Decorative material and method for manufacturing same

Abstract

Provided is a decorative material capable of imparting an excellent stereoscopic impression and exhibiting good natural properties. The decorative material has, on a first main surface side, a plurality of independent recesses (A) and a groove-shaped parallel concave-convex pattern group (B) disposed in at least a part of a portion where the plurality of independent recesses (A) are not present. When the average depth of the plurality of independent recesses (A) is defined as XA and the average depth of the recesses of the groove-shaped parallel concave-convex pattern group (B) is defined as XB, the relationship XB < XA is satisfied.

Description

[0001] This application is a divisional application, whose parent application application number is 202080024701.2 (PCT / JP2020 / 013945), application date is March 27, 2020, and invention title is: Decorative Material and Manufacturing Method Thereof. Technical Field

[0002] This invention relates to decorative materials and their manufacturing methods. Background Technology

[0003] Decorative materials are widely used in the interior and exterior decoration of furniture, doors, and windows. In recent years, to improve the decorative effect, there has been a demand for decorative materials that can impart a three-dimensional feel. As such decorative materials, a proposed approach is to create areas with different gloss levels within the surface of the material, using the contrast of gloss levels to create a three-dimensional effect.

[0004] As a method to impart a three-dimensional effect through the contrast of gloss, examples include methods that partially expose the matte layer, methods that partially create unevenness through embossing, methods that partially form a glossy ink layer, and combinations of the above methods (Patent Documents 1-3).

[0005] Prior art literature

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2000-62081

[0008] Patent Document 2: Japanese Patent Application Publication No. 7-314630

[0009] Patent Document 3: Japanese Patent Application Publication No. 2018-122575 Summary of the Invention

[0010] The problem that the invention aims to solve

[0011] The decorative material in Patent Document 1 forms a glossy layer locally on a matte layer that covers the entire surface. This allows for a three-dimensional effect by contrasting the exposed portion of the matte layer (low-gloss area) with the glossy portion (high-gloss area). However, the decorative material in Patent Document 1 suffers from insufficient three-dimensionality and the exposed matte layer is easily stained. Furthermore, because the decorative material in Patent Document 1 lacks anisotropy in its gloss, it strongly resembles an artificial material, limiting its design possibilities when aiming to represent natural materials such as wood grain.

[0012] The decorative material in Patent Document 2 is locally textured by embossing, which creates a three-dimensional effect through the contrast between concave areas (low-gloss areas) and flat areas (high-gloss areas). However, like the decorative material in Patent Document 1, the decorative material in Patent Document 2 suffers from insufficient design when aiming to represent natural objects.

[0013] The decorative material in Patent Document 3 can impart a three-dimensional effect through the contrast between an area with a matte layer (low-gloss area) and an adjacent area with pearlescent pigment (high-gloss area). However, like the decorative material in Patent Document 1, the decorative material in Patent Document 3 also suffers from the following problems: insufficient three-dimensional effect, the matte layer is easily stained, and the design is insufficient when aiming to represent natural objects. Furthermore, the decorative material in Patent Document 3 requires the use of relatively expensive materials such as pearlescent pigments and metallic flakes.

[0014] The purpose of this invention is to provide decorative materials that can impart excellent three-dimensionality and good representation of natural objects, as well as a method for manufacturing such decorative materials.

[0015] Methods for solving problems

[0016] In order to solve the above-mentioned problems, the inventors have provided the following [1] to

[11] .

[0017] [1] A decorative material, wherein a plurality of independent recesses (A) are provided on a first main surface side of the decorative material, and a groove-shaped parallel concave-convex pattern group (B) is formed on at least a portion of the portion where the plurality of independent recesses (A) are not present, wherein the average depth of the plurality of independent recesses (A) is defined as X. A The average depth of the recesses in the above-mentioned grooved parallel concave-convex pattern group (B) is defined as X. B When X is satisfied B <X A The relationship.

[0018] [2] According to the decorative material described in [1] above, wherein the X above A The range is 40–150 μm, and the above X B The range is 5–100 μm.

[0019] [3] According to the decorative material described in [1] or [2] above, wherein the X above A -X B It is above 20μm.

[0020] [4] The decorative material according to any one of [1] to [3] above, wherein the average width of the above-mentioned individual plurality of recesses (A) is defined as Y A The average width of the recess in the above-mentioned grooved parallel concave-convex pattern group (B) is defined as Y.B1 The average width of the convex portion of the above-mentioned grooved parallel concave-convex pattern group (B) is defined as Y. B2 At that time, Y A The value is 150–500 μm, and the above-mentioned Y B1 The value is 10–200 μm, and the above Y B2 The range is 10–250 μm.

[0021] [5] The decorative material according to any one of [1] to [4] above, wherein the extending direction of the above-mentioned individual plurality of recesses (A) is defined as D A The extension direction of the above-mentioned grooved parallel concave-convex pattern group (B) is defined as D. B At that time, D A With D B Not parallel.

[0022] [6] According to the decorative material described in [5] above, wherein the above-mentioned D A With the above D B The angle formed is 5 to 70 degrees.

[0023] [7] The decorative material according to any one of [1] to [6] above, wherein the top view shape of each grooved parallel concave-convex pattern constituting the grooved parallel concave-convex pattern group (B) is wavy.

[0024] [8] The decorative material according to any one of [1] to [7] above, wherein the top view shape of the recess (A) is selected from one or more of the vascular bundles, wood fibers and knots of the wood.

[0025] [9] The decorative material according to any one of [1] to [8] above is formed by filling at least a portion of the depth direction of the above-mentioned individual plurality of recesses (A) with a colorant.

[0026]

[10] The decorative material described in [9] above satisfies either one of the following conditions (i) and (ii).

[0027] (i) At least a portion of the recess in the depth direction of the grooved parallel concave-convex pattern group (B) is not filled with colorant.

[0028] (ii) At least a portion of the recess in the depth direction of the grooved parallel concave-convex pattern group (B) is filled with a colorant, wherein the amount of colorant filled per unit area is defined as W. B The amount of colorant filling per unit area in which at least a portion of the aforementioned independent recesses (A) is filled in the depth direction is defined as W. A When W is satisfied B <W A The relationship.

[0029]

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

[0030] (1) A process of shaping a single layer of a substrate selected from plastic film or a composite of plastic film and paper, or a laminate containing the substrate, using an embossing plate to obtain the decorative material described in any one of [1] to [8].

[0031] (2) The process of scraping off the filling ink after applying a filling ink containing a colorant and an adhesive resin to the first main surface of the decorative material obtained in (1) above.

[0032] The effects of the invention

[0033] The decorative material of the present invention can impart excellent three-dimensionality and has good representation of natural materials, thus enabling extremely good design possibilities. Furthermore, the manufacturing method of the decorative material of the present invention allows for the simple production of decorative materials possessing the above-mentioned effects. Attached Figure Description

[0034] Figure 1 This is a top view of the first main side of one embodiment of the decorative material of the present invention.

[0035] Figure 2 It is Figure 1 A magnified top view of the circular portion surrounded by a single-dotted line.

[0036] Figure 3 This is an image showing the elevation of the decorative material of Example 1 measured from the first main surface side, with varying shades representing the measured elevation.

[0037] Figure 4 It is contained Figure 1 The A-A' line and Figure 1 A cross-sectional view formed by cut surfaces parallel to the z-axis.

[0038] Figure 5 This describes how to calculate the average depth (X) of multiple independent recesses (A). A A top view of one of the processes.

[0039] Figure 6 This is a flowchart illustrating one embodiment of the process of forming the concave-convex shape of the first main surface of the decorative material of the present invention.

