Resin-impregnated decorative sheet

Abstract

To provide a resin-impregnated decorative sheet having excellent abrasion resistance while exhibiting an ornamental design feeling of a gloss / mat tone.SOLUTION: A resin-impregnated decorative sheet includes a porous base material 1, an ornamental design layer 2, a resin film layer 3, and a pattern layer 4 having a pattern shape and including a cured product of a curable resin X, in this order in a thickness direction. The porous base material contains a cured product of a curable resin Y.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a resin-impregnated decorative board.

Background Art

[0002] Conventionally, a resin-impregnated decorative board obtained by impregnating a porous substrate with a precursor (uncured resin) such as a melamine resin and then performing hot pressing to cure the precursor of the resin is known. Resin-impregnated decorative boards are used for wall surfaces, furniture, floor surfaces, etc. in houses, stores, public facilities, etc.

[0003] Melamine decorative boards expressing a design feeling of a gloss matte tone are known. For example, in Patent Document 1, a decorative board having a cured layer in a partial region of the surface of a porous substrate and having a thermosetting resin layer in the remaining region of the surface of the porous substrate that does not have the cured layer and in which the thermosetting resin is impregnated and cured in the porous substrate is disclosed. In the production of such a melamine decorative board, for example, a decorative sheet in which a cured layer (release layer) synchronized with a pattern is arranged on a part of the surface of titanium paper is used, and a step of impregnating a precursor (uncured resin) such as a melamine resin into the decorative sheet, a step of obtaining a melamine layer by thermosetting the uncured resin after arranging a release film on the uncured resin layer, and a peeling step of peeling the melamine layer in the region covering the cured layer by peeling the release film are performed.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] As described above, in the manufacturing process of a melamine decorative board expressing the conventional glossy matte design feeling, a peeling process of peeling a part of the melamine layer is performed. Therefore, it is difficult to use a method of laminating an overlay paper or the like on the design layer to improve the wear resistance, which is performed in the manufacture of conventional melamine decorative boards.

[0006] Further, in the peeling process, the melamine layer cracks between the region overlapping the release layer and the region not overlapping the release layer, so that the melamine layer in the region overlapping the release layer is partially peeled off. At this time, if the melamine layer is thick, the strength increases, it is difficult to crack, and the peelability decreases. Therefore, from the viewpoint of maintaining peelability, it is difficult to thicken the melamine layer. As a result, it is difficult to improve the wear resistance of a melamine decorative board expressing a glossy matte design feeling.

[0007] The present disclosure has been made in view of the above circumstances, and the main object thereof is to provide a resin-impregnated decorative board having excellent wear resistance while expressing a glossy matte design feeling.

Means for Solving the Problems

[0008] In the present disclosure, there is provided a resin-impregnated decorative board, which has, in this order in the thickness direction, a porous base material, a design layer, a resin film layer, and a pattern layer having a pattern shape and containing a cured product of a curable resin X, wherein the porous base material contains a cured product of a curable resin Y.

Effects of the Invention

[0009] In the present disclosure, there is an effect that a resin-impregnated decorative board having excellent wear resistance while expressing a glossy matte design feeling can be provided.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0011] Hereinafter, embodiments will be described with reference to the drawings and the like. However, the present disclosure can be implemented in many different modes and is not limited to the description content of the embodiments illustrated below. In addition, for the purpose of making the description clearer, the drawings may schematically represent the width, thickness, and shape of each part compared to the actual form, but this is merely an example and should not be construed restrictively.

[0012] In this specification, when expressing the manner of arranging one member on another member, if simply expressed as "on" or "under", unless otherwise specified, it includes both the case where another member is arranged directly above or directly below in contact with a certain member, and the case where another member is arranged above or below a certain member with yet another member interposed therebetween. Also, in this specification, when expressing the manner of arranging one member on the surface of another member, if simply expressed as "on the surface", unless otherwise specified, it includes both the case where another member is arranged directly above or directly below in contact with a certain member, and the case where another member is arranged above or below a certain member with yet another member interposed therebetween.

[0013] As described above, in the production of melamine decorative boards expressing the conventional gloss-matte design sense, it has been difficult to improve the abrasion resistance. The inventors of the present application focused on producing a melamine decorative board expressing the gloss-matte design sense without performing the conventional peeling process. Then, by laminating a sheet obtained by forming a pattern layer having a pattern shape and a cured product of a curable resin on a resin film layer on a decorative sheet having a porous base material and a design layer, it was found that a resin-impregnated decorative board having excellent abrasion resistance while expressing the gloss-matte design sense was obtained, and the present invention was completed.

[0014] Figs. 1 to 4 are schematic cross-sectional views illustrating the resin-impregnated decorative board in the present disclosure. As shown in Fig. 1, the resin-impregnated decorative board 10 in the present disclosure includes a porous base material 1, a design layer 2, a resin film layer 3, and a pattern layer 4 having a pattern shape and containing a cured product of a curable resin X, in this order in the thickness direction D T Moreover, the porous base material 1 contains a cured product of a curable resin Y. The resin-impregnated decorative board in the present disclosure may have a porous layer 5 containing a cured product of a curable resin Z between the design layer 2 and the resin film layer 3, as shown in Fig. 2. The resin-impregnated decorative board in the present disclosure may have a gloss adjustment layer 6 formed between the resin film layer 3 and the pattern layer 4, as shown in Figs. 3(a) and 3(b). It is preferable that the resin-impregnated decorative board in the present disclosure has an adhesive layer 7 disposed on the surface of the resin film layer 3 opposite to the pattern layer 4, as shown in Fig. 4.

[0015] The resin-impregnated decorative board in the present disclosure has a resin film layer between the design layer and the pattern layer. Since the resin film layer generally has a certain thickness, the thickness of the layer disposed on the design layer in the resin-impregnated decorative board (specifically, the distance from the surface of the design layer on the resin film layer side to the surface of the resin film layer on the pattern layer side) increases. Therefore, the design layer is less likely to be worn. That is, the wear resistance of the resin-impregnated decorative board is improved. Further, by having the pattern layer 4 having a pattern shape and containing a cured product of the curable resin X, a gloss difference occurs between the first region R1 overlapping the pattern layer and the second region R2 not overlapping the pattern layer, and by showing different design senses, a design sense of a gloss-matte tone can be expressed.

[0016] Also, for the purpose of protecting the design layer from wear, it is also conceivable to dispose a porous layer containing a cured product of a curable resin Z (for example, a melamine resin) between the design layer and the pattern layer. In this case, the ink for forming the pattern layer is applied on the porous layer, but in the application region, the ink for forming the pattern layer may penetrate into the porous layer. There is a problem that the curable resin Z is not impregnated into the porous layer into which the ink for forming the pattern layer has penetrated. If the curable resin Z does not penetrate into the porous layer, the transparency decreases and the visibility of the design layer is impaired.

[0017] On the other hand, according to the present disclosure, since the pattern layer is disposed on the resin film layer, the penetration of the ink for forming the pattern layer is suppressed as compared with the case where it is disposed on the porous layer. Therefore, the visibility of the design layer is good. Hereinafter, the resin-impregnated decorative board in the present disclosure will be described in detail.

[0018] 1. Resin film layer In the present disclosure, the resin film layer is disposed between the design layer and the pattern layer. Since the resin-impregnated decorative board in the present disclosure has a resin film layer, its abrasion resistance is improved. Further, in the manufacturing process of the resin-impregnated decorative board of the present disclosure, when forming the pattern layer on the resin film layer, bleeding of the ink for forming the pattern layer can be suppressed as compared with the case of forming the pattern layer on the porous layer. Therefore, a decrease in transparency is suppressed, and the visibility of the design layer is improved.

