JP2021055315A - Decorative material - Google Patents

Abstract

To provide a decorative material having a design property with a high texture, which has a sense of high quality as well as a sense of reality for faithfully reproducing a design appearance of a real object, in order to respond to a demand for high-quality goods by consumers in recent years.SOLUTION: There is provided a decorative material having a pattern composed of a recessed part shape and a projecting part shape, in which an edge side of a shape in a plan view of the recessed part shape is composed by repetition of irregular unevenness, and the recessed part shape presents a joint (also referred to as a "joint groove") part.SELECTED DRAWING: Figure 1

Description

The present invention relates to a decorative material.

Scratch resistance to decorative materials used on the surface of building materials such as walls, ceilings, floors, etc., cabinets, desks, dining tables, cupboards, various cabinets, furniture such as various counters, and fittings such as doors. High-pressure melamine resin veneer, low-pressure melamine resin veneer, diallyl phthalate (DAP) resin veneer, polyester veneer, guanamine resin veneer, etc. , A thermosetting resin decorative board such as a phenol resin decorative board is used.

With the increasing consumer preference for luxury products in recent years, it has become desirable for these thermosetting resin decorative boards to have a more realistic and luxurious feel that is closer to the real thing.
In a decorative board having a tiled pattern, it is equivalent to a joint (also referred to as a "joint groove", but hereinafter, the term "joint" is used) in order to give the decorative board a feeling of unevenness similar to that of a real tile. A method has been proposed in which the brightness of the peripheral portion of the tile corresponding portion close to the portion is lower than the brightness of the other portion of the tile corresponding portion (Patent Document 1).
On the other hand, in order to improve the texture and the high-class feeling, a method of providing an uneven shape on the surface of the decorative board has also been proposed (Patent Documents 2 and 3).

Japanese Unexamined Patent Publication No. 2001-173201 Japanese Unexamined Patent Publication No. 7-164519 JP-A-2002-240227

As described in Patent Document 1, for a flat decorative board, by changing the brightness, etc., a three-dimensional effect is visually expressed to produce a realistic and luxurious feeling that faithfully reproduces the actual design appearance. Has a limit.
Further, in order to provide a joint-like uneven shape to improve the texture and improve the sense of quality, it is required to make the concave shape particularly delicate. However, in the decorative board described in Patent Document 2, after the uneven shape is formed on the surface layer (unsaturated polyester resin layer) of the decorative board by the shaping sheet, before the polyester resin of the surface layer is cured. Due to the flow, sagging, and leveling, the uneven shape was slumped, and it was not possible to give a sufficient texture. Further, even if the press upper die is pressed against the decorative plate to form a joint as in Patent Document 3, the uneven shape may be lost and a sufficient texture may not be imparted. Such a phenomenon becomes more remarkable as an attempt is made to impart a more delicate uneven shape. Further, in the methods such as Patent Documents 2 and 3, the edge of the concave shape becomes a regular and smooth shape, and the reproducibility of the texture may be low.
Therefore, there are increasing cases where the techniques described in Patent Documents 1 to 3 cannot meet the demands of consumers for high-end products in recent years, and makeup having a high-quality feel as well as a realistic feel and a high-quality design. Materials are required.

The present invention has been made under such circumstances, and an object of the present invention is to provide a cosmetic material having a high-quality feel as well as a realistic feeling and having a high-quality design.

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

[1] A decorative material having a pattern composed of a concave shape and a convex shape, the edge of the concave shape in a plan view is formed by repeating irregular irregularities, and the concave shape exhibits a joint portion.
[2] The decorative material according to the above [1], wherein the convex portion shape is a region defined by the concave portion shape of the joint portion.
[3] The concave joints are vertical joints provided at substantially equal intervals and horizontal joints provided at substantially equal intervals, and the convex portions partitioned by the joints are block-shaped [1] or [1] or [ 2] The decorative material described in.
[4] It has a base material, a first pattern region, a second pattern region, and a first cured product layer formed of a curable resin, and the first pattern region is a part of one surface side of the base material. The second pattern region is formed on the rest of one surface side of the base material, the first cured product layer is present immediately above the first pattern region, and the second pattern region is formed. The recessed shape is formed in the first cured product layer because it does not exist immediately above, and the bottom surface of the recessed shape is formed by the surface immediately above the second pattern region [1] to [3]. The decorative material according to any one of.
[5] The decorative material according to the above [4], which has a second cured product layer formed of a curable resin immediately above the second pattern region.
[6] The decorative material according to the above [4] or [5], wherein the curable resin forming the first cured product layer is a thermosetting resin.
[7] The decorative material according to any one of [4] to [6], which further has a decorative layer between the base material and the first cured product layer.
[8] The decorative material according to the above [7], wherein the second pattern region and the pattern of the decorative layer are synchronized.

According to the present invention, it is possible to provide a decorative material having a high-quality design as well as a realistic feeling.

It is a schematic perspective view which shows the appearance of an example of the decorative material of this invention. It is a schematic view of the enlarged part A of FIG. It is a schematic diagram which shows the layer structure in the cross-sectional view of an example of the decorative material of this invention. It is a schematic diagram which shows the layer structure in the cross-sectional view of an example of the decorative material of this invention. It is a schematic diagram which shows the layer structure in the cross-sectional view of an example of the decorative material of this invention. It is a schematic perspective view which shows the appearance of an example of the decorative material of this invention. It is a schematic perspective view which shows the appearance of an example of the decorative material of this invention. The microscope magnified image of the cross section of the decorative material of Example 1 is shown. A microscope magnified image of a cross section of the decorative material of Comparative Example 1 is shown.

[Cosmetic material]
The decorative material 1 of the present invention has a concave shape on the surface, and the edge of the concave shape in a plan view is formed by repeating irregular irregularities. In the present invention, "planar view" means that the decorative material of the present invention is visually recognized in the plane direction from the side having the concave shape (surface side). A typical example of "planar view" will be described with reference to FIGS. 1 and 3, and the line-of-sight direction is the surface of the decorative material 1 having the concave shape 2 (hereinafter, may be simply referred to as "surface"). Although it is a case of visual inspection in line with the normal direction N, the "planar view" in the present invention is not limited to this form, and the decorative material of the present invention is originally applied from the side (surface) of the surface having the concave shape 2. It also includes any case of visual inspection in the assumed line-of-sight direction. Further, in the present invention, as shown in FIG. 3, the “cross-sectional view” extends a cross section parallel to the normal direction N of the surface of the decorative material of the present invention and orthogonal to the extending direction L of the concave shape 2. It means to visually recognize from the direction L, and includes at least an arbitrary case of visually recognizing from a direction in which the cross-sectional shape of the decorative material of the present invention is visible.

Hereinafter, the constitution of the decorative material of the present invention will be described with reference to FIGS. 1 to 7. FIG. 1 is a schematic perspective view showing the appearance of the decorative material 1 of the present invention, and shows that the decorative material 1 of the present invention has a concave shape 2 on the surface. FIG. 2 is a schematic view of the enlarged portion A of the edge 21 of the concave portion shape in FIG. 1 in a plan view (when viewed from the line of sight from the + direction to the − direction along the Z axis of FIG. 1). It is shown that the edge 21 of the concave shape is formed by repeating irregular irregularities. A shape in which a cape or peninsula-shaped protrusion 21C protruding inward of the concave shape 2 and a bay or cove-shaped recess 21B recessed toward the convex shape 23 side are alternately arranged adjacent to each other. It is presented.
3 to 5 are schematic views showing one of the preferred embodiments of the decorative material of the present invention, and correspond to a cross-sectional view or a cross-sectional view when cut in a plane parallel to the ZX plane in the same figure. The bottom surface 22 of the concave shape 2 is a non-curved surface, indicating that the shape in cross section is trapezoidal.
FIGS. 4 and 5 further show an embodiment having a decorative layer 6 in which the pattern on the decorative layer 6 and the second cured product layer 4 are synchronized. FIG. 5 shows an aspect in which the surface property improving layer 7 is further provided in FIG.

For example, FIGS. 1 and 6 are schematic views showing one of the preferred aspects of the surface of the decorative material of the present invention, and in the case of a decorative material exhibiting a tiled pattern, the concave shape 2 exhibits a joint portion. It is a portion, and the convex portion shape 23 is a portion that exhibits a tile portion. In the case of a decorative material exhibiting a brick (brick) stacking pattern, the concave shape 2 is a portion exhibiting a joint portion, and the convex portion shape 23 is a portion exhibiting a brick portion.
For example, FIG. 7 is a schematic view showing the surface of a decorative material exhibiting a stone-grained pattern. In the case of a decorative material exhibiting a stone-grain pattern, the concave shape 2 is a portion exhibiting the boundary of the stone-grain pattern (marble pattern), and the convex shape 23 is a portion exhibiting a region divided by the boundary.

