Decorative material and manufacturing method thereof

Abstract

To provide a decorative material that can impart an excellent three-dimensional effect and has a good expression of natural objects.SOLUTION: A decorative material comprises a plurality of independent concavities (A) on a first main surface side and a groove-shaped parallel concavity-convexity pattern group (B) arranged at least partially in a location where the plurality of independent concavities (A) do not exist. When defining the average depth of the plurality of independent concavities (A) as XA and the average depth of the concavities in the groove-shaped parallel concavity-convexity pattern group (B) as XB, XB<XA is satisfied.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a decorative material and a method for producing the same. [Background technology]

[0002] Decorative materials are widely used to decorate interior and exterior materials such as furniture and fittings, and in recent years, there has been a demand for decorative materials that can impart a three-dimensional effect to enhance the decorative effect. As such decorative materials, there has been proposed a material that forms areas with different glossiness within the surface of the decorative material, imparting a three-dimensional effect by the contrast of glossiness.

[0003] Means for imparting a three-dimensional effect by the contrast of glossiness include a means for partially exposing a matte layer, a means for partially forming unevenness by embossing, a means for partially forming a glittering ink layer, and a combination of the aforementioned means (Patent Documents 1 to 3). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2000-62081 A [Patent Document 2] Japanese Patent Application Publication No. 7-314630 [Patent Document 3] JP 2018-122575 A DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0005] The decorative material of Patent Document 1 is capable of imparting a three-dimensional effect by forming a glossy layer partially on a matte layer formed on the entire surface, and by contrasting the part where the matte layer is exposed (low gloss part) with the part where the glossy layer is present (high gloss part). However, the decorative material of Patent Document 1 has a problem that the three-dimensional effect is insufficient, and the exposed part of the matte layer is easily soiled. In addition, since the decorative material of Patent Document 1 does not have anisotropic gloss, it gives a strong artificial impression, and the design is insufficient when it is desired to express natural objects such as wood grain.

[0006] The decorative material of Patent Document 2 is partially embossed to form concaves and convexes, and the contrast between concaves (low gloss areas) and flat areas (high gloss areas) creates a three-dimensional effect. However, like the decorative material of Patent Document 1, the decorative material of Patent Document 2 has a problem in that it is insufficient in terms of design when it is desired to express natural objects.

[0007] The decorative material of Patent Document 3 can impart a three-dimensional effect by contrasting an area having a matte layer (low gloss area) with an area having a pearl pigment adjacent to the area (high gloss area). However, like the decorative material of Patent Document 1, the decorative material of Patent Document 3 also has problems in that the three-dimensional effect is insufficient, the matte layer part is easily soiled, and the design is insufficient when expressing natural objects. Furthermore, the decorative material of Patent Document 3 requires the use of relatively costly materials such as pearl pigments and metal flakes.

[0008] An object of the present invention is to provide a cosmetic material that can impart an excellent three-dimensional effect and that satisfactorily expresses natural objects, and a method for producing said cosmetic material. [Means for solving the problem]

[0009] In order to achieve the above object, the present inventors provide the following [1] to

[11] . [1] A decorative material, comprising a first main surface side of the decorative material having a plurality of independent recesses (A) and a group of groove-like parallel uneven patterns (B) arranged in at least a portion of a region where the plurality of independent recesses (A) are not present, and the average depth of the plurality of independent recesses (A) is XA The average depth of the recesses of the groove-shaped parallel uneven patterns (B) is X B When we define B <X A A cosmetic material that satisfies the above requirements. [2] X above A is 40 to 150 μm, B The decorative material according to the above [1], wherein the average particle size is 5 to 100 μm. [3] X A -X B The decorative material according to the above [1] or [2], wherein the particle size is 20 μm or more. [4] The average width of the independent recesses (A) is Y A The average width of the recesses of the groove-shaped parallel uneven patterns (B) is Y B1 The average width of the convex portions of the groove-shaped parallel concave-convex patterns (B) is Y B2 When you define Y A is 150 to 500 μm, B1 is 10 to 200 μm, B2 The decorative material according to any one of the above [1] to [3], wherein the thickness is 10 to 250 μm. [5] The extension direction of the independent recesses (A) is D A The stretching direction of the groove-shaped parallel uneven patterns (B) is D B When we define A and D B and are non-parallel. [6] D above A and the above D B The decorative material according to [5] above, wherein the angle between the surface and the surface is 5 to 70 degrees. [7] The decorative material according to any one of the above [1] to [6], wherein each of the groove-like parallel uneven patterns constituting the group of groove-like parallel uneven patterns (B) has a wavy shape in a plan view. [8] The decorative material according to any one of the above [1] to [7], wherein the shape of the recess (A) in a plan view is one or more selected from the group consisting of a vessel, fall wood, and a knot of wood. [9] The decorative material according to any one of the above [1] to [8], wherein a colorant is filled into at least a portion of the depth direction of the plurality of independent recesses (A).

[10] The decorative material according to [9] above, which satisfies either of the following conditions (i) or (ii). (i) At least a portion of the recesses of the group of groove-like parallel uneven patterns (B) in the depth direction is not filled with colorant. (ii) A colorant is filled in at least a part of the recesses in the groove-like parallel uneven pattern group (B) in the depth direction, and the filling amount of the colorant per unit area is W B The amount of the colorant filled in at least a portion of the independent recesses (A) in the depth direction per unit area is W A When we define B <W A Satisfy the relationship.

[11] A method for producing a decorative material, comprising the following steps (1) and (2): (1) A process for obtaining the decorative material according to any one of the above [1] to [8] by shaping a single layer of a substrate selected from a plastic film or a composite of a plastic film and paper, or a laminate including the substrate, with an embossing plate. (2) A process of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in (1) above, and then scraping off the filler ink. Effect of the Invention

[0010] The decorative material of the present invention can impart an excellent three-dimensional effect and has excellent expression of natural objects, so that the design can be very good. Furthermore, the manufacturing method of the decorative material of the present invention can easily manufacture the decorative material having the above-mentioned effects. [Brief description of the drawings]

[0011] [Figure 1] 1 is a plan view of a first main surface side showing one embodiment of a decorative material of the present invention. [Diagram 2] FIG. 2 is an enlarged plan view of a circular portion enclosed by a dashed line in FIG. [Diagram 3] 1 is an image in which the elevation of the decorative material of Example 1 was measured from the first main surface side, and the measured elevation is expressed in shades of gray. [Figure 4]2 is a cross-sectional view taken along a line AA' in FIG. 1 and parallel to the z-axis in FIG. [Diagram 5] FIG. 11 is a plan view illustrating one step of calculating the average depth (XA) of a plurality of independent recesses (A). [Figure 6] FIG. 2 is a diagram showing a flow of one embodiment of a process for forming an uneven shape on the first main surface of the decorative material of the present invention. [Figure 7] FIG. 7 is a diagram showing a scene of a step of producing a plate by a laser, which is an example of step S14 in FIG. 6. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] [Cosmetic materials] The decorative material of the present invention has, on a first main surface side, a plurality of independent recesses (A) and a group of groove-like parallel uneven patterns (B) arranged in at least a portion of a region where the plurality of recesses (A) are not present, and the average depth of the plurality of independent recesses (A) is X A The average depth of the recesses of the groove-shaped parallel uneven patterns (B) is X B When we define B <X A The relationship is as follows:

[0013] <First main surface of decorative material> Fig. 1 is a plan view of the first main surface side showing one embodiment of the decorative material 100 of the present invention. As shown in Fig. 1, the decorative material 100 of the present invention has, on the first main surface side, a plurality of independent recesses (A) 10 and a group of groove-like parallel uneven patterns (B) 20 arranged in places where the plurality of recesses (A) 10 are not present. In Fig. 1, the group of groove-like parallel uneven patterns (B) 20 is composed of groove-like uneven patterns 20a, 20b, ..., and 20l, and each groove-like uneven pattern is parallel. Fig. 2 is an enlarged plan view of the circular portion surrounded by the dashed line in Fig. 1. As shown in Fig. 2, the group of groove-like parallel concave-convex patterns (B) 20 is composed of a concave portion 21 and a convex portion 22 surrounded by the concave portion 21. In this specification, the term "parallel" in the group of groove-shaped parallel uneven patterns means that adjacent recesses are parallel when the decorative material is viewed in a plane. Furthermore, the term "parallel" in the group of groove-shaped parallel uneven patterns is not limited to being completely parallel, but includes being approximately parallel. "Approximately parallel" means that when tangents are drawn to the edges of a pair of adjacent recesses, the angle formed by the two tangents is within 7.0 degrees, preferably within 5.0 degrees, and more preferably within 3.0 degrees.

