decorative material

Abstract

Provided is a decorative material having an appearance design with excellent visual effects. A decorative material has a texture region on a base material, the texture region being formed of a plurality of mutually independent sets of convex portions (20), the convex portions (20) containing a resin binder (23) and shiny flaky particles (21).

Description

Technical Field

[0001] The present disclosure relates to decorative materials. Background Art

[0002] Decorative materials are widely used in the surface decoration of building interiors, building materials, furniture, door and window equipment, decoration components, vehicles, home appliances, bathroom products such as integral bathrooms, and kitchen products. As such decorative materials, there are decorative materials obtained by laminating a paper or resin sheet printed with a pattern on a substrate to be adhered, decorative materials obtained by forming a pattern on the surface of a metal plate such as a steel plate by printing, and the like.

[0003] In the above-mentioned decorative materials, sometimes by further imparting surface uneven patterns, an exterior design property having a texture (tactile sensation) and a sense of luxury that is coordinated with the pattern is imparted.

[0004] As a decorative material having an uneven shape on the surface, an embossed decorative material using an embossing plate formed with an uneven shape has been proposed (for example, Patent Documents 1 and 2). In addition, a decorative material in which uneven patterns are imparted to the surface of a substrate by overprinting (Japanese: nishikidashi printing) has been proposed (for example, Patent Document 3).

[0005] Prior Art Documents

[0006] Patent Documents

[0007] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2015-193209

[0008] Patent Document 2: Japanese Unexamined Patent Application Publication No. 2017-87544

[0009] Patent Document 3: Japanese Patent Publication No. 63-17613 Summary of the Invention

[0010] Problems to be Solved by the Invention

[0011] However, as described in Patent Documents 1 and 2, in the case of imparting an exterior design with uneven patterns by embossing, an embossing plate is required for each pattern, so there are problems of high cost and difficulty in manufacturing. In addition, the uneven patterns are relatively large, and it is difficult to make the uneven shape coordinate with the pattern on the base, and there is a problem that it is difficult to impart a high level of exterior design property.

[0012] In the method of Patent Document 3, only a visually monotonous pattern can be formed, and it is difficult to obtain a decorative material having a three-dimensional and depth sense.

[0013] In view of the above problems, an object of the present disclosure is to provide a decorative material having an exterior design with excellent visual effects.

[0014] Means for Solving the Problems

[0015] In order to solve the above problems, this disclosure provides the following [1] to

[18] .

[0016] [1] A decorative material having a textured area on a substrate consisting of a plurality of mutually independent protrusions, wherein the protrusions comprise a resin adhesive and glossy flake particles.

[0017] [2] According to the decorative material described in [1], the average height of the above-mentioned protrusion is 10 μm to 60 μm.

[0018] [3] According to the decorative material described in [1] or [2], the average diameter of the circumscribed circle of the above-mentioned protrusion is 100 μm to 500 μm.

[0019] [4] According to any one of [1] to [3], the area ratio of the above-mentioned protrusion in the above-mentioned textured area is 20% to 70% within a 1cm square.

[0020] [5] According to any one of [1] to [4], the decorative material wherein the average value of the diameter of the circumcircle of a set of adjacent protrusions is set as d ave When the distance between the centers of a set of adjacent circumcircles is set as D, D / d ave The proportion of a group of adjacent convex parts that satisfy the following relationship is more than 90% of all combinations.

[0021] 0.5≤D / d ave ≤6.0

[0022] [6] According to any one of [1] to [5], the shortest distance between adjacent protrusions is 5 to 120 μm.

[0023] [7] The decorative material described in any one of [1] to [6], wherein the content of the glossy flake particles is 3 parts by mass or more and 40 parts by mass or less relative to 100 parts by mass of the resin adhesive.

[0024] [8] According to any one of [1] to [7], the amount of glossy flaky particles in the gap region between the above-mentioned protrusions is 500 μm. 2 No more than 3.

[0025] [9] The decorative material described in any one of [1] to [8] further comprises an organic filler with a particle size of 5 μm or more and 60 μm or less.

[0026]

[10] According to the decorative material described in [9], the content of the organic filler is 15 parts by mass or more and 50 parts by mass or less relative to 100 parts by mass of the above-mentioned resin adhesive.

[0027]

[11] The decorative material described in any one of [1] to

[10] , wherein the protrusion further comprises an inorganic filler.

[0028]

[12] According to the decorative material described in

[11] , the content of the inorganic filler is 1 part to 40 parts by mass relative to 100 parts by mass of the above-mentioned resin adhesive.

[0029]

[13] The decorative material described in any one of [1] to

[12] , wherein the above-mentioned glossy flake particles are particles on a flake-shaped glass substrate having a coating of metal or metal oxide formed thereon.

[0030]

[14] The decorative material described in any one of [1] to

[13] , wherein the decorative material has areas other than the textured area described above.

[0031]

[15] According to the decorative material described in

[14] , when the 60-degree specular gloss of the textured area is defined as G60A and the 60-degree specular gloss of the other areas is defined as G60B, the ratio of G60A / G60B is 0.8 or less.

[0032]

[16] The decorative material described in any one of [1] to

[15] has a raised layer on the substrate, and the surface of the portion of the decorative material having the raised layer is the textured area.

[0033]

[17] The decorative material described in any one of [1] to

[16] , wherein the area ratio of the textured region in the surface of the decorative material is 10% or more and 90% or less.

[0034]

[18] The decorative material described in any one of [1] to

[17] , wherein the substrate is a metal substrate.

[0035] Invention Effects

[0036] According to this disclosure, decorative materials with excellent visual effects and appearance designs can be obtained. Attached Figure Description

[0037] Figure 1 This is a perspective view of a decorative material according to one embodiment of the present disclosure.

[0038] Figure 2 It is Figure 1 A magnified planar diagram of the region represented by the symbol R.

[0039] Figure 3 This is a cross-sectional schematic diagram of a portion of a decorative material having a textured area, according to one embodiment of this disclosure.

[0040] Figure 4 This is a diagram used to illustrate the definitions of "circumcircle of the convex portion", "diameter of the circumcircle" and "distance between the centers of a set of adjacent circumcircles" in this disclosure.

[0041] Figure 5 This is a photograph of the appearance of the decorative material in Example 1.

[0042] Figure 6 This is a photograph of the appearance of the decorative material in Example 2.

[0043] Figure 7 These are microscope images of the textured areas in the decorative material of Example 1.

[0044] Figure 8 These are microscope photographs of the textured areas in the decorative material of Comparative Example 1.

[0045] Figure 9 These are microscope photographs of the textured areas in the decorative material of Comparative Example 2. Detailed Implementation

[0046] The decorative materials disclosed herein will be described in detail below. It should be noted that the numerical range of "AA~BB" in this specification refers to "AA and above and BB and below".

[0047] The decorative material disclosed herein has a textured area on a substrate consisting of a plurality of independent protrusions, wherein the protrusions comprise resin adhesive and glossy flake particles.

[0048] Figure 1 This is a perspective view of a decorative material according to one embodiment of the present disclosure. When viewed from the surface side, the decorative material 1 has a pattern (texture). When viewed from above, the decorative material 1 has a textured area 10 on the substrate on the surface side.

[0049] The textured region 10 can be provided on the entire surface of the decorative material 1 or in a partial area. In this disclosure, the area that is not the textured region 10 is referred to as the other region 11. The textured region 10 and the other regions can be distinguished, for example, by the area ratio of the raised region described later.

[0050] There is no particular limitation on the area ratio of the textured region within the surface of the decorative material. In order to give the textured region a contrast with other regions, the area ratio of the textured region within the surface of the decorative material is preferably 10% or more and 90% or less, more preferably 20% or more and 80% or less, and even more preferably 30% or more and 70% or less.

[0051] When the textured area 10 is set locally, the textured area 10 can be formed into a pattern corresponding to the appearance design of the decorative material 1 (e.g., striped pattern, checkered pattern, pattern composed of geometric shapes such as quadrilaterals, triangles, circles, and lines, or irregular pattern as described later). Alternatively, it can be formed into a pattern that coordinates with at least a portion of the pattern brought about by the pattern layer described later.

[0052] The cross-section where the decorative material is cut along its thickness (refer to...) Figure 3 In this invention, at least a portion of the substrate contains a layer formed by multiple protrusions constituting the textured area. In this specification, such a layer formed by multiple protrusions is sometimes referred to as a "raised layer." That is, when the textured area is viewed from the Y-axis direction orthogonal to the thickness direction of the decorative material, a structure identified as a layer formed by protrusions is called a raised layer. Figure 3 ).

[0053] It should be noted that, in this specification, "top view" refers to visually identifying the decorative material of this disclosure in a planar direction from the side of the surface where the textured area is located (surface side). For example, in Figures 1-4 In the XYZ coordinate system shown, the XY plane, represented by the X-axis and Y-axis directions, is roughly parallel to the surface of the substrate. "Looking down" is equivalent to observing the surface of the substrate from the Z-axis direction, which is the thickness direction of the decorative material.