[0040] Figure 7 It means as Figure 6 The diagram shows a scene of a process using laser to create a printing plate, which is an example of process S14. Detailed Implementation

[0041] [Decorative Materials]

[0042] For the decorative material of the present invention, a plurality of independent recesses (A) and a groove-shaped parallel concave-convex pattern group (B) formed on at least a portion of the portion where the plurality of recesses (A) are not present are provided. The average depth of the plurality of independent recesses (A) is defined as X. A The average depth of the recesses in the above-mentioned grooved parallel concave-convex pattern group (B) is defined as X. B When X is satisfied B <X A The relationship.

[0043] <The First Main Aspect of Decorative Materials>

[0044] Figure 1 This is a top view showing the first main surface side of one embodiment of the decorative material 100 of the present invention. (See attached image.) Figure 1 As shown, the decorative material 100 of the present invention has a plurality of independent recesses (A) 10 on the surface of the first main surface and a groove-shaped parallel concave-convex pattern group (B) 20 formed in the portion where the plurality of recesses (A) 10 are not present. It should be noted that in Figure 1 In the middle, the grooved parallel concave-convex pattern group (B) 20 is composed of grooved concave-convex patterns 20a, 20b, ... and 20l, and each grooved concave-convex pattern is parallel.

[0045] Figure 2 It is Figure 1 A magnified top view of the circular portion enclosed by a single-dotted line. (Example) Figure 2 As shown, the grooved parallel concave-convex pattern group (B) 20 is composed of a concave portion 21 and a convex portion 22 surrounded by the concave portion 21.

[0046] It should be noted that, in this specification, "parallel" in the context of the grooved parallel recessed pattern set means that adjacent recesses are parallel when viewed from above the decorative material. Furthermore, "parallel" in the context of the grooved parallel recessed pattern set is not limited to perfect parallelism, but also includes approximately parallelism. Approximate parallelism means that when tangent lines are drawn from the edges of an adjacent set of recesses, the angle between the two tangent lines is within 7.0 degrees, preferably within 5.0 degrees, and more preferably within 3.0 degrees.

[0047] Figure 3 This is a top view showing the elevation of the decorative material in Example 1 measured from the first main surface side, with varying shades representing the measured elevation. Figure 3 In this context, a lower concentration indicates a higher elevation, while a higher concentration indicates a lower elevation. Figure 3 In the middle, the slender, high-concentration portion extending vertically is the concave portion (A). Figure 3 Within the surface of the decorative material, multiple recesses (A) exist independently. Additionally, in Figure 3In the middle, the low-concentration portion extending diagonally downward to the right is the groove-shaped parallel concave-convex pattern group (B). The groove-shaped parallel concave-convex pattern group (B) is arranged in the part where there are no independent multiple concave portions (A).

[0048] Figure 4 It is contained Figure 1 The A-A' line and Figure 1 A cross-sectional view formed by cut surfaces parallel to the z-axis.

[0049] Due to the average depth X of the recessed portion (A) in the first main surface of the decorative material A The depth of the recess (A) causes light incident on it to be scattered and attenuated due to multiple reflections. Therefore, the area with the recess (A) appears darker. On the other hand, for the area with the grooved parallel concave-convex pattern group (B), since no multiple reflections occur in the convex area, the average depth X in the recess is higher. B The shallower area has fewer multiple reflections, thus appearing brighter than the recess (A). Furthermore, the area with the grooved parallel convex-concave pattern group (B) exhibits different brightness when viewed from the direction of the groove's extension versus from a direction orthogonal to the groove's extension. This is because, when viewed from the direction of the groove's extension, there are fewer multiple reflections of light incident on the recess.

[0050] As described above, the decorative material of the present invention has multiple independent recesses (A) and a group of grooved parallel concave-convex patterns (B), and satisfies X B <X A Because of this relationship, the area with the grooved parallel relief pattern group (B) appears relatively brighter compared to the area with the concave portion (A), thus giving a sense of three-dimensionality through the contrast of lightness. Furthermore, since the lightness produced by the grooved parallel relief pattern group (B) can be anisotropically imparted, it is possible to represent natural objects well.

[0051] The area occupied by the recess (A) (the total area of ​​the individual recesses (A)) relative to the total area of ​​the first main surface is preferably 20-50%, more preferably 30-40%.

[0052] <<Depth>>

[0053] The average depth X of multiple independent recesses (A) A For example, it can be calculated using the steps A1 to A3 below.

[0054] A1: Regarding each recess (A), height data is measured at 5 randomly selected locations in the direction transverse to each recess (A), resulting in 5 cross-sectional curves with height data. When the top view of a recess (A) is an elongated shape extending in any direction, height data is measured in a direction orthogonal to the extension direction of the recess (A). For example, when the top view shape is... Figure 5 In the case of the recess (A), at 5 locations from a to e, the direction of extension of the recess (A) is measured. Figure 5 The height data is the direction orthogonal to the vertical direction (i.e., the direction of the dashed line).

[0055] A2: Extract the maximum depth of each measurement site from the height data measured in A1, and take the average of the maximum depths of the 5 sites as the average depth of each recess (A).

[0056] A3: Average the average depth of each concave part (A) calculated in A2 to calculate X. A .

[0057] For example, in Figure 4 In the middle, the average depth of the left-side recess (A) (the average of the maximum depths of the 5 locations) is set as X. A-1 Let the average depth of the right-side recess (A) (the average of the maximum depths of the five locations) be X. A-2 At that time, the average depth X of multiple independent recesses (A) A It can be calculated using the following formula.

[0058] Average depth of recess (A) X A = (X) A-1 +X A-2 ) / 2

[0059] The average depth X of the recesses in the grooved parallel concave-convex pattern group (B) B It can be calculated based on B1 to B3 below.

[0060] B1: For each recess of the groove-shaped parallel concave-convex pattern group (B) existing in the surface of the decorative piece, the height data in the direction transverse to each recess is measured at 5 randomly selected locations to obtain 5 cross-sectional curves with height data. The measurement direction of each measurement location is set to be orthogonal to the extension direction of the recess. It should be noted that, in order to simultaneously measure the width of the convex part of the groove-shaped parallel concave-convex pattern group (B), it is preferable to set it to the cross-sectional curve transverse to the convex part.

[0061] B2: Extract the maximum depth of each measurement site from the height data measured in B1, and take the average of the maximum depths of the 5 sites as the average depth of each concave part.

[0062] B3: Average the average depths of the various concave parts calculated in B2 to calculate X. B .

[0063] For example, in Figure 4 In the diagram, the average depth of the concave portion located at the nth position from the left (the average of the maximum depths of the five locations) is denoted as X. B1-n . Figure 4There are 9 groove-shaped parallel concave-convex pattern groups (B) in the recess ( Figure 4 (20d~20l), therefore the average depth X of the recess in the grooved parallel concave-convex pattern group (B) B It can be calculated using the following formula.

[0064] The average depth X of the recesses in the grooved parallel concave-convex pattern group (B) B = (X) B1-1 +X B1-2 +X B1-3 +X B1-4 +X B1-5 +X B1-6 +X B1-7 +X B1-8 +X B1-9 ) / 9

[0065] The average depth (X) of multiple independent recesses (A) A The preferred size is 40–150 μm, more preferably 45–120 μm, and even more preferably 50–100 μm. By making X… A With a thickness of 40 μm or more, it is possible to easily reduce the brightness of areas with recesses (A). Furthermore, by making X... A The design is designed to reproduce the realistic feel of the darkness of the recess (A) and the brightness of the grooved parallel concave-convex pattern group (B) with a resolution of less than 150μm.

[0066] The average depth (X) of the recesses in the grooved parallel concave-convex pattern group (B) B The preferred size is 5–100 μm, more preferably 10–70 μm, and even more preferably 15–60 μm. By making X… B With a thickness of 5μm or more, it is easy to impart anisotropy in lightness. Furthermore, by making X... B With a thickness of 100 μm or less, it is possible to easily improve the contrast in brightness between individual recesses (A) and the group of grooved parallel embossed patterns (B). It should be noted that, from the viewpoint that it is difficult to fill the recesses of the grooved parallel embossed pattern (B) with colorant during the erasing process described later, X... B Preferably, it is below 60μm.

