decorative material

Abstract

A decorative material has a first surface and a second surface opposite to the first surface, and has a base material layer and a surface protective layer disposed closer to the first surface than the base material layer, the base material layer has a plurality of grooves on the surface closer to the first surface, at least some of the grooves have a filling portion inside the groove, the average value of 85-degree specular glossiness according to JIS Z8741:1997 of the first surface is 18% or less, and the standard deviation σ of 85-degree specular glossiness according to JIS Z8741:1997 is 1.0% or more.

Description

Technical Field

[0001] This invention relates to decorative materials. Background Technology

[0002] Decorative materials include interior and exterior materials used for decorating furniture, accessories, and walls. To impart a specific texture, there are also decorative materials with multiple grooves filled with ink.

[0003] Decorative materials filled with ink inside a groove can be manufactured, for example, by a process of "applying ink containing colorant to the grooved surface of the decorative material and then scraping off the ink in a predetermined direction." In this specification, the above process is sometimes referred to as "scraping" or "wiping."

[0004] When ink containing colorant is applied to the grooved surface of a decorative material, a portion of the filling material is filled with ink. During ink scraping, excess ink is removed, and ink can be pressed into the groove.

[0005] As a decorative material manufactured by scraping, for example, the decorative material described in Japanese Patent Application Publication No. 1-314168 and International Publication No. WO2021 / 060530. Summary of the Invention

[0006] The decorative materials described in Japanese Patent Application Publication No. 1-314168 and International Publication No. WO2021 / 060530 are required to possess a specified texture. Compared with the decorative materials described in Japanese Patent Application Publication No. 1-314168 and International Publication No. WO2021 / 060530, decorative materials made of artificial materials such as plastics are required to have a thinner texture and a texture similar to natural materials such as wood grain and stone grain.

[0007] The purpose of this invention is to provide a decorative material with a texture that is closer to that of natural materials.

[0008] In order to solve the above problems, one embodiment of the present invention provides the following [1]. [1]

[0010] A decorative material having a first surface and a second surface opposite to the first surface.

[0011] The decorative material has a substrate layer and a surface protective layer disposed closer to the first surface than the substrate layer.

[0012] The aforementioned substrate layer has multiple grooves on the surface near the first surface.

[0013] At least a portion of the aforementioned grooves has a filling portion inside the groove.

[0014] The average value of the 85-degree specular gloss of the first surface mentioned above, according to JIS Z8741:1997, is less than 18%, and the standard deviation σ of the 85-degree specular gloss of JIS Z8741:1997 is greater than 1.0%.

[0015] Furthermore, one embodiment of the present invention provides the following [2] to

[15] . [2]

[0017] According to the decorative materials described in [1], the average value of the above-mentioned 85-degree specular gloss is more than 1.5% and less than 18%. [3]

[0019] According to the decorative materials described in [1] or [2], the standard deviation σ of the above-mentioned 85-degree specular gloss is more than 1.0% and less than 7.0%. [4]

[0021] According to any one of the decorative materials described in [1] to [3], the average value of the static friction coefficient of the first surface is 1.200 or less. [5]

[0023] According to any one of the decorative materials described in [1] to [4], the standard deviation σ of the static friction coefficient of the first surface is 0.180 or more. [6]

[0025] According to any one of [1] to [5], the decorative material wherein the above-mentioned surface protective layer contains a matting agent. [7]

[0027] The decorative material described in any one of [1] to [6] has an undercoat layer between the substrate layer and the surface protective layer. [8]

[0029] According to any one of [1] to [7], the decorative material has a transparent resin layer, an adhesive layer, a decorative layer and a substrate layer in sequence from the first surface toward the second surface. [9]

[0031] According to any one of the decorative materials described in [1] to [8], wherein the average width of the groove is 10 μm or more and 2000 μm or less,

[0032] The standard deviation of the width of the aforementioned groove is greater than 20 μm and less than 600 μm.

[10]

[0034] According to any one of the decorative materials described in [1] to [9], the average depth of the groove is 10 μm or more and 100 μm or less.

[0035] The standard deviation of the depth of the aforementioned groove is greater than 1 μm and less than 20 μm.

[11]

[0037] According to any one of the decorative materials described in [1] to

[10] , wherein the average length of the aforementioned groove is 5 mm or more,

[0038] The standard deviation of the length of the aforementioned groove is greater than 5 mm.

[12]

[0040] According to any one of the decorative materials described in [1] to

[11] , the proportion of the groove having the above-mentioned filling part is 80% or more.

[13]

[0042] According to any one of [1] to

[12] , the decorative material also has a bonding layer disposed at a position closer to the second surface than the substrate layer described above.

[14]

[0044] According to any one of [1] to

[13] , the decorative material, wherein the filling portion contains a colorant.

[15]

[0046] According to any one of [1] to

[14] , the decorative material wherein the filling portion contains a matting agent.

[0047] According to the present invention, the texture of decorative materials can be made closer to that of natural materials. Attached Figure Description

[0048] Figure 1 This is a cross-sectional view of a decorative material used to illustrate one embodiment of the present invention.

[0049] Figure 2 This is a cross-sectional view illustrating one embodiment of the decorative material according to one embodiment of the present invention.

[0050] Figure 3 This is a cross-sectional view showing one embodiment of the substrate layer of the decorative material constituting one embodiment of the present invention.

[0051] Figure 4 This is a top view of a decorative material according to one embodiment of the present invention.

[0052] Figure 5 yes Figure 4 A magnified view of the V-shaped wireframe.

[0053] Figure 6 It is a diagram used to illustrate the method of calculating the direction, depth, width, and length of a slot. Detailed Implementation

[0054] [Decorative Materials]

[0055] A decorative material according to one embodiment of the present invention will be described.

[0056] In one embodiment of the present invention, the decorative material has a first surface and a second surface opposite to the first surface.

[0057] The decorative material has a substrate layer and a surface protective layer disposed closer to the first surface than the substrate layer.

[0058] The aforementioned substrate layer has multiple grooves on the surface near the first surface.

[0059] At least a portion of the aforementioned grooves has a filling portion inside the groove.

[0060] The average value of the 85-degree specular gloss of the first surface mentioned above, according to JIS Z8741:1997, is less than 18%, and the standard deviation σ of the 85-degree specular gloss of JIS Z8741:1997 is greater than 1.0%.

[0061] One embodiment of the decorative material is referred to as a low-gloss decorative material. By reducing the specular gloss level by 85 degrees, the gloss of the decorative material is reduced. As a result, the decorative material can be given a texture similar to natural materials such as wood and stone.

[0062] Figure 1 This is a cross-sectional view of a decorative panel 100A according to one embodiment. The decorative panel 100A includes a decorative sheet 100B and a substrate 101. The decorative sheet 100B is bonded to the substrate 101. The decorative panel 100A is a plate-shaped component such as wall material or fittings. The decorative sheet 100B is a film-shaped component such as wallpaper or other interior decoration materials.

[0063] The substrate 101 is the substrate to which the decorative sheet 100B is adhered. The substrate 101 can be made of materials such as: wood components used as boards or three-dimensional articles made of various types of wood, including veneer, plywood, particleboard, MDF (medium-density fiberboard), and engineered wood; metal components used as boards, steel plates, three-dimensional articles, or sheets made of iron, aluminum, etc.; kiln components used as boards or three-dimensional articles made of ceramic materials such as glass and ceramics, non-ceramic kiln materials such as gypsum, and non-ceramic kiln materials such as ALC (lightweight aerated concrete) boards; and resin components used as boards, three-dimensional articles, or sheets made of acrylic resin, polyester resin, polystyrene, polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) resin, phenolic resin, vinyl chloride resin, cellulose resin, rubber, etc.