[0054] [Texture area]

[0055] Figure 2 It is Figure 1 A magnified planar diagram of the region represented by the symbol R. That is, Figure 2 This is a diagram of the textured region viewed from the Z-axis direction of the XYZ coordinate system. Figure 2 Such surfaces can be observed using microscopes such as optical microscopes and scanning electron microscopes.

[0056] Textured areas can give decorative material surfaces a tactile feel.

[0057] like Figure 2As shown, a plurality of independent protrusions 20 are aggregated in the textured region. Within the textured region, gaps exist between the protrusions. That is, in the textured region of the decorative material of this disclosure, a plurality of independent protrusions 20 are aggregated together through gaps. The protrusions 20 are so-called "island areas" having a closed, curved profile with protrusions and recesses when viewed from above. Figure 2 The diagram shows an irregular collection of protrusions 20, each having a closed, curved profile with protrusions and recesses when viewed from above. The area between the protrusions 20 forming gaps is the so-called "sea area" exposed by the transparent base layer or pattern layer, described later. The protrusions 20 exist independently of each other by the presence of sea areas between the islands. Figure 2 A structure with both an island section and a sea section is also known as an island structure. Additionally, in Figure 2 In the structure, the "island structure" can also be called the "phase separation structure", the "island part" can also be called the "continuous phase", and the "sea part" can also be called the "isolated phase".

[0058] The height is measured across the entire texture area. With the maximum height set to 100 and the minimum height set to 0, the "island area" mentioned above is defined as an area with a height of 10 or more. Conversely, the "sea area" mentioned above is defined as an area with a height less than 10.

[0059] It should be noted that, preferably, other areas 11 do not have protrusions.

[0060] The protrusion 20 can be irregular or regular. To improve the feel of the natural object, the protrusion 20 is preferably irregular.

[0061] In this disclosure, "irregular convexity" may also refer to a shape having any of the following characteristics.

[0062] (1) When viewed from above, the shapes of multiple protrusions are not all identical, but rather a mixture of two or more protrusions with different shapes and sizes. All the protrusions within the textured area can have different shapes and sizes, and can also contain two or more identical or similar protrusions.

[0063] (2) When viewed from above, the shapes of the multiple convex parts are different from the relatively monotonous shapes such as regular polygons, circles, ellipses, and hearts. For example, the outline of the convex part is a complex shape that requires a combination of complex functions such as polynomials and infinite series to approximate.

[0064] (3) A form that has both (1) and (2) characteristics.

[0065] [convex part]

[0066] Each protrusion 20 contains luminous flaky particles 21 internally. The number of luminous flaky particles contained in one protrusion 20 is not particularly limited. On the other hand, it is preferable that the aforementioned "sea area (gap)" does not substantially contain luminous flaky particles. Here, "substantially does not contain" means that every 500 μm of the sea area contains luminous flaky particles. 2 The number of bright, sheet-like particles present in the area is less than three.

[0067] Preferably, each protrusion 20 contains a plurality of organic fillers 22. The organic fillers 22 are preferably present in the protrusion 20 in a state of aggregation in the plane or in the thickness direction, and more preferably in a state of aggregation in both the plane and the thickness direction. In view of the protrusion 20 from above, in addition to protrusions formed by aggregation of two or more organic fillers, for example, protrusions in which only one particle exists in an island of continuous resin may also exist.

[0068] Figure 3 This is a cross-sectional schematic diagram of a portion of a decorative material in one embodiment of this disclosure where a textured region 10 is provided. That is, Figure 3 It is Figure 1 A schematic diagram of the cross-section when the textured area of ​​the illustrated decorative material is cut along the Z-axis direction, which is the thickness direction of the decorative material. Figure 3 In the textured area of ​​the decorative material 1, a primer layer 3, a base coat layer 4, a pattern layer 5, a transparent base layer 6, a raised layer 7 (which is the textured area 10 when viewed from above), and a surface coating 8 are sequentially disposed on the substrate 2. The textured area is formed on the surface of the decorative material where the raised layer 7 is located. Preferably, no raised layer is disposed in other areas.

[0069] like Figure 3 As schematically shown, in the decorative material 1 of one embodiment of this disclosure, glossy flake particles 21 and organic filler 22 of the protrusion 20 are present on the transparent base layer 6 (or pattern layer 5), and the glossy flake particles 21 and organic filler 22 are coated with resin adhesive 23. Figure 3 In decorative material 1, due to the thin coating caused by the resin adhesive, the surface of the protrusion 20 becomes an uneven shape that roughly mimics the surface shape of the glossy flake particles and organic fillers. That is, in Figure 3 In the textured area of ​​the decorative material 1, there are unevenness (larger unevenness) caused by a plurality of protrusions 20 arranged in a pattern, and unevenness (smaller unevenness) caused by glossy flaky particles 21 and organic fillers 22 on the surface of each protrusion 20.

[0070] In the decorative material 1 disclosed herein, since the raised portions contain glossy flaky particles while the seams (gap areas) substantially do not, it can be said that the glossy flaky particles are predominantly present in the microstructure. Therefore, when observing the textured area, compared to the case where the glossy flaky particles are distributed approximately uniformly, the perceived brightness brought by the glossy flaky particles can be enhanced, and the brightness contrast between the raised portions and seams (gap areas) within the textured area can be increased. Furthermore, the brightness contrast between the textured area and other areas can be increased. In addition, when the decorative material is observed at different angles using the glossy flaky particles, a visual design that allows for the perception of brightness changes becomes possible. The brightness change caused by changing the aforementioned angle can become an extremely complex change due to the diffusion caused by the inclined surface of the raised portion, thus greatly enhancing the visual effect. Furthermore, as described above, by the unevenness of the raised surface, a difference in glossiness is created between the raised and non-raised areas, resulting in a so-called glossy matte effect. Therefore, the decorative material 1 disclosed herein can exhibit excellent visual effects, namely, a visual design with a three-dimensional and depth-of-motion feel. Furthermore, the unevenness caused by the protrusion 20 and the unevenness of the surface of the protrusion 20 can provide an excellent tactile feel. In particular, by setting the textured area 10 with a pattern that coordinates with at least a portion of the pattern brought by the pattern layer as described later, an aesthetic and tactile feel corresponding to the pattern can be obtained.

[0071] To achieve excellent visual effects and tactile feel, the average height of the protrusion 20 is preferably 10μm to 60μm, more preferably 15μm to 45μm, and even more preferably 25μm to 35μm.

[0072] The protrusion 20 is irregular or regular; therefore, in this disclosure, the size of the protrusion 20 is expressed by the diameter of its circumscribed circle when viewed from above (when viewed from the surface). Figure 4 This is a magnified planar diagram of the textured area, which is related to... Figure 2 The same diagram. The circumcircle of protrusion 20-1 is the circle indicated by symbol C1. The diameter of circumcircle C1 is indicated by the arrow in symbol d1. Similarly, the circumcircle of protrusion 20-2 is the circle indicated by symbol C2. The diameter of circumcircle C2 is indicated by the arrow in symbol d2. The average diameter of the circumcircle of protrusion 20 across the entire textured region is defined as "average diameter d".

[0073] In this disclosure, the average diameter d of the circumcircle of the protrusion 20 is preferably 100 μm to 500 μm. When the average diameter d is 100 μm or more, the aforementioned visual effect is easily obtained, and a sufficient tactile feel can be achieved. By setting the average diameter d to 500 μm or less, the protrusion becomes less visually distinguishable. The average diameter d is more preferably 150 μm to 350 μm, and more preferably 200 μm to 250 μm.

[0074] If the protrusions 20 are too far apart, the desired visual effect and sufficient tactile feel may not be achieved. Therefore, it is preferable that the protrusions 20 are densely packed in the textured area.

[0075] For both visual appeal and tactile feel, in the decorative material disclosed herein, the area ratio of the protrusions 20 in the textured region is preferably 20% to 70% within a 1cm square area. 1cm square is a specification that takes into account the contact area of ​​the fingers when touching the decorative material. More preferably, the area ratio is 30% to 60%, and even more preferably 40% to 50%. The area ratio of the protrusions is a value obtained through image analysis of an optical microscope photograph (300x), and is set as the average value obtained by measuring 10 points within the textured region.

[0076] The area ratio of the gap region in the textured region is preferably 30% to 80% within a 1cm square range, more preferably 40% to 70%, and even more preferably 50% to 60%.

[0077] The decorative material in this embodiment may also have other areas (areas other than the textured areas). These other areas preferably have a different feel and gloss than the textured areas.

[0078] To distinguish the textured area from the tactile feel of other areas, the area ratio of the raised areas in other areas is preferably less than 20% within a 1cm square range, more preferably less than 10%, more preferably less than 5%, more preferably less than 3%, more preferably less than 1%, and more preferably 0%.

