Decorative material

Abstract

To provide a decorative material on which partial peel-off of ink disposed in a concavity is not noticeable.SOLUTION: A decorative material has a base coloring layer that is a colored layer, an unevenness application layer that is stacked on the base coloring layer and has an uneven pattern, and an ink layer formed of ink disposed in a concavity of the uneven pattern. When a site including the ink layer is a site A and a site not including the ink layer is a site B in plan view of the decorative material, color difference ΔE1 between the site A and the site B is 12 or less, and when a site seen through the base coloring layer by removing the ink layer in the unevenness application layer in plan view of the decorative material is a site C, color difference ΔE2 between the site A and the site C is 3 or less.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to decorative materials.

Background Art

[0002] Decorative materials are widely used as surface decorative materials for furniture, building materials, wall surfaces, the outer surfaces of household appliances, the interior parts of vehicles such as cars, and the like. Among them, there is a decorative material that expresses a predetermined texture by filling ink into recesses (grooves) provided on the surface (this is called "wiping").

[0003] For example, Patent Document 1 discloses a decorative material in which ink is filled in embossed recesses. According to this, by filling the embossed recesses with ink by wiping, it is possible to obtain a synchronization between the shape of the embossed recesses and the pattern and color tone and a matting effect to express a realistic feeling.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, there has been a problem that when using a decorative material, the part filled with ink is removed due to abrasion or chipping, and the difference in color between the part where the filled ink has disappeared and the other part where the filled ink remains is conspicuous. The detachment of the filled ink in the recess due to the use of the decorative material itself is inevitable to a certain extent.

[0006] Therefore, an object of the present disclosure is to provide a decorative material in which even if a part of the ink disposed in the recess is detached, the detachment is not conspicuous.

Means for Solving the Problems

[0007] One aspect of the present disclosure is a decorative material, comprising: a base color layer which is a colored layer; a concavo-convex imparting layer laminated on the base color layer and having a concavo-convex pattern; and an ink layer made of ink disposed inside a concave portion of the concavo-convex pattern. When the decorative material is viewed in plan view, with the portion including the ink layer being defined as portion A and the portion not including the ink layer being defined as portion B, the color difference ΔE1 between portion A and portion B is 12 or less. When the decorative material is viewed in plan view and the ink layer in the concavo-convex imparting layer is removed to see through the base color layer, with the resulting portion being defined as portion C, the color difference ΔE2 between portion A and portion C is 3 or less.

Advantages of the Invention

[0008] According to the decorative material of the present disclosure, even if a part of the ink layer and / or the concavo-convex imparting layer is missing due to, for example, abrasion, the missing part will not be conspicuous.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Embodiments for Carrying Out the Invention

[0010] Hereinafter, each embodiment will be described with reference to the drawings. The present invention is not limited to these embodiments. In the drawings shown below, for the sake of clarity, the size and ratio of the members may be changed or exaggerated. Also, for the sake of visibility, the illustration of parts unnecessary for explanation and repeated reference numerals may be omitted.

[0011] 1. First Embodiment FIG. 1 is an enlarged plan view (top view) of a part of the cosmetic material 10 according to one embodiment, as viewed from the side of the concavo-convex imparting layer 12. In FIGS. 1 and the following figures, for convenience, arrows (x, y, z) indicating directions, that is, a coordinate system, are also shown as needed. Here, the xy direction is the in-plane direction of the cosmetic material 10, and the z direction is the thickness direction. Therefore, FIG. 1 shows the cosmetic material 10 as viewed (top view) particularly from the z direction on the side of the concavo-convex imparting layer 12.

[0012] As can be seen from FIG. 1, in this embodiment, as a whole, the surface is configured to give the appearance of so-called "burned cedar" where the surface of a cedar board is burned and moderately carbonized, with crack-like recesses present on the surface. However, the aspect to be expressed in the present disclosure is not limited to the burned cedar tone, and normal wood grain tones, tile sticker or brick stack tones with joints, cloth grain tones having a large number of fibrous recesses, leather texture tones having a large number of wrinkled recesses, etc. can also be targeted.

