Decorative plate

Abstract

To provide a decorative plate having a realistic feeling and a high-class impression and having a design property with high texture, and to provide a simple method of producing the decorative plate.SOLUTION: A decorative plate includes a first region and a second region having different refractive indices on its surface. A height difference between the first region and the second region is 1 μm or less. A refractive index (n1) of a resin included in the surface of the first region and a refractive index (n2) of a resin included in the surface of the second region satisfy a relationship of n1<n2.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a decorative board and a method for making a decorative board. [Background technology]

[0002] For interior and exterior building materials, for example, cabinets for furniture and kitchen products, tabletops used for various counters and desks, doors and other residential building materials, thermosetting resin decorative boards such as high-pressure melamine resin decorative boards, low-pressure melamine resin decorative boards, diallyl phthalate (DAP) resin decorative boards, polyester decorative boards, guanamine resin decorative boards and phenolic resin decorative boards are used because they have excellent properties such as scratch resistance, impact resistance, heat resistance and stain resistance.

[0003] In recent years, with the increasing trend of consumers toward luxury goods, it has become desirable for these thermosetting resin decorative boards to have a realistic appearance (hereinafter, simply referred to as "realistic appearance") that is closer to the visual appearance of the surface unevenness of real wood, stone, fabric, leather, etc., especially the surface unevenness that is in sync with the position of the pattern, and a luxurious appearance. As a method for improving the realistic appearance and luxurious appearance, a method of imparting an uneven shape to at least the surface layer of the decorative board, for example, a method of improving the realistic appearance by embossing using an embossing plate, a molding sheet, or a transfer sheet in which a pattern transfer layer is releasably laminated on the molding surface of the molding sheet, has long been practiced. However, in order to improve the realistic appearance by embossing, a separate process of making an embossing plate and a process of forming a resin layer for forming unevenness by embossing are required. Furthermore, the manufacturing process is lengthened because the embossing plate is made and embossed. In addition, since the surface is uneven, dirt can accumulate in the recesses, causing contamination problems. Furthermore, when embossing is performed to give a realistic and luxurious feel to a pattern such as wood grain, it is necessary to adjust, i.e., align, the position of the pattern such as wood grain and the embossing, but this is very difficult and reduces the yield of non-defective products.

[0004] As a method for imparting a textured shape to the surface of a decorative board while solving the problems of the length of the manufacturing process, the difficulty of alignment, and the reduced yield associated with such embossing, for example, Patent Document 1 proposes a decorative board having a release layer in the form of a picture pattern on a portion of the surface, and a thermosetting resin layer on the remaining area of ​​the surface that does not have the release layer, thereby producing a decorative board with an excellent sense of realism and a design sense of clear textured shapes that are accurately registered with the picture pattern of the release layer, and a method for manufacturing the same. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2016-182808 A DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0006] However, even with the decorative panel and its manufacturing method disclosed in Patent Document 1, there remains an issue in that it is not possible to simultaneously achieve the appearance of a surface irregularity shape that is positionally synchronized with the picture pattern and the appearance of stain resistance due to the retention of contaminants in the recesses.

[0007] The present invention has been made under these circumstances, and aims to provide a decorative board with a high-quality design that has excellent stain resistance, a realistic feel due to the expression of surface irregularities that are positionally synchronized with the picture pattern, and a luxurious feel, as well as a simple method for manufacturing said decorative board. [Means for solving the problem]

[0008] As a result of intensive research into solving the above problems, the present inventors have found that the above problems can be solved by an invention relating to a decorative board having the following configuration.

[0009] The present invention aims to provide [1] to

[17] . [1] A method for producing a decorative board, comprising the following steps (1) to (5): (1) A step of forming a release layer on a part of one side of a releasable support, and forming a primer layer on the side of the releasable support where the release layer is formed and at least on a part that does not have the release layer, to obtain Sheet (1). (2) A step of obtaining a laminate (A) by stacking a substrate (1) impregnated with an uncured thermosetting resin on the release layer side of the Sheet (1).

[0010] (3) A step of curing the uncured thermosetting resin while allowing a part of the uncured thermosetting resin to penetrate into the primer layer of the transfer sheet by thermally pressing the laminate (A) with mirror plates on both sides. (4) A step of taking out the laminate (A) from between the mirror plates. (5) A step of peeling off and removing the releasable support from the laminate (A) to obtain a decorative board having a first region with the release layer in the plane and a second region without the release layer in the plane.

[0011] [2] The method for manufacturing a decorative board according to [1], further including a step of forming a decorative layer on the primer layer of the Sheet (1) in the step (1). [3] The method for manufacturing a decorative board according to [1] or [2], wherein the substrate (1) is a substrate formed on a core layer. [4] The method for manufacturing a decorative board according to any one of [1] to [3], wherein the difference in elevation between the first region and the second region on the surface having the first region and the second region of the decorative board is within 1 μm.

[0012] [5] The method for manufacturing a decorative board according to any one of [1] to [4], wherein the refractive index (n1) of the resin contained in the surface of the first region and the refractive index (n2) of the resin contained in the surface of the second region satisfy the relationship n1 < n2. [6] The method for manufacturing a decorative board according to any one of [1] to [5], wherein in the step (1), a releasable support having a release layer on the releasable support is used as the releasable support, and the release layer is formed on the release layer. [7] The method for manufacturing a decorative panel according to any one of [1] to [6], wherein in the step (1), the primer layer is also formed on the release layer.

[0013] [8] The method for manufacturing a decorative panel according to any one of [1] to [8], wherein the release layer is a cured product of an ionizing radiation curable resin composition containing a reactive silicone. [9] A decorative panel having a resin layer on a substrate, the resin layer having a first region and a second region on the surface, the difference between the elevation of the first region and the elevation of the second region being 1 μm or less, and the refractive index (n1) of the resin contained in the surface of the first region and the refractive index (n2) of the resin contained in the surface of the second region satisfying the relationship n1 < n2.

[10] The decorative panel according to [9], wherein at least one outermost surface of the decorative panel includes the first region and the second region.

[0014]

[11] The decorative panel according to [9] or

[10] , wherein the resin layer corresponding to the first region has a release layer from the substrate side, and the resin layer corresponding to the second region has a primer layer from the substrate side.

[12] The decorative panel according to any one of [9] to

[11] , wherein the resin layer corresponding to the first region has a primer layer and a release layer in this order from the substrate side, and the resin layer corresponding to the second region has a primer layer from the substrate side.

[13] The decorative panel according to any one of [9] to

[12] , having a decorative layer between the substrate and the resin layer.

[0015]

[14] The decorative panel according to any one of [9] to

[13] , further including a core layer on the side of the substrate opposite to the resin layer.

[15] The decorative panel according to any one of [9] to

[14] , wherein the surface of the resin layer corresponding to the first region includes a cured product of an ionizing radiation curable monomer containing a reactive silicone.

[0016]

[16] The content of triazine residues (TA1) in the first region and the content of triazine residues (TA2) in the second region satisfy the relationship TA1 < TA2. The decorative panel according to any one of [9] to

[15] .

[17] The contact angle of water (θ1) in the first region and the contact angle of water (θ2) in the second region on at least one outermost surface of the decorative panel satisfy the relationship θ1 > θ2. The decorative panel according to any one of [9] to

[16] .

Advantages of the Invention

[0017] According to the present invention, it is possible to provide a decorative panel having excellent antifouling properties, a high-class feeling along with a realistic feeling, and a high-quality design feeling, and a simple manufacturing method of the decorative panel.

Brief Description of the Drawings

[0018] [Figure 1] It is a schematic perspective view showing the appearance of an example of the decorative panel of the present invention. [Diagram 2] It is a schematic diagram showing the layer structure in a cross-sectional view of an example of the transfer sheet of the present invention. [Diagram 3] It is a schematic diagram showing the layer structure in a cross-sectional view of an example of the transfer sheet of the present invention. [Figure 4] It is a schematic diagram showing the layer structure in a cross-sectional view of an example of the transfer sheet of the present invention. [Diagram 5] It is a conceptual diagram of peeling and removing a peelable support. [Figure 6] It is a schematic diagram of a decorative panel.

