阅读说明：本技术 装饰材料 (Decorative material ) 是由 东川荣一 于 2018-12-20 设计创作，主要内容包括：本发明提供一种赋予设计性,同时具有优异的耐擦伤性、优异的防粘性和优异的耐污染性的装饰材料。本实施方式涉及的装饰材料(1)具备在表层侧设置的第1光泽调整层(5)、以及在第1光泽调整层(5)的一部分上设置的第2光泽调整层(6)。第1光泽调整层(5)包含由疏水性无机材料构成的光泽调整剂、以及具有反应性末端的有机硅系防粘剂。具有反应性末端的有机硅系防粘剂的反应性末端优选具有羟基和氨基中的至少一者。第2光泽调整层(6)包含具有反应性末端的有机硅系防粘剂,该反应性末端优选具有丙烯酰基和甲基丙烯酰基中的至少一者。(The present invention provides a decorative material which imparts design properties and has excellent scratch resistance, excellent release properties and excellent stain resistance. The decorative material (1) according to the present embodiment includes a 1 st gloss adjustment layer (5) provided on the surface layer side, and a 2 nd gloss adjustment layer (6) provided on a part of the 1 st gloss adjustment layer (5). The 1 st gloss control layer (5) contains a gloss control agent composed of a hydrophobic inorganic material and a silicone-based release agent having a reactive end. The reactive end of the silicone-based releasing agent having a reactive end preferably has at least one of a hydroxyl group and an amino group. The 2 nd gloss adjustment layer (6) contains a silicone-based releasing agent having a reactive end, preferably having at least one of an acryloyl group and a methacryloyl group.)

1. A decorative material characterized by comprising: a 1 st gloss adjustment layer provided on the surface layer side, and a 2 nd gloss adjustment layer provided on a part of the 1 st gloss adjustment layer,

the 1 st gloss control layer contains a gloss control agent composed of a hydrophobic inorganic material and a silicone-based anti-blocking agent having a reactive end,

when the same mass of inorganic material is used, and the mass reduction amount by the following evaluation method a is MA and the mass reduction amount by the following evaluation method B is MB, the hydrophobic inorganic material satisfies the following formula (1):

1.2＜(MB/MA)＜10.0 ···(1)

(evaluation method A)

An inorganic material as an object was left to stand at 110 ℃ for 2 hours, and then the mass reduction thereof was measured;

(evaluation method B)

The inorganic material to be evaluated was left to stand at 950 ℃ for 2 hours under the same conditions as in the evaluation method a except for the atmospheric temperature, and then the mass reduction thereof was measured.

2. The decorating material as claimed in claim 1, wherein the reactive end of the silicone-based releasing agent having a reactive end has at least one of a hydroxyl group and an amino group.

3. The decorating material according to claim 1 or claim 2, wherein the amount of the silicone-based releasing agent added to the 1 st gloss adjustment layer is such that the effective component of the silicone-based releasing agent is 1 part by mass or more and 6 parts by mass or less with respect to 100 parts by mass of the solid component constituting the 1 st gloss adjustment layer.

4. The decorating material as claimed in any one of claims 1 to 3, wherein a main material of the resin component constituting the 1 st gloss adjustment layer is a mixture of a urethane-based thermosetting resin having a polyol and an isocyanate and an ionizing radiation curing resin having an acryloyl group or a methacryloyl group, and the urethane-based thermosetting resin is contained in an amount of 3 parts by mass or more and 100 parts by mass or less with respect to 100 parts by mass of the ionizing radiation curing resin.

5. The decorating material as claimed in any one of claims 1 to 4, wherein the 2 nd gloss adjustment layer contains a silicone-based releasing agent having a reactive end having at least one of an acryl group and a methacryl group.

6. The decorating material according to claim 5, wherein the amount of the silicone-based releasing agent added to the 2 nd gloss adjustment layer is such that the effective component of the silicone-based releasing agent is 0.5 to 5 parts by mass, relative to 100 parts by mass of the solid component constituting the 2 nd gloss adjustment layer.

7. The decorating material as claimed in any one of claims 1 to 6, wherein a main material of the resin component constituting the 2 nd gloss adjustment layer is a mixture of a urethane-based thermosetting resin having a polyol and an isocyanate and an ionizing radiation curing resin having an acryloyl group or a methacryloyl group, and the urethane-based thermosetting resin is contained in an amount of 25 parts by mass or less with respect to 100 parts by mass of the ionizing radiation curing resin.

8. The decorating material as claimed in any one of claims 1 to 6, wherein a main material of the resin component constituting the 2 nd gloss adjustment layer is an ionizing radiation curing resin having an acryloyl group or a methacryloyl group.

9. The decorating material as claimed in any one of claims 1 to 8, wherein a pattern ink layer is provided on the lower layer side of the 1 st gloss adjustment layer,

the 2 nd gloss control layer is formed in a portion overlapping with the pattern of the pattern ink layer when viewed from the front surface side, and the pattern of the pattern ink layer is synchronized with the gloss of the 2 nd gloss control layer.

10. The decorating material as claimed in any one of claims 1 to 8, wherein a pattern ink layer is provided on the lower layer side of the 1 st gloss adjustment layer,

the 2 nd gloss adjustment layer is formed in a portion of the design ink layer other than a portion directly above the design pattern, and the design pattern of the design ink layer is synchronized with the gloss of the 1 st gloss adjustment layer.

Technical Field

The present invention relates to a decorative material used for interior and exterior finishing of buildings, surface finishing of doors and windows, furniture, and the like. More specifically, the present invention relates to a decorative material that three-dimensionally exhibits unevenness due to a difference in gloss of a surface.

