Resin-impregnated decorative sheet and method of producing resin-impregnated decorative sheet

Abstract

To provide a resin-impregnated decorative sheet that has, while developing ornamental design feeling of gross-matte tone, excellent wear resistance and recognizability of a design layer.SOLUTION: Provided is a resin-impregnated decorative sheet 10, which includes a porous substrate 1, a decorative layer 2, a porous layer 3, and a release layer 4 that has a patterned shape and contains a cured product of a curable resin X, arranged in that order in the thickness direction. Viewed from the thickness direction, the resin-impregnated decorative sheet has a first region R1 that overlaps with the release layer and a second region R2 that does not overlap with the release layer. In the second region, on the side opposite to the decorative layer of the porous layer, a cured resin layer 5 containing a cured product of a curable resin Y is arranged. The porous substrate, the porous layer in the first region, and the porous layer in the second region contain the cured product of the curable resin Y.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to resin-impregnated decorative boards and methods for making resin-impregnated decorative boards. [Background technology]

[0002] Conventionally, resin-impregnated decorative boards have been known, which are obtained by impregnating a porous substrate with a precursor (uncured resin) such as melamine resin, and then curing the resin precursor by hot pressing. Resin-impregnated decorative boards are used for walls, furniture, floors, etc. in homes, stores, public facilities, etc.

[0003] Melamine decorative boards that express a design with a glossy matte look are known. For example, Patent Document 1 discloses a decorative board in which a release layer is provided in a part of the surface of a porous substrate, and the remaining part of the surface of the porous substrate does not have the release layer, and a thermosetting resin layer is provided, and the thermosetting resin is impregnated and cured in the porous substrate. In the manufacture of such melamine decorative boards, for example, a decorative sheet having a release layer that matches a pattern on a part of the surface of titanium paper is used, and a process of impregnating the decorative sheet with a precursor (uncured resin) of melamine resin or the like is performed, a process of placing a release film on the uncured resin layer, and then thermally curing the uncured resin to obtain a melamine layer, and a peeling process of peeling off the melamine layer in the area covering the release layer by peeling off the release film. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6716877 Summary of the Invention [Problem to be solved by the invention]

[0005] As described above, in the manufacturing process of a melamine decorative board that expresses a gloss matte design, a peeling process is required to peel off a part of the melamine layer. In the peeling process, the melamine layer cracks between the area that overlaps with the release layer and the area that does not overlap with the release layer, so that the melamine layer in the area that overlaps with the release layer is partially peeled off. In this case, if the melamine layer is thick, its strength increases, it is less likely to crack, and the peelability decreases. Therefore, from the viewpoint of maintaining the peelability, it is difficult to make the melamine layer thick. As a result, it becomes difficult to improve the wear resistance of the melamine decorative board.

[0006] The inventors of the present application attempted to improve the abrasion resistance of the resin-impregnated decorative board by disposing a porous layer on the surface of the design layer opposite to the porous substrate. By providing a porous layer, the same effect as when the thickness of the melamine layer is increased is obtained, and the design layer can be protected from abrasion and the abrasion resistance can be improved. In addition, the transparency of the porous layer is improved by including a cured product of the curable resin (curable resin Y) that forms the melamine layer. On the other hand, when a release layer is formed on the surface of the porous layer opposite to the design layer, the ink for forming the release layer soaks into the porous layer in the release layer formation region (first region). Since the ink for forming the release layer repels the curable resin Y, a problem occurs in which the curable resin Y is not impregnated into the porous layer in the first region. Therefore, it was newly discovered that the transparency of the porous layer in the first region is reduced, and the visibility of the design layer is hindered.

[0007] The present disclosure has been made in consideration of the above-mentioned circumstances, and has as its main object to provide a resin-impregnated decorative board that exhibits a gloss matte design feel, has excellent abrasion resistance, and has good visibility of the design layer. [Means for solving the problem]

[0008] The present disclosure provides a resin-impregnated decorative board having, in that order in the thickness direction, a porous substrate, a design layer, a porous layer, and a release layer having a patterned shape and containing a cured product of curable resin X, wherein, when viewed in the thickness direction, the resin-impregnated decorative board has a first region that overlaps with the release layer and a second region that does not overlap with the release layer, and in the second region, a cured resin layer containing a cured product of curable resin Y is disposed on the side of the porous layer opposite the design layer, and the porous substrate, the porous layer in the first region, and the porous layer in the second region contain the cured product of curable resin Y.

[0009] The present disclosure also provides a method for producing a resin-impregnated decorative board, which includes a laminate production step of producing a laminate having, in that order in the thickness direction, a porous substrate, a design layer, a porous layer, a release layer having a pattern shape and containing a cured product of curable resin X, a curable resin layer containing curable resin Y, and a release film; a heating and pressurizing step of heating and pressurizing the laminate to cure the curable resin Y while forming a cured resin layer from the curable resin layer to obtain a cured laminate; and a peeling step of peeling the release film from the cured laminate to remove the cured resin layer arranged in a first region that overlaps with the release layer in the thickness direction, while leaving the cured resin layer arranged in a second region that does not overlap with the release layer in the thickness direction. In the laminate production step, the porous substrate, the porous layer in the first region, and the porous layer in the second region are impregnated with the curable resin Y. Effect of the Invention

[0010] The present disclosure has the effect of providing a resin-impregnated decorative board that exhibits a gloss matte design, has excellent abrasion resistance, and provides good visibility of the design layer. [Brief description of the drawings]

[0011] [Figure 1]1 is a schematic cross-sectional view illustrating a resin-impregnated decorative board according to the present disclosure. [Diagram 2] 1 is a schematic cross-sectional view illustrating a resin-impregnated decorative board according to the present disclosure. [Diagram 3] 1 is a schematic cross-sectional view illustrating a resin-impregnated decorative board according to the present disclosure. [Figure 4] 1 is a schematic cross-sectional view illustrating a resin-impregnated decorative board according to the present disclosure. [Diagram 5] 1 is a schematic cross-sectional view illustrating a resin-impregnated decorative board according to the present disclosure. [Figure 6] 1 is a schematic cross-sectional view illustrating a method for producing a resin-impregnated decorative board according to the present disclosure. [Figure 7] 1 is a schematic cross-sectional view illustrating a method for producing a resin-impregnated decorative board according to the present disclosure. [Figure 8] 1 is a schematic cross-sectional view illustrating a method for producing a resin-impregnated decorative board according to the present disclosure. [Figure 9] 1 is a schematic cross-sectional view illustrating a method for producing a resin-impregnated decorative board according to the present disclosure. [Figure 10] 1 is a schematic cross-sectional view illustrating a method for producing a resin-impregnated decorative board according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The following describes the embodiments with reference to the drawings. However, the present disclosure can be implemented in many different forms and is not limited to the description of the embodiments exemplified below. In addition, in order to clarify the description, the drawings may show the width, thickness, and shape of each part in a schematic manner compared to the actual form, but this is merely an example and should not be interpreted as being limiting.

[0013] In this specification, when describing a mode in which another component is disposed on a certain component, the term "above" or "below" includes both cases in which another component is disposed directly above or below the certain component so as to be in contact with the component, and cases in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified. In addition, in this specification, when describing a mode in which another component is disposed on the surface of a certain component, the term "on the surface" includes both cases in which another component is disposed directly above or below the certain component so as to be in contact with the component, and cases in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified.

[0014] The inventors of the present application have found that by arranging a porous layer on the surface of the design layer opposite the porous substrate, and by forming a resin-impregnated decorative board in which the porous layer in the first and second regions contains a cured product of curable resin Y, it is possible to obtain a resin-impregnated decorative board that exhibits a gloss matte design while having excellent abrasion resistance and in which deterioration of the design due to the design layer is suppressed. The resin-impregnated decorative board and the method for manufacturing the resin-impregnated decorative board in the present disclosure will be described in detail below.

[0015] A. Resin-impregnated decorative board 1 is a schematic cross-sectional view illustrating a resin-impregnated decorative board according to the present disclosure. As shown in FIG. 1, the resin-impregnated decorative board 10 according to the present disclosure is a porous substrate 1, a design layer 2, a porous layer 3, and a release layer 4 having a pattern shape and containing a cured product of a curable resin X. The porous substrate 1, the design layer 2, the porous layer 3, and the release layer 4 are arranged in a thickness direction D. T In the thickness direction D T Viewed from the top, the resin-impregnated decorative board 10 has a first region R1 that overlaps with the release layer 4, and a second region R2 that does not overlap with the release layer 4. In the second region R2, a cured resin layer 5 containing a cured product of the curable resin Y is disposed on the surface of the porous layer 3 opposite the design layer 2, and the porous substrate 1, the porous layer 3a in the first region R1, and the porous layer 3b in the second region R2 contain the cured product of the curable resin Y.

[0016] According to the present disclosure, the release layer 4 containing the cured product of the curable resin X arranged in the first region R1 and the cured resin layer 5 containing the cured product of the curable resin Y arranged in the second region R2 show different design impressions, so that a glossy matte design impression can be expressed. In addition, by arranging the porous layer 3 on the surface side of the design layer 2 opposite the porous substrate 1, the thickness from the design layer 2 to the top surface of the cured resin layer 5 (the surface of the cured resin layer 5 opposite the porous layer 3) is increased, and the same effect as when the thickness of the cured resin layer 5 is increased is obtained, and the design layer becomes less susceptible to wear. That is, the wear resistance of the resin-impregnated decorative board 10 is improved. Furthermore, since the porous layer 3a in the first region R1 and the porous layer 3b in the second region R2 each contain the cured product of the curable resin Y, they become layers with excellent transparency. Therefore, the visibility of the design layer is good. In particular, the ink for forming the release layer is likely to permeate into the porous layer in the release layer-forming region (first region), and the permeation of the curable resin Y is likely to be hindered. In the present disclosure, the porous layer in the first region contains a cured product of the curable resin Y, so that the visibility of the design layer is good even in the first region.

[0017] 1.Porous layer The resin-impregnated decorative board of the present disclosure has a porous layer on the surface opposite the porous substrate of the design layer. The resin-impregnated decorative board of the present disclosure has excellent abrasion resistance because the porous layer protects the design layer even if the release layer and the cured resin layer are worn. In addition, the porous layer in the first region and the porous layer in the second region contain a cured product of curable resin Y. By containing the cured product of curable resin Y, the porous layer has improved light transmittance to the extent that the design layer can be visually recognized.

[0018] In this specification, "the porous layer in the first region contains a cured product of curable resin Y" is defined as follows. Figs. 2(a) to 2(c) are schematic cross-sectional views illustrating examples of resin-impregnated decorative boards in the present disclosure. In Figs. 2(a) to 2(c), the release layer and the cured resin layer are omitted. As shown in Fig. 2(a), the porous layer 3a in the first region R1 contains, for example, a cured product α of the curable resin Y, as well as a permeated portion β which is a cured product of the curable resin X formed by the permeation of the ink for forming the release layer when forming the release layer 4. When the resin-impregnated decorative board 10 is viewed in cross section, the width of the release layer in the first region R1 is W1, and the sum of the widths of the cured products of the curable resin Y in the first region R1 (W in Fig. 2(a)) is W2. 21 +W 22 When W2 is the total thickness of the porous layer, and the ratio of W2 to W1 (W2 / W1) is 0.50 or more, it is defined that "the porous layer in the first region contains the curable resin Y." The ratio (W2 / W1) may be preferably 0.60 or more, 0.70 or more, 0.80 or more, 0.90 or more, or 1.0. The above ratio (W2 / W1) is the average value of W2 / W1 calculated at any ten points in a cross-sectional image of the resin-impregnated decorative board.

[0019] In the present disclosure, it is preferable that W2 / W1 is 0.50 or more in the first region where W1 is 300 μm or more. The above ratio (W2 / W1) is the average value of W2 / W1 calculated at any 10 points where W1 is 300 μm or more in a cross-sectional image of the resin-impregnated decorative board.