The plan view shape of the convex shape 23 is not particularly limited and may be appropriately determined according to a desired design. For example, a triangle, a quadrangle (square, rectangle, rhombus, trapezoid, etc.), a pentagon, or a hexagon. In various shapes such as polygonal shape, circular shape, elliptical shape, heart shape, etc., the outer edge thereof is formed by lines formed by repeating irregular irregularities, and these are combined to partition the convex shape. For example, if a tiling pattern or a brickwork pattern is desired, it is generally a polygon such as a square, a rectangle (FIG. 1 corresponds to this), a triangle, a hexagon, or a combination of these. In the above, a shape whose outer edge is composed of lines formed by repeating irregular irregularities is preferably selected, and a shape whose outer edge is composed of lines formed by repeating irregular irregularities is preferably selected. When a leather pattern is desired, a polygonal, circular, elliptical, or combination of these shapes, in which the outer edge is composed of lines formed by repeating irregular irregularities, is preferably selected.
Ceramics are used as materials for the original material (also referred to as "manuscript") that constitutes the so-called tiled or brick-laying convex shape 23 portion, which is the object for which the decorative material 1 aims to reproduce the appearance and design. Ceramics such as glass are typical, but there are also stone materials such as marble, granite, and sandstone, and wood such as cedar, pine, cypress, oak, and teak. When the color, pattern, appearance and design of fine irregularities superimposed on the convex shape are also reproduced, the layer structure shown in FIGS. 4 and 5 or the pattern of the decorative layer 6 described later is known. The fine uneven shape embossed (formed) by the embossing method of the above, or both of them reproduces the appearance and design of the original that cannot be reproduced only by the convex shape 23 and the concave shape 2.

(Concave shape 2 and convex shape 23)
The concave shape 2 requires that the edge 21 of the shape in a plan view is formed by repeating irregular irregularities. Unless the edge of the concave shape in a plan view is formed by repeating irregular irregularities, only a monotonous design is exhibited, and a high-quality design with a realistic feeling and a high-quality feeling cannot be obtained. The irregular unevenness may be composed of a straight line portion having a finite length consisting of a part of a straight line, a curved line component, or a combination of the straight line component and the curved line component. It may be a thing. From the viewpoint of obtaining a design with a higher texture, the irregular unevenness is preferably composed of a curved line or a combination of a straight line component and a curved line, that is, a line composed of at least a curved line. It is more preferable that it is composed of curved lines. As a specific example of the irregular uneven shape, for example, as shown in FIG. 2, the cape or peninsula-shaped protrusion 21C protruding inward of the concave shape and the bay or cove-shaped recess 21B alternately alternate. Examples thereof include shapes arranged adjacent to each other.

The decorative material of the present invention has a pattern composed of a concave shape and a convex shape on the surface, and the convex shape is a region partitioned by the concave shape as shown in FIGS. 1, 6 and 7. Preferably, the surface of the decorative material is partitioned into a plurality of convex shapes by the concave shape.
The contour line shape of the concave shape in a plan view is not particularly limited and may be appropriately determined according to a desired design, and is a shape composed of straight lines such as a sig zag type polygonal line, amplitude modulation or frequency modulation. A curve such as a sine wave whose amplitude, period, or both are not constant, or a combination thereof, and a line formed by repeating irregular irregularities on the outer edge or outer periphery constituting the contour line of the convex portion shape 23. The shape configured by is mentioned. This straight line or curve may intersect or abut with another straight line or curve, or may be circular to partition the convex shape.
Here, the "line due to the repetition of irregular irregularities" means a line having vibrations and irregularities in the direction intersecting the extending direction and having neither a constant repetition period nor a constant amplitude. Therefore, a line that does not meander, curve, and curvature in the direction that intersects the extending direction, such as a straight line, a curve that curves in only one direction with respect to the extending direction, such as a parabola or a bicurve, and an amplitude such as a sinusoidal curve. Curves with a constant period do not correspond to "lines due to repeated irregular irregularities".

For example, in FIG. 1, a convex portion shape 23 having a rectangular plan view shape has a gap between the X direction and the Y direction, and a large number are periodically arranged, and the surface of the gap portion is convex. This is a typical example in which the concave shape 2 is formed by being recessed from the surface of the partial shape 23, and the contour line shape of the outer peripheral portion of the convex shape 23 is formed by repeating irregular irregularities in a plan view. FIG. 6 shows a typical example in which the convex shape 23 has an irregular shape and the concave shape 2 is formed by gaps of a large number of convex shapes 23 and is formed by an irregular curve. FIG. 7 shows an irregular concave shape. This is a typical example composed of regular curves.

The pattern presented by the concave shape presents a joint portion, but the joint in the present application not only means a seam when stacking bricks or attaching tiles, but also has a certain width for dividing into a plurality of areas. It may mean a boundary line, and the pattern exhibited by the concave shape differs depending on the pattern exhibited by the convex shape.
The patterns exhibited by the concave and convex shapes are tiled patterns, brickwork patterns, wood grain patterns, marble patterns, fabric patterns, leather patterns, relief or engraved characters, geometric patterns, and parquet patterns. Alternatively, patchwork style can be mentioned.
When the pattern exhibited by the concave portion shape and the convex portion shape is a tiled pattern, it is preferable that the concave portion shape exhibits a joint portion and the convex portion shape exhibits a tile portion made of various materials and shapes.
When the pattern exhibited by the concave shape and the convex shape is a brick-like pattern, it is preferable that the concave shape exhibits a joint portion and the convex shape exhibits a brick portion.
When the pattern exhibited by the concave shape and the convex shape is a wood grain pattern, the concave shape exhibits a wood grain conduit portion, an autumn wood portion, a knot portion or a heather portion, and the convex portion shape exhibits a spring wood portion. Is preferable.
When the pattern exhibited by the concave shape and the convex shape is a marble-like pattern, the concave shape is a portion exhibiting the boundary of a stone grain pattern (marble pattern), and the convex shape is a portion exhibiting a region divided by the boundary. Is preferable.
When the concave shape and the pattern exhibited by the convex shape are a fabric-like pattern, a leather-like pattern, or a patchwork-like pattern, the concave shape is a patchwork-like stitched portion or a fabric pattern imitating a cloth texture or a cloth-like pattern. It is preferable that the concave portion of the (texture) and the wrinkled concave portion of the leather pattern expressing the grain of the leather are exhibited, and the convex portion shape exhibits the cloth portion or the leather portion.
When the pattern exhibited by the concave shape and the convex shape is a character pattern or a geometric pattern, it is preferable that either the concave shape or the convex shape exhibits the character portion or the geometric figure portion.
When the concave shape and the convex shape have a parquet-like pattern, it is preferable that the concave shape exhibits a joint portion and the convex shape exhibits a xylem portion.

When the convex shape is a block shape, the concave pattern is a vertical joint portion provided at substantially equal intervals and a horizontal joint portion provided at substantially equal intervals, and the convex shape is irregular. Or, if the shapes are similar but different in size, it is a shape that fills the space between the convex shapes, and if the convex shape is a geometric pattern or a character, the geometric pattern or It is a shape to represent the area required to express characters. Further, the pattern exhibited by the concave shape may be the same color as the pattern exhibited by the convex shape, may be a different color, may be a single color, may be a plurality of colors, and may be a gradation. It is also preferable to produce a three-dimensional effect.

The concave shape is preferably a color that imitates silicone-based, modified silicone-based, urethane-based, plaster, mortar, cement, or a sealing material.

The number of irregularities on the edge is preferably 3 to 300, more preferably 10 to 200, and even more preferably 20 to 100 per 1 cm length of the edge. When the number of irregularities is within the above range, it is easy to stably produce a decorative board, and it is easy to obtain a design with a higher texture. The number of irregularities on the edge is the average value of the number of irregularities at any ten points on the edge.
The width of the concave shape is not particularly limited and may be appropriately determined according to a desired design, but the width may be constant or irregularly changed. If the width changes from place to place, it may change regularly or irregularly. The average value is preferably 0.1 to 50 mm, more preferably 0.3 to 30 mm, further preferably 0.5 to 20 mm, even more preferably 0.8 to 15 mm, and if you want to emphasize the joints, the exterior wall tile. When using a paste-like decorative material, a brick-like decorative material, a geometric pattern-like decorative material, or a character-patterned decorative material, it is preferable to widen the thickness to 3 to 15 mm. It is preferably 5 to 13 mm, more preferably 7 to 12 mm, and preferably narrower when it is desired to emphasize the convex shape or when it is used as a decorative material having an interior tiled pattern, preferably 0.5 to 12 mm. 0.8 to 8 mm is more preferable, 0.9 to 6 mm is further preferable, 1 to 4 mm is more preferable, and when a travertin marble pattern decorative material is used, a fabric pattern decorative material imitating a texture or a cloth-like pattern is used. In the case of a leather-patterned decorative material expressing the grain of leather, a hairline-like decorative material, or a universal groove-like decorative material, it is preferable to make the material even narrower. 01 to 2 mm is preferable, 0.01 to 1 mm is more preferable, 0.02 to 0.5 mm is further preferable, and 0.02 to 0.3 mm is further preferable.
The ratio of the area of the concave shape to the area of the decorative material is preferably 0.1 to 50%, preferably 1 to 30%, preferably 2 to 10%, preferably 3 to 8%, and is set to the lower limit or more. It is preferable that the visibility and the sense of quality are improved, and the yield at the time of manufacturing is improved by setting the value to the upper limit or less. Further, the number of convex portions in the decorative material is preferably 3 or more, more preferably 5 or more, further preferably 10 or more, and even more preferably 20 or more. ..

Regarding the concave shape, it is preferable that the bottom surface thereof is flat. By having such a bottom surface, the shape of the concave portion becomes clearer, so that it becomes easier to obtain a design with a higher texture. Here, the flat surface means that the average line of the roughness curve of the shape of the cross-sectional view of the bottom surface is composed of straight lines and does not show a curve. That is, although there are fine irregularities on the bottom surface, it means that the bottom surface is flat when viewed as an overall shape without considering the fine irregularities.
For example, the shape of the concave portion of the decorative material of the present invention in cross-sectional view is preferably a square, a rectangle, or a trapezoid, rather than a shape having a curved bottom such as a semicircle or a semi-elliptical shape. Is more preferable. The shape of the concave portion of the decorative material shown in FIG. 3 in cross-sectional view is a trapezoid with its short side on the bottom surface side. 21D in FIG. 2 is a portion corresponding to a trapezoidal leg.