[0019] Since the resin-impregnated decorative board in the present disclosure has a resin film layer, the thickness of the layer disposed on the design layer can be increased. Specifically, as shown in FIG. 1, the distance L from the surface q on the resin film layer 3 side of the design layer 2 to the surface p on the pattern layer 4 side of the resin film layer 3 can be increased. The distance L is preferably, for example, 20 μm or more, more preferably 30 μm or more, and particularly preferably 60 μm or more. When the distance L is within the above range, the abrasion resistance of the resin-impregnated decorative board is further improved. On the other hand, the distance L is, for example, 300 μm or less, and may be 200 μm or less. When the distance L is within the above range, the transparency is good and the visibility of the design layer is good. Further, if the distance L is too thick, the adhesion between the design layer and the resin film layer may decrease.

[0020] The thickness of the resin film layer is preferably 10 μm or more, and more preferably 50 μm or more. When the thickness of the resin film layer is within the above range, it is easy to adjust the distance L to be equal to or greater than the above-described value. On the other hand, the thickness of the resin film layer is, for example, 200 μm or less, and may be 100 μm or less. When the thickness of the resin film layer is within the above range, it is easy to adjust the distance L to be equal to or less than the above-described value. Further, if the resin film layer is too thick, the adhesion between the design layer and the resin film layer decreases.

[0021] Since the resin film layer has no voids as compared with the porous layer, it is difficult for the ink for forming the pattern layer to penetrate. The resin film layer is, for example, a film containing a polyester resin such as polyethylene terephthalate and polybutylene terephthalate, a polyolefin resin such as polyethylene and polypropylene, an acrylic resin, or the like.

[0022] The resin film layer only needs to be transparent enough to visually recognize the design layer, and may be colored transparent or translucent in addition to being colorless and transparent. The total light transmittance of the resin film layer is preferably, for example, 85% or more, more preferably 88% or more, and even more preferably 90% or more. Since the total light transmittance is high in this way, the transparency becomes good and the visibility of the design layer becomes good.

[0023] Here, the total light transmittance of the resin film layer can be measured in accordance with JIS K7361-1:1999, and can be measured, for example, by a haze meter HM150 manufactured by Murakami Color Research Laboratory.

[0024] In the present disclosure, the haze of the resin film layer is preferably 5% or less, more preferably 4% or less, and even more preferably 3% or less. Since the haze is low in this way, the transparency becomes good and the visibility of the design layer becomes good.

[0025] Here, the haze of the resin film layer can be measured in accordance with JIS K-7136:2000, and can be measured, for example, by a haze meter HM150 manufactured by Murakami Color Research Laboratory.

[0026] The resin film layer may or may not contain a matting agent. Examples of the matting agent include the matting agents exemplified in the pattern layer described later.

[0027] 2. Pattern layer The pattern layer in the present disclosure is disposed on the surface of the resin film layer opposite to the design layer, has a pattern shape, and contains a cured product of a curable resin X. The resin-impregnated decorative board in the present disclosure has a pattern layer, so that a difference in gloss occurs between a first region R1 overlapping with the pattern layer and a second region R2 not overlapping with the pattern layer.

[0028] In the case of the resin-impregnated decorative board shown in FIG. 1, for example, the first region R1 overlapping with the pattern layer 4 becomes a matte region, and the second region R2 not overlapping with the pattern layer 4 (the region where the resin film 3 is exposed from the pattern layer 4) becomes a gloss region. Although not particularly shown, the resin film layer may contain a matting agent. In such a case, a gloss-matte design feeling can be expressed in which the first region overlapping with the pattern layer is a gloss region and the second region not overlapping with the pattern layer (the region where the resin film 3 is exposed from the pattern layer 4) is a matte region.

[0029] On one hand, as in the resin-impregnated decorative board 10 shown in FIGS. 3(a) and 3(b), a gloss adjustment layer 6 may be formed between the resin film layer 3 and the pattern layer 4. The gloss adjustment layer 6 is preferably arranged to cover the entire surface of the resin film 3 on the side opposite to the design layer 2. By the gloss difference between the gloss adjustment layer 6 and the pattern layer 4, a gloss-matte design feeling can be expressed. For example, a gloss-matte design feeling can be expressed by setting the first region R1 overlapping with the pattern layer 4 as a matte region and the second region R2 not overlapping with the pattern layer 4 (the region where the gloss adjustment layer 6 is exposed from the pattern layer 4) as a gloss region, or by setting the first region R1 overlapping with the pattern layer 4 as a gloss region and the second region R2 not overlapping with the pattern layer 4 (the region where the gloss adjustment layer 6 is exposed from the pattern layer 4) as a matte region. From the viewpoint of improving the design property of the resin-impregnated decorative board described later, in FIG. 3(a), it is preferable that the first region R1 is a matte region and the second region R2 is a gloss region, and in FIG. 3(b), it is preferable that the first region R1 is a gloss region and the second region R2 is a matte region. Further, when the gloss adjustment layer 6 is arranged between the resin film layer 3 and the pattern layer 4, since the gloss adjustment layer 6 covers the resin film 3, the physical properties such as scratch resistance and stain resistance are improved, and the gloss adjustment of the entire design becomes easier as compared with the case where the resin film 3 and the pattern layer 4 are in direct contact as shown in FIG. 1, for example.

[0030] When the design layer has a pattern, the pattern layer is preferably arranged to be in sync with the pattern of the design layer. "In sync" means that the shapes and positions of the two patterns in question generally match. Specifically, it means that the shape and position of the pattern of the pattern layer and at least a part of the pattern constituting the pattern of the design layer match to such an extent that the sense of reality and the sense of luxury are not impaired. By arranging the pattern of the pattern layer to be in sync with the pattern of the design layer, a high texture can be obtained.

[0031] In FIG. 1, the design layer 2 has a pattern layer 2a and a pattern layer 2b, and a pattern layer 4 that expresses a matte feeling is in sync with the pattern layer 2a. By arranging the pattern layer 4 so as to be in sync with the pattern of the design layer, the design property of the resin-impregnated decorative board can be improved by the synergistic effect between the pattern layer 4 and the pattern of the design layer. For example, when the resin-impregnated decorative board is viewed in plan view, when the total area of the pattern layer (pattern layer 2a in FIG. 1) is 100, the area of the pattern layer that is in sync with the pattern layer is preferably 90 or more, more preferably 95 or more, still more preferably 97 or more, and even more preferably 99 or more. On the other hand, the pattern layer may not be arranged so as to be in sync with the pattern of the design layer.

[0032] For example, when the design layer has a wood grain pattern, as shown in FIG. 1, by synchronizing the pattern of the pattern layer 4 with a dark pattern such as a conduit (pattern layer 2a in FIG. 1), the design property of the resin-impregnated decorative board can be improved by the synergistic effect between the pattern layer 4 and the pattern of the design layer 2.

[0033] Also, when there is a gloss adjustment layer 6 between the resin film 3 and the pattern layer 4, the pattern layer 4 on the gloss adjustment layer 6 may be arranged so as to be in sync with the pattern of the design layer. For example, when the first region R1 is a matte region and the second region R2 is a gloss region in FIG. 3(a), by synchronizing the pattern of the pattern layer 4 that expresses a matte feeling with a dark pattern such as a conduit (pattern layer 2a in FIG. 3(a)), the design property of the resin-impregnated decorative board can be improved.

[0034] On the other hand, the pattern layer 4 on the gloss adjustment layer 6 may not be in sync with the pattern of the design layer. For example, when the first region R1 is a gloss region and the second region R2 is a matte region in FIG. 3(b), by not synchronizing the pattern of the pattern layer 4 that expresses a gloss feeling with a dark pattern such as a conduit (pattern layer 2a in FIG. 3(b)), the design property of the resin-impregnated decorative board can be improved. In this case, it is preferable to arrange the pattern layer 4 so that the second region R2 that does not overlap with the pattern layer 4 is in sync with a dark pattern such as a conduit (pattern layer 2a in FIG. 3(b)).

[0035] The pattern layer contains a cured product (crosslinked structure) of a curable resin. In the present disclosure, the curable resin in the pattern layer may be referred to as curable resin X.