Background

Conventionally, decorative materials used for interior and exterior finishing of buildings, surface finishing of doors and windows, furniture, and the like, for example, are generally applied with a desired grain pattern such as a wood grain pattern or a stone grain pattern. In addition, decorative materials that exhibit not only a grain pattern such as a wood grain pattern or a stone grain pattern but also a surface relief feeling of natural wood or stone in a three-dimensional manner are also widely used mainly for applications requiring a high-grade feeling.

As a method for expressing a planar pattern and a three-dimensional uneven feeling on the surface of a decorative material, various methods have been studied and used separately according to the purpose. Among them are methods of: the surface gloss state (specifically, glossiness) of a portion intended to express the concave portion or the convex portion is changed without actually forming the concave and convex portions on the surface of the decorative material, and thereby the stereoscopic impression of the concave and convex portions is visually expressed by the illusion of the human eyes. According to this method, even if there is substantially no uneven shape, the human eye can recognize a portion with relatively high gloss as a convex portion and a portion with relatively low gloss as a concave portion.

Specifically, for example, a transparent or translucent synthetic coating layer having low gloss is formed on the entire surface of the printing surface of a substrate on which a suitable pattern including a concave pattern is printed, and then a transparent or translucent synthetic coating layer having high gloss is formed at a portion of the surface of the formed synthetic coating layer other than a portion corresponding to the concave pattern. Of course, if the relationship between the gloss level and the gloss level is reversed, a decorative material having a reversed uneven relationship can be obtained.

According to this method, a three-dimensional uneven feel can be easily imparted to any substrate by preparing only 2 kinds of coating materials having different gloss without using a special reagent or the like. Further, since the formation of the synthetic coating layer having different gloss can be performed by continuing the conventional printing method such as gravure printing after the formation of the design pattern (design ink layer), no special equipment is required, the production efficiency is high, and the synthetic coating layer can be easily synchronized with the design pattern. Further, since the thickness of the synthetic paint layer is much thinner than the height difference of the unevenness to be expressed, the amount of resin used can be reduced, and the decorative material is advantageous in terms of flexibility, and can be easily realized with excellent bending workability. Further, the surface of the decorative material has no large unevenness, and therefore, there is an advantage that contaminants do not remain in the recessed portion.

In view of the above-described great number of advantages, a decorative material using this method has been used in large quantities, but it is a real situation that this method still does not exceed the method of actually forming the irregularities in the sense of high-quality feeling. The reason for this may be: for example, if the mechanical embossing method is adopted, the uneven shape of the duct or the like of the natural wood including the sectional shape of the duct or the like can be faithfully reproduced. In contrast, in the method of using 2 kinds of paints having different gloss, since the grades of the surface gloss are two, the grades of the unevenness that can be expressed are also two. Therefore, there is a problem that: it is difficult to express a concavo-convex shape having a slope portion whose depth (height) continuously changes, such as a duct of natural wood or the like.

Therefore, in recent years, a decorative material has been proposed in which a concave-convex shape such as a duct of natural wood or the like can be expressed by providing a synthetic coating layer (hereinafter also referred to as a "gloss adjustment layer") that forms a slope portion whose depth continuously changes to express the concave-convex shape (for example, refer to patent document 1).

Here, as a method of adjusting the gloss of the gloss adjustment layer, a method of adding a gloss adjuster (matting agent) to a transparent resin as a binder is generally used. As the gloss adjuster, fine particles of an inorganic material or an organic material are mainly used, and particularly, fine particles of an inorganic material such as silica fine particles are widely used because they have a strong matting ability. By adding the gloss adjuster, the gloss adjuster imparts unevenness to the surface of the gloss adjustment layer, and the unevenness scatters light, thereby obtaining a matting effect. By adjusting the kind and the amount of these gloss control agents, desired gloss can be freely produced.

Urethane-based resins using various polyols and isocyanates are often used as the transparent resin of the adhesive in view of workability, price, cohesion of the resin itself, and the like. The urethane resin is characterized in that various properties can be controlled by the combination of a polyol and an isocyanate, but since the molecular weights of the polyol and the isocyanate are relatively large and the number of functional groups per molecule is small, there is a problem that it is generally difficult to increase the crosslinking density. The crosslinking density is a parameter having a large influence on the scratch resistance in particular, and therefore, it is difficult in principle for the urethane resin to satisfy the requirement of high scratch resistance, such as scratch resistance required for horizontal surfaces such as ceiling panels and partition panels of furniture.

In the case of the gloss control layer using the gloss control agent, the convex portions on the surface are selectively scraped off in the scratch resistance test, and the gloss control agent is peeled off, resulting in further deterioration of scratch resistance. Since the tendency of the deterioration of the abrasion resistance is approximately proportional to the amount of the gloss adjuster added, it can be said that it is very difficult to satisfy the abrasion resistance required for the above-mentioned horizontal surface for a decorative material having low gloss and high design.

On the other hand, it is considered that the ionizing radiation curing resin having an acryloyl group or a methacryloyl group as the transparent resin has a relatively low molecular weight and a large number of functional groups per molecule, and thus the crosslinking density is high and the scratch resistance is easily improved. By using such an ionizing radiation curing resin as a transparent resin, a decorative material having excellent scratch resistance can be provided. Since the scratch resistance mainly depends on the strength of the outermost surface of the decorative material, the ionizing radiation curing resin may be used only for the constituent material of the outermost surface layer.

However, in the case where the gloss adjustment layer is divided into 2 layers and the outermost gloss adjustment layer covers not the entire surface of the decorative material but only a part thereof, the gloss adjustment layer located immediately below and covering the entire surface of the decorative material is also in a state where a part of the surface is exposed. Therefore, in order to impart high scratch resistance to the decorative material, it is preferable to use an ionizing radiation curing resin for both the transparent resins of the gloss adjustment layers. In addition, in this case, the upper gloss adjustment layer is laminated to cover a part of the lower gloss adjustment layer, which covers the entire surface of the decoration material. However, since the ionizing radiation curing resin is not cured unless irradiated with ionizing radiation, a gloss adjustment layer covering a part of and located above is laminated on a gloss adjustment layer covering the entire surface of an uncured decorative material and located below during processing by various printers that are generally used for manufacturing decorative materials. Therefore, there is a possibility that such a trouble as the gloss adjustment layer covering the entire surface is dissolved or scratched may occur.