[0064] In this invention, the decorative material 100 includes both a decorative sheet 100B for bonding with a substrate 101 and a decorative plate 100A after the decorative sheet 100B is bonded to the substrate 101. In one embodiment described below, the case where the decorative material 100 is a decorative sheet 100B for bonding with a substrate 101 will be described.

[0065] Figure 2 This is a cross-sectional view showing one embodiment of the decorative material 100 of the present invention. For example... Figure 2 As shown, the decorative material 100 has a first surface S1 and a second surface S2. The first surface S1 and the second surface S2 are the main surfaces of the decorative material 100. The second surface S2 is opposite to the first surface S1. Figure 2 The decorative material 100 shown has a substrate layer 10 and a surface protective layer 40. The surface protective layer 40 is positioned closer to the first surface S1 than the substrate layer 10. The substrate layer 10 has a plurality of grooves 21 on the first surface. Figure 2 As shown, the groove 21 has a filling portion 22 inside it. Figure 2 The decorative material 100 shown also has a base coating 30 between the substrate layer 10 and the surface protective layer 40. For example... Figure 2 As shown, the shape of the groove in the substrate layer 10 is reflected on the surfaces of the base coating 30 and the surface protective layer 40. The shape of the groove is also reflected on the first surface S1 of the decorative material 100. Figure 2 The decorative material 100 shown also has a bonding layer 50 for bonding the decorative material 100, which is a decorative piece 100B, to the substrate 101. The bonding layer 50 is disposed in the decorative material 100 at a position closer to the second surface S2 than the substrate layer 10.

[0066] Figure 3This is a cross-sectional view showing one embodiment of the substrate layer 10 constituting the decorative material of the present invention. The substrate layer 10 may be a single layer or a multilayer layer. Figure 3 As shown, it is a multi-layered structure made by stacking multiple layers. Figure 3 In the example shown, the substrate layer 10 has a transparent resin layer 11, an adhesive layer 12, a decorative layer 13 and a substrate 14 in sequence from the first surface S1 to the second surface S2.

[0067] Figure 4 This is a top view of a decorative material 100 according to one embodiment. Figure 4 The first surface S1 of the decorative material 100 is shown. Figure 4 In the example shown, decorative material 100 is given the texture of wood as a natural material. Decorative material 100 is given the patterns and tactile feel of wood. The wood patterns include cracks, vessels, downwood, and knots in sintered cedar. Figure 4 In the example shown, a conduit pattern is formed in region A.

[0068] Figure 5 yes Figure 4 A magnified view of the V-shaped wireframe. In Figure 5 The enlarged view shows the vicinity of region A, where a conduit pattern is formed. In region A of the decorative material 100, a groove 21 is formed in the substrate layer 10.

[0069] Figures 1-5 This is a schematic diagram illustrating a decorative material for the purpose of explaining one embodiment of the present invention. The composition of the decorative material is not limited to... Figures 1-5 One embodiment is shown. The decorative materials of the present invention are not limited to those shown. Figure 1 and Figure 2 The shape and scale.

[0070] <Mirror Gloss>

[0071] In one embodiment of the present invention, the decorative material requires that the average value of the 85-degree specular gloss of the first surface according to JIS Z8741:1997 be less than 18%. If the average value of the 85-degree specular gloss exceeds 18%, the gloss is too strong, making it difficult to make the texture approximate that of natural materials.

[0072] In this specification, the term "85-degree specular gloss of the first surface of the decorative material" is sometimes referred to as "85-degree specular gloss of the surface of the decorative material".

[0073] The shape of the groove is reflected on the first surface of the decorative material. Depending on the shape of the groove, the 85-degree specular gloss level can vary significantly compared to 20-degree and 60-degree specular gloss levels. This is believed to be due to the strong influence of reflections from the sides of the groove. The glossiness of the decorative material is achieved through reflections on its first surface. By forming grooves on the first surface of the decorative material, the 85-degree specular gloss level of the surface is reduced, thereby suppressing the glossiness and lowering the shine. This allows the decorative material to acquire a texture close to that of natural materials.

[0074] If the average 85-degree specular gloss of the surface of a decorative material is 18% or less, it is easy to obtain a texture close to that of a natural object. If the average 85-degree specular gloss of the surface of the decorative material is 16% or less, it is easy to obtain a texture even closer to that of a natural object, and if it is 14% or less, it is easy to obtain a texture even closer to that of a natural object. Even if the average specular gloss is 18% or less, it is sometimes difficult to make the texture close to that of a natural object. The inventors conducted research and found that when the standard deviation σ of the specular gloss is small, in other words, when the deviation of the specular gloss is small, the surface of the decorative material is observed uniformly. If the surface of the decorative material is observed uniformly, the texture of the decorative material is close to that of an artificial object. Since the surface shape of natural objects is uneven, there is a tendency for the deviation of the specular gloss to be large. The inventors conducted in-depth research and found that by setting the average value of the specular gloss to 18% or less and the standard deviation σ of the specular gloss to 1.0% or more, it is possible to make the texture close to that of a natural object. If the standard deviation σ of the specular gloss is set to 1.5% or higher, the texture can be made closer to that of natural objects; if it is set to 2.0% or higher, the texture can be made even closer to that of natural objects. On the other hand, even if the average value of the above-mentioned specular gloss is below 18%, if the standard deviation σ of the above-mentioned specular gloss is less than 1.0%, it is easy to achieve a texture similar to that of artificial objects.

[0075] If the average value of the 85-degree specular gloss of the surface of the decorative material is too small, the reflected light will be less, and the texture of the decorative material may appear artificial. The average value of the aforementioned specular gloss is preferably 1.5% or more, more preferably 2.0% or more, and even more preferably 2.5% or more.

[0076] If the standard deviation σ of the 85-degree specular gloss of the surface of the decorative material is too large, the decorative material may sometimes appear to have spots. The standard deviation σ of the aforementioned specular gloss is preferably 7.0% or less, more preferably 5.0% or less, and even more preferably 4.0% or less.

[0077] In this specification, the average value and standard deviation σ of the 85-degree specular gloss of the decorative material's surface are calculated based on the 85-degree specular gloss measured at 20 locations on the surface of the decorative material. These 20 measurement locations are 10 locations along the width direction and 10 locations along the length direction of the decorative material. The measurement locations are arranged in a cross or L-shape along the width and length directions of the decorative material. If the decorative material is roller-shaped, the width direction of the roller is defined as the width direction, and the direction perpendicular to the width direction is defined as the length direction. If the decorative material is rectangular, the direction of extension of one set of opposite sides is defined as the width direction, and the direction of extension of the other set of sides is defined as the length direction. The reason for determining the directions as described above is that the measuring light for the 85-degree specular gloss in JIS Z 8741:1997 is parallel light. The measuring light is parallel to the length direction of the decorative material.

[0078] The 85-degree specular gloss is the value measured using a gloss meter (BYK-Gardner "Microgloss: Cat. No. 4563") according to Method 1 described in JIS Z8741:1997.

[0079] To ensure that the average value of the 85-degree specular gloss of the decorative material's surface and the standard deviation σ of the 85-degree specular gloss are within the aforementioned range, methods can be employed such as setting the proportion of grooves in the substrate layer to a specified range, or setting the content of the matting agent in the surface protective layer to a specified range. Specific methods for adjusting the average value of the specular gloss and the standard deviation σ will be described later.