[0067] Additionally, X A -X B Preferably, it is 20 μm or more, more preferably 30 μm or more, and even more preferably 40 μm or more. By making X... A -X B With a resolution of 20 μm or higher, it is possible to easily improve the contrast in brightness between individual recesses (A) and the group of parallel groove-shaped concave-convex patterns (B). Furthermore, by making X... A -X BWith a thickness of 20 μm or more, during the erasure process described later, a large amount of colorant is filled into the recess (A). On the other hand, the amount of colorant filled into the recess of the groove-shaped parallel convex and concave pattern (B) can be reduced, resulting in better contrast.

[0068] <<Width and Length>>

[0069] Furthermore, regarding the decorative material of the present invention, when the average width of the recess (A) is defined as Y... A The average width of the recesses in the grooved parallel concave-convex pattern group (B) is defined as Y. B1 The average width of the convex portion of the grooved parallel concave-convex pattern group (B) is defined as Y. B2 When, Y is preferred A Y B1 and Y B2 The range is as follows. It should be noted that the convex part of the grooved parallel concave-convex pattern group (B) refers to the convex part located between the concave parts of the grooved parallel concave-convex pattern group (B).

[0070] Y A Preferably, it is 150–500 μm, more preferably 170–450 μm, and even more preferably 200–400 μm.

[0071] By making Y A With a diameter of 150 μm or more, each recess (A) can be easily identified as an independent region. It should be noted that by making Y... A With a thickness of 150 μm or more, a large amount of colorant can be easily filled into the recess (A) during the erasure process described later. Furthermore, by making Y... A With a diameter of less than 500 μm, light incident into the recess (A) is easily reflected multiple times, making the recess (A) appear darker.

[0072] Y B1 Preferably, it is 10–200 μm, more preferably 15–150 μm, and even more preferably 20–100 μm. By making Y… B1 With a value of 10 μm or more, reflected light from the concave portions of the grooved parallel concave-convex pattern group (B) can be easily observed. Furthermore, it allows for easy impartation of anisotropy in brightness. Additionally, by making Y... B1 With a value below 200 μm, it is easy to increase the difference in brightness when viewed from the direction of the groove's extension versus when viewed from a direction orthogonal to the direction of the groove's extension, thus easily imparting anisotropy in brightness. It should be noted that by making Y... B1 With a diameter of 200 μm or less, the colorant can be filled into the recesses of the grooved parallel embossed pattern group (B) during the erasure process described later.

[0073] Y B2Preferably, it is 10–250 μm, more preferably 20–200 μm, and even more preferably 40–180 μm. By making Y… B2 With a thickness of 10 μm or more, the brightness of areas with grooved parallel concave-convex patterns (B) can be easily improved. Furthermore, by making Y... B2 With a value below 200 μm, it can suppress excessive reflection of the convex portion of the grooved parallel concave-convex pattern group (B) and easily identify the anisotropy of the brightness of the concave portion based on the grooved parallel concave-convex pattern group (B).

[0074] To make it easier to represent three-dimensionality and natural objects well, Y A Y B1 and Y B2 Preferably, either equation (1) or (2) below is satisfied, and more preferably, either equation (1) or (2) below is satisfied. Furthermore, if either equation (1) or (2) below is satisfied, it is more preferable to further satisfy either equation (3) or (4) below. Furthermore, if either equation (1) or (2) below is satisfied, it is more preferable to further satisfy equation (3) or (4) below. Y in equation (3) B1 / Y A More preferably, it is 0.20 or more and 0.40 or less. Y in equation (4) B2 / Y A More preferably, it is 0.20 or higher and 0.60 or lower.

[0075] Y B1 <Y A (1)

[0076] Y B2 <Y A (2)

[0077] 0.06≤Y B1 / Y A ≤0.40 (3)

[0078] 0.10≤Y B2 / Y A ≤1.00 (4)

[0079] The average width Y of multiple independent recesses (A) A It can be calculated using C1 to C2 below.

[0080] C1: Calculate the width of the concave part (A) at each measurement location based on the five cross-sectional curves measured in A1 above, and take the average width of the five locations as the average width of each concave part (A).

[0081] C2: Average the average width of each recess (A) calculated in C1 above, and calculate Y. A .

[0082] For example, in Figure 4 In the middle, the average width of the left concave part (A) (the average width of the 5 parts) is set as Y. A-1 Let the average width of the right-side recess (A) (the average width of the 5 parts) be Y. A-2 In the case of multiple independent recesses (A), the average width Y A It can be calculated using the following formula.

[0083] The average width Y of the recess (A) A = (Y A-1 +Y A-2 ) / 2

[0084] The average width Y of the recesses in the grooved parallel concave-convex pattern group (B) B1 It can be calculated using D1 to D2 below.

[0085] D1: Calculate the width of the concave part at each measurement location based on the five cross-sectional curves measured in B1 above, and take the average width of the five locations as the average width of each concave part.

[0086] D2: Average the average widths of the various concave portions calculated in D1 above to calculate Y. B1 .

[0087] For example, in Figure 4 In the middle, let the average width of the concave part located at the nth position from the left (the average width of the 5 parts) be set as Y. B1-n .because Figure 4 There are 9 groove-shaped parallel concave-convex pattern groups (B) in the recess ( Figure 4 (20d~20l), so the average width Y of the concave portion of the grooved parallel concave-convex pattern group (B) is... B1 It can be calculated using the following formula.

[0088] The average width Y of the recesses in the grooved parallel concave-convex pattern group (B) B1 = (Y B1-1 +Y B1-2 +Y B1-3 +Y B1-4 +Y B1-5 +Y B1-6 +Y B1-7 +Y B1-8 +Y B1-9 ) / 9

[0089] The average width Y of the convex portion of the grooved parallel concave-convex pattern group (B) B2 It can be calculated using E1 to E2 below. It should be noted that the convex part of the grooved parallel concave-convex pattern group (B) refers to the convex part located between the concave parts of the grooved parallel concave-convex pattern group (B).

[0090] E1: Calculate the width of the convex part at each measurement location based on the five cross-sectional curves measured in B1 above, and take the average width of the five locations as the average width of each convex part.

[0091] E2: Average the average widths of the various protrusions calculated in E1 above to calculate Y. B2 .

[0092] For example, in Figure 4 In the diagram, the average width of the convex part located at the nth position from the left (the average width of the 5 parts) is set as Y. B2-n .because Figure 4 There are 6 groove-shaped parallel concave-convex pattern groups (B) with convex parts, so the average width Y of the convex parts of the groove-shaped parallel concave-convex pattern group (B) is B2 It can be calculated using the following formula.

[0093] The average width Y of the convex portion of the grooved parallel concave-convex pattern group (B) B2 = (Y B2-1 +Y B2-2 +Y B2-3 +Y B2-4 +Y B2-5 +Y B2-6 ) / 6

[0094] The length of the individual recesses (A) is not particularly limited; the preferred length range varies depending on the design being represented, and therefore cannot be generalized. For example, in the case where the overall design of the decorative piece is a wood pattern, the average length (L) of the recesses (A) is... A The preferred diameter is 2 to 50 mm, and more preferably 5 to 30 mm.

[0095] The average length of the recess (A) can be calculated by measuring the length of each recess (A) and taking its average value. It should be noted that the length of each recess (A) refers to the maximum distance between any two points within each recess (A).