[0020] Methods for obtaining a resin-impregnated decorative board in which the porous layer in the first region contains a cured product of curable resin Y include, for example, (i) a method of arranging a permeation suppression layer between the porous layer and the release layer, (ii) a method of increasing the solids concentration of the ink for forming the release layer, (iii) a method of increasing the basis weight of the porous layer, etc. In the present disclosure, a resin-impregnated decorative board in which the porous layer in the first region contains a cured product of curable resin Y can be obtained by using these methods alone or in combination.

[0021] As described above, the porous layer in the first region may contain a cured product of the curable resin X (permeation portion β). That is, the porous layer in the first region may contain both a cured product of the curable resin X and a cured product of the curable resin Y. As shown in FIG. 2(b), when the resin-impregnated decorative board 10 is viewed in cross section, the thickness of the porous layer 3 is T1, and the maximum thickness of the cured product of the curable resin X (permeation portion β) contained in the porous layer 3 in the first region R1 is T2, it is preferable that T2 / T1 is 0.8 or less. The above T2 / T1 is more preferably 0.6 or less, and particularly preferably 0.4 or less.

[0022] In the present disclosure, the porous layer in the second region contains a cured product of the curable resin Y. For example, as shown in Fig. 2(c), when the resin-impregnated decorative board 10 is viewed in cross section, the width of the second region R2 is W3, and the width of the cured product α of the curable resin Y in the second region R2 is W4, the ratio of W4 to W3 (W4 / W3) is preferably 0.9 or more, and more preferably 1.0.

[0023] The hardening resin X is the hardening resin in the release layer, which will be described in detail later.The hardening resin Y is the hardening resin in the cured resin layer, which will be described in detail later.

[0024] The porous layer preferably contains a fiber material. The fiber material is preferably paper or nonwoven fabric. The porous layer in the present disclosure preferably has good abrasion resistance, improves light transmission by containing a cured product of the curable resin Y, and has good printability of the release layer and the permeation suppression layer. Examples of papers having such properties include papers made from cellulosic pulp, such as wood pulp fiber paper containing a large amount of α-cellulose components, Manila hemp valve fiber paper, linter paper, and cotton fiber paper. These papers may be mixed with non-cellulosic resin fibers such as vinylon and acrylic resin as necessary. In addition, in order to ensure sufficient light transmission after resin impregnation, it is preferable that the paper does not contain any obscuring pigments such as titanium white and carbon black, or that only a small amount is added. Examples of nonwoven fabrics include nonwoven fabrics containing fibers such as cellulose fibers and non-cellulosic resin fibers such as acrylic resin.

[0025] The thickness of the porous layer is preferably 10 μm or more, more preferably 50 μm or more. By having the thickness of the porous layer in the above range, the wear resistance of the resin-impregnated decorative board is further improved. On the other hand, the thickness of the porous layer is, for example, 100 μm or less, and may be 80 μm or less. If the thickness of the porous layer is too thick, the visibility of the design layer may be reduced.

[0026] The basis weight of the porous layer (before impregnation with the curable resin Y) is, for example, 15 g / m 2 More than 20g / m 2 It is preferable that the thickness is 30 g / m or more. 2 More preferably, it is 40 g / m or more. 2 It is more preferable that the basis weight of the porous layer is within the above range, so that the ink for forming the release layer is less likely to penetrate into the porous layer, and the porous layer in the first region is more likely to contain the cured product of the curable resin Y. In particular, when the basis weight of the porous layer is 45 g / m 2 By satisfying the above, the porous layer in the first region is likely to contain the cured product of the curable resin Y without using other methods such as the above (i) and (ii). On the other hand, the basis weight of the porous layer is, for example, 100 g / m2 or less, 80 g / m 2 It may be the following.

[0027] 2.Release layer The release layer in the present disclosure is disposed on the opposite side of the porous layer to the design layer, has a pattern shape, and contains a cured product of the curable resin X. When the design layer has a pattern, it is preferable that the release layer is disposed so as to be in harmony with the pattern of the design layer. "In harmony" means that the shapes and positions of the two target patterns generally match. Specifically, it means that the shapes and positions of the pattern of the release layer and at least a part of the pattern constituting the design layer's design match to an extent that does not impair realism and luxury. By arranging the pattern of the release layer so as to be in harmony with the pattern of the design layer, a high quality texture can be obtained.

[0028] The release layer contains a cured product (crosslinked structure) of the curable resin. In the present disclosure, the curable resin in the release layer may be referred to as curable resin X. This is because a release layer having good abrasion resistance can be obtained. In addition, the release layer contains a cured product of the curable resin, which improves the releasability of the cured resin layer.

[0029] Examples of the curable resin include ionizing radiation curable resins and thermosetting resins. Examples of the ionizing radiation curable resin include electron beam curable resins and ultraviolet ray curable resins.

[0030] The ionizing radiation curable resin (ionizing radiation curable compound) is not limited as long as it undergoes a crosslinking polymerization reaction upon irradiation with ionizing radiation and changes into a three-dimensional polymer structure. Examples of the ionizing radiation curable resin include prepolymers, oligomers, and monomers having polymerizable unsaturated bonds or epoxy groups in the molecule that can be crosslinked upon irradiation with ionizing radiation. In the present disclosure, only one type of ionizing radiation curable resin may be used, or two or more types may be used. Among them, it is preferable to use at least one of a polyfunctional monomer and an oligomer as the ionizing radiation curable resin.

[0031] Examples of the ionizing radiation curable compound include (meth)acrylate-based resins such as urethane (meth)acrylate, ester (meth)acrylate, and epoxy (meth)acrylate; silicon-based resins such as siloxane; ester-based resins; and epoxy-based resins. (Meth)acrylate-based resins refer to acrylate-based resins or methacrylate-based resins.

[0032] The weight average molecular weight of the ionizing radiation curable compound is, for example, from 500 to 80,000, and may be from 1,000 to 50,000. The weight average molecular weight is a value measured by gel permeation chromatography (GPC) using polystyrene as a standard substance.

[0033] The ionizing radiation curable compound preferably contains at least a polyfunctional monomer or oligomer having a weight average molecular weight of at least 500. Examples of such polyfunctional monomers or oligomers include (meth)acrylate resins such as dipentaerythritol hexa(meth)acrylate, dipentaerythritol penta(meth)acrylate, urethane (meth)acrylate, ester (meth)acrylate, and epoxy (meth)acrylate.

[0034] On the other hand, examples of thermosetting resins include unsaturated ester resins, urethane resins (including two-component curing polyurethanes), epoxy resins, aminoalkyd resins, phenolic resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, melamine urea co-condensation resins, silicon resins, and siloxane resins.

[0035] The release layer may contain a matting agent. Examples of the matting agent include inorganic particles and synthetic resin particles. Examples of the inorganic particles include silica, alumina, calcium carbonate, magnesium carbonate, calcium sulfate, barium sulfate, and kaolin. Examples of the synthetic resin particles include acrylic beads, urethane beads, nylon beads, silicone beads, silicone rubber beads, polycarbonate beads, and polyolefin wax (e.g., polypropylene wax, polyethylene wax).

[0036] The average particle size of the matting agent is, for example, 0.3 μm or more and 10 μm or less, and may be 0.5 μm or more and 7 μm or less, or 1 μm or more and 5 μm or less. The average particle size is D50 according to the volume-based particle size distribution measured by a laser diffraction scattering method. The content of the matting agent may be, for example, 5 parts by mass or more and 40 parts by mass or less, and may be 10 parts by mass or more and 35 parts by mass or less, relative to 100 parts by mass of the resin component of the release layer.

[0037] The release layer may contain a release agent. The addition of the release agent improves the releasability. Examples of the release agent include silicone-based release agents such as silicone oil, wax-based release agents such as polyolefin wax, and fluorine-based release agents. The silicone oil may be reactive silicone oil or non-reactive silicone oil.

[0038] Reactive silicone oil refers to modified silicone oils that have an organic group introduced into the side chain or end, and have reactivity due to the nature of the organic group introduced.Specific examples of reactive silicone oils include modified silicone oil side chain type, modified silicone oil both ends type, modified silicone oil one end type, modified silicone oil side chain both ends type, etc., in which the organic group introduced is amino-modified, epoxy-modified, mercapto-modified, carboxyl-modified, carbinol-modified, phenol-modified, methacryl-modified, heterogeneous functional group-modified, etc.These reactive silicone oils can be used alone or in combination of two or more.

[0039] The non-reactive silicone oil is not particularly limited as long as it is a silicone oil that does not have a reactive functional group such as an amino group, an epoxy group, a mercapto group, a carboxy group, a hydroxy group, a (meth)acryloyl group, or an allyl group. Examples of the non-reactive silicone oil include silicone oils made of polysiloxane, polyether-modified silicone oils, aralkyl-modified silicone oils, fluoroalkyl-modified silicone oils, long-chain alkyl-modified silicone oils, higher fatty acid ester-modified silicone oils, higher fatty acid amide-modified silicone oils, and phenyl-modified silicone oils. These non-reactive silicone oils can be used alone or in combination of two or more kinds.

[0040] The content of the release agent is, for example, 0.1 parts by mass or more and 50 parts by mass or less, 0.5 parts by mass or more and 20 parts by mass or less, 3 parts by mass or more and 20 parts by mass or less, or 3 parts by mass or more and 10 parts by mass or less, based on 100 parts by mass of the resin component of the release layer. The release layer may be colorless or colored. In the latter case, it is preferable that the release layer contains a colorant. The colorant may be the same as the colorant used in the design layer described later.

[0041] The pure water contact angle of the surface of the release layer is, for example, 90° or more, and preferably 100° or more. The release layer having the above pure water contact angle has good releasability of the cured resin layer, and is therefore likely to become a resin-impregnated decorative plate with improved gloss matte design. The pure water contact angle of the release layer is, for example, 130° or less, and preferably 125° or less.

[0042] In the present disclosure, the pure water contact angle of the surface of the release layer is a value obtained by measuring by the following method. The surface of the release layer refers to the surface of the release layer opposite to the design layer. That is, the decorative sheet is placed on a horizontal surface so that the release layer is the upper surface. Next, a water droplet (pure water, 2.0 μL) is dropped on the release layer (first region) from a direction perpendicular to the horizontal surface. At this time, the water droplet is not dropped on the boundary between the first region and the second region, but is dropped so that the entire water droplet is in contact with the release layer. After dropping the water droplet, wait for 1 second, and use a contact angle meter to measure the contact angle between the release layer and pure water. The above measurement is performed at any 10 points, and the average value is taken as the pure water contact angle.

[0043] The pure water contact angle can be adjusted by adjusting the content of the release agent and the thickness of the release layer. For example, the pure water contact angle can be increased by increasing the content of the release agent. For example, the pure water contact angle can be increased by increasing the thickness of the release layer.

[0044] The release layer may contain additives such as ultraviolet absorbers, infrared absorbers, light stabilizers, polymerization inhibitors, crosslinking agents, antistatic agents, antioxidants, leveling agents, coupling agents, plasticizers, defoamers, fillers, thermal radical generators, and aluminum chelating agents, as necessary.

[0045] The thickness of the release layer is not particularly limited, but may be, for example, 0.1 μm or more, or 1.0 μm or more, while the thickness of the release layer is, for example, 20 μm or less, or may be 10 μm or less, or may be 5 μm or less.

[0046] The release layer can be obtained, for example, by applying a release layer forming ink containing a curable resin X to one side of the porous layer (for example, the side opposite the design layer) and curing it.

[0047] The solid content concentration of the ink for forming the release layer, i.e., the ink containing the curable resin X, is preferably 60% by mass or more, more preferably 70% by mass or more, based on the total amount of the ink. When the solid content concentration of the ink is in the above range, the penetration of the ink for forming the release layer into the porous layer can be suppressed, and the porous layer in the first region is more likely to contain the cured product of the curable resin Y. In particular, when the solid content concentration of the ink containing the curable resin X is 80% by mass or more, the porous layer in the first region is more likely to contain the cured product of the curable resin Y without using other methods such as the above (i) and (iii). On the other hand, the solid content concentration of the ink is, for example, 90% by mass or less.