[0014] Fig. 3 is a plan view showing the elevation of the decorative material of Example 1 measured from the first main surface side, and the measured elevation is expressed by shading. In Fig. 3, the lower the density, the higher the elevation, and the higher the density, the lower the elevation. In Fig. 3, the elongated high-density portion extending in the vertical direction is the recess (A). There are a plurality of independent recesses (A) within the surface of the decorative material in Fig. 3. In Fig. 3, the low-density portion extending diagonally downward to the right is the group of groove-shaped parallel uneven patterns (B). The group of groove-shaped parallel uneven patterns (B) is arranged in a location where there are no independent recesses (A). 4 is a cross-sectional view taken along a line AA' in FIG. 1 and parallel to the z-axis in FIG.

[0015] The first main surface of the decorative material has a recess (A) having an average depth X A Since the area is deep, the light incident on the area is easily scattered and attenuated by multiple reflections. Therefore, the area having the concave portion (A) is visually recognized as dark. On the other hand, in the area having the group of groove-like parallel concave-convex patterns (B), multiple reflections do not occur in the convex portions, and the average depth X B Since the grooves are shallow and there is little multiple reflection, the area having the groove-shaped parallel uneven pattern group (B) is perceived as brighter than the recesses (A). Furthermore, the brightness of the area having the groove-shaped parallel uneven pattern group (B) differs when viewed from the extension direction of the grooves and when viewed from a direction perpendicular to the extension direction of the grooves. This is because there is less multiple reflection of light incident on the recesses when viewed from the extension direction of the grooves. As described above, the decorative material of the present invention has a plurality of independent concave portions (A) and a group of groove-like parallel concave-convex patterns (B), and B <X ASince the relationship above is satisfied, the area having the groove-shaped parallel uneven pattern group (B) can be visually recognized as being relatively brighter than the area having the recess (A), and a three-dimensional effect can be imparted by the contrast in brightness. Furthermore, since anisotropy can be imparted to the brightness by the groove-shaped parallel uneven pattern group (B), natural objects can be expressed well.

[0016] The ratio of the area occupied by the recesses (A) (the total area of ​​the plurality of independent recesses (A)) to the total area of ​​the first main surface is preferably 20 to 50%, and more preferably 30 to 40%.

[0017] <<Depth>> Average depth of multiple independent recesses (A) X A can be calculated, for example, by the following steps A1 to A3. A1: For each recess (A), the height data in the direction crossing each recess (A) is measured at five randomly selected points to obtain five cross-sectional curves with height data. If the planar shape of the recess (A) is an elongated shape extending in any direction, the height data is measured in a direction perpendicular to the extension direction of the recess (A). For example, if the planar shape is the recess (A) in Figure 5, the height data is measured in the dotted line direction, which is a direction perpendicular to the extension direction of the recess (A) (the vertical direction in Figure 5), at five points a to e. A2: From the height data measured in A1, the maximum depth of each measurement point is extracted, and the average value of the maximum depths at the five points is regarded as the average depth of each recess (A). A3: Average the average depth of each recess (A) calculated in A2, and calculate X A Calculate.

[0018] For example, in Figure 4, the average depth of the left concave portion (A) (average of the maximum depths of the five points) is X A-1 Let the average depth of the right concave portion (A) (the average of the maximum depths of the five points) be X. A-2 Then, the average depth of the independent recesses (A) is X A can be calculated using the following formula. Average depth of recess (A) X A =(X A-1 +X A-2) / 2

[0019] The average depth of the concaves of the groove-like parallel uneven pattern group (B) is X B can be calculated using B1 to B3 below. B1: For each recess in the group of groove-like parallel uneven patterns (B) present in the plane of the decorative sheet, the height data in the direction crossing each recess is measured at five randomly selected locations to obtain five cross-sectional curves with height data. The measurement direction at each measurement location is perpendicular to the extension direction of the recess. In addition, in order to simultaneously measure the width of the protrusions in the group of groove-like parallel uneven patterns (B), it is preferable to use a cross-sectional curve crossing the protrusions. B2: From the height data measured in B1, the maximum depth of each measurement point is extracted, and the average value of the maximum depths at the five points is regarded as the average depth of each recess. B3: Average the average depth of each recess calculated in B2 to obtain X B Calculate.

[0020] For example, in Fig. 4, the average depth of the nth recess from the left (the average of the maximum depths of the five recesses) is X B1-n In FIG. 4, there are nine recesses in the group of groove-like parallel uneven patterns (B) (20d to 20l in FIG. 4), so the average depth X B can be calculated using the following formula. Average depth X of the concaves of the groove-like 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

[0021] The average depth (X) of multiple independent recesses (A) A ) is preferably 40 to 150 μm, more preferably 45 to 120 μm, and further preferably 50 to 100 μm. A By making X 40 μm or more, it is easy to reduce the brightness of the area having the recess (A). ABy setting the thickness to 150 μm or less, a realistic design can be reproduced in which the darkness of the recesses (A) and the brightness of the groove-like parallel uneven patterns (B) are well harmonised. The average depth of the concaves of the groove-like parallel uneven patterns (B) (X B ) is preferably 5 to 100 μm, more preferably 10 to 70 μm, and further preferably 15 to 60 μm. B By making X 5 μm or more, it is easy to impart anisotropy to the lightness. B By making X 100 μm or less, it is possible to easily increase the contrast in brightness between the independent concave portions (A) and the group of groove-like parallel concave-convex patterns (B). Note that, from the viewpoint of making it difficult for a colorant to be filled into the concave portions of the groove-like parallel concave-convex pattern (B) when performing the wiping step described later, B It is preferable that the thickness is 60 μm or less.

[0022] Also, X A -X B X is preferably 20 μm or more, more preferably 30 μm or more, and even more preferably 40 μm or more. A -X B By making the X diameter 20 μm or more, it is possible to easily increase the contrast in brightness between the independent concave portions (A) and the group of parallel groove-like concave-convex patterns (B). A -X B By making the thickness 20 μm or more, when performing the wiping process described later, a large amount of colorant is filled into the recesses (A), while the amount of colorant filled into the recesses of the groove-shaped parallel uneven pattern (B) is reduced, thereby making it possible to achieve better contrast.

[0023] <<Width and length>> In addition, the decorative material of the present invention has an average width of the recess (A) of Y A The average width of the concaves of the groove-like parallel concave-convex patterns (B) is Y B1 The average width of the convex parts of the groove-shaped parallel uneven patterns (B) is Y B2 When you define Y A , Y B1 and Y B2is preferably in the following range: The convex portions of the group of groove-like parallel concave-convex patterns (B) refer to those located between the concave portions of the group of groove-like parallel concave-convex patterns (B).