On the other hand, the characteristics required as the decorative material include the scratch resistance as described above, and it is required to have overall durability in daily use. In particular, since the decorative material is mainly used for decorative parts requiring design such as furniture, contamination resistance is an important required characteristic. In addition, in the case of assembling furniture, a sealing material indicating an assembling procedure or the like may be attached during packaging, and these materials may be peeled off during or after assembling, and in this case, it is also important to provide a release property so as not to cause peeling in the decorative material. In order to impart such stain resistance and releasing property, a method of adding a releasing agent to a gloss control layer forming the surface of the decorating material is effective.

The stain resistance here is: when various staining materials are attached to the surface of the decorative material and wiped off with water, alcohol or the like after a certain period of time, the presence or absence and the degree of the staining material residue or the change in color of the decorative material due to the staining material are judged. Therefore, in order to exhibit excellent stain resistance, it is required to achieve all of "the stain material is not fixed on the surface of the decorating material", "the stain material does not permeate into the decorating material", and "the stain material does not chemically change the surface of the decorating material", and even in the case where only one of them is poor, an evaluation of the overall poor stain resistance is obtained.

As described above, the gloss control layer is mainly composed of the transparent resin and the matting agent, but as described above, silica fine particles are generally used as the matting agent, and the interaction between the silica fine particles and the transparent resin is very weak, and it is considered that minute voids are present at the interface thereof. Further, the contaminants to be evaluated in daily use include hydrophilic substances such as water-based inks, which are characterized by being easily adsorbed on the surfaces of silica fine particles having a similar hydrophilicity. Therefore, as described above, even if the releasing agent is added to impart stain resistance, it is effective for "the staining substance is not fixed on the surface of the decorating material", but is less effective for "the staining substance does not permeate into the decorating material". As a result, when the silica fine particles are used as a matting agent, contamination resistance against hydrophilic contaminants is lowered. Since such a decrease in contamination resistance due to the silica fine particles depends on the mixing ratio of the silica fine particles, in the case of a decorative material obtained by laminating the 2 nd gloss adjustment layer as the upper gloss adjustment layer on a part of the 1 st gloss adjustment layer as the lower gloss adjustment layer, the contamination resistance of the 1 st gloss adjustment layer having a relatively low gloss is easily decreased, and in order to secure the contamination resistance of the entire decorative material, it is necessary to take measures against the first gloss adjustment layer.

Disclosure of Invention

Problems to be solved by the invention

In order to solve the above problems, an object of the present invention is to provide a decorative material in which a gloss adjustment layer positioned above is laminated on a part of a gloss adjustment layer positioned below to impart design properties, and which can exhibit excellent scratch resistance, excellent release properties, and excellent contamination resistance.

Means for solving the problems

The present inventors have found that a decorative material exhibiting excellent abrasion resistance and stain resistance can be provided by optimizing the surface treatment and the treatment amount of a gloss-adjusting agent, combining the gloss-adjusting layer with a silicone-based release agent having an optimum reactive end, and setting the resin composition of the gloss-adjusting layer to a dual-curing type in which an ionizing radiation curing resin and a urethane-based resin are combined, that is, by repeating various studies and experiments on a preferable combination.

In order to achieve the object, a finishing material according to an aspect of the present invention includes: a first gloss control layer provided on a surface layer side, and a second gloss control layer provided on a part of the first gloss control layer, wherein the first gloss control layer contains a gloss control agent composed of a hydrophobic inorganic material and a silicone-based release agent having a reactive terminal, and the hydrophobic inorganic material satisfies the following formula (1) when the same mass of inorganic material is used, and a mass reduction amount obtained by the following evaluation method a is MA and a mass reduction amount obtained by the following evaluation method B is MB:

1.2＜(MB/MA)＜10.0···(1)

(evaluation method A)

The inorganic material as an object was left to stand at 110 ℃ for 2 hours, and then the mass reduction thereof was measured.

(evaluation method B)

The inorganic material to be evaluated was left to stand at 950 ℃ for 2 hours under the same conditions as in the evaluation method a except for the atmospheric temperature, and then the mass reduction thereof was measured.

Here, the hydrophobic inorganic material refers to an inorganic material having a hydrophobic surface. As a representative example of the hydrophobic inorganic material, a surface-treated or surface-modified silica, that is, a silica having a surface subjected to hydrophobic treatment with an organic compound, or the like can be given.

ADVANTAGEOUS EFFECTS OF INVENTION

According to an aspect of the present invention, by selecting the kind of gloss adjuster added to the gloss adjustment layer (i.e., the 1 st gloss adjustment layer) located below, which becomes the base layer, and making the silicone-based release agent have a reactive end, it is possible to provide a decorative material that imparts design properties while also having excellent scratch resistance, excellent release properties, and excellent stain resistance.

Brief description of the drawings

Fig. 1 is a cross-sectional view showing a finishing material according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a modified example of the decorative material.

Detailed Description

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

Here, the drawings are schematic, and the relationship between the thickness and the planar size, the ratio of the thicknesses of the respective layers, and the like are different from the actual case. The embodiments described below are examples of configurations for embodying the technical ideas of the present invention, and the technical ideas of the present invention are not limited to the following materials, shapes, structures, and the like of the components. The technical idea of the present invention can be variously changed within the technical scope defined by the claims described in the claims.