[0048] When the ink for forming the release layer contains an electron beam curable resin, the cured product of the electron beam curable resin is usually obtained by irradiating it with an electron beam. Examples of the electron beam source include various electron beam accelerators such as Cockcroft-Walt type, Van de Graff type, resonant transformer type, insulating core transformer type, linear type, dynamitron type, and high frequency type. The energy of the electron beam is, for example, 100 kV or more and 1000 kV or less, or may be 100 kV or more and 300 kV or less. The irradiation dose of the electron beam is, for example, 2 Mrad or more and 15 Mrad or less.

[0049] When the ink for forming the release layer contains an ultraviolet-curable resin, the ultraviolet-curable resin is usually cured by irradiating it with ultraviolet light. Examples of ultraviolet light sources include ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black light fluorescent lamps, and metal halide lamps. The wavelength of the ultraviolet light is, for example, 190 nm or more and 380 nm or less.

[0050] When the ink for forming the release layer contains a thermosetting resin, it is usually heated to obtain a cured product of the thermosetting resin. The heating temperature is appropriately set according to the type of the thermosetting resin. The ink for forming the release layer may contain a crosslinking agent, a curing agent such as a polymerization initiator, and a polymerization accelerator together with the thermosetting resin. Examples of the curing agent include isocyanate, organic sulfonate, organic amine, peroxide (e.g., methyl ethyl ketone peroxide), and radical initiator (azoisobutylnitrile).

[0051] The ink for forming the release layer may contain a solvent as necessary. Examples of the solvent include water; hydrocarbon compounds such as toluene and xylene; alcohol compounds such as methanol, ethanol and methyl glycol; ketone compounds such as acetone and methyl ethyl ketone; ester compounds such as methyl formate and ethyl acetate; nitrogen-containing compounds such as N-methylpyrrolidone and N,N-dimethylformamide; ether compounds such as tetrahydrofuran and dioxane; halogenated hydrocarbon compounds such as methylene chloride and chloroform; and dimethyl sulfoxide. The ink for forming the release layer is preferably less hydrophilic than uncured resins such as hydrophilic melamine resins.

[0052] 3.Cured resin layer The resin-impregnated decorative board of the present disclosure has, in the second region, a cured resin layer containing a cured product of curable resin Y. The cured resin layer has a pattern shape, which corresponds to, for example, a reversed pattern shape of the release layer.

[0053] A wide variety of thermosetting resins can be used as the curable resin Y. Examples of the curable resin Y include melamine-based resins (melamine-based resin precursors), melamine-urea co-condensation resins, unsaturated polyester-based resins, polyurethane-based resins (including two-component curing polyurethanes), epoxy-based resins, aminoalkyd-based resins, phenol-based resins, urea-based resins, diallyl phthalate-based resins, guanamine-based resins, silicon-based resins, and polysiloxane-based resins.

[0054] The thickness of the cured resin layer is not particularly limited, but is preferably 1 μm or more, more preferably 5 μm or more. When the thickness of the cured resin layer is within the above range, the wear resistance of the resin-impregnated decorative board is further improved. On the other hand, the thickness of the cured resin layer is preferably, for example, 30 μm or less, more preferably 20 μm or less. When the thickness of the cured resin layer is within the above range, the cured resin layer in the first region can be easily peeled off and removed in the manufacturing process of the resin-impregnated decorative board. The thickness of the cured resin layer is preferably larger than the thickness of the release layer. That is, it is preferable that the cured resin layer protrudes from the release layer in the thickness direction.

[0055] 4. Design layer The decorative layer in the present disclosure is disposed between the porous substrate and the porous layer. The decorative layer preferably has a pattern.

[0056] Examples of patterns of the design layer include organic patterns, inorganic patterns, and abstract patterns. Organic patterns are patterns derived from the life activities of living organisms such as animals and plants. Inorganic patterns are patterns that do not fall under the category of organic patterns. Abstract patterns are patterns that interpret objects (e.g., images that exist in nature) abstractly and do not express a clear shape. Examples of organic patterns include wood grain patterns, leather patterns, floral patterns, and botanical patterns. Examples of inorganic patterns include stone patterns, concrete patterns, sand patterns, cloth patterns, metal patterns, tile patterns, and brick masonry patterns. Examples of abstract patterns include flickering patterns (e.g., ink flickering patterns), smoke patterns, and marble patterns.

[0057] The design layer has, for example, a pattern layer. The design layer may have a solid layer on the porous substrate side of the pattern layer. In the present disclosure, the pattern layer means a layer formed partially (particularly in a pattern) on one side of the porous substrate. The solid layer means a layer formed on the entire surface of one side of the porous substrate.

[0058] The design layer contains, for example, a colorant and a resin component. Examples of the colorant include inorganic pigments such as carbon black, titanium white, zinc oxide, red iron oxide, Prussian blue, and cadmium red; organic pigments such as azo pigments, lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazine pigments; metal powder pigments such as aluminum powder and bronze powder; pearlescent pigments such as titanium oxide-coated mica and bismuth oxide chloride; fluorescent pigments; and luminous pigments. Dyes may also be used as the colorant.

[0059] Examples of the resin component include (meth)acrylic resins, ester urethane resins, acrylamide resins, ethylene oxide resins, N-vinylpyrrolidone resins, ester resins, amide resins, vinyl acetate resins, vinyl chloride resins, urethane (meth)acrylic resins, natural rubber, and synthetic rubber. Among these, (meth)acrylic resins and urethane (meth)acrylic resins are preferred.

[0060] It is preferable that the resin component contains a resin having at least one polar group selected from the group consisting of a hydroxyl group, an amino group, and a carboxyl group. By containing the resin having the polar group, the impregnation of the curable resin Y into the porous substrate is improved.

[0061] Examples of the resin having a polar group include the same types of resins as those exemplified for the permeation suppression layer described below.

[0062] The design layer in the present disclosure preferably contains one or more of casein, melamine-based resin, polyvinyl alcohol, polyvinyl alcohol derivative, cellulose, and cellulose derivative as a resin having a polar group, and more preferably contains casein. As casein, α-casein, β-casein, γ-casein, or a mixture thereof can be used. As casein, derivatives such as sodium caseinate and ammonium caseinate can be used alone or in combination.

[0063] The ratio of the resin having the polar group to the resin components contained in the design layer is, for example, 20% by mass or more, 30% by mass or more, 40% by mass or more, or 50% by mass or more. On the other hand, the ratio of the resin having the polar group is, for example, 100% by mass or less, or 90% by mass or less. If the content of the resin having the polar group is within the above range, the penetration of the ink for forming the release layer into the porous substrate can be further suppressed without inhibiting the penetration of the curable resin Y into the porous substrate.

[0064] The design layer may contain additives such as fillers (e.g., silica), extender pigments (e.g., organic beads), neutralizers, surfactants, etc., as necessary. The thickness of the design layer is not particularly limited, but is, for example, 0.1 μm or more and 20 μm or less.

[0065] The method for forming the design layer includes, for example, a coating method using an ink for forming the design layer containing a colorant, a binder resin, and a solvent (or a dispersion medium). For example, the ink for forming the design layer is applied to one side of the porous substrate and dried to obtain the design layer.

[0066] Examples of the solvent (or dispersion medium) include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water.

[0067] Examples of the coating method include printing. Examples of the printing method include gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing. Examples of the coating method for forming a solid layer include various coating methods such as roll coating, knife coating, air knife coating, die coating, lip coating, comma coating, kiss coating, flow coating, and dip coating.

[0068] 5. Porous base material The porous substrate in the present disclosure contains a cured product of an uncured resin (curable resin Y). Examples of the porous substrate include permeable fibrous substrates. Examples of the permeable fibrous substrate include paper, synthetic paper, nonwoven fabric, and woven fabric. Examples of the paper include titanium paper, tissue paper, craft paper, linter paper, paperboard, gypsum board paper, fine paper, coated paper, parchment paper, and Japanese paper. In addition, vinyl wallpaper rolls (paper dry-laminated with polyvinyl chloride resin) can also be used as the fibrous substrate. Other examples of the fibrous substrate include nonwoven fabrics or woven fabrics containing inorganic fibers such as glass fiber, asbestos, potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber. Other examples of the fibrous substrate include nonwoven fabrics or woven fabrics containing synthetic resin fibers such as polyester, vinylon, polyethylene, and polypropylene. Among these porous substrates, titanium paper, thin paper, kraft paper, coated paper, art paper, parchment paper, paraffin paper and Japanese paper are preferred in terms of impregnation with uncured resin. Titanium paper is particularly preferred as a porous substrate because it has excellent impregnation with uncured resin and excellent hiding power.

[0069] The porous substrate may be colored. For example, a colorant is added at the manufacturing stage of the porous substrate to obtain a colored porous substrate. For example, when the porous substrate is paper, a colorant is added at the papermaking stage to obtain colored paper. Examples of colorants include inorganic pigments such as titanium dioxide, carbon black, and iron oxide, organic pigments such as phthalocyanine blue, and various dyes. In addition, the porous substrate may contain various additives such as fillers, matting agents, foaming agents, flame retardants, lubricants, antistatic agents, antioxidants, ultraviolet absorbers, and light stabilizers, as necessary.

[0070] The basis weight of the porous substrate is not particularly limited, but is, for example, 40 g / m 2 More than 150g / m 2 The thickness of the porous substrate is not particularly limited, but is, for example, 50 μm or more and 170 μm or less. For example, in order to improve the adhesion of the ink that forms the design layer, the surface of the porous substrate on the design layer side may be subjected to a corona discharge treatment.

[0071] The cured product of the curable resin Y filled in the porous layer, the cured product of the curable resin Y filled in the porous substrate, and the cured product of the curable resin Y contained in the cured resin layer are formed from the same curable resin Y, as described below.

[0072] 6. Penetration suppression layer In the resin-impregnated decorative board of the present disclosure, as shown in FIG. 3(a) and FIG. 3(b), it is preferable that a permeation suppression layer 6 is disposed between the porous layer 3 and the release layer 4. By disposing the permeation suppression layer 6 between the porous layer 3 and the release layer 4, it is possible to suppress the permeation of the ink for forming the release layer into the porous layer. The permeation suppression layer 6 may be a solid layer as shown in FIG. 3(a). On the other hand, the permeation suppression layer 6 may have a pattern shape as shown in FIG. 3(b). In this case, it is preferable that the pattern shape of the permeation suppression layer 6 corresponds to the pattern shape of the release layer 4. In this way, it is preferable that the permeation suppression layer 6 has a pattern shape, because the impregnation of the curable resin Y is further improved.

[0073] The permeation suppression layer preferably contains a resin containing one or more polar groups, such as a hydroxyl group, an amino group, and a carboxyl group. By containing the resin having the polar group, the permeation suppression layer can reduce the permeability of the release layer-forming ink into the porous layer without inhibiting the impregnation of the uncured resin (curable resin Y) such as a hydrophilic melamine resin into the porous substrate and the porous layer.

[0074] A resin having a polar group contains at least one of the following polar groups: a hydroxy group (-OH), an amino group (-NH2), and a carboxy group (-COOH). The polar group may be ionized and stabilized, for example, by the influence of a solvent or other functional groups. Therefore, the "hydroxy group (-OH)" is in the ionized state, "-O - " and the above "amino group (-NH2)" is in the ionized state "-NH3 + " is a concept that includes "carboxyl group (-COOH)" in its ionized state, "-COO - " is a concept that includes

[0075] The resin having a polar group is preferably a resin that dissolves or disperses in water, methanol, or ethanol. This is because the impregnation of uncured resins such as hydrophilic melamine resins is improved. Here, "dissolves or disperses in water, methanol, or ethanol" means that the following test is performed and certain standards are met. That is, the following operations are performed with reference to JIS K8001:2017, Section 3.2. 1) Prepare 100 ml each of water, methanol or ethanol as a solvent. 2) At 20°C ± 5°C, add 0.1 g of each resin (0.1 ml if liquid) to each of the above solvents. 3) Shake vigorously for 30 seconds every 5 minutes. 4) After 30 minutes, shake vigorously for 30 seconds and then leave to stand for 1 minute. If the following phenomena are not visually confirmed, it is determined that the solution has "dissolved or dispersed." -Solids are present at the bottom of the container. Phase separation of the solvent and resin (oil droplets) occurs on the top surface of the solvent, in the solvent, or at the bottom of the container.

