阅读说明：本技术 装饰材料及装饰材料的制造方法 (Decorative material and method for producing decorative material ) 是由 臼井宽咏 助川佳夫 田中秀夫 于 2020-03-17 设计创作，主要内容包括：提供一种装饰材料,其能够赋予优异的立体感,并且基于观察角度的阴影的变化大,具有高度的设计性。所述装饰材料在第一主面侧配置有具有槽状平行凹凸图案的独立的多个封闭区域,至少一部分封闭区域是槽状平行凹凸图案的凹部的深度在封闭区域内变动而成的,在各个封闭区域内的上述槽状平行凹凸图案的凹部的深度方向的至少一部分填充有着色剂。(Provided is a decorative material which can impart an excellent three-dimensional effect, has a large change in shade depending on the angle of observation, and has high design properties. The decorative material has a plurality of independent closed regions having groove-like parallel uneven patterns arranged on the first main surface side, at least a part of the closed regions are formed by varying the depth of the recessed portions of the groove-like parallel uneven patterns within the closed regions, and at least a part of the recessed portions of the groove-like parallel uneven patterns within each closed region in the depth direction is filled with a coloring agent.)

1. A decorative material wherein a plurality of independent closed regions having a groove-like parallel uneven pattern are arranged on the first main surface side of the decorative material, at least a part of the closed regions are formed by varying the depth of the recessed portions of the groove-like parallel uneven pattern within the closed regions, and at least a part of the recessed portions of the groove-like parallel uneven pattern within each closed region in the depth direction thereof is filled with a coloring agent.

2. The decorating material according to claim 1, wherein a ratio of the closed region in which the depth of the recessed portion of the groove-like parallel concavo-convex pattern varies within the closed region to the entire closed region is 80% or more based on the number of the closed regions.

3. The decorating material according to claim 1 or 2, wherein at least a part of adjacent closed regions satisfies one or more selected from the following (a) to (d),

(a) the width of the recessed part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A is defined as X_AAnd defining the width of the concave part of the groove-shaped parallel concave-convex pattern in any closed area B adjacent to the closed area A as X_BWhen, X_A≠X_B，

(b) Y represents the width of the convex part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A_AAnd Y represents the width of the convex portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen is, the X_AThe Y mentioned_AThe X_BAnd said Y_BIs Y_A/X_A≠Y_B/X_B，

(c) Z represents the average depth of the recessed portions of the groove-like parallel uneven pattern in any closed region A_AAnd Z is the average of the depths of the concave parts of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen Z is_AZ_B，

(d) D is the extending direction of the groove-like parallel concave-convex pattern in the arbitrary closed region A_AAnd D is defined as the extending direction of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen is in contact with D_AAnd said D_BNot parallel.

4. The trim material of claim 3, wherein at least a portion of adjacent enclosed areas satisfy (d).

5. The trim material of claim 4, wherein D is_AAnd said D_BThe angle is 10 to 90 degrees.

6. A decorative material according to any one of claims 1 to 5, wherein the extending direction of the groove-like parallel concavo-convex pattern in each closed region is arranged at random in the first main surface.

7. A decorative material according to any one of claims 1 to 6, wherein at least a part of adjacent closed regions satisfies the following (e),

(e) w represents the filling amount per unit area of the colorant filled in the recessed portions of the groove-like parallel uneven pattern in the arbitrary closed region A_AAnd defining W as the filling amount per unit area of the colorant filled in the recessed portion of the groove-like parallel uneven pattern in an arbitrary closed region B adjacent to the closed region A_BWhen W is_A≠W_B。

8. The decorating material according to any one of claims 1 to 7, wherein when a width of a concave portion of the groove-like parallel concavo-convex pattern is defined as X, a width of a convex portion of the groove-like parallel concavo-convex pattern is defined as Y, and a depth of a concave portion of the groove-like parallel concavo-convex pattern is defined as Z, the X is 20 μm to 250 μm, the Y is 20 μm to 250 μm, and the Z is 5 μm to 120 μm.

9. A decorative material according to any one of claims 1 to 8, wherein the average area of the closed region is 300mm²～2000mm²。

10. A method for producing a decorative material, comprising the following steps (1) to (2),

(1) a step of obtaining a decorative material in which a single layer of a base material selected from a plastic film or a composite of a plastic film and paper, or a laminate including the base material is shaped by an embossing plate so that a plurality of independent closed regions having groove-like parallel uneven patterns are arranged on the first main surface side, at least a part of the closed regions being formed by varying the depth of the recessed portions of the groove-like parallel uneven patterns within the closed regions,

(2) and (3) applying a filling ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in the step (1), and then scraping the filling ink.

Technical Field

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

Background

Decorative materials are widely used as interior materials and exterior materials for decorating furniture, door and window sashes, and the like. As such a decorative material, a decorative material having a pattern is widely used in order to improve design.

The decorative material may be provided with various patterns, for example, a mosaic-like pattern such as a stone pattern or a tile pattern. As a decorative material to which a mosaic-like pattern such as a stone pattern is imparted, decorative materials of patent documents 1 to 2 can be cited.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2001-353784

Patent document 2: japanese patent laid-open publication No. 2001-191697

Disclosure of Invention

Problems to be solved by the invention

Patent document 1 discloses a method for manufacturing a decorative sheet, in which a base material formed by printing patterns of different colors on surfaces defined by grooves and a transparent covering material formed by printing patterns of different colors are thermally bonded via an adhesive. The method for producing a decorative material of patent document 1 has a problem in that a pattern having a high-grade feeling is obtained by superimposing colors, and a beautiful printed surface which does not fade is obtained by covering the printed surface with a transparent covering material.

However, the decorative material of patent document 1 has a problem that the three-dimensional effect of the stone pattern is lacking. Further, the decorative material of patent document 1 has a problem that the yield is liable to be lowered because 2 sheets (the base material and the transparent covering material) need to be aligned in the process of manufacturing the decorative material.

Patent document 2 discloses a decorative material having a pseudo-three-dimensional effect, which is formed by superimposing a pseudo-three-dimensional stone pattern in which a plane is divided into polygons each having an arbitrary shape and size and a part of each polygon is colored in a dark color, and which is formed by a printing process alone, instead of forming a concave-convex shape by an embossing process or the like.

However, the decorative material of patent document 2 does not have a high-level three-dimensional appearance, and also has no high degree of design because the change in the in-plane shade is small even if the viewing direction is changed.

The invention aims to provide a decorative material which can provide excellent stereoscopic impression, has large change of shadow caused by an observation angle and has high designability, and a manufacturing method of the decorative material.

Means for solving the problems

In order to solve the above problems, the present inventors provide the following [1] to [10 ].

[1] A decorative material wherein a plurality of independent closed regions having groove-like parallel uneven patterns are arranged on the first main surface side of the decorative material, at least a part of the closed regions are formed by varying the depth of the recessed portions of the groove-like parallel uneven patterns within the closed regions, and at least a part of the recessed portions of the groove-like parallel uneven patterns within each closed region in the depth direction thereof is filled with a coloring agent.

[2] The decorating material according to item [1], wherein a ratio of a closed region in which a depth of the recessed portion of the groove-like parallel concavo-convex pattern varies within the closed region to the entire closed region is 80% or more based on the number of the closed regions.

[3] The decorating material according to [1] or [2], wherein at least a part of the adjacent closed regions satisfies one or more selected from the following items (a) to (d).

(a) The width of the recessed part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A is defined as X_AAnd X is the width of the concave part of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen, X_A≠X_B。

(b) Groove-like parallel concave-convex pattern in arbitrary closed region AThe width of the convex portion of (2) is defined as Y_AAnd Y represents the width of the convex portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen, X is above_AY is as defined above_AX is mentioned above_BAnd the above Y_BIs Y_A/X_A≠Y_B/X_B。

(c) Z represents the average depth of the recessed portions of the groove-like parallel uneven pattern in any closed region A_AAnd Z is the average of the depths of the recessed portions of the groove-like parallel uneven pattern in an arbitrary closed region B adjacent to the closed region A_BWhen Z is_A≠Z_B。

(d) D is the extending direction of the groove-like parallel concave-convex pattern in the arbitrary closed region A_AAnd D is defined as the extending direction of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen D is above_AAnd the above D_BNot parallel.

[4] The finishing material according to [3], wherein at least a part of the adjacent closed regions satisfies the above (d).

[5]According to [4]]The decorative material, wherein D is_AAnd the above D_BThe angle formed is 10 to 90 degrees.

[6] The decorating material according to any one of [1] to [5], wherein the extending direction of the groove-like parallel uneven pattern in each closed region is randomly arranged in the first main surface.

[7] The decorating material according to any one of [1] to [6], wherein at least a part of adjacent closed regions satisfies the following (e).