(constitution)

As shown in fig. 1, the decorative material 1 of the present embodiment includes a gloss adjustment layer on the surface layer side, and as the gloss adjustment layer, a 1 st gloss adjustment layer 5 located below which becomes a base layer, and a 2 nd gloss adjustment layer 6 provided on a part of the 1 st gloss adjustment layer 5 for improving design properties are provided.

Between the base material 2 and the 1 st gloss adjustment layer 5, other known layers such as a ground solid ink layer 3, a pattern ink layer 4, and a transparent resin layer (not shown) may be disposed.

< gloss control layer >

The 1 st gloss adjustment layer 5 is provided on the bottom solid ink layer 3 and the pattern ink layer 4, and is a layer for adjusting the gloss state of the surface of the decorative material 1. The 1 st gloss adjustment layer 5 is formed at a position over the entire surface (upper surface in fig. 1) on the surface side of the base solid ink layer 3 and the pattern ink layer 4, and covers the entire surface on the surface side of the base material 2. The 2 nd gloss adjustment layer 6 is provided on the 1 st gloss adjustment layer 5, has a gloss different from that of the 1 st gloss adjustment layer 5, and is a layer for adjusting the gloss state of the surface of the decorating material 1. The formation position of the 2 nd gloss adjustment layer 6 is a part of the surface of the 1 st gloss adjustment layer 5. Then, the difference in gloss between the 1 st and 2 nd gloss adjustment layers 5 and 6 can express the uneven shape and improve the design.

The thickness of the 1 st and 2 nd gloss adjustment layers 5 and 6 is preferably 1 μm to 15 μm. The 1 st and 2 nd gloss control layers 5 and 6 are layers that become the outermost surfaces of the decorative material 1, and therefore need to have surface properties such as abrasion resistance, scratch resistance, solvent resistance, and stain resistance, which are required for the decorative material 1. Among them, the abrasion resistance and scratch resistance are influenced by the thickness, and the larger the thickness is, the more advantageous. Therefore, the thickness of the 1 st and 2 nd gloss adjustment layers 5 and 6 is more preferably 2 μm or more and 12 μm or less. If the thickness is less than 1 μm, the abrasion resistance and scratch resistance are significantly deteriorated, and thus the use of the decorative material 1 is limited. When the thickness is more than 15 μm, the flexibility of the 1 st and 2 nd gloss adjustment layers 5 and 6 themselves is deteriorated, and thus the workability as the finishing material 1 is deteriorated.

The 1 st and 2 nd gloss control layers 5 and 6 include at least a resin material and a gloss control agent and a releasing agent added to the resin material. Note that the gloss adjuster may be added only to the 1 st gloss adjusting layer 5 having relatively low gloss.

[ resin component ]

The resin material constituting the 1 st and 2 nd gloss adjustment layers 5 and 6 preferably has transparency enough to allow visual recognition of the lower layer.

The main material of the transparent resin used for the 1 st gloss adjustment layer 5 is preferably a mixture of a 2 liquid ammonia-based urethane-based thermosetting resin composed of various polyols and isocyanates, and an ionizing radiation curing resin having an acryloyl group or a methacryloyl group. In this case, the thermosetting resin is preferably contained by 3 parts by mass or more and 100 parts by mass or less, more preferably 10 parts by mass or more and 50 parts by mass or less, with respect to 100 parts by mass of the ionizing radiation curing resin. In the case of this configuration, the ionizing radiation curing resin constituting the resin component can be cured by irradiating the ionizing radiation after the decorative material 1 is prepared, thereby improving the scratch resistance of the 1 st gloss-adjusting layer 5. Further, by setting the urethane-based thermosetting resin to 10 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the ionizing radiation curing resin, it is possible to remarkably achieve both elimination of the trouble at the time of laminating the 2 nd gloss adjustment layer 6 and the scratch resistance of the 1 st gloss adjustment layer 5.

Here, when the proportion of the thermosetting resin is less than 3 parts by mass, when the 2 nd gloss adjustment layer 6 is laminated, troubles such as dissolution or scratching of the 1 st gloss adjustment layer 5 are likely to occur. On the other hand, when the proportion of the thermosetting resin exceeds 100 parts by mass, the degree of crosslinking of the resin composition decreases, and therefore the scratch resistance of the 1 st gloss adjustment layer 5 significantly decreases.

As described above, according to the decorative material 1 of the present embodiment, it is possible to exhibit high abrasion resistance while suppressing defects at the time of lamination.

Here, in the present specification, the main material is a resin material having a content of 90 parts by mass or more, preferably 97 parts by mass or more, with respect to 100 parts by mass of the total resin components constituting the target layer.

The main material of the resin component constituting the 2 nd gloss adjustment layer 6 is preferably a mixture of a urethane-based thermosetting resin having a polyol and an isocyanate, and an ionizing radiation curing resin having an acryloyl group or a methacryloyl group. In this case, the urethane-based thermosetting resin is preferably contained by 25 parts by mass or less with respect to 100 parts by mass of the ionizing radiation curing resin.

When the addition ratio of the urethane-based thermosetting resin exceeds 25 parts by mass, the crosslinking degree of the resin composition is lowered and the scratch resistance of the 2 nd gloss control layer 6 is remarkably lowered because the ratio of the urethane-based thermosetting resin is too large. When the addition ratio of the urethane-based thermosetting resin is less than 3 parts by mass, the properties required for the decorative material 1 requiring processability (prevention of cracking) may not be satisfied although there is no practical problem in scratch resistance. Further, since the urethane-based thermosetting resin of the 2 nd gloss adjustment layer 6 is set to 25 parts by mass or less, the ionizing radiation curing resin constituting the resin component can be sufficiently cured by irradiating the decorative material 1 with ionizing radiation after the preparation thereof, and the scratch resistance of the 2 nd gloss adjustment layer 6 can be improved.