[0076] Examples of resins having one or more polar groups, such as a hydroxy group (-OH), an amino group (-NH2), or a carboxy group (-COOH), include aqueous proteins such as casein, cellulose derivatives such as cellulose, acetyl cellulose, cellulose nitrate, hydroxypropyl cellulose, and carboxymethyl cellulose, polyvinyl alcohol derivatives such as polyvinyl butyral resin, amino resins such as melamine resin, (meth)acrylic acid resins, phenolic resins, acrylic polyols, and natural polymers (for example, polynucleotides, polypeptides, and polysaccharides).

[0077] The permeation-suppressing layer in the present disclosure preferably contains one or more of casein, acrylic polyol, melamine resin, polyvinyl alcohol, polyvinyl alcohol derivative, cellulose and cellulose derivative as a resin having a polar group, and more preferably contains casein. As casein, α-casein, β-casein, γ-casein or a mixture thereof can be used. Also, as casein, derivatives such as sodium caseinate and ammonium caseinate can be used alone or in combination.

[0078] The ratio of the resin having the polar group to the resin components contained in the permeation suppression layer is, for example, 20% by mass or more, may be 30% by mass or more, may be 40% by mass or more, or may be 50% by mass or more. If the content of the resin having the polar group is within the above range, the permeation of the ink for forming the release layer into the porous layer can be further suppressed without inhibiting the permeation of the curable resin Y into the porous substrate and the porous layer. On the other hand, the ratio of the resin having the polar group is, for example, 100% by mass or less, and may be 90% by mass or less.

[0079] The permeation suppression layer may contain other resins as a resin component in addition to the above-mentioned resin having a polar group. Examples of other resins include (meth)acrylic resins, ester urethane resins, acrylamide resins, ethylene oxide resins, N-vinylpyrrolidone resins, ester resins, amide resins, vinyl acetate resins, vinyl chloride resins, urethane (meth)acrylic resins, natural rubber, and synthetic rubber. Among these, (meth)acrylic resins and urethane (meth)acrylic resins are preferred.

[0080] The permeation suppression layer may contain additives such as colorants, extender pigments (eg, organic beads), neutralizing agents, and surfactants, as necessary.

[0081] The permeation suppression layer may have a single-layer structure, or may have a multi-layer structure in which a plurality of layers are laminated.

[0082] The method for forming the permeation suppression layer may be, for example, a coating method using an ink for the permeation suppression layer that contains a resin component containing at least a resin having a polar group, an additive, and a solvent (or a dispersion medium). The ink for the permeation suppression layer may contain a curing agent. Examples of the curing agent include isocyanate, organic sulfonate, organic amine, peroxide (e.g., methyl ethyl ketone peroxide), and radical initiator (azoisobutylnitrile). For example, the ink for forming the permeation suppression layer is applied to one side of the porous layer and dried to obtain the permeation suppression layer.

[0083] Examples of the solvent (or dispersion medium) include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water.

[0084] Examples of the coating method for forming the permeation-suppressing layer include various coating methods such as roll coating, knife coating, air knife coating, die coating, lip coating, comma coating, kiss coating, flow coating, and dip coating, and various printing methods such as gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing.

[0085] The thickness of the permeation suppression layer is not particularly limited, but is, for example, 0.1 μm or more, preferably 0.5 μm or more, and more preferably 1 μm or more. On the other hand, the thickness of the permeation suppression layer is, for example, 10 μm or less, and preferably 8 μm or less. If the thickness of the permeation suppression layer is the above value or more, the permeation of the ink for forming the release layer into the porous layer can be further suppressed. If the thickness of the permeation suppression layer is the above value or less, the impregnation of the curable resin Y becomes better. The thickness of the permeation suppression layer is the average value of the thicknesses measured at 10 points by observing the cross section obtained by cutting the decorative sheet in the thickness direction with an optical microscope.

[0086] The coating amount (grammage) of the permeation suppression layer is not particularly limited, but is, for example, 0.1 g / m 2 More than 0.5 g / m 2If the coating amount of the permeation suppression layer is equal to or more than the above value, the permeation of the ink for forming the release layer into the porous layer can be further suppressed. On the other hand, the coating amount (basis weight) of the permeation suppression layer is, for example, 10 g / m 2 Less than or equal to 8 g / m 2 When the coating amount of the permeation suppression layer is equal to or less than the above value, the impregnation of the curable resin Y becomes better.

[0087] 7.Adhesive layer As shown in FIG. 4, the resin-impregnated decorative board 10 according to the present disclosure has a thickness direction D T In the present disclosure, it is preferable that an adhesive layer 7 is disposed between the design layer 2 and the porous layer 3. Here, it is assumed that a resin-impregnated decorative board that does not have an adhesive layer between the design layer and the porous layer is manufactured by impregnating a first sheet (a sheet having a porous substrate and a design layer) and a second sheet (a sheet having a porous layer and a release layer) with a curable resin Y separately, and then laminating the first sheet impregnated with the curable resin Y and the second sheet impregnated with the curable resin Y to produce a laminate. In this case, due to the difference in expansion and contraction of the paper during resin impregnation, the positions of the release layer and the design layer may be shifted from the positions at the time of coating, resulting in a decrease in synchronization. On the other hand, when the resin-impregnated decorative board in the present disclosure has an adhesive layer between the design layer and the porous layer, it is possible to integrate the first sheet (a sheet having a porous substrate and a design layer) and the porous layer before resin impregnation (before the resin impregnation process) by interposing an adhesive layer therebetween. Therefore, it becomes easier to synchronize the designs.

[0088] The adhesive constituting the adhesive layer may be a general-purpose pressure-sensitive adhesive, heat-sensitive adhesive, or curable adhesive (thermosetting adhesive, photosetting adhesive, two-component curing adhesive, etc.). Among them, urethane-based adhesives are preferred because of their good adhesion. Examples of urethane-based adhesives include adhesives that utilize two-component curing urethane resins that contain various polyol compounds such as polyether polyol, polyester polyol, and acrylic polyol, and a curing agent such as an isocyanate compound.

[0089] The thickness of the adhesive layer is preferably 10 μm or less, more preferably 5 μm or less. By having the thickness of the adhesive layer in the above range, the impregnation of the curable resin Y becomes better. On the other hand, the thickness of the adhesive layer may be, for example, 0.1 μm or more, or 1 μm or more, from the viewpoint of efficiently obtaining excellent adhesion.

[0090] 8. First and second areas 1, the resin-impregnated decorative board according to the present disclosure has a first region R1 that overlaps with the release layer 4, and a second region R2 that does not overlap with the release layer 4. In the first region R1, the release layer 4 may be the outermost layer. In the second region R2, the cured resin layer 5 may be the outermost layer.

[0091] Thickness direction D T In the above, the height of the second region R2 may be higher than the height of the first region R1. In this case, the surface height difference between the first region and the second region may be, for example, 3.0 μm or more, or 4.0 μm or more. On the other hand, the surface height difference may be, for example, 10 μm or less, 7.0 μm or less, or 6.0 μm or less. The surface height difference between the first region and the second region is, as shown in FIG. 1, the difference in the surface height in the thickness direction D T In this case, it refers to the length from the surface (outermost surface p) of the resin-impregnated decorative board 10 on the release layer 4 side in the first region R1 to the surface (outermost surface q) of the resin-impregnated decorative board 10 on the cured resin layer 5 side in the second region R2.

[0092] On the other hand, in the present disclosure, since a release layer is disposed on the porous layer, the release layer may penetrate into the porous layer. Therefore, as shown in FIG. 5, the surface height difference between the first region R1 and the second region R2 may become small, and the height of the second region may become the same as the height of the first region. "The height of the second region is the same as the height of the first region" means, for example, that the surface height difference is less than 3.0 μm.

[0093] In addition, when the area of ​​the first region is S1 and the area of ​​the second region is S2 when viewed from the thickness direction of the decorative sheet, the ratio of S1 to S2 (S1 / S2) is, for example, 5% or more, and may be 10% or more, whereas S1 / S2 is, for example, 80% or less, and may be 70% or less, or may be 60% or less.

[0094] In the resin-impregnated decorative board of the present disclosure, the second region R2 gives a glossy design, and the first region R1 gives a matte design, thereby expressing a glossy matte design. The 60° gloss value of the first region is, for example, 10 or less, preferably 6.5 or less, and more preferably 4.0 or less. This is because the difference in gloss with the second region becomes large, and the gloss matte design is more prominently expressed. On the other hand, the 60° gloss value is, for example, 0.5 or more, 1.0 or more, and preferably 2.0 or more.

[0095] In the present disclosure, the 60° gloss value of the first region refers to the 60° specular gloss measured in accordance with Method 3 of JIS Z 8741:1997, and is a value measured by the following method. The resin-impregnated decorative board is placed with the release layer side facing up, and the 60° specular gloss is measured from the release layer side using a gloss meter in accordance with Method 3 of JIS Z 8741:1997. The 60° gloss value of the first region is the average value of the measured values ​​at any 10 points. At each measurement point, the measurement is performed after confirming that the first region is at the center of the measurement area of ​​the gloss meter and that the proportion of the area of ​​the first region to the area of ​​the measurement area is 50% or more.

[0096] The 60° gloss value of the first region can be adjusted by the average particle size of the matting agent contained in the release layer, the content of the matting agent, and the thickness of the release layer. For example, the 60° gloss value can be lowered by reducing the thickness of the release layer. For example, the 60° gloss value can be lowered by increasing the content of the matting agent. For example, the 60° gloss value can be lowered by increasing the average particle size of the matting agent.

[0097] The 60° gloss value of the second region is preferably greater than the 60° gloss value of the first region. This is because a gloss matte design can be expressed. The 60° gloss value of the second region is, for example, 11 or more, or may be 15 or more, or may be 20 or more. On the other hand, the 60° gloss value of the second region is, for example, 60 or less, or may be 55 or less, or may be 50 or less.

[0098] 9. Other materials The resin-impregnated decorative board of the present disclosure may have a porous core substrate on the surface of the porous substrate opposite to the design layer. Examples of the core substrate include phenolic resin-impregnated paper. The phenolic resin-impregnated paper is, for example, paper obtained by impregnating a kraft paper core paper with a phenolic resin and drying it.

[0099] 10.Applications The resin-impregnated decorative board in the present disclosure is used, for example, by being disposed on the surface of a substrate. Examples of substrates include wood members, resin members, metal members, and ceramic members. Examples of wood members include wood veneer, wood plywood, particle board, and wood fiberboard. Examples of wood used for wood members include cedar, cypress, pine, and lauan. Examples of resins used for resin members include vinyl chloride resins, (meth)acrylic resins, ester resins, styrene resins, olefin resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), phenolic resins, cellulose resins, carbonate resins, melamine resins, and rubber. Examples of metals used for metal members include iron and aluminum. The material of the ceramic members may be ceramics such as glass and porcelain, non-cement ceramic materials such as gypsum, and non-ceramic ceramic materials such as ALC (lightweight aerated concrete).

[0100] The resin-impregnated decorative board of the present disclosure can be used, for example, as a building material or furniture. The building material can be an interior material or an exterior material. The building material can be, for example, a wall, a floor, a ceiling, a door, or a shelf. The furniture can be, for example, a table, a desk, or a cabinet.