[0036] Examples of the curable resin X include thermosetting resins and radiation-curable resins. Examples of the radiation-curable resins include electron beam-curable resins and ultraviolet ray-curable resins.

[0037] Examples of the thermosetting resins include acrylic resins such as acrylic polyol, unsaturated ester resins, urethane resins (including two-component curable polyurethanes), epoxy resins, amino alkyd resins, phenolic resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, melamine-urea co-condensation resins, silicone resins, and siloxane resins.

[0038] On the other hand, the radiation-curable resin (radiation-curable compound) is not limited as long as it is a material that causes a crosslinking polymerization reaction by irradiation with radiation and changes into a three-dimensional polymer structure. Examples of the radiation-curable resins include prepolymers, oligomers, and monomers having a polymerizable unsaturated bond or an epoxy group that can be crosslinked by irradiation with radiation in the molecule. In the present disclosure, only one type of 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 polyfunctional monomers and oligomers as the radiation-curable resin.

[0039] Examples of the radiation-curable compounds include (meth)acrylate resins such as urethane (meth)acrylate, ester (meth)acrylate, and epoxy (meth)acrylate; silicone resins such as siloxane; ester resins; and epoxy resins. The (meth)acrylate resin refers to an acrylate resin or a methacrylate resin.

[0040] The weight average molecular weight of the radiation-curable compound is, for example, 500 or more and 80,000 or less, and may be 1,000 or more and 50,000 or less. The weight average molecular weight is a value measured by gel permeation chromatography (GPC) using polystyrene as a standard substance.

[0041] As the radiation-curable compound, it is preferable to contain at least a polyfunctional monomer or oligomer having a weight average molecular weight of 500 or more. 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.

[0042] The pattern 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 waxes (e.g., polypropylene wax, polyethylene wax).

[0043] 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 based on the volume-based particle size distribution measured by the laser diffraction scattering method. The content of the matting agent is, for example, 5 parts by mass or more and 50 parts by mass or less, and may be 10 parts by mass or more and 40 parts by mass or less with respect to 100 parts by mass of the resin component of the pattern layer.

[0044] The pattern layer may be colorless or colored. In the latter case, the pattern layer preferably contains a colorant. As the colorant, the same colorants as those used in the design layer described later can be used.

[0045] The pattern layer may contain additives such as an ultraviolet absorber, an infrared absorber, a light stabilizer, a polymerization inhibitor, a crosslinking agent, an antistatic agent, an antioxidant, a leveling agent, a coupling agent, a plasticizer, a defoaming agent, a filler, a thermal radical generator, and an aluminum chelating agent, as necessary.

[0046] The thickness of the pattern layer is not particularly limited. For example, it may be 0.1 μm or more, and may be 1.0 μm or more. On the other hand, the thickness of the pattern layer may be, for example, 20 μm or less, 10 μm or less, or 5 μm or less.

[0047] As a method for forming the pattern layer, for example, by gravure printing using a printing plate pattern, a grid, etc., an ink for forming a pattern layer containing a curable resin X is applied to one surface of the resin film layer and cured, thereby forming a pattern layer having a pattern shape.

[0048] When the ink for forming the pattern layer contains a thermosetting resin, usually, a cured product of the thermosetting resin is obtained by heating. The heating temperature is appropriately set according to the type of the thermosetting resin. The ink for forming the pattern layer may contain a curing agent such as a crosslinking agent and a polymerization initiator, and a polymerization accelerator together with the thermosetting resin. Examples of the curing agent include isocyanate, organic sulfonate, organic amine, peroxide (for example, methyl ethyl ketone peroxide), and radical initiator (azoisobutyronitrile).

[0049] When the ink for forming a pattern layer contains an electron beam curable resin, usually, by irradiating an electron beam, a cured product of the electron beam curable resin is obtained. Examples of the electron beam source include various electron beam accelerators such as a Cockcroft-Walton type, a Van de Graaff type, a resonant transformer type, an insulated core transformer type, a linear type, a Dynamitron type, and a high frequency type. Examples of the energy of the electron beam are, for example, 100 kV or more and 1000 kV or less, and 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.

[0050] When the ink for forming a pattern layer contains an ultraviolet curable resin, usually, by irradiating ultraviolet rays, a cured product of the ultraviolet curable resin is obtained. Examples of the ultraviolet ray source include, for example, an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, and a metal halide lamp. Examples of the wavelength of the ultraviolet rays are, for example, 190 nm or more and 380 nm or less.

[0051] The ink for forming a pattern layer may contain a solvent, if 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.

[0052] 3. Design layer The design layer in the present disclosure is disposed between a porous base material and a resin film layer. The design layer preferably has a pattern.

[0053] Examples of the patterns on the design layer include organic patterns, inorganic patterns, and abstract patterns. The organic pattern refers to a pattern derived from the life activities of organisms such as animals and plants. The inorganic pattern refers to a pattern not corresponding to the organic pattern. The abstract pattern refers to a pattern that abstractly interprets an object (such as an image existing in nature) and does not represent a distinct form. Examples of the organic pattern include wood grain pattern, leather pattern, floral pattern, and botanical pattern. Examples of the inorganic pattern include stone grain pattern, concrete pattern, sand grain pattern, cloth grain pattern, metal pattern, tile pasted pattern, and brick laid pattern. Examples of the abstract pattern include wavy pattern (such as the wavy pattern of ink), smoke pattern, and marble pattern.

[0054] The design layer has, for example, a pattern layer. Further, the design layer may have a solid layer on the side of the porous substrate from the pattern layer. In the present disclosure, the pattern layer means a layer formed partially (particularly in a pattern) on one surface of the porous substrate. The solid layer means a layer formed on the entire surface of one surface of the porous substrate.

[0055] 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 white, indigo, ultramarine blue, cadmium red; organic pigments such as azo pigment, lake pigment, anthraquinone pigment, quinacridone pigment, phthalocyanine pigment, isoindolinone pigment, dioxazine pigment; metal powder pigments such as aluminum powder and bronze powder; pearlescent pigments such as titanium oxide-coated mica and bismuth oxychloride; fluorescent pigments; and phosphorescent pigments. A dye may be used as the colorant.

[0056] 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 rubbers, and synthetic rubbers. Among them, (meth)acrylic resins and urethane (meth)acrylic resins are preferred. In addition, aqueous proteins such as casein, cellulose, acetyl cellulose, nitrocellulose, hydroxypropyl cellulose, cellulose derivatives typified by carboxymethyl cellulose, polyvinyl alcohol derivatives such as polyvinyl alcohol and polyvinyl butyral resins, amino resins such as melamine resins, (meth)acrylic acid resins, phenol resins, acrylic polyols, natural polymers (for example, polynucleotides, polypeptides, polysaccharides), etc. can also be used. In the present disclosure, only one kind of the above resin component may be used, or two or more kinds may be used.

[0057] The design layer may contain additives such as a filler (for example, silica), an extender pigment (for example, organic beads), a neutralizing agent, and a surfactant, if 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.

[0058] Examples of the method for forming the design layer include a coating method using an ink for forming a design layer containing a colorant, a binder resin, and a solvent (or a dispersion medium). For example, the ink for forming a design layer is coated on one surface of a porous substrate and dried to obtain the design layer.

[0059] Examples of the above 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; and inorganic solvents such as water.

[0060] Examples of the above coating method include, for example, printing methods. Examples of printing methods include, for example, gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing. Further, examples of coating methods 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.

