied to the easy-adhesion surface of a 100 μm-thick polyethylene terephthalate film (trade name “Lumirror S34” of Toyobo Co., Ltd.), and an electron beam (pressurized voltage: 165 KeV, 5Mrad (50 kGy)). ) Was irradiated to cure, and a cured product layer having a thickness of 5 μm was formed to obtain a release film.

<< Ionizing radiation curable resin composition >>
100 parts by mass of ionizing radiation curable resin (ethylene bottom oxide modified product of trimethylolpropane triacrylate, trade name "Aronix M350" manufactured by Toagosei Co., Ltd.)
-Silicone-based release agent 2 parts by mass (both-terminal methacryloyloxyalkyl-modified organopolysiloxane, trade name "X-22-164B" manufactured by Shin-Etsu Chemical Co., Ltd.)
-Silica particles 8 parts by mass (trade name "Silicia 450" manufactured by Fuji Silysia Chemical Ltd., average particle size: 5.2 μm)
・ Ethyl acetate 50 parts by mass

[Example 2]
In Example 1, "paper not containing a colorant" is referred to as "orange colored paper (paper having the same composition as KJ Special Paper Co., Ltd.'s product number" OLP-38 "except that a colorant is blended, basis weight: A decorative material of Example 2 was obtained in the same manner as in Example 1 except that it was changed to "42 g / m ^2)". In Example 2, the total light transmittance of the base material A was 40% or more in the entire plane, and the haze was 96% or less. Further, Hz1-Hz2 in the main text of the specification was about 10%.

[Comparative Example 1]
Printing ink (DIC Graphics Co., Ltd.) on one side of the base material (titanium paper base paper for building materials, trade name "PM-67P" manufactured by KJ Special Paper Co., Ltd., basis weight: 80 g / m ^{2, thickness: 100 μm)} A first decorative layer (conduit portion of wood grain) and a second decorative layer (bark portion of wood grain) having a thickness of 3 μm were formed by gravure printing using “Ode SPTI” manufactured by the company.
Next, the curable resin composition for forming the first cured product layer is printed on the decorative layer, irradiated with an electron beam (pressurized voltage: 165 KeV, 3Mrad (30 kGy)) and cured to have a thickness of t1. A laminate A'formed by forming a first cured product layer having a thickness of 2.0 μm was obtained.
Next, the laminate A'was impregnated with the curable resin composition for forming the second cured product layer, dried, and uncured on the entire surface of the laminate A'on the side having the first cured product layer. A laminate B'formed by forming a sex resin composition layer was obtained (impregnated so that the amount of the cured resin composition at the time of drying was 80 g / m ^2).
Next, the above-mentioned release film is laminated on the surface of the laminate B'on the side having the uncured curable resin composition layer, and the reinforcing layer (on kraft paper) is laminated on the surface of the laminate B'on the substrate side. Laminated three sheets of phenol resin impregnated core paper (manufactured by Ota Sangyo Co., Ltd., Ota core) obtained by impregnating a liquid uncured resin composition made ^{of phenol resin with a basis weight of 245 g / m 2.} A laminated body C'was obtained.
Next, both sides of the laminate C'was sandwiched between mirror plates, and heat and pressure molding was performed at a molding temperature of 150 ° C. and a molding pressure of 100 kg / cm ^{2 for 10 minutes using a hot press.} By the molding, a second cured product layer formed by curing the uncured curable resin composition layer was formed. Further, by the molding, the uncured curable resin composition impregnated in the base material was cured. After molding, the laminate C'was taken out from between the two mirror plates, and the release film was peeled from the laminate C'to obtain the decorative plate of Comparative Example 1.
When the release film is peeled off from the laminate C', the second cured product layer on the first cured product layer is removed together with the release film, and a concave first region is formed. rice field. In addition, a second region was formed in which the second cured product layer remained in the portion having no first cured product layer.
The decorative material of Comparative Example 1 had a thickness t1 of 2.0 μm and t2 of 5 μm. The ratio (S2 / S1) of the area S1 of the first region to the area S2 of the second region was about 5.0. The decorative material of Comparative Example 1 does not have a base material between the first cured product layer and the second cured product layer and the decorative layer, and the decorative layer is directly below the first cured product layer and the second cured product layer. It has.

[Comparative Example 2]
A decorative material of Comparative Example 2 was obtained in the same manner as in Example 1 except that the first cured product layer was not formed. The decorative material of Comparative Example 2 has a second cured product layer having an average thickness of 40 μm on the entire surface opposite to the decorative layer of the base material A, does not have a first region and a second region, and does not have a three-dimensional effect. It is a thing.

From the results in Table 1, it can be confirmed that the decorative material of the example has a visual three-dimensional effect and is excellent in abrasion resistance. Further, among the examples, it can be confirmed that the decorative material of Example 2 in which the base material A contains a colorant has a clear design and is excellent in designability.