[0101] B. Manufacturing method of resin-impregnated decorative panels Hereinafter, the manufacturing method of the resin-impregnated decorative board in the present disclosure will be described in detail. FIG. 6 is a schematic cross-sectional view illustrating the manufacturing method of the resin-impregnated decorative board in the present disclosure. First, as shown in FIG. 6(a), a laminate 11 having a porous substrate 1, a design layer 2, a porous layer 3, a release layer 4 having a pattern shape and containing a cured product of a curable resin X, a curable resin layer 30 containing a curable resin Y, and a release film 20 in this order in the thickness direction is manufactured (laminate manufacturing process). In the present disclosure, in the laminate manufacturing process, the porous substrate 1, the porous layer 3 in the first region R1, and the porous layer 3 in the second region R2 are impregnated with the curable resin Y. Next, as shown in FIG. 6(b), the laminate 11 is heated and pressurized to form a cured resin layer 5 from the curable resin layer 30 while curing the curable resin Y, thereby obtaining a cured laminate 12 (heating and pressing process). Next, as shown in FIG. 6(c), the release film 20 is peeled off from the cured laminate 12, thereby T In the thickness direction D, the cured resin layer 5 arranged in the first region R1 overlapping with the release layer 4 is removed. T In this process, the cured resin layer 5 arranged in the second region R2 that does not overlap with the release layer 4 is left (peeling process).

[0102] According to the present disclosure, it is possible to manufacture a resin-impregnated decorative board that exhibits a gloss matte design, has excellent abrasion resistance, and provides good visibility of the design layer.

[0103] 1.Laminate manufacturing process In this step, a laminate 11 is produced that has, in the thickness direction, a porous substrate 1, a design layer 2, a porous layer 3, a release layer 4 having a pattern shape and containing a cured product of a curable resin X, a curable resin layer 30 containing a curable resin Y, and a release film 20, in this order. In this disclosure, in the laminate production step, the porous substrate 1, the porous layer 3 in the first region R1, and the porous layer 3 in the second region R2 are impregnated with the curable resin Y. The method for producing the laminate in this step is roughly divided into a first laminate production method and a second laminate production method.

[0104] 1-1. First laminate manufacturing method FIG. 7 is a schematic cross-sectional view showing an example of the first laminate preparation method. First, as shown in FIG. 7(a), a first sheet 15 having a porous substrate 1 and a design layer 2 is prepared (first sheet preparation step). Also, as shown in FIG. 7(b), a second sheet 16 having a porous layer 3 and a release layer 4 is prepared (second sheet preparation step). Next, as shown in FIG. 7(c) and FIG. 7(d), the first sheet 15 and the second sheet 16 are impregnated with a curable resin Y (resin impregnation step). Next, as shown in FIG. 7(e), the first sheet 15 impregnated with the curable resin Y, the second sheet 16 impregnated with the curable resin Y, and the release film 20 are laminated to prepare a laminate 11 (lamination step).

[0105] (1) First sheet preparation process In this process, a first sheet 15 is prepared having a porous substrate 1 and a design layer 2. The porous substrate, the design layer, and the method of forming the design layer are the same as those described in detail above in "A. Resin-impregnated decorative board."

[0106] (2) Second sheet preparation process In this step, a second sheet 16 is prepared having a porous layer 3 and a release layer 4. When producing the second sheet, it is preferable to use three methods alone or in combination in order to suppress the penetration of the ink for forming the release layer (the ink containing the curable resin X) into the porous layer.

[0107] The first method is (i) a method of disposing a permeation suppression layer between a porous layer and a release layer. When using this method, the second sheet preparation step preferably includes a permeation suppression layer forming step of forming a permeation suppression layer 6 on one side of the porous layer 3, and a release layer forming step of forming a release layer 4 on the side of the permeation suppression layer 6 opposite the porous layer 3 using an ink containing a curable resin X, as shown in Fig. 8(a) to (c). The permeation suppression layer 6 may be formed over the entire surface as shown in Fig. 8, or may be formed in a pattern. The porous layer, the permeation suppression layer, and the release layer, as well as the method of forming them, are the same as those described in detail in "A. Resin-impregnated decorative board" above.

[0108] The second method is (ii) a method of increasing the solid content concentration of the ink for forming the release layer. When this method is used, the second sheet preparation step includes a release layer formation step of forming a release layer on one side of the porous layer using an ink containing a curable resin X, and the solid content concentration of the ink containing the curable resin X is preferably 60% by mass or more, more preferably 70% by mass or more. When the solid content concentration of the ink is in the above range, the penetration of the curable resin X into the porous layer can be suppressed, and the porous layer in the first region is more likely to contain the cured product of the curable resin Y. In particular, when the solid content concentration of the ink containing the curable resin X is 80% by mass or more, the porous layer in the first region is more likely to contain the cured product of the curable resin Y without using other methods such as the above (i) and (iii). On the other hand, the solid content concentration of the ink is, for example, 90% by mass or less.

[0109] The third method is (iii) a method of increasing the basis weight of the porous layer. When this method is used, the second sheet preparation step includes a release layer formation step of forming a release layer on one side of the porous layer using an ink containing a curable resin X. The basis weight of the porous layer is, for example, 15 g / m 2 More than 20g / m 2 It is preferable that the thickness is 30 g / m or more. 2 More preferably, it is 40 g / m or more. 2It is more preferable that the basis weight of the porous layer is within the above range, so that the ink for forming the release layer is less likely to penetrate into the porous layer, and the porous layer in the first region is more likely to contain the cured product of the curable resin Y. In particular, when the basis weight of the porous layer is 45 g / m 2 By satisfying the above, the porous layer in the first region is likely to contain the cured product of the curable resin Y without using other methods such as the above (i) and (ii). On the other hand, the basis weight of the porous layer is, for example, 100 g / m 2 or less, 80 g / m 2 It may be the following.

[0110] (3) Resin impregnation process In this step, the first sheet 15 and the second sheet 16 are impregnated with the curable resin Y. For example, the first sheet 15 and the second sheet 16 are immersed in a curable resin composition containing the curable resin Y. After immersion, it is preferable to dry them. At this time, a part of the curable resin may be cured to a semi-cured state. Examples of the method for impregnating the curable resin Y include a method of immersing the first sheet and the second sheet in a bath containing the curable resin Y; a method of applying the curable resin Y to the first sheet and the second sheet by a coater such as a kiss coater or a comma coater; and a method of spraying the curable resin Y to the first sheet and the second sheet by a spray device or a shower device.

[0111] The ratio of the curable resin Y in the curable resin composition is, for example, 50 mass % or more, or may be 70 mass % or more, or may be 90 mass % or more. The curable resin composition may contain, for example, water, alcohol, or an organic solvent as a solvent.

[0112] (4)Lamination process In this step, a first sheet 15 impregnated with the curable resin Y, a second sheet 16 impregnated with the curable resin Y, and a release film 20 are laminated to produce a laminate 11. At this time, a core substrate may be disposed on the surface of the first sheet opposite to the second sheet.

[0113] The release film is, for example, a film containing a polyester resin such as polyethylene terephthalate or polybutylene terephthalate, a polyolefin resin such as polyethylene or polypropylene, an acrylic resin, etc. The release film may have a release layer containing a cured product of the ionizing radiation curable resin composition on the surface facing the curable resin layer.

[0114] 1-2. Second method for producing laminate 9 and 10 are schematic cross-sectional views showing an example of the second laminate preparation method. In the second laminate preparation method, first, as shown in FIG. 9(a), a first sheet 15 having a porous substrate 1 and a design layer 2 is prepared (first sheet preparation step). Next, as shown in FIG. 9(b), an adhesive layer 7 is formed on the surface of the design layer 2 of the first sheet 15 (adhesive layer formation step). Next, as shown in FIG. 9(c), a porous layer 3 is arranged on the surface of the adhesive layer 7 opposite to the design layer 2 (porous layer arrangement step). Next, as shown in FIG. 9(d), a release layer 4 is formed on the surface of the porous layer 3 opposite to the adhesive layer 7 to obtain a precursor laminate 17 (precursor laminate preparation step). Next, as shown in FIG. 10(a), the precursor laminate 17 is impregnated with a curable resin Y (resin impregnation step). Next, the precursor laminate 17 impregnated with the curable resin Y and a release film 20 are laminated together to produce the laminate 11 (lamination step).

[0115] (1) First sheet preparation process In this step, a first sheet 15 is prepared, which has a porous substrate 1 and a design layer 2. The first sheet preparation step is the same as the first sheet preparation step in the first laminate production method described above.

[0116] (2) Adhesive layer formation process In this step, an adhesive layer is formed on the side of the first sheet facing the design layer 2. By forming the adhesive layer, the adhesion between the porous layer and the design layer is improved. The adhesive layer is the same as described above.

[0117] (3) Porous layer arrangement process In this step, a porous layer is disposed on the adhesive layer on the side opposite to the design layer. When using the third method, that is, (iii) the method of increasing the basis weight of the porous layer, it is preferable to use the basis weight of the porous layer as described in detail in the first laminate production method described above.

[0118] (4) Penetration suppression layer formation process When using the first method, that is, (i) the method of arranging a permeation suppression layer between the porous layer and the release layer, the second laminate production method preferably has a permeation suppression layer formation step of forming a permeation suppression layer on the surface of the porous layer opposite the adhesive layer between the porous layer arrangement step and the precursor laminate preparation step described below. The permeation suppression layer and the method of forming it are the same as those described in detail in "A. Resin-impregnated decorative board" above.

[0119] (5) Pre-laminated body preparation process In this step, a release layer is formed on the surface of the porous layer opposite to the adhesive layer to obtain a precursor laminate. When using the second method, that is, (ii) the method of increasing the solids concentration of the ink for forming the release layer, in this step, it is preferable that the solids concentration of the ink containing the curable resin X is the solids concentration of the ink described in detail in the first laminate preparation method described above.

[0120] (6)Lamination process In this step, the precursor laminate 17 is laminated so that the curable resin layer 30 impregnated with the curable resin Y faces the release film 20. This results in a laminate 11. At this time, a core substrate may be disposed so as to face the porous substrate 1.

[0121] 2. Heat and pressure process In this step, as shown in FIG. 6(b), the laminate 11 is heated and pressurized to cure the curable resin Y while forming the cured resin layer 5 from the curable resin layer 30, thereby obtaining the cured laminate 12. The heating temperature is, for example, 90° C. or higher and 160° C. or lower. The applied pressure is, for example, 50 kg / cm. 2 More than 150kg / cm 2The heating and pressing time is, for example, 30 seconds or more and 30 minutes or less. The release layer has releasability with respect to the cured resin layer located between the release layer and the transfer sheet.

[0122] 3. Peeling process In this step, as shown in FIG. 6(c), the release film 20 is peeled off from the cured laminate 12. As a result, as shown in FIG. T In the thickness direction D, the cured resin layer 5 arranged in the first region R1 overlapping with the release layer 4 is removed. T In this way, the cured resin layer 5 disposed in the second region R2 that does not overlap with the release layer 4 remains. In this manner, the resin-impregnated decorative board 10 is obtained.

[0123] 4. Resin-impregnated decorative panels The resin-impregnated decorative board obtained by each of the above-mentioned steps is the same as that described above in "A. Resin-impregnated decorative board."

[0124] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are merely examples, and anything that has substantially the same configuration as the technical idea described in the claims of the present disclosure and exhibits similar effects is included in the technical scope of the present disclosure. EXAMPLES

[0125] [Example 1] (Preparation of the first sheet) As a porous substrate, the basis weight is 80g / m 2 Titanium paper (PM-77P, manufactured by KJ Specialty Paper Co., Ltd.) was prepared. A design layer (picture layer) with a thickness of 2 μm was partially laminated on the porous substrate to create a stone-patterned design by gravure printing using the following printing ink. This produced a first sheet having a porous substrate and a design layer.