In addition, the main material of the resin component constituting the 2 nd gloss adjustment layer 6 may be an ionizing radiation curing resin having an acryloyl group or a methacryloyl group. In this case, the resin component constituting the 2 nd gloss adjustment layer 6 is preferably only an ionizing radiation curing resin having an acryloyl group or a methacryloyl group.

Here, as the ionizing radiation curing resin having an acryloyl group or a methacryloyl group, for example, various known materials such as various monomers and commercially available oligomers can be used, but it is preferable to use, for example, a polyfunctional monomer such as pentaerythritol triacrylate (PET3A), pentaerythritol tetraacrylate (PET4A), trimethylolpropane triacrylate (TMPTA), dipentaerythritol hexaacrylate (DPHA), a polyfunctional oligomer such as "violet UV-1700B" manufactured by japan synthetic chemistry, or a mixture thereof.

Examples of the isocyanate in the urethane thermosetting resin composed of a polyol and an isocyanate include a curing agent such as an adduct of a derivative such as Toluene Diisocyanate (TDI), Xylene Diisocyanate (XDI), hexamethylene diisocyanate (HMDI), diphenylmethane diisocyanate (MDI), Lysine Diisocyanate (LDI), isophorone diisocyanate (IPDI), methylhexane diisocyanate (HTDI), bis (isocyanatomethyl) cyclohexane (HXDI), and trimethylhexamethylene diisocyanate (TMDI), a biuret or isocyanurate. Examples of the polyol include acrylic polyol, polycarbonate polyol, and polyester polyol.

Further, as the ionizing radiation curing resin having an acryloyl group or a methacryloyl group, which constitutes the 1 st and 2 nd gloss adjusting layers 5 and 6, it is preferable to use a polyfunctional (meth) acrylate monomer or oligomer having a number average molecular weight of 300 to 5000 and a functional group number or an average functional group number of 4 to 15. By setting the amount to this range, the degree of crosslinking of the resin component in the gloss control layer can be sufficiently increased, and high scratch resistance can be exhibited. Further, it is more preferable to use a polyfunctional (meth) acrylate monomer having a number average molecular weight of 300 to 1500 and a functional group number or an average functional group number of 4 to 8. By setting the amount to the above range, the viscosity of the ionizing radiation curing resin itself can be reduced, and therefore, even when an ink for forming a gloss adjusting layer is prepared, the solid content concentration at the viscosity can be increased, and the stability of the ink itself and the coating state can be improved. Examples of the polyfunctional (meth) acrylate monomer include: pentaerythritol tetra (meth) acrylate (PET4A) and its modified product, ditrimethylolpropane tetra (meth) acrylate and its modified product, dipentaerythritol penta (meth) acrylate (DPPA) and its modified product, dipentaerythritol hexa (meth) acrylate (DPHA) and its modified product.

The method for measuring the number average molecular weight of the ionizing radiation curable resin is not particularly limited, but Gel Permeation Chromatography (GPC) is preferably used. Although the measuring apparatus is not particularly limited, the packing material of the GPC column is preferably polystyrene gel, and Tetrahydrofuran (THF) is preferably used as an eluent. The standard substance for GPC may be a commercially available standard polystyrene polymer. Since the polyfunctional (meth) acrylate monomer is composed of a monomer, the number average molecular weight can be calculated from the structural formula if the structure is known.

[ gloss adjuster ]

In the present embodiment, fine particles of an inorganic material having a hydrophobic surface (hydrophobic inorganic material) are used as the gloss adjuster added to at least the 1 st gloss adjustment layer 5.

As the hydrophobic inorganic material, for example, a known inorganic material having been subjected to surface treatment or surface modification (that is, hydrophobization of the surface with a certain organic compound) can be used. Examples of the gloss adjuster that can constitute such a hydrophobic inorganic material include fine particles made of an inorganic material such as silica, glass, alumina, calcium carbonate, or barium sulfate. The surface of the inorganic material subjected to the surface treatment or surface modification has hydrophobicity because hydroxyl groups present on the surface are almost eliminated or covered during the production of the inorganic material. Therefore, adsorption of hydrophilic contaminants and permeation into voids present at the interface between the transparent resin and the matting agent can be suppressed, and excellent stain resistance can be exhibited.

The hydrophobic inorganic material is preferably surface-treated or surface-modified with an organic compound. As an index of whether or not sufficient surface treatment or surface modification is performed, it is preferable to use an inorganic material used as a gloss adjuster, for example, an inorganic material satisfying "1.2 < (the value MB of the amount of mass reduction in the evaluation method B/the value MA of the amount of mass reduction in the evaluation method A) < 10.0" in the following 2 evaluation methods A and B. In the case of obtaining the above ratio, the quality of the inorganic materials (gloss control agents) evaluated in the 2 evaluation methods a and B was set to be the same quality.

Evaluation method A (Heat loss evaluation)

The gloss adjuster was heated to 110 ℃ and its mass loss was measured. First, since moisture adsorbed on the surface of the gloss adjuster is desorbed, a reduction in the mass of the portion occurs. On the other hand, in the case of surface treatment, since the component is not desorbed and volatilized at 110 ℃, if the gloss adjuster raw materials are the same, the difference in value depending on whether surface treatment is performed is the same value. However, since the amount of moisture adsorption depends on the method of producing the gloss adjuster, the value differs depending on the gloss adjuster.

In a specific measurement method, for example, according to JIS K5101,23, it is left for a sufficient time (for example, 2 hours) at 110 ℃ and then the mass reduction thereof is measured.