[0024] Y A The thickness is preferably 150 to 500 μm, more preferably 170 to 450 μm, and further preferably 200 to 400 μm. Y A By making Y 150 μm or more, it is possible to easily recognize each recess (A) as an independent region. A By making Y 150 μm or more, it is possible to easily fill a large amount of colorant into the recesses (A) when performing the wiping step described later. A By making the thickness 500 μm or less, light incident on the recess (A) is likely to be multiple-reflected, and the recess (A) can be easily visually recognized as being dark.

[0025] Y B1 is preferably 10 to 200 μm, more preferably 15 to 150 μm, and further preferably 20 to 100 μm. B1 By making Y 10 μm or more, it is possible to make the reflected light from the recesses of the groove-like parallel concave-convex pattern group (B) more easily visible to the human eye, and thus it is possible to easily impart anisotropy in lightness. B1 By making Y 200 μm or less, it is possible to easily increase the difference in brightness between when viewed from the extension direction of the grooves and when viewed from a direction perpendicular to the extension direction of the grooves, and it is easy to impart anisotropy to the brightness. B1 By making the distance 200 μm or less, it is possible to make it difficult for the colorant to fill in the recesses of the group of groove-like parallel uneven patterns (B) when performing the wiping step described later.

[0026] Y B2 is preferably 10 to 250 μm, more preferably 20 to 200 μm, and further preferably 40 to 180 μm. B2 By making the thickness of the groove-shaped parallel concave-convex pattern group (B) 10 μm or more, the brightness of the area having the groove-shaped parallel concave-convex pattern group (B) can be easily increased.B2 By setting the gap to 200 μm or less, the reflection from the convex parts of the group of groove-like parallel uneven patterns (B) can be prevented from becoming too strong, making it easier to recognize the anisotropy of brightness based on the concave parts of the group of groove-like parallel uneven patterns (B).

[0027] In order to improve the three-dimensional effect and the expression of natural objects, A , Y B1 and Y B2 satisfies preferably any one of the following formulae (1) and (2), and more preferably satisfies the following formulae (1) and (2). When either of the following formulae (1) and (2) is satisfied, it is more preferable that either of the following formulae (3) and (4) is satisfied. When either of the following formulae (1) and (2) is satisfied, it is more preferable that either of the following formulae (3) and (4) is satisfied. Y in formula (3) B1 / Y A More preferably, Y in formula (4) is 0.20 or more and 0.40 or less. B2 / Y A It is more preferable that the ratio is 0.20 or more and 0.60 or less. Y B1 <Y A (1) Y B2 <Y A (2) 0.06≦Y B1 / Y A ≦0.40 (3) 0.10≦Y B2 / Y A ≦1.00 (4)

[0028] Average width Y of multiple independent recesses (A) A can be calculated using C1 to C2 below. C1: From the five cross-sectional curves measured in A1 above, the width of the recess (A) at each measurement point is calculated, and the average value of the widths at the five points is regarded as the average width of each recess (A). C2: The average width of each recess (A) calculated in C1 above is averaged to obtain Y A Calculate.

[0029] For example, in FIG. 4, the average width of the left recess (A) (average of the widths at five points) is YA-1 The average width of the right recess (A) (average of the widths of the five recesses) is Y A-2 Then, the average width Y of the multiple independent recesses (A) is A can be calculated using the following formula. Average width Y of recess (A) A =(Y A-1 +Y A-2 ) / 2

[0030] Average width Y of the concaves of the groove-like parallel concave-convex pattern group (B) B1 can be calculated using D1 to D2 below. D1: From the five cross-sectional curves measured in B1 above, calculate the width of the recess at each measurement point, and use the average value of the widths at the five points as the average width of the individual recesses. D2: Average the average width of each recess calculated in D1 above to obtain Y B1 Calculate.

[0031] For example, in FIG. 4, the average width of the nth recess from the left (average of the widths of five recesses) is Y B1-n In FIG. 4, there are nine recesses in the group of groove-like parallel concave-convex patterns (B) (20d to 20l in FIG. 4), so the average width Y B1 can be calculated using the following formula. Average width Y of the concaves of the groove-like 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

[0032] Average width Y of the convex parts of the groove-like parallel uneven pattern group (B) B2 can be calculated using E1 to E2 below. Note that the convex portions of the group of groove-like parallel uneven patterns (B) refer to those located between the concave portions of the group of groove-like parallel uneven patterns (B). E1: From the five cross-sectional curves measured in B1 above, the width of the convex portion at each measurement point is calculated, and the average value of the widths at the five points is regarded as the average width of each convex portion. E2: Average the average width of each convex part calculated in E1 above to obtain Y B2 Calculate.

[0033] For example, in Fig. 4, the average width of the nth convex part from the left (average of the widths of five parts) is Y B2-n In FIG. 4, there are six convex portions of the group of groove-like parallel uneven patterns (B), so the average width Y B2 can be calculated using the following formula. Average width Y of the convex parts of the groove-like parallel uneven pattern group (B) B2 =(Y B2-1 +Y B2-2 +Y B2-3 +Y B2-4 +Y B2-5 +Y B2-6 ) / 6

[0034] The length of the independent recesses (A) is not particularly limited, and the preferred length range cannot be generalized because it varies depending on the design to be expressed. For example, when the design to be expressed by the entire decorative sheet is a wood pattern, the average length (L A ) is preferably from 2 to 50 mm, and more preferably from 5 to 30 mm. The average length of the recess (A) can be calculated as the average value by measuring the length of each recess (A). Note that the length of each recess (A) means the maximum distance between any two points in each recess (A).

[0035] The length of each of the groove-shaped parallel uneven patterns that make up the group of groove-shaped parallel uneven patterns (B) is not particularly limited, but as shown in Figure 1, it is preferable that it is roughly the length that crosses from any end to the other end of the decorative sheet (excluding the area where the recess (A) is present, and if necessary, also excluding the vicinity of the recess (A)).

[0036] <<Examples of planar shapes>> The shape of the recess (A) in a plan view is not particularly limited, and various patterns can be mentioned. When the design to be expressed by the entire decorative sheet is a wood pattern, the planar shape of the recesses (A) preferably forms one or more patterns selected from vessels, fall wood and knots. Vessels are cylindrical cells that serve as a passageway for moisture, and the arrangement of tiny vessels gives the human eye the appearance of a dark pattern along the arrangement. Autumn wood is the narrow, dark-colored part that forms from summer to autumn. The wide-grained part that forms from spring to summer is called spring wood, and the alternation of spring wood and autumn wood forms the annual rings of wood. Knots are traces of branches that have been incorporated into the trunk, and are circular or nearly oval in shape and darker in color than the surrounding tissue.

[0037] Furthermore, when the design to be expressed by the entire decorative sheet is a stone pattern such as travertine, the shape of the recess (A) in plan view is preferably a concave portion. Furthermore, when the design to be expressed by the entire decorative sheet is a tile pattern or a brick pattern, the shape of the recess (A) in plan view is preferably a joint pattern. Furthermore, when the design to be expressed by the entire decorative sheet is a fabric pattern, the shape of the recess (A) in plan view is preferably a recess in the fabric. Furthermore, when the design to be expressed by the entire decorative sheet is a leather pattern, the shape of the recess (A) in plan view is preferably a wrinkled pattern.