[0126] <Printing ink> Casein / acrylic resin 20 parts by weight ·Water 70 parts by mass Dipropyl glycol 5 parts by weight Isopropyl alcohol 5 parts by weight

[0127] (Preparation of the second sheet) As a porous layer, overlay base paper 1 (basis weight 42 g / m 2 A 5-μm-thick release layer (80 μm thick, made of cellulose) was prepared. The following ink 1 for permeation suppression layer was applied to the porous layer to form a 3 μm-thick permeation suppression layer. The following ink 1 for forming release layer was then applied to the surface on which the permeation suppression layer was laminated so as to have a shape that was in sync with the pattern layer, and then the ink was irradiated with an electron beam of 3 Mrad at an acceleration voltage of 165 kV to form a 5-μm-thick release layer. The solid content of the ink 1 for forming release layer was 60% by mass. This produced a second sheet having a porous layer, a permeation suppression layer, and a release layer in this order.

[0128] <Ink for permeation suppression layer 1> Acrylic polyol 20 parts by weight Ethyl acetate 80 parts by weight

[0129] <Release layer forming ink 1> Ionizing radiation curable monomer (Aronix M-400, manufactured by Toagosei Co., Ltd.) 48 parts by weight Reactive silicone (X-22-164B, manufactured by Shin-Etsu Chemical Co., Ltd.) 4 parts by weight (6.7 parts by weight per 100 parts by weight of total solids) Silane coupling treated silica (particle size 2 μm) 8 parts by weight (13.3 parts per 100 parts by weight of total solids) Methyl ethyl ketone 40 parts by weight

[0130] (Preparation of release film) A coating solution containing 100 parts by mass of ionizing radiation curable monomer, 2 parts by mass of reactive silicone, 8 parts by mass of silica, and 50 parts by mass of ethyl acetate was applied at 5 g / m to the adhesive side of a 50 μm-thick PET film (Cosmoshine (registered trademark) A4100 manufactured by Toyobo Co., Ltd.). 2(when dry) and cured by irradiation with an electron beam of 5 Mrad at an accelerating voltage of 165 kV to produce a release film having a cured resin layer (peeling layer).

[0131] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0132] The first sheet impregnated with the uncured melamine resin composition was produced by impregnating craft paper with a phenolic resin liquid, with a basis weight of 245 g / m 2 The first decorative sheet was laminated on a core substrate consisting of three sheets of phenolic resin-impregnated core paper (obtained by impregnating a core craft paper with a liquid uncured resin composition made of phenolic resin) so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the laminate was laminated so that the picture pattern of the design layer of the first sheet and the release layer of the second sheet were in harmony with each other.

[0133] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0134] [Example 2] (Preparation of the first sheet) The titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the printing ink to form a stone grain pattern. This produced a first sheet having a porous substrate and a design layer.

[0135] (Preparation of the second sheet) The above-mentioned overlay base paper 1 was prepared as the porous layer. The following release layer forming ink 2 was laminated on the porous layer so as to have a shape in sync with the pattern layer, and then an electron beam of 3 Mrad was irradiated at an acceleration voltage of 165 kV to form a release layer having a thickness of 5 μm. The solid content of the release layer forming ink 2 was 80 mass %. This produced a second sheet having a porous layer and a release layer in this order.

[0136] <Release layer forming ink 2> Ionizing radiation curable monomer (Aronix M-400, manufactured by Toagosei Co., Ltd.) 64 parts by weight Reactive silicone (X-22-164B, manufactured by Shin-Etsu Chemical Co., Ltd.) 5.3 parts by weight (6.7 parts by weight per 100 parts by weight of total solids) Silane coupling treated silica (particle size 2 μm) 10.7 parts by weight (13.3 parts per 100 parts by weight of total solids) Methyl ethyl ketone 20 parts by weight

[0137] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0138] The first sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the two sheets were laminated so that the design pattern of the design layer of the first sheet was in harmony with the release layer of the second sheet.

[0139] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2 The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0140] [Example 3] (Preparation of the first sheet) The above titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the above printing ink so as to form a stone grain pattern design. This produced a first sheet having a porous substrate and a design layer.

[0141] (Preparation of the second sheet) The above-mentioned overlay base paper 1 was prepared as a porous layer. The following ink 2 for permeation suppression layer was used to coat the porous layer, and a permeation suppression layer having a thickness of 3 μm was laminated. Furthermore, the above-mentioned ink 1 for forming the release layer was laminated on the surface on which the permeation suppression layer was laminated so as to have a shape that matches the pattern layer, and then an electron beam of 3 Mrad was irradiated at an acceleration voltage of 165 kV to form a release layer having a thickness of 5 μm. This produced a second sheet having a porous layer, a permeation suppression layer, and a release layer in this order.

[0142] <Ink for permeation suppression layer 2> Casein / acrylic resin (mass ratio 45:55) 10 parts by mass ·Water 80 parts by mass Dipropyl glycol 5 parts by weight Isopropyl alcohol 5 parts by weight

[0143] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0144] The first sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the two sheets were laminated so that the design pattern of the design layer of the first sheet was in harmony with the release layer of the second sheet.

[0145] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2 The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0146] [Example 4] (Preparation of the first sheet) The titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the printing ink to form a stone grain pattern. This produced a first sheet having a porous substrate and a design layer.

[0147] (Preparation of the second sheet) The above-mentioned overlay base paper 1 was prepared as a porous layer. The above-mentioned ink 1 for permeation suppression layer was used to coat the porous layer, and a permeation suppression layer having a thickness of 3 μm was laminated in a pattern so as to be formed only directly under the release layer (first region). Furthermore, the ink 1 for forming the release layer was laminated on the surface on which the permeation suppression layer was laminated so as to have a shape that was in harmony with the pattern layer, and then an electron beam of 3 Mrad was irradiated at an acceleration voltage of 165 kV to form a release layer having a thickness of 5 μm. This produced a second sheet having a porous layer, a permeation suppression layer, and a release layer in this order.

[0148] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0149] The first sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the two sheets were laminated so that the design pattern of the design layer of the first sheet was in harmony with the release layer of the second sheet.

[0150] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0151] [Example 5] (Preparation of the first sheet) The above titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the above printing ink so as to form a stone grain pattern design. This produced a first sheet having a porous substrate and a design layer.

[0152] (Preparation of the second sheet) The above-mentioned overlay base paper 1 was prepared as a porous layer. The ink (permeation suppression layer ink 3) obtained by adding 5 parts by mass of a curing agent (hexamethylene diisocyanate) to the above-mentioned permeation suppression layer ink 1 was applied onto the porous layer to form a permeation suppression layer having a thickness of 3 μm. Furthermore, the above-mentioned release layer forming ink 1 was laminated on the surface on which the permeation suppression layer was laminated so as to have a shape in harmony with the pattern layer, and then an electron beam of 3 Mrad was irradiated at an acceleration voltage of 165 kV to form a release layer having a thickness of 5 μm. This produced a second sheet having a porous layer, a permeation suppression layer, and a release layer in this order.

[0153] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0154] The first sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the two sheets were laminated so that the design pattern of the design layer of the first sheet was in harmony with the release layer of the second sheet.

[0155] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2 The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0156] [Example 6] (Preparation of the first sheet) The titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the printing ink to form a stone grain pattern. This produced a first sheet having a porous substrate and a design layer.

[0157] (Preparation of the second sheet) As a porous layer, overlay base paper 2 (basis weight 50 g / m 2A 5-μm-thick release layer was formed by laminating the above-mentioned ink 1 for forming a release layer on the porous layer so as to have a shape that matches the pattern layer, and then irradiating the layer with an electron beam of 3 Mrad at an acceleration voltage of 165 kV. This produced a second sheet having a porous layer and a release layer.

[0158] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0159] The first sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the two sheets were laminated so that the design pattern of the design layer of the first sheet was in harmony with the release layer of the second sheet.

[0160] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a pressure of 100 kg / cm using a heat press. 2The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0161] [Comparative Example 1] (Preparation of the first sheet) The above titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the above printing ink so as to form a stone grain pattern design. This produced a first sheet having a porous substrate and a design layer.

[0162] (Preparation of the second sheet) The above-mentioned overlay base paper 1 was prepared as the porous layer. The above-mentioned ink for forming the release layer 1 was laminated on the porous layer so as to have a shape in sync with the pattern layer, and then an electron beam of 3 Mrad was irradiated at an acceleration voltage of 165 kV to form a release layer of 5 μm in thickness. This produced a second sheet having a porous layer and a release layer in this order.

[0163] (Preparation of release film) A coating solution containing 100 parts by mass of ionizing radiation curable monomer, 2 parts by mass of reactive silicone, 8 parts by mass of silica, and 50 parts by mass of ethyl acetate was applied at 5 g / m to the adhesive side of a 50 μm-thick PET film (Cosmoshine (registered trademark) A4100 manufactured by Toyobo Co., Ltd.). 2 (when dry) and cured by irradiation with an electron beam of 5 Mrad at an accelerating voltage of 165 kV to produce a release film having a cured resin layer (peeling layer).

[0164] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of an uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated into the first sheet and the second sheet thus prepared at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then the base paper was dried to produce a first sheet impregnated with the uncured melamine resin composition and a second sheet impregnated with the uncured melamine resin composition.

[0165] The first sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the first decorative sheet was in contact with the core substrate. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet 1 and the porous layer of the second sheet faced each other. At this time, the two sheets were laminated so that the design pattern of the design layer of the first sheet was in harmony with the release layer of the second sheet.

[0166] Further, a release film was laminated on the second sheet so that the release layer of the release film was in contact with the surface of the second sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2 The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0167] [Comparative Example 2] (Making decorative sheets) The titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by a gravure printing method using the printing ink, so as to form a stone-patterned design. This produced a first sheet having a porous substrate and a design layer. The ink 1 for forming a release layer was laminated on the design layer side of the first sheet so as to have a shape that matches the picture layer, and then an electron beam of 3 Mrad was irradiated at an acceleration voltage of 165 kV to form a release layer having a thickness of 5 μm. This produced a decorative sheet having a porous substrate, a design layer, and a release layer in this order.

[0168] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was applied to the prepared decorative sheet at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then dried to produce a decorative sheet impregnated with the uncured melamine resin composition.

[0169] The decorative sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the decorative sheet was in contact with the core substrate.

[0170] Furthermore, a release film was laminated on the decorative sheet so that the release layer of the release film was in contact with the surface of the decorative sheet coated with the release layer, to obtain a laminate. The laminate thus formed was sandwiched between two mirror plates and pressed with a pressure of 100 kg / cm using a heat press. 2The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0171] [Reference example] (Making decorative sheets) The above titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was laminated partially on the porous substrate to form a stone grain design by gravure printing using the above printing ink. This produced a first sheet having a porous substrate and a design layer. Overlay base paper 1 (basis weight 42 g / m2) was laminated as a porous layer on the design layer side of the first sheet. 2 A decorative sheet having a porous substrate, a design layer, and a porous layer in this order was thus produced.

[0172] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was applied to the prepared decorative sheet at a concentration of 80 g / m using an impregnation device. 2 The melamine resin was scraped off from the front and back of the base paper with a rubber spatula, and then dried to produce a decorative sheet impregnated with the uncured melamine resin composition.

[0173] The decorative sheet impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the decorative sheet was in contact with the core substrate. Furthermore, a release film was laminated on the decorative sheet so that the release layer of the release film was in contact with the surface of the decorative sheet coated with the release layer to obtain a laminate. The formed laminate was sandwiched between two mirror plates and pressed with a heat press at a pressure of 100 kg / cm. 2 The uncured melamine resin composition was heat-cured at a molding temperature of 150° C. for 10 minutes to form a cured resin layer containing a cured product of the melamine resin. The release film was peeled off to produce a resin-impregnated substrate.

[0174] [Example 7] (Preparation of the first sheet) The above titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the above printing ink so as to create a stone grain pattern design. This produced a first sheet having a porous substrate and a design layer. A 4 μm thick adhesive layer was laminated on the design layer of the first sheet by gravure printing using the following adhesive layer ink (adhesive 1). Next, nonwoven fabric 1 (basis weight 17 g / m2) was laminated as a porous layer. 2 A 100-m-thick sheet (80 μm thick, made of cellulose) was prepared and placed on the adhesive layer, and then the first sheet and the porous layer were bonded together by dry lamination. Furthermore, a permeation-suppressing layer and a release layer similar to those in Example 1 were provided on the surface of the porous layer opposite the adhesive layer using ink 1 for permeation-suppressing layer and ink 1 for forming release layer. This produced a precursor laminate.