[0013] For example, in the case of the burned cedar tone aspect, the groove-like recess 13 with the ink layer 14 disposed inside can reproduce the shadow due to cracks and steps, and further the three-dimensional effect, thereby well reproducing the appearance of cracks and steps on the surface of a surface-carbonized wood board such as burned cedar. In the case of the wood grain tone aspect, the groove-like recess 13 with the ink layer 14 disposed inside can reproduce the shadow due to early wood and late wood in the growth rings, and further the three-dimensional effect, thereby well reproducing the appearance due to the growth rings of the wood grain. In the case of the tile sticker or brick stack tone aspect, the recess 13 with the ink layer 14 disposed inside can reproduce the shadow due to the steps and recesses at the joints of the tile sticker or brick stack, and further the three-dimensional effect, thereby reproducing the appearance of the joint grooves. In the case of the cloth-like pattern aspect, the groove-shaped recess 13 with the ink layer 14 disposed therein can reproduce the steps of knots, tangles, or tumor-like uneven portions (also referred to as "neps") where fiber bundles are intertwined, the shadows due to the recesses, and furthermore, the three-dimensional effect, thereby reproducing the appearance of the recesses in the structure (texture) of the fiber aggregate. In the case of the leather grain pattern aspect, the groove-shaped recess 13 with the ink layer 14 disposed therein can reproduce the steps of the wrinkled uneven portions of the leather, the shadows due to the recesses, and furthermore, the three-dimensional effect, thereby reproducing the appearance of the wrinkled recesses on the leather surface.

[0014] FIG. 2 is an enlarged perspective view schematically showing a part of the decorative material 10 to explain the form of the decorative material 10. Further, FIG. 3 shows a cross-sectional view in the thickness direction along III-III parallel to the x direction in FIG. 2. As can be seen from FIGS. 1 to 3, in this embodiment, the decorative material 10 has a base material 11, an unevenness-imparting layer 12 provided on one surface of the base material 11 (the upper surface in FIG. 3, that is, the surface on the + side in the z-axis direction in the coordinate system), and an ink layer 14.

[0015] Hereinafter, each component will be described in more detail.

[0016] 1.1. Base Material The base material 11 is a sheet-like member that holds the unevenness-imparting layer 12, imparts strength to the decorative material 10, and has a function of maintaining the shape of the decorative material 10. Further, in this embodiment, the base material 11 also functions as an undercoat coloring layer. Here, the form of the base material 11 may be any of a film, a sheet, and a plate. Generally, those with relatively thin thicknesses are sequentially referred to as a film, a sheet, and a plate. However, in this embodiment, the differences in the thickness forms of these base materials are neither essential nor important matters. Therefore, in this specification, any of the terms film, sheet, and plate may be appropriately read as other terms without changing the essence of the present invention or the interpretation of the claims.

[0017] As described above, in this embodiment, since the base material 11 also serves as the undercoat coloring layer, the base material 11 is colored in a predetermined color. Specific color modes will be described later.

[0018] In this embodiment, the base material 11 is formed by containing a coloring material in a base transparent resin. [Transparent resin] As the transparent resin, conventionally known materials for cosmetic materials can be used. For example, polyolefin resins such as polyethylene, polypropylene, olefin-based thermoplastic elastomers, ionomers, acrylic resins such as polymethyl methacrylate and polybutyl methacrylate, thermoplastic polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymer, terephthalic acid-ethylene glycol-1,4-cyclohexanedimethanol copolymer, various polyester-based thermoplastic elastomers, thermoplastic urethane resins, vinyl chloride resins such as polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, ethylene-vinyl chloride copolymer, polycarbonate resins, ABS resins (acrylonitrile-butadiene-styrene copolymer), thermoplastic resins such as styrene resins, thermosetting resins such as melamine resins, unsaturated polyester resins, epoxy resins, two-component curable urethane resins, or ionizing radiation curable resins such as radical polymerization type acrylate-based or cationic polymerization type epoxy-based monomers and prepolymers cured by ionizing radiation (ultraviolet rays, electron beams, etc.) are used.

[0019] [Colorant] As the colorant, known ones can be used. In the case of so-called achromatic colors (white, black), for example, inorganic black pigments such as carbon black (soot), iron black, organic black pigments (or dyes) such as azomethine azo black, perylene black, and white pigments such as titanium white, antimony white, and zinc white can be appropriately used alone or in a mixture of two or more. Note that gray can be obtained by mixing white and black. On the one hand, as the coloring agent for colored substances, for example, inorganic pigments such as lead yellow, titanium yellow, safflower, cadmium red, ultramarine, cobalt blue, etc., organic pigments or dyes such as quinacridone red, isoindolinone yellow, nickel azo complex, phthalocyanine blue, etc., metal pigments composed of flaky foil pieces such as aluminum and brass, and pearl pigments composed of flaky foil pieces such as titanium dioxide-coated mica and basic lead carbonate can be appropriately used alone or in a mixture of two or more.