[0038] The planar shape of each of the groove-like parallel uneven patterns constituting the group of groove-like parallel uneven patterns (B) is not particularly limited, and various patterns can be mentioned, but a wavy shape as shown in FIG. 1 is preferable. By making the planar shape of the groove-like uneven pattern wavy, the brightness of the area having the group of groove-like parallel uneven patterns (B) changes along the shape of the waves. Therefore, the brightness contrast between the recesses (A) and the group of groove-like parallel uneven patterns (B) is not uniform at each location on the surface of the decorative sheet, and the expression of natural objects can be improved. In addition, the distribution of the brightness contrast changes when the direction of light incidence changes or when the observer moves, so the design can be improved. The wavelength (period) and wave height of the wavy pattern are not particularly limited, and the wavelength (period) can be appropriately adjusted within the range of about 1 to 100 mm, and the wave height can be appropriately adjusted within the range of about 1 to 20 mm.

[0039] <<Stretching direction>> In the decorative material of the present invention, the extending direction of the independent recesses (A) is D A The stretching direction of the groove-shaped parallel uneven patterns (B) is D B When we define A and D B It is preferable that the and are non-parallel. A and D B The ink scraping direction in the wiping process described later is set to D. A By carrying out the process in a direction parallel to the groove-shaped parallel uneven pattern (B), a large amount of colorant is filled into the recesses (A), while the amount of colorant filled into the recesses of the groove-shaped parallel uneven pattern (B) is reduced, thereby achieving better contrast.

[0040] The extension direction (D A ) means the average direction of the stretching directions of the individual recesses (A). The stretching direction of each recess (A) means the direction in which the distance between any two points in each recess (A) is the maximum. For example, in the case of the recess (A) in FIG. 5, the direction connecting the two points A and B is the stretching direction D. A It becomes. The stretching direction of the groove-shaped parallel uneven patterns (B) (D B ) means the average direction of the extension directions of the individual recesses. The extension direction of each recess means the direction of a straight line connecting the start point and the end point of each recess.

[0041] D A and D B The angle between them is preferably 5 to 70 degrees, more preferably 7 to 50 degrees, and even more preferably 10 to 40 degrees. By setting the angle to 5 degrees or more, the ink scraping direction in the wiping process described later is set to D A By performing the process in a direction parallel to the groove-shaped parallel concave-convex pattern (B), a large amount of coloring agent is filled in the concave portion (A), while the amount of coloring agent filled in the concave portion of the groove-shaped parallel concave-convex pattern (B) is reduced, thereby improving the contrast. A When wiping in a direction parallel to the groove-like parallel concave-convex patterns (B), it is possible to easily prevent the scraping blade from getting caught in the groove-like parallel concave-convex patterns (B).

[0042] <<Coloring agent>> As shown in Fig. 4, the decorative material of the present invention is preferably configured such that at least a portion of the depth direction of a plurality of independent recesses (A) is filled with colorant 30. This configuration can improve the design of the decorative material. In addition, by using a dark-colored colorant as the colorant, the recesses (A) can be made darker, and the brightness contrast within the surface of the decorative material can be increased. Dark colors refer to colors with low brightness and low saturation that give a dark impression, such as dark gray, dark green, navy blue, black, dark purple, maroon, and brown.

[0043] The method for filling the colorant into at least a portion of the depth of the recess (A) includes applying a filling ink containing a colorant and a binder resin to the first main surface side of the decorative material, and scraping off the ink with a scraping blade such as a doctor blade. In this case, the amount of colorant filled into the recess (A) can be adjusted by adjusting the material of the blade, the angle at which the blade is applied, the viscosity of the ink, etc.

[0044] Examples of colorants include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue; and dyes. Examples of binder resins for filling inks 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.

[0045] The decorative material of the present invention, in which a colorant is filled into at least a portion of the depth direction of a plurality of independent recesses (A), preferably further satisfies either of the following conditions (i) or (ii). (i) At least a portion of the recesses of the group of groove-like parallel uneven patterns (B) in the depth direction is not filled with colorant. (ii) A colorant is filled in at least a part of the recesses in the groove-like parallel uneven patterns (B) in the depth direction, and the filling amount of the colorant per unit area is W B The amount of the colorant filled in at least a portion of the independent recesses (A) in the depth direction per unit area is W A When we define B <W A Satisfy the relationship.

[0046] By satisfying either of the above conditions (i) and (ii), a contrast based on the difference in the amount of colorant is generated between the recesses (A) and the recesses constituting the group of groove-like parallel uneven patterns (B), and the design can be improved. Furthermore, by using a dark colorant as the colorant, the brightness contrast between the recesses (A) and the recesses constituting the group of groove-like parallel uneven patterns (B) is increased, and the three-dimensional effect can be more prominent. In this specification, W A means the average amount of colorant filled per unit area of ​​each recess (A), and W B means the average amount of colorant filled per unit area of ​​each recess constituting the group of groove-like parallel concave-convex patterns (B).

[0047] In order to facilitate the satisfaction of either of the above conditions (i) and (ii), X A , X B , X A -X B , Y A , Y B1 and Y B2 The range of, and D A and D B It is preferable that at least one embodiment selected from the above relationships is the preferred embodiment described above.

[0048] <Second main surface> The shape of the surface (second main surface) opposite to the first main surface of the decorative material is not particularly limited, and may be smooth or may have irregularities.

[0049] <Layer structure of decorative material> The decorative material of the present invention may have the following layered configurations (1) to (8): In addition, " / " indicates the interface of layers, and the surface of the layer located on the left side indicates the first main surface of the decorative material. (1) Single layer of substrate (2) Decorative layer / substrate (3) Surface protection layer / decorative layer / substrate (4) Transparent resin layer / decorative layer / substrate (5) Surface protection layer / transparent resin layer / decorative layer / substrate (6) Surface protection layer / primer layer / transparent resin layer / decorative layer / substrate (7) Surface protection layer / substrate / decorative layer (8) Surface protection layer / primer layer / substrate / decorative layer

[0050] <<Base material>> The decorative material preferably includes a substrate. The material of the substrate is not particularly limited, but is preferably a plastic film or a composite of a plastic film and paper, in consideration of the ease of forming a plurality of independent depressions (A) and a group of groove-like parallel concave-convex patterns (B) by embossing.

[0051] Specific examples of resins constituting the plastic film include polyolefin resins such as polyethylene and polypropylene, vinyl resins such as vinyl chloride resin, vinylidene chloride resin, polyvinyl alcohol and ethylene-vinyl alcohol copolymer, 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, polycarbonate, etc. Among these, polyolefin resins, vinyl chloride resins, polyester resins, and acrylic resins are preferred from the viewpoints of various physical properties such as weather resistance and water resistance, printability, moldability, price, etc.

[0052] The substrate may be a transparent substrate or a colored substrate. The substrate may also be a laminated substrate in which a plurality of substrates are laminated. In the case where the laminated structure of the decorative material is the above (7) or (8), a transparent substrate is used as the substrate so that the decorative layer can be visually recognized through the substrate.

[0053] The thickness of the substrate is not particularly limited, but is preferably from 20 to 200 μm, more preferably from 40 to 160 μm, and even more preferably from 40 to 100 μm.

[0054] In order to improve adhesion to a layer provided on the substrate, one or both sides of the substrate may be subjected to an adhesion enhancing treatment such as a physical treatment or a chemical surface treatment.

[0055] <<Decorative layer>> From the viewpoint of improving the design, the decorative sheet preferably has a decorative layer at any location on the decorative sheet. The location where the decorative layer is formed is preferably close to the substrate in terms of improving the weather resistance of the decorative layer. If the substrate is transparent, the decorative layer may be located on the inner layer side (opposite side to the first main surface) of the substrate as in the above-mentioned laminated structures (7) and (8).

[0056] The decorative layer may be, for example, a colored layer (a so-called solid colored layer) that covers the entire surface, or a pattern layer formed by printing various patterns using ink and a printing press, or a combination of these.