[0079] The area ratio of the convex region is a value obtained by image analysis of an optical microscope photograph (magnification: 300x), and is set as the average value obtained by measuring 10 points in other regions.

[0080] Furthermore, to differentiate the tactile feel of the textured areas from those of other areas, the other areas preferably do not contain particles with a diameter of 5 μm or larger. When viewed from above, the area percentage of particles with a diameter of 5 μm or larger present is preferably 3% or less, more preferably 1% or less, more preferably 0.3% or less, and even more preferably 0%.

[0081] Furthermore, when defining the 60-degree specular gloss level of the textured area as G60A and the 60-degree specular gloss level of other areas as G60B, the ratio of G60A / G60B is preferably 0.8 or less, more preferably 0.6 or less, and even more preferably 0.5 or less. By setting G60A / G60B to the above values, it is easy to distinguish the gloss level of the textured area from that of other areas. The 60-degree specular gloss levels G60A and G60B are set as the average of the measured values ​​of 10 locations.

[0082] Furthermore, for both visual appeal and tactile feel, in the decorative material disclosed herein, the average diameter of the circumcircle of a group of adjacent protrusions 20 is set as d throughout the entire textured area 10 when viewed from above. ave When the distance between the centers of a set of adjacent circumcircles is set as D, the preferred value is D / d. ave The proportion of a group of adjacent protrusions that satisfy the following relationship is more than 90% of all combinations.

[0083] 0.5≤D / d ave ≤6.0

[0084] use Figure 4 Regarding the above d ave Let's explain with D. The diameters of the circumcircles of the adjacent pair of protrusions 20-1 and 20-2 are d1 and d2, respectively. Therefore, d ave = (d1+d2) / 2. Additionally, the distance between centers D is... Figure 4 The distance of the double-dotted arrow.

[0085] D / d ave A large value indicates a large distance between adjacent convex parts, while a large value indicates that the convex parts are sparsely distributed. D / d ave The upper limit is preferably 5.5, more preferably 5.0, and even more preferably 4.5. On the other hand, D / d ave A smaller value indicates a denser density of convex regions. On the other hand, in D / d... ave When D / d is less than 1, depending on the shape of the convex part, the area where adjacent convex parts partially overlap when viewed from above becomes larger. Specifically, D / d... ave When D / d is 0, geometrically the convex parts overlap to form a single region. To ensure that the two convex parts are independent through the gap, D / d... ave The lower limit is preferably 0.5 as described above.

[0086] D / d ave More preferably, a group of adjacent protrusions that meet the above range constitutes more than 95% of all combinations.

[0087] Furthermore, the shortest distance between adjacent protrusions is preferably 5μm to 120μm, more preferably 10μm to 80μm, and even more preferably 20μm to 60μm. If the shortest distance is within the above range, the protrusions become denser in the textured area, making it easier to obtain a good tactile feel.

[0088] Here, "adjacent convexities" can be defined by performing Voronoi tessellation on a magnified top view of the textured region. Voronoi tessellation refers to finding the perpendicular bisecting lines between adjacent parent points distributed in a plane, and using the obtained perpendicular bisecting lines to divide the plane into cellular regions.

[0089] Specifically, firstly, for a magnified top view of the texture region, the centers of the circumcircles of the convex parts and the islands not considered as convex parts are determined. Using the center B of the circumcircle of each convex part and island as the "mother point," the Voronoi region of the texture region is divided into cellular regions. Furthermore, if two cellular regions corresponding to any extracted convex part share a common boundary line (Voronoi boundary), they are defined as "convex parts adjacent to each other."

[0090] The raised portion 20 can be formed, for example, using an ink (ink for raised portions) containing a resin composition comprising a resin binder and glossy flake particles. In this specification, "ink for raised portions" is sometimes referred to as "ink for raised layers." It should be noted that if ink for raised portions (ink for raised layers) is used to form the raised portion, gaps are simultaneously formed between the raised portions.

[0091] <Resin Adhesives>

[0092] Examples of resin adhesives for the protrusion 20 include, for example, urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene resins, urethane-acrylic acid copolymers, polycarbonate-urethane-acrylic acid copolymers (urethane-acrylic acid copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer backbone and two or more hydroxyl groups at the ends and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic acid copolymer resins, chloropropylene resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, fluorine resins, etc., which can be used alone or in combination.

[0093] <Bright, sheet-like particles>

[0094] Examples of glossy, flaky particles include pearlescent pigments, metallic flakes, and metallic-coated glass flakes; one or more of these can be used. These particles are incorporated into the ink, either individually or in combination. Pearlescent pigments are preferred, and pearlescent pigments using a glass substrate are particularly preferred.

[0095] The average particle size of the glossy flake particles is preferably 5 μm to 100 μm, more preferably 10 μm to 80 μm, and even more preferably 20 μm to 60 μm. The average thickness of the glossy flake particles is preferably 0.5 μm to 5 μm.

[0096] Particle size refers to the diameter of the bright, sheet-like particles assuming they are perfect spheres. The particle size of the bright, sheet-like particles is set as the diameter obtained by known methods such as Stokes diameter and light scattering diameter. The thickness of the bright, sheet-like particles is the thickness determined by laser diffraction.

[0097] The aspect ratio (maximum length / thickness) of the planar portion of the bright, sheet-like particles is preferably 10 or more and 180 or less. The length of the sheet-like bright particles refers to the maximum length in the planar direction when the particles are observed under a microscope. The thickness of the sheet-like bright particles is obtained by dividing the cross-sectional image of the particles obtained through microscopic observation into multiple regions of equal length along the length direction, and averaging the measured thickness values ​​of the central portion of each region.

[0098] Pearl pigments using a glass substrate are specifically particles with a metal oxide coating formed on a flake-like glass substrate.

[0099] Examples of glass substrates include flake glass and glass sheets. Examples of metal oxides used as coatings include titanium oxide and iron oxide. By changing the material and thickness of the coating, different colors of the pigment can be achieved.

[0100] Other pearlescent pigments include those made by covering a matrix of mica, aluminum, etc., with a coating layer containing metal oxides such as titanium dioxide and ferric oxide.

[0101] Thus, the pearlescent pigment is no longer the metal itself, but a substance mainly composed of metal oxides, and is a colorant capable of producing a metallic luster. In this disclosure, any pigment selected from white pearlescent pigments, interference pearlescent pigments, and colored pearlescent pigments can be used as the aforementioned pearlescent pigment.

[0102] The length of the other pearlescent pigments mentioned above is preferably 5 μm to 90 μm, more preferably 10 μm to 60 μm. The thickness of the other pearlescent pigments mentioned above is preferably 0.5 μm to 50 μm, more preferably 1 μm to 30 μm. It should be noted that the length of the pearlescent pigment refers to its maximum length in the planar direction when the pigment is observed under a microscope. The thickness of the pearlescent pigment is obtained by dividing the cross-sectional image of the pigment obtained by microscopic observation into multiple regions of equal length in the length direction, and averaging the measured thickness values ​​of the central part of each region.

[0103] Materials used for metal scales include aluminum, gold, silver, brass, titanium, chromium, nickel, nickel-chromium, stainless steel, and other metals and alloys.

[0104] Metal-coated glass flakes are particles with a metallic coating formed on the surface of a sheet-like glass substrate. Examples of glasses that constitute the glass substrate include soda-lime glass, potassium glass, phosphate glass, borosilicate glass, and lead glass. Examples of metals include aluminum, gold, silver, brass, titanium, chromium, nickel, nickel-chromium alloys, and stainless steel.

[0105] The length of the metal scales or metal-coated glass scales is preferably 2 μm to 90 μm, more preferably 10 μm to 60 μm. The thickness of the aforementioned metal scales or metal-coated glass scales is preferably 0.5 μm to 50 μm, more preferably 1 μm to 30 μm. It should be noted that the length of the metal scales or metal-coated glass scales refers to the maximum length in the planar direction when the scales are observed under a microscope. The thickness of the metal scales or metal-coated glass scales is obtained by dividing the cross-sectional image of the scales obtained by microscopic observation into multiple regions of equal length in the length direction, and averaging the measured thickness values ​​of the central portion of each region.

[0106] To impart a high-gloss appearance due to the glossy flaky particles and to increase the contrast between areas where the glossy flaky particles are present and areas where they are absent, the content of glossy flaky particles is preferably 3 parts by weight or more, more preferably 10 parts by weight or more, and even more preferably 15 parts by weight or more, relative to 100 parts by weight of the resin binder. Furthermore, to impart a matte finish appearance due to the organic filler and the inorganic filler described later, the content of glossy flaky particles is preferably 40 parts by weight or less, more preferably 30 parts by weight or less, and even more preferably 20 parts by weight or less, relative to 100 parts by weight of the resin binder.