[0096] The length of each groove-shaped convex and concave pattern constituting the groove-shaped parallel concave-convex pattern group (B) is not particularly limited, such as Figure 1 As shown, the preferred length is approximately the length transversely cut from one end of the decorative piece to the other end (however, excluding the portion where the recess (A) exists. The vicinity of the recess (A) may also be excluded if necessary).

[0097] <<Specific Examples of Top-Down Shapes>>

[0098] The top view shape of the recess (A) is not particularly limited, and various patterns can be given.

[0099] When the overall design of the decorative piece is a wood pattern, the top view shape of the recess (A) preferably forms a pattern selected from ducts, wood fibers, and knots.

[0100] Vessels are cylindrical cells that act as passageways for water. The arrangement of these tiny vessels creates the illusion of dark grain patterns to the human eye. Autumnwood refers to the narrower, darker-colored grain that forms from summer to autumn. It's important to note that the wider grain that forms from spring to summer is called springwood. The alternation of springwood and autumnwood creates the annual rings of wood. A knot is a mark left by a branch entering the trunk; it is nearly circular or oval in shape and has a darker color than the surrounding tissue.

[0101] Furthermore, when the overall design of the decorative piece resembles a stone pattern such as travertine, the top view shape of the recess (A) is preferably a concave portion. When the overall design of the decorative piece resembles a tile or brick pattern, the top view shape of the recess (A) is preferably a seam pattern. When the overall design of the decorative piece resembles a fabric pattern, the top view shape of the recess (A) is preferably a fabric recess. When the overall design of the decorative piece resembles a leather pattern, the top view shape of the recess (A) is preferably a pleated pattern.

[0102] The top-view shape of each groove-shaped convex and concave pattern constituting the groove-shaped parallel concave and convex pattern group (B) is not particularly limited, and various patterns can be cited, preferably such as Figure 1 The image shows a wavy shape.

[0103] By making the top view shape of the grooved embossed pattern wavy, the brightness of the area with the grooved parallel embossed pattern group (B) varies along the shape of the wave. Therefore, in each part of the decorative piece, the contrast between the recess (A) and the grooved parallel embossed pattern group (B) becomes uneven, which allows for good representation of natural objects. In addition, by changing the incident direction of light or moving the observer, the distribution of the above-mentioned contrast changes, thus enabling extremely good design.

[0104] There are no particular limitations on the wavelength (period) and wave height of the wavy pattern. The wavelength (period) can be adjusted appropriately within the range of about 1 to 100 mm, and the wave height can be adjusted appropriately within the range of about 1 to 20 mm.

[0105] <<Extended Directions>>

[0106] For the decorative material of the present invention, the extending direction of the multiple independent recesses (A) is defined as D. A The extension direction of the grooved parallel concave-convex pattern group (B) is defined as D. B When, D is preferredA With D B Not parallel. By making D A With D B The lines are not parallel, and the ink scraping direction of the subsequent erasure process is parallel to D. A Traveling in a parallel direction allows for the filling of a large amount of colorant in the recess (A), while on the other hand, it reduces the amount of colorant filling the recess in the grooved parallel convex and concave pattern (B), resulting in better contrast.

[0107] The extension direction (D) of multiple independent recesses (A) A The direction of extension of each recess (A) is the average direction. Furthermore, the direction of extension of each recess (A) refers to the direction in which the distance between any two points within each recess (A) is maximized. For example, in... Figure 5 In the case of the concave portion (A), the direction connecting points A and B becomes the extension direction D. A .

[0108] The extension direction (D) of the grooved parallel concave-convex pattern group (B) B The direction is obtained by averaging the extension directions of each recess. Furthermore, the extension direction of each recess refers to the direction of the straight line connecting the start and end points of each recess.

[0109] D A With D B The angle formed is preferably 5 to 70 degrees, more preferably 7 to 50 degrees, and even more preferably 10 to 40 degrees.

[0110] By making the angle greater than 5 degrees, and by making the ink scraping direction of the subsequent erasure process align with D... A Traveling in a parallel direction allows for a large amount of colorant to be filled in the recess (A), while reducing the amount of colorant filling the recesses of the grooved parallel convex-concave pattern (B), resulting in better contrast. Furthermore, by keeping this angle below 70 degrees, it improves the contrast with D. A When erasing in a parallel direction, it is easy to prevent the scraping tool from getting caught on the grooved parallel embossed pattern group (B).

[0111] <<Coloring Agent>>

[0112] like Figure 4As shown, the decorative material of the present invention is preferably formed by filling at least a portion of the depth direction of a plurality of independent recesses (A) with a colorant 30. This configuration allows for better design flexibility of the decorative material. Furthermore, by using a dark-colored colorant, the recesses (A) can be made darker, further enhancing the contrast of lightness within the surface of the decorative material. Dark colors refer to colors with low lightness and low chromaticity, such as dark gray, dark green, navy blue, black, dark purple, carmine, and brown.

[0113] One method for filling at least a portion of the recess (A) with colorant in the depth direction is to apply a filling ink containing colorant and adhesive resin to the first main surface of the decorative material and scrape off the ink with a scraping tool such as a scraper. In this case, the amount of colorant filled in the recess (A) can be adjusted by adjusting the material of the tool, the angle of contact with the tool, and the viscosity of the ink.

[0114] Examples of colorants 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 such as quinacridone red, isoindolinone yellow, and phthalocyanine blue, or dyes.

[0115] Examples of adhesive resins used as filler inks include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, and rubber resins.

[0116] Based on the fact that the decorative material of the present invention is formed by filling at least a portion of the depth direction of a plurality of independent recesses (A) with a colorant, it is preferable to further satisfy any one of the following conditions (i) and (ii).

[0117] (i) At least a portion of the recess in the depth direction of the grooved parallel concave-convex pattern group (B) is not filled with colorant.

[0118] (ii) At least a portion of the recess in the depth direction of the grooved parallel concave-convex pattern group (B) is filled with a colorant, wherein the amount of colorant filled per unit area is defined as W. B The amount of colorant filling per unit area in which at least a portion of the aforementioned independent recesses (A) is filled in the depth direction is defined as W. A When W is satisfied B <W A The relationship.

[0119] By satisfying either condition (i) or (ii) above, a contrast based on the difference in the amount of colorant can be generated between the recess (A) and the recesses constituting the grooved parallel concave-convex pattern group (B), thereby improving the design. Furthermore, by using a dark-colored colorant as the colorant, the contrast in brightness between the recess (A) and the recesses constituting the grooved parallel concave-convex pattern group (B) becomes higher, making the three-dimensional effect more pronounced.

[0120] It should be noted that in this specification, W A W refers to the average amount of colorant filled per unit area of ​​each recess (A). B It refers to the average amount of colorant per unit area of ​​each recess in the grooved parallel concave-convex pattern group (B).

[0121] To easily satisfy either condition (i) or (ii) above, it is preferable to select from X A X B X A -X B Y A Y B1 and Y B2 The scope, and D A With D B At least one or more of the embodiments in the relationship are designated as the preferred embodiments described above.

[0122] <Second Main Page>

[0123] The shape of the decorative material's surface opposite to the first main surface (the second main surface) is not particularly limited; it can be smooth or it can be textured.

[0124] <Layered Composition of Decorative Materials>

[0125] The decorative material of the present invention can be described by the following layered configurations (1) to (8). It should be noted that " / " indicates the interface of the layers, and the surface of the layer on the left side represents the first main surface of the decorative material.

[0126] (1) Single layer of substrate

[0127] (2) Decorative layer / substrate

[0128] (3) Surface protective layer / decorative layer / substrate

[0129] (4) Transparent resin layer / decorative layer / substrate

[0130] (5) Surface protective layer / transparent resin layer / decorative layer / substrate

[0131] (6) Surface protective layer / primer layer / transparent resin layer / decorative layer / substrate

[0132] (7) Surface protective layer / substrate / decorative layer

[0133] (8) Surface protective layer / primer layer / substrate / decorative layer

[0134] <<Substrate>>

[0135] The decorative material preferably includes a substrate. The material of the substrate is not particularly limited, but considering the ease of forming multiple independent recesses (A) and a group of parallel grooved embossed patterns (B) through embossing, a plastic film or a composite of plastic film and paper is preferred.