[0057] The pattern imparted by the decorative layer is not particularly limited, and examples thereof include a wood pattern, a stone pattern, a tile pattern, a brick pattern, a fabric pattern, and a leather pattern. By forming these patterns with the decorative layer, the effect based on the shape of the first main surface described above can be further emphasized.

[0058] The pattern of the wood is preferably formed by combining the bark portion with one or more patterns selected from vessels, fall wood and knots. The stone pattern is preferably formed by combining stone surface portions and recessed portions. The tile or brick pattern is preferably formed by combining the bare parts of tiles or bricks with a joint pattern. The fabric pattern is preferably formed by combining the surface portion of the fabric with recesses in the fabric. The leather pattern is preferably formed by combining the surface portion of the leather with a wrinkled pattern.

[0059] The decorative layer can be formed, for example, by applying and drying a decorative layer ink containing a colorant such as a pigment or dye and a binder resin. The ink can be mixed with additives such as an extender pigment, an antioxidant, a plasticizer, a catalyst, a curing agent, an ultraviolet absorber, and a light stabilizer, as necessary. The colorant and binder resin of the decorative layer are not particularly limited, and for example, the same ones as those exemplified for the filling ink can be used.

[0060] The thickness of the decorative layer may be appropriately selected depending on the desired pattern, but from the viewpoint of concealing the base color of the adherend and improving the design, the thickness 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.

[0061] <<Surface protective layer>> The decorative material may have a surface protective layer in order to improve scratch resistance. From the viewpoint of improving the scratch resistance of the decorative sheet, the surface protective layer preferably contains a cured product of a curable resin composition.

[0062] Examples of the curable resin composition include a thermosetting resin composition containing a thermosetting resin, an ionizing radiation curable resin composition containing an ionizing radiation curable resin, and a mixture thereof. Among them, an ionizing radiation curable resin composition is preferred from the viewpoint of increasing the crosslink density of the surface protective layer and improving surface properties such as scratch resistance. Furthermore, among the ionizing radiation curable resin compositions, an electron beam curable resin composition is more preferred from the viewpoint of being able to be applied without a solvent and being easy to handle.

[0063] The 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 the thermosetting resin include acrylic resin, urethane resin, phenol resin, urea melamine resin, epoxy resin, unsaturated polyester resin, silicone resin, etc. In the thermosetting resin composition, a curing agent is added to the curable resin as necessary.

[0064] 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 crosslinks and cures by irradiation with ionizing radiation, and preferred examples thereof include functional groups having an ethylenic double bond such as a (meth)acryloyl group, a vinyl group, and an allyl group. In this specification, the (meth)acryloyl group refers to an acryloyl group or a methcroyl group. In addition, in this specification, the (meth)acrylate refers to an acrylate or a methacrylate. In addition, ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Usually, ultraviolet rays (UV) or electron beams (EB) are used, but it also includes other electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams. Specifically, the ionizing radiation curable compound can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation curable resins.

[0065] As the polymerizable monomer, a (meth)acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferable, and among them, a polyfunctional (meth)acrylate monomer is preferable. Here, "(meth)acrylate" means "acrylate or methacrylate". The polyfunctional (meth)acrylate monomer includes a (meth)acrylate monomer having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the functional group.

[0066] Examples of the polymerizable oligomer include (meth)acrylate oligomers having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth)acryloyl group as the functional group, such as 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. Further examples of the polymerizable oligomer include highly hydrophobic polybutadiene (meth)acrylate oligomers having (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers having polysiloxane bonds in the main chain, aminoplast resin (meth)acrylate oligomers obtained by modifying aminoplast resins having many reactive groups in a small molecule, and oligomers having cationically polymerizable functional groups in the molecule, such as novolac type epoxy resins, bisphenol type epoxy resins, aliphatic vinyl ethers, and aromatic vinyl ethers.

[0067] These polymerizable oligomers may be used alone or in combination. From the viewpoint of improving processing characteristics, scratch resistance, and weather resistance, one or more selected from 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 are preferred, one or more selected from urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers are more preferred, and urethane (meth)acrylate oligomers are even more preferred.

[0068] In the ionizing radiation curable resin composition, a monofunctional (meth)acrylate can be used in combination for the purpose of reducing the viscosity of the ionizing radiation curable resin composition, etc. These monofunctional (meth)acrylates may be used alone or in combination of two or more kinds.

[0069] When the ionizing radiation curable compound is an ultraviolet ray curable compound, the ionizing radiation curable resin composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator. The photopolymerization initiator may be one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, α-acyloxime ester, thioxanthones, and the like. The photopolymerization accelerator can reduce polymerization inhibition caused by air during curing and increase the curing speed, and examples of the accelerator include one or more types selected from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, etc.

[0070] The surface protective layer may contain additives such as an ultraviolet absorbing agent, a light stabilizer, and a coloring agent, if necessary.

[0071] From the viewpoint of a balance between processing characteristics, scratch resistance and weather resistance, the thickness of the surface protective layer is preferably from 1.5 μm to 30 μm, more preferably from 2 μm to 15 μm, and even more preferably from 3 μm to 10 μm.

[0072] <<Transparent resin layer>> The decorative sheet may have a transparent resin layer from the viewpoint of increasing strength, etc. 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. Also, 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.

[0073] Resins constituting the transparent resin layer include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylic resins, vinyl chloride resins, etc., and among these, polyolefin resins are preferred from the viewpoint of processability. The transparent resin layer may be a mixture of these exemplified resins, or may be a laminate of layers made of one or more of these exemplified resins.

[0074] Examples of the polyolefin resin of the transparent resin layer include polyethylene (low density, medium density, high density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-propylene-butene copolymer, etc. Among these, polyethylene (low density, medium density, high density), polypropylene, ethylene-propylene copolymer, propylene-butene copolymer are preferred, and polypropylene is more preferred.

[0075] The transparent resin layer may contain additives such as an ultraviolet absorber, a light stabilizer, a colorant, etc. When the transparent resin layer contains an ultraviolet absorber, the ultraviolet absorber is preferably a triazine-based compound, and more preferably a hydroxyphenyltriazine-based compound.

[0076] From the viewpoint of a balance between scratch resistance, processability and weather resistance, the thickness of the transparent resin layer is preferably from 20 to 150 μm, more preferably from 40 to 120 μm, and even more preferably from 60 to 100 μm.

[0077] <<Primer layer>> When the decorative sheet has a surface protective layer, it is preferable that the decorative sheet has a primer layer in contact with the surface of the surface protective layer on the substrate side. The primer layer improves the adhesion between the substrate and the surface protective layer (when the decorative sheet has a transparent resin layer, the adhesion between the transparent resin layer and the surface protective layer), and can easily ensure long-term interlayer adhesion when exposed to the outdoors (so-called weather-resistant adhesion) and improve scratch resistance.

[0078] The primer layer is mainly composed of a binder resin, and may contain additives such as an ultraviolet absorber and a light stabilizer, if necessary.

[0079] Examples of the binder resin of the primer layer include urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, polycarbonate-based urethane-acrylic copolymer (urethane-acrylic copolymer derived from a polymer (polycarbonate polyol) having a carbonate bond in the polymer main chain and having two or more hydroxyl groups at the end and side chain), vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, chlorinated propylene resin, nitrocellulose resin (nitrocellulose), and cellulose acetate resin, which can be used alone or in combination. The binder resin may be a resin obtained by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent to the resin and crosslinking and curing it. Among these, a polyol-based resin such as an acrylic polyol resin is preferably crosslinked and cured with an isocyanate-based curing agent, and an acrylic polyol resin is more preferably crosslinked and cured with an isocyanate-based curing agent.