[0020] [Thickness of the substrate] There is no particular limitation on the thickness of the substrate. However, in the case of a sheet-like substrate or a film-like substrate, for example, those with a thickness of about 20 μm or more and 1000 μm or less are used. In the case of a plate-like substrate, for example, those with a thickness of about 1 mm or more and 20 mm or less are used.

[0021] 1.2. Concavo-convex imparting layer The concavo-convex imparting layer 12 imparts characteristics to the surface of the decorative material visually and tactilely through concavo-convexities. The concavo-convex pattern formed by the concavo-convex imparting layer 12 can be based on the pattern to be expressed (for example, the above-mentioned "charred cedar texture", "wood grain texture", "tile pasted texture", "brick stacked texture", "cloth texture", "leather texture", etc.).

[0022] The cross-sectional shape of the concave portion 13 forming the concavo-convex pattern is not particularly limited and can be appropriately set according to the desired mode. For example, it is possible by combining the cross-sectional shape of the concave portion (such as a triangle or a square), the presence or absence of rounding at the outer and inner corners of the concave portion, the width of the concavo-convexity (the size in the x direction), the depth of the concavo-convexity (the size in the z direction), etc.

[0023] The material constituting the concavo-convex imparting layer 12 is transparent to such an extent that it can be seen through the base coloring layer directly or through the ink layer, and it is preferably at least one selected from two-component curable resins, thermoplastic resins, thermosetting resins, and radiation-curable resins.

[0024] Examples of the two-component curable resin include two-component curable urethane resins with a polyol compound as the main agent and an isocyanate compound as the curing agent, two-component curable epoxy resins, two-component curable urethane-modified acrylic resins, two-component curable polyester resins, and the like.

[0025] Examples of the thermoplastic resin include acrylic resins, cellulose resins, urethane resins, vinyl chloride resins, polyester resins, polyolefin resins, polycarbonate, nylon, polystyrene, and ABS resins.

[0026] Examples of the thermosetting resin include acrylic resins, urethane resins, phenolic resins, urea resins, melamine resins, epoxy resins, unsaturated polyester resins, silicone resins, and the like. A curing agent is added to the thermosetting resin as necessary.

[0027] The radiation-curable resin is a composition containing a compound having a radiation-curable functional group. Examples of the radiation-curable functional group include ethylenically unsaturated bond groups such as (meth)acryloyl group, vinyl group, allyl group, and epoxy group, oxetanyl group, and the like. As the radiation-curable resin, a compound having an ethylenically unsaturated bond group is preferable. Further, from the viewpoint of suppressing damage to the resin layer during the production of the cosmetic sheet, as the radiation-curable resin, a compound having two or more ethylenically unsaturated bond groups is more preferable, and among them, a polyfunctional (meth)acrylate compound having two or more ethylenically unsaturated bond groups is even more preferable. As the polyfunctional (meth)acrylate compound, either a monomer or an oligomer can be used. Note that the radiation refers to those having energy quanta capable of polymerizing or crosslinking molecules among electromagnetic waves or charged particle beams. Usually, ultraviolet rays (UV) or electron beams (EB) are used, but other electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion beams can also be used.

[0028] Among polyfunctional (meth)acrylate compounds, examples of bifunctional (meth)acrylate monomers include ethylene glycol di(meth)acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, 1,6-hexanediol diacrylate, and the like. Examples of trifunctional or higher (meth)acrylate monomers include trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, dipentaerythritol tetra(meth)acrylate, isocyanuric acid-modified tri(meth)acrylate, and the like. In addition, the above (meth)acrylate monomers may be those in which a part of the molecular skeleton is modified, and those modified with ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl, cyclic alkyl, aromatic, bisphenol, etc. can also be used.

[0029] Examples of polyfunctional (meth)acrylate oligomers include acrylate-based polymers such as urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, and polyether (meth)acrylate. Urethane (meth)acrylate is obtained, for example, by the reaction of a polyhydric alcohol, an organic diisocyanate, and hydroxy(meth)acrylate. Preferred epoxy (meth)acrylates are (meth)acrylates obtained by reacting an aromatic epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin, etc. having a functionality of 3 or more with (meth)acrylic acid, (meth)acrylates obtained by reacting an aromatic epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin, etc. having a functionality of 2 or more with a polybasic acid and (meth)acrylic acid, and (meth)acrylates obtained by reacting an aromatic epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin, etc. having a functionality of 2 or more with phenols and (meth)acrylic acid. The above-mentioned radiation-curable resin can be used alone or in combination of two or more kinds.