In the shape of the concave portion in cross-sectional view, the arithmetic surface roughness Ra of the bottom surface thereof is not particularly limited, but the concave shape is visually recognized as the concave shape, and it is easy to obtain a design with a higher texture. Considering this, it is preferably 0.5 to 10 μm, more preferably 1 to 5 μm. In the present specification, the arithmetic surface roughness Ra is the arithmetic mean roughness of JIS B0601: 2013 when the cutoff value is 0.8 mm, and the arithmetic surface roughness Ra at any ten points on the bottom surface of the concave shape. Is measured and used as the average value.

The maximum depth of the concave shape is not particularly limited and may be appropriately determined according to a desired design, and the average value thereof is about 1 to 30 μm, which is preferable from the viewpoint of obtaining a design with a higher texture. It is 3 to 20 μm, more preferably 5 to 15 μm. In the present specification, the maximum depth of the concave shape is a value measured using a three-dimensional surface roughness measuring instrument in accordance with the method specified in JIS B0601: 2013, and more specifically, The maximum height roughness (Rz) of the surface at any ten points is measured, and the average value is taken as the average value of the maximum depth of the concave shape.

The shape of the decorative material of the present invention is not particularly limited and may be appropriately selected as desired. For example, a flat plate shape, a curved surface shape, a corner shape, or the like may be used. It may be non-flat. Although a flat plate-shaped decorative material is shown in FIG. 1, the shape of the decorative material of the present invention is not limited to this. Considering the ease of manufacturing the decorative material, the application, and the like, the flat plate shape is preferable.

(About layer structure)
Next, a preferred embodiment of the layer structure of the decorative material of the present invention will be described by taking the decorative material 1 shown in FIGS. 2 to 4 as an example. The decorative material 1 shown in FIG. 3 is formed of a first pattern region 31 formed on a part of one surface side of the base material 5, a second pattern region 41 formed on the rest thereof, and a curable resin. The first cured product layer 3 is present, and the first cured product layer 3 is present immediately above the first pattern region 31 and is not present immediately above the second pattern region 41. The concave shape 2 is formed in the first cured product layer 3 by the above method. Further, the first cured product layer 3 has a recessed edge 21, the bottom surface 22 of the recessed shape 2 is formed by the surface immediately above the second pattern region 41, and the bottom surface 22 is the second. It is the surface of the second cured product layer 4 preferably provided immediately above the pattern region 41. When the second cured product layer 4 is not provided, one surface of the base material 5 becomes the surface immediately above the second pattern region, forming the bottom surface 22.

The decorative material 1 shown in FIG. 4 is obtained by further providing the second cured product layer 4 and the decorative layer 6 on the decorative material 1 shown in FIG. 3, and the second cured product layer 4 is the second pattern region 41. The decorative layer 6 is provided between the base material 5 and the first cured product layer 3 and the second cured product layer 4.
Further, the decorative material 1 shown in FIG. 5 is obtained by further providing a surface property improving layer 7 on the decorative material 1 shown in FIG. 4, and the surface property improving layer 7 is a first cured product layer 3. It is provided on the top (surface).

(Base material 5)
The base material used for the decorative material of the present invention holds a first cured product layer, and preferably provided layers such as a decorative layer and a second cured product layer. The base material is not particularly limited and may be appropriately selected according to the desired performance. From the viewpoint of handleability, a paper base material, a fiber base material, a resin base material and the like are preferably mentioned, and more excellent mechanical properties. From the viewpoint of obtaining a decorative material having the above, a paper base material and a fiber base material having liquid permeability are more preferable, and a paper base material is further preferable.
Examples of the paper base material include kraft paper, titanium paper, linter paper, resin impregnated paper, thin paper, Japanese paper and the like. Examples of the fiber base material include non-woven fabrics and woven fabrics. For example, a fiber base material composed of inorganic fibers such as glass fiber, alumina fiber, silica fiber, and carbon fiber, polyester resin, acrylic resin, polyethylene resin, and polypropylene resin. Examples thereof include a fiber base material composed of organic fibers of various synthetic resins such as, and a base material such as a composite thereof.

The thickness of the base material is not particularly limited and may be appropriately selected according to the desired performance, and is usually about 10 to 3000 μm, preferably 20 to 500 μm, more preferably 20 to 500 μm from the viewpoint of ensuring mechanical physical characteristics and handleability. It is 50 to 200 μm. When a paper base material is used as the base material, the basis weight thereof is usually ^{about 20} to 150 g / m 2, preferably 30 to 100 g / m ² , from the same viewpoint.

When the base material used for the decorative material of the present invention is a base material having liquid permeability, that is, a paper base material or a fiber base material, it is preferable to impregnate these base materials with a curable resin. That is, a preferred embodiment of the decorative material of the present invention is pressure molding or heat pressure molding using a paper base material or a fiber base material impregnated with a liquid uncured product of a thermosetting resin as a base material. It becomes a thermosetting resin decorative board obtained by applying.
As the curable resin, a curable resin such as a thermosetting resin or an ionizing radiation curable resin can be used, and the first cured product has a high affinity with the curable resin forming the first cured product layer. A resin that can be integrated with the curable resin that forms the layer is preferable. With such a configuration, the mechanical strength of the decorative material of the present invention is improved.

As the curable resin to be impregnated in the base material, for example, a melamine resin, a urea resin, a melamine-urea resin, from the viewpoint of obtaining a higher texture design of the decorative material of the present invention and improving the mechanical strength. Guanamin resin, diallyl phthalate resin, polyester resin, phenol resin, epoxy resin, aminoalkyd resin, silicon resin, polysiloxane resin and the like are preferably mentioned, and melamine resin, urea resin, melamine-urea resin, guanamine resin, sulfonamide resin and the like are preferable. The thermosetting resin of the above is preferable, and melamine resin, melamine-urea resin, and phenol resin are preferable, and melamine resin is particularly preferable.

In order to impregnate these thermosetting resins into a base material having liquid permeability, an uncured resin composition containing a liquid uncured product of the thermosetting resin is prepared, and the uncured resin composition is prepared. The material may be impregnated in the base material. The impregnated uncured resin composition becomes a cured product of a thermosetting resin by heating and curing the uncured resin composition by a reaction such as a crosslinking reaction or a polymerization reaction at an appropriate time point. In the present specification, the term "thermosetting resin" simply means a cured product obtained by curing an uncured product of a thermosetting resin. The same applies to other curable resins such as ionizing radiation curable resins.

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

(First pattern area 31 and second pattern area 41)
The decorative material of the present invention has a first pattern region on a part of one surface side of the base material and a second pattern region on the rest of the surface side. Here, the "remaining portion on the surface side" means a region on one surface side of the base material where the first pattern region is not provided.
In the decorative material of the present invention, one surface side of the base material, that is, one surface of the base material, and when a decorative layer described later is provided, a part of one surface of the decorative layer is used as the first pattern region and the rest. The second pattern region is formed, and the concave shape is developed by allowing the first cured product layer to exist immediately above the first pattern region and not having the first cured product layer immediately above the second pattern region. It can be said that the region where the first cured product layer is provided is the first pattern region, and the region where the first cured product layer is not provided is the second pattern region. Therefore, it can be said that the various patterns expressed by the decorative material of the present invention are formed corresponding to the first pattern region and the second pattern region. Therefore, even if either the first pattern region or the second pattern region is missing, a high-quality decorative board having a high-quality design of the present invention cannot be obtained.

The first pattern region and the second pattern region may be one continuous region or a plurality of discontinuous regions. For example, the first pattern region may form one continuous region together with the second pattern region, or the first pattern region may be formed so as to surround a part or all of the second pattern region. On the contrary, the second pattern region may be formed so as to surround a part or all of the first pattern region, or a combination thereof may be used. The decorative material shown in FIG. 1 has a convex shape forming a closed region surrounded by edges, that is, has a first pattern region surrounded by a second pattern region.

(First cured product layer 3)
The first cured product layer is a cured product layer formed of a curable resin, which is provided immediately above the first pattern region provided on one surface side of the base material. The first cured product layer is provided directly above the first pattern region and is not provided directly above the second pattern region to form a concave shape immediately above the second pattern region, that is, It can be said that the portion where the first cured product layer is provided forms a convex shape. Further, the first cured product layer is also a layer having a shape in which irregular curves of the edge of the concave portion are repeated, and is a layer that expresses a high-quality design in the decorative material of the present invention.

The first cured product layer is a layer formed of a curable resin, more specifically, a layer formed of a cured product of a liquid uncured product of a curable resin. As the curable resin, a thermosetting resin and an ionizing radiation curable resin are preferably mentioned, and a thermosetting resin is more preferable, from the viewpoint of obtaining a design property with a higher texture. These curable resins may be used alone or in combination of two or more, for example, a thermosetting resin and an ionizing radiation curable resin may be used in combination, or these curable resins and thermoplastics may be used in combination. It may be used in combination with a resin.
As the thermosetting resin, the same ones as those exemplified as the thermosetting resins capable of impregnating the base material with a liquid uncured material as described above can be preferably exemplified, and the above-mentioned various thermosetting resins can be preferably exemplified. The same applies to the preference of the resin, particularly the preference of the melamine resin. By using such a curable resin, a design property with a higher texture can be obtained, the adhesion to the base material is improved, and more excellent mechanical strength can be obtained. The ionizing radiation curable resin will be described later as a resin that can be used for the second cured product layer. When the curable resin and the thermoplastic resin are used in combination, the content of the curable resin with respect to the total of these resins is usually about 50 to less than 100% by mass, preferably 60 to 90% by mass.