[0080] The thickness of the primer layer is preferably from 0.5 μm to 10 μm, more preferably from 0.7 μm to 8 μm, and even more preferably from 1 μm to 6 μm.

[0081] <<Other layers>> The decorative material of the present invention may have other layers, such as an adhesive layer and a backside primer layer.

[0082] When the decorative sheet has a transparent resin layer, it is preferable to form an adhesive layer between the substrate and the transparent resin layer in order to improve the adhesion between the two layers. In addition, 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 in this order from the side closer to the substrate, or the adhesive layer, decorative layer, and transparent resin layer may be provided in this order from the side closer to the substrate.

[0083] The adhesive layer can be made of a general-purpose adhesive such as a urethane adhesive, an acrylic adhesive, an epoxy adhesive, a rubber adhesive, etc. Among these adhesives, a urethane adhesive is preferred in terms of adhesive strength. Examples of urethane-based adhesives include adhesives that utilize a two-liquid curing urethane resin that contains various polyol compounds such as polyether polyol, polyester polyol, and acrylic polyol, and a curing agent such as an isocyanate compound.

[0084] The thickness of the adhesive layer is preferably from 0.1 μm to 30 μm, more preferably from 1 μm to 15 μm, and even more preferably from 2 μm to 10 μm.

[0085] The back surface primer layer is a layer formed on the surface of the decorative material opposite to the first main surface for the purpose of improving adhesion between the decorative material and various adherends.

[0086] The material used to form the back primer layer is not particularly limited, and examples thereof include urethane resin, acrylic resin, polyester resin, vinyl chloride / vinyl acetate copolymer, chlorinated polypropylene resin, chlorinated polyethylene resin, etc., and may be selected appropriately depending on the material of the adherend. The thickness of the back surface primer layer is preferably 0.5 to 5.0 μm, and more preferably 1 to 3 μm.

[0087] The decorative layer, surface protective layer, primer layer, adhesive layer and back primer layer described above can be formed by applying an ink containing a composition for forming each layer by a known method such as gravure printing, bar coating, roll coating, reverse roll coating or comma coating, and drying and curing as necessary. The transparent resin layer can be formed, for example, by hot melt extrusion.

[0088] <Uses of decorative materials> The decorative material of the present invention can be used for various applications as it is, or as a laminate attached to an adherend, or after the decorative material or laminate is subjected to a predetermined molding process or the like. Various applications include interior materials for buildings such as walls, ceilings, and floors; building materials such as window frames, doors, and handrails; furniture; housings for home appliances and office automation equipment; and exterior materials for entrance doors, etc.

[0089] Examples of the substrate include wood boards such as veneer, wood plywood, particle board, MDF (medium density fiberboard), and laminated lumber; gypsum-based boards such as gypsum boards and gypsum slag boards; cement boards such as calcium silicate boards, asbestos slate boards, lightweight foamed concrete boards, and hollow extruded cement boards; fiber cement boards such as pulp cement boards, asbestos cement boards, and wood chip cement boards; ceramic boards such as pottery, porcelain, earthenware, glass, and enamel; metal boards such as iron boards, galvanized steel boards, polyvinyl chloride sol-coated steel boards, aluminum boards, and copper boards; polyolefin resin boards, acrylic resin boards, and ABS resin boards. thermoplastic resin plates such as polycarbonate plates; thermosetting resin plates such as phenolic resin plates, urea resin plates, unsaturated polyester resin plates, polyurethane resin plates, epoxy resin plates, and melamine resin plates; and so-called FRP plates formed by impregnating and curing resins such as phenolic resins, urea resins, unsaturated polyester resins, polyurethane resins, epoxy resins, melamine resins, and diallyl phthalate resins into glass fiber nonwoven fabrics, cloth, paper, and other various fibrous base materials. These may be used alone, or two or more of these may be laminated together to form a composite substrate.

[0090] <Method of forming the first principal surface> The plurality of independent concave portions (A) and the groove-shaped parallel concavo-convex pattern group (B) on the first main surface can be formed, for example, by shaping with an embossing plate engraved by a laser.

[0091] Shaping with an embossing plate engraved by a laser can be carried out, for example, in the steps (S11 to S15) of FIG. 6. Hereinafter, each step will be described.

[0092] <<S11: Creation of density distribution data for concave portion (A)>> In the density distribution data creation step (step S11), a density distribution image that is the basis of the pattern of the plurality of independent concave portions (A) to be expressed on the surface of the decorative material is acquired, and this is used as density distribution data. As an example of the density distribution image, an image in which only the vessel pattern of the wood grain is expressed can be mentioned.

[0093] The density distribution image acquired in step S11 is preferably a two-dimensional density pattern that does not have height information. Examples of such density patterns include photographs, paintings, and printed materials. Also, a three-dimensional image having height information may be used, but in that case, it is preferable to use only the information based on the density in two dimensions when viewed in plan, excluding the height information.

[0094] In step S11, for the obtained density distribution image, a density value D(x, y) is obtained for each two-dimensional coordinate (x, y) to obtain density distribution data. The two-dimensional coordinate (x, y) is not particularly limited, but it is preferably made to correspond to the coordinates on the surface of a plate (in this embodiment, an embossing plate in the shape of a metal roll) described later. Also, the specific expression of the density value D is not particularly limited, but for example, the densest part of the density distribution image is set to 255, the thinnest part is set to 0, and the values in between are evenly divided by integers to express the density value in 256 gradations. As described above, a set of data of density values D expressed in 256 gradations at each coordinate (x, y) is obtained, and this is used as density distribution data.

[0095] As described above, the density distribution data is preferably digital data. Therefore, when the original density distribution image is not digital data, it is digitized by using a method of reading a two-dimensional image such as the original manuscript or a photograph of the manuscript with a scanner and performing AD conversion. Also, when the pattern has been designed from the beginning using digital data with CAD or the like, the digital data can be used.

[0096] The means for creating the density distribution data is not particularly limited. For example, using the graphic design drawing software "Photoshop" manufactured by Adobe Systems, density distribution data with a resolution of 2540 dpi and 8-bit density gradation (256 gradations) in TIF format can be created.

[0097] <<S12: Conversion of Density Distribution Data to Depth Data>> In the conversion step to depth data (step S12), the density value D(x, y) of the density distribution data of the recess (A) obtained in step S11 is converted to the depth F(x, y) for each coordinate (x, y) to obtain depth data. This depth data is depth data corresponding to the unevenness of a plurality of independent recesses (A). Therefore, by this step, the shapes of a plurality of independent recesses (A) are determined. Here, the conversion of the density value D(x, y) to the depth F(x, y) is performed based on a predetermined rule. Thereby, the density distribution and the depth distribution are associated with each other, and in the surface pattern of the decorative material, a unique texture based on the density distribution image can be obtained.

[0098] For example, in step S11, the darkest part in the density distribution image is set as gradation 255, and in step S12, this is set to a depth of 300 μm. On the other hand, in step S11, the lightest part in the density distribution image is set as gradation 0, and in step S12, this is set as the reference (depth 0 μm). Then, for gradations 0 to 255 in step S11, 0 μm to 300 μm are proportionally distributed and assigned to the depth in step S12. Therefore, according to this example, the thinnest part in the concentration distribution image becomes the reference (depth 0 μm), and the deeper it gets as it gets denser, with the depth being 300 μm at the densest part.