[0107] The orientation of the glossy flake particles 21 within the protrusion 20 is not particularly limited. If the orientation is random, changes in brightness can be perceived when observing the decorative material 1 from different angles, thus giving the decorative material 1 a sense of three-dimensionality and depth, which is preferred. If the protrusion 20 contains at least one of organic particles and inorganic fillers, the orientation of the glossy flake particles can be easily made random.

[0108] <Organic fillers>

[0109] Examples of organic fillers include acrylic resins, urethane resins, nylon resins, polypropylene resins, and urea-based resins. Among these, acrylic resin fillers are preferred. Acrylic resin fillers have good heat resistance, so after the baking process, the organic filler is less likely to be buried in the lower layers, making it easier to maintain its height. Furthermore, because acrylic resin fillers are less likely to be buried in the lower layers, they are more prone to aggregation, easily forming protrusions.

[0110] To impart a glossy / matte finish to the decorative material 1 and provide a suitable tactile feel, the particle size of the organic filler is preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more. Furthermore, to prevent the organic filler from detaching from the decorative material 1 and to achieve the desired visual effect and tactile feel, the particle size of the organic filler is preferably 60 μm or less, more preferably 50 μm or less, and even more preferably 40 μm or less. Especially when forming raised areas using gravure printing, if the organic filler is too large, it may not be able to enter the cells of the printing plate, or the number of particles entering may be insufficient, thus making it difficult to obtain the desired visual effect and tactile feel. Therefore, organic fillers with the above-mentioned particle sizes are particularly preferred.

[0111] In this specification, the particle size of each particle is expressed as the 50% particle size when the particle size distribution is determined by the dynamic light scattering method, in terms of volume cumulative distribution (d50: median particle size).

[0112] The content of organic filler is preferably 15 parts by mass or more, more preferably 20 parts by mass or more, and even more preferably 25 parts by mass or more, relative to 100 parts by mass of resin adhesive constituting the protrusion 20. If the content of organic filler is within the above range, the organic fillers can easily aggregate to form the protrusion. Therefore, excellent visual effects can also be obtained, and an appearance design that feels three-dimensional and deep can be created. In addition, it can give the decorative material 1 an excellent tactile feel. On the other hand, in order to reliably bond the organic filler with resin adhesive to prevent detachment, and to make the resin composition flow well so as to facilitate the forming process, the content of organic filler is preferably 50 parts by mass or less, more preferably 45 parts by mass or less, and even more preferably 40 parts by mass or less, relative to 100 parts by mass of resin adhesive.

[0113] <Inorganic packing>

[0114] The protrusion 20 may further comprise inorganic filler. Examples of inorganic fillers include silica, clay, heavy calcium carbonate, light calcium carbonate, precipitating barium sulfate, calcium silicate, and synthetic silicates. The size of the inorganic filler is preferably 1 μm to 20 μm, more preferably 3 μm to 10 μm, and even more preferably 3 μm to 7 μm. It should be noted that the size of the inorganic filler is preferably selected within a range that does not impair the tactile feel of the organic filler.

[0115] The content of inorganic filler is preferably 1 to 40 parts by mass relative to 100 parts by mass of resin adhesive constituting protrusion 20, more preferably 2 to 30 parts by mass, and even more preferably 3 to 25 parts by mass.

[0116] By including inorganic fillers in addition to glossy flakes, the gloss of decorative materials can be adjusted. Furthermore, it can increase the gloss difference between textured areas and other areas, thereby giving decorative materials a sophisticated appearance.

[0117] The ink for raised areas (ink for raised layers) may contain organic solvents as needed. There are no particular limitations on the organic solvents used, but it is preferable to select them appropriately considering the viscosity of the ink and the evaporation rate of the solvent.

[0118] Specifically, if the solvent's viscosity coefficient is too low, the ink viscosity will be low. Therefore, even if glossy flake particles and organic filler aggregates form, there will be insufficient resin to create raised areas. As a result, the glossy flake particles are scattered throughout the textured area, resulting in low contrast and a monotonous appearance. Furthermore, it may be difficult to achieve the glossy matte effect and good tactile feel provided by the organic fillers. On the other hand, if a solvent with a high viscosity coefficient is used, the ink viscosity will be high, leading to poor coatability. Moreover, when forming raised areas through gravure printing, individual cells may form independently, or the organic fillers may be embedded in the resin, making it difficult to achieve a good gloss and tactile feel. Additionally, if the solvent evaporation rate is too slow, it will be difficult to form large raised areas, resulting in a poor gloss and tactile feel.

[0119] Based on the above, by selecting an organic solvent with an appropriate viscosity coefficient and evaporation rate, decorative materials with excellent gloss and tactile feel can be easily obtained. The organic solvent can be a single type or a mixture of multiple solvents. Specifically, examples of organic solvents with a viscosity coefficient suitable for this disclosure include xylene, cyclohexanone, toluene, methyl isobutyl ketone, butyl acetate, methoxypropyl acetate, and propylene glycol monomethyl ether propionate. Cyclohexanone is an example of a solvent with a fast evaporation rate. A mixture of xylene and cyclohexanone (a 1:1 weight ratio) is particularly preferred.

[0120] The preferred coating weight of the ink for raised areas (ink for raised layers) after drying is 10 g / m². 2 ~500g / m 2 .

[0121] To improve weather resistance, the protrusion 20 preferably contains weather-resistant agents such as ultraviolet absorbers and light stabilizers.

[0122] The following describes in detail the layers other than the raised layer 7 of the decorative material 1.

[0123] [Substrate]

[0124] As for substrate 2, there are no particular limitations as long as it is a substrate commonly used as a decorative material. For example, resin substrates, metal substrates, kiln-based substrates, fibrous substrates, wood-based substrates, etc., can be appropriately selected depending on the application. The above-mentioned substrates can be used individually or in a laminate based on any combination. When substrate 2 is a laminate, it can be configured by further providing adhesive layers between the layers of the laminate.

[0125] Examples of resin base materials include various synthetic resins. Examples of synthetic resins include polyethylene resin, polypropylene resin, polymethylpentene resin, polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl alcohol copolymer resin, polyethylene terephthalate resin, polybutylene terephthalate resin, ethylene glycol-naphthalate-isophthalate copolymer resin, polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, polyamide resins represented by nylon 6 or nylon 66, cellulose triacetate resin, celluloid, polystyrene resin, polycarbonate resin, polyarylate resin, and polyimide resin.

[0126] Examples of metal substrates include pure metals composed of a single metallic element such as aluminum, iron, copper, or titanium; and substrates formed from alloys containing one or more of these metals, such as carbon steel, stainless steel, duralumin, brass, and bronze. Alternatively, substrates obtained by applying these metals through plating or the like can also be used. Metal substrates exhibit excellent heat resistance, thus possessing resistance to deformation during high-temperature heat treatments (drying and final baking after the base coating is formed) in the manufacturing method described later, making them preferable. Furthermore, by using a metal substrate, the effect of the bright, flaky particles can be further enhanced through the reflection of the metal substrate.

[0127] Examples of ceramic substrates include gypsum board, calcium silicate board, wood chip cement board, ceramics, glass, enamel, and fired ceramic tiles. Ceramic substrates also exhibit excellent heat resistance, thus exhibiting resistance to deformation during high-temperature heat treatment in the manufacturing methods described later, making them preferable.

[0128] As a fibrous substrate, paper substrates such as tissue paper, kraft paper, titanium dioxide paper, lint paper, cardboard, and gypsum board base paper can be used. For these paper substrates, to improve the inter-fiber or interlayer strength between the paper substrate and other layers, and to prevent fuzzing, resins such as acrylic resin, styrene-butadiene rubber, melamine resin, and urethane resin can be further added (either through resin impregnation after papermaking or by filling during papermaking). Examples of paper substrates with added resins include inter-paper reinforced paper and resin-impregnated paper.

[0129] In addition, as a fibrous substrate, vinyl wallpaper materials with a vinyl chloride resin layer on the surface of a paper substrate can also be used.

[0130] In addition, as fibrous substrates, examples include woven and nonwoven fabrics made of various fibers that differ from the paper substrates mentioned above but have a similar appearance and properties to paper. Examples of these fibers include inorganic fibers such as glass fiber, asbestos fiber, potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber. Examples of these fibers include synthetic resin fibers such as polyester fiber, acrylic fiber, and vinylon fiber. From the perspective of adaptability to embossed patterns, these paper types are preferably used in combination with plastic substrates that have excellent adaptability to embossing.

[0131] Examples of wood-based substrates include veneers, plywood, laminates, particleboard, and medium-density fiberboard (MDF) made from woods such as cedar, cypress, pine, beech, oak, and lauan.