[0030] When the radiation-curable resin is an ultraviolet-curable resin, the composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator. Examples of the photopolymerization initiator include, in the case of a compound having an ethylenically unsaturated group, one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyldimethyl ketal, benzoyl benzoate, α-acyl oxime ester, thioxanthones, and the like. The photopolymerization accelerator can reduce the polymerization inhibition by air during curing and increase the curing rate. Examples of the photopolymerization accelerator include one or more selected from isoamyl p-dimethylaminobenzoate, ethyl p-dimethylaminobenzoate, and the like.

[0031] These compositions 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, a light stabilizer, a radical scavenger, a soft component (such as rubber), etc. as necessary.

[0032] The thickness of the unevenness-providing layer 12 is not particularly limited, but is preferably larger than the depth of the recess. By making the thickness of the unevenness-providing layer 12 thicker than the depth of the recess, the durability of the surface of the decorative material can be improved.

[0033] 1.3. Ink layer The ink layer 14 is a part composed of ink disposed inside the recess 13. By using the ink, a decorative material 10 having a different appearance and touch can be obtained compared to the case of only the recess 13.

[0034] The material of the ink constituting the ink layer 14 is not particularly limited, and known materials can be used. For example, those containing any one or more of coloring pigments, matting pigments, dyes, ultraviolet absorbers, etc. in a vehicle can be applied. The vehicle can be appropriately selected from various thermoplastic resins, thermosetting resins, and radiation effect type resins.

[0035] 1.4. Regarding color In this embodiment, it is configured such that the color difference ΔE between the surface on the unevenness-providing layer 12 side of the decorative material 10 and the base coloring layer (which also serves as the base material 11 in this embodiment) falls within a predetermined range. Here, the color difference ΔE means "L * a * b * Color difference ΔE in the color space * ab ". That is, the color distance in the L * a * b * color space between the two parts to be compared is ΔE, and the colors of the two parts are respectively (L * 1, a * 1, b * 1), (L * 2, a * 2, b * 2). When set like this, it is represented by the following formula. ΔE = {(L * 2 - L * 1) 2 + (a * 2 - a * 1) 2 + (b * 2 - b * 1) 2} 0.5

[0036] [Color difference between the ink part and the non-ink part] When the decorative material is viewed in plan view, as shown by A in FIG. 3, there is an ink part (part A) which is a predetermined range including the ink layer 14, and a non-ink part (part B) which is a predetermined range not including the ink layer 14 as shown by B. And in this embodiment, the color difference ΔE between such part A and part B is set as ΔE1, and it is assumed that the ΔE1 is 12 or less. Such a color difference ΔE1 is obtained from the distance between the color in the L * a * b * color space at site A and the color in the L * a * b * color space at site B. The measurement of such a color difference is performed using the following measuring device and measurement conditions. · Measuring device: Spectrophotometer CM-3700A manufactured by Konica Minolta · Measurement conditions: Measurement method of regular reflection light SCI (Specular component Include including regular reflection light) · Light source: D65 · Field of view: 2° field of view · Measuring diameter φ: 8 mm · Wavelength range: 360 nm to 740 nm

[0037] [Color difference before and after removal of the ink layer of the concavo-convex imparting layer] Furthermore, as shown in FIG. 4, when the ink layer 14 in the concavo-convex imparting layer 12 at site A is removed so that the base coloring layer (substrate 11 also serving as this in this embodiment) can be seen through without passing through the ink layer 14, when the site in this state is defined as site C, when the color difference ΔE between site A and site C is defined as ΔE2, ΔE2 is set to 3 or less. That is, the color of site C is the color of the base coloring layer visually recognized without passing through the ink layer 14. Note that the removal of such a concavo-convex imparting layer reproduces a state in which the ink layer 14 in the concave portion of the concavo-convex imparting layer 12 is lost due to surface wear when the decorative material 10 is used. Such a color difference ΔE2 is obtained from the distance between the color in the L * a * b * color space at site A and the color in the L * a * b * color space at site C. The measurement of such a color difference is performed under the same measuring device and measurement conditions as described above. Also, the means for removing the ink layer in the concavo-convex imparting layer 12 to obtain the portion C is not particularly limited. For example, a method of removing a part or all of the concavo-convex imparting layer under the test conditions of 1000 revolutions with a wear wheel CS-10, a load of 9.8 N, and a rotational speed of 60 rpm in accordance with JIS K 7204 using a Taber abrasion tester (manufactured by Toyo Seiki, 5130 ABRASER) can be mentioned. When the ink layer 14 in the concavo-convex imparting layer 12 can be completely removed, the number of revolutions of the wear wheel may be less than 1000. Also, when the ink layer 14 cannot be completely removed even at 1000 revolutions of the wear wheel, the number of revolutions of the wear wheel is set to be more than 1000 until the ink layer 14 can be removed.