[0099] <<S13: Conversion to height data and superposition of data of groove-shaped uneven pattern group (B)>> In the conversion step to height data (step S13), the depth F(x, y) of a plurality of independent concave portions (A) obtained in step S12 is converted into the height H1(x1, y1) for producing a corresponding plate to obtain depth data. That is, the height H1(x1, y1) for forming an uneven pattern that is the complementary shape of the concave portion (A) having the depth F(x, y) on the surface of the plate is created. Here, the height H2(x2, y2) for forming, on the surface of the plate, an unevenness that is complementary to the unevenness of the groove-shaped uneven pattern group (B) having predetermined depth data is superimposed on the height H1(x1, y1). The result of superimposing the height H2(x2, y2) on the height H1(x1, y1) is defined as the height H3(x3, y3). If unevenness is formed on the surface of the plate based on this height data H3(x3, y3), the unevenness on the surface of the decorative material shaped by this plate will conform to the height data of the first main surface.

[0100] In this embodiment, when converting the depth F(x, y) to the height H(x, y), the conversion is performed so that it is inverse with the same scale. That is, if "depth" is represented as negative and "height" as positive, then F(x, y) = -H(x, y). However, it is not limited to this, and if necessary for expression, the depth F(x, y) may be converted to the height H(x, y) by multiplying by a predetermined coefficient α. For example, it may be converted as F(x, y) = αH(x, y). Here, α can be either positive or negative. According to this, it is possible to manufacture a plurality of types of decorative materials that give different impressions from the same height data by simply changing α.

[0101] <<S14: Plate production>> In the plate preparation step (S14), a plate having a concave-convex surface is prepared using the height data of the height H3 (x3, y3) obtained in step S13. Here, an embossed plate made of a metal roll is used as an example. More specifically, the embossed plate is prepared as follows.

[0102] First, a metal roll 50 that will eventually become an embossing plate 50 is prepared as shown in Fig. 7. The metal roll 50 can be, for example, a hollow iron cylinder having a rotary drive shaft 51 at both axial ends, the surface of which is plated with a copper layer. It is preferable that the surface of the metal roll 50 is roughened by grinding with a grindstone or the like to suppress a decrease in engraving efficiency due to specular reflection of the engraving laser light.

[0103] Then, as shown in FIG. 7, a laser beam direct engraving machine is used to engrave the surface of the prepared metal roll 50 based on the height data for each coordinate created in step S13. The metal roll 50 is driven by an electric motor via its rotary drive shaft 51, and rotates around the rotary drive shaft 51 as a central axis. At that time, the surface of the metal roll 50 is scanned with light L emitted from a laser head 52. An example of the laser light L is a fiber laser light having an oscillation wavelength of 1024 nm, a spot diameter of 10 μm, and an output of 360 W. When the surface of the metal roll is scanned with laser light L, the laser light is switched ON / OFF (switching between irradiation or non-irradiation) for each coordinate (x, y) according to the height H3 (x3, y3) created in step S13, and a depression is formed at the irradiation position by evaporation of the metal with one laser light irradiation (the depression in the plate corresponds to the protrusion in the decorative material. Therefore, the higher the coordinate, the fewer the number of laser irradiations.) Under the laser conditions exemplified above, a depression 10 μm deep is formed with one laser light irradiation. The scanning of the metal roll surface with the laser light is repeated, for example, about 10 times. In order to prevent the evaporated metal from turning into powder and remaining or adhering to the surface of the metal roll 50, it is preferable to perform the laser light irradiation in a state where the engraving liquid T is sprayed from the engraving liquid outlet 53 onto the laser light irradiated area on the surface of the metal roll. Thus, by finely engraving the surface of the metal roll 50 with a laser, a metal roll having a shape capable of forming the surface shape of the first main surface can be obtained.

[0104] After engraving the unevenness in this way, it is preferable to wash the engraving liquid and then perform electrolytic polishing to remove the metal residue adhering to the surface of the metal roll 20. And, in order to improve the durability, it is preferable to perform plating treatment such as hard chromium plating on the surface of the metal roll 20. The thickness of the plating layer is usually about 10 μm.

[0105] Through the above steps S11 to S14, a plate 50 (a forming die for a decorative material, an embossing plate in this embodiment) having a shape complementary to the uneven shape of the first main surface of the decorative material can be obtained.

[0106] <<S15: Shaping>> In the shaping step (S15), using the plate (embossing plate) produced in steps S11 to S14, embossing is performed on the decorative material before forming the first main surface to produce the decorative material. The embossing can be performed by any appropriate known method and is not particularly limited. The temperature and pressure during embossing may be appropriately adjusted according to the material of the decorative material. If the base material of the decorative material and the transparent resin layer are polyolefin, it is 140 to 180 ° C, 10 to 50 kg / cm 2 or so. Typical methods of embossing are as follows, for example. First, an embossing plate is pressed against the surface of the softened resin base material to form the uneven pattern on the embossing plate surface on the base material surface. Then, the resin base material is solidified by cooling or light irradiation to fix the uneven pattern on the resin base material. After that, the resin with the uneven pattern formed is released from the embossing plate.

[0107] [Manufacturing method of decorative material] The manufacturing method of the decorative material of the present invention includes the following steps (1) to (2). (1) A step of shaping a single layer of a substrate selected from a plastic film or a composite of a plastic film and paper, or a laminate including the substrate, with an embossing plate to obtain the above-mentioned decorative material of the present invention. (2) A process of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in (1) above, and then scraping off the filler ink.

[0108] The decorative material obtained through the above steps (1) and (2) has the colorant filled into at least a portion of the recess (A) in the depth direction, which can improve the design of the decorative material. In particular, X regarding the first main surface of the decorative material obtained in step (1) A , X B , X A -X B , Y A , Y B1 and Y B2 The range of, and D A and D B By making at least one or more embodiments selected from the above relationship into the preferred embodiments described above, the filling amount of the colorant in the decorative material obtained in step (2) satisfies either of the above-mentioned conditions (i) and (ii), the brightness contrast between the depressions (A) and the depressions that make up the group of groove-shaped parallel uneven patterns (B) is increased, and a decorative material with a more pronounced three-dimensional effect can be obtained.

[0109] The embossing conditions in step (1) are not particularly limited, and examples thereof include the conditions described above in step S15.

[0110] Moreover, the step (2) preferably includes the following steps (2-1) to (2-3). (2-1) A step of aligning the decorative material obtained in step (1) along at least a portion of the surface of a roll having a circular cross section, with the first main surface of the decorative material facing away from the roll. (2-2) A step of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in step (1). (2-3) A process of pressing a blade against the first main surface of the decorative material and scraping off the filler ink adhering to the first main surface.

[0111] In step (2-1), the material of the roll may be metal, rubber, resin, etc., among which rubber and resin are preferred, and rubber is more preferred. By using a material having cushioning properties such as rubber and resin for the roll, it is possible to easily suppress the colorant from remaining excessively in the recesses. In addition, by using a material having cushioning properties such as rubber and resin for the roll, it is possible to easily satisfy either of the above conditions (i) and (ii).

[0112] The filling ink in step (2-2) contains a colorant and a binder resin, and preferably contains a solvent as necessary. The higher the viscosity of the filling ink, the more difficult it is to scrape out the ink in the recesses, and the lower the viscosity of the filling ink, the more easily the ink in the recesses is scraped out. For this reason, it is preferable to appropriately adjust the viscosity of the filling ink according to the desired filling amount. The colorant for the filler ink is preferably a dark color.