[0132] The thickness of the substrate 2 is not particularly limited and can be appropriately set according to the application, required specifications, etc. For example, the thickness of the substrate 2 is preferably 0.02 mm or more and 5 mm or less, and more preferably 0.4 mm or more and 3 mm or less.

[0133] [Primer layer]

[0134] The primer layer 3 is applied between the substrate 2 and the pattern layer 5. The primer layer 3 serves to ensure good adhesion between the substrate 2 and the pattern layer 5.

[0135] The primer layer 3 can be formed using an ink (primer ink) formed from a resin composition containing a resin binder. The primer ink may appropriately contain a solvent.

[0136] As resin binders, preferred examples include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene resins, urethane-acrylic acid copolymers, polycarbonate-urethane-acrylic acid copolymers (urethane-acrylic acid copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer backbone and two or more hydroxyl groups at the ends and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic acid copolymer resins, chloropropylene resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, fluorine resins, etc., which can be used alone or in combination.

[0137] In addition to single-component curing types, various types of resins can also be used, such as two-component curing types that use curing agents such as toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPID), and phenyl diisocyanate (XDI).

[0138] To improve weather resistance, the primer layer 3 preferably contains weather-resistant agents such as ultraviolet absorbers and light stabilizers.

[0139] To improve interlayer adhesion, the thickness of the primer layer 3 is preferably 1 μm or more, more preferably 2 μm or more. Furthermore, as an upper limit for the thickness of the primer layer 3, it is preferably 10 μm or less, more preferably 7 μm or less, and even more preferably 5 μm or less.

[0140] [Undercoat]

[0141] The base coating 4 is a layer that is provided between the substrate 2 and the surface coating 8 as needed to improve the appearance design.

[0142] The base coating 4 is usually formed as an opaque layer, serving to obscure the substrate 2 when viewed by an observer and to impart the desired color. However, the base coating 4 can also be formed as a translucent or transparent layer to bring out the patterns and colors of the substrate 2.

[0143] The base coat 4 can be formed using an ink (base coat ink) formed from a resin composition. The base coat ink may appropriately contain a solvent.

[0144] There are no particular limitations on the resin used in the formation of the base coating 4. Examples include thermoplastic resins such as fluoropolymers, (meth)acrylic resins, polyurethane resins, polyester resins, polyamide resins, (meth)acrylic ester-olefin copolymer resins, vinyl chloroacetate resins, ethylene-vinyl acetate copolymer resins (EVA resins), ionomer resins, and olefin-α-olefin copolymer resins; and curable resins such as fluoropolymers, epoxy resins, phenolic resins, urea-formaldehyde resins, polyester resins, melamine resins, alkyd resins, polyimide resins, silicone resins, hydroxyl-functional acrylic resins, carboxyl-functional acrylic resins, amide-functional copolymers, and urethane resins. Curable resins include thermosetting resins, ionizing radiation-curable resins, and two-component curable resins.

[0145] In addition, when the base layer 4 is set as a masking layer, the base layer 4 contains colorants such as pigments in addition to the resin mentioned above.

[0146] There is no particular limitation on the colorant incorporated in the undercoat layer 4. For example, inorganic pigments such as carbon black, iron black, titanium white, antimony white, titanium yellow, iron yellow, iron oxide red, cadmium red, ultramarine, cobalt blue, etc.; organic pigments or dyes such as quinacridone red, isoindolinone yellow, phthalocyanine blue, etc.; metallic pigments formed from scaly foils such as aluminum and brass; pearlescent pigments formed from scaly foils such as titanium dioxide-coated mica and basic lead carbonate, etc. These colorants can be used alone as one kind, or two or more kinds can be used in combination.

[0147] In addition to the above components, various additives can be incorporated in the undercoat layer 4 according to the desired physical properties. As additives, for example, weather resistance improvers such as ultraviolet absorbers and light stabilizers, wear resistance improvers, polymerization inhibitors, infrared absorbers, defoamers, fillers, etc. can be cited. In addition, if a curable resin is used in the formation of the undercoat layer 4, a curing agent can also be included. These additives can be appropriately selected and used from commonly used additives.

[0148] There is no particular limitation on the thickness of the undercoat layer 4, and it can be appropriately set according to the use, required specifications, etc. For example, the thickness of the undercoat layer 4 is preferably 5 μm to 40 μm, more preferably 10 μm to 30 μm.

[0149] 〔Pattern layer〕

[0150] The pattern layer 5 is a layer provided on the surface side of the substrate 2 and imparting a design property to the decorative material. When observed from the surface side, the pattern layer 5 can be provided on the entire surface of the substrate 2 or on a part thereof.

[0151] There is no particular limitation on the pattern of the pattern layer 5, and it can be set to the desired pattern. For example, wood grain patterns, marble patterns (e.g., travertine marble patterns), stone grain patterns imitating the cleavage surface of rocks such as granite slabs, fabric patterns imitating cloth patterns or cloth-like patterns, leather (leather wrinkles) patterns showing the wrinkles of leather, tile pasting patterns, bricklaying patterns, thin lines, ten thousand groove (Japanese: 万 条溝), pear skin patterns, sand patterns, characters, symbols, geometric patterns, etc., and patterns such as parquet and patchwork patterns formed by combining them.

[0152] The pattern layer 5 can be configured as a single layer or as a configuration in which multiple layers are stacked. For example, it can be configured as follows: the layer on the substrate side is used as an undercoat layer that becomes the base color, and a pattern layer that becomes the pattern pattern is stacked on this undercoat layer.

[0153] The pattern layer 5 can be formed using an ink (pattern layer ink) formed from a resin composition containing a resin binder and a colorant. This ink can appropriately contain a solvent.

[0154] Examples of resin binders preferably include urethane resins, acrylic polyol resins, acrylic resins, polyester resins, alkyd resins, amide resins, butyral resins, styrene resins, urethane-acrylic acid copolymers, vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic acid copolymer resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, and fluoropolymers. Additionally, two-component curable resins using polyols as the main component and isocyanates as the curing agent can also be used. These can be used alone or in combination.

[0155] As colorants used in pattern layer 5, pigments, dyes, and combinations thereof can be used. Examples of pigments include white pigments such as titanium dioxide, inorganic pigments such as iron black, chrome yellow, titanium yellow, iron oxide red, cadmium red, ultramarine, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolineone yellow, phthalocyanine blue, nickel-azo complexes, azomethyl alkali azo black pigments, and perylene black pigments; metallic pigments formed from flake-like foils such as aluminum and brass; and pearlescent (pearlescent) pigments formed from flake-like foils such as titanium dioxide coated with mica and basic lead carbonate.

[0156] To improve weather resistance, pattern layer 5 may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers.

[0157] To easily achieve the visual effect resulting from the gloss difference with the protrusion 20, the pattern layer 5 may contain a matting agent. Examples of matting agents include organic fillers such as urethane resin, nylon resin, polypropylene resin, or urea resin; and inorganic fillers such as silica, clay, heavy calcium carbonate, light calcium carbonate, precipitating barium sulfate, calcium silicate, and synthetic silicates.

[0158] The particle size (volume average particle size) of the matting agent is preferably 1 μm to 15 μm, more preferably 2 μm to 10 μm, and even more preferably 3 μm to 7 μm.

[0159] Furthermore, the content of the matting agent in the pattern layer relative to 100 parts by weight of the resin binder is preferably 3 parts by weight or more, more preferably 10 parts by weight or more, and even more preferably 20 parts by weight or more. As an upper limit, it is generally 100 parts by weight or less, preferably 70 parts by weight or less, more preferably 50 parts by weight or less, and even more preferably 30 parts by weight or less. If the content of the matting agent is within the above range, the pattern layer can be visually identified as a low-gloss layer, thus improving the visual effect (gloss-matte effect).

[0160] The thickness of pattern layer 5 can be appropriately selected according to the desired pattern. The thickness of pattern layer 5 is preferably 1 μm or more, more preferably 3 μm or more, and even more preferably 5 μm or more. The upper limit of the thickness of pattern layer 5 is preferably 10 μm or less, more preferably 7 μm or less, and even more preferably 5 μm or less. When forming multiple pattern layers, the total thickness of all layers is set within the above-mentioned range.

[0161] [Transparent base layer]

[0162] A transparent substrate layer 6 is disposed between the pattern layer 5 and the protrusion 20, which facilitates visual identification of the pattern layer 5 and improves the adhesion between the pattern layer 5 and the protrusion 20. When viewed from the surface side, the transparent substrate layer 6 can be disposed on the entire surface of the substrate 2 or on a portion thereof.

[0163] The transparent substrate 6 can be formed using an ink (ink for transparent substrate) formed from a resin composition containing a resin binder. The ink for transparent substrate may appropriately contain a solvent.

[0164] Examples of resin binders preferably include urethane resins, acrylic polyol resins, acrylic resins, polyester resins, alkyd resins, amide resins, butyral resins, styrene resins, urethane-acrylic acid copolymers, vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic acid copolymer resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, and fluorinated resins. Additionally, two-component curable resins using polyols as the main component and isocyanates as the curing agent can also be used. These can be used alone or in combination.