[0080] <Coefficient of Friction>

[0081] In one embodiment of the present invention, the decorative material preferably has an average static friction coefficient of 1.200 or less on its first surface. By making the average static friction coefficient of 1.200 or less, a tactile feel close to that of natural materials can be imparted. If the average static friction coefficient of the first surface of the decorative material is 1.000 or less, a tactile feel even closer to that of natural materials can be imparted; if it is 0.850 or less, a tactile feel even closer to that of natural materials can be imparted.

[0082] In this specification, the "static friction coefficient of the first surface of the decorative material" is sometimes referred to as the "static friction coefficient of the surface of the decorative material".

[0083] If the static friction coefficient of the decorative material's surface is too small, it will result in a sliding feel, and thus sometimes the feel will resemble that of an artificial object. Therefore, the average value of the aforementioned static friction coefficient is preferably 0.300 or more, more preferably 0.400 or more, and even more preferably 0.500 or more.

[0084] When the standard deviation σ of the static friction coefficient of a decorative material's surface is small—in other words, when the deviation of the static friction coefficient is small—the surface feel of the decorative material becomes uniform. If the surface feel of a decorative material becomes uniform, then the feel of the decorative material is close to that of a man-made object. Natural objects, due to their varying surface shapes, tend to have larger deviations in their static friction coefficients. To make the feel close to that of natural objects, it is preferable that the standard deviation σ of the static friction coefficient of the decorative material's surface is large.

[0085] Specifically, the standard deviation σ of the static friction coefficient of the decorative material's surface is preferably 0.180 or higher. By setting the standard deviation σ of the static friction coefficient to 0.180 or higher, it is easy to impart a tactile feel close to that of natural materials. By setting the standard deviation σ of the static friction coefficient of the decorative material's surface to 0.190 or higher, it is easy to impart a tactile feel even closer to that of natural materials. By setting it to 0.200 or higher, it is easy to impart a tactile feel even closer to that of natural materials.

[0086] If the standard deviation σ of the static friction coefficient is too large, it will be difficult to obtain a tactile feel close to that of natural materials. The standard deviation σ of the static friction coefficient is preferably 0.300 or less, more preferably 0.290 or less, and even more preferably 0.280 or less.

[0087] In this specification, the average value and standard deviation σ of the static friction coefficient are calculated based on the static friction coefficient measured at 20 random locations on the surface of the decorative material. The direction of the static friction coefficient measurements at these 20 locations is random.

[0088] The static friction coefficient was measured according to JIS P8147:2010 using a tribometer (Shinto Science's portable tribometer "3D MUSE TYPE: 37i") with nitrile rubber mounted on the measuring surface of the tribometer's slider. The reason for mounting nitrile rubber on the slider is to approximate the friction of a human finger. The slider of the tribometer is a hard chrome-plated aluminum cylinder with a bottom diameter of 26 mm.

[0089] To ensure that the average value and standard deviation σ of the static friction coefficient are within the aforementioned range, methods can be employed such as setting the proportion of grooves in the substrate layer to a specified range, or setting the content of the matting agent in the surface protective layer to a specified range. Specific methods for adjusting the average value and standard deviation σ of the static friction coefficient will be described later.

[0090] <Layer Composition>

[0091] In one embodiment of the present invention, the decorative material may consist of two layers: a substrate layer and a surface protective layer, or it may consist of three or more layers. Examples of the layer composition of the decorative material include (A1) to (A8) described below. In (A1) to (A8) described below, " / " indicates the interface between the layers. In (A1) to (A8) described below, it is preferable that the layer located on the left side forms the first surface.

[0092] (A1) Surface protective layer / substrate layer

[0093] (A2) Surface protective layer / primer / substrate layer

[0094] (A3) Surface protective layer / substrate layer / backside undercoat

[0095] (A4) Surface protective layer / primer / substrate layer / backside primer

[0096] (A5) Surface protective layer / substrate layer / bonding layer

[0097] (A6) Surface protective layer / primer / substrate layer / bonding layer

[0098] (A7) Surface protective layer / substrate layer / backside undercoat / bonding layer

[0099] (A8) Surface protective layer / primer / substrate layer / backside primer / bonding layer

[0100] <Substrate Layer>

[0101] The substrate layer needs to have multiple grooves on its first surface. At least a portion of the grooves needs to have a filling portion inside the groove.

[0102] For the decorative material according to one embodiment of the present invention, since the substrate layer has multiple grooves and the grooves have filling portions, there is a tendency for the 85-degree specular gloss to decrease in areas with a large proportion of groove area, and a tendency for the 85-degree specular gloss to increase in areas with a small proportion of groove area. By adjusting the proportion of grooves, the decorative material according to one embodiment of the present invention can easily make the average value and standard deviation σ of the 85-degree specular gloss within the aforementioned range.

[0103] The shape of the grooves in the substrate layer is also easily reflected on the surface of the protective layer (see reference). Figure 2 By making the shape of the grooves in the substrate layer reflect the surface of the surface protective layer, it is easier to make the average value of the 85-degree specular gloss and the standard deviation σ of the 85-degree specular gloss within the above range.

[0104] The value of the static friction coefficient tends to be related to the contact area of ​​the contacting objects. Therefore, by making the shape of the groove in the substrate layer reflect the surface of the surface protective layer, it is easy to make the average value and standard deviation σ of the static friction coefficient fall within the above range.

[0105] There are no particular restrictions on the top view shape of the groove, and various patterns can be given.

[0106] When the design of the decorative material as a whole is based on the pattern of wood, the top view shape of the groove preferably forms one or more patterns selected from scorched cedar cracks, vessels, downwood, and knots. "Scorched cedar cracks" refers to cracks formed in a direction perpendicular to the grain when the surface of the cedar board is charred to form a carbon layer.

[0107] When the overall design of the decorative material is a pattern of stone such as travertine, the top view shape of the groove is preferably a recessed part.

[0108] The ratio of the area with grooves to the total area of ​​the substrate layer is preferably 50% or more and 95% or less, more preferably 60% or more and 90% or less, and even more preferably 70% or more and 80% or less. By setting the area ratio of the grooves to the above range, it is easy to set the average value of the 85-degree specular gloss, the standard deviation σ of the 85-degree specular gloss, the average value of the static friction coefficient, and the standard deviation σ of the static friction coefficient to the above range.

[0109] If the proportion of the area with grooves becomes too high relative to the total area of ​​the substrate layer, the values ​​of 85-degree specular gloss and static friction coefficient tend to become uniform, and therefore there is a trend that the standard deviation σ of 85-degree specular gloss and the standard deviation σ of static friction coefficient become smaller.

[0110] The proportion of the area formed in the grooves within the substrate layer is determined as follows. A 10cm section of the substrate layer surface is observed using a laser microscope. 2 The area within a square is defined. The proportion of the area within this square is calculated. This calculation is performed at 10 random locations on the surface of the substrate layer. The average of the proportions of the areas with grooves at these 10 locations is taken as the proportion of the area with grooves in the entire substrate layer. A KEYENCE VK-X1000 laser microscope is used.

[0111] To increase the standard deviation σ of the 85-degree specular gloss and the standard deviation σ of the static friction coefficient, it is preferable to set at least one or more of the conditions for each groove to random and different values. Examples of groove conditions include the groove proportion, groove width, groove depth, groove length, and groove orientation. The preferred range for the groove proportion is as described above. The preferred ranges for the groove depth, groove length, and groove orientation will be described later. The groove condition with randomness can be one or more.