[0061] 4. Porous substrate The porous substrate in the present disclosure contains a cured product of an uncured resin (curable resin Y). Examples of the porous substrate include a permeable fibrous substrate. Examples of the permeable fibrous substrate include paper, synthetic paper, non-woven fabric, and woven fabric. Examples of the paper include titanium paper, tissue paper, kraft paper, linter paper, cardboard, gypsum board paper, fine paper, coated paper, parchment paper, and Japanese paper. Further, as the fibrous substrate, a vinyl wallpaper base material (a material obtained by dry laminating a polyvinyl chloride resin on paper) can also be used. Other examples of the fibrous substrate include non-woven fabrics or woven fabrics containing inorganic fibrous materials such as glass fiber, asbestos, potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber. Other examples of the fibrous substrate include non-woven fabrics or woven fabrics containing synthetic resin fibers such as polyester, vinylon, polyethylene, and polypropylene. Among these porous substrates, titanium paper, tissue paper, kraft paper, coated paper, art paper, sulfuric acid paper, glassine paper, parchment paper, paraffin paper, and Japanese paper are preferable in terms of the impregnability of the curable resin Y. In particular, titanium paper is preferable as the porous substrate because it is excellent in the impregnability of the curable resin Y and also excellent in concealability.

[0062] The porous substrate may be colored. For example, a colored porous substrate can be obtained by blending a colorant at the manufacturing stage of the porous substrate. For example, when the porous substrate is paper, colored paper can be obtained by blending a colorant at the papermaking stage. Examples of the colorant include inorganic pigments such as titanium dioxide, carbon black, and iron oxide, organic pigments such as phthalocyanine blue, and various dyes. Further, the porous substrate may contain various additives such as a filler, a matting agent, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, and a light stabilizer, if necessary.

[0063] The basis weight of the porous substrate is not particularly limited. For example, 40 g / m 2 or more and 150 g / m 2The following is the case. The thickness of the porous substrate is not particularly limited, and for example, it is 50 μm or more and 170 μm or less. For example, in order to enhance the adhesion of the ink for forming the design layer, the surface of the porous substrate on the design layer side may be subjected to corona discharge treatment.

[0064] As the curable resin Y, thermosetting resins can be widely used. Examples of the curable resin Y include melamine resins (melamine resin precursors), melamine-urea co-condensation resins, unsaturated polyester resins, polyurethane resins (including two-component curable polyurethanes), epoxy resins, aminoalkyd resins, phenolic resins, urea resins, diallyl phthalate resins, guanamine resins, silicone resins, and polysiloxane resins.

[0065] 5. Porous layer The resin-impregnated decorative board in the present disclosure may have a porous layer containing a cured product of a curable resin Z between the design layer and the resin film layer. By having the porous layer, the resin-impregnated decorative board in the present disclosure can further increase the thickness of the layer disposed on the design layer and has excellent abrasion resistance. By containing the cured product of the curable resin Z, the porous layer improves the light transmittance to such an extent that the design layer can be visually recognized.

[0066] The porous layer preferably contains a fibrous material. The fibrous material is preferably paper or a non-woven fabric. The porous layer in the present disclosure preferably has good abrasion resistance, and the light transmittance is improved by including the cured product of the curable resin Z, and further preferably has good printability of the pattern layer. Examples of the paper having such properties include papers made from cellulose-based pulp such as wood pulp fibers with a high α-cellulose component, Manila hemp pulp fibers, lint paper, and cotton fiber paper. Non-cellulose resin fibers such as vinylon and acrylic resin may be mixed into these papers as needed. In addition, in order to ensure sufficient light transmittance after resin impregnation, it is preferable to add no concealing pigments such as titanium white and carbon black to the paper, or to add a small amount if added. Examples of the non-woven fabric include non-woven fabrics containing fibers such as cellulose fibers and non-cellulose resin fibers such as acrylic resin.

[0067] The porous layer may be a single layer or a laminate of two or more layers. In the case of a laminate, the porous layer may have two or more layers of the same type, or may have two or more layers of different types.

[0068] The thickness of the porous layer is preferably 10 μm or more, and more preferably 50 μm or more. On the other hand, the thickness of the porous layer may be, for example, 100 μm or less, or 80 μm or less. When the thickness of the porous layer is within the above range, it is easy to adjust the distance L to the above-mentioned range. Also, if the thickness of the porous layer is too thick, the visibility of the design layer may decrease. Note that the thickness of the porous layer, when the porous layer is a laminate of two or more layers, refers to the total thickness of the layers constituting the porous layer.

[0069] The basis weight of the porous layer (basis weight before impregnation with the curable resin Z) is, for example, 15 g / m 2 or more, preferably 20 g / m 2 or more, more preferably 30 g / m 2 or more, and most preferably 40 g / m 2More preferably, it is as described above. When the basis weight of the porous layer is within the above range, it becomes easier to contain the cured product of the curable resin Z. On the other hand, the basis weight of the porous layer may be, for example, 100 g / m 2 or less, and may be 80 g / m 2 or less.

[0070] As the curable resin Z, the thermosetting resins exemplified by the above-described curable resin Y can be widely used. Among them, the curable resin Z is preferably the same thermosetting resin as the curable resin Y. This is because the interlayer adhesion can be improved. Similarly, the cured product of the curable resin Z 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 preferably formed of the same curable resin. On the other hand, the curable resin Z and the curable resin Y may be different curable resins.

[0071] 6. Cured resin layer In the step of impregnating the first sheet described later with the curable resin Y, an uncured resin layer containing the curable resin Y may be formed on the surface of the design layer opposite to the porous substrate. Therefore, the resin-impregnated decorative board in the present disclosure may have a cured resin layer containing the cured product of the curable resin Y on the surface of the design layer opposite to the porous substrate. The thickness of the cured resin layer is, for example, 1 μm or more, and may be 5 μm or more. On the other hand, the thickness of the cured resin layer is, for example, 10 μm or less.

[0072] 7. Adhesive layer As shown in Fig. 4, it is preferable that the adhesive layer 7 is disposed on the surface of the resin-impregnated decorative board 10 in the present disclosure, which is opposite to the pattern layer 4 of the resin film layer 3. In the lamination step of the manufacturing method of the resin-impregnated decorative board, the design layer in the first sheet impregnated with the curable resin Y and the resin film layer in the second sheet not impregnated with the curable resin Y are opposed and laminated. Therefore, the adhesion between the resin film layer and the design layer is likely to be low. By disposing the adhesive layer, the adhesion between the resin film layer and the design layer of the resin-impregnated decorative board in the present disclosure is improved. Examples of the adhesive layer include an adhesive layer, a heat seal layer, and a primer layer.

[0073] The adhesive used for the adhesive layer is not particularly limited, and known adhesives can be used and appropriately selected according to the application. As the adhesive, general-purpose pressure-sensitive adhesives, heat-sensitive adhesives, curable adhesives (such as thermosetting adhesives, photocuring adhesives, two-component curing adhesives, etc.) can be used. Among them, urethane-based adhesives are preferable because of their good adhesion. Examples of the resins used in these adhesives include acrylic resins, urethane resins, vinyl chloride-based resins, vinyl acetate-based resins, vinyl chloride-vinyl acetate copolymers, styrene-acrylic copolymers, polyester resins, amide resins, cyanoacrylate resins, epoxy resins, etc. These can be used alone or in combination of multiple types. Examples of urethane-based adhesives include adhesives using two-component curing type urethane resins containing various polyol compounds such as polyether polyols, polyester polyols, and acrylic polyols, and curing agents such as isocyanate compounds.

[0074] An adhesive can also be used for the adhesive layer. As the adhesive, various adhesives such as acrylic-based, urethane-based, silicone-based, and rubber-based adhesives can be appropriately selected and used.

[0075] The thickness of the adhesive layer is not particularly limited, but in order to obtain excellent adhesiveness, it is preferably 1 μm or more and 100 μm or less, more preferably 5 μm or more and 50 μm or less, and even more preferably 10 μm or more and 30 μm or less.

[0076] The primer layer is mainly composed of a binder resin and may contain additives such as an ultraviolet absorber and a light stabilizer as required.