The first cured product layer is a layer formed of an uncured resin composition containing a liquid uncured product of a curable resin, and more specifically, an uncured resin containing a liquid uncured product of a curable resin. It may be a layer formed by a cured product of the composition. Examples of the uncured resin composition include a liquid uncured product of the above-mentioned curable resin, a weather resistant agent such as an ultraviolet absorber and a light stabilizer, and other additives as desired, such as a cross-linking agent and polymerization. Examples thereof include a resin composition containing various curing agents such as an initiator and a polymerization accelerator, and various additives such as a catalyst.
As the ultraviolet absorber, an ultraviolet absorber generally used for cosmetic materials can be used without particular limitation. For example, a benzotriazole-based ultraviolet absorber, a benzophenone-based ultraviolet absorber, a triazine-based ultraviolet absorber, and a hydroxyphenyltriazine-based ultraviolet absorber can be used. Examples include agents. As the light stabilizer, an ultraviolet absorber that is widely used in cosmetic materials can be used without particular limitation, and examples thereof include hindered amine-based light stabilizers such as piperidinyl sebacate-based light stabilizers. From the viewpoint of improving the strength of the first cured product layer, these weather resistant agents have a reactive functional group having an ethylenic double bond such as a (meth) acryloyl group, a vinyl group, or an allyl group in the molecule. There may be.

The thickness of the first cured product layer is not particularly limited as long as the concave shape can be formed, and is usually about 1 to 50 μm, preferably 3 to 40 μm, more preferably from the viewpoint of more easily obtaining a high-quality design. Is 5 to 30 μm.

(Second cured product layer 4)
The second cured product layer is a cured product layer formed of a curable resin, which is provided immediately above the second pattern region provided on one surface side of the base material. By providing the second cured product layer, it becomes easier to form the edge of the concave-shaped plan view by repeating irregular irregularities, and the bottom surface of the concave-shaped cross-sectional view becomes non-curved, so that the texture becomes more textured. High design quality will be obtained.

The second cured product layer is a layer formed of a curable resin, more specifically, a layer formed of a cured product of a liquid uncured product of a curable resin. As the curable resin, a thermosetting resin and an ionizing radiation curable resin are preferably mentioned, and an ionizing radiation curable resin is more preferable, from the viewpoint of obtaining a design property with a higher texture and better surface characteristics. As the thermosetting resin, the same ones as those exemplified as the thermosetting resin that can be impregnated in the base material can be preferably exemplified.

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

As the polymerizable monomer, a (meth) acrylate-based monomer having a radically polymerizable unsaturated group in the molecule is preferable, and a polyfunctional (meth) acrylate monomer is particularly preferable. Here, "(meth) acrylate" means "acrylate or methacrylate".
Examples of the polyfunctional (meth) acrylate monomer include a (meth) acrylate monomer having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth) acryloyl group as the functional group. An acrylate monomer having an acryloyl group is preferable from the viewpoint of obtaining a design property with a higher texture and better surface properties.
From the viewpoint of obtaining a higher quality design and better surface properties, the number of functional groups is preferably 2 or more, more preferably 3 or more, further preferably 4 or more, and the upper limit is preferably 8 or less. More preferably, it is 6 or less. These polyfunctional (meth) acrylates may be used alone or in combination of two or more.

Examples of such polymerizable monomers include bifunctional (meth) acrylates such as ethylene glycol di (meth) acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate; trimethylol. Propanetri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, Trifunctional or higher (meth) acrylates such as isocyanuric acid-modified tri (meth) acrylates; are preferred. Among them, dipentaerythritol such as dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, and dipentaerythritol hexa (meth) acrylate from the viewpoint of obtaining higher texture design and better surface characteristics. A system-polymerizable monomer is preferable, dipentaerythritol penta (meth) acrylate and dipentaerythritol hexa (meth) acrylate are more preferable, and dipentaerythritol penta (meth) acrylate and dipentaerythritol hexa (meth) acrylate are used in combination. Is particularly preferable.

Examples of the polymerizable oligomer include a (meth) acrylate oligomer having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth) acryloyl group as the functional group. For example, urethane (meth) acrylate oligomer, epoxy (meth) acrylate oligomer, polyester (meth) acrylate oligomer, polyether (meth) acrylate oligomer, polycarbonate (meth) acrylate oligomer, acrylic (meth) acrylate oligomer, polycaprolactone urethane (meth). ) Acrylate oligomer, polycaprolactone diol urethane (meth) acrylate and the like.

From the viewpoint of obtaining a higher quality design and better surface properties, the number of functional groups of these polymerizable oligomers is preferably 2 or more, and the upper limit is preferably 8 or less, more preferably 6 or less, still more preferably. It is 4 or less, particularly preferably 3 or less.

The weight average molecular weight of these polymerizable oligomers is preferably 500 or more, more preferably 500 or more, from the viewpoint of obtaining a higher quality design and better surface characteristics, and considering the ease of forming the second cured product layer. Is 1,000 or more, and the upper limit is preferably 80,000 or less, more preferably 50,000 or less. As used herein, the weight average molecular weight is the average molecular weight measured by GPC analysis and converted to standard polystyrene.

The second cured product layer preferably contains a release agent. By including the release agent, it becomes easier to form the edge of the concave shape in a plan view by repeating irregular irregularities, and the bottom surface of the concave shape in a cross-sectional view becomes easy to be non-curved, so that the texture is higher. The design will be obtained.
Examples of the release agent include a fluorine-based release agent, a silicone-based release agent, and the like, and a silicone-based release agent is preferable from the viewpoint of obtaining a design with a higher texture.
Examples of the silicone-based mold release agent include those having a polysiloxane structure as a basic structure, and among them, modified silicone oil in which an organic group is introduced into at least one of the side chain and the terminal thereof is preferable, and organic groups are present at both ends. The introduced modified silicone oil is more preferred. As the organic group, from the viewpoint of obtaining a design with a higher texture, a reactive functional group such as a (meth) acrylic group, an amino group, an epoxy group, a mercapto group, a carbinol group, a phenol group or a carboxyl group, or a polyether group , Non-reactive group functional groups such as aralkyl group, fluoroalkyl group, alkyl group, fatty acid amide group and phenyl group are preferably mentioned. Of these, a reactive functional group is preferable, and a (meth) acrylic group is particularly preferable, that is, a (meth) acrylic-modified silicone oil is particularly preferable. Further, these organic groups may have substituents such as a nitrogen atom, a sulfur atom, a hydroxyl group and an alkyl group.

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

The second cured product layer preferably contains an inorganic filler. By including the inorganic filler, it becomes easy to form the edge of the concave shape in a plan view by repeating irregular irregularities, and the bottom surface of the concave shape in a cross-sectional view tends to be non-curved, so that it becomes physically uneven. In addition, since there is a visual difference in luster and brightness, a higher quality design can be obtained.
Examples of the inorganic filler include oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide, zinc oxide and zirconia oxide; hydroxides such as aluminum hydroxide, magnesium hydroxide and calcium hydroxide; magnesium carbonate and carbon dioxide. Carbonates such as calcium; sulfates such as calcium sulfate and barium sulfate; particles made of inorganic materials such as silicates such as magnesium silicate, aluminum silicate, calcium silicate and aluminosilicate. Of these, oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide and zinc oxide are preferable, and silica is particularly preferable.

The average particle size of the inorganic filler is preferably 0.3 to 20 μm, more preferably 0.5 to 10 μm, from the viewpoint of obtaining a design with a higher texture. In the present specification, the average particle size of the filler is a value measured by a laser diffraction / scattering method.

These inorganic fillers are preferably surface-treated. Examples of the surface treatment agent for surface treating the inorganic filler include reactivity of alkoxysilane, (meth) acryloyloxy group, epoxy group, vinyl group, styryl group, amino group, isocyanate group, ureido group, sulfide group, mercapto group and the like. Examples thereof include a silane coupling agent having a group. From the viewpoint of obtaining a higher quality design, a silane coupling agent having a (meth) acryloyloxy group, an epoxy group, a vinyl group, and an amino group, that is, a (meth) acryloyloxy-based silane coupling agent, an epoxy-based silane coupling agent. Agents, vinyl-based silane coupling agents, and amino-based silane coupling agents are preferable. These surface treatment agents may be used alone or in combination of two or more.

Examples of the alkoxysilane include methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, hexyltrimethoxysilane, hexyltriethoxysilane, and octyltrimethoxysilane. Preferred examples include trialkoxysilanes such as decyltrimethoxysilane and dodecyltrimethoxysilane.
Examples of the (meth) acryloyloxy-based silane coupling agent include 3- (meth) acryloyloxypropylmethyldimethoxysilane, 3- (meth) acryloyloxypropyltrimethoxysilane, and 3- (meth) acryloyloxypropylmethyldiethoxy. Preferred examples include silane and 3- (meth) acryloyloxypropyltriethoxysilane. Examples of the epoxy-based silane coupling agent include diethoxy (glycidyloxypropyl) methylsilane and 2- (3,4 epoxycyclohexyl) ethyltrimethoxysilane. , 3-Glysidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, 3-glycidoxypropyltriethoxysilane and the like are preferable, and vinyl trimethoxysilane is a vinyl-based silane coupling agent. , Vinyl triethoxysilane and the like are preferably mentioned, and examples of the amino-based silane coupling agent include N-2 (aminoethyl) 3-aminopropylmethyldimethoxysilane, N-2 (aminoethyl) 3-aminopropyltrimethoxysilane, and the like. N-2 (aminoethyl) 3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N- (1,3-dimethyl-butylidene) propylamine , N-Phenyl-3-aminopropyltrimethoxysilane and the like are preferable.