[0175] <Ink for adhesive layer> Polyester polyol resin 27 parts by weight Hexamethylene diisocyanate 2 parts by weight Ethyl acetate 71 parts by weight

[0176] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was applied to the above-prepared precursor laminate by using an impregnation device at a concentration of 80 g / m of the uncured melamine resin composition. 2 The melamine resin on the front and back of the base paper was scraped off with a rubber spatula, and then dried to produce a precursor laminate impregnated with the uncured melamine resin composition.

[0177] The precursor laminate impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the precursor laminate was in contact with the core substrate. Furthermore, a release film was laminated on the precursor laminate so that the release layer of the release film was in contact with the surface of the precursor laminate coated with the release layer to obtain a laminate. The formed laminate was sandwiched between two mirror plates and pressed with a pressure of 100 kg / cm using a heat press machine. 2 The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0178] [Example 8] (Preparation of the first sheet) The above titanium paper was prepared as a porous substrate. A design layer (picture layer) having a thickness of 2 μm was partially laminated on the porous substrate by gravure printing using the above printing ink so as to create a stone grain pattern design. This produced a first sheet having a porous substrate and a design layer. An adhesive layer having a thickness of 4 μm was laminated on the design layer of the first sheet by gravure printing using the above adhesive layer ink (adhesive 1). Next, nonwoven fabric 2 (basis weight 25 g / m2) was laminated as a porous layer. 2A 130 μm thick sheet (made of acrylic) was prepared and placed on the adhesive layer, and then the first sheet and the porous layer were bonded by dry lamination. Furthermore, a permeation suppression layer and a release layer similar to those in Example 1 were provided on the surface of the porous layer opposite the adhesive layer using ink 1 for permeation suppression layer and ink 1 for forming release layer. This produced a precursor laminate.

[0179] (Manufacture of resin-impregnated decorative panels) A liquid uncured melamine resin composition containing 60 parts by mass of uncured melamine resin (water-soluble methylol melamine resin, NikaResin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was applied to the above-prepared precursor laminate by using an impregnation device at a concentration of 80 g / m of the uncured melamine resin composition. 2 The melamine resin on the front and back of the base paper was scraped off with a rubber spatula, and then dried to produce a precursor laminate impregnated with the uncured melamine resin composition.

[0180] The precursor laminate impregnated with the uncured melamine resin composition was laminated on the core substrate so that the porous substrate side of the precursor laminate was in contact with the core substrate. Furthermore, a release film was laminated on the precursor laminate so that the release layer of the release film was in contact with the surface of the precursor laminate coated with the release layer to obtain a laminate. The formed laminate was sandwiched between two mirror plates and pressed with a pressure of 100 kg / cm using a heat press machine. 2 The uncured melamine resin composition was heat-molded at a molding temperature of 150°C for 10 minutes to thermally cure the uncured melamine resin composition, thereby forming a cured resin layer containing a cured product of the melamine resin. The film was peeled off from the cured resin layer containing the cured product of the melamine resin, thereby removing the portion of the cured resin layer that covered the release layer, and leaving the cured resin layer on the remaining portion of the surface of the coating layer (the portion of the surface of the coating layer where the release layer was not provided). In this way, a resin-impregnated substrate was produced.

[0181] [Determination of the presence or absence of a cured product of the curable resin Y in the porous layer in the first region] The melamine decorative board obtained above was cut in the thickness direction, and the cross section was observed under the following conditions. The width of the release layer in the first region was W1, and the total width of the melamine layer in the first region where W1 was 300 μm or more was W2. The ratio of W2 to W1 (W2 / W1) was calculated. The results are shown in Tables 1 and 2. A ratio (W2 / W1) of 0.50 or more was determined to indicate the presence of a melamine layer, and a ratio of less than 0.50 was determined to indicate the absence of a melamine layer.

[0182] [evaluation] (Gloss matte design evaluation) The gloss matte design of the obtained melamine decorative board was evaluated visually. Specifically, under a light source of natural color fluorescent lamp color rendering AA (manufactured by Panasonic Corporation, model number: FLR40S·D-SDL / M), the obtained decorative board was visually observed from a position 50 cm away at an oblique angle, and the state of expression of the gloss matte design was confirmed. The observers scored the gloss matte design on a 5-point scale from 1 to 5 points (1 point being the worst and 5 points being the best). The evaluation was performed on a gradation basis, with 1 point being when most of the melamine was peeled off in the matte part and its vicinity and sufficient gloss matte design could not be confirmed, and 5 points being when no peeled off melamine was confirmed in the matte part and sufficient gloss matte design could be confirmed. Ten observers performed the evaluation, and the average score of all observers was calculated, and the gloss matte design was evaluated according to the following criteria. Evaluation criteria A: The average score for the evaluation of gloss matte design is 3 points or more. B: The average score when evaluating the gloss matte design is 2 points or more but less than 3 points. C: The average score for the evaluation of gloss matte design is less than 2 points.

[0183] (Pattern layer visibility in the first area) The visibility of the pattern layer in the first region (matte part) of the obtained melamine decorative board was visually evaluated. Specifically, under a light source of natural color fluorescent lamp color rendering AA (manufactured by Panasonic Corporation, model number: FLR40S·D-SDL / M), the obtained decorative board was visually observed from a position 50 cm away and directly in front of the surface of the decorative board to confirm the visibility of the pattern layer in the first region. The observers scored the condition of the first region on a five-point scale from 1 to 5 (1 being the worst and 5 being the best). The evaluation was made on a scale of 1 point when significant whitening was observed in the first region and the pattern layer was completely invisible, and 5 points when no whitening or other changes were observed in the first region and the pattern layer was easily visible. Ten observers performed the evaluation, and the average score of all observers was calculated, and the pattern layer visibility was evaluated according to the following criteria. Evaluation criteria A: The average score when evaluating the visibility of the pattern layer in the first area is 3 points or more. B: The average score when evaluating the visibility of the pattern layer in the first area is 2 points or more and less than 3 points C: The average score when evaluating the visibility of the pattern layer in the first area is less than 2 points

[0184] (Visibility of the second area pattern layer) In the same manner as in the method for evaluating the visibility of the pattern layer in the first region, the evaluation was performed by focusing on the portion other than the first region (the second region). In this evaluation, the case where the pattern visibility was equivalent to that of the reference example was evaluated as 5 points. Evaluation criteria A: The average score when evaluating the visibility of the pattern layer in the second area is 3 points or more. B: The average score when evaluating the visibility of the pattern layer in the second area is 2 points or more and less than 3 points C: The average score when evaluating the visibility of the pattern layer in the second area is less than 2 points

[0185] (Wear resistance evaluation) The resulting melamine decorative board was subjected to an abrasion test based on the JAS Flooring Abrasion Test A to evaluate its abrasion resistance. Using a Taber abrasion tester, the number of revolutions required to remove 95% of the pattern was measured in 25 revolution increments using abrasive paper: S-42 and a load of 1000g. This test was performed three times at different positions on the melamine decorative board, and the arithmetic average value of the number of revolutions was calculated and evaluated according to the following criteria. Evaluation criteria A: More than 200 spins until 95% of the symbols are taken B: 100 or more spins until 95% of the symbols are taken C: Less than 100 spins until 95% of the symbols are taken

[0186] [Table 1]

[0187] [Table 2]

[0188] As shown in Table 1, the resin-impregnated decorative boards of Examples 1 to 8 in which the porous layer of the first region contains a melamine layer have excellent abrasion resistance while expressing a gloss matte design, and the deterioration of the design due to the design layer is suppressed. It is presumed that Examples 1, 3, 4, 5, 7, and 8 have a permeation suppression layer, which suppresses the permeation of the ink for forming the release layer into the porous layer, and as a result, the porous layer in the first region is impregnated with melamine. In addition, it is presumed that in Example 2, the solid content concentration of the ink for forming the release layer is high, and the permeation of the ink for forming the release layer into the porous layer is suppressed. In Example 6, the basis weight of the porous layer is high, and the permeation of the ink for forming the release layer into the porous layer is suppressed. On the other hand, in the resin-impregnated decorative board of Comparative Example 1, the porous layer of the first region does not contain a melamine layer, and the design due to the design layer is reduced. In addition, the resin-impregnated decorative board of Comparative Example 2 does not contain a porous layer, and therefore the abrasion resistance is poor.

[0189] Thus, in the present disclosure, for example, the following inventions are provided:

[0190] [1] A resin-impregnated decorative board, The resin-impregnated decorative board has a porous substrate, a design layer, a porous layer, and a release layer having a pattern shape and containing a cured product of a curable resin X, in this order in the thickness direction; When viewed in the thickness direction, the resin-impregnated decorative board has a first region that overlaps with the release layer and a second region that does not overlap with the release layer, In the second region, a cured resin layer containing a cured product of the curable resin Y is disposed on the surface of the porous layer opposite to the design layer, the porous substrate, the porous layer in the first region, and the porous layer in the second region each contain a cured product of the curable resin Y, forming a resin-impregnated decorative board.

[0191] [2] The resin-impregnated decorative board described in [1], in which, when the resin-impregnated decorative board is viewed in cross section, the width of the release layer in the first region is W1, and the total width of the cured material of the curable resin Y in the first region is W2, the ratio of W2 to W1 (W2 / W1) is 0.50 or more.

[0192] [3] The resin-impregnated decorative board according to [1] or [2], wherein in the first region where W1 is 300 μm or more, W2 / W1 is 0.50 or more.

[0193] [4] the porous layer in the first region contains a cured product of a curable resin X, The resin-impregnated decorative board according to any one of [1] to [3], wherein, when the resin-impregnated decorative board is viewed in cross section, the thickness of the porous layer is T1, and the maximum thickness of the cured product of the curable resin X contained in the porous layer in the first region is T2, T2 / T1 is 0.8 or less.

[0194] [5] A resin-impregnated decorative board described in any of [1] to [4], wherein when the width of the release layer in the first region is W1, in the first region where W1 is 300 μm or more, T2 / T1 is 0.8 or less.

[0195] [6] The resin-impregnated decorative board according to any one of [1] to [5], wherein a permeation suppression layer is disposed between the porous layer and the release layer.

[0196] [7] The permeation suppression layer has a pattern shape, The resin-impregnated decorative board according to [6], wherein the pattern shape of the permeation suppression layer corresponds to the pattern shape of the release layer.

[0197] [8] The resin-impregnated decorative board according to [6], wherein the permeation suppression layer is a solid layer.

[0198] [9] The resin-impregnated decorative board according to any one of [1] to [8], wherein the porous layer contains a fibrous material.

[0199]

[10] The resin-impregnated decorative board according to [9], wherein the fiber material is paper or nonwoven fabric.

[0200]

[11] The resin-impregnated decorative board according to any one of [1] to

[10] , wherein the thickness of the porous layer is 10 μm or more and 100 μm or less.

[0201]

[12] The basis weight of the porous layer is 15 g / m 2 The resin-impregnated decorative board according to any one of [1] to

[11] above.

[0202]

[13] The resin-impregnated decorative board according to any one of [1] to

[12] , wherein the release layer is arranged in harmony with the pattern of the design layer.

[0203]

[14] The resin-impregnated decorative board according to any one of [1] to

[13] , wherein the height of the second region is greater than the height of the first region in the thickness direction.

[0204]

[15] The resin-impregnated decorative board according to any one of [1] to

[13] , wherein the height of the second region in the thickness direction is the same as the height of the first region.

[0205]

[16] The resin-impregnated decorative board according to any one of [1] to

[15] , wherein an adhesive layer is disposed between the design layer and the porous layer in the thickness direction.