[0077] Examples of the binder resin include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene resins, urethane-acrylic copolymers, polycarbonate-based urethane-acrylic copolymers (urethane-acrylic copolymers derived from polymers having carbonate bonds in the polymer main chain and two or more hydroxyl groups at the terminals and side chains (polycarbonate polyols)), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated propylene resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, etc. These can be used alone or in combination of two or more. Further, the binder resin may be those obtained by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent to these resins and subjecting them to crosslinking curing. Among these, those obtained by crosslinking and curing a polyol-based resin such as an acrylic polyol resin with an isocyanate-based curing agent are preferred, and those obtained by crosslinking and curing an acrylic polyol resin with an isocyanate-based curing agent are more preferred.

[0078] The thickness of the primer layer is preferably 0.1 μm or more and 10 μm or less, more preferably 1 μm or more and 8 μm or less, and even more preferably 2 μm or more and 6 μm or less.

[0079] The heat seal layer exhibits adhesiveness by heat. Examples of the resin contained in the heat seal layer include thermoplastic resins. Examples of the thermoplastic resins include (meth)acrylic resins, polyacrylic polyols, urethane resins, vinyl chloride resins, vinyl acetate resins, vinyl chloride-vinyl acetate copolymer resins, styrene-acrylic copolymer resins, acrylic-vinyl acetate copolymer resins, polyester resins, amide resins, cyanoacrylate resins, epoxy resins, etc. These can be used alone or in combination of two or more.

[0080] (Meta)acrylic resin's glass transition temperature (Tg) is not particularly limited. For example, it may be 90°C or higher and 150°C or lower, and may also be 95°C or higher and 120°C or lower. Also, the glass transition temperature (Tg) of vinyl chloride-vinyl acetate copolymer resin is not particularly limited. For example, it may be 50°C or higher and 85°C or lower, and may also be 55°C or higher and 80°C or lower. Further, when the heat seal layer contains (meta)acrylic resin and vinyl chloride-vinyl acetate copolymer resin, the proportion of (meta)acrylic resin to the total of (meta)acrylic resin and vinyl chloride-vinyl acetate copolymer resin may be, for example, 30% by mass or more and 70% by mass or less, and may also be 40% by mass or more and 60% by mass or less.

[0081] The thickness of the heat seal layer is preferably, for example, 1 μm or more and 50 μm or less, and more preferably 10 μm or more and 30 μm or less.

[0082] 8. The first region and the second region As shown in FIG. 1, the resin-impregnated decorative board in the present disclosure has a first region R1 overlapping with the pattern layer 4 and a second region R2 not overlapping with the pattern layer 4. As shown in FIG. 1, in the first region R1, the pattern layer 4 may be the outermost layer in the thickness direction D T In the second region R2, the resin film layer 3 may be the outermost layer in the thickness direction D T On the other hand, as shown in FIGS. 3(a) and 3(b), in the second region R2, the gloss adjustment layer 6 may be the outermost layer in the thickness direction D T In the thickness direction D, the height of the first region R1 is usually higher than the height of the second region R2. The surface height difference between the first region and the second region is, for example, the same as the thickness of the pattern layer.

[0083] In the thickness direction D T In the thickness direction D, the height of the first region R1 is usually higher than the height of the second region R2. The surface height difference between the first region and the second region is, for example, the same as the thickness of the pattern layer.

[0084] In the present disclosure, since the pattern layer is formed on the resin film layer, there is no risk of the ink for forming the pattern layer penetrating into the resin film layer, as compared with the case where the pattern layer is formed on the porous layer, and therefore the surface height difference between the first region R1 and the second region R2 can be increased.

[0085] In addition, when the area of ​​the first region is S1 and the area of ​​the porous substrate is S2, the ratio of S1 to S2 (S1 / S2) is, for example, 5% or more, and may be 10% or more, while S1 / S2 is, for example, 80% or less, and may be 70% or less, or may be 60% or less.

[0086] As shown in the preferred embodiment of Figures 1, 2, and 3(a), the resin-impregnated decorative board of the present disclosure can express a glossy and matte design by providing a glossy design in the second region R2 and a matte design in the first region R1. That is, the 60° gloss value of the first region R1 can be made smaller than the 60° gloss value of the second region R2.

[0087] In this case, the 60° gloss value of the first region R1 is, for example, 10 or less, preferably 8.0 or less, and more preferably 6.0 or less. This is because the difference in gloss with the second region R2 becomes large, and the gloss matte design is more prominent. On the other hand, the 60° gloss value of the first region R1 is, for example, 0.5 or more, preferably 1.0 or more, and 2.0 or more. Also, the 60° gloss value of the second region R2 may be, for example, 15 or more, and may be 20 or more. On the other hand, the 60° gloss value of the second region R2 is, for example, 60 or less, may be 50 or less, or may be 30 or less.

[0088] In this case, the difference between the 60° gloss value of the first region and the 60° gloss value of the second region is preferably 3.0 or more, and more preferably 5.0 or more.

[0089] On the one hand, as shown in the preferred embodiment of FIG. 3(b), the resin-impregnated decorative board in the present disclosure can express a gloss-matte design sense by giving the second region R2 a matte design sense and the first region R1 a gloss design sense. That is, the 60° gloss value of the first region R1 can be made larger than the 60° gloss value of the second region R2. In this case, the 60° gloss value of the first region R1 is, for example, 8.0 or more, and preferably 10.0 or more. This is because the difference in gloss with the second region R2 becomes larger, and the gloss-matte design is more prominently expressed. On the other hand, the 60° gloss value of the first region R1 may be, for example, 30 or less, and may be 20 or less. Also, the 60° gloss value of the second region R2 may be, for example, 7.0 or less, and may be 6.0 or less. On the other hand, the 60° gloss value of the second region R2 is, for example, 1 or more.

[0090] In this case, the difference between the 60° gloss value of the first region and the 60° gloss value of the second region is preferably 1.0 or more, and more preferably 2.0 or more.

[0091] In the present disclosure, the 60° gloss value of the first region R1 is a value measured by the following method. Place the resin-impregnated decorative board with the pattern layer side facing up, and measure the 60° specular glossiness of the first region from the pattern 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 locations in the first region. At each measurement location, the first region is at the center of the measurement site of the gloss meter, and the measurement is performed such that 50% or more of the area of the measurement site overlaps with the first region. The center of the measurement site of the gloss meter refers to the center of the incident region where the light from the light source of the gloss meter is incident.

[0092] The measurement method of the 60° gloss value of the second region R2 is the same as the measurement method of the 60° gloss value of the first region R1 described above, except that the second region R2 is at the center of the measurement site of the gloss meter, and the measurement is performed such that 50% or more of the area of the measurement site overlaps with the second region R2.

[0093] The 60° gloss value of the first region R1 can be adjusted by the average particle diameter of the matting agent contained in the pattern layer, the content of the matting agent, and the thickness of the pattern layer. For example, by reducing the thickness of the pattern layer, the 60° gloss value can be decreased. For example, by increasing the content of the matting agent, the 60° gloss value can be decreased. For example, by increasing the average particle diameter of the matting agent, the 60° gloss value can be decreased.

[0094] When the second region R2 does not have the gloss adjustment layer 6 between the resin film layer 3 and the pattern layer 4, the 60° gloss value of the second region R2 corresponds to the 60° gloss value of the surface of the resin film 3. Also, as shown in FIGS. 3(a) and 3(b), the 60° gloss value of the second region R2 can be adjusted by disposing the gloss adjustment layer 6 between the resin film layer 3 and the pattern layer 4. The gloss adjustment layer is disposed, for example, on the entire surface of the surface of the resin film layer on the pattern layer side. The entire surface of the surface of the resin film layer on the pattern layer side means a region of 90% or more of the surface of the resin film layer on the pattern layer side. The gloss adjustment layer may be disposed so as to cover 95% or more of the surface of the resin film layer on the pattern layer side, or may be disposed so as to cover 100% thereof.