Embodiments for Carrying Out the Invention

[0019] 〔Decorative Panel〕 The decorative panel of the present invention has a resin layer on a base material. The resin layer has a first region and a second region on its surface. The difference between the elevation of the first region and the elevation of the second region is 1 μm or less. The refractive index (n1) of the resin contained on the surface of the first region and the refractive index (n2) of the resin contained on the surface of the second region satisfy the relationship n1 < n2. It is a decorative panel.

[0020] The shape of the decorative board of the present invention is not particularly limited and may be appropriately selected as desired, and may be, for example, flat, curved, or non-flat, such as having corners. Although a flat decorative board is shown in Fig. 1, the shape of the decorative board of the present invention is not limited to this. Considering the ease of manufacturing the decorative board and its applications, a flat shape is preferable.

[0021] <Resin layer> The decorative board of the present invention has a resin layer, and the resin layer must have a first region and a second region on the surface thereof. The elevations of the first and second regions vary depending on the layers they contain, as described below, but in order to ensure sufficient stain resistance on the surface of the decorative board, the elevations of the first and second regions are visually substantially identical (i.e., there is substantially no elevation difference between the two regions). Here, "visually substantially identical elevations of the first and second regions" requires that the difference in elevation between the first and second regions is 1 μm or less.

[0022] In this specification, "altitude" refers to the thickness direction of the decorative material, and refers to the z direction in Fig. 6. Note that a specific location (specific surface, specific position, etc.) having a high (or low) altitude means that the value of the z coordinate in the thickness direction of the specific location is relatively large (or small). In Fig. 6, the higher the specific location is in the figure, the higher the altitude, and the lower the specific location is in the figure, the lower the altitude.

[0023] The difference in elevation between the two regions, i.e., the first region and the second region, improves the prevention of dirt accumulation in the concave portions of the surface, thereby enhancing the antifouling property. Also, to prevent the physical three-dimensional effect (or unevenness) caused by the elevation difference between the two regions from inhibiting the manifestation of the three-dimensional effect based on the refractive index difference between the two regions described below, the elevation difference between the two regions is preferably 0.8 μm or less, which is the maximum wavelength of visible light, more preferably 0.6 μm or less, and even more preferably 0.4 μm or less, which is the minimum wavelength of visible light. There is no particular limitation on the lower limit value, and 0 μm is most preferable. However, when it is difficult to make the elevation difference between the two regions exactly 0 μm, within the range that does not complicate the manufacturing process or material selection or increase the manufacturing cost, it is sufficient that the elevation difference (i.e., unevenness) between the two regions is visually imperceptible and sufficient antifouling property can be ensured. Although it also depends on the planar shape (pattern) of the two regions, the decorative layer, or both of them, generally, an elevation difference of 0.3 μm between the two regions is sufficient. Here, "substantially" means that it is below the visually distinguishable threshold value. The difference in elevation between the elevation of the first region and the elevation of the second region can be determined, for example, by the method described in the examples.

[0024] The refractive index (n1) of the resin contained on the surface of the first region and the refractive index (n2) of the resin contained on the surface of the second region are different. n1 and n2 vary depending on the resin contained on the surface of the first region and the resin contained on the surface of the second region, and their absolute values can be adjusted as appropriate. To impart a high design quality with a three-dimensional effect by visually recognizing an uneven shape despite the physical elevation difference being substantially 0 based on the principle mechanism as described below due to the difference in light reflectance between the surfaces of the respective regions, it is necessary to satisfy the relationship n1 < n2.

[0025] That is, when the refractive index of the resin contained on the surface of the first region is n1, the refractive index of the resin contained on the surface of the second region is n2, and the refractive index of air is n0, the light reflectance R1 of the surface of the first region, when the incident angle of light from the air to the surface of the first region is φ0, is R1 P =tan 2 {φ0 - sin-1 (n0sinφ0 / n1)} / tan 2 {φ0+sin -1 (n0sinφ0 / n1)} [Formula 1'] R1 S =sin 2 (φ0-sin -1 (n0sinφ0 / n1)) / sin 2 (φ0+sin -1 (n0sinφ0 / n1)) [Formula 1''] Here, R1 P , R1 S are the reflectances for the P-polarized light component and the S-polarized light component, respectively.

[0026] (These formulas are well known in the field of optics, but please refer to, for example, pages 20-29 of "Science Library Physics = 9 Optics," first edition, second printing published on September 30, 1980, published by Science Co., Ltd.) Similarly, if the incident angle of light from the air to the surface of the second region is φ0, the reflectance R2 of the light on the surface of the second region is, for the P-polarized component and the S-polarized component, respectively, R2 P =tan 2 {φ0-sin -1 (n0sinφ0 / n2)} / tan 2 {φ0+sin -1 (n0sinφ0 / n2)} [Formula 2'] R2 S =sin 2 (φ0-sin -1 (n0sinφ0 / n2)) / sin 2 (φ0+sin -1 (n0sinφ0 / n2)) [Formula 2''] It becomes.

[0027] Incidentally, in order to facilitate understanding of the principle and simplify the formulas, consider the case where the angle of incidence of light to each region 21, 22 is φ0 ≒ 0 degrees, that is, nearly perpendicular incidence (meaning that the light is incident from the direction of the normal N to the surface of the decorative plate 3). In this case, there is no distinction between P-polarized light and S-polarized light, and [Formula 1'] to [Formula 2''] can be approximated to the following simple form.

[0028] The reflectance R1 of light on the surface of the first region is R1 = (n1 - n0) / (n1 + n0) [Equation 1’’’] The reflectance R2 of light on the surface of the second region is R2 = (n2 - n0) / (n2 + n0) [Equation 2’’’] Since the refractive index of air is approximately 1, approximating n0 = 1, Equations [1’’’] and [2’’’] further become The reflectance R1 of light on the surface of the first region is R1 = (n1 - 1) / (n1 + 1) [Equation 1] The reflectance R2 of light on the surface of the second region is R2 = (n2 - 1) / (n2 + 1) [Equation 2] and can be approximated as such.

[0029] As is apparent from Equations [1’’’] and [2’’’], or Equations [1] and [2], if n1 < n2, then R1 < R2 [Equation 3] and it becomes so.

[0030] As is apparent from Equation [3], when the refractive index n1 of the resin contained in the surface of the first region is made smaller (relatively) than the refractive index n2 of the resin contained in the surface of the second region, and when illuminated at the same light incident angle and observed in the same line-of-sight direction, (relatively), the reflectance R1 of light on the surface of the first region becomes smaller than the reflectance R2 of light on the surface of the second region. Therefore, the second region becomes relatively brighter than the first region, resulting in a difference in brightness and gloss, and a three-dimensional effect is manifested.

[0031] To more strongly manifest a three-dimensional effect and impart a sense of reality and luxury, it is preferable to increase the difference between n1 and n2. It is preferably 0.02 or more, more preferably 0.03 or more, and still more preferably 0.05 or more. From the viewpoints of easy availability of the resin contained in the surface of the first region and the resin contained in the surface of the second region and maintaining the strength of a practical decorative material, it is preferably 0.20 or less, more preferably 0.18 or less, and still more preferably 0.16 or less. n1 and n2 can be determined, for example, by the method described in the examples.

[0032] In the present invention, "plan view" means viewing the decorative board of the present invention in a planar direction from the side (surface side) having the first region and the second region. A typical example of "plan view" is a case where the line of sight is aligned with the normal direction N of the decorative board surface, as described with reference to Figures 1 and 2, but "plan view" in the present invention is not limited to this form and includes any case where the decorative board of the present invention is viewed in the originally expected line of sight from the side (surface) of the surface having the resin layer consisting of the first region 21 and the second region 22. In addition, in the present invention, "cross-sectional view" means viewing a cross section parallel to the normal direction N of the surface of the decorative board of the present invention from the normal direction N and a direction perpendicular to the cross section, as shown in Figure 1, and also includes any case where the decorative board of the present invention is viewed from a direction in which at least the cross-sectional shape can be seen.