[0038] 1.5. Other Layers In addition to the above, layers such as the following can be provided as necessary.

[0039] [Protective Layer] In the decorative material, a protective layer may be further laminated on the concavo-convex imparting layer. A cross-sectional view of the decorative material 10 having the protective layer 15 is shown in FIG. 5. The protective layer 15 protects the decorative material from contamination and damage. Such a protective layer 15 can be composed of a transparent resin, transparent glass, or the like. When using a transparent resin, for example, a layer made of a thermoplastic resin or a cured resin can be mentioned. Note that when sufficient surface durability performance such as stain resistance and scratch resistance can be ensured in the intended use with only the base material 11 and the concavo-convex imparting layer 12, the protective layer can be omitted.

[0040] Examples of the thermoplastic resin include acrylic resins such as polymethyl (meth)acrylate and polyethyl (meth)acrylate, polyolefin resins such as polypropylene and polyethylene, fluororesins such as polyvinyl fluoride and polyvinylidene fluoride, polyester resins such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polyethylene naphthalate (PEN), polycarbonate resin, vinyl chloride-based resin, acrylonitrile-butadiene-styrene resin (ABS resin), acrylonitrile-styrene-acrylic ester resin, and the like. Note that “(meth)acrylic” means acrylic or methacrylic.

[0041] The layer made of the cured resin is a layer obtained by curing the curable resin composition, and the curable resin composition is a composition containing a curable resin. Examples of the curable resin composition include a thermosetting resin composition containing a thermosetting resin, an ionizing radiation curable resin composition containing an ionizing radiation curable resin, and the like. Examples of the thermosetting resin include unsaturated polyester resin, polyurethane resin (including two-component curable polyurethane), epoxy resin, aminoalkyd resin, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, melamine-urea co-condensation resin, silicone resin, polysiloxane resin, and the like. The thermosetting resin composition may contain, if necessary, components involved in the curing reaction of the thermosetting resin, such as a catalyst, a curing agent (including a crosslinking agent, a polymerization initiator, a polymerization accelerator, etc.). The ionizing radiation curable resin is a resin that undergoes a crosslinking polymerization reaction upon irradiation with ionizing radiation and changes into a three-dimensional polymer structure. Ionizing radiation is one of electromagnetic waves and charged particle beams that has energy quanta capable of polymerizing or crosslinking molecules. In addition to ultraviolet rays (UV) and electron beams (EB), it also includes electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion beams. Usually, ultraviolet rays (UV) or electron beams (EB) are used. Among the ionizing radiation curable resins, the electron beam curable resin can be solvent-free, does not require a photoinitiator for polymerization, and can obtain stable curing characteristics. As the ionizing radiation-curable resin, for example, a composition containing one or more of monomers, oligomers, or prepolymers having a polymerizable unsaturated bond such as a (meth)acryloyl group that can be crosslinked by irradiation with ionizing radiation, an epoxy group, etc. in the molecule can be used.

[0042] The thickness of the protective layer is not particularly limited, but it can be 0.1 μm or more and 35 μm or less. When it is thin, the durability against bending, etc. is high, but the scratch resistance is weak. When it is thick, it is strong against scratches and damage, but weak against deformation such as bending, and cracks, etc. may occur. Therefore, by setting the thickness within the above range, a well-balanced protective layer can be obtained. Thus, it may be 1 μm or more and 10 μm or less.

[0043] [Adhesive layer] An adhesive layer (not shown) may be provided between at least one of the layers of the decorative material. The adhesive layer has a function of assisting the bonding of each layer and can strengthen the bonding of each layer. As the adhesive layer, it is preferably at least one selected from two-component curable resins, thermoplastic resins, thermosetting resins, and ionizing radiation-curable resins.

[0044] [Primer layer] An adhesive layer (not shown) may be provided between at least one of the layers of the decorative material. The primer layer has a function of assisting the bonding of each layer and can strengthen the bonding of each layer. As the primer layer, a resin that improves the adhesion of both layers facing each other with the primer layer in between may be appropriately selected, and there is no particular limitation.

[0045] 2. Second form FIG. 6 shows a cross-sectional view of the decorative material 20 according to the second form. FIG. 6 shows the decorative material 20 from the same perspective as FIG. 3. In the decorative material 20, a base material 21 and an undercoat coloring layer 22 are arranged instead of the base material 11 of the decorative material 10. Otherwise, since the decorative material 20 is the same as the decorative material 10, the same reference numerals are given and the description is omitted.