[0095] When the gloss adjustment layer 6 is disposed between the resin film layer 3 and the pattern layer 4, the 60° gloss value of the second region R2 can be adjusted by the average particle diameter of the matting agent contained in the gloss adjustment layer, the content of the matting agent, the thickness of the gloss adjustment layer, and the like. The average particle diameter and content of the matting agent, the thickness of the gloss adjustment layer, and the like may be adjusted so that a gloss difference occurs between the gloss adjustment layer and the pattern layer. For example, by reducing the thickness of the gloss adjustment layer, the 60° gloss value can be decreased. For example, by increasing the content of the matting agent, the 60° gloss value can be decreased. For example, by increasing the average particle diameter of the matting agent, the 60° gloss value can be decreased.

[0096] The gloss adjustment layer contains, for example, a resin component and a matting agent. Examples of the resin component include the same types as the cured product of the curable resin exemplified in the above-described pattern layer. Examples of the matting agent include the same types as the inorganic particles and synthetic resin particles exemplified in the above-described pattern layer. The content of the matting agent in the gloss adjustment layer is not particularly limited as long as a gloss difference occurs between the gloss adjustment layer and the pattern layer, and can be appropriately adjusted so as to obtain the above 60° gloss value. Similarly, the average particle diameter of the matting agent in the gloss adjustment layer is not particularly limited as long as a gloss difference occurs between the gloss adjustment layer and the pattern layer, and can be appropriately adjusted so as to obtain the above 60° gloss value.

[0097] The average thickness of the gloss adjustment layer is not particularly limited as long as a gloss difference occurs between the gloss adjustment layer and the pattern layer, and can be appropriately adjusted so as to obtain the above 60° gloss value. The average thickness of the gloss adjustment layer is, for example, 1 μm or more, preferably 5 μm or more. When the average thickness of the gloss adjustment layer is within the above range, a gloss adjustment effect can be obtained. On the other hand, the average thickness of the gloss adjustment layer is, for example, 50 μm or less, may be 30 μm or less, or may be 20 μm or less.

[0098] 9. Regarding other members The resin-impregnated decorative board in the present disclosure may have a porous core substrate on the surface of the porous base material 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 kraft paper, which is core paper, with a phenolic resin and drying it.

[0099] 10. Use The resin-impregnated decorative board in the present disclosure is, for example, disposed on the surface of a substrate and used. Examples of the substrate include wooden members, resin members, metal members, and ceramic members. Examples of the wooden members include wood veneers, plywood, particle boards, and wood fiber boards. Examples of the wood used for the wooden members include cedar, cypress, pine, and lauan. Examples of the resin used for the 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 the metal used for the metal members include iron and aluminum. The material of the ceramic member may be ceramics such as glass and porcelain, may be a non-cement ceramic material such as gypsum, or may be a non-porcelain ceramic material such as ALC (lightweight cellular concrete).

[0100] Examples of the uses of the resin-impregnated decorative board in the present disclosure include, for example, building materials and furniture. The building materials may be interior materials or exterior materials. Examples of the building materials include walls, floors, ceilings, doors, and shelves. Examples of the furniture include tables, desks, and cabinets.

[0101] 11. Manufacturing method of resin-impregnated decorative board FIG. 5 is a schematic cross-sectional view illustrating a method for manufacturing a resin-impregnated decorative board according to the present disclosure. As shown in FIGS. 5(a) and 5(b), the method for manufacturing a resin-impregnated decorative board according to the present disclosure includes a step of forming a design layer 2 on one surface of a porous base material 1 and preparing a first sheet 15 (first sheet preparation step); a step of impregnating the first sheet 15 with a curable resin Y as shown in FIG. 5(c) (resin impregnation step); a step of forming a pattern layer 4 having a pattern shape and containing a cured product of a curable resin X on one surface of a resin film layer 3 and preparing a second sheet 16 as shown in FIGS. 5(d) and 5(e) (second sheet preparation step); a step of laminating the first sheet 15 impregnated with the curable resin Y and the second sheet 16 to produce a laminate 11 as shown in FIG. 5(f) (lamination step); and a step of heating and pressurizing the laminate 11 to cure the curable resin Y to obtain a resin-impregnated decorative board 10 as shown in FIG. 5(g) (heating and pressurizing step).

[0102] (1) First sheet preparation step In this step, a design layer 2 is formed on one surface of the porous base material 1, and the first sheet 15 is prepared. The porous base material, the design layer, and the method for forming the design layer are the same as those described above.

[0103] (2) Resin impregnation step In this step, the first sheet 15 is impregnated with the curable resin Y. For example, the first sheet 15 is immersed in a curable resin composition containing the curable resin Y. After immersion, it is preferably dried. 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 in a bathtub containing the curable resin Y; a method of coating the curable resin Y on the first sheet with a coater such as a kiss coater or a comma coater; and a method of spraying the curable resin Y on the first sheet with a spray device or a shower device.

[0104] The proportion of the curable resin Y in the curable resin composition is, for example, 50% by mass or more, may be 70% by mass or more, and may be 90% by mass or more. The curable resin composition may contain, for example, water, alcohol, or an organic solvent as a solvent.

[0105] In the first sheet impregnated with the curable resin Y obtained by this step, an uncured resin layer containing the curable resin Y may be formed on the surface opposite to the porous base material of the design layer.

[0106] (3) Second Sheet Preparation Step In this step, a pattern layer 4 having a pattern shape and containing a cured product of the curable resin X is formed on one surface of the resin film layer 3 to prepare a second sheet 16. At this time, the pattern layer is preferably formed so as to be synchronized with the design layer in the first sheet. The method for forming the resin film layer and the pattern layer is the same as described above. On the surface of the second sheet opposite to the pattern layer of the resin film layer, an easy-adhesion layer such as a primer layer and a heat-seal layer may be disposed.

[0107] (4) Laminating Step In this step, the first sheet 15 impregnated with the curable resin Y and the second sheet 16 are laminated to produce a laminate 11. At this time, the surface of the first sheet 15 on the side of the design layer 2 is laminated so as to face the resin film layer 3 of the second sheet 16. In this step, it is preferable to align the design layer in the first sheet and the pattern layer in the second sheet. Among them, it is preferable to laminate so that the pattern of the design layer in the first sheet is synchronized with the pattern layer in the second sheet. Also, a core base material may be disposed on the surface of the first sheet opposite to the second sheet. The first sheet and the second sheet may be laminated via the above-described easy-adhesion layer in the second sheet, or may be laminated via an adhesive layer disposed between the first sheet and the second sheet.

[0108] In this step, a porous layer impregnated with the curable resin Z may be disposed between the first sheet 15 and the second sheet 16 impregnated with the curable resin Y.

[0109] (5) Heating and Pressing Step In this step, the laminate 11 is heated and pressed to cure the curable resin Y (and curable resin Z), thereby obtaining the resin-impregnated decorative board 10. 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 or higher and 150 kg / cm 2 or lower. Also, the heating and pressing time is, for example, 30 seconds or longer and 30 minutes or shorter.

[0110] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are examples, and any configuration that has substantially the same configuration as the technical idea described in the claims of the present disclosure and exhibits the same operational effects is included in the technical scope of the present disclosure.

Example

[0111] [Example 1] (Production of the First Sheet) As the porous base material, titanium paper (manufactured by KJ Special Paper Co., Ltd., PM-77P) with a basis weight of 80 g / m 2 was prepared. By the gravure printing method using the following printing ink, a design layer (pattern layer) with a thickness of 2 μm was partially laminated on the porous base material so as to have a stone-patterned design. Thereby, the first sheet having the porous base material and the design layer was produced.