Evaluation method B (evaluation of ignition loss)

The temperature was heated to 950 ℃ and the mass loss was measured. The organic matter treated (adhered) on the surface of the gloss adjuster is released from the gloss adjuster by heating to 950 ℃. Therefore, if the temperature is maintained at 950 ℃, the reduction in the quality of the surface-treated gloss adjuster becomes greater than the reduction in the quality of the gloss adjuster not subjected to the surface treatment. The difference represents the surface treatment amount.

In the specific measurement method, the same conditions as in evaluation method A except for the atmospheric temperature were used, and the sample was left at 950 ℃ for a sufficient time (for example, 2 hours) and then the mass decrease was measured.

Then, if the inorganic material satisfies 1.2 < (MB/MA) < 10.0, it is considered that surface treatment or surface modification is performed which can exert the effect of the present embodiment. In the case where (MB/MA) is greater than 1.2, it can be presumed that: the surface of the inorganic material used as the gloss adjuster becomes hydrophobic due to disappearance or coverage of hydroxyl groups. When (MB/MA) is 10.0 or more, the organic compound used for surface treatment or surface modification may be excessive, and when it is excessive, the excessive organic compound bleeds out to deteriorate the scratch resistance or adversely affect the long-term release property when the organic compound is mixed with a transparent resin to prepare an ink or when a film is formed.

Here, when a gloss adjuster is added to the 2 nd gloss adjustment layer 6, the gloss adjuster is also preferably a hydrophobic inorganic material, but a commercially available known gloss adjuster may be used. For example, fine particles made of an inorganic material such as silica, glass, alumina, calcium carbonate, or barium sulfate, which are the same as the gloss adjuster added to the 1 st gloss adjustment layer 5, may be used. Alternatively, fine particles made of an organic material such as acrylic may be used. However, when high transparency is required, it is desirable to use fine particles of silica, glass, acrylic or the like having high transparency. In particular, among fine particles such as silica and glass, a gloss adjuster having a low bulk density, which is obtained by aggregating fine particles 1 time, not solid spherical particles, is high in matting effect with respect to the amount added. Therefore, by using such a gloss adjuster, the amount of the gloss adjuster to be added can be reduced.

The particle size of the gloss adjuster can be selected to any value, but is preferably 2 μm or more and 15 μm or less. More preferably 4 μm to 12 μm. The gloss adjuster having a particle size of less than 2 μm has a low matting effect, and thus a feeling of unevenness due to a difference in gloss cannot be sufficiently obtained. Further, the gloss adjuster having a particle size of more than 15 μm causes white turbidity of the layer to which the gloss adjuster is added among the 1 st and 2 nd gloss adjustment layers 5 and 6, or a visual graininess of the gloss adjuster becomes large due to large scattering of light, and the uneven feeling due to the gloss difference may be adversely impaired.

[ anti-blocking agent ]

Since the decorative material 1 of the present embodiment is required to have excellent stain resistance and stable release property for a long period of time, it is important to add a silicone-based release agent having a reactive end to the 1 st gloss adjustment layer 5. The silicone-based antiblocking agent also serves as a slip agent.

In particular, silicone-based releasing agents having a hydroxyl group or an amino group or both as reactive terminals are preferred. In this case, the structure of the silicone skeleton is not particularly limited in kind, and the reactive end may be appropriately selected in view of necessary stain resistance, compatibility when mixed with a resin and a solvent to form a coating agent, and the like. Since a urethane-based thermosetting resin is used as the resin constituting the 1 st gloss-adjusting layer 5, by introducing a hydroxyl group or an amino group into the resin skeleton during the urethane curing reaction, it is possible to exhibit stain resistance and release property which are stable for a long period of time.

The amount of the above-mentioned silicone-based releasing agent having a hydroxyl group or an amino group is preferably 1 to 6 parts by mass as an effective component of the silicone-based releasing agent, relative to 100 parts by mass of the total solid content constituting the 1 st gloss adjustment layer 5. In the case of less than 1 part by mass, it is difficult to express desired stain resistance and releasing property, and in the case of more than 6 parts by mass, a part of the silicone-based releasing agent is not introduced into the resin backbone, and it may not be possible to stably express stain resistance and releasing property for a long period of time.

The releasing agent added to the 2 nd gloss adjustment layer 6 is also preferably a silicone-based releasing agent having a reactive end. Importantly, the silicone-based detackifier has either acryloyl or methacryloyl groups or both as reactive ends. The kind of the silicone skeleton is not particularly limited, as in the case of the above-described 1 st gloss adjustment layer 5. The amount of the silicone-based releasing agent having an acryloyl group or a methacryloyl group or both of them is preferably 0.5 to 5 parts by mass as an effective component of the silicone-based releasing agent, based on 100 parts by mass of the total solid content constituting the 2 nd gloss adjusting layer 6. In the case of less than 0.5 parts by mass, it is difficult to express desired stain resistance and releasing property, and in the case of more than 5 parts by mass, a part of the silicone-based releasing agent is not introduced into the resin skeleton, and it may not be possible to stably express stain resistance and releasing property for a long period of time.

The amount of the gloss adjuster added is preferably 5 parts by mass or more and 40 parts by mass or less with respect to 100 parts by mass of the resin composition. More preferably 10 parts by mass or more and 30 parts by mass or less. When the amount is less than 5 parts by mass, the matting effect is insufficient, the gloss difference from the gloss adjusting layer having a relatively high gloss is small, and the feeling of unevenness may be insufficient. In addition, in the case of more than 40 parts by mass, the resin composition becomes relatively insufficient with respect to the gloss adjuster, and thus, the peeling of the gloss adjuster and the reduction of the scratch resistance due to the peeling may be caused, which may greatly impair the durability required for the finishing material 1.

An arbitrary gloss adjuster may be added to the gloss adjusting layer having a relatively high gloss. These requirements are appropriately adjusted according to the final feeling of irregularity or design. The gloss control agent and the resin composition used for the 1 st and 2 nd gloss control layers 5 and 6 may be the same or different. These can be freely selected depending on the feeling of unevenness and various desired properties.