[0112] Regarding the orientation of the grooves, the closer the distribution of groove orientations is to a normal distribution, the smaller the standard deviation σ of the 85-degree specular gloss tends to be. The distribution of groove orientations refers to the distribution of the angles formed by the orientations of each groove when the specified orientation is taken as 0 degrees.

[0113] Grooves in the substrate layer can be formed by shaping the substrate layer with an embossing plate. Even if the depth of the grooves formed by the embossing plate is the same, the shape of the grooves may differ depending on the number of layers in the embossing plate. Therefore, there is a tendency for the 85-degree specular gloss and static friction coefficient to exhibit different values. Recesses in the embossing plate are formed by etching-based corrosion or laser-based engraving. These recesses are usually formed not in one stage, but in multiple stages (the recesses are formed in a stepped manner). These stages are referred to as layers. Even if the depth of the grooves formed by the embossing plate is the same, if the number of layers or the standard deviation σ of the layers in the embossing plate is different, the number of layers or the standard deviation σ of the layers in the substrate layer may also be different. As a result, the 85-degree specular gloss and static friction coefficient tend to exhibit different values. When using an embossing plate with a higher number of layers or a larger standard deviation σ of the layers, the width of the achievable 85-degree specular gloss and static friction coefficient of the decorative material increases, thus making it easier to increase the standard deviation σ of the 85-degree specular gloss and the standard deviation σ of the static friction coefficient of the decorative material.

[0114] Embossed sheets with a high number of layers or a large standard deviation σ of the layers can be produced, for example, by using laser-engraved metal rollers. A method for using laser-engraved metal rollers is described, for example, in International Publication No. WO2020 / 203737.

[0115] The temperature and pressure used for embossing can be adjusted appropriately based on the material of the substrate layer. If the substrate layer and the transparent resin layer are made of polyolefin, the temperature should be above 140°C and below 180°C, and the pressure should be 10 kg / cm². 2 Above and 50kg / cm 2 the following.

[0116] Representative methods for shaping using embossed plates are as follows.

[0117] An embossed plate is pressed onto the surface of a softened substrate layer to create a pattern. The substrate layer is then cured by cooling or other methods, thereby fixing the pattern formed on the substrate layer. The embossed plate is then demolded from the substrate layer with the pattern formed on it.

[0118] The width of each groove is preferably 10 μm or more and 2000 μm or less, more preferably 50 μm or more and 1800 μm or less, and even more preferably 100 μm or more and 1600 μm or less. The standard deviation σ of the groove width is preferably 20 μm or more and 600 μm or less, more preferably 40 μm or more and 500 μm or less, and even more preferably 60 μm or more and 400 μm or less. By satisfying these conditions for the groove width, for example, the grooves can be used to reproduce the vascular bundles of wood, making the texture of the decorative material closer to that of natural materials.

[0119] The depth of each groove is preferably 10 μm or more and 100 μm or less, more preferably 15 μm or more and 95 μm or less, and even more preferably 20 μm or more and 90 μm or less. The standard deviation σ of the groove depth is preferably 1 μm or more and 20 μm or less, more preferably 2 μm or more and 18 μm or less, and even more preferably 3 μm or more and 16 μm or less. By satisfying such conditions for the groove depth, for example, the grooves can reproduce the vascular bundles of wood, making the texture of the decorative material closer to that of natural materials.

[0120] The length of each groove is preferably 5 mm or more, more preferably 10 mm or more, and even more preferably 15 mm or more. The length of the groove can be the length from one end of the decorative material to the other. The standard deviation σ of the groove length is preferably 5 mm or more, more preferably 10 mm or more, and even more preferably 15 mm or more. By making the groove length meet such conditions, for example, the grooves can be used to reproduce the vascular bundles of wood, so that the texture of the decorative material can be close to that of natural materials.

[0121] The length of each slot refers to the maximum distance between any two points within that slot. Figure 6 In the case of the groove shown, the distance between point A and point B is called the length of the groove.

[0122] When the specified direction is set to 0 degrees, the direction of each groove is preferably randomly selected from a range of 0 degrees to 80 degrees. By making the direction of the grooves meet such conditions, for example, the grooves can be used to reproduce the vascular bundles of wood, thus making the texture of the decorative material closer to that of a natural object.

[0123] The direction of each slot refers to the direction that maximizes the distance between any two points within that slot. For example, in... Figure 6 In the case of the groove shown, the direction connecting points A and B is the direction D1 of the groove.

[0124] The depth of each groove can be calculated using the steps B1 to B2 below.

[0125] B1: For each groove, height data in the direction of the cross-section of the groove is measured at 5 randomly selected locations, resulting in 5 cross-sectional curves with height data. When the top view of the groove is an elongated shape extending in any direction, height data is measured in a direction orthogonal to the groove direction D1. For example, when the top view shape is... Figure 6 In the case of the groove with the shape shown, the height data is measured at the five locations a to e in the direction orthogonal to the groove direction D1, i.e., in the direction of the dashed line.

[0126] B2: Extract the maximum depth of each measurement point from the height data measured in B1, and take the average of the maximum depths of the 5 points as the depth of each groove.

[0127] The width of each slot can be calculated, for example, according to C1 below.

[0128] C1: Based on the five cross-sectional curves measured in B1 above, calculate the width of the groove at each measurement location. Take the average width of the five locations as the width of each groove.

[0129] The proportion of grooves with filling portions is preferably 80% or more, more preferably 90% or more, and even more preferably 95% or more, based on the number of grooves. By having grooves with filling portions in sufficient proportion, the grooves with filling portions can reproduce the vascular bundles of wood, etc., so that the texture of the decorative material can be close to that of natural materials.

[0130] In one embodiment of the present invention, a "groove with a filling portion" and a "groove without a filling portion" can be determined in the following manner.

[0131] The proportion of the groove with the filling portion is determined as follows. For 10cm of the surface of the substrate layer... 2 Within a square area, the grooves were observed visually and using a laser microscope. Grooves where the area containing filler is 50% or more of the total area were defined as "grooves with filler," while grooves where the area containing filler is less than 50% of the total area were defined as "grooves without filler." The proportion of grooves with filler relative to the total number of grooves within this range was calculated. This calculation was performed at 10 random locations on the surface of the substrate layer. The average proportion of grooves with filler at these 10 locations was taken as the proportion of grooves with filler in the substrate layer. A KEYENCE VK-X1000 laser microscope was used.

[0132] The filler portion preferably contains a colorant. A method for forming a filler portion containing a colorant in the groove can be exemplified by the following: applying a filler ink containing a colorant and a binder resin, etc., to the grooved surface of the substrate layer, and scraping off the ink with a scraping blade such as a doctor blade. In this case, the amount of colorant filling the groove can be adjusted by adjusting the material of the blade and the angle of contact with the blade. For easy pressing of the ink into the groove, the blade material is preferably soft. Similarly, for easy pressing of the ink into the groove, the angle of the blade relative to the substrate layer is preferably inclined in the direction of travel of the substrate layer.

[0133] Examples of coloring agents include inorganic pigments such as carbon black (ink), iron black, titanium dioxide, antimony white, chrome yellow, titanium yellow, iron oxide red, cadmium red, ultramarine, and cobalt blue, as well as organic pigments or dyes such as quinacridone red, isoindolinone yellow, and phthalocyanine blue.

[0134] The content of colorant is preferably 1 part or more and 90 parts or less, more preferably 2 parts or more and 50 parts or less, relative to 100 parts by weight of binder resin.