[0136] 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 methacrylate, and polyethyl methacrylate; polystyrene; acrylonitrile-butadiene-styrene copolymer (ABS resin); cellulose triacetate; and polycarbonate. Among these, from the perspectives of weather resistance, water resistance, printability, molding and processing adaptability, and price, polyolefin resins, vinyl chloride resins, polyester resins, or acrylic resins are preferred.

[0137] The substrate can be a transparent substrate or a colored substrate. Alternatively, the substrate can be a laminated substrate composed of multiple substrates. It should be noted that when the decorative material is laminated as described in (7) and (8) above, a transparent substrate is used in order to observe the decorative layer through the substrate.

[0138] The thickness of the substrate is not particularly limited, but is preferably 20 to 200 μm, more preferably 40 to 160 μm, and even more preferably 40 to 100 μm.

[0139] 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.

[0140] <<Decorative Layer>>

[0141] From the perspective of improving design, decorative panels preferably have a decorative layer on any part of the decorative panel.

[0142] From the viewpoint of improving the weather resistance of the decorative layer, the area where the decorative layer is formed is preferably on the side closer to the substrate. It should be noted that if the substrate is transparent, the decorative layer can also be located on the inner side (opposite to the first main surface) of the substrate, as in the above-described laminated configurations (7) and (8).

[0143] Decorative layers can be, for example, a coloring layer covering the entire surface (so-called solid coloring layer), a patterned layer formed by printing various patterns using ink and a printing press, or a combination thereof.

[0144] The patterns applied by the decorative layer are not particularly limited; examples include patterns of wood, stone, tile, brick, fabric, and leather. By using the decorative layer to form these patterns, the effect of the shape based on the aforementioned first main surface can be further emphasized.

[0145] The preferred pattern for the wood is formed by combining the bark portion with one or more patterns selected from vessels, downwood, and knots.

[0146] The preferred pattern for a stone is formed by combining the surface and recessed parts of the stone.

[0147] The tile pattern or brick pattern is preferably formed by combining the base portion of the tile or brick with the joint pattern.

[0148] The preferred fabric pattern is formed by combining the base portion of the fabric with the concave portion of the fabric.

[0149] The preferred leather pattern is formed by combining the base part of the leather with a pleated pattern.

[0150] The decorative layer can be formed, for example, by applying a decorative ink containing colorants such as pigments and dyes, as well as adhesive resin, and then drying it. This ink may contain additives such as extender pigments, antioxidants, plasticizers, catalysts, curing agents, UV absorbers, and light stabilizers, which can be mixed in as needed.

[0151] The colorant and adhesive resin of the decorative layer are not particularly limited; for example, the same substance as exemplified in the filling ink can be used.

[0152] The thickness of the decorative layer can be appropriately selected according to the desired pattern. From the viewpoint of concealing the background color of the object to be adhered and improving the design, it is preferably 0.1μm or more and 20μm or less, more preferably 0.5μm or more and 10μm or less, and even more preferably 1.0μm or more and 5.0μm or less.

[0153] <<Surface Protective Layer>>

[0154] To improve scratch resistance, decorative materials can have a surface protective layer.

[0155] From the viewpoint of ensuring good scratch resistance of the decorative sheet, the surface protective layer preferably comprises a cured product containing a curable resin composition.

[0156] 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. Among these, ionizing radiation-curable resin compositions are preferred from the viewpoint of improving the crosslinking density of the surface protective layer and enhancing surface properties such as scratch resistance. Furthermore, from the viewpoint of being able to be coated without solvents and being easy to handle, electron beam-curable resin compositions are more preferred among ionizing radiation-curable resin compositions.

[0157] A thermosetting resin composition is a composition comprising 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 curable resins.

[0158] 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"). As the ionizing radiation-curable functional group, it is a group that is cross-linked and cured by irradiation with ionizing radiation rays; preferably, functional groups having olefinic double bonds, such as (meth)acryloyl, vinyl, and allyl, are examples. It should be noted that in this specification, (meth)acryloyl means acryloyl or methacryloyl. Furthermore, in this specification, (meth)acrylate means acrylate or methacrylate.

[0159] In addition, ionizing radiation refers to rays in electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing or cross-linking molecules. Ultraviolet (UV) or electron beams (EB) are commonly used. In addition, it also includes electromagnetic waves such as X-rays and gamma rays, as well as charged particle beams such as alpha rays and ionizing rays.

[0160] 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.

[0161] As polymerizable monomers, (meth)acrylate monomers having free radical polymerizable unsaturated groups in the molecule are preferred, and polyfunctional (meth)acrylate monomers are preferred. Here, "(meth)acrylate" means "acrylate or methacrylate".

[0162] As a multifunctional (meth)acrylate monomer, examples include (meth)acrylate monomers that have two or more ionizing radiation curable functional groups in their molecules, and at least have a (meth)acryloyl group as such a functional group.

[0163] Examples of polymerizable oligomers include (meth)acrylate oligomers that have two or more ionizing radiation-curable functional groups in their molecules, and at least one (meth)acryloyl group. 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.

[0164] In addition, 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 obtained by modifying 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.

[0165] 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.

[0166] For purposes such as reducing the viscosity of ionizing radiation-curable resin compositions, monofunctional (meth)acrylates may be incorporated into the ionizing radiation-curable resin compositions. These monofunctional (meth)acrylates can be used alone or in combination in various ways.

[0167] When the ionizing radiation curable compound is an ultraviolet curable compound, the ionizing radiation curable resin composition preferably contains additives such as photopolymerization initiators and photopolymerization accelerators.

[0168] As photopolymerization initiators, one or more can be selected from acetophenone, benzophenone, α-hydroxyalkyl phenyl ketone, milchone, benzoin, benzoyl dimethyl ether, benzoylbenzoate, α-acyl oxime ester, thioxanone, etc.

[0169] In addition, photopolymerization accelerators are substances that can reduce polymerization hindrance caused by air during curing and accelerate the curing speed. Examples include one or more selected from p-dimethylaminobenzoate isoamyl ester, p-dimethylaminobenzoate ethyl ester, etc.

[0170] The surface protective layer may contain additives such as UV absorbers, light stabilizers, and colorants, as needed.

[0171] From the viewpoint of balancing processing characteristics, scratch resistance and weather resistance, the thickness of the surface protective layer is preferably 1.5 μm or more and 30 μm or less, more preferably 2 μm or more and 15 μm or less, and even more preferably 3 μm or more and 10 μm or less.

[0172] <<Transparent Resin Layer>>

[0173] From the viewpoint of improving strength, decorative sheets can have a transparent resin layer. When the decorative sheet has a surface protective layer, the transparent resin layer is preferably located between the substrate and the surface protective layer. When the decorative sheet has a primer layer, the transparent resin layer is preferably located between the substrate and the primer layer. Furthermore, when the decorative sheet has a decorative layer, from the viewpoint of protecting the decorative layer, the transparent resin layer is preferably located between the decorative layer and the surface protective layer.

[0174] 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. Furthermore, the transparent resin layer may be formed by mixing these illustrated resins, or it may be formed by laminating layers of one or more of these illustrated resins.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] <<Primer Layer>>

[0179] When the decorative sheet has a surface protective layer, it is preferable to have a primer layer in contact with the substrate side of the surface protective layer. The primer layer improves the adhesion between the substrate and the surface protective layer (or the adhesion between the transparent resin layer and the surface protective layer in the case of a transparent resin layer), which can easily ensure long-term interlayer adhesion (so-called weather-resistant adhesion) and good scratch resistance when exposed to outdoor conditions.