(e) W represents the filling amount per unit area of the colorant filled in the recessed portions of the groove-like parallel uneven pattern in the arbitrary closed region A_AW represents the filling amount per unit area of the colorant filled in the recessed portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen W is_A≠W_B。

[8] The decorating material according to any one of [1] to [7], wherein when a width of a concave portion of the groove-like parallel uneven pattern is defined as X, a width of a convex portion of the groove-like parallel uneven pattern is defined as Y, and a depth of a concave portion of the groove-like parallel uneven pattern is defined as Z, the X is 20 to 250 μm, the Y is 20 to 250 μm, and the Z is 5 to 120 μm.

[9]According to [1]～[8]The decorating material as described in any one of the above, wherein the average area of the closed region is 300 to 2000mm²。

[10] A method for producing a decorative material, comprising the following steps (1) to (2).

(1) And a step of obtaining a decorative material in which a single layer of a base material selected from a plastic film or a composite of a plastic film and paper, or a laminate including the base material is shaped by an embossing plate so that a plurality of independent closed regions having groove-like parallel uneven patterns are arranged on the first main surface side, and at least a part of the closed regions are formed by varying the depth of the recessed portions of the groove-like parallel uneven patterns within the closed regions.

(2) And (3) applying a filling ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in the above (1), and then scraping the filling ink.

ADVANTAGEOUS EFFECTS OF INVENTION

The decorative material of the present invention can impart an excellent three-dimensional appearance and is extremely excellent in design because the change in shade due to the viewing angle is large. In addition, the method for manufacturing a decorative material of the present invention can easily manufacture a decorative material having the above-described effects.

Drawings

Fig. 1 is a plan view showing a first main surface side of one embodiment of the decorative material of the present invention.

Fig. 2 is an enlarged plan view of a circular portion surrounded by a one-dot chain line in fig. 1.

Fig. 3 is an image in which the level of the decorative material of example 1 is measured from the first main surface side, and the measured level is expressed in shading.

Fig. 4 is a cross-sectional view of enclosed areas 10d and 10j of fig. 1.

Fig. 5 is a view showing a flow of an embodiment of a process of forming the concave-convex shape of the first main surface of the finishing material of the present invention.

Fig. 6 is an example of an image used for creating density distribution data in step S11 in fig. 5.

Fig. 7 is a diagram showing one scenario of a process of making a plate by a laser as an example of the process S16 in fig. 5.

Detailed Description

[ decorative Material ]

The decorative material of the present invention is such that a plurality of independent closed regions having groove-like parallel uneven patterns are arranged on the first main surface side, at least a part of the closed regions are formed by varying the depth of the recessed portions of the groove-like parallel uneven patterns within the closed regions, and at least a part of the recessed portions of the groove-like parallel uneven patterns within each closed region in the depth direction is filled with a coloring agent.

< first major surface of decorative Material >

Fig. 1 is a plan view showing a first main surface side of one embodiment of a finishing material 100 of the present invention. The decorative material 100 of fig. 1 has a plurality of independent closed regions (11 closed regions 10a to 10k in a substantially clockwise direction from the upper left end) on the first main surface side surface. In addition, the finishing material 100 of fig. 1 has groove-like parallel concave-convex patterns in the respective independent closed regions.

Here, the "first main surface" refers to a surface of the decorative material 10 to be an object to be provided with a designed appearance (decorated), and refers to a surface exposed to the outside and viewed when the decorative material 100 is used for an interior material of a building or the like. When the decorative material 100 is a plate-like rectangular parallelepiped (6 surfaces exist), generally, any one of 1 pair of surfaces having the largest area is selected as the first main surface.

Fig. 2 is an enlarged plan view of a circular portion surrounded by a one-dot chain line in fig. 1. As shown in fig. 2, the groove-like parallel uneven pattern in the closed region is composed of a concave portion 21 and a convex portion 22.

In the present specification, the phrase "parallel" in the groove-like parallel uneven pattern means that the recessed portions in each closed region are parallel to each other (in this case, the raised portions in each closed region are also parallel to each other) when the finishing material is viewed in plan. The "parallel" of the groove-like parallel uneven pattern is not limited to being completely parallel, and includes being substantially parallel. By substantially parallel is meant that a tangent is drawn at the edge of a set of adjacent recesses within the enclosed area, and the angle formed by the 2 tangents is within 2.0 degrees, preferably within 0.5 degrees, and more preferably within 0.2 degrees.

FIG. 3 is a plan view showing the measured level of the decorative material of example 1 as measured from the n-side and expressed in shade. In fig. 3, the lower the density means the higher the altitude, and the higher the density means the lower the altitude, and the thin and long high-density portion extending in any direction corresponds to the recess.

In addition, the directions of extension of the groove-like parallel uneven patterns of the closed regions adjacent to each other in fig. 3 are different from each other.

Fig. 4 a relates to a closed region 10d of fig. 1, which is a cross-sectional view taken in a direction perpendicular to the extending direction of the groove-like parallel uneven pattern in the closed region 10d (a direction parallel to the y direction of fig. 1) and in a direction parallel to the z direction of fig. 1. Fig. 4B is a cross-sectional view of the closed region 10j in fig. 1, taken along a direction perpendicular to the extending direction of the groove-like parallel uneven pattern in 10j (a direction parallel to the x direction in fig. 1) and a direction parallel to the z direction in fig. 1.

In the groove-like parallel uneven patterns of fig. 4(a) and 4(B), the depth of the recessed portion 21 varies within the closed region.

Effect of the first principal surface

When the decorative material of the present invention is viewed from the first main surface side, a person feels excellent three-dimensional appearance, and also feels a change in shade due to the viewing direction, and feels an impression of extremely excellent design. The reason why this effect is produced will be described below.

First, in each closed region of the first main surface of the decorative material, light incident on the convex portions of the groove-like parallel uneven pattern is reflected to the vicinity of the regular reflection direction with little attenuation, and therefore a large amount of light reaches the human eyes. On the other hand, although light incident on the concave portions of the groove-like parallel uneven pattern is attenuated by multiple reflections, predetermined reflected light reaches human eyes. Therefore, for each closed area, a human can feel gloss based on reflected light.

In addition, the degree of reflection of light incident on the concave portions of the groove-like parallel uneven pattern in the regular reflection direction differs between when viewed from the extending direction of the groove and when viewed from the direction orthogonal to the extending direction of the groove in each closed region. This is because attenuation due to multiple reflections of light incident on the concave portion is reduced when viewed from the extending direction of the groove. In this way, the intensity of the reflected light of each closed region differs depending on the direction of observation due to the presence of the recessed portion (groove), and therefore, a person can feel a change in gloss (a change in shade) of each closed region depending on the direction of observation, and can feel an impression of extremely excellent design. Further, by devising the shape of the closed region and/or the pattern of the decorative layer, it is possible to feel an impression of excellent natural feeling by the change in the gloss (change in the shade) of the closed region caused by the above-described observation direction.

The above is the basic function of the groove-like parallel concavo-convex pattern.

In at least a part of the closed region of the decorative material of the present invention, the depth of the recessed portion of the groove-like parallel uneven pattern varies within the closed region. If the depth of the recess is different, the degree of attenuation by multiple reflection is also different (the deeper the recess is, the more easily the attenuation is). Therefore, a closed region in which the depth of the recess varies within the closed region can generate a difference in gloss within the closed region. Therefore, the decorative material of the present invention having the closed region in which the depth of the concave portion of the groove-like parallel uneven pattern varies within the closed region can also exhibit a three-dimensional effect due to the difference in gloss.

The decorative material of the present invention is obtained by filling a colorant in at least a part of the recessed portions of the groove-like parallel uneven pattern in the depth direction. Therefore, the gloss difference can be set to a gloss difference having a color tone, and a person can feel a three-dimensional impression having depth.

As can be seen from the cross-sectional view of fig. 4, the filling amount of the colorant 30 per unit area tends to increase when the recessed portion 21 is deep, and the filling amount of the colorant 30 per unit area tends to decrease when the recessed portion 21 is shallow. Therefore, in addition to the gloss difference having the above color tone, a density difference can be added, and the stereoscopic effect can be further emphasized.

The decorative material of the present invention can provide the above-described effects by a printing method without providing a decorative layer. That is, the decorative material of the present invention can exhibit a design of a three-dimensional pattern by using a specific closed region and a colorant filled in a recessed portion of the closed region without a printing process, even without a decorative layer, from the viewpoint of a layer structure or from the viewpoint of a manufacturing process. Further, the decorative material of the present invention can provide a three-dimensional impression to the recessed portion without a decorative layer by a printing process, and therefore, the design appearance and the tactile sensation of the uneven shape can be synchronized.