[0033] In order to obtain a design with a high quality texture that has a sense of realism and a luxurious feel, it is preferable that at least one of the outermost surfaces of the decorative board of the present invention includes the first region and the second region, and it is more preferable that the outermost surface of the main surface of the decorative board that is viewed by the viewer includes the first region and the second region.

[0034] In order to obtain a design with a high quality texture that has a sense of realism and luxury, the resin layer corresponding to the first region preferably has a release layer, as described below, on the substrate side, and preferably has a primer layer and a release layer, as described below, in that order, on the substrate side. The resin layer corresponding to the second region preferably has a primer layer (described later) on the substrate side (described later) in order to obtain a design with a high texture having a realistic and luxurious feel.

[0035] The area of ​​the first region (S1) and the area of ​​the second region (S2) on at least one of the outermost surfaces of the decorative board can be appropriately adjusted according to the desired design. In order to obtain a design with a high texture that has a realistic and luxurious feel, the total ratio of S1 and S2 to the outermost surface is preferably 80% or more, more preferably 90% or more, and further preferably, the outermost surface is substantially composed of only the first region and the second region.

[0036] The area ratio value [(S1) / (S2)] of the area of ​​the first region (S1) and the area of ​​the second region (S2) can be appropriately adjusted depending on the desired design, but is preferably 10 / 90 or more and 90 / 10 or less, more preferably 20 / 80 or more and 80 / 20 or less, and even more preferably 30 / 70 or more and 70 / 30 or less.

[0037] (first area) The first region preferably has a release layer on the outermost surface of the resin layer. The release layer makes it easy to peel off and remove the releasable support described below, and also makes it difficult for the uncured thermosetting resin impregnated in the substrate (1) described below to seep into the first region. As a result, the first region has a different resin composition from the second region described below, and the n1 <n2とすることができる。

[0038] (Release layer) The release layer in the decorative board of the present invention preferably contains a cured product of an ionizing radiation curable resin composition containing a reactive silicone. By containing the reactive silicone, the uncured thermosetting resin impregnated in the substrate (1) is less likely to penetrate into the release layer in the first region, so that a decorative board having a high-quality design with a realistic and luxurious feel can be obtained by a simple manufacturing method.

[0039] The ionizing radiation curable resin composition is a resin composition that is crosslinked and cured by irradiation with ionizing radiation. The ionizing radiation curable resin composition contains a compound having an ionizing radiation curable functional group. Here, the ionizing radiation curable functional group is a group that is crosslinked and cured by irradiation with ionizing radiation, and preferred examples thereof include functional groups having an ethylenic double bond such as a (meth)acryloyl group, a vinyl group, and an allyl group. In addition, the ionizing radiation means an electromagnetic wave or a charged particle beam that has an energy quantum capable of polymerizing or crosslinking molecules, and usually ultraviolet rays (UV) or an electron beam (EB) are used, but also includes electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

[0040] Specifically, the ionizing radiation curable resin can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation curable resins. As the ionizing radiation curable resin, it is preferable to use an ionizing radiation curable resin containing reactive silicone. In addition, it is more preferable to use, as the ionizing radiation curable resin, a combination of an ionizing radiation curable resin containing reactive silicone and an ionizing radiation curable resin containing reactive silicone.

[0041] As the polymerizable monomer, a (meth)acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferable, and among them, a polyfunctional (meth)acrylate monomer is preferable. Here, "(meth)acrylate" means "acrylate or methacrylate". Examples of polyfunctional (meth)acrylate monomers include (meth)acrylate monomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the functional group. From the viewpoint of obtaining a design with a higher texture and better surface properties, acrylate monomers having an acryloyl group are preferred.

[0042] From the viewpoint of obtaining a design with a higher quality texture and more excellent surface properties, the number of functional groups is preferably 2 or more, and the upper limit is preferably 8 or less, more preferably 6 or less, even more preferably 4 or less, and particularly preferably 3 or less. These polyfunctional (meth)acrylates may be used alone or in combination of two or more kinds.

[0043] Preferred examples of such polymerizable monomers include bifunctional (meth)acrylates such as ethylene glycol di(meth)acrylate, bisphenol A tetraethoxy diacrylate, bisphenol A tetrapropoxy diacrylate, and 1,6-hexanediol diacrylate; and trifunctional or higher (meth)acrylates such as trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and isocyanuric acid-modified tri(meth)acrylate. Among these, from the viewpoint of obtaining a design with a higher quality texture and more excellent surface characteristics, dipentaerythritol-based polymerizable monomers such as dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate are preferred, dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate are more preferred, and it is particularly preferred to use dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate in combination.

[0044] Examples of the polymerizable oligomer include (meth)acrylate oligomers having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth)acryloyl group as the functional group. Examples of the polymerizable oligomer include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, acrylic (meth)acrylate oligomers, polycaprolactone urethane (meth)acrylate oligomers, polycaprolactone diol urethane (meth)acrylates, etc.

[0045] In order to obtain a design with a higher quality texture and better surface properties, the number of functional groups of these polymerizable oligomers is preferably 2 or more, and the upper limit is preferably 8 or less, more preferably 6 or less, even more preferably 4 or less, and particularly preferably 3 or less.

[0046] From the viewpoint of obtaining a design with a higher texture and better surface properties, and taking into consideration ease of forming the second cured product layer, the weight average molecular weight of these polymerizable oligomers is preferably 500 or more, more preferably 1,000 or more, and the upper limit is preferably 80,000 or less, more preferably 50,000 or less. In this specification, the weight average molecular weight is the average molecular weight measured by GPC analysis and converted into standard polystyrene.

[0047] The reactive silicone may be one having a polysiloxane structure as a basic structure, and further having at least one reactive functional group, which is preferably an ionizing radiation-curable functional group. The reactive silicone is preferably a modified silicone oil having an organic group introduced at least in one of its side chain and terminal, and more preferably a modified silicone oil having an organic group introduced at both terminals. From the viewpoint of obtaining a design with a higher texture, the organic group is preferably a reactive functional group such as a (meth)acrylic group, an amino group, an epoxy group, a mercapto group, a carbinol group, a phenol group, or a carboxyl group, or a non-reactive functional group such as a polyether group, an aralkyl group, a fluoroalkyl group, an alkyl group, a fatty acid amide group, or a phenyl group. Among them, a reactive functional group is preferred, and a (meth)acrylic group is particularly preferred, that is, a (meth)acrylic modified silicone oil is particularly preferred. In addition, these organic groups may have a substituent such as a nitrogen atom, a sulfur atom, a hydroxyl group, or an alkyl group.

[0048] The content of the reactive silicone is preferably 0.1 to 5 mass %, more preferably 0.5 to 3 mass %, and even more preferably 0.8 to 2 mass %, based on the total amount of the resin components forming the release layer. When the content of the reactive silicone is within the above range, the effect of adding the reactive silicone can be efficiently obtained.

[0049] When the ionizing radiation curable resin composition is of an ultraviolet ray curable type, the ionizing radiation curable resin composition preferably contains a photopolymerization initiator.

[0050] The release layer preferably contains an inorganic filler. By containing an inorganic filler, a visual difference in brightness is created, and therefore a design with a higher quality texture can be obtained. Examples of inorganic fillers include particles made of inorganic materials such as oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide, zinc oxide, and zirconia oxide, hydroxides such as aluminum hydroxide, magnesium hydroxide, and calcium hydroxide, carbonates such as magnesium carbonate and calcium carbonate, sulfates such as calcium sulfate and barium sulfate, and silicates such as magnesium silicate, aluminum silicate, calcium silicate, and aluminosilicate. Among these, oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide, and zinc oxide are preferred, and silica is particularly preferred.