[0165] To enhance the visual effect (gloss / matte effect) resulting from the gloss difference with the protrusion 20, the transparent substrate 6 preferably has a higher gloss compared to the protrusion 20. The transparent substrate 6 preferably contains a matting agent as needed.

[0166] Examples of matting agents include silica, clay, heavy calcium carbonate, light calcium carbonate, precipitating barium sulfate, calcium silicate, synthetic silicates, and inorganic fillers such as silicate micropowder. The volume average particle size of the matting agent is preferably 1 μm to 20 μm, more preferably 3 μm to 10 μm, and even more preferably 3 μm to 7 μm.

[0167] Furthermore, the content of the matting agent in the transparent base layer 6 relative to 100 parts by weight of the resin binder is preferably 1 part by weight or more, more preferably 3 parts by weight or more, and even more preferably 5 parts by weight or more. As an upper limit, it is generally 100 parts by weight or less, preferably 80 parts by weight or less, more preferably 50 parts by weight or less, and even more preferably 30 parts by weight or less. If the content of the matting agent is within the above range, an excellent visual effect (glossy matte effect) can be obtained.

[0168] To improve weather resistance, the transparent substrate 6 may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers.

[0169] The thickness of the transparent substrate 6 can be appropriately selected according to the desired pattern. The transparent substrate 6 is preferably 2 μm or more, more preferably 4 μm or more, and even more preferably 6 μm or more. Furthermore, the upper limit of the thickness is preferably 20 μm or less, more preferably 15 μm or less, and even more preferably 10 μm or less.

[0170] [Surface coating]

[0171] To improve durability such as weather resistance, scratch resistance, abrasion resistance, and stain resistance, as well as aesthetics such as gloss, a surface coating 8 can be formed on the outermost surface of the decorative material 1 as needed. When a surface coating 8 is formed, the transparent base layer 6 can be omitted. Even if the shape of the protrusion 20 exposed on the outermost surface exhibits the desired durability and aesthetics, the surface coating can be omitted.

[0172] When a surface coating is formed on a raised layer, the raised layer and the surface coating can be used to form the protrusions and gaps in the textured area.

[0173] The surface coating 8 can be formed using an ink (surface coating ink) formed from a resin composition. The surface coating ink may appropriately contain a solvent.

[0174] There are no particular limitations on the resin used in the formation of surface coating 8. Examples include thermoplastic resins such as (meth)acrylic resin, polyurethane resin, polyester resin, polyamide resin, (meth)acrylic ester-olefin copolymer resin, vinyl chloroacetate resin, ethylene-vinyl acetate copolymer resin (EVA resin), ionomer resin, and olefin-α-olefin copolymer resin; epoxy resin, phenolic resin, urea-formaldehyde resin, unsaturated polyester resin, melamine resin, alkyd resin, polyimide resin, silicone resin, hydroxyl-functional acrylic resin, carboxyl-functional acrylic resin, amide-functional copolymer, urethane resin, and fluoropolymer resin. One of these resins may be used alone, or two or more may be used in combination.

[0175] Various additives can be incorporated into the surface coating 8 according to the desired physical properties. Examples of additives include, for instance, weather-resistant improvers such as ultraviolet absorbers (benzotriazole ultraviolet absorbers, triazine ultraviolet absorbers, etc.), light stabilizers (hindered amine free radical scavengers, etc.), wear-resistant improvers (silica, alumina, kaolinite particles, etc.), polymerization inhibitors, infrared absorbers, defoamers, and fillers.

[0176] To impart durability and gloss to the surface of the decorative material 1, the thickness of the surface coating 8 is preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more. On the other hand, considering the time, energy, and material costs required for drying and curing the surface coating, the upper limit of the thickness of the surface coating 8 is preferably 40 μm or less, more preferably 35 μm or less, and even more preferably 30 μm or less.

[0177] The decorative material in this embodiment can be illustrated by the following layered structure. It should be noted that the symbol " / " refers to the boundary between each layer.

[0178] (1) Substrate / Primer Layer / Undercoat Layer / Pattern Layer / Transparent Base Layer / Raised Layer / Surface Coating

[0179] (2) Substrate / Primer Layer / Undercoat Layer / Pattern Layer / Transparent Base Layer / Raised Layer

[0180] (3) Substrate / Primer Layer / Undercoat Layer / Pattern Layer / Raised Layer / Surface Coating

[0181] (4) Substrate / Primer Layer / Undercoat Layer / Pattern Layer / Raised Layer

[0182] (5) Substrate / Raised Layer

[0183] (6) Substrate / Raised Layer / Surface Coating

[0184] (7) Substrate / Primer / Raised Layer

[0185] (8) Substrate / Primer / Raised Layer / Surface Coating

[0186] (9) Substrate / Primer / Pattern Layer / Raised Layer / Surface Coating

[0187] [Manufacturing methods for decorative materials]

[0188] The decorative material 1 disclosed herein is preferably formed in layers other than the substrate by a known coating process.

[0189] The following example, using a metal sheet as the substrate, illustrates the manufacturing method of the decorative material disclosed herein.

[0190] (1) Primer layer formation process

[0191] Apply a primer layer of ink to one surface of the metal plate (substrate). It should be noted that this step can be omitted.

[0192] The primer layer ink is preferably applied to the entire surface of the metal sheet. Coating methods include roller coating, reverse coating, air spraying, electrostatic coating, and powder coating.

[0193] After application, the ink is heated and dried at 100℃~300℃ to form a primer layer.

[0194] (2) Primer coating process

[0195] Apply primer ink over the primer layer. It should be noted that this step can be omitted.

[0196] The ink for the primer layer is preferably applied to the entire surface of the primer layer. Coating methods include flow coating, roller coating, reverse coating, air spraying, electrostatic coating, and powder coating.

[0197] After coating, the material is dried at a heating temperature (substrate temperature) of 165°C to 270°C (preferably 200°C to 250°C). This forms a base coat.

[0198] By heating and curing the base coat ink within the aforementioned temperature range, the depression of the lower layer of the raised portion 20 in the portion containing organic filler, caused by baking after the formation of the raised portion 20, is suppressed, and a sufficiently high raised portion 20 is easily formed. Furthermore, during heating after the raised portion 20 is formed, the particles of the raised portion 20 tend to aggregate. As a result, a decorative material with the desired visual effect and good tactile feel can be obtained. Particularly in the case of a thermosetting polyester resin base coat, by heating the substrate to a temperature of 200°C or higher, a decorative material with excellent tactile feel can be easily obtained.

[0199] (3) Pattern layer formation process

[0200] Apply the pattern layer ink to the base coat in any pattern. It should be noted that this step can be omitted.

[0201] As a coating method, gravure printing, offset printing, flexographic printing, letterpress printing, screen printing, inkjet printing, transfer printing, etc. can be applied.

[0202] After application, allow the pattern layer to dry with ink to form the pattern layer.

[0203] (4) Transparent substrate formation process

[0204] Apply a transparent base layer ink onto the pattern layer (texture layer). It should be noted that this step can be omitted.

[0205] The transparent base layer is preferably coated with ink on the entire surface of the metal plate. Coating methods include gravure printing, offset printing, flexographic printing, letterpress printing, and screen printing.

[0206] After coating, the ink is heated and dried at 150℃~250℃ (the temperature reached by the substrate) to form a transparent base layer.

[0207] (5) Formation process of raised layer

[0208] A raised layer is formed in the textured area that becomes the decorative material. Based on the raised layer, a textured area with multiple independent protrusions is formed, and gaps are further formed between the protrusions.

[0209] Specifically, a raised layer ink (a raised layer ink) is applied to a transparent base layer or a pattern layer. The raised layer ink can be applied to the entire surface of the metal plate or to a portion thereof. In particular, if the ink is applied in accordance with the pattern of the pattern layer, an aesthetic and tactile feel corresponding to the pattern can be obtained, which is especially preferred.

[0210] In this disclosure, the application of ink to the raised layer is preferably performed by gravure printing. The gravure printing plate has multiple cells on its surface. Immediately after printing, the cell-shaped inks printed from each cell to the substrate side exist independently, but during the process from printing to drying, a portion of the multiple cell-shaped inks randomly integrates within the textured area, forming a raised portion. In gravure printing, gravure offset printing is particularly preferred from the perspective of facilitating the integration of adjacent inks on the rubber roller. In this process, the raised portion can be formed by a single printing pass or by multiple printing passes.

[0211] Furthermore, by including an organic solvent with an appropriate viscosity coefficient and evaporation rate in the ink used for the raised layer, adjacent cell-like inks can easily integrate. However, if the ink viscosity is too low, this integration is less likely to occur; therefore, it is preferable to set the particle amount within the range described above, or to select the solvent as described above.