[0046] In the decorative material 10, the base material 11 also served as the undercoat coloring layer, so the base material 11 was colored. However, in the decorative material 20, the functions of the base material 21 and the undercoat coloring layer 22 are separated and provided as separate layers. Therefore, in this embodiment, the base material 21 is composed of a transparent resin among the base materials 11. On the other hand, the undercoat coloring layer 22 is made of the same material as the base material 11 and is a layer with a smaller thickness than the base material 11. And the undercoat coloring layer 22 is disposed between the base material 21 and the unevenness-providing layer 12. Matters related to the color of the decorative material 20 can be considered in the same way as those of the decorative material 10, and with such a configuration, the same effects as those of the decorative material 10 can be achieved.

[0047] 3. Effects, etc. According to the decorative materials 10 and 20 configured as described above, by satisfying the regulations of ΔE1, which is particularly the "color difference between the ink part and the non-ink part (color difference between part A and part B)", and ΔE2, which is the "color difference before and after removing the unevenness-providing layer (color difference between part A and part C)", even if a part of the ink layer or a part of the unevenness-providing layer detaches from the decorative material for some reason, the color difference from its surroundings is suppressed to be small, and the decorative material becomes one in which the detachment is not noticeable.

[0048] 4. Manufacturing method of decorative material Next, taking the decorative material 10 as an example, an example of the manufacturing method of the decorative material will be described. However, the method of manufacturing the decorative material is not limited to this. The manufacturing method described below includes a step of producing a manuscript image, a step of producing an image under the plate, a step of producing a plate, a step of forming a concave portion of the unevenness-providing layer, and a step of filling ink.

[0049] In the step of producing a manuscript image, a pattern (for example, a pattern of charred cedar) in a plan view to be represented by the concave portions of the unevenness-providing layer 12 is obtained and used as the manuscript image.

[0050] In the process of creating the image for the mold, the pattern in the plan view to be expressed is obtained as image density (shading), and this is used as the image for the mold. Since the image for the mold is preferably digital data, when the original image is not digital data, a method of reading the original image with a scanner and performing AD conversion is used to obtain digital data in which pixels are arranged in a two-dimensional coordinate plane (x, y), and each pixel corresponds to a unique density value. Also, when the original image has been designed from the beginning using digital data such as CAD, that digital data can be used. Then, using a conversion program from density to concavity / convexity for the digital data, the pattern of each region as a binary image corresponding to the gradation image of the pattern is generated and arranged on a two-dimensional virtual plane, and an image for the mold is obtained as digital data.

[0051] In the process of creating the mold, an embossing mold (molding die for decorative material) having a pattern of the planar shape by the concave portion 13 on the surface is created based on the image for the mold. Specifically, the manufacturing process of the concavity / convexity pattern consists of the following steps (1) to (5).

[0052] [(1) Shading image data creation process] Using the graphic design drawing software "Photoshop" (registered trademark) manufactured by Adobe Systems, shading image data with an 8-bit image density gradation (256 gradations) and a resolution of 2540 dpi in TIFF format was created. This shading image data is also referred to as concavity / convexity pattern image data.

[0053] [(2) Metal roll preparation process] A metal roll 30 for embossing mold engraving as shown in FIG. 7 was prepared. The metal roll 30 is a hollow iron cylinder having rotary drive shafts (shafts) 31 at both axial ends, with a copper layer plated on its surface. The surface of the metal roll 30 was polished with a grindstone to roughen it, and a process was performed to prevent a decrease in engraving efficiency due to specular reflection of the laser light for engraving.

[0054] [(3) Laser engraving process] As schematically shown in FIG. 7, using a laser direct engraving machine, the surface of the metal roll 30 prepared in step (2) is engraved based on the concavo-convex pattern image data created in step (1). As a result, an uneven shape is formed on the surface thereof having the same planar view shape as the uneven pattern formed by the concave portions 13 of the decorative material surface and reverse unevenness (the portions corresponding to the convex lines of the decorative material are concave lines on the embossing plate surface). Therefore, the shape that the uneven pattern on the embossing plate should have is a mode in which the uneven relationship of the uneven pattern formed by the concave portion 13 in the above-described decorative material is reversed, and the same can be considered. The metal roll 30 is driven by an electric motor via its rotational drive shaft 31 and rotates about the rotational drive shaft 31 as the central axis. The surface of the metal roll 30 is scanned with the laser beam P emitted from the laser head 32. In order to prevent the evaporated metal from becoming powder and remaining or adhering to the surface of the metal roll 30, laser light irradiation is performed while spraying the engraving liquid T from the engraving liquid discharge port 33 onto the laser light irradiation region on the surface of the metal roll 30.