[0051] From the viewpoint of obtaining a design with a higher texture, the average particle size of the inorganic filler is preferably 0.3 μm or more and 20 μm or less, more preferably 0.5 μm or more and 10 μm or less. In this specification, the average particle size of the filler is a value measured by a laser diffraction scattering method.

[0052] These inorganic fillers are preferably surface-treated. Examples of surface treatment agents for surface-treating the inorganic fillers include alkoxysilanes, and silane coupling agents having reactive groups such as (meth)acryloyloxy groups, epoxy groups, vinyl groups, styryl groups, amino groups, isocyanate groups, ureido groups, sulfide groups, and mercapto groups. From the viewpoint of obtaining a design with a higher texture, silane coupling agents having (meth)acryloyloxy groups, epoxy groups, vinyl groups, and amino groups, that is, (meth)acryloyloxy-based silane coupling agents, epoxy-based silane coupling agents, vinyl-based silane coupling agents, and amino-based silane coupling agents are preferred. These surface treatment agents may be used alone or in combination.

[0053] Preferred examples of the alkoxysilane include trialkoxysilanes such as methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, hexyltrimethoxysilane, hexyltriethoxysilane, octyltrimethoxysilane, decyltrimethoxysilane, and dodecyltrimethoxysilane. Preferred examples of the (meth)acryloyloxy-based silane coupling agent include 3-(meth)acryloyloxypropylmethyldimethoxysilane, 3-(meth)acryloyloxypropyltrimethoxysilane, 3-(meth)acryloyloxypropylmethyldiethoxysilane, and 3-(meth)acryloyloxypropyltriethoxysilane. Preferred examples of the epoxy-based silane coupling agent include diethoxy(glycidyloxypropyl)methylsilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, and 3-glycidoxypropyltriethoxysilane. Preferred examples of the vinyl silane coupling agent include vinyltrimethoxysilane and vinyltriethoxysilane. Preferred examples of the amino silane coupling agent include N-2(aminoethyl)3-aminopropylmethyldimethoxysilane, N-2(aminoethyl)3-aminopropyltrimethoxysilane, N-2(aminoethyl)3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N-(1,3-dimethyl-butylidene)propylamine, and N-phenyl-3-aminopropyltrimethoxysilane.

[0054] Among the above, from the viewpoint of obtaining a design with a higher quality of texture, the inorganic filler is preferably a surface-treated silica particle obtained by surface-treating silica particles with a silane coupling agent. It has a high affinity with the silicone-based release agent preferably used in the release layer, and the synergistic effect between the reactive silicone and the inorganic filler can provide an especially excellent effect of improving the design with a high quality of texture.

[0055] The content of the inorganic filler is preferably 1 to 50 parts by mass, more preferably 10 to 40 parts by mass, and even more preferably 20 to 35 parts by mass, based on 100 parts by mass of the resin component forming the release layer. When the content of the inorganic filler is within the above range, the effect of adding the inorganic filler can be efficiently obtained.

[0056] The release layer further includes an uncured resin composition containing weathering agents such as ultraviolet absorbers and light stabilizers, and various additives as desired, such as ultraviolet blockers, polymerization inhibitors, crosslinking agents, infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixotropic agents, coupling agents, plasticizers, defoaming agents, antiblocking agents, lubricants, solvents, and other various additives. These weathering agents and other additives may be used alone or in combination of multiple types.

[0057] As the ultraviolet absorber, an ultraviolet absorber commonly used in decorative panels can be used without particular limitation, such as benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, triazine-based ultraviolet absorbers, hydroxyphenyltriazine-based ultraviolet absorbers, and the like. As the light stabilizer, an ultraviolet absorber commonly used in decorative panels can also be used without particular limitation, such as hindered amine-based light stabilizers such as piperidinyl sebacate-based light stabilizers. From the viewpoint of improving the strength of the first cured layer, these weathering agents may have a reactive functional group having an ethylenic double bond such as a (meth)acryloyl group, vinyl group, allyl group, etc. in the molecule.

[0058] The thickness of the release layer is not particularly limited as long as the difference in elevation between the elevation of the first region and the elevation of the second region can be 1 μm or less, and is usually about 0.1 to 20 μm. From the viewpoint of more easily obtaining a highly textured design property, it is preferably 0.5 to 10 μm, more preferably 1 to 5 μm.

[0059] (Second region) It is preferable that the second region has a primer layer on the outermost surface of the resin layer. Due to the primer layer, the uncured thermosetting resin impregnated in the base material (1) described later will penetrate into the second region. As a result, the second region will have a resin composition different from that of the first region, and it is preferable that n1 < n2 as described above.

[0060] (Primer layer) In the decorative board of the present invention, the primer layer has the role of adjusting the refractive index, and is also preferable for improving the adhesion of each layer as described later. In the first region 21, the primer layer 12 may have the primer layer 12 and the release layer 11 in this order from the side of the base material 16 as shown in FIG. 6 to be described later. Thereby, it is preferable because the adhesion of the decorative layer (1) 13 to be described later is increased by the release layer 11.

[0061] Examples of the resin material for forming the primer layer include urethane resin, polyester resin, acrylic resin, acrylic urethane resin, vinyl chloride-vinyl acetate copolymer resin, and the like. Further, from the viewpoint of efficiently obtaining excellent adhesion, the thickness of the primer layer is usually about 0.1 μm to 15 μm, preferably 0.3 μm to 10 μm, and more preferably 0.5 μm to 5 μm.

[0062] As described above, due to the relationship of n1 < n2, although the physical height difference between the two regions is substantially 0, the second region reflects more external light compared to the first region. Therefore, the first region appears relatively dark visually, expressing the appearance of a concave portion, and the second region appears relatively bright visually, expressing the appearance of a convex portion. Without creating unevenness on the surface of the decorative board like embossing as in Patent Document 1 described above, the decorative board of the present invention can express the design of the visual appearance of the surface uneven shape.

[0063] In the decorative board of the present invention, the pattern exhibited by the first region is not particularly limited, but examples thereof include a wood grain vessel pattern, a concave pattern on the surface of a marble board (for example, a concave portion of a travertine marble pattern), a stone grain pattern imitating the surface of a rock such as the cleavage surface of a granite board, a concave portion of a fabric pattern (texture) imitating a cloth grain or a cloth-like pattern, a wrinkled concave portion of a leather pattern expressing leather grain, a tiled pattern or a brick masonry pattern, a concave portion of a hairline, a concave portion of a multi-line groove, a concave portion of a matte finish, a concave portion of a sand grain, and also concave portions of letters, symbols, geometric patterns, etc., and patterns such as parquet and patchwork that combine these. In addition, examples of patterns that combine these include concave portions in a pattern such as an artificial stone made by mixing crushed stone such as marble with white cement, solidifying it, and polishing it to look like marble, i.e., a so-called artificial marble.

[0064] The width of the first region is not particularly limited and may be appropriately determined according to the desired design, with the average value being about 0.1 to 10 mm, and in particular when a wood grain vessel pattern is adopted, the average value is preferably 0.05 to 2 mm, more preferably 0.1 to 1 mm, from the viewpoint of obtaining a design with a higher texture. The average value of the width of the first region is the average value of the maximum width measured at any 10 points of the first region.

[0065] The length of the first region is not particularly limited and may be appropriately determined according to the desired design, with the average length being about 1 to 300 mm, and in particular when a wood grain vessel pattern is adopted, the average length is preferably 2 to 50 mm, more preferably 3 to 45 mm, from the viewpoint of obtaining a design with a higher texture. The average length of the first region is the average value of the measured lengths of the first region at any 10 points.

[0066] The arithmetic surface roughness Ra of the outermost surface of the first region and the second region is not particularly limited, but is preferably 0.2 to 0.6 μm, more preferably 0.3 to 0.5 μm, in consideration of the fact that the shape of the recesses is visually recognized as being more concave and that a design with a higher texture is more likely to be obtained. In this specification, the arithmetic surface roughness Ra is the arithmetic average roughness according to JIS B0601:2013 when the cutoff value is set to 0.8 mm, and is calculated by measuring the arithmetic surface roughness Ra at any ten points on the outermost surface and averaging the results.