[0112] <Printing Ink> · Casein / acrylic resin 20 parts by mass · Water 70 parts by mass · Dipropyl glycol 5 parts by mass · Isopropyl alcohol 5 parts by mass

[0113] (Production of the Second Sheet) As the resin film layer, a LUMIRROR (registered trademark) #75-T60 (PET film with a thickness of 75 μm) manufactured by Toray Industries, Inc. was prepared. After applying the following ink for forming a pattern layer so as to have a pattern shape synchronized with the pattern layer, it was thermally cured under the conditions of 120 °C for 15 minutes to form a pattern layer with a thickness of 5 μm. Thereby, a second sheet having a resin film layer and a pattern layer in this order was produced.

[0114] <Ink for forming pattern layer> · 20 parts by mass of acrylic polyol · 8 parts by mass of silica particles (particle size 4 μm) · 47 parts by mass of ethyl acetate · 15 parts by mass of a curing agent (hexamethylene diisocyanate) · 10 parts by mass of silicone oil

[0115] (Manufacture of resin-impregnated decorative board) To the above-prepared first sheet, a liquid uncured melamine resin composition containing 60 parts by mass of an uncured product of melamine resin (water-soluble methylol melamine resin, Nikalectin 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 using an impregnation device for impregnation so that the uncured melamine resin composition was at a rate of 80 g / m 2 (when dried). After scraping off the melamine resin on the front and back of the base paper with a rubber spatula, it was dried to produce a first sheet impregnated with the uncured melamine resin composition.

[0116] The first sheet impregnated with the uncured melamine resin composition was laminated on a core base material composed of three sheets of phenolic resin-impregnated kraft paper (obtained by impregnating core kraft paper with a liquid uncured resin composition composed of phenolic resin) having a basis weight of 245 g / m 2 such that the porous base material side of the first sheet was in contact. Next, the second sheet was laminated on the first sheet so that the design layer of the first sheet and the resin film layer of the second sheet faced each other. At this time, the pattern layer of the second sheet was laminated in synchronization with the pattern of the design layer of the first sheet to obtain a laminate.

[0117] The formed laminate was sandwiched between two mirror-finished plates and heat-pressed using a hot press machine at a pressure of 100 kg / cm 2 at a molding temperature of 150 °C for 10 minutes to heat-mold and thermally cure the uncured melamine resin composition impregnated in the first sheet. Thereby, a resin-impregnated substrate was manufactured. Table 1 shows the distance L from the surface q on the resin film layer side of the design layer to the surface p on the pattern layer side of the resin film layer.

[0118] [Example 2] (Manufacture of Resin-Impregnated Decorative Board) With respect to the prepared first sheet and the overlay base paper (basis weight 42 g / m 2 , thickness 80 μm, material: cellulose) prepared as the porous layer, a liquid uncured melamine resin composition containing 60 parts by mass of an uncured product of melamine resin (water-soluble methylol melamine resin, Nikalectin 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 using an impregnation device for impregnation so that the uncured melamine resin composition was at a rate of 80 g / m 2 (when dried). After scraping off the melamine resin on both sides of the base paper with a rubber spatula, it was dried to manufacture a first sheet impregnated with the uncured melamine resin composition and a porous layer impregnated with the uncured melamine resin composition.

[0119] The first sheet impregnated with the uncured melamine resin composition was impregnated with a phenol resin solution on kraft paper and manufactured with a basis weight of 245 g / m 2Three sheets of phenolic resin-impregnated core paper (obtained by impregnating core craft paper with a liquid uncured resin composition made of phenolic resin) were laminated on a core substrate such that the porous substrate side of the first sheet was in contact. Next, a sheet for porous layer was laminated on the first sheet such that the design layer of the first sheet and the sheet for porous layer impregnated with an uncured melamine resin composition faced each other. Next, a second sheet was laminated on the sheet for porous layer such that the sheet for porous layer and the resin film layer of the second sheet faced each other. At this time, they were laminated so that the pattern of the design layer of the first sheet and the pattern layer of the second sheet were synchronized, and a laminate was obtained.

[0120] The formed laminate 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, and the uncured melamine resin composition impregnated in the first sheet and the uncured melamine resin composition impregnated in the sheet for porous layer were thermally cured. Thereby, a resin-impregnated substrate was manufactured. Table 1 shows the distance L from the surface q on the resin film layer side of the design layer to the surface p on the pattern layer side of the resin film layer.

[0121] [Comparative Example 1] (Production of Decorative Sheet) The above titanium paper was prepared as a porous substrate. A design layer (pattern layer) with a thickness of 2 μm was partially laminated on the porous substrate by the gravure printing method using the above printing ink so as to have a stone-patterned design. Thereby, a first sheet having a porous substrate and a design layer was produced. After laminating the following mold release layer-forming ink on the surface on the design layer side of the first sheet so as to have a shape synchronized with the pattern layer, electron beam irradiation was performed at an acceleration voltage of 165 kV with 3 Mrad, thereby forming a mold release layer with a thickness of 5 μm. Thereby, a decorative sheet having a porous substrate, a design layer, and a mold release layer in this order was manufactured.

[0122] [Mold Release Layer-Forming Ink] · 48 parts by mass of a radiation-curable monomer (manufactured by Toagosei Co., Ltd., Aronix M-400) · Reactive silicone (manufactured by Shin-Etsu Chemical Co., Ltd., X-22-164B) 4 parts by mass (6.7 parts by mass based on 100 parts by mass of total solid content) · Silica treated with silane coupling agent (particle size 2 μm) 8 parts by mass (13.3 parts based on 100 parts by mass of total solid content) · Methyl ethyl ketone 40 parts by mass

[0123] (Manufacture of resin-impregnated decorative board) To the prepared decorative sheet, a liquid uncured melamine resin composition containing 60 parts by mass of an uncured product of melamine resin (water-soluble methylol melamine resin, Nikalectin 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 using an impregnation device for impregnation so that the uncured melamine resin composition was at a rate of 80 g / m 2 (when dried). After scraping off the melamine resin on both sides of the base paper with a rubber spatula, it was dried to produce a decorative sheet impregnated with the uncured melamine resin composition.

[0124] As shown in Fig. 6(a), a decorative sheet 25 impregnated with the uncured melamine resin composition was laminated on the core base material 40 such that the porous base material 1 side of the decorative sheet 25 was in contact. Further, a release film 50 was laminated on the impregnated decorative sheet such that the release layer of the release film 50 was in contact with the curable resin layer 30 of the impregnated decorative sheet to obtain a laminate 51.

[0125] Next, as shown in Fig. 6(b), the formed laminate 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 thermally cure the uncured melamine resin composition, thereby forming a cured resin layer 31 (melamine layer) containing a cured product of melamine resin. Thus, a cured laminate 52 was obtained.

[0126] Next, as shown in FIG. 6(c), by peeling the release film 50 from the cured resin layer 31 containing the cured product of the melamine resin, while removing the cured resin layer 31 disposed in the first region overlapping the release layer in the thickness direction among the cured resin layers, the cured resin layer 31 disposed in the second region not overlapping the release layer was left intact. Thereby, the resin-impregnated decorative board 60 was obtained.

[0127] [Reference Example] (Production of Decorative Sheet) The above titanium paper was prepared as a porous substrate. By the gravure printing method using the above printing ink, a design layer (pattern layer) with a thickness of 2 μm was partially laminated on the porous substrate so as to form a stone pattern design. Thereby, a decorative sheet having a porous substrate and a design layer was produced. Further, an overlay base paper (basis weight 42 g / m 2 , thickness 80 μm, material: cellulose) was prepared.

[0128] (Manufacture of Resin-Impregnated Decorative Board) With respect to the produced decorative sheet and porous layer, a liquid uncured melamine resin composition containing 60 parts by mass of an uncured product of melamine resin (water-soluble methylol melamine resin, Nikalectin 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 using an impregnation device for impregnation so that the uncured melamine resin composition was at a rate of 80 g / m 2 (at the time of drying). After scraping off the melamine resin on both sides of the base paper with a rubber spatula, it was dried to produce a decorative sheet impregnated with the uncured melamine resin composition and a porous layer impregnated with the uncured melamine resin composition.