[0055] [(4) Electrolytic polishing process] After washing the engraving liquid, electrolytic polishing is performed to remove the metal residues adhering to the surface of the metal roll 30.

[0056] [(5) Chromium plating process] After step (4), a chromium layer with a thickness of 10 μm is formed on the surface of the metal roll by plating.

[0057] As described above, a plate (a forming die for a decorative material, an embossing plate in this embodiment) having a surface with an uneven shape in which the unevenness of the uneven pattern formed by the concave portion 13 on the surface of the unevenness-imparting layer 12 is reversed can be obtained.

[0058] Next, in the step of forming the concave portions of the unevenness-imparting layer, if embossing is performed on the material that will become the unevenness-imparting layer using the fabricated plate (embossing plate), the concave portions 13 can be obtained. The embossing can be performed by any appropriate known method and is not particularly limited. Representative methods of embossing are as follows, for example. Heat-soften the material for the concavo-convex imparting layer, press an embossing plate on its surface, and impart the concavo-convex pattern on the surface of the embossing plate to the surface of the resin sheet. Then cool and solidify the resin sheet to fix the concavo-convex pattern on the resin sheet. Thereafter, release the resin sheet with the concavo-convex pattern from the embossing plate. Here, regarding various embossing methods, further explanation is as follows. For example, there are methods such as the following (A) to (E).

[0059] (A) Heat-soften the resin sheet as the base material, press the embossing plate, and perform embossing. (B) By heat-sealing the resin sheet (base material) serving as the surface sheet and the resin sheet (second base material) serving as the base sheet with the thermal pressure when pressing the embossing plate, perform embossing by the doubling embossing method that simultaneously performs embossing and lamination. (C) Melt-extrude the resin sheet (base material) serving as the surface sheet from a T-die, bring it into contact with a cylindrical embossing plate that also serves as a cooling roller, and perform embossing simultaneously with the film formation of the surface sheet. At this time, further heat-seal the resin sheet (second base material) serving as the base sheet inserted on the back side of the surface sheet to perform doubling embossing simultaneously with the film formation. (D) As disclosed in Japanese Patent Application Laid-Open No. 57-87318, Japanese Patent Application Laid-Open No. 7-32476, etc., apply an uncured liquid material of a radiation-curable resin to the surface of a cylindrical embossing plate. Further, irradiate with radiation in a state where a base sheet made of a resin sheet or the like is stacked thereon to cure the uncured liquid material into a cured product. At that time, after adhering the cured product to the base sheet, release it from the embossing plate, and use the base sheet and the cured product on the base sheet as a base material to perform embossing on the base material. (E) Place an impregnated paper impregnated with an uncured product of a thermosetting resin such as melamine resin on paper such as titanium paper on a backing material such as core paper or wood plywood, and thermally press and mold the plurality of stacked layers to laminate and integrate each layer to produce a thermosetting resin decorative material. At that time, by inserting an embossing plate on the surface side of the impregnated paper, perform embossing simultaneously with the thermal press on the surface when impregnating and curing the thermosetting resin to make a decorative material.

[0060] Note that as the material of the base material used in the embossing methods (A) to (C), typically a thermoplastic resin is used. As the material of the base material used in the embossing method (D), typically a radiation-curable resin is used. As the material of the base material used in the embossing method (E), typically a thermosetting resin is used.

[0061] In the step of filling the ink, the ink is filled into the recesses 13 formed on the surface of the uneven-imparting layer 12, and the ink is arranged in the recesses 13 with a desired thickness distribution to form the ink layer 14. This is done by supplying the ink (in an uncured state), which is the material to become the ink layer 14, to the surface of the uneven-imparting layer on the side where the recesses 13 are formed by a coating method such as the curtain flow coating method or the roll coating method, and then scraping the excess ink outside the recesses 13 (wiping) with a doctor blade, squeegee, sponge roller, etc. The method itself of filling and arranging such ink into the recesses is a method known as the so-called "wiping" method.

[0062] The use of the decorative material described above is not particularly limited. For example, it can be used as an interior material for buildings such as walls, floors, and ceilings, an exterior material for buildings such as exterior walls, roofs, doors, fences, and walls, a fitting such as a door, window frame, and door frame, a surface material for trim members such as moldings, baseboards, and handrails, a surface material for the casings of household appliances such as televisions and refrigerators and office equipment such as copiers, a surface material for furniture such as wardrobes, a surface material for containers such as boxes and resin bottles, an interior or exterior material for vehicles, an interior or exterior material for ships, etc.