[ other additives ]

In order to impart various functions to the 1 st and 2 nd gloss adjustment layers 5 and 6, functional additives such as an antibacterial agent and a fungicide may be added. Further, an ultraviolet absorber and a light stabilizer may be added as necessary. Examples of the ultraviolet absorber include benzotriazole, benzoate, benzophenone, triazine, and cyanoacrylate. Further, as the light stabilizer, for example, a hindered amine type can be used.

< substrate >

The base material 2 is not particularly limited as long as it is used as a base paper of the upholstery material 1. For example, there can be used paper such as tissue paper, resin-mixed paper, titanium paper, resin-impregnated paper, flame-retardant paper, inorganic paper, woven or nonwoven fabric made of natural fibers or synthetic fibers, polyolefin resin such as homo-or random polypropylene resin or polyethylene resin, copolyester resin, amorphous crystalline polyester resin, polyethylene naphthalate resin, polybutylene resin, acrylic resin, polyamide resin, polycarbonate resin, polyvinyl chloride resin, conventionally known materials include synthetic resin-based substrates such as polyvinylidene chloride resins and fluororesins, wood-based substrates such as wood veneers, plywood, laminates, particle boards and medium density fiberboard, inorganic substrates such as gypsum boards, cement boards, calcium silicate boards and ceramic boards, metal-based substrates such as iron, copper, aluminum and stainless steel, and composite materials and laminates thereof. The shape of the substrate 2 may be, for example, a film, a sheet, a plate, a shaped body, or the like.

< Pattern ink layer >

A pattern ink layer 4 for applying a pattern to the decorative material 1 may be provided between the base material 2 and the 1 st gloss adjustment layer 5. As the pattern, for example, a wood grain pattern, a stone grain pattern, a sand grain pattern, a tile pattern, a brick pattern, a cloth grain pattern, a leather pattern, a geometric figure, or the like can be used. In the example of fig. 1, pattern ink layer 4 is formed in a portion directly below 2 nd gloss adjustment layer 6. In other words, the 2 nd gloss adjustment layer 6 is formed only at a portion overlapping the pattern ink layer 4. In addition, the pattern of the pattern ink layer 4 is synchronized with the gloss of the 2 nd gloss control layer 6. This makes it possible to add the design of the 2 nd gloss adjustment layer 6 to the design of the pattern ink layer 4. Therefore, the finishing material 1 having a design expression close to the high-grade feeling of the natural wood or the natural stone can be formed.

Although this embodiment shows an example in which 2 nd gloss adjustment layer 6 is formed only in a portion overlapping pattern ink layer 4 (that is, only in a portion directly above pattern ink layer 4), other configurations may be employed. For example, in a plan view (when viewed from the front surface side), the 2 nd gloss adjustment layer 6 may be formed in a portion overlapping the pattern ink layer 4, and the 2 nd gloss adjustment layer 6 may be formed in a portion other than the portion immediately above the pattern ink layer 4.

< solid ink layer of primer layer >

Further, a primer solid ink layer 3 may be provided between the base material 2 and the pattern ink layer 4 depending on the degree of the desired design. The bottom solid ink layer 3 is provided so as to cover the entire surface of the substrate 2 on the 1 st gloss control layer 5 side. The ground ink layer 3 may be a multilayer having 2 or more layers, as required for concealing properties and the like. In addition, in order to express a desired design, pattern ink layer 4 may be formed by laminating a necessary number of individual sheets. As described above, although the pattern ink layer 4 and the ground ink layer 3 are combined in various ways according to a desired design (i.e., a design to be expressed), there is no particular limitation.

The constituent materials of base solid ink layer 3 and pattern ink layer 4 are not particularly limited. For example, a printing ink or a coating agent in which a substrate and a colorant such as a dye or a pigment are dissolved and dispersed in a solvent can be used. Examples of the matrix include various synthetic resins such as oily nitrocellulose resin, 2-amino urethane resin, acrylic resin, styrene resin, polyester resin, urethane resin, polyvinyl resin, alkyd resin, epoxy resin, melamine resin, fluorine resin, silicone resin, and rubber resin, and mixtures and copolymers thereof. As the colorant, for example, an inorganic pigment such as carbon black, titanium white, zinc white, red iron oxide, chrome yellow, prussian blue, or cadmium red, an organic pigment such as azo pigment, lake pigment, anthraquinone pigment, phthalocyanine pigment, isoindolinone pigment, or dioxazine pigment, or a mixture thereof can be used. Examples of the solvent include toluene, xylene, ethyl acetate, butyl acetate, methanol, ethanol, isopropanol, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, water, and a mixture thereof.

In order to impart various functions to base solid ink layer 3 and pattern ink layer 4, functional additives such as an extender pigment, a plasticizer, a dispersant, a surfactant, an adhesion imparting agent, an adhesion auxiliary agent, a drying agent, a curing accelerator, and a curing retarder may be added.

The base solid ink layer 3, the pattern ink layer 4, and the 1 st and 2 nd gloss control layers 5 and 6 can be formed by various printing methods such as a gravure printing method, an offset printing method, a screen printing method, an electrostatic printing method, and an inkjet printing method, for example. The base solid ink layer 3 and the 1 st gloss adjustment layer 5 may be formed by various coating methods such as a roll coating method, a knife coating method, a micro-gravure coating method, and a die coating method, for example, in order to cover the entire surface of the front surface side surface of the base material 2. These printing method and coating method may be selected individually according to the layer to be formed, or may be selected and processed together in the same manner.