[0067] <Decorative layer> The decorative board of the present invention preferably has a decorative layer between the substrate and the resin layer in order to express a design with a higher texture and to accommodate a variety of designs. The decorative layer may be, for example, a colored layer that covers the entire surface (so-called solid colored layer), a patterned layer formed with various patterns, or a combination of these. For example, when the background color of the substrate or the like is to be colored and concealed, a solid colored layer can be used to obtain a design with a higher texture while concealing the color, and from the viewpoint of expressing a variety of designs, a solid colored layer and a patterned layer may be combined. On the other hand, when the background pattern of the adherend is to be utilized, only a patterned layer may be provided without using a solid colored layer. The decorative layer is preferably provided between the substrate and the resin layer.

[0068] When the decorative layer has a pattern layer, the patterns exhibited by the decorative layer include the patterns exemplified by the patterns exhibited by the first region, such as wood grain vascular patterns, marble patterns (e.g., travertine marble patterns), stone patterns imitating the surface of rocks such as the cleavage surface of a granite slab, fabric patterns imitating cloth grain or cloth-like patterns, leather patterns expressing leather grain, tile patterns, brickwork patterns, hairlines, linear grooves, pear-textured surfaces, sand grain, letters, symbols, geometric patterns, patterns such as inlay and patchwork that combine these, and other patterns such as the artificial marble mentioned above.

[0069] Among these patterns, the wood grain vascular pattern is preferred, considering the characteristics of the decorative board of the present invention, which has a high-quality design. When adopting a wood grain vascular pattern, if a second pattern area is set to match the pattern of the decorative layer, more specifically, a region that matches the darker vascular groove portion in the wood grain vascular pattern of the decorative layer, and a first area is provided directly above it, the vascular groove portion will be visually perceived as darker because it coincides with the first area, and therefore, although the elevation difference between the two areas is essentially zero and the surface of the decorative board is essentially flat, the vascular groove portion will be visually perceived as a recess. As a result, a high-quality design with a high-quality feel and a more realistic wood grain vascular pattern can be obtained while maintaining the stain resistance of the surface.

[0070] For example, in the decorative board 3 shown in Fig. 6, there is a first region 21 in harmony with the pattern of the decorative layer (1) 13, and a primer layer 12 and a release layer 11 are provided in this order directly on the decorative layer (1) 13. In addition, there is a second region 22 in harmony with the pattern of the decorative layer (2), and the primer layer 12 is provided directly on the decorative layer (2) 14. With this configuration, the pattern of the decorative layer has excellent stain resistance because the physical elevation difference is substantially zero due to the difference in refractive index between the first and second regions, and also visually expresses an uneven design appearance. In particular, by harmonizing the decorative layer with the first and second regions, a realistic feel close to that of a real wooden board and a luxurious feel can be obtained, resulting in a decorative board with a high-quality design.

[0071] The thickness of the decorative layer may be appropriately selected depending on the desired pattern, but from the viewpoint of coloring and concealing the background color of the substrate, etc., and obtaining a design with a higher texture, the thickness is preferably 0.5 to 20 μm, more preferably 1 μm to 10 μm, and even more preferably 2 to 5 μm.

[0072] <Base material> The substrate used in the decorative board of the present invention is impregnated with an uncured thermosetting resin as described below. The substrate serves to support the release layer, the primer layer and the decorative layer which is preferably provided. The substrate is not particularly limited and may be appropriately selected depending on the desired performance. From the viewpoint of ease of handling, preferred substrates include paper substrates, fiber substrates, resin substrates, etc. From the viewpoint of obtaining a decorative board having superior mechanical properties, etc., a paper substrate or fiber substrate having liquid permeability is more preferred, and a paper substrate is even more preferred.

[0073] Examples of the paper substrate include kraft paper, titanium paper, linter paper, resin-impregnated paper, tissue paper, Japanese paper, etc. Examples of the fiber substrate include nonwoven fabrics and woven fabrics, and examples of the fiber substrate include fiber substrates made of inorganic fibers such as glass fibers, alumina fibers, silica fibers, and carbon fibers, fiber substrates made of organic fibers of various synthetic resins such as polyester resins, acrylic resins, polyethylene resins, and polypropylene resins, and substrates such as composites of these.

[0074] The thickness of the substrate is not particularly limited and may be appropriately selected depending on the desired performance. From the viewpoints of holding the necessary amount of uncured thermosetting resin, ensuring mechanical properties, and ease of handling, the thickness is usually about 10 to 200 μm, preferably 20 to 150 μm, and more preferably 30 to 120 μm. When a paper substrate is used as the substrate, the basis weight is usually 20 to 150 g / m2 from the same viewpoint. 2 Approximately 30 to 100 g / m 2 It is.

[0075] A preferred embodiment of the decorative board of the present invention is a thermosetting resin decorative board obtained by using a paper or fiber substrate impregnated with a liquid uncured thermosetting resin as the substrate and subjecting the substrate to pressure molding or hot pressure molding. The thermosetting resin must be capable of being soaked into the primer layer, and is preferably a resin capable of being integrated with the curable resin forming the primer layer. With this configuration, a refractive index difference occurs between the first region and the second region of the decorative board of the present invention, and high designability is achieved while improving mechanical strength.

[0076] As the curable resin to be impregnated into the base material, from the viewpoint of obtaining a more textured design property of the decorative board of the present invention and improving the mechanical strength, for example, melamine resin, urea resin, melamine-urea resin, guanamine resin, diallyl phthalate resin, polyester resin, phenol resin, epoxy resin, amino alkyd resin, silicone resin, polysiloxane resin, etc. are preferably mentioned. Thermosetting resins such as melamine resin, urea resin, melamine-urea resin, guanamine resin, and sulfonamide resin are preferred. Among them, melamine resin, melamine-urea resin, and phenol resin are preferred, and particularly melamine resin is preferred.

[0077] When using melamine resin as the curable resin, since the uncured product of the melamine resin hardly penetrates into the outermost peeling layer of the first region, and the uncured product of the melamine resin easily penetrates into the outermost primer layer of the second region, there is a difference in the content of the components derived from the uncured product of the melamine resin between the first region and the second region. This difference in content causes a difference in refractive index between the two regions.

[0078] The difference in the content of the components derived from the uncured product of this melamine resin can be evaluated by the content of the triazine residue present in the skeleton of the melamine resin. The content of the triazine residue (TA1) in the first region and the content of the triazine residue (TA2) in the second region preferably satisfy the relationship of TA1 < TA2.

[0079] It is preferable that the contact angle of water (θ1) in the first region and the contact angle of water (θ2) in the second region on at least one outermost surface of the decorative board satisfy the relationship of θ1 > θ2. Since the outermost surface of the second region is a peeling layer and is preferably a cured product containing reactive silicone, it is preferable that the contact angle with water is smaller than that of the first region, and it is preferable to satisfy the relationship of θ1 > θ2. For improving the design property, θ2 - θ1 is preferably 10 degrees or more and 70 degrees or less.

[0080] The substrate may be subjected to a surface treatment such as a physical surface treatment, such as an oxidation method or a roughening method, or a chemical surface treatment on one or both sides thereof in order to improve interlayer adhesion between the substrate and other layers, strengthen adhesion to various adherends, etc. Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone-ultraviolet light treatment, etc., and examples of the roughening method include sandblasting, solvent treatment, etc. These surface treatments are appropriately selected depending on the type of substrate, but generally, corona discharge treatment is preferably used in terms of the effect of the surface treatment, operability, etc. In order to improve interlayer adhesion between the substrate and other layers and to strengthen adhesion to various adherends, the substrate may be subjected to treatment such as forming a primer layer or a back primer layer.