[0129] A decorative sheet impregnated with an uncured melamine resin composition was laminated on the core base material such that the porous base material side of the decorative sheet was in contact. Next, a sheet for porous layer was laminated on the decorative sheet such that the design layer of the decorative sheet faced the sheet for porous layer impregnated with the uncured melamine resin composition. Further, a release film was laminated on the sheet for porous layer such that the release layer of the release film was in contact with the porous layer, thereby obtaining a laminate. The formed laminate 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 thermally cure the uncured melamine resin composition. By peeling off the release film, a resin-impregnated substrate was manufactured.

[0130] [Evaluation] (Glossy matte design evaluation) The glossy matte design of the obtained melamine decorative board was visually evaluated. Specifically, under a light source of natural color form 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 to the surface of the decorative board to confirm the state of appearance of the glossy matte design. The observer scored the glossy matte design on a 5-point scale from 1 to 5 (1 point being the worst and 5 points being the highest). In addition, when the glossy matte design could not be confirmed, it was rated 1 point, and when a sufficient glossy matte design could be confirmed, it was rated 5 points, and the evaluation was carried out step by step. It was carried out by 10 observers respectively, and the average score of all was calculated, and the glossy matte design was evaluated according to the following criteria. ·Evaluation criteria A: The average score when evaluating the glossy matte design is 3 points or more B: The average score when evaluating the glossy matte design is 2 points or more and less than 3 points C: The average score when evaluating the glossy matte design is less than 2 points

[0131] (Wear resistance evaluation) The obtained melamine decorative board was subjected to a wear test based on the JAS flooring wear A test to evaluate its wear resistance. Using a Taber abrasion tester, the number of rotations at which the pattern begins to be removed (IP) and the number of rotations until 95% of the pattern is removed (FP) were measured in 25-rotation increments under the conditions of abrasive paper: S-42 and a load of 1000 g. The rotation number P was calculated by the formula (IP + FP) / 2. This test was performed three times at different positions on the melamine decorative board, and the arithmetic mean value of the above rotation number P was calculated and evaluated according to the following criteria. · Evaluation criteria AA: 800 rotations or more A: 400 rotations or more B: 200 rotations or more C: Less than 200 rotations

[0132]

Table 1

[0133] As shown in Table 1, it was confirmed that the resin-impregnated decorative boards of Example 1 and Example 2 having a resin film layer exhibit an excellent wear resistance while expressing a glossy matte design feeling. Since Example 2 contains a porous layer, it resulted in better wear resistance than Example 1. On the other hand, although the resin-impregnated decorative board of Comparative Example 1 exhibited a glossy matte design between the release layer and the melamine layer, the thickness of the layer disposed on the design layer was thin, resulting in poor wear resistance. The resin-impregnated decorative board of the reference example did not have a pattern-shaped release layer and did not exhibit a glossy matte design.

[0134] Thus, in the present disclosure, for example, the following inventions are provided.

[0135] [1] A resin-impregnated decorative board, wherein the resin-impregnated decorative board has, in this order in the thickness direction, a porous substrate, a design layer, a resin film layer, and a pattern layer having a pattern shape and containing a cured product of a curable resin X. The porous substrate contains a cured product of a curable resin Y, the resin-impregnated decorative board.

[0136] [2] The resin-impregnated decorative board according to [1], having a porous layer containing a cured product of the curable resin Z between the design layer and the resin film layer.

[0137] [3] The resin-impregnated decorative board according to [1] or [2], wherein the pattern layer is arranged to be synchronized with the pattern of the design layer.

[0138] [4] The resin-impregnated decorative board according to any one of [1] to [3], wherein the distance from the surface of the design layer on the resin film layer side in the thickness direction to the surface of the resin film layer on the pattern layer side is 20 μm or more.

[0139] [5] The resin-impregnated decorative board has a first region overlapping with the pattern layer and a second region not overlapping with the pattern layer when viewed from the thickness direction. The resin-impregnated decorative board according to any one of [1] to [4], wherein the 60° gloss value of the first region is smaller than the 60° gloss value of the second region.

[0140] [6] The resin-impregnated decorative board according to [5], wherein the difference between the 60° gloss value of the first region and the 60° gloss value of the second region is 3.0 or more.

[0141] [7] The resin-impregnated decorative board has a first region overlapping with the pattern layer and a second region not overlapping with the pattern layer when viewed from the thickness direction. The resin-impregnated decorative board according to any one of [1] to [4], wherein the 60° gloss value of the first region is larger than the 60° gloss value of the second region.

[0142] [8] The resin-impregnated decorative board according to [7], wherein the difference between the 60° gloss value of the first region and the 60° gloss value of the second region is 1.0 or more.

[0143] [9] An adhesive layer is disposed on the surface of the resin film layer opposite to the pattern layer in the resin-impregnated decorative board according to any one of [1] to [8].

[0144]

[10] The haze of the resin film layer is 5.0% or less in the resin-impregnated decorative board according to any one of [1] to [9].

[0145]

[11] The resin film layer is a film containing polyethylene terephthalate in the resin-impregnated decorative board according to any one of [1] to

[10] .

[0146]

[12] A cured resin layer containing a cured product of the curable resin Y is disposed on the surface of the design layer opposite to the porous base material in the resin-impregnated decorative board according to any one of [1] to

[11] .

[0147]

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

[12] has a gloss adjustment layer between the resin film layer and the pattern layer.

Explanation of Signs

[0148] 1... Porous base material 2... Design layer 3... Resin film layer 4... Pattern layer 5... Porous layer 6... Gloss adjustment layer 7... Adhesive layer 10... Resin-impregnated decorative board

Claims

1. A resin-impregnated decorative board, wherein the resin-impregnated decorative board has, in a thickness direction, in this order, a porous substrate, a design layer, a resin film layer, and a pattern layer having a pattern shape and containing a cured product of a curable resin X. The porous substrate contains a cured product of a curable resin Y, and is a resin-impregnated decorative board.

2. The resin-impregnated decorative board according to claim 1, having a porous layer containing a cured product of a curable resin Z between the design layer and the resin film layer.

3. The resin-impregnated decorative board according to claim 1, wherein the pattern layer is arranged so as to be in sync with the pattern of the design layer.

4. The resin-impregnated decorative board according to claim 1, wherein a distance from a surface of the design layer on the resin film layer side in the thickness direction to a surface of the resin film layer on the pattern layer side is 20 μm or more.

5. The resin-impregnated decorative board has, when viewed from the thickness direction, a first region overlapping with the pattern layer and a second region not overlapping with the pattern layer. The resin-impregnated decorative board according to claim 1, wherein a 60° gloss value of the first region is smaller than a 60° gloss value of the second region.

6. The resin-impregnated decorative board according to claim 5, wherein a difference between the 60° gloss value of the first region and the 60° gloss value of the second region is 3.0 or more.

7. The resin-impregnated decorative board has, when viewed from the thickness direction, a first region overlapping with the pattern layer and a second region not overlapping with the pattern layer. The resin-impregnated decorative board according to claim 1, wherein a 60° gloss value of the first region is larger than a 60° gloss value of the second region.

8. The resin-impregnated decorative board according to claim 7, wherein a difference between the 60° gloss value of the first region and the 60° gloss value of the second region is 1.0 or more.

9. The resin-impregnated decorative board according to claim 1, wherein an adhesive layer is arranged on a surface of the resin film layer opposite to the pattern layer.

10. The resin-impregnated decorative board according to claim 1, wherein a haze of the resin film layer is 5.0% or less.

11. The resin-impregnated decorative board according to claim 1, wherein the resin film layer is a film containing polyethylene terephthalate.

12. The resin-impregnated decorative board according to claim 1, wherein a cured resin layer containing a cured product of the curable resin Y is arranged on a surface of the design layer opposite to the porous substrate.

13. The resin-impregnated decorative board according to claim 1, having a gloss adjustment layer between the resin film layer and the pattern layer.

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