When the thicknesses of the 1 st and 2 nd gloss control layers 5 and 6 are adjusted, the coating amounts may be adjusted in the printing method and the coating method. In various printing methods and coating methods, samples in which the gloss control layer was formed on the substrate 2 and samples in which the gloss control layer was not formed on the substrate 2 were prepared, and the coating amount was calculated from the difference in mass between the samples.

< transparent resin layer >

In the case where abrasion resistance is particularly required, a transparent resin layer (not shown) may be provided between the pattern ink layer 4 and the 1 st gloss control layer 5. As the transparent resin layer, for example, a resin composition mainly composed of an olefin resin is preferably used. The olefin-based resin may be, for example, a resin obtained by reacting an alpha-olefin (e.g., propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-eicosene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-hexene, 4, 4-dimethyl-1-pentene, 4-ethyl-1-hexene, 3-ethyl-1-hexene, 9-methyl-1-decene, 11-methyl-1-dodecene, 12-ethyl-1-tetradecene, etc.) or 2 or more species, or a copolymer obtained by copolymerizing ethylene or an α -olefin with a monomer other than ethylene, such as an ethylene-vinyl acetate copolymer, an ethylene-vinyl alcohol copolymer, an ethylene-methyl methacrylate copolymer, an ethylene-ethyl methacrylate copolymer, an ethylene-butyl methacrylate copolymer, an ethylene-methyl acrylate copolymer, an ethylene-ethyl acrylate copolymer, and an ethylene-butyl acrylate copolymer. In particular, when further improvement in surface strength is desired, polypropylene having high crystallinity is preferably used.

Further, additives such as a heat stabilizer, an ultraviolet absorber, a light stabilizer, an anti-blocking agent, a catalyst scavenger, and a colorant may be added to the transparent resin layer. These additives may be suitably selected from known additives and used. The transparent resin layer can be formed by various lamination methods such as a hot press method, an extrusion lamination method, and a dry lamination method.

(action and others)

(1) The decorative material 1 of the present embodiment includes a 1 st gloss adjustment layer 5 and a 2 nd gloss adjustment layer 6 provided on a part of the 1 st gloss adjustment layer 5. As a result, the design is excellent.

In the decorative material 1 of the present embodiment, since the pattern of the pattern ink layer 4 and the gloss of the 2 nd gloss adjustment layer 6 are synchronized, the design of the 2 nd gloss adjustment layer 6 can be added to the design of the pattern ink layer 4, and the decorative material 1 having a design expression close to the high-grade feeling of natural wood or natural stone can be formed.

(2) In the decorative material 1 of the present embodiment, the 1 st gloss control layer 5 on the bottom layer side contains a gloss control agent made of a hydrophobic inorganic material and a silicone-based releasing agent having a reactive end.

In this case, the reactive end of the silicone-based releasing agent having a reactive end preferably has at least one of a hydroxyl group and an amino group.

According to this configuration, by using the hydrophobic gloss adjuster and the silicone-based releasing agent, adsorption of hydrophilic contaminants and permeation into voids present at the interface between the transparent resin and the matting agent can be suppressed, and excellent stain resistance can be exhibited. Further, by using an inorganic material such as silica as a gloss adjuster, excellent transparency can be exhibited, and the visibility of the lower layer can be improved.

Thereby, the decorative material 1 having excellent visual recognition to the lower layer, excellent stain resistance and stable releasing property for a long period of time can be provided.

(3) In addition, the decorative material 1 of the present embodiment uses a gloss adjuster made of an inorganic material having a high matting effect. Therefore, the gloss of the added gloss adjustment layer can be significantly reduced. Therefore, the difference between the gloss of the 1 st gloss adjustment layer 5 and the gloss of the 2 nd gloss adjustment layer 6 can be increased, and the resulting uneven feeling can be increased. Thereby, an excellent design expression with a greater depth can be achieved.

(4) In the decorative material 1 of the present embodiment, the resin component constituting the 1 st gloss adjustment layer 5 is a mixture of a 2-ammonia urethane-based thermosetting resin composed of various polyols and isocyanates and an ionizing radiation curing resin having an acryloyl group or a methacryloyl group, and the mixing ratio of the thermosetting resin is 3 parts by mass or more and 100 parts by mass or less with respect to 100 parts by mass of the ionizing radiation curing resin.

According to this configuration, the 1 st gloss adjustment layer 5 is a dual curing system of thermal curing and ionizing radiation curing, and thus the decorative material 1 having excellent abrasion resistance without causing troubles in laminating the 2 nd gloss adjustment layer 6 can be provided.

(modification example)

(1) As shown in fig. 1, in the present embodiment, the 2 nd gloss adjustment layer 6 is formed at a portion overlapping the pattern ink layer 4, and the pattern of the pattern ink layer 4 and the gloss of the 2 nd gloss adjustment layer 6 are synchronized, but another configuration may be adopted.

For example, as shown in fig. 2, 2 nd gloss adjustment layer 6 may be formed at a portion other than just above pattern ink layer 4, with the pattern of pattern ink layer 4 synchronized with the gloss of 1 st gloss adjustment layer 5. Thus, the exposed gloss of the 1 st gloss control layer 5 can be imparted to the design pattern of the pattern ink layer 4, and the design property of the 1 st gloss control layer 5 can be added to the design property of the pattern ink layer 4. Therefore, the finishing material 1 having a design expression close to the high-grade feeling of the natural wood or the natural stone can be formed.

(2) Although the resin component constituting the 2 nd gloss adjustment layer 6 is exemplified as a mixture of a urethane-based thermosetting resin having a polyol and an isocyanate, and an ionizing radiation curing resin having an acryloyl group or a methacryloyl group, other configurations may be adopted.

For example, the resin component constituting the 2 nd gloss adjustment layer 6 may be only an ionizing radiation curing resin having an acryloyl group or a methacryloyl group. This can improve the scratch resistance of the 2 nd gloss adjustment layer 6.