Among the above, from the viewpoint of obtaining a design with a higher texture, the surface-treated silica particles in which silica particles are surface-treated with a silane coupling agent are preferable as the inorganic filler. It has a high affinity with the silicone-based mold release agent preferably used for the second cured product layer, and the synergistic effect of the mold release agent and the inorganic filler gives an effect of improving the design with a particularly excellent texture.

The content of the inorganic filler is preferably 1 to 50 parts by mass, more preferably 10 to 40 parts by mass, and further preferably 20 to 35 parts by mass with respect to 100 parts by mass of the curable resin forming the second cured product layer. Is. When the content of the inorganic filler is within the above range, the effect of adding the inorganic filler can be efficiently obtained.

When the second cured product layer contains a silicone-based mold release agent and an inorganic filler, the second cured product layer is formed of an uncured resin composition containing the liquid uncured product of the curable resin, the silicone-based mold release agent and the inorganic filler. It can be said that there is. That is, the second cured product layer is a layer formed of an uncured resin composition containing at least a liquid uncured product of a curable resin, and more specifically, at least a liquid uncured product of a curable resin. It may be a layer formed by a cured product of an uncured resin composition containing.
Examples of the uncured resin composition include a liquid uncured product of the above-mentioned curable resin, a preferably used silicone-based mold release agent, an inorganic filler, a weather-resistant agent such as an ultraviolet absorber and a light stabilizer, and other materials as desired. Various additives such as UV shielding agents, polymerization inhibitors, cross-linking agents, infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixo-imparting agents, coupling agents, plasticizers, defoaming agents, etc. Examples thereof include uncured resin compositions containing various additives such as antiblocking agents, lubricants and solvents. These weather resistant agents and other additives may be used alone or in combination of two or more.

The thickness of the second cured product layer is not particularly limited as long as a concave shape can be formed in relation to the first cured product layer, that is, the surface of the second cured product layer is lower than the surface of the first cured product layer. The thickness of the surface of the second cured product layer is not particularly limited as long as it forms a concave bottom surface, and is usually about 0.1 to 20 μm, from the viewpoint of more easily obtaining a high-quality design. , It is preferably 0.5 to 10 μm, and more preferably 1 to 5 μm.

(Decorative layer 6)
The decorative material of the present invention preferably has a decorative layer 6 in order to express a design property with a higher texture and to correspond to various design properties. The decorative layer may be, for example, a colored layer that covers the entire surface (so-called solid colored layer), a pattern layer formed by various patterns, or a combination thereof. May be good. For example, when the ground color of a base material or the like is colored and concealed, a solid colored layer is used to obtain a design with a higher texture while concealing the color, and from the viewpoint of expressing correspondence to a wider variety of design characteristics. Therefore, the solid coloring layer and the pattern layer may be combined, and on the other hand, when the ground pattern of the adherend is utilized, only the pattern layer may be provided without the solid coloring layer.

When a pattern layer is provided as the decorative layer, the pattern exhibited by the decorative layer includes a pattern exemplified as a pattern represented by the concave shape and the convex shape, for example, a tiled pattern having a joint portion and a brickwork pattern having a joint portion. , Wood grain pattern, marble pattern, stone pattern, fabric pattern that imitates cloth grain or cloth pattern, leather pattern that expresses grain of leather (natural or synthetic leather), tile pattern, brick pattern , Hairline, Mangoku groove, satin finish, grain, letters, symbols, geometric patterns, parquet that combines these, patterns such as patchwork, and other patterns such as the above-mentioned artificial marble.

Among these patterns, considering the characteristics of the decorative material of the present invention having a high-quality design, the pattern is preferably a tile portion or a brick portion as a convex shape and a joint portion as a concave shape. When the joint portion is adopted as the concave shape, the second pattern region is a region that is more specifically synchronized with the darker joint pattern in the tile portion or the brick portion of the decorative layer so as to be synchronized with the pattern of the decorative layer. If a second cured product layer is provided immediately above the joint layer, the joint pattern matches the concave shape, so that the joint portion physically becomes a concave portion and is visually recognized as darker. A high-quality design with a high-class feel as well as an excellent realism can be obtained. Further, in the tiled pattern, the hues of the convex shape and the concave shape are preferably different, and the concave shape is preferably white or gray, but colors such as warm red and yellow and neutral green are used. It is also preferable to use it as a joint. In the brickwork pattern, the concave shape is preferably gray or white. In the wood grain pattern, the marble pattern, the fabric pattern, the leather pattern, the geometric pattern, the character pattern and the parquet pattern, the concave shape is preferably dark.
If the convex shape is tile, pastel colors and primary colors are preferable, and if it is brick, red, beige, ivory and the like are preferable.

For example, in the decorative materials shown in FIGS. 4 and 5, a second pattern region is provided so as to be synchronized with the pattern of the decorative layer, and a second cured product layer is provided immediately above the second pattern region. It corresponds to the concave shape. Therefore, in the decorative materials shown in FIGS. 4 and 5, if the pattern of the decorative layer is a joint pattern, the pattern of the decorative layer and the second pattern region, and the second cured product layer and the concave shape provided immediately above the decorative layer are formed. Since the joints of the decorative layer pattern are physically recessed and visually darker, it is closer to a real tiling pattern or brickwork pattern. It is a decorative material with a high-quality design that gives a sense of quality as well as a realistic feel.
On the other hand, it is also preferable to increase the brightness of the concave shape rather than the convex shape in order to enhance the joint portion with respect to the tiled pattern or the brick-laid pattern. In this case, it is preferable to use a color scheme that emphasizes the hue contrast between the tile portion or the brick portion and the joint portion, rather than the effect that the joint pattern of the decorative layer pattern is darkly visible.

The thickness of the decorative layer may be appropriately selected according to the desired pattern, but is preferably 0.5 to 20 μm from the viewpoint of coloring and concealing the ground color of the base material and obtaining a higher quality design. 1, 1 μm to 10 μm is more preferable, and 2 to 5 μm is further preferable.

(Surface property improvement layer 7)
Since the decorative material of the present invention has the effect of improving surface properties such as scratch resistance, impact resistance, and stain resistance, it is first cured on the first cured product layer (surface) or with the base material. It is preferable to provide a surface property improving layer between the material layer and the material layer. Further, by providing the surface characteristic improving layer, the difference between the height directly above the first pattern area and the height directly above the second pattern area is physically increased, and the depth of the concave shape is increased, so that the texture is further improved. High design quality can also be obtained. The surface property improving layer is preferably provided on the first cured product layer (surface) as shown in FIG. 4 from the viewpoint of obtaining more excellent surface properties.

The surface property improving layer may be formed by using either a thermoplastic resin or a curable resin, and from the viewpoint of obtaining more excellent surface properties, a layer formed of the curable resin, more specifically cured. It is preferably a layer formed by a cured product of a liquid uncured product of a sex resin. As the curable resin, a thermosetting resin and an ionizing radiation curable resin are preferably mentioned, and a thermosetting resin is more preferable, from the viewpoint of obtaining more excellent surface characteristics. Examples of the thermosetting resin used for forming the surface property improving layer include unsaturated polyester resin, melamine resin, urea resin, epoxy resin, and alkyd resin. In addition, a two-component curable urethane containing various polyols such as polyether polyol, acrylic polyol, polyester polyol, and urethane acrylic polyol as the main component and various isocyanates such as aromatic isocyanate and aliphatic (or alicyclic) isocyanate as the curing agent. Resin is also preferably mentioned. Among these thermosetting resins, a two-component curable urethane resin is preferable because it has an effect of improving surface characteristics and it is easy to obtain a design with a higher texture.

Further, as a resin material for forming the surface property improving layer, the effect of improving the surface property can be obtained, and the design property with a higher texture can be easily obtained. Therefore, the water of the thermoplastic resin obtained by dispersing the thermoplastic resin in water. Dispersions are also preferred. Thermoplastic Resin Examples of the thermoplastic resin of the aqueous dispersion include urethane resin, polyester resin, olefin resin, and styrene resin, and urethane resin is particularly preferable.
The average particle size of the aqueous dispersion is usually about 5 to 500 nm, preferably 10 to 250 nm, and more preferably 15 to 100 nm. In the present specification, the average particle size of the aqueous dispersion is 25 ° C. for the dispersion liquid diluted with water so ^{that the concentration of the particles to be measured is 5 × 10 -3% by mass using a laser particle analyzer.} The angle between the incident light and the detector is 90 °, the number of integrations is 100, and the refractive index of the dispersion solvent is a value measured under the conditions of the refractive index of water (1.333).

It is preferable that the surface property improving layer contains various fillers such as an inorganic filler and an organic filler from the viewpoint of improving the surface property, particularly the wear resistance.
Examples of the inorganic filler include those exemplified as the inorganic filler that can be used for the second cured product layer, and examples of the organic filler include polyolefin resin, acrylic resin, styrene resin, epoxy resin, urea resin, polyester resin, and phenol resin. Examples thereof include particles made of an organic material such as.

The shape of these fillers is not particularly limited and may be spherical, polyhedral or the like.
The average particle size of the filler is preferably 3 to 50 μm, more preferably 5 to 30 μm from the viewpoint of improving wear resistance. In the present specification, the average particle size of the filler is a value measured by the laser diffraction / scattering method.
The content of the filler is preferably 50 to 300 parts by mass, and more preferably 100 to 200 parts by mass with respect to 100 parts by mass of the resin.