The direction in which the depth of the recessed portions of the groove-like parallel uneven pattern varies may vary in the extending direction of the pattern, may vary in a direction orthogonal to the extending direction of the pattern, or may vary in combination of the two. The variation in depth of the recessed portions in the extending direction of the pattern means that the depth varies in the extending direction of the groove-like recessed portions. The fact that the depth of the recessed portions varies in the direction perpendicular to the extending direction of the pattern means that the depth of adjacent groove-like recessed portions varies.

In one embodiment of the finishing material, the ratio of the closed region in which the depth of the concave portion of the groove-like parallel uneven pattern varies within the closed region to the entire closed region is preferably 80% or more, more preferably 90% or more, further preferably 95% or more, and still further preferably 99% or more, based on the number of closed regions. By setting this ratio to 80% or more, the design can be further improved.

The depth of the concave part of the groove-shaped parallel concave-convex pattern is changed in a closed areaAnd the maximum depth of the recess of the closed region is defined as Z_maxDefining the minimum depth of the recess as Z_minWhen Z is_max/Z_minPreferably 2 or more, and more preferably 5 to 10.

In one embodiment of the finishing material, at least a part of the adjacent closed regions preferably satisfies one or more selected from the following items (a) to (d).

(a) The width of the recessed part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A is defined as X_AAnd X is the width of the concave part of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen, X_A≠X_B。

(b) Y represents the width of the convex part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A_AAnd Y represents the width of the convex portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen, X is above_AY is as defined above_AX is mentioned above_BAnd the above Y_BIs Y_A/X_A≠Y_B/X_B。

(c) Z represents the average depth of the recessed portions of the groove-like parallel uneven pattern in any closed region A_AAnd Z is the average of the depths of the recessed portions of the groove-like parallel uneven pattern in an arbitrary closed region B adjacent to the closed region A_BWhen Z is_AZ_B。

(d) D is the extending direction of the groove-like parallel concave-convex pattern in the arbitrary closed region A_AAnd D is defined as the extending direction of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen D is above_AAnd the above D_BNot parallel.

By satisfying at least any one of the above (a) to (d), a difference in gloss can be generated in adjacent closed regions. Therefore, the human can feel an impression of more excellent stereoscopic feeling from the difference in gloss. Further, since the recessed portions of the groove-like parallel uneven pattern are colored, the difference in gloss can be made to be a difference in gloss having a color tone, and a person can feel the impression of having a three-dimensional impression of depth. Further, by satisfying at least any one of the above (a) to (d), the feel can be changed in the surface of the decorative material.

On the first main surface side, a plurality of combinations exist in adjacent closed regions. That is, "at least a part of adjacent closed regions satisfy one or more selected from (a) to (d)" means that there may be one combination satisfying at least any one of (a) to (d) for all combinations of adjacent closed regions. A preferable ratio of a combination satisfying at least any one of (a) to (d) with respect to all combinations of adjacent closed regions will be described later.

The actions of the above (a) to (d) will be described further below.

With respect to (a)

(a) Stipulating: the width of the recessed part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A is defined as X_AAnd X is the width of the concave part of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen, X_A≠X_B。

As described above, the light incident on the concave portions of the groove-like parallel uneven pattern attenuates the reflected light due to multiple reflections. The attenuation amount of the reflected light by the multiple reflection varies depending on the width of the concave portion (the attenuation ratio is large when the width is narrow, and the attenuation ratio is small when the width is wide). Therefore, by satisfying (a), a difference in gloss can be generated in the adjacent regions.

With respect to (b)

(b) Stipulating: y represents the width of the convex part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A_AAnd Y represents the width of the convex portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen, X is above_AY is as defined above_AX is mentioned above_BAnd the above Y_BIs Y_A/X_A≠Y_B/X_B。

Satisfying (b) means that the ratio of the concave portion and the convex portion in the area of the closed region is different in adjacent closed regions. As described above, the gloss of each closed region is the sum of the reflected light of the convex portion and the reflected light of the concave portion, and particularly the ratio of the reflected light of the convex portion is large. Therefore, by satisfying (b), a difference in gloss can be generated in the adjacent closed region. Further, since the recessed portion is filled with the colorant at least in a part in the depth direction, satisfying (b) makes it possible to make the color density different in adjacent closed regions based on the colorant, and thus the three-dimensional effect and the mosaic effect can be further emphasized.

With respect to (c)

(c) Stipulating: z represents the average depth of the recessed portions of the groove-like parallel uneven pattern in any closed region A_AAnd Z is the average of the depths of the recessed portions of the groove-like parallel uneven pattern in an arbitrary closed region B adjacent to the closed region A_BWhen Z is_A≠Z_B。

As described above, the light incident on the concave portions of the groove-like parallel uneven pattern attenuates the reflected light due to multiple reflections. The attenuation amount of the reflected light by the multiple reflection varies depending on the depth of the concave portion (the attenuation ratio is large when the concave portion is deep, and the attenuation ratio is small when the concave portion is shallow). Therefore, by satisfying (c), a difference in gloss can be generated in the adjacent region.

The filling amount of the colorant per unit area tends to be increased when the recessed portion is deep, and the filling amount of the colorant per unit area tends to be decreased when the recessed portion is shallow. Therefore, by satisfying (c), the following (e) can be easily satisfied.

With respect to (d)

(d) Stipulating: d is the extending direction of the groove-like parallel concave-convex pattern in the arbitrary closed region A_AAnd D is defined as the extending direction of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen D is above_AAnd the above D_BNot parallel.

As described above, the degree to which light incident on the recessed portions of the groove-like parallel uneven pattern is reflected in the specular reflection direction differs between when viewed from the extending direction of the grooves and when viewed from the direction orthogonal to the extending direction of the grooves. Therefore, by satisfying (d), a difference in gloss can be generated in the adjacent region.

In addition, when the recessed portions are filled with the colorant in the steps (1) to (2) described later, the filling ease of the colorant into the recessed portions differs depending on the relationship between the scraping direction of the filling ink containing the colorant and the extending direction of the groove-like parallel uneven pattern. Specifically, the closer the scraping direction of the filling ink and the extending direction of the groove-like parallel uneven pattern are parallel, the easier the colorant is filled in the recessed portion. Therefore, by satisfying (d), the following (e) can be easily satisfied.

As described above, by causing at least a part of adjacent closed regions to satisfy at least any one of the conditions (a) to (d), it is possible to cause a difference in gloss between the closed regions satisfying the condition.

On the first main surface side, a plurality of combinations exist in adjacent closed regions. The proportion of combinations satisfying at least any one of (a) to (d) is preferably 50% or more, more preferably 70% or more, more preferably 80% or more, more preferably 90% or more, more preferably 95% or more, and more preferably 99% or more, by number, relative to the total combinations of adjacent closed regions.

In addition, a combination of a plurality of adjacent closed regions existing in a plane may satisfy different conditions in each combination. For example, any one set of adjacent closed regions may satisfy the above (a), and the other adjacent closed regions may satisfy the above (d).

Among (a) to (d), (b) and (d) tend to impart a difference in gloss to adjacent closed regions, and (d) tends to impart a difference in gloss more readily than (b).

Therefore, at least a part of the adjacent closed regions preferably satisfies at least any one of (b) and (d), more preferably satisfies (d), and further preferably satisfies (b) and (d). In addition, it is still further preferable that at least a part of the adjacent closed regions satisfy (b) and (d), and at least either one of (a) and (c).

The finishing material of the present invention preferably further satisfies the following (e) at least a part of the adjacent closed regions.

(e) W represents the filling amount per unit area of the colorant filled in the recessed portions of the groove-like parallel uneven pattern in the arbitrary closed region A_AW represents the filling amount per unit area of the colorant filled in the recessed portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen W is_A≠W_B。

Fig. 4 a relates to a closed region 10d of fig. 1, which is a cross-sectional view taken in a direction perpendicular to the extending direction of the groove-like parallel uneven pattern in the closed region 10d (a direction parallel to the y direction of fig. 1) and in a direction parallel to the z direction of fig. 1. Fig. 4B is a cross-sectional view of the closed region 10j in fig. 1, taken along a direction perpendicular to the extending direction of the groove-like parallel uneven pattern in 10j (a direction parallel to the x direction in fig. 1) and a direction parallel to the z direction in fig. 1.

In both fig. 4(a) and 4(B), the colorant 30 is filled in a part of the recess 21 in the depth direction. In fig. 4(B), the filling amount of the colorant 30 per unit area is large, and satisfies the relationship (e). As a method for setting the filling amount per unit area of the colorant 30 to the magnitude relationship of fig. 4(a) and 4(B), the following method can be mentioned: a method of making the scraping direction of the filling ink closer to parallel with the extending direction of the groove-like parallel uneven pattern in the closed region 10j than the extending direction of the groove-like parallel uneven pattern in the closed region 10 d.