[0212] (6) Surface coating formation process

[0213] Apply a surface coating ink to the raised layer. It should be noted that this step can be omitted.

[0214] The ink used for surface coating is preferably applied to the entire surface of the decorative material. Coating methods include flow coating, roller coating, reverse coating, air spraying, electrostatic coating, and powder coating.

[0215] After application, the ink is heated and dried at 100℃~300℃ to form a surface coating.

[0216] (7) Baking process

[0217] After the raised layer or surface coating is formed, the substrate is baked at a heating temperature (substrate temperature) of 150°C to 270°C (preferably 200°C to 250°C).

[0218] [Layered Body]

[0219] The laminate of this disclosure comprises an adhesive and the decorative material of this disclosure laminated on the adhesive. The adhesive and the decorative material are preferably fixed together using an adhesive layer, rivets, or the like.

[0220] The substrate to be bonded can be selected appropriately based on the intended use of the laminate. For example, metal components, wooden components, kiln components, and resin components can be used as substrates.

[0221] [Uses of Decorative Materials and Laminates]

[0222] The decorative materials and laminates disclosed herein can be used, for example, as surface decorative panels for interior or exterior components.

[0223] Examples of interior components include surface materials for interior building components such as walls, floors, and ceilings; partitions, doors, window frames, railings, and ceiling trim. Surface materials for interior furnishings such as unit bathrooms; interior materials for vehicles such as automobiles and trams; surface materials for household appliances; etc.

[0224] Examples of exterior building components include surface materials for exterior building components such as roofs, walls, floors, balcony enclosures, eaves, and ceilings; surface materials for exterior equipment such as entrance doors, doors, window frames, railings, ceiling trims, and tree-lined walkways; and exterior materials for vehicles such as automobiles and trams.

[0225] Example

[0226] The present disclosure will now be described in more detail by way of examples, but the present disclosure is not limited by these examples.

[0227] [Measurement and Evaluation]

[0228] The decorative materials prepared in the examples and comparative examples were measured and evaluated as follows. The results are shown in Table 1.

[0229] <Appearance Observation>

[0230] The decorative materials of the embodiments and comparative examples were visually observed.

[0231] <Visual Effects Evaluation>

[0232] For the decorative materials in the embodiments and comparative examples, the visual effects of brightness and three-dimensionality were evaluated. A score of 2 was assigned to cases where the perceived visual effect was excellent, 1 point to cases where the visual effect was acknowledged but not perceived as sufficient, and 0 points to cases where the perceived visual effect was insufficient. Twenty test takers evaluated the materials, and the average score was calculated. Based on the average score, the following indicators were used for further evaluation.

[0233] A: Average score above 1.5

[0234] B: Cases with an average score above 1.2 and below 1.5

[0235] C: Cases where the average score is less than 1.2

[0236] <Observation using an optical microscope (fine shapes in textured areas)>

[0237] The textured areas of the decorative material were observed using an optical microscope (KEYENCE, VHX-2000 digital microscope) at magnifications of 200x to 700x.

[0238] <Calculation of Area Ratio>

[0239] For the decorative materials in the embodiments and comparative examples, the optical microscope images (magnification: 300x) described above were binarized. The convex portions were extracted from the binarized images, and the area ratio of the convex portions relative to the overall image was calculated.

[0240] <Average diameter of the circumcircle>

[0241] For the decorative materials of the embodiments and comparative examples, the diameters of all the circumcircle circles of the protrusions that can be identified in the binarized image are calculated. Furthermore, the average diameter of the obtained circumcircle diameters is calculated.

[0242] <D / d aye >

[0243] For the decorative materials of the embodiments and comparative examples, five groups of adjacent protrusions were selected using the aforementioned optical microscope images (magnification: 300x). The average value d of the diameter of the circumcircle was calculated for each group. ave The distance D between the centers of the circumcircles was used to obtain D / d. ave Furthermore, the obtained D / d is calculated. ave The average value.

[0244] <Height of the convex part (average height)>

[0245] For the decorative materials of the embodiments and comparative examples, the optical microscope images (magnification: 700x) were analyzed using high-definition depth-synthesized 3D to determine the average height of the protrusions. The height of the protrusions was set as the average height of the following heights: four lines were drawn that pass through the center of the circumcircle and divide the circumcircle into eight equal parts; for the protrusions located on these four lines, the height from the region where no protrusions exist was calculated.

[0246] <Touch>

[0247] The textured areas of the decorative materials were examined by touch. A strong, palpable texture was scored as 2 points, a palpable texture as 1 point, and almost no texture as 0 points. Twenty participants evaluated the materials, and the average score was calculated. Based on the average score, the following criteria were used for evaluation.

[0248] A: Average score above 1.5

[0249] B: Cases with an average score above 1.2 and below 1.5

[0250] C: Cases where the average score is less than 1.2

[0251] [Example 1]

[0252] The primer layer ink of the following formulation is applied by roller coating to the entire surface of a steel plate (SGCC-QM, size 800mm × 2000mm, thickness 0.6mm) to achieve a film thickness of 2μm after drying. It is then dried at 230°C (the temperature reached by the substrate) to form the primer layer.

[0253] <Ink for primer layer>

[0254] Thermosetting polyester resin

[0255] • Diluent

[0256] • Solid content: 74% by mass

[0257] The primer coating ink of the following formulation is applied to the entire surface of the primer layer using a curtain coating machine, resulting in a dried film thickness of 22 μm. It is then dried at 210°C (the temperature reached by the substrate) to form the primer coating.

[0258] <Ink for base coating>

[0259] • Thermosetting polyester resin: 100 parts by weight

[0260] • Colorants (carbon black, titanium dioxide, iron oxide (iron oxide red), yellow iron oxide (iron yellow)): 25 parts by weight

[0261] • Solvents (xylene, cyclohexanone)

[0262] · Solid content: 35% by mass

[0263] A pattern layer with a specified pattern is formed on the primer coat. Specifically, an ink for the pattern layer containing a thermosetting polyester resin and a colorant is applied to the entire surface of the primer coat by gravure printing so that the film thickness after drying becomes 1 μm. Thus, a pattern layer with a marble pattern is formed.

[0264] An ink for the transparent base layer with the following formulation is applied to the entire surface of the pattern layer by offset gravure printing so that the film thickness after drying becomes 2 μm.

[0265] <Ink for transparent base layer>

[0266] · Thermosetting acrylic resin: 100 parts by mass

[0267] · Silicon dioxide: 8 parts by mass

[0268] · Solvent (xylene, cyclohexanone)

[0269] An ink 1 for the raised layer with the following formulation is applied to the entire surface of the transparent base layer by gravure printing and dried (coating amount after drying: 200 g / m 2 ) to form a raised layer. Thus, a textured area with multiple independent convex portions is formed on the transparent base layer. A bevel-engraved gravure cylinder (Japanese: 斜掘グラビア版胴) is used for printing. As this gravure cylinder, a gravure cylinder produced by the following method is used: after laser beam exposure of the photosensitive resist film on the surface of the metal plate-making material, the metal plate material is subjected to etching to form a desired cell pattern.

[0270] <Ink 1 for raised layer>

[0271] · Thermosetting acrylic resin: 100 parts by mass

[0272] · Glossy flaky particles (glass flakes, 2025PSTM manufactured by Nippon Sheet Glass Co., Ltd.): 7 parts by mass

[0273] · Silicon dioxide: 20 parts by mass

[0274] · Acrylic beads (diameter 30 μm): 20 parts by mass

[0275] · Solvent (butyl carbitol, xylene, cyclohexanone)

[0276] · Solid content: 40% by mass

[0277] After the raised layer is formed, baking is performed under the condition of 220 °C (substrate reaching temperature). Thus, the decorative material of Example 1 is obtained.

[0278] [Example 2]

[0279] The primer layer ink with the same formulation as in Example 1 was applied to the entire surface of an aluminum plate (A3004PH32, 800mm × 2000mm, 2mm thick) by roller coating, resulting in a dried film thickness of 2μm. It was then dried at 230°C (the temperature reached by the substrate) to form the primer layer.

[0280] A primer coating ink with the same formulation as in Example 1 was applied to the entire surface of the primer layer using a curtain coating machine, resulting in a dried film thickness of 22 μm. The film was then dried at 210°C (the temperature reached by the substrate) to form the primer coating.

[0281] A patterned layer with a specified design is formed on the base coating. An ink containing thermosetting polyester resin and colorant is then applied to the entire surface of the base coating using gravure printing, resulting in a dried film thickness of 1 μm. This forms a striped patterned layer.

[0282] On the pattern layer, a raised layer of ink 1 is applied in a striped pattern using gravure printing and then dried (coating weight after drying: 250 g / m²). 2 This forms a raised layer. Thus, a textured area with multiple independent raised sections is formed on the pattern layer. Printing uses a slanted gravure cylinder. This gravure cylinder is made by laser-exposing a photosensitive resist film on the surface of a metal plate, followed by etching the metal plate to form the desired cell pattern.