[0135] To reduce the average gloss level of an 85-degree specular surface, dark-colored colorants are preferred. Dark-colored colorants darken the grooves, thus improving the contrast of brightness within the decorative material's surface. Dark colors refer to low-brightness, low-saturation colors with a somber feel, such as dark gray, dark green, dark blue, black, dark purple, dark red, and brown.

[0136] Examples of adhesive resins include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral, alkyd resins, petroleum-based resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, and rubber-based resins.

[0137] To make the texture closer to that of natural materials, the filling can contain a matte agent.

[0138] Examples of matting agents include inorganic particles such as silica, calcium carbonate, titanium dioxide, and barium sulfate; and organic particles such as acrylic microspheres and styrene microspheres. The average particle size of the matting agent is preferably 1 μm or more and 20 μm or less. In this specification, the average particle size is determined by the following method: A scanning electron microscope (SEM) is used to observe the cross-section of the substrate layer in the thickness direction under conditions of an accelerating voltage of 3.0 kV and a magnification of 20,000 to 50,000 times. Among the observed matting agents, the particle size of 100 randomly selected unagglomerated matting agents is measured. The average particle size is determined by the average particle size of the 100 matting agents. The particle size is the value obtained by measuring the distance between the two lines that maximize the distance between them when the particle is held between two parallel lines.

[0139] The content of matting agent is preferably 1 part or more and 30 parts or less, more preferably 2 parts or more and 20 parts or less, relative to 100 parts by weight of adhesive resin.

[0140] The filler may contain additives such as UV absorbers, light stabilizers, and antioxidants.

[0141] <<Layer Composition of Substrate Layer>>

[0142] The substrate layer can be a single layer or a multilayer structure with multiple layers stacked together. Examples of substrate layer structures include (D1) to (D10) described below. In (D1) to (D10) below, " / " indicates the layer interface. The substrate layers (D1) to (D10) below are preferably arranged with the layer described on the left side facing the first surface. For example, the substrate layer (D8) below preferably has a transparent resin layer, an adhesive layer, a decorative layer, and a substrate layer arranged sequentially from the first surface to the second surface.

[0143] (D1) Single layer of substrate

[0144] (D2) Decorative layer / substrate

[0145] (D3) Substrate / Decorative Layer

[0146] (D4) Transparent resin layer / substrate

[0147] (D5) Transparent resin layer / decorative layer / substrate

[0148] (D6) Transparent resin layer / substrate / decorative layer

[0149] (D7) Transparent resin layer / adhesive layer / substrate

[0150] (D8) Transparent resin layer / adhesive layer / decorative layer / substrate

[0151] (D9) Transparent resin layer / decorative layer / adhesive layer / substrate

[0152] (D10) Transparent resin layer / adhesive layer / substrate / decorative layer

[0153] -Substrate-

[0154] To facilitate the formation of grooves through processes such as embossing, the substrate material is preferably a plastic film or a composite of plastic film and paper.

[0155] Specific examples of resins constituting plastic films include polyolefin resins such as polyethylene and polypropylene; vinyl chloride resins, vinylidene chloride resins, polyvinyl alcohol, ethylene-vinyl alcohol copolymers, and other vinyl resins; polyester resins such as polyethylene terephthalate and polybutylene terephthalate; acrylic resins such as polymethyl methacrylate, polymethyl acrylate, and polyethyl methacrylate; polystyrene; acrylonitrile-butadiene-styrene copolymer (ABS resin); cellulose triacetate; and polycarbonate. Among these, polyolefin resins, vinyl chloride resins, polyester resins, and acrylic resins with excellent printability and molding / processing adaptability are preferred.

[0156] The substrate can be a transparent substrate or a colored substrate. The substrate can also be a laminated substrate composed of multiple substrates. It should be noted that when the substrate layer is configured as described above (D6) and (D10), a transparent substrate is preferred in order to view the decorative layer through the substrate.

[0157] The thickness of the substrate is preferably 20 μm or more and 200 μm or less, more preferably 40 μm or more and 160 μm or less, and even more preferably 40 μm or more and 100 μm or less.

[0158] In order to improve the adhesion to the layers disposed on the substrate, one or both sides can be subjected to physical or chemical surface treatments or other easy-to-adhere treatments.

[0159] -Decorative Layer-

[0160] To enhance the design appeal of decorative materials, the substrate layer can have a decorative layer.

[0161] Decorative layers can be, for example, coloring layers that cover the entire surface (so-called full-coverage coloring layers), patterned layers with various designs, or combinations thereof.

[0162] Patterns imparted by the decorative layer can include natural objects such as wood or stone. By forming these patterns with the decorative layer, it is easy to make the pattern and texture consistent, even when giving the decorative material a tactile feel close to that of natural objects.

[0163] Decorative layers can be formed, for example, by applying and drying an ink containing colorants such as pigments and dyes, as well as binder resins. The inks used for decorative layers can be mixed with additives such as extender pigments, antioxidants, plasticizers, catalysts, curing agents, UV absorbers, and light stabilizers, as needed.

[0164] Examples of coloring agents include inorganic pigments such as carbon black (ink), iron black, titanium dioxide, antimony white, chrome yellow, titanium yellow, iron oxide red, cadmium red, ultramarine, and cobalt blue, as well as organic pigments or dyes such as quinacridone red, isoindolinone yellow, and phthalocyanine blue.

[0165] The content of colorant is preferably 1 part or more and 90 parts or less, more preferably 2 parts or more and 50 parts or less, relative to 100 parts by weight of binder resin.

[0166] Examples of adhesive resins include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral, alkyd resins, petroleum-based resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, and rubber-based resins.

[0167] The thickness of the decorative layer is preferably 0.1 μm or more and 20 μm or less, more preferably 0.5 μm or more and 10 μm or less, and even more preferably 1.0 μm or more and 5.0 μm or less.

[0168] -Transparent resin layer-

[0169] To improve strength, the substrate layer can have a transparent resin layer.

[0170] Examples of resins constituting the transparent resin layer include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylic resins, and vinyl chloride resins. Among these, polyolefin resins are preferred from the viewpoint of processing adaptability. The transparent resin layer can be formed by mixing these exemplary resins or by layering one or more of these exemplary resins.

[0171] Examples of polyolefin resins used as transparent resin layers include polyethylene (low-density, medium-density, and high-density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, and ethylene-propylene-butene copolymer. Among these, polyethylene (low-density, medium-density, and high-density), polypropylene, ethylene-propylene copolymer, and propylene-butene copolymer are preferred, and polypropylene is more preferred.

[0172] The transparent resin layer may contain additives such as ultraviolet absorbers, light stabilizers, and colorants. When the transparent resin layer contains an ultraviolet absorber, the ultraviolet absorber is preferably a triazine compound, and more preferably a hydroxyphenyltriazine compound.

[0173] From the viewpoint of balancing scratch resistance, processing adaptability and weather resistance, the thickness of the transparent resin layer is preferably 20 μm or more and 150 μm or less, more preferably 40 μm or more and 120 μm or less, and even more preferably 60 μm or more and 100 μm or less.

[0174] -Adhesive layer-

[0175] To improve interlayer adhesion, the substrate layer may have an adhesive layer.

[0176] The adhesive layer can be composed of general-purpose adhesives such as urethane adhesives, acrylic adhesives, epoxy adhesives, and rubber adhesives. Among these adhesives, urethane adhesives are preferred from the perspective of adhesive strength.