By satisfying the above (e), the color density based on the colorant can be made different in adjacent closed regions, and the mosaic feeling and the three-dimensional feeling can be further emphasized. As described above, as a method for satisfying the above (e), there is a method of applying a filling ink containing a colorant on the first main surface of the decorative material satisfying the above (c) and/or (d) and scraping off the filling ink adhered thereto.

On the first main surface side, a plurality of combinations are present in adjacent closed regions. That is, "at least a part of adjacent closed regions satisfies (e)" means that all combinations of adjacent closed regions are present, and one combination satisfying (e) may be present. The preferable proportion of the combination satisfying (e) is preferably 50% or more, more preferably 70% or more, more preferably 80% or more, more preferably 90% or more, more preferably 95% or more, and more preferably 99% or more by number with respect to the total combination of adjacent closed regions.

Calculation of Width, depth, and extension Direction

The groove-like parallel uneven pattern in each closed region can be calculated, for example, based on the measured level of the decorative material from the first main surface side, an image (for example, fig. 3) displayed by dividing the measured level into 256 gradations, and the measured value of the level, based on the width X of the recessed portion, the width Y of the protruding portion, the depth Z of the recessed portion, and the extending direction D of the pattern. When there is a slight variation in the width X of the concave portion, the width Y of the convex portion, the depth Z of the concave portion, and the extending direction D of the pattern in each closed region, the average value of these values may be set as the width X of the concave portion, the width Y of the convex portion, the depth Z of the concave portion, and the extending direction D of the pattern in each closed region. The convex portions in each closed region are convex portions located between the concave portions.

In fig. 3, the lighter the concentration means the higher the altitude, the denser the concentration means the lower the altitude, the thin and long high concentration portion extending in any direction corresponds to the concave portion, and the convex portion between the concave portions corresponds to the convex portion.

Since fig. 3 is a case of being formed using an embossing plate engraved by laser, the edge of the concave portion has a fine step corresponding to the shape cut by the 1-shot laser. The width X of the concave portion, the width Y of the convex portion, and the extending direction D of the pattern may be calculated by smoothing the fine height difference.

Preferred embodiment of Width and depth

In the decorative material of the present invention, when the width of the recessed portion of the groove-like parallel uneven pattern is defined as X, the width of the raised portion of the groove-like parallel uneven pattern is defined as Y, and the depth of the recessed portion of the groove-like parallel uneven pattern is defined as Z, it is preferable that X is 20 to 250 μm, Y is 20 to 250 μm, and Z is 5 to 120 μm.

By setting the width X of the concave portion to 20 μm or more, it is possible to make it easy for a person to observe the reflected light from the concave portion, and further, it is possible to easily feel a change in the gloss of each closed region due to a difference in the observation direction. Further, by setting the width X of the concave portion to 20 μm or more, the tactile sensation can be easily provided. By setting the width X of the recessed portion to 250 μm or less, it is possible to suppress the difficulty in feeling a difference in gloss between when viewed from the extending direction of the groove and when viewed from the direction orthogonal to the extending direction of the groove.

The width X of the recess is more preferably 40 to 230 μm, still more preferably 50 to 200 μm, and still more preferably 60 to 190 μm.

In the above (a), X is defined_A≠X_BBut X_AAnd X_BThe difference of (c) is preferably in a predetermined range. Specifically, X_AAnd X_BThe absolute value of the difference is preferably 50 to 150 μm, and more preferably 80 to 120 μm. By setting the absolute value to 50 μm or more, the difference in gloss in the adjacent closed region can be easily perceived. Further, by setting the absolute value to 150 μm or less, it is possible to suppress discomfort or a foreign substance sensation caused by an excessively large difference in gloss between adjacent closed regions.

By setting the width Y of the convex portion to 20 μm or more, it is possible to make it easy for a person to observe the regular reflection light from the convex portion, and it is possible to easily secure a predetermined gloss. Further, by setting the width Y of the convex portion to 250 μm or less, the reflection of the convex portion can be suppressed from becoming excessively strong, and anisotropy of gloss based on reflection from the concave portion can be easily recognized.

The width Y of the projection is more preferably 40 to 230 μm, still more preferably 50 to 200 μm, and still more preferably 60 to 190 μm.

Further, Y/X is preferably 0.5 to 4.0, more preferably 0.7 to 3.0.

In the above (b), Y is defined_A/X_A≠Y_B/X_BBut Y is_A/X_AAnd Y_B/X_BThe difference of (c) is preferably in a predetermined range. Specifically, Y_A/X_AAnd Y_B/X_BThe absolute value of the difference of (a) is preferably 0.5 to 3.0, more preferably 0.8 to 2.5. By setting the absolute value to 0.5 or more, the difference in gloss in the adjacent closed area can be easily perceived. Further, by setting the absolute value to 0.5 or more, the difference in color density between the colorants in the adjacent closed regions can be easily increased, and the mosaic feeling and the three-dimensional feeling can be further emphasized. Further, by setting the absolute value to 3.0 or less, it is possible to suppress discomfort or a foreign object sensation caused by an excessively large difference in gloss between adjacent closed regions.

By setting the depth Z of the concave portion to 5 μm or more, a change in gloss of each closed region due to a difference in the direction of observation can be easily perceived. Further, by setting the depth Z of the concave portion to 5 μm or more, the tactile sensation can be easily provided. By setting the depth Z of the concave portion to 120 μm or less, excessive attenuation of reflected light from the concave portion can be suppressed regardless of the direction of observation, and the difference in gloss of each closed region due to the difference in the direction of observation can be easily maintained.

The depth Z of the recess is more preferably 7 to 100 μm, still more preferably 8 to 90 μm, and still more preferably 10 to 80 μm.

In the above (c), Z is defined_A≠Z_BBut Z is_AAnd Z_BThe difference of (c) is preferably in a predetermined range. Specifically, Z_AAnd Z_BThe absolute value of the difference is preferably 5 to 50 μm, and more preferably 10 to 40 μm. By setting the absolute value to 5 μm or more, the difference in gloss in the adjacent closed region can be easily perceived. Further, by setting the absolute value to 50 μm or less, it is possible to suppress discomfort or a foreign substance sensation caused by an excessively large difference in gloss between adjacent closed regions.

Preferred embodiment of the extending Direction

In the decorative material of the present invention, it is preferable that the groove-like parallel uneven patterns in each closed region have an extending direction randomly arranged in the first main surface. With this configuration, when the decorative material is viewed from the first main surface side, the impression as if it is a natural object can be easily given.

The term "random extending direction" includes a case where the extending direction selected from a specific angle group is random. When the extending direction selected from the specific angle group is random, the number of 0 to 180 degrees is preferably 6 or more, more preferably 8 or more, and still more preferably 10 or more at regular intervals. For example, there is a method of dividing 0 to 180 degrees into 6 at 30-degree intervals, and randomly selecting the extending direction of the groove-like parallel uneven pattern in each closed region from 6 angle groups of 30 degrees, 60 degrees, 90 degrees, 120 degrees, 150 degrees, and 180 degrees.

In the above (D), D is defined_AAnd D_BNon-parallel, D_AAnd D_BThe angle is preferably 10 to 90 degrees, more preferably 12 to 85 degrees, still more preferably 13 to 80 degrees, and still more preferably 14 to 78 degrees.

By mixing D_AAnd D_BThe angle formed is 10 degrees or more, and the difference in gloss between adjacent regions can be easily increased.

The extending direction of the groove-like parallel uneven pattern in the closed region may include curves such as arcs and sinusoids, but is preferably a straight line as shown in fig. 1 and the like. By making the extending direction of the groove-like parallel uneven pattern straight, the effect when the above (d) is satisfied can be more remarkable.

Shape and area of closed region

The shape of the independent closed region in a plan view is not particularly limited, and examples thereof include polygons such as triangles and quadrangles, circles, ellipses, and indefinite shapes, and may be individual shapes thereof or combinations thereof. When the decorative material is given a natural feeling, it is preferable to randomly combine various shapes.

By the shape of the closed region, natural objects such as crystals of stone and crystals of metal, geometric patterns, and the like can be expressed.

The average area of the independent closed areas is preferably 300-2000 mm²More preferably 400 to 1500mm²More preferably 500 to 1000mm²。

The ratio of the area occupied by the independent closed regions having the groove-like parallel uneven pattern (total area of the independent closed regions) to the total area of the first main surface is preferably 70% or more, more preferably 80% or more, further preferably 90% or more, and still further preferably 95% or more.