[0113] In the step (2-3), it is preferable to use a scraping blade such as a doctor blade as a means for scraping off the filler ink. In this case, the direction in which the ink is scraped off is D A Approximately equal to (D A It is preferable to set the angle within ±10 degrees, preferably within ±5 degrees, and more preferably within ±3 degrees relative to the angle. The angle of the blade to the first main surface of the decorative material is preferably approximately perpendicular. Approximately perpendicular means within a range of 90±10 degrees, preferably 90±5 degrees, and more preferably 90±3 degrees. Note that a tilt toward the direction of travel of the decorative material is indicated as positive, and a tilt toward the opposite direction of travel of the decorative material is indicated as negative. The blade may be made of a material such as metal, rubber, or resin, with metal being preferred.

[0114] In step (2-3), the pressure with which the blade is applied to the decorative material can be appropriately adjusted within a range that does not cause streaks or unevenness in the ink. EXAMPLES

[0115] The present invention will now be described in more detail with reference to examples, but the present invention is not limited to these examples. In addition, "parts" are based on mass unless otherwise specified.

[0116] 1. Evaluation 1-1. Three-dimensional effect The cosmetic materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting to determine whether or not they felt a three-dimensional effect. AA: 18 or more people answered that the three-dimensional effect was good. A: 15 to 17 people answered that the three-dimensional effect was good. B: 11 to 14 people answered that the three-dimensional effect was good. C: 10 or fewer people answered that the three-dimensional effect was good.

[0117] 1-2.Natural texture The cosmetic materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting to determine whether or not they had a natural texture. AA: More than 18 people answered that it has a natural texture. A: Between 15 and 17 people answered that it has a natural texture. B: 11 to 14 people answered that it has a natural texture. C: Fewer than 10 people answered that it has a natural texture.

[0118] 2. Making an embossed plate Embossed plate A, the surface of which was hard chrome plated, was produced in accordance with steps S11 to S14 of the specification. Embossed plates B to C were produced in the same manner as plate A, except that the shapes of the recesses (A) and the group of groove-like parallel uneven patterns (B) were changed as shown in Table 1. Embossed plates D to E were produced in the same manner as plate A, except that the group of groove-like parallel uneven patterns (B) was not formed and the shape of the recesses (A) was changed as shown in Table 1.

[0119] 3. Preparation of cosmetic materials [Example 1] A picture layer of a vessel groove pattern printed in black ink and a picture layer of a wood grain pattern excluding the vessel parts printed in brown ink were formed on a colored substrate (a 60 μm thick white polypropylene film) by gravure multicolor printing, forming a wood pattern decorative layer with a total thickness of 1 μm. Next, an adhesive layer (polyester resin, thickness: 5 μm) was formed on the decorative layer, and then a transparent resin layer (transparent polypropylene resin sheet, thickness: 80 μm) was laminated on the adhesive layer by extrusion lamination. Next, the transparent resin layer was heated to a softened state, and the surface on the transparent resin layer side was embossed using the embossing plate A prepared in "2" above, to form a concave-convex shape on the surface on the transparent resin layer side (the surface on the first principal surface side). The measured values ​​of the concave-convex shape are shown in Table 1. Furthermore, after applying a dark brown filler ink to the surface on the transparent resin layer side (the surface on the first main surface side), a doctor blade was pressed perpendicularly against the first main surface to scrape off the filler ink, thereby obtaining the decorative material of Example 1. The filler ink was scraped off in the direction of D A The direction was the same as that of the

[0120] [Examples 2 to 3] Except for changing the embossing plate A to embossing plates B to C, the same procedure as in Example 1 was carried out to obtain decorative materials of Examples 2 and 3.

[0121] [Comparative Examples 1 to 2] Decorative materials of Comparative Examples 1 and 2 were obtained in the same manner as in Example 1, except that the embossing plate A was changed to embossing plates D to E.

[0122] [Table 1]

[0123] As shown in Table 1, the decorative materials of the examples can impart an excellent three-dimensional effect and have excellent expression of natural objects, and therefore, it can be confirmed that they have extremely good design properties. [Explanation of symbols]

[0124] 10: Recess (A) 20: Grooved uneven pattern group (B) 20a, 20b, 20c, 20d, 20e, 20f, 20g, 20h, 20i, 20j, 20k, 20l: Grooved uneven pattern 30: Coloring agent 100: Cosmetic materials 50: Plate (embossed plate, metal roll) 51: Rotating drive shaft 52: Laser Head 53: Engraving fluid outlet

Claims

1. A decorative material, the first main surface of the decorative material having a plurality of independent recesses (A) and a group of groove-like parallel uneven patterns (B) arranged in at least a portion of an area where the plurality of independent recesses (A) are not present, the first main surface is located on the outermost surface, The average depth of the plurality of independent recesses (A) is X Ａ The average depth of the recesses of the groove-like parallel uneven patterns (B) is X Ｂ When we define Ｂ <X Ａ Fulfilling the relationship, A decorative material that satisfies at least one of the following formulas (1) and (2), when the average width of the independent recesses (A) is defined as Y A , the average width of the recesses of the group of groove-shaped parallel uneven patterns (B) is defined as Y B1 , and the average width of the convex portions of the group of groove-shaped parallel uneven patterns (B) is defined as Y B2 . Y B1 <Y A (1) Y B2 < Y A (2)

2. A cosmetic material as described in claim 1, which, when satisfying either of the formula (1) and the formula (2), further satisfies either of the following formulas (3) and (4). 0.06≦Y B1 / Y A ≦0.40 (3) 0.10≦Y B2 / Y A ≦1.00 (4)

3. A cosmetic material as described in claim 1, which, when satisfying the formula (1) and the formula (2), further satisfies the following formulas (3) and (4). 0.06≦Y B1 / Y A ≦0.40 (3) 0.10≦Y B2 / Y A ≦1.00 (4) 4. The cosmetic material according to claim 1, wherein X A is 40 to 150 μm and X B is 5 to 100 μm.

5. The decorative material according to claim 1, wherein X A -X B is 20 μm or more.

6. The cosmetic material according to claim 1, wherein Y A is 150 to 500 μm, Y B1 is 10 to 200 μm, and Y B2 is 10 to 250 μm.

7. A decorative material according to any one of claims 1 to 6, wherein when the extension direction of the independent recesses (A) is defined as D A and the extension direction of the group of groove-like parallel uneven patterns (B) is defined as D B , D A and D B are non-parallel.

8. The decorative material according to claim 7, wherein the angle between D A and D B is 5 to 70 degrees.

9. A decorative material described in any one of claims 1 to 8, wherein each of the groove-shaped parallel uneven patterns constituting the group of groove-shaped parallel uneven patterns (B) has a wavy shape when viewed in a plane.

10. A decorative material described in any one of claims 1 to 9, wherein the planar shape of the recess (A) is one or more selected from wood vessels, fall wood, and knots.

11. A cosmetic material described in any one of claims 1 to 10, wherein a colorant is filled in at least a portion of the depth direction of the independent plurality of recesses (A).

12. A cosmetic material as described in claim 11, which satisfies either of the following conditions (i) and (ii). (i) At least a part of the recesses in the groove-like parallel uneven patterns (B) in the depth direction is not filled with colorant. (ii) A colorant is filled into at least a portion of the recesses of the group of groove-like parallel uneven patterns (B) in the depth direction, and when the filling amount of the colorant per unit area is defined as W B and the filling amount of the colorant per unit area filled into at least a portion of the independent plurality of recesses (A) in the depth direction is defined as WA, the relationship W B < WA is satisfied.

13. A method for manufacturing a cosmetic material, comprising the following steps (1) to (2): (1) A process for obtaining the decorative material according to any one of claims 1 to 10 by shaping a single layer of a substrate selected from a plastic film or a composite of a plastic film and paper, or a laminate including the substrate, using an embossing plate. (2) A step of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in (1), and then scraping off the filler ink.

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