[0180] The primer layer is mainly composed of adhesive resin and may contain additives such as UV absorbers and light stabilizers as needed.

[0181] Preferred adhesive resins for the primer layer 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. Alternatively, the adhesive resin can be 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.

[0182] The thickness of the primer layer is preferably 0.5 μm or more and 10 μm or less, more preferably 0.7 μm or more and 8 μm or less, and even more preferably 1 μm or more and 6 μm or less.

[0183] <<Other Layers>>

[0184] The decorative material of the present invention may have other layers such as an adhesive layer and a back primer layer.

[0185] In the case where the decorative sheet has a transparent resin layer, in order to improve the adhesion between the two layers, it is preferable to form an adhesive layer between the substrate and the transparent resin layer.

[0186] It should be noted that when a decorative layer is further provided between the substrate and the transparent resin layer, the positional relationship between the adhesive layer and the decorative layer is not particularly limited. Specifically, the decorative layer, adhesive layer, and transparent resin layer may be provided sequentially from the side closest to the substrate, or the adhesive layer, decorative layer, and transparent resin layer may be provided sequentially from the side closest to the substrate.

[0187] 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.

[0188] Examples of urethane-based adhesives include two-component curing urethane resins that utilize curing agents such as polyol compounds including polyether polyols, polyester polyols, acrylic polyols, and isocyanate compounds.

[0189] 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.

[0190] The back primer layer is a layer formed on the side of the decorative material opposite to the first main surface, with the purpose of improving the adhesion between the decorative material and various adhered objects.

[0191] There are no particular limitations on the materials used to form the back primer layer. Examples include urethane resins, acrylic resins, polyester resins, vinyl chloride / vinyl acetate copolymers, chlorinated polypropylene resins, and chlorinated polyethylene resins. The appropriate material can be selected based on the material to be bonded.

[0192] The thickness of the back primer layer is preferably 0.5 to 5.0 μm, more preferably 1 to 3 μm.

[0193] The aforementioned decorative layer, surface protective 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.

[0194] Alternatively, the transparent resin layer can be formed, for example, by heating and melting extrusion.

[0195] <Uses of Decorative Materials>

[0196] The decorative material of the present invention can be used in various applications, either directly, or as a laminate bonded to an object, or by performing a prescribed forming process on the decorative material or laminate.

[0197] For various purposes, examples include interior building materials such as walls, ceilings, and floors; window and door partitions such as window frames, doors, and handrails; furniture; housings for home appliances and OA equipment; and exterior building materials such as entrance doors.

[0198] Examples of materials that can be bonded include: wood veneer, plywood, particleboard, MDF (medium-density fiberboard), engineered wood products, and other wood-based panels; gypsum boards such as gypsum board and gypsum slag board; cement boards such as calcium silicate board, asbestos rock board, lightweight foamed concrete board, and hollow extruded cement board; fiber cement boards such as pulp cement board, asbestos cement board, and wood chip cement board; ceramic boards such as pottery, porcelain, earthenware, glass, and enamel; metal plates such as iron plates, galvanized steel plates, PVC sol-coated steel plates, aluminum plates, and copper plates; and polyolefin resin boards, acrylic resin boards, ABS resin boards, and polycarbonate boards. Thermoplastic resin boards such as ester boards; thermosetting resin boards such as phenolic resin boards, urea resin boards, unsaturated polyester resin boards, polyurethane resin boards, epoxy resin boards, and melamine resin boards; and so-called FRP boards, which are composites obtained by impregnating and curing resins such as phenolic resin, urea resin, unsaturated polyester resin, polyurethane resin, epoxy resin, melamine resin, and diallyl phthalate resin into glass fiber nonwoven fabric, cloth, paper, and other various fibrous substrates. These can be used individually or as composite substrates formed by laminating two or more of them.

[0199] <Method for forming the first principal face>

[0200] The multiple independent recesses (A) and the group of parallel groove-shaped concave and convex patterns (B) on the first main surface can be formed, for example, by shaping using an embossing plate engraved with a laser.

[0201] Using laser-engraved embossing plates, for example, in... Figure 6 The process is carried out in steps (S11 to S15). Each step will be described below.

[0202] <<S11: Concentration distribution data for the concave region (A)>>

[0203] In the concentration distribution data production process (process S11), a concentration distribution image is obtained as the basis for a pattern of multiple independent recesses (A) that are represented on the surface of the decorative material, and this image is used as concentration distribution data. As an example of a concentration distribution image, an image showing only a conduit pattern of wood grain can be cited.

[0204] The concentration distribution image obtained in step S11 is preferably a two-dimensional concentration pattern without height information. Examples of such concentration patterns include photographs, drawings, and printed materials. Alternatively, a three-dimensional image with height information can be used, but in this case, it is preferable to remove the height information and use only the concentration information based on the two-dimensional view from above.

[0205] In process S11, for the obtained concentration distribution image, the concentration value D(x,y) is obtained according to each two-dimensional coordinate (x,y) as the concentration distribution data.

[0206] The two-dimensional coordinates (x, y) are not particularly limited, but preferably correspond to the coordinates of the surface of the plate (in this embodiment, a metal roller-shaped embossing plate) described later. Furthermore, the specific representation of the concentration value D is not particularly limited; for example, the densest part in the concentration distribution image can be set to 255, the lightest part to 0, and the remainder can be evenly distributed with integers, representing the concentration value with a grayscale of 256.

[0207] Based on the above, a set of concentration values ​​D represented by 256 gray levels is obtained in each coordinate (x, y), which is used as the concentration distribution data.

[0208] As described above, concentration distribution data is preferably digital data. Therefore, if the underlying concentration distribution image is not digital data, it can be digitized by scanning the original document itself or a photograph of the original document and using an analog-to-digital (AD) conversion method. Furthermore, if the pattern is designed using CAD or similar methods from the outset and digital data is employed, this digital data can be used.

[0209] There are no particular limitations on the method for creating concentration distribution data. For example, you can use Adobe Systems' graphic design software "Photoshop" to create concentration distribution data with a resolution of 2540 dpi in 8-bit grayscale (256 grayscale) in TIF format.

[0210] <<S12: Conversion of Concentration Distribution Data to Depth Data>>

[0211] In the process of converting to depth data (process S12), the concentration values ​​D(x, y) of the concentration distribution data of the recesses (A) obtained in process S11 are converted into depths F(x, y) according to each coordinate (x, y) to obtain depth data. This depth data corresponds to the depth of the individual recesses (A). Therefore, through this process, the shape of the individual recesses (A) is determined.

[0212] Here, the conversion of concentration value D(x,y) to depth F(x,y) is based on prescribed rules. Thus, a correspondence is established between concentration distribution and depth distribution, enabling the creation of a unique texture in the surface pattern of decorative materials based on the concentration distribution image.

[0213] For example, in step S11, the densest part of the concentration distribution image is set to grayscale 255, and in step S12, it is set to a depth of 300 μm. On the other hand, in step S11, the lightest part of the concentration distribution image is set to grayscale 0, and in step S12, it is set as a baseline (depth 0 μm). Then, for grayscale values ​​of 0 to 255 in step S11, depths are allocated proportionally from 0 μm to 300 μm in step S12.

[0214] Therefore, according to this example, the lightest part in the concentration distribution image becomes the baseline (depth 0 μm), and the deeper the concentration, the deeper the depth. In the most concentrated part, the depth becomes 300 μm.