[0081] <Core layer> The core layer is a layer that reinforces the decorative board of the present invention, and is a layer that is provided as desired on the opposite side of the base material from the resin layer. The core layer can be made of various materials and materials that compose various layers depending on the type and use of the decorative board, but in particular, when the decorative board is a thermosetting resin decorative board, the core layer is preferably formed from a thermosetting resin-impregnated sheet. When a fiber base material or paper base material impregnated with a thermosetting resin is used as the base material, a thermosetting resin decorative board with better mechanical properties can be obtained by combining it with a core layer formed from a thermosetting resin-impregnated sheet.

[0082] Examples of the core layer include a fiber substrate impregnated with an uncured resin composition containing a liquid uncured product of a thermosetting resin, a paper substrate, etc. The type of fiber substrate and paper substrate used in the core layer is not particularly limited as long as it is one of the fiber substrates and paper substrates exemplified in the base material, and the basis weight is preferably 100 to 300 g / m 2 , more preferably 150 to 250 g / m 2In addition, the thermosetting resin may preferably be the same as the thermosetting resin exemplified as the thermosetting resin that can be impregnated into the above-mentioned substrate in the form of a liquid uncured resin composition, and the liquid uncured resin composition of the above-mentioned various thermosetting resins is also preferable. Among these thermosetting resins, phenolic resin is preferable, and as the core layer, phenolic resin-impregnated paper, which is widely used as core paper for melamine resin decorative boards, etc., is preferable.

[0083] The phenol resin-impregnated paper has a basis weight of 150 to 250 g / m 2 The one produced by impregnating the kraft paper with a phenol resin to an impregnation rate of about 20 to 60% and drying at about 100 to 140° C. is preferably used.

[0084] <Layer configuration> The configuration of the decorative board of the present invention will be described below with reference to Figures 1 and 6. Figure 1 is a schematic perspective view showing the appearance of a decorative board 3 of the present invention. The decorative board 3 of the present invention has a first region 21 and a second region 22 on its outermost surface. FIG. 6 is a schematic diagram showing a layer structure in a cross-sectional view of one example of the decorative board of the present invention.

[0085] The first region 21 comprises, in this order from the outermost surface 5, a release layer 11, an optional primer layer 12, an optional decorative layer (1) 13, a substrate 16, and an optional core layer 18. The second region 22 includes, from the outermost surface 5, a primer layer 12, an optional decorative layer (2) 14, a substrate 16, and an optional core layer 18 in this order.

[0086] (Use of decorative panels) The decorative board of the present invention is a decorative board with a high-quality design that has excellent stain resistance and at the same time has a realistic and luxurious feel. Therefore, the decorative board of the present invention can be used for various purposes as it is or after a predetermined molding process. For example, it can be laminated on a substrate such as a flat plate, a curved plate, or a sheet (or film) made of various materials and used as an interior and exterior building material, for example, cabinets for furniture and kitchen products, top plates used for various counters and desks, and building materials for homes such as doors.

[0087] Examples of the substrate include wood members used as plate materials and three-dimensional articles, such as wood veneers made of various types of wood such as cedar, cypress, pine, and lauan, wood plywood, particle boards, and wood fiberboards such as MDF (medium density fiberboard); metal members used as plate materials and steel plates, three-dimensional articles, and sheets, such as iron and aluminum; ceramic members used as plate materials and three-dimensional articles, such as glass, ceramics such as porcelain, non-cement ceramic materials such as gypsum, and non-ceramic ceramic materials such as ALC (aerated lightweight concrete) boards; and resin members used as plate materials, three-dimensional articles, and sheets, such as acrylic resins, polyester resins, polystyrene resins, polypropylene and other polyolefin resins, ABS (acrylonitrile-butadiene-styrene copolymer) resins, phenolic resins, vinyl chloride resins, cellulose resins, and rubber. These members can be used alone or in combination of two or more types.

[0088] (Manufacturing method of decorative panels) The method for producing the decorative board of the present invention will be described with reference to FIGS.

[0089] The method for producing a decorative board of the present invention must include the following steps (1) to (5). (1) A step of forming a release layer on a portion of one side of a releasable support, and forming a primer layer on at least a portion of the side of the releasable support on which the release layer is formed but which does not have the release layer, to obtain sheet (1). (2) A step of obtaining a laminate (A) by laminating a substrate (1) impregnated with an uncured thermosetting resin on the release layer side of the sheet (1).

[0090] (3) A process of sandwiching both sides of the laminate (A) between mirror-finished plates and hot pressing the laminate (A) to cause a portion of the uncured thermosetting resin to soak into the primer layer of the transfer sheet and to cure the uncured thermosetting resin. (4) A step of removing the laminate (A) from between the mirror plates. (5) A process for peeling and removing the releasable support from the laminate (A) to obtain a decorative board having a first region having the release layer within its plane and a second region not having the release layer within its plane.

[0091] <Releasable Support Including Releasable Support Substrate> The releasable support 4 shown in FIG. 2 is required to include the releasable support 2 in order to obtain a design with a higher texture. The releasable support 2 preferably includes a releasable support substrate 15. Examples of the releasable support substrate 15 include sheets of various resins such as polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyolefin resins such as polyethylene and polypropylene, and acrylic resins.

[0092] The thickness of the releasable support 4 is usually about 20 to 200 μm, and preferably 30 to 100 μm, in order to obtain excellent mechanical strength.

[0093] The releasable support 2 including the releasable support substrate 15 may further have a release layer 17 as shown in FIG. <Release layer> The release layer preferably contains a release agent together with the curable resin. By containing a release agent, it is preferable because the release support can be easily peeled off and removed from the decorative plate. This makes it difficult for unevenness to occur on the outermost surface of the resin layer formed by peeling, and the elevation difference between the first region and the second region described below can be reduced, resulting in a design with a higher texture.

[0094] Examples of the release agent include fluorine-based release agents and silicone-based release agents. From the viewpoint of obtaining a design with a higher quality texture, silicone-based release agents are preferred. As the silicone-based release agent, the same reactive silicone as that used in the release layer can be used.

[0095] The content of the release agent is preferably 0.1 to 5 parts by mass, more preferably 0.5 to 3 parts by mass, and even more preferably 1 to 2 parts by mass, based on 100 parts by mass of the curable resin forming the release layer. When the content of the release agent is within the above range, the effect of adding the release agent can be efficiently obtained. The release layer may be an uncured resin composition containing various additives such as inorganic fillers, ultraviolet absorbers, light stabilizers, and other desired additives, for example, ultraviolet shielding agents, polymerization inhibitors, crosslinking agents, infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixotropy imparting agents, coupling agents, plasticizers, defoamers, antiblocking agents, lubricants, and solvents, as in the case of the release layer. These weather resistance agents and other additives may be used alone or in combination of two or more kinds.

[0096] The thickness of the release layer is not particularly limited as long as it is thick enough to exhibit the above-mentioned functions, and is usually about 0.1 to 20 μm. From the viewpoint of more easily obtaining a design with a high texture, the thickness is preferably 0.5 to 10 μm, and more preferably 1 to 5 μm.

[0097] <(1) Process> 2, in step (1), an ink used for forming a release layer is applied to a releasable support 2 to form a desired release layer 11. When the releasable support 2 includes the releasable support substrate 15, it is preferable to form the release layer 11 on the releasable support substrate 15. The ink used to form the release layer is applied by a known method such as gravure printing, bar coating, roll coating, reverse roll coating or comma coating, preferably by gravure printing.

[0098] The ink used to form the release layer preferably contains an ionizing radiation curable resin composition containing reactive silicone and a solvent. There are no particular limitations on the solvent as long as it dissolves the solute and does not interfere with application. As the solvent, ketones such as methyl ethyl ketone and acetone; ester solvents such as methyl acetate, ethyl acetate and butyl acetate; ether solvents such as diethyl ether, tetrahydrofuran and 1,4-dioxane; and alcohol solvents such as methanol, ethanol and propanol can be used alone or in combination.