[0283] The surface coating ink of the following formulation was applied using a flow coater to both the areas with and without the raised layer (i.e., covering the entire surface of the aluminum plate) to achieve a dried film thickness of 18 μm. Then, it was baked at 220°C (the temperature reached by the substrate) to form the raised layer and the surface coating. This yielded the decorative material of Example 2.

[0284] <Inks for Surface Coating>

[0285] Thermosetting polyester resin

[0286] • Solvents (xylene, cyclohexanone)

[0287] • Solid content: 35% by mass

[0288] [Comparative Example 1]

[0289] A primer layer to a transparent base layer is formed on the entire surface of a steel plate (SGCC-QM, size 800mm×2000mm, thickness 0.6mm) using the same formulation and process as in Example 1.

[0290] Then, the raised layer ink 2 of the following formulation was applied to the entire surface of the transparent substrate by gravure printing and dried (coating weight after drying: 300 g / m²). 2 Then, it was baked at 220°C (the temperature at which the substrate reaches) to form a raised layer, thus obtaining the decorative material of Comparative Example 1.

[0291] <Ink for Raised Layer 2>

[0292] • Thermosetting acrylic resin: 100 parts by weight

[0293] • Silicon dioxide: 8 parts by weight

[0294] • Solvents (xylene, cyclohexanone)

[0295] <Comparative Example 2>

[0296] A primer layer to a transparent base layer is formed on the entire surface of a steel plate (SGCC-QM, size 800mm×2000mm, thickness 0.6mm) using the same formulation and process as in Example 1.

[0297] Then, the raised layer ink 3 of the following formulation is applied by gravure printing and dried (coating weight after drying: 250 g / m²). 2 The printing used a slanted gravure cylinder. This gravure cylinder was manufactured by laser beam exposure of a photosensitive resist film on the surface of a metal plate, followed by etching of the metal plate to form the desired cell pattern. Then, it was baked at 220°C (the substrate temperature) to form a raised layer, resulting in the decorative material of Comparative Example 2.

[0298] <Ink for Raised Layer 3>

[0299] • Thermosetting acrylic resin: 100 parts by weight

[0300] • Silicon dioxide: 8 parts by weight

[0301] • Acrylic beads (30μm diameter): 20 parts by weight

[0302] • Solvents (butyl carbitol, xylene, cyclohexanone)

[0303] • Solid content: 40% by mass

[0304] exist Figure 5 and Figure 6 The images show photographs of the appearance of the decorative materials in Examples 1 and 2, respectively. Figures 7-9 Microscopic photographs (magnification: 300x) of the textured areas in the decorative materials of Examples 1 and Comparative Examples 1-2 are shown.

[0305] The evaluation results for the decorative materials of each embodiment and comparative example are shown in Table 1.

[0306] [Table 1]

[0307] Table 1

[0308] Example 1 Example 2 Comparative Example 1 Comparative Example 2 Average diameter of circumcircle (μm) 210 220 70 250 Area percentage (%) 34 30 2 37 <![CDATA[D / d ave ]]> 1.4 1.5 5.9 1.6 Average height (μm) 23 10 8 20 Visual effects A A C B tactile A B C A

[0309] In the decorative material of Example 1, the areas with increased brightness due to the aggregation of glossy flaky particles appear as randomly arranged patterns. Therefore, the contrast between the bright areas (the raised portions within the textured area) and other areas (the darker portions within the textured area) is strongly felt. Furthermore, this results in an appearance design where the brightness of the patterned areas changes when the viewing angle is changed. As a result, the decorative material of Example 1 has a three-dimensional feel and can exhibit an appearance design that conveys a high-end impression.

[0310] For the decorative material of Example 2, the brightness difference between the textured area (the patterned portion formed by the protrusions) and the rest (other areas) is significant, and the brightness change of the patterned portion is perceptible when the angle is changed. Even within the textured area, the contrast between the bright areas produced by the glossy flaky particles and the rest is noticeable. Furthermore, the gloss of areas other than the bright spots formed by the glossy flaky particles is suppressed, resulting in a moist texture. As a result, the decorative material of Example 2, as a whole, exhibits a three-dimensional appearance.

[0311] Furthermore, the tactile feel of the decorative materials in Examples 1 and 2 was rated as excellent.

[0312] like Figure 7 As shown, in Example 1, it can be confirmed that the protrusions are densely formed. Furthermore, the bright, flaky particles tend to be present within the protrusions (islands), while they are almost invisible in the areas outside the protrusions (sea areas). It is believed that by having such a fine structure, the protrusions appear to have higher brightness, while the sea areas have lower brightness, thus creating the aforementioned brightness contrast.

[0313] In Comparative Example 1, no difference in brightness or gloss was perceived between the textured areas and other areas. Because it does not contain glossy flaky particles, the decorative material in Comparative Example 1 did not exhibit a glossy appearance. While the decorative material in Comparative Example 1 could exhibit a matte finish, it resulted in a flat appearance. The decorative material in Comparative Example 1 did not exhibit a tactile feel based on the textured areas.

[0314] like Figure 8 As shown, although several protrusions can be identified in Comparative Example 1, they are smaller compared to Example 1.

[0315] Regarding the decorative material of Comparative Example 2, although a difference in gloss between the textured area and other areas was perceptible, it could not exhibit a glossy appearance compared to Examples 1 and 2 because it did not contain glossy flaky particles. Since the decorative material of Comparative Example 2 contained acrylic beads, it was able to achieve a tactile feel equivalent to that of Examples 1 and 2.

[0316] like Figure 9 As shown, it can be confirmed that in Comparative Example 2, the protrusions formed by particle aggregation are densely formed.

[0317] Explanation of reference numerals in the attached figures

[0318] 1. Decorative materials

[0319] 2. Substrate

[0320] 3. Primer layer

[0321] 4. Primer coating

[0322] 5. Pattern Layer

[0323] 6. Transparent base layer

[0324] 7. Uplifted layer

[0325] 8 Surface coating

[0326] 10 Texture Areas

[0327] 20 convex part

[0328] 21. Bright, flaky particles

[0329] 22 Organic fillers

[0330] 23 Resin adhesives

Claims

1. A decorative material having a textured area on a substrate, said textured area being composed of a plurality of independent protrusions. The protrusion comprises a resin adhesive and glossy flake particles. The shortest distance between adjacent protrusions is 5μm to 80μm. The average diameter of the circumscribed circle of the protrusion is 210 μm to 500 μm. The decorative material has areas other than the textured area. The area ratio of the textured region within the surface of the decorative material is more than 10% and less than 90%. When the 60-degree specular gloss of the textured area is defined as G60A and the 60-degree specular gloss of the other areas is defined as G60B, the ratio of G60A / G60B is less than 0.

8. The area ratio of the protrusions in the textured region is 20% to 70% within a 1cm square area.

2. The decorative material according to claim 1, wherein, The average height of the protrusion is 10μm to 60μm.

3. The decorative material according to claim 1 or 2, wherein, The average diameter of the circumscribed circle of the protrusion is 210μm to 250μm.

4. The decorative material according to claim 1 or 2, wherein, Let d be the average diameter of the circumcircle of a set of adjacent protrusions. ave When the distance between the centers of a set of adjacent circumcircles is set as D, D / d ave A group of adjacent convex parts that satisfy the following relationship accounts for more than 90% of all combinations. 0.5≤D / d ave ≤6.0。 5. The decorative material according to claim 1 or 2, wherein, The content of the glossy flaky particles is 3 parts by mass or more and 40 parts by mass or less, relative to 100 parts by mass of the resin adhesive.

6. The decorative material according to claim 1 or 2, wherein, The amount of bright, flaky particles in the gap region between the protrusions is per 500 μm 2 No more than 3.

7. The decorative material according to claim 1 or 2, wherein, The protrusion also includes organic fillers with a particle size of 5 μm or more and 60 μm or less.

8. The decorative material according to claim 7, wherein, The content of the organic filler is 15 parts by mass or more and 50 parts by mass or less, relative to 100 parts by mass of the resin binder.

9. The decorative material according to claim 1 or 2, wherein, The protrusion also contains inorganic filler.

10. The decorative material according to claim 9, wherein, The content of the inorganic filler is 1 to 40 parts by mass relative to 100 parts by mass of the resin binder.

11. The decorative material according to claim 1 or 2, wherein, The bright, sheet-like particles are particles on a sheet-like glass substrate with a coating of metal or metal oxide.

12. The decorative material according to claim 1 or 2, wherein, The substrate has a raised layer, and the surface of the decorative material having the raised layer is the textured area.

13. The decorative material according to claim 1 or 2, wherein, The substrate is a metal substrate.

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