[0215] <<S13: Conversion to height data and overlap of data in the grooved embossed pattern group (B)>>

[0216] In the conversion process to height data (process S13), the depth F(x, y) of the multiple independent recesses (A) obtained in process S12 is converted into the height H1(x1, y1) for making the corresponding plate, thus obtaining the depth data. That is, the height H1(x1, y1) of the embossed pattern is made to form a complementary shape of the recesses (A) with depth F(x, y) on the surface of the plate.

[0217] Here, height H2 (x2, y2) is overlapped with height H1 (x1, y1). This height H2 (x2, y2) is used to form a relief pattern on the surface of the plate that is complementary in shape to the relief pattern group (B) having a specified depth data. The height obtained by overlapping height H2 (x2, y2) with height H1 (x1, y1) is set as height H3 (x3, y3).

[0218] If a relief is formed on the surface of the plate based on the height data H3(x3, y3), then the relief of the surface of the decorative material shaped by the plate is based on the height data of the first main surface.

[0219] In this embodiment, when converting depth F(x, y) to height H(x, y), the conversion is performed in the same scale but in the opposite manner. That is, if "depth" is represented as negative and "height" as positive, then F(x, y) = -H(x, y). However, this is not a limitation; depth F(x, y) can also be transformed to height H(x, y) by multiplying by a predetermined coefficient α, depending on the representation requirements. For example, the conversion can also be performed using F(x, y) = αH(x, y). Here, α can be either positive or negative.

[0220] Therefore, by simply changing α, it is possible to create a variety of decorative materials that give different impressions based on the same height data.

[0221] <<S14: Production Version>>

[0222] In the plate-making process (S14), a plate with raised and recessed surfaces is created using height data H3(x3, y3) obtained in process S13. Here, as an example, an embossing plate based on a metal roller is illustrated. More specifically, the embossing plate is created as follows.

[0223] First, prepare Figure 7 The metal roller 50 shown is the final embossing plate 50. The metal roller 50 can be, for example, formed by plating a copper layer onto the surface of a hollow iron cylinder, which has rotation drive shafts 51 at both axial ends. The surface of the metal roller 50 is preferably roughened by grinding with a grinding stone or similar material to suppress the reduction in engraving efficiency caused by specular reflection from the engraving laser.

[0224] Then, as Figure 7 As illustrated in the diagram, a laser direct engraving machine is used to engrave the surface of the prepared metal roller 50 based on the height data of each coordinate produced in process S13.

[0225] The metal roller 50 is driven by an electric motor via its rotation drive shaft 51 and rotates around the rotation drive shaft 51 as its central axis. At this time, the surface of the metal roller 50 is scanned with light L emitted from the laser head 52. As an example of laser L, a fiber laser with an oscillation wavelength of 1024 nm, a spot diameter of 10 μm, and a power of 360 W can be cited.

[0226] When scanning the surface of the metal roller with laser L, the laser is switched ON-OFF (irradiation or non-irradiation) for each coordinate (x, y) according to the height H3 (x3, y3) created in process S13. At the irradiated position, a recess is formed by the evaporation of metal caused by a single laser irradiation (the recess corresponds to the protrusion of the decorative material. Therefore, the higher the coordinate, the fewer laser irradiations are needed). Under the laser conditions illustrated above, a recess with a depth of 10 μm is formed by a single laser irradiation.

[0227] The laser scan of the metal roller surface is repeated approximately 10 times. Furthermore, to prevent the evaporated metal from becoming powder and remaining or adhering to the surface of the metal roller 50, laser irradiation is preferably performed while the engraving liquid T is being blown from the engraving liquid outlet 53 into the laser irradiation area on the surface of the metal roller.

[0228] In this way, by micro-engraving the surface of the metal roller 50 with a laser, a metal roller with a surface shape capable of forming the first main surface can be obtained.

[0229] After such engraving, it is preferable to clean the engraving solution and then perform electrolytic polishing to remove metal residue adhering to the surface of the metal roller 20. Then, to improve durability, it is preferable to plate the surface of the metal roller 20 with hard chromium or similar materials. The thickness of the plating is typically around 10 μm.

[0230] Through the above processes S11 to S14, a plate 50 (a molding die for decorative materials, or an embossing plate in this embodiment) with a shape that complements the concave-convex shape of the first main surface of the decorative material can be obtained.

[0231] <<S15: Typing>>

[0232] In the shaping process (S15), the embossing plate (embossing plate) made in processes S11 to S14 is used to emboss the decorative material before the formation of the first main surface to make the decorative material.

[0233] Embossing can be performed using any known method without particular restrictions. The temperature and pressure during embossing should be adjusted according to the material of the decorative material. If the base material and the transparent resin layer are polyolefin, the pressure should be 140–180℃ and 10–50 kg / cm². 2 about.

[0234] Representative methods of embossing are shown below.

[0235] First, an embossing stencil is pressed onto the surface of a softened resin substrate to create a raised or recessed pattern. Then, the resin substrate is cured by cooling and light exposure, fixing the raised or recessed pattern. Finally, the resin with the raised or recessed pattern is demolded from the embossing stencil.

[0236] [Manufacturing methods for decorative materials]

[0237] The manufacturing method of the decorative material of the present invention includes the following steps (1) to (2).

[0238] (1) A process of shaping a single layer of a substrate selected from plastic film or a composite of plastic film and paper, or a laminate containing the above-mentioned substrate, using an embossing plate to obtain the decorative material of the present invention.

[0239] (2) The process of scraping off the filling ink after applying a filling ink containing a colorant and an adhesive resin to the first main surface of the decorative material obtained in (1) above.

[0240] The decorative material obtained through the above processes (1) to (2) has better designability because at least a portion of the recess (A) is filled with colorant in the depth direction.

[0241] In particular, by using materials selected from X related to the first main surface of the decorative material obtained in process (1), A X B X A -X B Y A Y B1 and Y B2 The scope, and D A With D B If at least one of the embodiments in the relationship is set as the preferred embodiment described above, the amount of colorant filling in the decorative material obtained in the step (2) satisfies either of the conditions (i) and (ii) above, the contrast of brightness between the recess (A) and the recess constituting the groove-shaped parallel concave-convex pattern group (B) is further improved, and a decorative material with a more prominent three-dimensional effect can be obtained.

[0242] There are no particular restrictions on the embossing conditions of process (1), for example, the conditions described in process S15 above can be cited.

[0243] In addition, process (2) preferably includes the following processes (2-1) to (2-3).

[0244] (2-1) A process of making the decorative material obtained in step (1) along at least a portion of the surface of a roller with a circular cross-section, such that the first main surface side of the decorative material faces the opposite side of the roller.

[0245] (2-2) A process of applying a filling ink containing colorant and adhesive resin to the first main surface of the decorative material obtained in process (1).

[0246] (2-3) The process of pressing the knife against the first main surface of the decorative material and scraping off the filler ink adhering to the first main surface.

[0247] In step (2-1), the roller can be made of materials such as metal, rubber, and resin, with rubber and resin being preferred, and rubber being more preferred. By making the roller a cushioning material such as rubber or resin, it is easy to suppress excessive residue of colorant in the recess. In addition, by making the roller a cushioning material such as rubber or resin, it is easy to satisfy either of the conditions (i) and (ii) above.

[0248] The filling ink in step (2-2) contains a colorant and a binder resin, and preferably includes a solvent as needed. It should be noted that there is a tendency for the higher the viscosity of the filling ink, the more difficult it is to scrape off the ink in the recesses; conversely, the lower the viscosity of the filling ink, the easier it is to scrape off the ink in the recesses. Therefore, it is preferable to adjust the viscosity of the filling ink appropriately according to the desired filling amount.

[0249] It should be noted that the colorant used for filling inks is preferably a dark-colored colorant.

[0250] As the mechanism for scraping off the filling ink in process (2-3), a scraping tool such as a doctor blade is preferably used. In this case, the direction of ink scraping is preferably perpendicular to D. A Roughly the same (relative to D) A Within ±10 degrees, preferably within ±5 degrees, and more preferably within ±3 degrees.