[0177] Examples of urethane-based adhesives include two-component curing urethane resins that utilize curing agents such as polyether polyols, polyester polyols, acrylic polyols, and isocyanate compounds.

[0178] From the viewpoint of obtaining appropriate adhesion, the thickness of the adhesive layer is preferably 0.1 μm or more and 30 μm or less, more preferably 1 μm or more and 15 μm or less, and even more preferably 2 μm or more and 10 μm or less.

[0179] <Surface Protective Layer>

[0180] Decorative materials have a surface protective layer.

[0181] To ensure good scratch resistance of decorative materials, the surface protective layer preferably comprises a cured product of a curable resin composition.

[0182] Examples of curable resin compositions include thermosetting resin compositions comprising thermosetting resins, ionizing radiation curable resin compositions comprising ionizing radiation curable resins, and mixtures thereof. Ionizing radiation curable resin compositions are preferred for improving the crosslinking density of the surface protective layer and enhancing surface properties such as scratch resistance. Ionizing radiation curable resin compositions cure instantaneously, thus easily reflecting the shape of the grooves formed in the substrate layer onto the surface of the surface protective layer, which is advantageous. Electron beam curable resin compositions are more preferred among ionizing radiation curable resin compositions because they can be applied without solvents and are easy to handle.

[0183] A thermosetting resin composition is a composition that contains at least a thermosetting resin and is a resin composition that is cured by heating. Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In these thermosetting resin compositions, a curing agent is added as needed to these curing resins.

[0184] The ionizing radiation curable resin composition is a composition containing a compound having an ionizing radiation curable functional group (hereinafter also referred to as "ionizing radiation curable compound"). The ionizing radiation curable functional group is a group that is cross-linked and cured by irradiation with ionizing radiation; preferably, functional groups having olefinic double bonds include (meth)acryloyl, vinyl, and allyl groups. It should be noted that in this specification, (meth)acryloyl means acryloyl or methacryloyl. In this specification, (meth)acrylate means acrylate or methacrylate.

[0185] Ionizing radiation refers to radiation containing energy quanta in electromagnetic waves or charged particle lines that can cause molecules to aggregate or cross-link. It can usually be ultraviolet (UV) or electron beam (EB). In addition, it also includes electromagnetic waves such as X-rays and gamma rays, as well as charged particle lines such as alpha rays and ionizing rays.

[0186] Specifically, ionizing radiation curing compounds can be appropriately selected from polymeric monomers and polymeric oligomers that have been conventionally used as ionizing radiation curing resins.

[0187] As polymerizable monomers, (meth)acrylate monomers having unsaturated groups with free radical polymerizability in the molecule are preferred, among which, multifunctional (meth)acrylate monomers are preferred. "(meth)acrylate" refers to "acrylate or methacrylate".

[0188] Examples of multifunctional (meth)acrylate monomers include those having two or more ionizing radiation curable functional groups in their molecules, and those having at least a (meth)acryloyl group in the functional group.

[0189] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in their molecules, with at least one (meth)acryloyl group among these functional groups. Examples include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers.

[0190] As polymerizable oligomers, there are also highly hydrophobic polybutadiene (meth)acrylate oligomers with (meth)acrylate groups on the side chains of polybutadiene oligomers, organosilicon (meth)acrylate oligomers with polysiloxane bonds in the main chain, amino plastic resin (meth)acrylate oligomers modified from amino plastic resins with multiple reactive groups in small molecules, or oligomers with cationic polymerizable functional groups in the molecules, such as phenolic epoxy resins, bisphenol epoxy resins, aliphatic vinyl ethers, and aromatic vinyl ethers.

[0191] These polymeric oligomers can be used alone or in combination. From the viewpoint of improving processing characteristics, scratch resistance, and weather resistance, it is preferable to select one or more of urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers; more preferably, one or more of urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers; and even more preferably, urethane (meth)acrylate oligomers.

[0192] In ionizing radiation curable resin compositions, monofunctional (meth)acrylates may be used in combination for purposes such as reducing the viscosity of the ionizing radiation curable resin composition. These monofunctional (meth)acrylates may be used alone or in combination.

[0193] When the ionizing radiation curing compound is an ultraviolet curing compound, the ionizing radiation curing resin composition preferably contains additives such as photopolymerization initiators and photopolymerization accelerators.

[0194] As photopolymerization initiators, one or more can be selected from acetophenone, benzophenone, α-hydroxyalkyl phenyl ketone, michaelone, benzoin, benzoyl dimethyl ketal, benzoylbenzoate, α-acyl oxime ester, thioxanone, etc.

[0195] Photopolymerization accelerators can reduce polymerization hindrance caused by air during curing and accelerate the curing speed. Examples include one or more selected from isoamyl p-dimethylaminobenzoate, ethyl p-dimethylaminobenzoate, etc.

[0196] The cured products contained in the surface protective layer include cured acrylic resin, cured urethane resin, cured phenolic resin, cured urea melamine resin, cured epoxy resin, cured unsaturated polyester resin, cured silicone resin, etc.

[0197] The surface protective layer preferably contains a matting agent.

[0198] By including a matting agent in the surface protective layer, the specular gloss of the entire surface of the decorative material is reduced, thus easily preventing the standard deviation σ of the 85-degree specular gloss from becoming excessive. By including a matting agent in the surface protective layer, the contact area between the surface of the decorative material and the contacting object is reduced, making it easy to set the average value of the static friction coefficient within the aforementioned range.

[0199] Examples of matting agents include inorganic particles such as silica, calcium carbonate, titanium dioxide, and barium sulfate; and organic particles such as acrylic microspheres and styrene microspheres. Inorganic particles are preferred. Inorganic particles are more prone to aggregation. The size of aggregates formed by inorganic particles tends to become random. By using inorganic particles, it is easy to make the standard deviation σ of the 85-degree specular gloss and the standard deviation σ of the static friction coefficient within the aforementioned ranges.

[0200] The average particle size of the matting agent is preferably 0.5 μm or more and 20 μm or less, more preferably 1 μm or more and 10 μm or less. A larger average particle size tends to decrease the average value of the 85-degree specular gloss and the average value of the static friction coefficient. In this specification, the average particle size is determined by the following method: A scanning electron microscope (SEM) is used to observe the cross-section of the substrate layer in the thickness direction under conditions of accelerating voltage 3.0 kV and magnification of 20,000 to 50,000 times. Among the observed matting agents, the particle size of 100 randomly selected unaggregated matting agents is measured. The average particle size is determined as the average particle size. The particle size is the value obtained by measuring the distance between the two lines that maximize the distance between them when the particles are held in a cross-section by two parallel lines.

[0201] The content of matting agent relative to 100 parts by weight of binder resin is preferably 1 part by weight or more and 30 parts by weight or less, more preferably 2 parts by weight or more and 20 parts by weight or less. The higher the content of matting agent, the lower the average value of the 85-degree specular gloss and the average value of the static friction coefficient tend to be.

[0202] If the matting agent agglomerates, the standard deviation σ of the 85-degree specular gloss and the standard deviation σ of the static friction coefficient tend to increase. Increasing the content of easily agglomerating matting agents decreases the average value of the 85-degree specular gloss and the average value of the static friction coefficient; conversely, sometimes the standard deviation σ of both the 85-degree specular gloss and the static friction coefficient increases.

[0203] The surface protective layer may contain additives such as UV absorbers, light stabilizers, and colorants, as needed.

[0204] From the viewpoint of balancing scratch resistance and weather resistance, the thickness of the surface protective layer is preferably 1.5 μm or more and 20 μm or less, more preferably 2 μm or more and 15 μm or less, and even more preferably 3 μm or more and 10 μm or less.