Coloring agent

The decorative material of the present invention is required to fill at least a part of the recessed portions of the groove-like parallel uneven pattern in each closed region in the depth direction with a coloring agent. As described above, by including the colorant in the recessed portions of the groove-like parallel uneven pattern, the difference in gloss in the surface of the decorative material can be made to have a hue difference in gloss, and a person can feel the impression of having a three-dimensional impression of depth.

The color of the colorant is not particularly limited, and it is preferable to use a dark-color colorant in that the difference in gloss in each closed region can be further increased. The dark color means a low lightness and low color perceived as dark color such as dark gray, dark green, navy blue, black, dark purple, rouge (Japanese inscription: え h), and brown.

Examples of a method for filling the colorant in at least a part of the recess in the depth direction include: a method of applying a filling ink containing a colorant and a binder resin to the first main surface side of the decorative material and scraping the ink with a scraping blade such as a doctor blade. In this case, the amount of the colorant filled in the concave portion can be adjusted by adjusting the material of the cutter, the angle of contact with the cutter, the viscosity of the ink, and the like.

Examples of the colorant include carbon black (ink), inorganic pigments such as iron black, titanium white, antimony white, chrome yellow, titanium yellow, iron oxide red, cadmium red, ultramarine blue, and cobalt blue, organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue, and dyes.

Examples of the binder resin of the filling ink include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, rubber resins, and the like.

< second major surface >

The shape of the surface (second main surface) of the decorative material opposite to the first main surface is not particularly limited, and may be smooth or may be provided with irregularities.

< laminated Structure of decorative Material >

The decorative material of the present invention may be a laminate of the following (1) to (8). Here, "/" denotes an interface of the layers, and a surface of the layer positioned on the left side denotes the first main surface of the decorative material.

(1) Monolayer of substrate

(2) Decorative layer/substrate

(3) Surface protection layer/decoration layer/substrate

(4) Transparent resin layer/decorative layer/substrate

(5) Surface protection layer/transparent resin layer/decorative layer/substrate

(6) Surface protection layer/primer layer/transparent resin layer/decorative layer/substrate

(7) Surface protection layer/substrate/decoration layer

(8) Surface protection layer/primer layer/substrate/decorative layer

Substrate

The trim material preferably comprises a substrate. The material of the substrate is not particularly limited, and a plastic film or a composite of a plastic film and paper is preferable in view of easiness of forming the first main surface by embossing.

Specific examples of the resin constituting the plastic film include polyolefin resins such as polyethylene and polypropylene, vinyl resins such as vinyl chloride resins, vinylidene chloride resins, polyvinyl alcohol and ethylene-vinyl alcohol copolymers, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, acrylic resins such as polymethyl methacrylate, polymethyl acrylate and polyethyl methacrylate, polystyrene, acrylonitrile-butadiene-styrene copolymers (ABS resins), cellulose triacetate and polycarbonate. Among them, polyolefin-based resins, vinyl chloride resins, polyester resins, or acrylic resins are preferable from the viewpoints of various physical properties such as weather resistance and water resistance, printability, suitability for molding, price, and the like.

The substrate may be a transparent substrate or a colored substrate. The substrate may be a laminated substrate obtained by laminating a plurality of substrates. In the case where the decorative material is laminated in the above-described (7) and (8), a transparent substrate is used as the substrate in order to observe the decorative layer through the substrate.

The thickness of the base material is not particularly limited, but is preferably 20 to 200. mu.m, more preferably 40 to 160 μm, and still more preferably 40 to 100. mu.m.

In order to improve adhesion to a layer provided on a substrate, one surface or both surfaces of the substrate may be subjected to an easy adhesion treatment such as a physical treatment or a chemical surface treatment.

Decoration layer

From the viewpoint of improving design, the decorative sheet preferably has a decorative layer at any portion of the decorative sheet. As described above, the decorative sheet can exhibit a pattern even without the decorative layer.

From the viewpoint of improving the weather resistance of the decorative layer, the portion where the decorative layer is formed is preferably on the side closer to the substrate. In addition, if the substrate is transparent, the decorative layer may be positioned further toward the inner layer side (the side opposite to the first main surface) than the substrate as in the above-described laminated structures (7) and (8).

The decorative layer may be, for example, a colored layer (so-called solid colored layer) covering the entire surface, a design layer formed by printing various patterns using ink or a printer, or a combination thereof.

As described above, the decorative sheet can express a pattern even without the decorative layer, and therefore the decorative layer is preferably only a solid colored layer for adjusting the color tone.

The decorative layer can be formed by applying ink for the decorative layer containing a coloring agent such as a pigment and a dye and a binder resin, and drying the ink. The ink may be mixed with additives such as extender pigments, antioxidants, plasticizers, catalysts, curing agents, ultraviolet absorbers, light stabilizers, and the like, as required.

The coloring agent and the binder resin of the decorative layer are not particularly limited, and for example, the same ones as exemplified in the filling ink can be used.

The thickness of the decorative layer may be appropriately selected depending on the desired pattern, and is preferably 0.1 μm or more and 20 μm or less, more preferably 0.5 μm or more and 10 μm or less, and further preferably 1.0 μm or more and 5.0 μm or less, from the viewpoint of shielding the ground color of the adherend and improving the design.

Surface protective layer

In order to increase the scratch resistance, the decorative material may have a surface protective layer.

The surface protective layer preferably contains a cured product of a curable resin composition from the viewpoint of improving the abrasion resistance of the decorative sheet.

Examples of the curable resin composition include a thermosetting resin composition containing a thermosetting resin, an ionizing radiation ray-curable resin composition containing an ionizing radiation ray-curable resin, and a mixture thereof. Among them, ionizing radiation ray-curable resin compositions are preferred from the viewpoint of improving the surface characteristics such as the crosslink density and scratch resistance of the surface protective layer. Among the ionizing radiation ray-curable resin compositions, an electron beam-curable resin composition is more preferable from the viewpoint of enabling coating without a solvent and facilitating handling.

The thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition cured by heating. Examples of the thermosetting resin include acrylic resins, urethane resins, phenol resins, urea melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In the thermosetting resin composition, a curing agent is added to these curable resins as needed.

The ionizing radiation ray-curable resin composition is a composition containing a compound having an ionizing radiation ray-curable functional group (hereinafter, also referred to as "ionizing radiation ray-curable compound"). The ionizing radiation ray-curable functional group is a group that is crosslinked and cured by irradiation with an ionizing radiation ray, and preferable examples thereof include functional groups having an olefinic double bond such as a (meth) acryloyl group, a vinyl group, and an allyl group. In the present specification, a (meth) acryloyl group means an acryloyl group or a methacryloyl group. In the present specification, the term (meth) acrylate means acrylate or methacrylate.

The ionizing radiation beam is a beam having an energy quantum capable of polymerizing or crosslinking molecules in an electromagnetic wave or a charged particle beam, and generally, Ultraviolet (UV) rays or Electron Beams (EB) are used, and electromagnetic waves such as X-rays and γ -rays, and charged particle beams such as α -rays and ion beams are also included.

Specifically, the ionizing radiation ray-curable compound can be suitably selected and used from polymerizable monomers and polymerizable oligomers which have conventionally been used as ionizing radiation ray-curable resins.

As the polymerizable monomer, a (meth) acrylate monomer having a radical polymerizable unsaturated group in the molecule is preferable, and among them, a polyfunctional (meth) acrylate monomer is preferable. Here, "(meth) acrylate" means "acrylate or methacrylate".

Examples of the polyfunctional (meth) acrylate monomer include (meth) acrylate monomers having 2 or more ionizing radiation ray-curable functional groups in the molecule and having at least a (meth) acryloyl group as the functional group.

Examples of the polymerizable oligomer include (meth) acrylate oligomers having 2 or more ionizing radiation ray-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, and the like can be given.

Further, as the polymerizable oligomer, there are a polybutadiene (meth) acrylate oligomer having a (meth) acrylate group in a side chain of the polybutadiene oligomer and having high hydrophobicity, a silicone (meth) acrylate oligomer having a polysiloxane bond in a main chain, an aminoplast resin (meth) acrylate oligomer obtained by modifying an aminoplast resin having a plurality of reactive groups in a small molecule, and an oligomer having a cationically polymerizable functional group in a molecule, such as a novolac epoxy resin, a bisphenol epoxy resin, an aliphatic vinyl ether, and an aromatic vinyl ether.

These polymerizable oligomers may be used alone or in combination of two or more. From the viewpoint of improving the processing characteristics, the scratch resistance, and the weather resistance, 1 or more selected from a urethane (meth) acrylate oligomer, an epoxy (meth) acrylate oligomer, a polyester (meth) acrylate oligomer, a polyether (meth) acrylate oligomer, a polycarbonate (meth) acrylate oligomer, and an acrylic (meth) acrylate oligomer is preferable, 1 or more selected from a urethane (meth) acrylate oligomer and a polycarbonate (meth) acrylate oligomer is more preferable, and a urethane (meth) acrylate oligomer is further preferable.