[0099] The uncured resin layer formed by coating the ink may be irradiated with ionizing radiation such as electron beams or ultraviolet rays to form a cured product. When electron beams are used as the ionizing radiation, the accelerating voltage can be appropriately selected depending on the resin used and the thickness of the layer, but it is usually preferable to cure the uncured resin layer at an accelerating voltage of about 70 to 300 kV. The exposure dose is preferably an amount at which the crosslink density of the ionizing radiation curable resin is saturated, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad).

[0100] The electron beam source is not particularly limited, and various electron beam accelerators such as Cockcroft-Walton type, Van de Graff type, resonant transformer type, insulating core transformer type, linear type, dynamitron type, high frequency type, etc. can be used. When ultraviolet light is used as the ionizing radiation, ultraviolet light having a wavelength of 190 to 380 nm is emitted. There are no particular limitations on the source of ultraviolet light, and examples of the source include high-pressure mercury lamps, low-pressure mercury lamps, metal halide lamps, and carbon arc lamps.

[0101] Furthermore, in the step (1), a primer layer must be formed on the side of the releasable support on which the peeling layer is formed, at least on the portion not having the peeling layer. As shown in FIG. 2, the primer layer 12 may not be formed on the peeling layer 11, and as shown in FIG. 3, the primer layer 12 may also be formed on the peeling layer 11. In the decorative layer forming step described later, it is easier to form the decorative layer by forming the decorative layer on the primer layer and then on the primer layer, rather than forming the decorative layer directly on the peeling layer. For this reason, it is preferable to form a primer layer on the peeling layer as well.

[0102] The primer layer can be formed in the same manner, except that a resin material for forming the primer layer is used instead of the ink used for forming the release layer. This makes it possible to obtain a sheet (1) 4 in which a release layer and a primer layer are formed on a release support, as shown in Figures 2 and 3.

[0103] <(2) Process> In the step (2), a substrate 16 impregnated with the uncured thermosetting resin is laminated on the release layer side of the sheet (1) 4 shown in FIG. 2 to obtain a laminate (A). In order to impregnate a substrate having liquid permeability, the above-mentioned uncured thermosetting resin composition in a liquid state is prepared, and the above-mentioned uncured thermosetting resin composition is impregnated into the substrate. The impregnated uncured thermosetting resin composition is heated at an appropriate time to be cured by a reaction such as a crosslinking reaction or a polymerization reaction, thereby becoming a cured product of the thermosetting resin. The substrate (1) may be a substrate formed on the core layer.

[0104] <(3) Process> In step (3), both sides of the laminate (A) are sandwiched between mirror plates and then heat-pressed, thereby causing a portion of the uncured thermosetting resin to soak into the primer layer of the transfer sheet and curing the uncured thermosetting resin.

[0105] The pressure of the heat press is 10kg / cm 2 More than 300kg / cm2 It is preferably 50 kg / cm 2 or more and more preferably 200 kg / cm 2 or less, still more preferably 80 kg / cm 2 or more and most preferably 150 kg / cm 2 or less. By performing hot pressing within this range, the uncured thermosetting resin penetrates into the primer layer, and the penetration of the uncured thermosetting resin into the release layer is suppressed, so that a decorative board satisfying the relationship of n1 < n2 can be obtained, which is preferable.

[0106] For obtaining excellent mechanical strength, the molding temperature is preferably 10°C or more and 300°C or less, more preferably 80°C or more and 200°C or less, and still more preferably 100°C or more and 180°C or less. The hot pressing time can be appropriately adjusted according to the thickness of the laminate (A) and the type of the uncured thermosetting resin. For obtaining excellent mechanical strength, it is preferably 1 minute or more and 60 minutes or less, more preferably 5 minutes or more and 30 minutes or less, and still more preferably 8 minutes or more and 20 minutes or less.

[0107] <(4) Process> In the process of (4), the laminate (A) is taken out from between the mirror finish plates.

[0108] <(5) Process> In the process of (5), the release support is peeled off and removed from the laminate (A) to obtain a decorative board having a first region with the release layer in the plane and a second region without the release layer in the plane. As shown in FIG. 5, the release support 2 which is a part of the sheet (1) 4 is peeled off and removed from the laminate (A) (illustrated by an arrow), thereby obtaining the decorative board 3. Thereby, the outermost surfaces of the first region and the second region are formed.

[0109] <Process of forming a decorative layer> After forming the primer layer in the process of (1), a process of further forming a decorative layer may be included. The decorative layer is formed by applying the ink used for forming the decorative layer onto the release layer and the primer layer or onto the primer layer to provide a desired color layer and a pattern layer. The ink is applied by a known method such as gravure printing, bar coating, roll coating, reverse roll coating, comma coating, etc., preferably gravure printing.

[0110] When the decorative layer has a wood grain vascular pattern, the vascular groove portion of the pattern of the decorative layer is designated as the first region, and the region other than the first region is designated as the second region, so that the vascular groove portion appears visually darker, and the decorative board of the present invention has a more realistic feel closer to real wood board and a luxurious feel, resulting in a decorative board with a high-quality design.

[0111] As a method for applying the ink for the decorative layer, any of the known methods exemplified above may be used. The method for curing the ink of the decorative layer may be selected according to the type of curable resin contained in the ink of the decorative layer. For example, when the uncured resin composition is a resin composition containing a liquid uncured thermosetting resin, the ink may be cured by carrying out a heat treatment according to the thermosetting resin used.

[0112] In the decorative board obtained by the method for producing a decorative board of the present invention, it is preferable that the elevation of the first region and the elevation of the second region are substantially the same on the surface having the first region and the second region, because this improves the antifouling properties. Here, "visually the elevation of the first region and the elevation of the second region are substantially the same" preferably means that the difference between the elevation of the first region and the elevation of the second region is 1 μm or less. The elevation of the first region and the elevation of the second region are as described above. EXAMPLES

[0113] The present invention will now be described in more detail with reference to examples, but the present invention is not limited to these examples in any way. (Evaluation and Observation Methods) (1) Evaluation of three-dimensional effect (design) The cosmetic materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting to determine whether or not they had a three-dimensional effect. The results are shown in Table 1.

[0114] A: More than 18 people answered that it has a highly three-dimensional design. B: 11 to 17 people answered that the design has a high three-dimensional feel. C: 6 to 10 people answered that the design has a high three-dimensional feel. D: Five or fewer people answered that the design had a high degree of three-dimensionality.

[0115] (2) Evaluation of stain resistance (marker erasability) A straight line was written on the surface of the decorative panel obtained in each example with a permanent marker (black), left for 5 minutes, then wiped dry, and the degree of the writing mark remaining on the surface of the decorative panel was visually evaluated according to the following criteria. A: No handwritten traces were found. B: Some traces of writing were found, but not to the extent that they would cause any practical problems. C: Handwriting was found.

[0116] (3) Measuring the difference between the elevation of the first area and the elevation of the second area. The first and second regions of the decorative board were identified, and the elevations of 10 points in each region of the cross section including the first and second regions were measured, and the average elevations were regarded as the elevations of each region. The difference in elevation between the first and second regions was calculated, and regarded as the difference between the elevation of the first region and the elevation of the second region.

[0117] (4) Measuring the refractive index (n1) of the resin contained in the surface of the first region and the refractive index (n2) of the resin contained in the surface of the second region The first and second regions of the decorative board were identified, and the refractive index of each region was measured by JIS K 7142:2014, Method B (Becke method by liquid immersion).

[0118] Example 1 (1) Preparation of ink for release layer An ink for the release layer was prepared by stirring 60 parts by mass of an ionizing radiation curable monomer (Aronix M400, manufactured by Toagosei Co., Ltd.), 0.9 parts by mass of a reactive silicone (X-22-164B, manufactured by Shin-Etsu Chemical Co., Ltd.), and 40 parts by mass of methyl ethyl ketone (Maruzen Petrochemical Co., Ltd.) at a rotation speed of 2000 rpm for 1 hour using a process homogenizer PH91 (manufactured by SMT Corporation).