10: Base material A
21: First cured product layer 22: Second cured product layer 22a: Curable resin composition layer 30: Decorative layer 31: First decorative layer 32: Second decorative layer 41: Penetration prevention layer 50: Base material B
60: Reinforcing layer 71: Laminated body A
72: Laminated body B
73: Laminated body C
74: Laminated body D
75: Laminated body E
76: Laminated body F
77: Laminated body G
78: Laminated body H
80: Release film 100: Decorative material

Claims

It ’s a cosmetic material,
The decorative material has a first region and a second region in a plane, and has a first region and a second region.
The surface of the first region has a lower elevation than the surface of the second region.
The decorative material at a portion corresponding to the first region has a first cured product layer having a releasable surface on one surface of the base material A.
The decorative material at a portion corresponding to the second region has a second cured product layer on one surface of the base material A.
The first cured product layer and the second cured product layer are formed on the same surface side of the base material A.
A decorative layer is provided on at least a part of the base material A on the side opposite to the side having the first cured product layer and the second cured product layer.
A decorative material in which the base material A is a resin-impregnated paper having light transmittance.
The decorative material according to claim 1, which contains a thermosetting resin as the resin impregnated in the base material A.
The decorative material according to claim 1 or 2, wherein the base material A contains a colorant.
The decorative material according to any one of claims 1 to 3, wherein the brightness of the first region is higher than that of the second region when the decorative material is observed from the side of the first cured product layer.
When the haze of the portion of the base material A having the first cured product layer is defined as Hz1 and the haze of the portion of the base material A having the second cured product layer is defined as Hz2, the relationship of Hz2 <Hz1 is satisfied. , The decorative material according to any one of claims 1 to 4.
The decorative material according to any one of claims 1 to 5, wherein the first cured product layer contains an ionizing radiation curable resin.
The decorative material according to any one of claims 1 to 6, wherein the first cured product layer contains a release agent.
The decorative material according to any one of claims 1 to 7, wherein the second cured product layer contains a thermosetting resin.
The decorative material according to any one of claims 1 to 8, which satisfies the relationship of t1 <t2 when the thickness of the first cured product layer is defined as t1 and the thickness of the second cured product layer is defined as t2.
A first decorative layer formed by forming the decorative layer on at least a part of a portion corresponding to the first region, and a second decorative layer formed on at least a part of a portion corresponding to the second region. The decorative material according to any one of claims 1 to 9, which has at least one of them.
The decorative material according to any one of claims 1 to 10, which has a permeation prevention layer between the base material A and the first cured product layer.
The eleventh claim, wherein when the thickness of the permeation prevention layer is defined as t0, the thickness of the first cured product layer is defined as t1, and the thickness of the second cured product layer is defined as t2, the relationship of t0 + t1 <t2 is satisfied. Cosmetic material.
The decorative material according to any one of claims 1 to 12, which has a base material B on the surface of the decorative layer opposite to the base material A.
The decorative material according to claim 13, wherein the base material B contains a thermosetting resin.
A method for producing a decorative material, which comprises the following steps (A1) to (A7).
(A1) A step of preparing a paper to be a base of a base material A.
(A2) A step of forming a first cured product layer having a releasable surface on at least a part of one surface of paper, and forming a laminate A having a decorative layer on the other surface.
(A3) The laminate A is impregnated with a curable resin composition, and the paper is impregnated with the curable resin composition to obtain a base material A, which is a resin-impregnated paper having light transmission, and the laminate A is obtained. A step of obtaining a laminate B formed by forming an uncured curable resin composition layer on the entire surface of the side having the first cured product layer.
(A4) A step of obtaining a laminate C, which comprises arranging a release film on the uncured curable resin composition layer side of the laminate B.
(A5) A step of hot-pressing the laminated body C with both sides sandwiched between mirror plates to form a second cured product layer obtained by curing the uncured curable resin composition layer.
(A6) A step of taking out the laminated body C from between the mirror surface plates.
(A7) When the release film is peeled off from the laminate C, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. A step of forming a second region in which a second cured product layer formed in a portion having no first region forming layer remains.
A method for producing a decorative material, which comprises the following steps (B1) to (B9).
(B1) A step of preparing a paper to be a base of the base material A.
(B2) A step of obtaining a laminate D formed by forming a first cured product layer having a releasable surface on at least a part of one surface of paper.
(B3) A step of obtaining a laminated body E formed by forming a decorative layer on at least a part of one surface of the base material B.
(B4) A step of obtaining a laminated body F formed by laminating a surface of the laminated body D opposite to the first cured product layer and a surface of the laminated body E on the decorative layer side.
(B5) The laminate F is impregnated with a curable resin composition, and the paper is impregnated with the curable resin composition to obtain a base material A, which is a resin-impregnated paper having light transmission, and the laminate F is obtained. A step of obtaining a laminate G formed by forming an uncured curable resin composition layer on the entire surface of the side having the first cured product layer.
(B6) A step of obtaining a laminate H, which comprises arranging a release film on the uncured curable resin composition layer side of the laminate G.
(B7) A step of heat-pressing the laminated body H with both sides sandwiched between mirror plates to form a second cured product layer obtained by curing the uncured curable resin composition layer.
(B8) A step of taking out the laminated body H from between the mirror surface plates.
(B9) When the release film is peeled off from the laminate H, the second cured product layer on the first cured product layer of the second cured product layer is removed together with the release film to form the first region. A step of forming a second region in which a second cured product layer formed in a portion having no first region forming layer remains.