[0063] 5. Examples In the examples, a decorative material was created based on the layer configuration of the decorative material 20 described in the second form, and tests were conducted by changing ΔE1 and ΔE2.

[0064] [Base material] · Material: Polypropylene · Thickness: 60 μm · Color: Brown

[0065] [Base coloring layer] · Material: The main component of the pigment in the urethane / acrylic resin is the valve handle, and titanium white, lead yellow, and carbon black are added to it. · Thickness: 2 μm · Color: Brown (single color)

[0066] [Convexity and concavity imparting layer] · Material: Polypropylene · Thickness: 80 μm · Color: Colorless and transparent · Convexity and concavity pattern: An uneven shape including concave portions formed by chiseling the surface of a pinewood board and performing naguri processing.

[0067] [Ink layer] · Colorant 1: Medium (colorless and transparent acrylic urethane resin without pigment addition) · Colorant 2: Color... black ink, Material... Add a black pigment composed of carbon black (ink) to the acrylic urethane resin. · Colorant 3: Color... red, Material... Add a red pigment composed of quinacridone to the acrylic urethane resin. · Colorant 4: Color... yellow, Material... Add a yellow pigment composed of isoindolinone to the acrylic urethane resin. · Mixing ratio: Refer to Table 1

[0068] [Measurement of ΔE1] For each obtained cosmetic material of the examples and comparative examples, when viewed in plan view, the color difference ΔE1 between the ink portion (site A) including the ink layer in the concave portion and the non-ink portion (site B) not including such an ink layer was measured under the following measuring device and measuring conditions. · Measuring device: Spectrophotometer CM-3700A manufactured by Konica Minolta · Measuring conditions: Measurement method of regular reflection light SCI (Specular component Include including regular reflection light) · Light source: D65 · Field of view: 2° field of view · Measuring diameter φ: 8 mm · Wavelength range: 360 nm to 740 nm

[0069] [Measurement of ΔE2] [Removal of the convexity and concavity imparting layer] Removal of the concavo-convex imparting layer reproduces a state in which the ink layer in the concave portion of the concavo-convex imparting layer is lost due to wear of the surface during use of the decorative material, and was performed by a Taber abrasion test in accordance with JIS K 7204. As the Taber abrasion tester, 5130 ABRASER manufactured by Toyo Seiki was used, and the abrasion wheel was CS-10, the load was 9.8 N, and the test was conducted under the test conditions of a rotational speed of 60 rpm and a number of rotations of 1,000 rotations. <Measurement of ΔE2> Regarding the decorative materials of each example and comparative example, for the portion C where the ink layer in the portion A of the concavo-convex imparting layer was removed and the base coloring layer was exposed so as to be visible without passing through the ink layer, the color difference ΔE2 between the corresponding portion A and portion C was measured under the same measuring device and measuring conditions as those for measuring the color difference ΔE1 described above.

[0070] [Evaluation] Regarding the decorative materials of each example and comparative example, the change in the design appearance between the test pieces before and after removing the concavo-convex imparting layer was visually evaluated. In such visual evaluation, 10 subjects visually compared the same test pieces, and when the number of people who judged that the change in the design appearance of the test pieces before and after removing the concavo-convex imparting layer was unrecognizable or recognizable but minor was 5 or more, which was a majority, it was rated as "good", and when the number of people who judged that it was unrecognizable or recognizable but minor was less than 4 (including the case of 0 people), it was rated as "unacceptable".

[0071] [Results] The results of Example 1, Example 2, Comparative Example 1, and Comparative Example 2 are shown in Table 1. Table 1 also shows the blending ratio (mass %) of the coloring material.

[0072]

Table 1

[0073] As can be seen from Table 1, good results could be obtained by changing the values of ΔE1 and ΔE2.

Explanation of Signs

[0074] 10 Decorative material 11 Base material (also serves as the base coloring layer). 12 Concave-convex imparting layer 13 Concave part 14 Ink layer 20 Decorative material 21 Base material 22 Undercoat coloring layer

Claims

【Claim 1】 A decorative material comprising: a base colored layer which is a colored layer; a concavo-convex imparting layer laminated on the base colored layer and having a concavo-convex pattern; and an ink layer made of ink disposed inside a recess of the concavo-convex pattern. When the cosmetic material is viewed in plan view, when the part including the ink layer is defined as part A and the part not including the ink layer is defined as part B, the color difference ΔE １ is 12 or less, and When the part where the base coloring layer is seen through by removing the ink layer in the concavo-convex imparting layer when the cosmetic material is viewed in plan view is defined as part C, the color difference ΔE between part A and part C ２ is 3 or less. The decorative material.

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