[0119] (2) Preparation of releasable support A release layer-forming ink containing 100 parts by mass of an ionizing radiation curable monomer (ARONIX (registered trademark) M350 manufactured by Toagosei Co., Ltd.), 2 parts by mass of a reactive silicone (X-22-164B manufactured by Shin-Etsu Chemical Co., Ltd.), 8 parts by mass of silica (Silisia 450 manufactured by Fuji Silysia Chemical Ltd.), and 50 parts by mass of ethyl acetate was applied at a rate of 5 g / m to the entire surface of the easy-adhesion surface of a support (50 μm-thick PET film, Lumirror (registered trademark) S34 manufactured by Toray Industries, Inc.). 2 (when dried), and then irradiated with an electron beam of 5 Mrad at an acceleration voltage of 165 kV to cure, thereby preparing a releasable support having a release layer on the support.

[0120] (3) Preparation of transfer sheet On the releasable support obtained in (2), a pattern with a uniform width (30 μm) and length (50 mm) was printed by gravure printing using the ink for the release layer produced in (1), and the sheet was irradiated with an electron beam of 3 Mrad at an acceleration voltage of 165 kV to form a release layer, thereby obtaining sheet (1). The thickness of the release layer was 2 μm. Next, a primer layer made of acrylic urethane resin was printed on the top surface so that the film thickness when dried was 1 μm, and then a decorative layer with a wood grain pattern 3 μm thick was formed using a picture printing ink (Ode SPTI, manufactured by DIC Graphics Co., Ltd.) By forming a primer layer on the release layer as well, the adhesion of the picture layer was improved.

[0121] (4) Manufacture of decorative plates Base material (titanium paper base paper for building materials, product name "PM-67P" manufactured by KJ Specialty Paper Co., Ltd., basis weight: 80g / m 2, with a thickness of 100 μm, a liquid uncured composition of a thermosetting resin composed of 60 parts by mass of melamine formaldehyde resin, 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was impregnated using an impregnation device for impregnation so that the uncured composition was in a ratio of 80 g / m 2 (when dry), and dried to obtain a substrate impregnated with an uncured thermosetting resin.

[0122] On the substrate impregnated with this uncured thermosetting resin, two sheets of kraft paper impregnated with a resin solution composed of phenol resin, with a basis weight of 245 g / m 2 of phenol resin-impregnated core paper (manufactured by Ota Sangyo Co., Ltd., Ota Core) were laminated to create a laminate of the core layer and the substrate. On the substrate side of the laminate impregnated with the uncured thermosetting resin, the sheet (1) obtained in (3) was laminated so that the uncured thermosetting resin-impregnated substrate and the pattern layer were in contact, and laminate (A) was obtained.

[0123] The obtained laminate (A) was sandwiched between two mirror-finished plates and heat-molded under the conditions of a pressure of 100 kg / cm 2 at a molding temperature of 150 °C for 10 minutes to thermoset the uncured thermosetting resin composition to form a laminate (A) containing a melamine resin. Finally, a decorative board was manufactured by peeling and removing the release support from the laminate (A). Regarding the first region and the second region, it was confirmed that the relationship was n1 < n2 and TA1 < TA2. The above evaluation was performed on the obtained decorative board, and the results are shown in Table 1.

[0124] (Comparative Example 1) Referring to JP-A-2016-182808, a decorative board was manufactured. After printing a pattern layer on the base paper for titanium paper for building materials used in the production of the decorative board in (4) of Example 1 using pattern printing ink (manufactured by DIC Graphics Co., Ltd., Ode SPTI), in the preparation of the release layer ink in (1) of Example 1, a release layer ink adjusted was used to print a melamine resin and a pattern layer with releasability to form a decorative layer, and then, in the same manner as in Example 1, it was cured by electron beam irradiation to obtain laminate (C1). Next, (4) the liquid uncured composition of the thermosetting resin used in the production of the decorative plate was impregnated into the laminate (C1) using an impregnation device, and then dried to obtain a laminate (C1) impregnated with the uncured thermosetting resin.

[0125] The release support produced in Example 1 was laminated on the surface of the decorative layer side of this laminate (C1) so that the release layer and the decorative layer were in contact with each other, and the base paper side of the laminate (C1) was impregnated with a resin liquid made of phenol resin into kraft paper, with a basis weight of 245 g / m 2 The laminate (C2) was sandwiched between two mirror-finished plates and pressed with a heat press at a pressure of 100 kg / cm. 2 The uncured thermosetting resin composition was heat-cured by heating at a molding temperature of 150° C. for 10 minutes to form a laminate (C3) containing a melamine resin. Finally, the releasable support was peeled off and removed from the laminate (C3) together with the melamine resin and the releasable pattern layer of the decorative layer, thereby producing a decorative panel in which the melamine resin and the melamine resin directly above the releasable pattern layer were removed to form a recess. The obtained decorative panels were subjected to the above evaluations, and the results are shown in Table 1.

[0126] Comparative Example 2 In the preparation of the transfer sheet in Example 1 (3), the ink for the release layer prepared in (1) was replaced with A decorative board was produced in the same manner as in Example 1, except that the liquid uncured composition of thermosetting resin described in (4) Production of Decorative Board in Example 1 was used. The obtained decorative panels were subjected to the above evaluations, and the results are shown in Table 1.

[0127] [Table 1]

[0128] From the results of Example 1, the decorative board of the present invention was evaluated as a decorative board with a high-quality design that has a realistic feel and a luxurious feel, compared to the decorative boards of Comparative Examples 1 and 2, which were decorative boards obtained by manufacturing methods different from the present invention. Furthermore, when the second hardened product layer was provided in accordance with the vascular groove portion of the wood grain vascular pattern, the decorative board of Example 1 was evaluated as having excellent design. In addition, the stain resistance was also evaluated as excellent. [Explanation of symbols]

[0129] 1. Transfer sheet 2.Releasable support 3. Decorative panels 4. Seat (1) 5. Top surface 11. Release layer 12. Primer layer 13.Decorative layer (1) 14.Decorative layer (2) 15.Releasable support substrate 16. Impregnated substrate 17.Release layer 18. Core demographic 21.First area 22.Second area N.Normal direction

Claims

1. a resin layer on a substrate, the resin layer having a first region and a second region on a surface thereof, a difference between an elevation of the first region and an elevation of the second region being 1 μm or less, a refractive index (n1) of a resin contained in the surface of the first region and a refractive index (n2) of a resin contained in the surface of the second region satisfying a relationship of n1<n2; A decorative board, wherein the resin layer corresponding to the first region has a release layer from the substrate side, the release layer contains a cured product of an ionizing radiation curable resin composition containing a reactive silicone, and the thickness of the release layer is 0.1 μm or more and 2 μm or less.

2. The decorative board according to claim 1 , wherein at least one outermost surface of the decorative board includes the first region and the second region.

3. the resin layer corresponding to the second region has a primer layer on the substrate side, 3. The decorative board according to claim 1, wherein the primer layer contains any one of a urethane resin, a polyester resin, an acrylic resin, an acrylic urethane resin, and a vinyl chloride-vinyl acetate copolymer resin.

4. The decorative board according to any one of claims 1 to 3, wherein the resin layer corresponding to the first region has a primer layer and a release layer in this order from the substrate side, and the resin layer corresponding to the second region has a primer layer from the substrate side.

5. The decorative board according to any one of claims 1 to 4, further comprising a decorative layer between the substrate and the resin layer.

6. The decorative board according to any one of claims 1 to 5, further comprising a core layer on the side of the substrate opposite the resin layer.

7. The decorative board according to any one of claims 1 to 6, wherein the surface of the resin layer corresponding to the first region comprises a cured product of an ionizing radiation curable monomer containing a reactive silicone.

8. The decorative board according to any one of claims 1 to 7, wherein the content (TA1) of triazine residues in the first region and the content (TA2) of triazine residues in the second region satisfy the relationship TA1 < TA2.

9. The decorative board according to any one of claims 1 to 8, wherein the water contact angle (θ1) of the first region and the water contact angle (θ2) of the second region on at least one outermost surface of the decorative board satisfy the relationship θ1 > θ2.

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