The monofunctional (meth) acrylate may be used in combination in the ionizing radiation ray-curable resin composition for the purpose of, for example, reducing the viscosity of the ionizing radiation ray-curable resin composition. These monofunctional (meth) acrylates may be used singly or in combination of two or more.

When the ionizing radiation ray-curable compound is an ultraviolet ray-curable compound, the ionizing radiation ray-curable resin composition preferably contains an additive such as a photopolymerization initiator or a photopolymerization accelerator.

Examples of the photopolymerization initiator include 1 or more selected from acetophenone, benzophenone, α -hydroxyalkylphenone, michler's ketone, benzoin dimethyl ether, benzoyl benzoate, α -acyloxime ester, thioxanthone, and the like.

The photopolymerization accelerator is capable of reducing polymerization inhibition by air during curing and accelerating the curing rate, and examples thereof include 1 or more selected from isoamyl p-dimethylaminobenzoate and ethyl p-dimethylaminobenzoate.

The surface protective layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant, if necessary.

The thickness of the surface protective layer is preferably 1.5 μm or more and 30 μm or less, more preferably 2 μm or more and 15 μm or less, and further preferably 3 μm or more and 10 μm or less, from the viewpoint of the balance of processability, scratch resistance and weather resistance.

Transparent resin layer

The decorative sheet may have a transparent resin layer from the viewpoint of improving strength and the like. In the case where the decorative sheet has a surface protective layer, the transparent resin layer is preferably located between the base material and the surface protective layer. In the case where the decorative sheet has a primer layer, the transparent resin layer is preferably located between the substrate and the primer layer. In addition, in the case where the decorative sheet has a decorative layer, the transparent resin layer is preferably located between the decorative layer and the surface protective layer from the viewpoint of protecting the decorative layer.

Examples of the resin constituting the transparent resin layer include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylic resins, vinyl chloride resins, and the like, and among them, polyolefin resins are preferable from the viewpoint of processability. The transparent resin layer may be a mixture of the above-mentioned resins, or a laminate of 1 or 2 or more of the above-mentioned resins.

Examples of the polyolefin resin of the transparent resin layer include polyethylene (low density, medium density, high density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymers, propylene-butene copolymers, ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, ethylene-propylene-butene copolymers, and the like. Among them, polyethylene (low density, medium density, high density), polypropylene, ethylene-propylene copolymer, and propylene-butene copolymer are preferable, and polypropylene is more preferable.

The transparent resin layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant. When the transparent resin layer contains an ultraviolet absorber, the ultraviolet absorber is preferably a triazine compound, and more preferably a hydroxyphenyltriazine compound.

From the viewpoint of a balance among scratch resistance, processability, and weather resistance, the thickness of the transparent resin layer is preferably 20 μm or more and 150 μm or less, more preferably 40 μm or more and 120 μm or less, and further preferably 60 μm or more and 100 μm or less.

Primer layer

In the case where the decorative sheet has a surface protective layer, it is preferable to have a primer layer in contact with the substrate-side surface of the surface protective layer. The primer layer improves the adhesion between the substrate and the surface protective layer (in the case of having a transparent resin layer, the adhesion between the transparent resin layer and the surface protective layer), and makes it possible to easily ensure long-term interlayer adhesion (so-called weather-resistant adhesion) and satisfactory scratch resistance when exposed outdoors.

The primer layer is mainly composed of an adhesive resin, and may contain additives such as an ultraviolet absorber and a light stabilizer, if necessary.

Examples of the binder resin of the primer layer include resins such as urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, polycarbonate-based urethane-acrylic copolymer (urethane-acrylic copolymer derived from a polymer (polycarbonate polyol) having a carbonate bond in the polymer main chain and 2 or more hydroxyl groups at the terminal and side chains), vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, chlorinated acrylic resin, nitrocellulose resin (nitrocellulose), and cellulose acetate resin, and these resins may be used alone or in combination of a plurality of them. The adhesive resin may be obtained by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent to these resins and crosslinking and curing the resulting mixture. Among these, a resin obtained by crosslinking and curing a polyol resin such as an acrylic polyol resin with an isocyanate curing agent is preferable, and a resin obtained by crosslinking and curing an acrylic polyol resin with an isocyanate curing agent is more preferable.

The thickness of the primer layer is preferably 0.5 μm or more and 10 μm or less, more preferably 0.7 μm or more and 8 μm or less, and further preferably 1 μm or more and 6 μm or less.

Other layers

The decorative material of the present invention may have other layers such as an adhesive layer and a back primer layer.

When the decorative sheet has a transparent resin layer, an adhesive layer is preferably formed between the base material and the transparent resin layer in order to improve the adhesion between the two layers.

When a decorative layer is further provided between the substrate and the transparent resin layer, the positional relationship between the adhesive layer and the decorative layer is not particularly limited. Specifically, the decorative layer, the adhesive layer, and the transparent resin layer may be provided in this order from the side close to the substrate, or the adhesive layer, the decorative layer, and the transparent resin layer may be provided in this order from the side close to the substrate.

The adhesive layer may be formed of a general-purpose adhesive such as a urethane adhesive, an acrylic adhesive, an epoxy adhesive, or a rubber adhesive. Among these adhesives, a urethane adhesive is preferable in terms of adhesion.

Examples of the urethane adhesive include adhesives using two-component curable urethane resins containing various polyol compounds such as polyether polyol, polyester polyol, and acrylic polyol, and curing agents such as isocyanate compounds.

The thickness of the adhesive layer is preferably 0.1 μm or more and 30 μm or less, more preferably 1 μm or more and 15 μm or less, and still more preferably 2 μm or more and 10 μm or less.

The back primer layer is a layer formed on the surface of the decorative material opposite to the first main surface for the purpose of improving the adhesion between the decorative material and various adherends.

The material used for forming the back primer layer is not particularly limited, and may be a urethane resin, an acrylic resin, a polyester resin, a vinyl chloride/vinyl acetate copolymer, a chlorinated polypropylene resin, a chlorinated polyethylene resin, or the like, and is appropriately selected depending on the material of the adherend.

The thickness of the back primer layer is preferably 0.5 to 5.0 μm, and more preferably 1 to 3 μm.

The decorative layer, the surface protective layer, the primer layer, the adhesive layer, and the back primer layer can be formed by applying an ink containing a composition for forming each layer by a known method such as a gravure printing method, a bar coating method, a roll coating method, a reverse roll coating method, or a comma coating method, and drying and curing the ink as necessary.

The transparent resin layer may be formed by, for example, heating, melting, and extruding.

< uses of decorative Material >

The decorative material of the present invention can be used in various applications as it is, or in the form of a laminate to be bonded to an adherend, or by subjecting the decorative material or laminate to a predetermined molding process or the like.

Examples of the various applications include interior materials for buildings such as walls, ceilings, floors, etc.; window and door partition building materials such as window frames, doors, handrails and the like; furniture; housings for home electric appliances, OA equipment, and the like; exterior materials such as a door.

Examples of the adherend include wooden boards such as wood veneers, wood plywood, particle boards, MDF (medium density fiberboard), and integrated materials; gypsum boards such as gypsum boards and gypsum slag boards; cement boards such as calcium silicate boards, asbestos rock boards, lightweight foamed concrete boards, hollow extruded cement boards, and the like; fiber cement boards such as pulp cement boards, asbestos cement boards, and wood cement boards; ceramic plates such as pottery, porcelain, earthenware, glass, enamel, and the like; metal plates such as iron plates, galvanized steel plates, polyvinyl chloride sol-coated steel plates, aluminum plates, copper plates, and the like; thermoplastic resin plates such as polyolefin resin plates, acrylic resin plates, ABS resin plates, and polycarbonate plates; thermosetting resin plates such as phenol resin plates, urea resin plates, unsaturated polyester resin plates, polyurethane resin plates, epoxy resin plates, and melamine resin plates; a so-called FRP plate obtained by impregnating and curing a resin such as a phenol resin, a urea resin, an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a melamine resin, or a diallyl phthalate resin into a glass fiber nonwoven fabric, a fabric, paper, or other various fibrous substrates and laminating them, and the like may be used alone or as a composite substrate obtained by laminating 2 or more of them.

< method for Forming first Main surface >

The uneven shape of the first main surface of the decorative material may be formed by, for example, shaping with an embossing plate engraved by laser.

The shaping by the embossing plate engraved by the laser can be performed, for example, in the steps (S11 to S17) of fig. 5. Hereinafter, each step will be explained.