[0205] By setting the thickness to 1.5 μm or more, good scratch resistance can be easily achieved. By setting the thickness to 20 μm or less, good processability can be easily achieved. By setting the thickness to 20 μm or less, the shape of the grooves formed in the substrate layer can be easily reflected on the surface of the surface protective layer.

[0206] <Undercoat>

[0207] To ensure good adhesion, an undercoat layer can be applied between the substrate layer and the surface protective layer.

[0208] The primer layer is mainly composed of adhesive resin. It may contain additives such as UV absorbers and light stabilizers.

[0209] Preferred adhesive resins for the base coating include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene resins, urethane-acrylic acid copolymers, polycarbonate-based 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, chlorinated propylene resins, nitrocellulose resins (nitrocellulose), and cellulose acetate resins. These resins can be used alone or in combination. The adhesive resin can be a resin obtained by adding isocyanate-based curing agents, epoxy-based curing agents, or other curing agents to these resins and then cross-linking and curing them. Among these, resins obtained by cross-linking and curing polyol resins such as acrylic polyol resins with isocyanate-based curing agents are preferred, and resins obtained by cross-linking and curing acrylic polyol resins with isocyanate-based curing agents are more preferred.

[0210] The thickness of the base coating is preferably 0.5 μm or more and 10 μm or less, more preferably 0.7 μm or more and 8 μm or less, and even more preferably 1 μm or more and 6 μm or less.

[0211] <Backside base coating>

[0212] In order to improve the adhesion of decorative materials to various adhered materials, one embodiment of the present invention provides a decorative material with a back undercoat layer located near the second surface of the substrate layer.

[0213] There are no particular limitations on the materials used to form the back undercoat, and examples include urethane resins, acrylic resins, polyester resins, vinyl chloride / vinyl acetate copolymers, chlorinated polypropylene resins, and chlorinated polyethylene resins.

[0214] The thickness of the back undercoat is preferably 0.5 μm or more and 5.0 μm or less, more preferably 1 μm or more and 3 μm or less.

[0215] The surface protective layer, decorative layer, primer layer, adhesive layer, and back primer layer can be formed by applying an ink containing the composition forming each layer using known methods such as gravure printing, bar coating, roller coating, reverse roller coating, and comma coating, and then drying and curing as needed.

[0216] A transparent resin layer can be formed, for example, by heating and melting extrusion.

[0217] <Joint Layer>

[0218] The bonding layer 50 serves as the decorative material 100 of the decorative sheet 100B, bonding it to the substrate 101. The bonding layer 50 can use an adhesive or bonding agent. The adhesive used in the bonding layer can be a known adhesive. The adhesive used in the bonding layer can be a heat-sensitive adhesive, a pressure-sensitive adhesive, or the like. The resin used in the adhesive can be an acrylic resin, a urethane resin, a vinyl chloride resin, a vinyl acetate resin, a vinyl chloride-vinyl acetate copolymer resin, a styrene-acrylic copolymer resin, a polyester resin, a polyamide resin, etc. The resin used in the adhesive can contain only these resins or a combination thereof. The resin used in the adhesive can be a two-component curing polyurethane adhesive or a polyester adhesive that uses isocyanate compounds as curing agents. The adhesive used in the bonding layer can be appropriately selected from acrylic, urethane, silicone, and rubber adhesives.

[0219] The bonding layer 50 can be manufactured by coating the resin into a solution or emulsion form that can be coated, such as by gravure printing, screen printing, or reverse coating using a gravure plate, and then drying it. From the viewpoint of obtaining excellent adhesion, the thickness of the bonding layer can be 1 μm or more and 100 μm or less, 5 μm or more and 50 μm or less, or 10 μm or more and 30 μm or less.

[0220] <Uses of Decorative Materials>

[0221] The decorative material of this invention can be used for a variety of purposes.

[0222] For various purposes, decorative materials can be used for interior materials of buildings such as walls, ceilings, and floors; accessories such as window frames, doors, and handrails; furniture; housings of home appliances and office equipment; and exterior materials for entrance doors, etc. Decorative materials can also be used for these repair components.

[0223]

Example

[0224] The invention is further illustrated in detail by way of examples, but the invention is not limited to these examples in any way. Unless otherwise specified, "part" refers to a quantity based on mass.

[0225] 1. Evaluation

[0226] 1-1.85 degrees of specular gloss

[0227] For the decorative materials obtained in the examples and comparative examples, as well as the decorative materials in the reference example, the specular gloss of 20 degrees, 60 degrees, and 85 degrees, according to JIS Z8741:1997, was measured at 20 locations on the surface of the decorative materials. Based on JIS Z8741:1997, the 20-degree specular gloss was measured using method 5 described in JIS Z8741:1997, the 60-degree specular gloss was measured using method 3 described in JIS Z8741:1997, and the 85-degree specular gloss was measured using method 1 described in JIS Z8741:1997. The decorative material was a rectangular material with a long side and a short side. The 20 measurement locations were 10 locations along the long side and 10 locations along the short side of the decorative material. The measuring apparatus used was BYK-Gardner's "Microgloss: Cat. No. 4563". Based on the values ​​of 20-degree, 60-degree, and 85-degree specular gloss at 20 locations, the average, average, and average values ​​of the 20-degree, 60-degree, and 85-degree specular gloss were calculated, along with the standard deviations σ for the 20-degree, 60-degree, and 85-degree specular gloss. The results are shown in Table 1.

[0228] 1-2. Texture

[0229] The surface texture of the decorative materials obtained in the Examples and Comparative Examples, as well as the decorative materials in the Reference Examples, was evaluated. Twenty adults were randomly selected to evaluate the materials according to the following criteria. The results are shown in Table 1.

[0230] AA: More than 18 people answered that it has a natural woody feel.

[0231] A: 15 to 17 people answered that it has a natural woody feel.

[0232] B: 11 to 14 people answered that it has a natural woody feel.

[0233] C: Fewer than 10 people answered that it has a natural woody feel.

[0234] 1-3. Static friction coefficient

[0235] For the decorative materials obtained in the embodiments and comparative examples, as well as the decorative materials in the reference example, the static friction coefficient was measured at any 20 locations on the surface of the decorative materials. The direction of the static friction coefficient measurement was random at these 20 locations.

[0236] The static friction coefficient was measured using a portable tribometer, the "3D MUSE TYPE: 37i," manufactured by Shin-To Science Co., Ltd. The slider of this tribometer is a hard-chrome-treated aluminum cylinder with a base diameter of 26 mm. During measurement, nitrile rubber was attached to the measuring surface of the slider using double-sided adhesive tape (Nitto Denko Co., Ltd.'s "Thick Double-Sided Adhesive Tape NO. 507"). The nitrile rubber was made by cutting an ASONE CLEAN KNOLL nitrile glove from ASONE Co., Ltd. into a piece slightly larger than the slider. The nitrile rubber was applied to cover the entire measuring surface of the slider. During application, the nitrile rubber was kept from loosening.

[0237] Based on the static friction coefficient values ​​of 20 locations, the average static friction coefficient and the standard deviation σ of the static friction coefficient were calculated. The results are shown in Table 1.

[0238] 1-4. Touch

[0239] The tactile feel of the surfaces of the decorative materials obtained in the Examples and Comparative Examples, as well as the decorative materials in the Reference Examples, was evaluated. Twenty adults were randomly selected to evaluate the materials according to the following criteria. The results are shown in Table 1.