[0206]

[17] The resin-impregnated decorative board according to any one of [1] to

[16] , wherein the porous substrate has titanium paper.

[0207]

[18] The resin-impregnated decorative board according to any one of [1] to

[17] , wherein the curable resin X is an ionizing radiation curable resin.

[0208]

[19] The resin-impregnated decorative board according to

[18] , wherein the ionizing radiation curable resin is an electron beam curable resin.

[0209]

[20] A resin-impregnated decorative board described in any one of [1] to

[19] , wherein a core substrate is disposed on the side of the porous substrate opposite the design layer in the thickness direction.

[0210] [twenty one] The resin-impregnated decorative board according to any one of [1] to

[20] , wherein the resin-impregnated decorative board is a melamine decorative board.

[0211] [twenty two] A method for producing a resin-impregnated decorative board, comprising: a laminate preparation step of preparing a laminate having, in the thickness direction, a porous substrate, a design layer, a porous layer, a release layer having a pattern shape and containing a cured product of curable resin X, a curable resin layer containing curable resin Y, and a release film in this order; a heating and pressurizing step of heating and pressurizing the laminate to cure the curable resin Y and form a cured resin layer from the curable resin layer to obtain a cured laminate; a peeling step of peeling the release film from the cured laminate to remove the cured resin layer arranged in a first region that overlaps with the release layer in the thickness direction, while leaving the cured resin layer arranged in a second region that does not overlap with the release layer in the thickness direction; having A method for producing a resin-impregnated decorative board, wherein in the laminate production process, the porous substrate, the porous layer in the first region, and the porous layer in the second region are impregnated with the curable resin Y.

[0212] [twenty three] The laminate preparation step includes: A first sheet preparation step of preparing a first sheet having the porous substrate and the design layer; a second sheet preparation step of preparing a second sheet having the porous layer and the release layer; a resin impregnation step of impregnating the first sheet and the second sheet with the curable resin Y; a lamination step of laminating the first sheet impregnated with the curable resin Y, the second sheet impregnated with the curable resin Y, and the release film to produce the laminate; The method for producing a resin-impregnated decorative board according to

[22] , comprising:

[0213] [twenty four] The second sheet preparation step includes: a permeation suppression layer forming step of forming a permeation suppression layer on one surface side of the porous layer; a release layer forming step of forming the release layer on the side of the permeation suppression layer opposite to the porous layer using an ink containing the curable resin X; The method for producing a resin-impregnated decorative board according to

[23] , comprising:

[0214] [twenty five] the second sheet preparation step includes a release layer formation step of forming the release layer on one surface side of the porous layer using an ink containing the curable resin X, The method for producing a resin-impregnated decorative board according to

[23] or

[24] , wherein the ink containing the curable resin X has a solids concentration of 60 mass % or more.

[0215]

[26] the second sheet preparation step includes a release layer formation step of forming the release layer on one surface side of the porous layer using an ink containing the curable resin X, The basis weight of the porous layer is 15 g / m 2 The method for producing a resin-impregnated decorative board according to any one of

[23] to

[25] above.

[0216]

[27] The laminate preparation step includes: A first sheet preparation step of preparing a first sheet having the porous substrate and the design layer; An adhesive layer forming step of forming an adhesive layer on the surface side of the design layer of the first sheet; A porous layer disposing step of disposing the porous layer on the surface of the adhesive layer opposite the design layer; a precursor laminate preparation step of forming the release layer on the surface of the porous layer opposite to the adhesive layer to obtain a precursor laminate; a resin impregnation step of impregnating the precursor laminate with the curable resin Y; a lamination step of laminating the precursor laminate impregnated with the curable resin Y and the release film to produce the laminate; A method for producing a resin-impregnated decorative board according to

[22] , comprising the steps of:

[0217]

[28] The method for manufacturing a resin-impregnated decorative board described in

[27] includes a permeation suppression layer formation step of forming a permeation suppression layer on the side of the porous layer opposite the adhesive layer, between the porous layer arrangement step and the precursor laminate preparation step.

[0218]

[29] In the precursor laminate preparation step, the release layer is formed on the surface of the porous layer opposite to the adhesive layer using an ink containing the curable resin X; The method for producing a resin-impregnated decorative board according to

[27] or

[28] , wherein the ink containing the curable resin X has a solids concentration of 60 mass % or more.

[0219]

[30] In the precursor laminate preparation step, the release layer is formed on the surface of the porous layer opposite to the adhesive layer using an ink containing the curable resin X; The basis weight of the porous layer is 15 g / m 2 The method for producing a resin-impregnated decorative board according to any one of

[27] to

[29] above. [Explanation of symbols]

[0220] 1...Porous base material 2…Design layer 3…Porous layer 4…Release layer 5…Cured resin layer 10...Resin-impregnated decorative board

Claims

1. A resin-impregnated decorative board, The resin-impregnated decorative board has a porous substrate, a design layer, a porous layer, and a release layer having a pattern shape and containing a cured product of a curable resin X, in this order in the thickness direction; When viewed in the thickness direction, the resin-impregnated decorative board has a first region that overlaps with the release layer and a second region that does not overlap with the release layer, In the second region, a cured resin layer containing a cured product of the curable resin Y is disposed on the surface of the porous layer opposite to the design layer, A resin-impregnated decorative board, wherein the porous substrate, the porous layer in the first region, and the porous layer in the second region contain a cured product of the curable resin Y.

2. The resin-impregnated decorative board is viewed in cross section, and the width of the release layer in the first region is W １ The total width of the cured product of the curable resin Y in the first region is W ２ In this case, the W １ The above W ２ The ratio of (W ２ / W １ 2. The resin-impregnated decorative board according to claim 1, wherein the coefficient of friction coefficient is 0.50 or more.

3. The W １ In the first region, the W ２ / W １ The resin-impregnated decorative board according to claim 2, wherein the σ is 0.50 or more.

4. the porous layer in the first region contains a cured product of a curable resin X, The resin-impregnated decorative board is viewed in cross section, and the thickness of the porous layer is T １ The maximum thickness of the cured material of the curable resin X contained in the porous layer in the first region is T ２ In this case, T ２ / T １ The resin-impregnated decorative board according to claim 1 , wherein the σ is 0.8 or less.

5. The width of the release layer in the first region is W １ In this case, the W １ In the first region, the T ２ / T １ The resin-impregnated decorative board according to claim 4, wherein the σ is 0.8 or less.

6. The resin-impregnated decorative board according to claim 1 , further comprising a permeation suppression layer disposed between the porous layer and the release layer.

7. The permeation suppression layer has a pattern shape, The resin-impregnated decorative board according to claim 6 , wherein the pattern shape of the permeation suppression layer corresponds to the pattern shape of the release layer.

8. The resin-impregnated decorative board according to claim 6 , wherein the permeation suppression layer is a solid layer.

9. The resin impregnated decorative board of claim 1 , wherein the porous layer comprises a fibrous material.

10. 10. The resin-impregnated decorative board according to claim 9, wherein the fibrous material is paper or nonwoven fabric.

11. 2. The resin-impregnated decorative board according to claim 1, wherein the porous layer has a thickness of 10 μm or more and 100 μm or less.

12. The basis weight of the porous layer is 15 g / m ２ The resin-impregnated decorative board according to claim 1 .

13. The resin-impregnated decorative board according to claim 1 , wherein the release layer is arranged in harmony with a pattern of the design layer.

14. The resin-impregnated decorative board according to claim 1 , wherein a height of the second region is greater than a height of the first region in the thickness direction.

15. The resin-impregnated decorative board according to claim 1 , wherein the height of the second region is the same as the height of the first region in the thickness direction.

16. The resin-impregnated decorative board according to claim 1 , wherein an adhesive layer is disposed between the decorative layer and the porous layer in the thickness direction.

17. 10. The resin impregnated decorative board of claim 1, wherein the porous substrate comprises titanium paper.

18. 2. The resin-impregnated decorative board according to claim 1, wherein the curable resin X is an ionizing radiation curable resin.

19. 19. The resin-impregnated decorative board according to claim 18, wherein the ionizing radiation curable resin is an electron beam curable resin.

20. The resin-impregnated decorative board according to claim 1 , wherein a core substrate is disposed on a surface of the porous substrate opposite the design layer in the thickness direction.

21. The resin-impregnated decorative board according to claim 1 , wherein the resin-impregnated decorative board is a melamine decorative board.

22. A method for producing a resin-impregnated decorative board, comprising: a laminate preparation step of preparing a laminate having, in the thickness direction, in this order, a porous substrate, a design layer, a porous layer, a release layer having a pattern shape and containing a cured product of a curable resin X, a curable resin layer containing a curable resin Y, and a release film; a heating and pressurizing step of heating and pressurizing the laminate to cure the curable resin Y and form a cured resin layer from the curable resin layer to obtain a cured laminate; a peeling process in which the release film is peeled off from the cured laminate, thereby removing the cured resin layer arranged in a first region that overlaps with the release layer in the thickness direction, while leaving the cured resin layer arranged in a second region that does not overlap with the release layer in the thickness direction; having In the laminate preparation process, the porous substrate, the porous layer in the first region, and the porous layer in the second region are impregnated with the curable resin Y.

23. The laminate preparation step includes: A first sheet preparation step of preparing a first sheet having the porous substrate and the design layer; a second sheet preparation step of preparing a second sheet having the porous layer and the release layer; a resin impregnation step of impregnating the first sheet and the second sheet with the curable resin Y; a lamination step of laminating the first sheet impregnated with the curable resin Y, the second sheet impregnated with the curable resin Y, and the release film to prepare the laminate; The method for producing the resin-impregnated decorative board according to claim 22, comprising:

24. The second sheet preparation step includes: a permeation suppression layer forming step of forming a permeation suppression layer on one surface side of the porous layer; a release layer forming step of forming the release layer on the side of the permeation suppression layer opposite to the porous layer using an ink containing the curable resin X; The method for producing the resin-impregnated decorative board according to claim 23, comprising:

25. the second sheet preparation step includes a release layer formation step of forming the release layer on one surface side of the porous layer using an ink containing the curable resin X, 24. The method for producing a resin-impregnated decorative board according to claim 23, wherein the ink containing the curable resin X has a solids concentration of 60% by mass or more.

26. the second sheet preparation step includes a release layer formation step of forming the release layer on one surface side of the porous layer using an ink containing the curable resin X, The basis weight of the porous layer is 15 g / m ２ The method for producing a resin-impregnated decorative board according to claim 23, wherein the resin-impregnated decorative board is made of a resin.

27. The laminate preparation step includes: A first sheet preparation step of preparing a first sheet having the porous substrate and the design layer; An adhesive layer forming step of forming an adhesive layer on the surface side of the design layer of the first sheet; A porous layer disposing step of disposing the porous layer on the surface of the adhesive layer opposite the design layer; a precursor laminate preparation step of forming the release layer on the surface of the porous layer opposite to the adhesive layer to obtain a precursor laminate; a resin impregnation step of impregnating the precursor laminate with the curable resin Y; a lamination step of laminating the precursor laminate impregnated with the curable resin Y and the release film to prepare the laminate; The method for producing the resin-impregnated decorative board according to claim 22, comprising:

28. The method for producing a resin-impregnated decorative board according to claim 27, further comprising a permeation suppression layer formation step of forming a permeation suppression layer on the surface of the porous layer opposite the adhesive layer between the porous layer arrangement step and the precursor laminate preparation step.

29. In the precursor laminate preparation step, the release layer is formed on a surface of the porous layer opposite to the adhesive layer using an ink containing the curable resin X; 28. The method for producing a resin-impregnated decorative board according to claim 27, wherein the ink containing the curable resin X has a solids concentration of 60 mass % or more.

30. In the precursor laminate preparation step, the release layer is formed on a surface of the porous layer opposite to the adhesive layer using an ink containing the curable resin X; The basis weight of the porous layer is 15 g / m ２ The method for producing a resin-impregnated decorative board according to claim 27, wherein the resin-impregnated decorative board is made of a resin.

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