S11: preparation of concentration distribution data

In step S11, a density distribution image that is the basis of the depth data of the groove-like parallel uneven pattern in each closed region on the trim material 100 is acquired as density distribution data. An example of the density distribution image is an image in which only a crystal pattern of a stone grain is expressed. Fig. 6 shows an example of a density distribution image.

The density distribution image acquired in step S11 is preferably a two-dimensional density pattern having no height information. Examples of such a density pattern include a photograph, a picture, and a printed matter. In this case, it is preferable to remove the height information and use only information based on the density in two dimensions in a plan view.

In step S11, a density value D (x, y) is obtained as density distribution data for each two-dimensional coordinate (x, y) of the obtained density distribution image.

The two-dimensional coordinates (x, y) are not particularly limited, and preferably correspond to coordinates on the surface of a plate (in the present embodiment, a metal roll-shaped embossing plate) to be described later. The specific expression of the density value D is not particularly limited, and for example, the density value may be expressed in 256 gradations by equally dividing the interval between 255 parts which are the thickest and 0 parts which are the lightest in the density distribution image.

As described above, a set of data of density values D expressed in 256 gradations is obtained in each coordinate (x, y) and is used as density distribution data.

As described above, the concentration distribution data is preferably digital data. Therefore, when the density distribution image to be the base is not digital data, the digital data is converted into digital data by a method of reading a two-dimensional image such as the original itself or a photograph of the original with a scanner and performing AD conversion. In addition, in the case of designing a pattern using digital data using CAD or the like from the beginning, the digital data can be used.

The method for creating the density distribution data is not particularly limited, and for example, density distribution data of 2540dpi resolution can be created in TIF format with 8-bit density gradation (256 gradation) using graphics design drawing software "photoshop" manufactured by Adobe Systems, inc.

S12: conversion of concentration distribution data into depth data

In the step of converting the density value D (x, y) of the density distribution data of the concave portion (a) obtained in step S11 into the depth F (x, y) for each coordinate (x, y) in the step of converting the density value D (x, y) into the depth data (step S12). The depth data is depth data corresponding to the concave portion of the groove-like parallel concave-convex pattern in the closed region.

Here, the conversion of the density value D (x, y) into the depth F (x, y) is performed based on a predetermined rule. Thereby, the density distribution and the depth distribution are associated with each other, and a unique texture based on the density distribution image can be obtained in the surface pattern of the decorative material.

For example, in step S11, the most dense part in the density distribution image is set to the grayscale 255, and in step S12, the depth is set to 300 μm. On the other hand, in step S11, the lightest portion of the density distribution image is set as the gray scale 0, and in step S12, this is set as the reference (depth 0 μm). Then, in the step S12, the gradations 0 to 255 in the step S11 are allocated 0 to 300 μm in proportion to the depth.

Therefore, according to this example, the lightest portion in the density distribution image is the reference (depth 0 μm), the darker the density, and the depth is 300 μm in the darkest portion.

S13: setting of closed area information other than depth data

In step S13, closed region information other than the depth data is set. The closed region information other than the depth data is information related to a method of dividing the closed region, such as the shape and size of each closed region, and the width of the concave portion of the groove-like parallel uneven pattern, the width of the convex portion, the extending direction of the groove-like parallel uneven pattern, and the like in each closed region.

The width of the recessed portion, the width of the projecting portion, and the extending direction of the groove-like parallel uneven pattern in each closed region may be determined by setting predetermined amounts of options, and randomly selecting the options.

S14: correlation of depth data with recesses of enclosed areas

Step S14 is a step of associating the depth data created in step S12 with the recessed portions of the groove-like parallel uneven pattern in each closed region set in step S13.

In step S14, data having a plurality of independent closed regions and depth information on the concave portions of the groove-like parallel uneven pattern in each closed region can be obtained.

S15: conversion of depth data to height data

In the step of converting the height data into the embossing plate (step S15), the depth F (x, y) of the concave portion of the groove-like parallel uneven pattern in the closed region on the finishing material 100 obtained in step S14 is converted into the height H (x, y) for producing the corresponding embossing plate (hereinafter, also referred to simply as "plate") to obtain the depth data. That is, the height data H (x, y) of the embossing plate for forming the concave-convex pattern having the complementary shape of the recessed portion of the decorative material having the depth F (x, y) on the surface of the plate is prepared.

If the surface of the plate is formed with the unevenness based on the height data H (x, y), the unevenness of the surface of the decorating material formed by the plate is based on the height data of the first main surface.

In the present embodiment, when the depth F (x, y) of the decoration material is converted into the height H (x, y) of the embossing plate, the conversion is performed in an opposite manner in the same scale. That is, if "depth" is represented as negative and "height" is represented as positive, F (x, y) — H (x, y). However, the present invention is not limited to this, and the depth F (x, y) may be converted into the height H (x, y) by multiplying the depth F (x, y) by a predetermined coefficient α according to the need of expression. For example, the conversion may be performed by F (x, y) ═ α H (x, y). Here, α may be either positive or negative.

Thus, a plurality of decorative materials giving different impressions can be produced from the same height data by simply changing α.

S16: preparation edition (making edition)

In the plate-making step (S16), a plate having concavities and convexities on its surface is made using the height data based on the height H (x, y) obtained in step S15. Here, as an example, an embossing plate based on a metal roll is exemplified. More specifically, an embossed plate was produced as follows.

First, a metal roll 50 which is finally an embossing plate 50 as shown in fig. 7 is prepared. The metal roll 50 is formed by plating a copper layer on the surface of a hollow iron cylinder having a rotation drive shaft (draft) 51 at both axial ends, for example. The surface of the metal roller 50 is preferably roughened by polishing with a grindstone or the like, and the reduction in engraving efficiency due to the specular reflection of the engraving laser light is suppressed.

Then, as schematically shown in fig. 7, the surface of the prepared metal roll 50 is engraved using a laser direct engraving machine based on the height data for each coordinate created in the process S15.

The metal roller 50 is driven by a motor via a rotation drive shaft 51, and rotates about the rotation drive shaft 51 as a center axis. At this time, the surface of the metal roller 50 is scanned with the light L emitted from the laser head 52. An example of the laser beam L is a fiber laser having an oscillation wavelength of 1024nm, a spot diameter of 10 μm, and a power of 360W.

When the surface of the metal roll is scanned with the laser light L, the laser light is switched ON-OFF (switching between irradiation and non-irradiation) for each coordinate (x, y) based ON the height of the height H (x, y) created in step S15, and a recessed portion is formed by evaporation of the metal at the irradiation position by 1 laser light irradiation (the recessed portion of the plate corresponds to the raised portion of the decorative material. Under the above exemplified laser conditions, a recess having a depth of 10 μm was formed by 1 laser irradiation.

The scanning of the surface of the metal roller with the laser is repeated, for example, about 10 times. In order to prevent the evaporated metal from remaining as powder or adhering to the surface of the metal roll 50, it is preferable to perform laser irradiation while the engraving liquid T is blown from the engraving liquid ejection port 53 to the laser irradiation region on the surface of the metal roll.

By engraving the surface of the metal roll 50 finely with a laser in this way, a metal roll having a shape that can form the surface shape of the first main surface can be obtained.

After the unevenness is engraved in this way, it is preferable to clean the engraving liquid and then perform electrolytic polishing to remove the metal residue adhering to the surface of the metal roller 20. Then, in order to improve the durability, it is preferable to perform plating treatment by plating hard chromium or the like on the surface of the metal roll 20. The thickness of the plating layer is usually about 10 μm.

Through the above steps S11 to S16, the plate 50 (the decorative material forming die, in the present embodiment, the embossed plate) having a shape complementary to the shape of the irregularities of the first main surface of the decorative material can be obtained.

S17: types of changes (excipients)

In the shaping step (S17), the decorative material before the first main surface is formed is embossed using the plate (embossing plate) produced in steps S11 to S16, thereby producing the decorative material.

The embossing process is not particularly limited as long as it is carried out by an appropriate known method. Temperature and pressure during embossing processing according to the decorative materialThe material of the decorative material can be properly adjusted, if the base material and the transparent resin layer of the decorative material are polyolefin, the temperature is 140-180 ℃ and 10-50 kg/cm²Left and right.

A representative method of the embossing process is as follows.

First, an embossing plate is pressed against the surface of a softened resin substrate, and the surface of the substrate is shaped into an uneven pattern on the surface of the embossing plate. Then, the resin base material is cured by cooling and light irradiation, and the uneven pattern on the resin base material is fixed. Then, the resin having the uneven pattern formed thereon is released from the embossing plate.

[ method for producing decorative Material ]

The method for producing a decorative material of the present invention includes the following steps (1) to (2).