When the surface property improving layer contains the filler, it can be said that the surface property improving layer is formed by using the liquid resin and the resin composition containing the filler. The resin composition for forming the surface property improving layer includes a liquid resin composition, a preferably used filler, a weather resistant agent such as an ultraviolet absorber and a light stabilizer, and various other additives as desired, for example. , UV shield, polymerization inhibitor, cross-linking agent, infrared absorber, antistatic agent, adhesive improver, leveling agent, thixo-imparting agent, coupling agent, plasticizer, defoaming agent, filler, anti-blocking agent , Resin compositions containing various additives such as lubricants and solvents. Additives such as these weather resistant agents may be used alone or in combination of two or more.

The thickness of the surface property improving layer is preferably 1 to 30 μm, more preferably 3 to 20 μm, from the viewpoint of improving wear resistance and easily obtaining a design with a higher texture.

(Reinforcement layer)
The reinforcing layer is a layer for reinforcing the decorative material of the present invention, and is a layer provided as desired on the surface (back surface side) opposite to the surface on which the layer such as the first cured product layer of the base material is provided. .. In particular, when the decorative material of the present invention is a thermosetting resin decorative board, a reinforcing layer is usually provided in many cases. As the reinforcing layer, various materials and materials constituting the various layers can be used depending on the type and application of the decorative material. Especially when the decorative material is a thermosetting resin decorative board, the reinforcing layer is impregnated with a thermosetting resin. It is preferably formed of a sheet. When a fiber base material or a paper base material impregnated with a thermosetting resin is used as the base material, the thermosetting property is more excellent by combining the reinforcing layer formed by the thermosetting resin impregnated sheet. A resin veneer can be obtained.

Examples of the thermosetting resin impregnated sheet include a fiber base material impregnated with an uncured resin composition containing a liquid uncured product of a thermosetting resin, a paper base material, and the like. The type of the fiber base material and the paper base material used for the thermosetting resin impregnated sheet is not particularly limited as long as it is exemplified as the base material fiber base material or the paper base material, and the basis weight is preferably 100 to 300 g. / ^{M 2} , more preferably 150 to 250 g / m ² . Further, as the thermosetting resin, the same thermosetting resin that can be impregnated in the base material in the state of the liquid uncured resin composition can be preferably exemplified, and the above-mentioned various heats can be preferably exemplified. Similarly, a liquid uncured resin composition of a curable resin is preferable. Among these thermosetting resins, a phenol resin is preferable, and as the reinforcing layer, a phenol resin impregnated paper which is widely used as a core paper such as a melamine resin decorative board is preferable.
The phenol resin impregnated paper is produced by, for example, impregnating ^{kraft paper having a basis weight of 150 to 250 g / m 2} with phenol resin so as to have an impregnation rate of about 20 to 60% and drying at about 100 to 140 ° C. Phenol formaldehyde is preferably used.

(Primer layer)
In the decorative material of the present invention, in order to improve the adhesion of each layer, for example, between the base material and the first cured product layer and the second cured product layer, and between the first cured product layer and the surface property improving layer, Further, a primer layer can be provided between the base material and the reinforcing layer.
Examples of the resin material forming the primer layer include urethane resin, polyester resin, acrylic resin, acrylic urethane resin, vinyl chloride-vinyl acetate copolymer resin and the like. The thickness of the primer layer is usually about 0.1 to 15 μm, preferably 1 to 10 μm from the viewpoint of efficiently obtaining excellent adhesion.

(Manufacturing method of decorative material)
Regarding the method for producing a decorative material of the present invention, the base material, decorative layer, first cured product layer, second cured product layer and surface characteristics improvement shown in FIG. 4, which is one of the preferred embodiments of the decorative material of the present invention. The manufacturing method will be described by taking a decorative material having a layer as an example.

(Manufacturing method of one decorative material)
The decorative material of the present invention has, for example, a step of providing a decorative layer on a base material, a step of providing a first cured product layer and a second cured product layer on the decorative layer, and surface characteristics on the first cured product layer. It can be manufactured by going through the steps of providing the improving layer in order.

The decorative layer is formed by applying an ink used for forming the decorative layer on a base material to provide a desired colored layer and a pattern layer. The ink is applied by a known method such as a gravure printing method, a bar coating method, a roll coating method, a reverse roll coating method, or a comma coating method, preferably a gravure printing method.

Further, when surface treatment is applied to the base material, when a decorative layer is formed, and when a primer layer is provided between the base material and the decorative layer, the primer layer may be provided before the formation of the decorative layer. When the back surface primer layer is provided on the surface (back surface) opposite to the decorative layer side of the base material, it may be provided before or after the formation of the decorative layer. The primer layer can be formed by using, for example, any of the known methods exemplified as the method of applying the ink of the decorative layer, the resin composition constituting the primer layer can be formed.

Next, it is a step of providing the first cured product layer and the second cured product layer on the decorative layer. For example, an uncured resin composition containing a liquid uncured product of a curable resin that forms a second cured product layer is applied onto the decorative layer to form a coating film, and the coating film is cured and cured. An uncured resin composition containing a liquid uncured product of a curable resin that forms a second cured product layer as a product and then forms the first cured product layer, except that the second cured product layer is provided. A coating film may be formed by applying to the region of the above, and the coating film may be cured to form a first cured product layer as a cured product.
When the decorative layer has a tiled pattern or a brick-like pattern as a convex shape and a joint pattern as a concave shape, the joint pattern of the decorative layer pattern is set as a second pattern area, and the second pattern area is used. By providing the second cured product layer immediately above, the area other than the second pattern region as the first pattern region, and providing the first cured product layer immediately above the first pattern region, the joint pattern and the second The pattern region, the second cured product layer provided immediately above the pattern region, and the concave shape are synchronized. With such a configuration, the joint pattern is physically recessed and visually darker, and the decorative material of the present invention is closer to a real tiling pattern or brickwork pattern. It has a high-class feel as well as a realistic feel, and is a decorative material with a high-quality design.

In forming the first cured product layer and the second cured product layer, the method of applying the uncured resin composition containing the liquid uncured product of the curable resin was exemplified as the method of applying the ink of the decorative layer. Any of the known methods may be adopted.
Further, the curing method of the uncured resin composition containing the liquid uncured product of the curable resin may be selected according to the type of the curable resin contained in the uncured resin composition. For example, when the uncured resin composition is a resin composition containing a liquid uncured product of a thermosetting resin, it may be cured by performing a heat treatment according to the thermosetting resin to be used.

When an uncured resin composition containing a liquid uncured product of an ionizing radiation resin is used, the uncured resin layer formed by coating the uncured resin composition is irradiated with ionizing radiation such as electron beam and ultraviolet rays. It may be a cured product. Here, when an electron beam is used as the ionizing radiation, the acceleration voltage thereof can be appropriately selected according to the resin to be used and the thickness of the layer, but usually the uncured resin layer can be cured at an acceleration voltage of about 70 to 300 kV. preferable. The irradiation dose is preferably an amount at which the crosslink density of the ionizing radiation curable resin is saturated, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad).
The electron beam source is not particularly limited, and for example, a cockloft Walton type, a bandegraft type, a resonance transformer type, an insulated core transformer type, or various electron beam accelerators such as a linear type, a dynamitron type, and a high frequency type are used. be able to.
When ultraviolet rays are used as ionizing radiation, those containing ultraviolet rays having a wavelength of 190 to 380 nm are emitted. The ultraviolet source is not particularly limited, and for example, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, a carbon arc lamp, or the like is used.

Further, in the laminated body in which the first cured product layer and the second cured product layer are formed, the portion corresponding to the second cured product layer is a convex portion, and the portion corresponding to the first cured product layer is a concave portion. It is also possible to form the first cured product layer and the second cured product layer by sandwiching the mirror surface plate with the mirror plate and performing heat and pressure molding using a hot press machine or the like. By performing heat and pressure molding, a design with a higher texture can be obtained.

The first cured product layer can also be formed by the following method. For example, after the second cured product layer is formed by the above method, the base material on which the second cured product layer is formed is in the form of a liquid thermosetting resin that forms the first cured product layer using an impregnation device. A liquid uncured resin composition containing an uncured product is ^{impregnated with the uncured resin composition so as to have a concentration of about 80 to 130 g / m 2} (when dried), dried, and then in a liquid state of a thermosetting resin. A base material having a second cured product layer impregnated with the uncured resin composition containing the uncured product of No. 1 is prepared. A laminate is prepared by laminating kraft paper (core paper) impregnated with phenol resin as a reinforcing layer, if necessary, and the portion corresponding to the second cured product layer is a convex portion. , The part corresponding to the first cured product layer is sandwiched between the embossed plate and the mirror surface plate, which are recesses, and heat and pressure molding is performed using a hot press machine or the like to perform the first cured product layer and the second cured product. Layers can also be formed.

The embossed plate used for heat and pressure molding can be replaced with a mirror plate and a shaping sheet. By making the edge of the first cured product layer composed of irregular irregularities by this embossed plate or the shaping sheet, the edge of the concave shape in a plan view is composed of irregular irregularities. It becomes a thing.
The conditions for heat-press molding may be appropriately adjusted according to the type of thermosetting resin used, and are not particularly limited, but usually under temperature conditions of 100 to 200 ° C., the pressure is 0.1 to 9.8 MPa. The time is from 10 seconds to 120 minutes.
Further, the fiber base material and the paper base material impregnated with the thermosetting resin used as the reinforcing layer may be one or more.