[0240] AA: More than 18 people answered that it felt like natural wood.

[0241] A: 15 to 17 people answered that it felt like natural wood to the touch.

[0242] B: 11 to 14 people answered that it felt like natural wood.

[0243] C: Fewer than 10 people answered that it felt like natural wood.

[0244] 2. Embossed sheet production

[0245] Make embossed panels 1-6.

[0246] Embossed plate 1 is made by etching an iron roller with a copper-plated surface and then applying a hard chromium plating treatment to the surface. Embossed plates 2 to 6 are made by laser engraving an iron roller with a copper-plated surface and then applying a hard chromium plating treatment to the surface.

[0247] The range and standard deviation σ of the depth of the embossing, the average value and standard deviation σ of the depth of the embossing, the range of the direction of the embossing (the range of the direction of the embossing extension when the width direction of the embossing is set to 0 degrees) and the range and standard deviation σ of the length of the embossing are shown in Table 1. The average value and standard deviation σ of the depth of the embossing are calculated by the steps (1) and (2) below.

[0248] (1) Obtain image data of 256 levels, from the minimum value of the embossing depth of each embossed plate to the maximum value of the embossing depth, from 0 to 255.

[0249] (2) The average value of the level of each pixel is taken as the level of the embossing depth of each plate. The standard deviation σ of the level of each pixel is taken as the standard deviation σ of the level of the embossing depth of each plate.

[0250] 3. Production of decorative materials

[0251] [Example 1]

[0252] On a colored substrate (a white polypropylene film with a thickness of 60 μm), a decorative layer with a wood pattern is formed by gravure multicolor printing. The pattern consists of a duct groove pattern formed by black ink and a wood grain pattern other than the duct portion formed by brown ink. The total thickness of the wood pattern is 1 μm.

[0253] An adhesive layer (polyester resin, thickness: 5 μm) is formed on the decorative layer. A transparent resin layer (transparent polypropylene resin sheet, thickness: 80 μm) is then laminated onto the adhesive layer by extrusion lamination, resulting in a substrate layer having a colored substrate, a decorative layer, an adhesive layer, and a transparent resin layer in sequence.

[0254] The transparent resin layer is heated to soften it, and the embossed plate 3 prepared in "2. Preparation of embossed plate" above is used to perform embossing on the surface of the transparent resin layer to form a concave-convex shape on the surface of the transparent resin layer.

[0255] After applying a dark brown filler ink to the surface of the transparent resin layer, press a squeegee perpendicular to the substrate layer to scrape off the filler ink, removing excess ink and pressing the ink into the groove. Allow the ink to dry and cure. The filler ink contains a copolymer resin of acrylic acid and urethane as a binder resin, carbon black, quinacridone, and isoindolinone as pigments, and ultraviolet absorbers, light stabilizers, silica, anti-settling agents, and dispersants as additives.

[0256] After performing corona discharge treatment on the surface of the transparent resin layer, the following primer composition is applied to the transparent resin layer and dried to form a primer coating with a thickness of 4 μm.

[0257] <Composition for Primer Coating>

[0258] The primer coating composition is a composition prepared by mixing 100 parts by weight of composition X (a composition formed by mixing a composition of polycarbonate-based urethane-acrylic copolymer and acrylic polyol with hexamethylene diisocyanate in a mass ratio of 100:5) with a diluent.

[0259] The following surface protective layer composition was applied to the base layer, and the surface protective layer composition was cross-linked and cured by irradiation with an electron beam, thereby forming a surface protective layer with a thickness of 5 μm, and the decorative material of Example 1 was obtained.

[0260] <Composition for Surface Protective Layer>

[0261] • 100 parts of an ionizing radiation-curable resin composition (trifunctional urethane acrylate oligomer with a weight average molecular weight of 4000)

[0262] • 15 parts matting agent (silica with an average particle size of 6 μm)

[0263] [Example 2]

[0264] The content of the matting agent in the composition for the surface protective layer was changed to the information recorded in Table 1. Otherwise, the same procedure as in Example 1 was followed to obtain the decorative material of Example 2.

[0265] [Example 3, Comparative Examples 1-4]

[0266] By changing the type of embossed board to the information recorded in Table 1, and otherwise operating in the same manner as in Example 1, decorative materials of Examples 3 and Comparative Examples 1 to 4 were obtained.

[0267] [Refer to Examples 1-2]

[0268] As decorative materials for reference examples 1 and 2, prepare boards made of natural wood.

[0269] Table 1

[0270]

[0271] As shown in Table 1, it can be confirmed that the decorative materials of the embodiments have a texture close to that of natural wood used as a reference example.

[0272] Explanation of reference numerals in the attached figures

[0273] 10: Substrate layer;

[0274] 11: Transparent resin layer;

[0275] 12: Adhesive layer;

[0276] 13: Decorative layer;

[0277] 14: Substrate;

[0278] 21: slot;

[0279] 22: Filler section;

[0280] 30: Primer coating;

[0281] 40: Surface protective layer;

[0282] 50: Bonding layer;

[0283] 100: Decorative materials;

[0284] 100A: Decorative panel;

[0285] 100B: Decorative piece;

[0286] 101: Substrate.

Claims

1. A decorative material having a first surface and a second surface opposite to said first surface, The decorative material has a substrate layer and a surface protective layer disposed closer to the first surface than the substrate layer. The substrate layer has multiple grooves on the surface near the first surface. At least a portion of the groove has a filling portion inside the groove. The average value of the 85-degree specular gloss of the first surface according to JIS Z8741:1997 is below 18%, and the standard deviation σ of the 85-degree specular gloss according to JIS Z8741:1997 is above 1.0%. The area where the groove is formed is 50% or more and 95% or less relative to the total area of ​​the substrate layer.

2. The decorative material according to claim 1, wherein, The average gloss level of the 85-degree specular surface is above 1.5% and below 18%.

3. The decorative material according to claim 1, wherein, The standard deviation σ of the 85-degree specular gloss is above 1.0% and below 7.0%.

4. The decorative material according to claim 1, wherein, The average static friction coefficient of the first surface is below 1.

200.

5. The decorative material according to claim 1, wherein, The standard deviation σ of the static friction coefficient of the first surface is greater than 0.

180.

6. The decorative material according to claim 1, wherein, The surface protective layer contains a matting agent.

7. The decorative material according to claim 1, wherein it has an undercoat layer between the substrate layer and the surface protective layer.

8. The decorative material according to claim 1, wherein, The substrate layer comprises, from the first surface toward the second surface, a transparent resin layer, an adhesive layer, a decorative layer, and a substrate layer in sequence.

9. The decorative material according to claim 1, wherein, The average width of the groove is greater than 10 μm and less than 2000 μm. The standard deviation of the width of the groove is greater than 20 μm and less than 600 μm.

10. The decorative material according to claim 1, wherein, The average depth of the groove is greater than 10 μm and less than 100 μm. The standard deviation of the depth of the groove is greater than 1 μm and less than 20 μm.

11. The decorative material according to claim 1, wherein, The average length of the groove is 5mm or more. The standard deviation of the length of the groove is greater than 5 mm.

12. The decorative material according to claim 1, wherein, The proportion of the groove having the filling portion is 80% or more.

13. The decorative material according to claim 1, further comprising a bonding layer disposed at a position closer to the second surface than the substrate layer.

14. The decorative material according to claim 1, wherein, The filling portion contains a colorant.

15. The decorative material according to claim 1, wherein, The filling portion contains a matting agent.

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