(1) And a step of obtaining a decorative material in which a single layer of a base material selected from a plastic film or a composite of a plastic film and paper, or a laminate including the base material is shaped by an embossing plate so that a plurality of independent closed regions having groove-like parallel uneven patterns are arranged on the first main surface side, and at least a part of the closed regions are formed by varying the depth of the recessed portions of the groove-like parallel uneven patterns within the closed regions.

(2) And (3) applying a filling ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in the above (1), and then scraping the filling ink.

The decorative material obtained through the steps (1) to (2) can provide an excellent three-dimensional appearance, and is extremely excellent in design because the shade is largely changed depending on the viewing angle.

In the method for producing a decorative material of the present invention, the decorative material obtained in the preferred step (1) satisfies the preferred embodiment of the decorative material of the present invention described above. For example, the first main surface of the decorative material obtained in the step (1) preferably satisfies one or more selected from the above-mentioned conditions (a) to (d).

The embossing conditions in the step (1) are not particularly limited, and examples thereof include the conditions described in the step S17.

The step (2) preferably includes the following steps (2-1) to (2-3).

(2-1) a step of causing the finishing material obtained in the step (1) to follow at least a part of the surface of the roll having a circular cross section so that the first principal surface side of the finishing material faces the opposite side to the roll.

(2-2) a step of applying a filling ink containing a colorant and a binder resin to the surface of the first main surface side of the decorative material obtained in the step (1).

(2-3) a step of pressing a cutter against the first main surface side of the decorating material to scrape off the filling ink adhering to the first main surface side.

In the step (2-1), examples of the material of the roller include metal, rubber, and resin, and among them, rubber and resin are preferable, and rubber is more preferable. By making the roller of a material having cushioning properties such as rubber or resin, it is possible to easily suppress the colorant from being excessively filled in the concave portion.

The filling ink in the step (2-2) contains a colorant and a binder resin, and preferably contains a solvent as needed. The ink in the concave portion tends to be more difficult to scrape as the viscosity of the filling ink is higher, and the ink in the concave portion tends to be more easily scraped as the viscosity of the filling ink is lower. Therefore, it is preferable to appropriately adjust the viscosity of the filling ink according to the desired filling amount.

The colorant of the filling ink is preferably a dark-color colorant.

As a mechanism for scraping off the filling ink in the step (2-3), a scraping blade such as a doctor blade is preferably used.

The angle of the knife relative to the first major face of the trim material is preferably substantially perpendicular. Substantially perpendicular means a range of 90 ± 10 degrees, preferably 90 ± 5 degrees, more preferably 90 ± 3 degrees. Note that, the case of inclining to the traveling direction side of the trim material is marked as positive, and the case of inclining to the opposite side of the traveling direction of the trim material is marked as negative.

The material of the cutter includes metal, rubber, resin, and the like, and among them, metal is preferable.

In the step (2-3), the pressure of the cutter against the decorating material can be appropriately adjusted within a range in which streaks and unevenness of ink are not generated.

Examples

The present invention will be described in further detail with reference to examples, but the present invention is not limited to these examples.

1. Evaluation of

1-1. third dimension

The decorative materials obtained in examples and comparative examples were visually evaluated for perception of three-dimensional appearance by observing 20 adults arbitrarily from each direction under the illumination of a fluorescent lamp.

AA: more than 18 people with good answer stereoscopic impression.

A: 15-17 people with good answer stereoscopic impression.

B: the answer is 11-14 people with good stereoscopic impression.

C: people with good answer and stereoscopic impression are below 10 people.

1-2. difference in gloss (shade) based on viewing direction

With respect to the decorative materials obtained in examples and comparative examples, arbitrary 20 adults were allowed to observe from each direction under the illumination of a fluorescent lamp, and differences in gloss (shading) of each closed region based on the observation direction were visually evaluated.

AA: the number of persons having a large difference in answer gloss (shading) is 18 or more.

A: the number of persons having a large difference in answer gloss (shade) is 15 to 17.

B: the number of persons having a large difference in answer gloss (shade) is 11 to 14.

C: the number of persons having a large difference in answer gloss (shading) is 10 or less.

1-3. natural texture

The decorative materials obtained in examples and comparative examples were visually evaluated for natural feeling (natural texture) by observing 20 adults arbitrarily from each direction under the illumination of a fluorescent lamp.

AA: more than 18 people with natural texture are answered.

A: 15-17 people with natural texture are answered.

B: responding to 11-14 persons with natural texture.

C: people with natural texture are answered below 10.

1-4. touch feeling

With respect to the decorative materials obtained in examples and comparative examples, the tactile sensation was evaluated by touching with fingers of arbitrary 20 adults. The evaluation criteria were 3 of "uneven feeling", "change in-plane feeling", and "synchronism of feeling with design", and the quality of feeling was evaluated by integrating the 3 criteria.

AA: people who answer with good touch feeling are more than 18 people.

A: 15-17 persons with good answer feeling.

B: people with good answer feeling are 11-14 people.

C: people who answer with good touch are 10 people or less.

2. Manufacture of embossed plate

Embossed plates A to C having hard chrome-plated surfaces were produced in accordance with the steps S11 to S16 described in the specification. The plates a to C were produced by changing the laser irradiation conditions so that the concave-convex patterns in the respective closed regions after the embossing were as shown in table 1. The entire surface of the plate C is formed of the same groove-like parallel uneven pattern, and has no closed region.

3. Production of decorative material

[ example 1]

On a colored substrate (white polypropylene film having a thickness of 60 μm), a solid printed layer having a thickness of 1 μm made of gray-tone ink was formed by gravure printing.

Next, an adhesive layer (polyester resin, thickness: 5 μm) was formed on the solid printed layer. Next, a transparent resin layer (transparent polypropylene resin sheet, thickness: 80 μm) was laminated on the adhesive layer by extrusion lamination.

Next, the transparent resin layer is heated to be in a softened state, and embossing treatment is performed from the surface on the transparent resin layer side using the embossing plate a manufactured in the above "2", so that a concave-convex shape is formed on the surface on the transparent resin layer side (surface on the first principal surface side). The measured values of the uneven shape by image analysis are shown in table 1.

After the blackish brown filling ink was applied to the surface on the transparent resin layer side (the surface on the first main surface side), the doctor blade was pressed perpendicularly to the first main surface to scrape off the filling ink, thereby obtaining the decorative material of example 1.

[ example 2]

A decorative material of example 2 was obtained in the same manner as in example 1, except that the embossing plate a was changed to the embossing plate B.

Comparative example 1

A decorative material of comparative example 1 was obtained in the same manner as in example 1, except that the embossing plate a was changed to the embossing plate C.

Comparative example 2

A decorative material of comparative example 2 was obtained in the same manner as in example 1, except that the step of applying the filling ink to the surface on the transparent resin layer side (the surface on the first main surface side) was not performed. The decorative material of comparative example 2 corresponds to the decorative material of example 1 in which no coloring agent was filled in the recessed portions.

[ Table 1]

TABLE 1

In table 1, (a) to (e) show the following configurations.

(a) The width of the recessed part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A is defined as X_AAnd X is the width of the concave part of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen, X_A≠X_B。

(b) Y represents the width of the convex part of the groove-like parallel concavo-convex pattern in an arbitrary closed region A_AAnd determining the width of the convex part of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area AIs defined as Y_BWhen, X is above_AY is as defined above_AX is mentioned above_BAnd the above Y_BIs Y_A/X_A≠Y_B/X_B。

(c) Z represents the average depth of the recessed portions of the groove-like parallel uneven pattern in any closed region A_AAnd Z is the average of the depths of the recessed portions of the groove-like parallel uneven pattern in an arbitrary closed region B adjacent to the closed region A_BWhen Z is_A≠Z_B。

(d) D is the extending direction of the groove-like parallel concave-convex pattern in the arbitrary closed region A_AAnd D is defined as the extending direction of the groove-like parallel concave-convex pattern in any closed area B adjacent to the closed area A_BWhen D is above_AAnd the above D_BNot parallel.

(e) W represents the filling amount per unit area of the colorant filled in the recessed portions of the groove-like parallel uneven pattern in the arbitrary closed region A_AW represents the filling amount per unit area of the colorant filled in the recessed portion of the groove-like parallel uneven pattern in any closed region B adjacent to the closed region A_BWhen W is_A≠W_B。

As shown in table 1, it was confirmed that the decorative material of the example can impart an excellent three-dimensional appearance, and also has a large change in shade depending on the viewing angle, and can impart a high degree of design. In addition, it was confirmed that the decorative material of the example is also excellent in touch.

Description of the reference numerals

10a, 10b, 10c, 10d, 10e, 10f, 10g, 10h, 10i, 10j, 10 k: closed area

21: concave part

22: convex part

30: coloring agent

100: decorative material

50: edition (embossing edition, metal roller)

51: rotary drive shaft

52: laser head

53: engraving liquid spray outlet