Next, it is a step of providing a surface property improving layer on the first cured product layer. A resin composition for forming a surface property improving layer is applied onto the first cured product layer formed by the above step and cured as necessary to form a surface property improving layer. When a thermoplastic resin aqueous dispersion is used for forming the surface property improving layer, it is preferable to carry out a drying treatment for about 1 to 10 minutes under a temperature condition of about 80 to 130 ° C.
The heat and pressure molding using the embossed plate may be performed after the surface property improving layer is formed, and when the resin composition forming the first cured product layer is impregnated by using an impregnating device, the embossed plate is impregnated. A resin composition for forming a surface property improving layer is applied onto the resin composition and then heat-press molded using an embossed plate and a mirror surface plate to form a first cured product layer and a surface property improving layer. It may be formed at the same time.

According to the above manufacturing method, a decorative layer is provided on the base material, a first cured product layer and a second cured product layer are provided on the decorative layer, and a surface property improving layer is provided on the first cured product layer. A decorative material having a concave shape formed in the first cured product layer can be obtained by the cured product layer and the second cured product layer on which the first cured product layer is not provided. When the above manufacturing method is adopted, by further etching or the like, the edge of the first cured product layer is made to be composed of more irregular repetitions of unevenness, and a higher quality design can be obtained. it can. In this way, the decorative material of the present invention can be produced.

(Manufacturing method of other decorative materials)
Further, the decorative material of the present invention is, in addition to the above-mentioned method for producing a decorative material, for example, a step of providing a decorative layer on a base material, a step of forming a second cured product layer on the decorative layer, and a first cured product. A step of impregnating an uncured resin composition containing a liquid uncured product of a curable resin forming a layer, and applying a resin composition for forming a surface property improving layer on the impregnated uncured resin composition. It is also produced by sequentially going through a step, a step of laminating a peeling sheet on a coating film of a resin composition forming the surface property improving layer, a step of heat and pressure molding, and a step of peeling the peeling sheet. Can be done.

A method of providing a decorative layer on a base material, a method of forming a second cured product layer on the decorative layer, and a method of impregnating an uncured resin composition containing a liquid uncured product of a curable resin forming the first cured product layer. The method for forming the surface property improving layer and the method for applying the resin composition for forming the surface property improving layer are the same as the methods described in the above-mentioned method for producing a decorative material.
In the step of laminating the release sheet, the uncured resin composition obtained by these methods is provided with a decorative layer on the base material and a second cured product layer on the decorative layer to form the first cured product layer. A resin that forms the surface property improving layer of a laminate in which a coating film of the resin composition that forms a surface property improving layer is formed on an uncured resin composition that is impregnated with a substance and forms a first cured product layer. This is a step of laminating a release sheet on the coating film of the composition.

As the peeling sheet, an easily adhesive resin sheet, a resin sheet having a cured product layer of a curable resin, or the like is preferably used from the viewpoint of obtaining a design with a higher texture.
Examples of the easily adhesive resin sheet used for the peeling sheet include polyester resins such as polyethylene terephthalate and polybutylene terephthalate; polyolefin resins such as polyethylene and polypropylene; acrylic resins; and other various resin sheets. The easy-adhesion layer provided on the resin sheet is preferably a resin sheet formed of a thermoplastic resin such as an acrylic resin, a vinyl chloride-vinyl acetate copolymer resin, a polyester resin, or a urethane resin.

The easy-adhesive resin sheet may further have an easy-adhesive layer. As the easy-adhesion layer, one having the same structure as the primer layer can be adopted.
Further, the resin sheet can be subjected to a physical surface treatment such as an oxidation method or an unevenness method, or a surface treatment such as a chemical surface treatment.

As the resin sheet used for the resin sheet having the cured product layer of the liquid uncured product of the curable resin, a resin sheet that can be used for the easily adhesive resin sheet is preferably mentioned. As the curable resin, a curable resin such as a thermosetting resin and an ionizing radiation curable resin is preferably mentioned. Examples of these thermosetting resins and ionizing radiation curable resins include thermosetting resins and ionizing resins exemplified as resins that can be used for forming the first cured product layer, the second cured product layer, and the surface property improving layer. A thermosetting resin is preferably mentioned. Among them, from the viewpoint of obtaining a design property with a higher texture, an ionizing radiation curable resin is preferable, and a polymerizable monomer is more preferable. The polymerizable monomer may be selected from the polymerizable monomers that can be used to form the second cured product layer, and from the viewpoint of obtaining a higher quality design, trimethylolpropane tri (meth) acrylate, in particular, A trifunctional (meth) acrylate monomer such as pentaerythritol tri (meth) acrylate is preferable, and trimethylolpropane tri (meth) acrylate is more preferable. Further, the curable resin used for the peeling sheet may be one that has undergone various modifications such as alkylene oxide modification such as ethylene oxide modification and propylene oxide modification.

In principle, the cured product layer provided on the release sheet is a release agent from the viewpoint of stabilizing the adhesion with the first cured product layer and the second cured product layer to obtain a higher quality design. Is preferably not contained, but a mold release agent may be contained for adjusting and optimizing the adhesion. As the release agent, a fluorine-based release agent, a silicone-based release agent and the like are preferably mentioned, and a silicone-based release agent is more preferable. Examples of the silicone-based release agent include those exemplified as the silicone release agent that can be used for the second cured product layer, and may be selected from these and used.
The content of the release agent in the cured product layer provided on the release sheet is adjusted with respect to 100 parts by mass of the curable resin forming the cured product layer from the viewpoint of efficiently obtaining a design with a higher texture. 0.1 to 5 parts by mass is preferable, 0.5 to 4 parts by mass is more preferable, and 1 to 3 parts by mass is further preferable.

Further, it is preferable that the cured product layer provided on the peeling sheet contains an inorganic filler. Examples of the inorganic filler include those exemplified as the inorganic filler that can be used for the second cured product layer, and may be selected from these.
The content of the inorganic filler in the cured product layer provided on the release sheet is 0 with respect to 100 parts by mass of the curable resin forming the cured product layer from the viewpoint of efficiently obtaining a design with a higher texture. .1 to 30 parts by mass is preferable, 1 to 20 parts by mass is more preferable, and 5 to 15 parts by mass is further preferable.

The step of heat and pressure molding is a step of heat and pressure molding of the laminated body in which the peeling sheets are laminated. Specifically, after laminating the above-mentioned peeling sheets, a laminate was prepared by laminating kraft paper (core paper) impregnated with phenol resin as a reinforcing layer, if necessary, and two of the laminates were laminated. It is sandwiched between the mirror plates of the above, and heat and pressure molding is performed using a heat press or the like. The method and conditions of heat and pressure molding using a hot press or the like are the same as those of heat and pressure molding described in the above-mentioned formation of the first cured product layer.

The laminate obtained through heat and pressure molding is a curable resin that forms a base material, a decorative layer, a second cured product layer, and a first cured product layer formed on one surface so as to cover the second cured product layer. It is a laminated body in which a cured product layer of the composition, a surface property improving layer, and a peeling sheet are laminated. The step of peeling the peeling sheet is a step of peeling the peeling sheet from the laminated body to obtain the decorative material of the present invention.
The peeling method of the peeling sheet is not particularly limited as long as it can be peeled so that the peeling sheet does not remain.

The cured product layer of the uncured resin composition containing the liquid uncured product of the curable resin forming the first cured product is provided immediately above the second cured product layer and in contact with the decorative layer. When the release sheet is peeled off from the laminate obtained through heat and pressure molding, the cured product layer portion provided in contact with the decorative layer having higher adhesion remains and becomes the first cured product layer, resulting in more adhesion. The cured product layer provided in contact with the second cured product layer having low properties and the surface property improving layer on the cured product layer are peeled off, and the first cured product layer is directly above the second cured product layer. Will not exist. Further, in the laminate obtained through thermosetting molding, the uncured resin composition containing the liquid uncured product of the curable resin forming the first cured product layer that was present over the entire surface is cured. When a part of the material layer is peeled off, the edge of the hardened material layer that remains without being peeled off and becomes the first hardened material layer is composed of repeated irregular irregularities. The edge is composed of repeated irregular irregularities. Further, according to the above-mentioned other method for producing a decorative material, the shape of the bottom portion in the cross-sectional view of the concave shape is a shape having a bottom surface that is not a curved surface because the surface of the bottom portion is the surface of the second cured product layer. It will be easier.
Therefore, according to the above-mentioned other method for producing a decorative material, it becomes easy to obtain a decorative material having a higher texture and design.

(Use of decorative material)
The decorative material of the present invention is a decorative material having a high-quality design with a high-class feeling as well as a realistic feeling. Therefore, the decorative material of the present invention can be used as it is or after undergoing a predetermined molding process or the like for various purposes. For example, flat plates of various materials, plates such as curved plates, substrates such as sheets (or films), and other building materials for interior and exterior, such as cabinets for furniture and kitchen products, top plates and doors used for various counters and desks, etc. It can be used as a building material for housing.

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

Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to this example.
(Evaluation and observation method)
(1) Evaluation of designability With respect to the cosmetic materials obtained in each Example and Comparative Example, 20 adults were allowed to visually evaluate whether or not the cosmetic material had a high-quality texture.
A: More than 18 out of 20 people answered that they had a high-quality design.
B: More than 15 out of 20 people answered that they had a high-quality design.
C: Less than 14 out of 20 people answered that they had a high-quality design.
(2) Observation of surface shape For the decorative materials obtained in each Example and Comparative Example, cross-sectional pieces were prepared with a microtome and used with a scanning electron microscope (“S-4800 TYPE2” manufactured by Hitachi High-Technologies Corporation). The cross section was observed under the conditions of acceleration voltage: 1 kV, acceleration current: 10 μA, and working distance: 8 mm.