[0251] The angle between the cutting tool and the first main surface of the decorative material is preferably approximately perpendicular. Approximately perpendicular means within the range of 90±10 degrees, preferably 90±5 degrees, and more preferably 90±3 degrees. It should be noted that the case of tilting towards the direction of travel of the decorative material is marked as positive, and the case of tilting towards the opposite direction of travel of the decorative material is marked as negative.

[0252] In addition, the materials for knives include metal, rubber and resin, among which metal is preferred.

[0253] In process (2-3), the pressure of the cutting tool on the decorative material can be adjusted appropriately within the range that does not produce ink streaks and unevenness.

[0254] Example

[0255] The invention will now be described in further detail through examples, but the invention is not limited to these examples. It should be noted that, unless otherwise specified, "part" refers to a mass standard.

[0256] 1. Evaluation

[0257] 1-1. Three-dimensionality

[0258] For the decorative materials obtained in the embodiments and comparative examples, under fluorescent lighting, any 20 adults were asked to visually evaluate whether they perceived a three-dimensional effect.

[0259] AA: More than 18 people answered that they had a good sense of three-dimensionality.

[0260] A: 15 to 17 people answered that they had a good sense of three-dimensionality.

[0261] B: 11 to 14 people answered that they had a good sense of three-dimensionality.

[0262] C: Fewer than 10 people answered that they had a good sense of three-dimensionality.

[0263] 1-2. Natural texture

[0264] For the decorative materials obtained in the examples and comparative examples, under fluorescent lighting, any 20 adults were asked to visually evaluate whether they had a natural texture.

[0265] AA: More than 18 people answered that they had a natural quality.

[0266] A: 15 to 17 people answered that they had a natural, tangible quality.

[0267] B: 11 to 14 people answered that they had a natural texture.

[0268] C: Fewer than 10 people answered that they had a natural quality.

[0269] 2. Making the embossed pattern

[0270] According to steps S11 to S14 in the main text of the instruction manual, embossing plate A with a hard chrome plated surface is produced. Additionally, except for changing the shape of the recess (A) and the grooved parallel embossed pattern group (B) as shown in Table 1, embossing plates B to C are produced in the same manner as plate A. Furthermore, without forming the grooved parallel embossed pattern group (B), the shape of the recess (A) is changed as shown in Table 1, except for this, embossing plates D to E are produced in the same manner as plate A.

[0271] 3. Production of decorative materials

[0272] [Example 1]

[0273] On a colored substrate (a white polypropylene film with a thickness of 60 μm), a decorative layer with a wood pattern with a total thickness of 1 μm is formed by gravure multicolor printing, consisting of a pattern layer with a duct groove pattern formed by black ink and a pattern layer with a bark pattern other than the duct portion formed by brown ink.

[0274] Next, an adhesive layer (polyester resin, thickness: 5 μm) is formed on the decorative layer. Then, a transparent resin layer (transparent polypropylene resin sheet, thickness: 80 μm) is laminated onto the adhesive layer by extrusion lamination.

[0275] Next, the transparent resin layer is heated to soften it, and using the embossing plate A prepared in "2" above, embossing is performed from the transparent resin layer side to form an uneven shape on the transparent resin layer side (the side of the first main surface). The measured values ​​of the uneven shape are shown in Table 1.

[0276] Furthermore, after applying a dark brown filler ink to the side of the transparent resin layer (the side of the first main surface), a scraper is pressed perpendicular to the first main surface to scrape off the filler ink, thus obtaining the decorative material of Example 1. The direction of scraping off the filler ink is set to be perpendicular to D. A Same direction.

[0277] [Examples 2-3]

[0278] Except for changing embossed plate A to embossed plates B to C, the same operation as in Example 1 was performed to obtain the decorative materials of Examples 2 to 3.

[0279] [Comparative Examples 1-2]

[0280] Except for changing embossed pattern A to embossed patterns D to E, the same procedure as in Example 1 was followed to obtain the decorative materials of Comparative Examples 1 to 2.

[0281] [Table 1]

[0282]

[0283] As shown in Table 1, it can be confirmed that the decorative materials in the embodiments can impart excellent three-dimensionality and express the natural objects well, thus exhibiting extremely good design.

[0284] Explanation of reference numerals in the attached figures

[0285] 10: Concave (A)

[0286] 20: Groove-shaped embossed pattern group (B)

[0287] 20a, 20b, 20c, 20d, 20e, 20f, 20g, 20h, 20i, 20j, 20k, 20l: Groove-shaped raised and recessed patterns

[0288] 30: Colorant

[0289] 100: Decorative materials

[0290] 50: Plate (embossed plate, metal roller)

[0291] 51: Rotary drive shaft

[0292] 52: Laser head

[0293] 53: Engraving fluid spray outlet

Claims

1. A decorative material, wherein, The decorative material has a plurality of independent recesses (A) on its first main surface side and a group of groove-shaped parallel concave and convex patterns (B) formed by at least a portion of the portion of which the plurality of independent recesses (A) are not present. The average depth of the individual recesses (A) is defined as X. A The average depth of the recesses in the grooved parallel concave-convex pattern group (B) is defined as X. B When X is satisfied B <X A The relationship.

2. The decorative material according to claim 1, wherein, The X A The size is 40μm to 150μm, and the X... B The range is from 5μm to 100μm.

3. The decorative material according to claim 1 or 2, wherein, The X A -X B It is above 20μm.

4. The decorative material according to any one of claims 1 to 3, wherein, The average width of the individual recesses (A) is defined as Y. A The average width of the recesses in the grooved parallel concave-convex pattern group (B) is defined as Y. B1 The average width of the convex portion of the groove-shaped parallel concave-convex pattern group (B) is defined as Y. B2 At that time, Y A The value is 150μm to 500μm, and the Y... B1 The Y ranges from 10 μm to 200 μm. B2 The range is from 10μm to 250μm.

5. The decorative material according to any one of claims 1 to 4, wherein, The extension direction of the plurality of independent recesses (A) is defined as D. A The extension direction of the groove-shaped parallel concave-convex pattern group (B) is defined as D. B At that time, D A With D B Not parallel.

6. The decorative material according to claim 5, wherein, The D A With the D B The angle formed is between 5 and 70 degrees.

7. The decorative material according to any one of claims 1 to 6, wherein, The top view shape of each grooved parallel concave-convex pattern constituting the grooved parallel concave-convex pattern group (B) is wavy.

8. The decorative material according to any one of claims 1 to 7, wherein, The top view shape of the recess (A) is selected from one or more of the following: wood vessels, wood chips, and wood knots.

9. The decorative material according to any one of claims 1 to 8, wherein at least a portion of the depth direction of the plurality of individual recesses (A) is filled with a colorant.

10. The decorative material according to claim 9, wherein it satisfies either (i) or (ii) below: (i) At least a portion of the recesses in the grooved parallel convex-concave pattern group (B) is not filled with colorant in the depth direction. (ii) At least a portion of the recess in the grooved parallel concave-convex pattern group (B) is filled with a colorant in the depth direction, wherein the amount of colorant filled per unit area is defined as W. B The amount of colorant filling per unit area in at least a portion of the depth direction of the plurality of independent recesses (A) is defined as W. A When W is satisfied B <W A The relationship.

11. A method for manufacturing a decorative material, comprising the following steps (1) to (2): (1) A process of shaping a single layer of a substrate selected from plastic film or a composite of plastic film and paper, or a laminate containing said substrate, using an embossing plate to obtain the decorative material according to any one of claims 1 to 8; (2) The process of scraping off the filling ink after applying a filling ink containing a colorant and an adhesive resin to the first main surface of the decorative material obtained in (1).

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