Example 1
Printing ink (DIC Graphics Co., Ltd., "Ode SPTI") on titanium paper base paper for building materials (KJ Specialty Paper Co., Ltd., "PM-67P", basis weight: 80 g / m ^{2, thickness: 100 μm)} Was used to form a decorative layer showing a pattern on the surface of a tiled wall surface having a thickness of 3 μm by gravure printing to obtain a tiled pattern. The tiled pattern has a plan view shape in which square tiles having a side of 50 mm are arranged vertically and horizontally between adjacent tiles with a joint having a width of 6 mm. An uncured resin composition containing a liquid uncured product of the following curable resin for forming a second cured product layer on the decorative layer is synchronized with the joint pattern portion of the tiled pattern. A plurality of lines having a width of 6 mm are printed in a joint pattern of tiles arranged in both vertical and horizontal directions at intervals of 50 mm, and the second cured product layer is cured by irradiating with an electron beam (pressurized voltage: 165 KeV, 3Mrad (30 kGy)). (Thickness: 2 μm) was formed. Next, an uncured resin composition containing a liquid uncured product of a curable resin that forms the following first cured product layer by impregnating the base material on which the decorative layer and the second cured product layer are formed with an impregnating device. The uncured resin composition ^{was impregnated to 80 g / m 2} (when dried), and the release film prepared by the following method was applied onto the dried product, and the release layer was the decorative layer and A phenol resin impregnated core ^{having a basis weight of 245 g / m 2} obtained by laminating in a direction facing the second cured product layer side and impregnating kraft paper with a liquid uncured resin composition made of phenol resin. A laminated body was prepared in which a base material and a reinforcing layer were laminated so as to face each other on a reinforcing layer in which three sheets of paper (Ota Core manufactured by Ota Sangyo Co., Ltd.) were laminated. The obtained laminate is sandwiched between two mirror plates, and heat and pressure molding is performed at a molding temperature of 150 ° C. and a molding pressure of 100 kg / cm ² for 10 minutes using a hot press, and then for peeling. A decorative board was produced by peeling off the film. The above evaluation was performed on the obtained decorative board, and the results are shown in Table 1. Further, the obtained decorative board was observed as described above, and a microscope magnified image thereof is shown in FIG.

(Uncured resin composition containing a liquid uncured product of a curable resin for forming a second cured product layer)
Each of the following components was stirred with a process homogenizer (manufactured by SMT Co., Ltd., "PH91") at a rotation speed of 2000 rpm for 1 hour to obtain a resin composition.
Ionizing radiation curable resin (dipentaerythritol penta (hexa) acrylate (pentaacrylate content: 40 to 50% by mass), manufactured by Toa Synthetic Co., Ltd., "Aronix M400") 60 parts by mass Silicone-based mold release agent (both ends) Methacryloyloxyalkyl modified organopolysiloxane, manufactured by Shin-Etsu Chemical Co., Ltd., "X-22-164B") 0.9 parts by mass silane coupling treated silica 18 parts by mass Methyl ethyl ketone (Maruzen Petrochemical Co., Ltd.) 40 parts by mass (first curing) Curable resin composition for forming a material layer)
Melamine Formaldehyde Resin 60 parts by mass Water 35 parts by mass Isopropyl alcohol 5 parts by mass (Preparation of peeling film)
On the easy-adhesion surface of a polyethylene terephthalate film (thickness: 50 μm, manufactured by Toyo Boseki Co., Ltd., “Cosmo Shine A4100”), an ionizing radiation curable resin (ethylene bottom oxide modified product of trimethyl propantriacrylate, manufactured by Toa Synthetic Co., Ltd., "Aronix M350") 100 parts by mass, silicone release agent (both-terminal methacryloyloxyalkyl-modified organopolysiloxane, manufactured by Shin-Etsu Chemical Co., Ltd., "X-22-164B"), 2 parts by mass, silica particles (Fuji Silicia Chemical Co., Ltd.) A uncured resin composition containing a liquid uncured product of an ionizing radiation curable resin containing 8 parts by mass of "Silicia 450" manufactured by the company, average particle size: 5.2 μm) and 50 parts by mass of ethyl acetate is applied. , Electron beam (pressurized voltage: 165 KeV, 5Mrad (50 kGy)) was irradiated and cured to form a release layer composed of a cured product layer having a thickness of 5 μm, and a release film was prepared.

Example 2
In Example 1, an uncured resin composition containing a liquid uncured product of a curable resin for forming a second cured product layer was applied so as to be synchronized with the joint pattern of the decorative layer. A decorative material was produced in the same manner as in 1. The above evaluation was performed on the obtained decorative board, and the results are shown in Table 1.

Comparative Example 1
In the first embodiment, the second cured product layer and the peeling sheet are not formed, and one mirror surface plate is replaced with an embossed plate in heat and pressure molding, and the embossed plate and the surface provided with the decorative layer face each other. An embossed veneer was produced by sandwiching the laminate and performing heat and pressure molding. The above evaluation was performed on the obtained decorative board, and the results are shown in Table 1. Further, the obtained decorative board was observed as described above, and a microscope magnified image thereof is shown in FIG.

From the results of Examples 1 and 2, it was evaluated that the decorative material of the present invention is a decorative material having a high-quality feel as well as a realistic feeling and a high-quality design. Further, the second pattern area is synchronized with the pattern of the decorative layer (tile-like pattern or brick-like pattern), and more specifically, the second hardened material layer is synchronized with the tile-like pattern or brick-like pattern. The decorative material of Example 2 provided above was evaluated to be superior in design to the decorative material of Example 1.
On the other hand, the decorative material of Comparative Example 1 having no second cured product layer was embossed, but was not evaluated as a decorative material having a high-quality design.
According to the microscopic magnified image of the decorative material of Example 1 of FIG. 5, the edge of the concave shape in a plan view is formed by repeating irregular irregularities, and the bottom surface of the concave shape is a non-curved surface (flat surface). It was also confirmed that the cross-sectional shape was substantially rectangular (approximately trapezoidal). On the other hand, according to the microscopic magnified image of the decorative material of Comparative Example 1 in FIG. 6, the edge of the concave shape in a plan view is gentle and smooth, the bottom surface of the concave shape is curved, and the shape in cross section is It was confirmed that it was composed of gentle and smooth curves and had a substantially semi-elliptical shape.

1. 1. Cosmetic material 2. Concave shape 21. Recessed edge 21B. Recessed portion 21C. Projection 21D. Recessed inclined part 22. Recessed bottom surface 23. Convex shape 3. First cured product layer 31. First pattern area 4. Second cured product layer 41. Second pattern area 5. Base material 6. Decorative layer 7. Surface property improving layer A. Enlarged part of the edge of the concave shape in a plan view L. Extension direction N. Normal direction

Claims (19)

A decorative material having a pattern composed of a concave shape and a convex shape, the edge of the concave shape in a plan view is formed by repeating irregular irregularities, and the concave shape exhibits a joint portion. The decorative material according to claim 1, wherein the concave shape in a plan view is a shape having a flat bottom surface. The decorative material according to claim 1 or 2, wherein the convex portion shape is a region defined by the concave portion shape of the joint portion. Any one of claims 1 to 3, wherein the concave shape is a vertical joint provided at substantially equal intervals and a horizontal joint provided at substantially equal intervals, and the convex shape defined by the concave joints is block-shaped. The cosmetic material described in the section. Claims 1 to 4 in which the pattern is a tiled pattern, a brickwork pattern, a wood grain pattern, a marble pattern, a fabric pattern, a leather pattern, a geometric pattern, a parquet pattern, or a patchwork pattern. The decorative material according to any one of the above. The decorative material according to any one of claims 1 to 5, wherein the proportion of the concave shape in the decorative material is 0.1 to 50%. The decorative material according to any one of claims 1 to 6, wherein the average maximum depth of the concave shape is 1 to 30 μm. It has a base material, a first pattern region, a second pattern region, and a first cured product layer formed of a curable resin, and the first pattern region is formed on a part of one surface side of the base material. , The second pattern region is formed on the rest on one surface side of the base material, the first cured product layer is present immediately above the first pattern region, and is directly above the second pattern region. The present aspect of any one of claims 1 to 7, wherein the concave shape is formed in the first cured product layer, and the bottom surface of the concave shape is formed by the surface immediately above the second pattern region. The listed cosmetic material. The decorative material according to claim 8, which has a second cured product layer formed of a curable resin immediately above the second pattern region. The decorative material according to claim 9, wherein the curable resin forming the second cured product layer is an ionizing radiation curable resin. The decorative material according to claim 9 or 10, wherein the second cured product layer contains a release agent. The decorative material according to claim 11, wherein the release agent is a silicone-based release agent. The decorative material according to any one of claims 9 to 12, wherein the second cured product layer contains an inorganic filler. The decorative material according to claim 13, wherein the inorganic filler is silica particles. The decorative material according to any one of claims 8 to 14, wherein the curable resin forming the first cured product layer is a thermosetting resin. The decorative material according to any one of claims 8 to 15, further comprising a decorative layer between the base material and the first cured product layer. The decorative material according to any one of claims 9 to 14, further comprising a decorative layer between the base material and the first cured product layer and the second cured product layer. The decorative material according to claim 16 or 17, wherein the second pattern region and the pattern of the decorative layer are synchronized. The decorative material according to any one of claims 8 to 18, further comprising a surface property improving layer on the first cured product layer or between the base material and the first cured product layer.

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