Resin-impregnated decorative paper and resin-impregnated decorative board, and methods for producing resin-impregnated decorative paper and resin-impregnated decorative board

Abstract

To provide resin-impregnated decorative paper and resin-impregnated decorative boards having improved tactile sensation, scratch resistance, and stain resistance, and methods for producing the resin-impregnated decorative paper and resin-impregnated decorative boards.SOLUTION: Resin-impregnated decorative paper 10 comprises: a decorative sheet 10a including base paper 3, a pattern layer 2 provided on an upper side UP of the base paper 3, and a foamed resin layer 1 partially provided by printing on the upper side UP of the pattern layer 2; and an impregnating resin 10b impregnated into the decorative sheet 10a. The foamed resin layer 1 is formed by printing with a printing plate having a line number of 10 L / cm or more and 50 L / cm or less, a cell interval of 2 μm or more and 20 μm or less, and a plate depth of 40 μm or more and 120 μm or less, and expands in volume by foaming.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a resin-impregnated decorative paper, a resin-impregnated decorative board, and a method for manufacturing a resin-impregnated decorative paper and a resin-impregnated decorative board.

Background Art

[0002] Conventionally, there have been a resin-impregnated decorative paper impregnated with a thermosetting resin and a resin-impregnated decorative board in which a base material is adhered to the resin-impregnated decorative paper. A resin-impregnated decorative board obtained by curing the impregnated resin impregnated in the resin-impregnated decorative paper has high surface hardness and is excellent in stain resistance, abrasion resistance, heat resistance, water resistance, and the like.

[0003] The resin-impregnated decorative board is used as a surface material for furniture such as desks or as a surface material for fixtures such as store counters. As a resin-impregnated decorative board, for example, there is a low-pressure melamine decorative board in which a resin-impregnated decorative paper impregnated with a melamine resin and a base material such as particle board are pressure-bonded at low pressure.

[0004] When a tactile sensation is required on the surface of the resin-impregnated decorative board, embossing is performed by applying pressure to the surface of the resin-impregnated decorative board with an embossing plate having an uneven pattern and transferring the uneven pattern to the surface of the resin-impregnated decorative board. By forming an uneven shape on the surface of the resin-impregnated decorative board by embossing, a tactile sensation can be imparted to the surface of the resin-impregnated decorative board.

[0005] When forming an uneven shape on the surface of the resin-impregnated decorative board with an embossing plate, it is necessary to prepare an embossing plate for each pattern in order to synchronize the uneven shape with the pattern of the resin-impregnated decorative board, and there is a possibility that the design expression is limited.

[0006] As a resin-impregnated decorative board that imparts a tactile sensation to the surface, there is a resin-impregnated decorative board described in Patent Document 1. The resin-impregnated decorative board described in Patent Document 1 forms an uneven shape by foaming a foaming agent disposed in a pattern layer, thereby imparting a tactile sensation to the surface of the resin-impregnated decorative board without performing embossing.

Prior Art Documents

Patent Document

[0007]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] However, when forming an uneven shape by foaming a foaming agent as in the resin-impregnated decorative board described in Patent Document 1, the tactile sensation imparted by the uneven shape may vary depending on the coating amount of the foaming layer containing the foaming agent. Further, when the coating amount of the foaming layer is small, the tactile sensation becomes weak, and when the coating amount of the foaming layer is large, the tactile sensation becomes strong, but there is a risk of inferior scratch resistance and stain resistance.

[0009] In view of the above circumstances, an object of the present invention is to provide a resin-impregnated decorative paper and a resin-impregnated decorative board with improved tactile sensation, scratch resistance, and stain resistance, as well as a method for manufacturing the resin-impregnated decorative paper and the resin-impregnated decorative board.

Means for Solving the Problems

[0010] In order to solve the above problems, the present invention proposes the following means. The resin-impregnated decorative paper of the present invention includes a base paper, a pattern layer provided on the upper side of the base paper, and a foamed resin layer partially provided on the upper side of the pattern layer by printing, a decorative sheet including the above, and an impregnated resin impregnated in the decorative sheet. The foamed resin layer is printed and formed by a printing plate having a line number of 10 L / cm or more and 50 L / cm or less, a cell interval of 2 μm or more and 20 μm or less, and a plate depth of 40 μm or more and 120 μm or less, and expands in volume by foaming.

[0011] In the above decorative resin-impregnated decorative paper, the foamed resin layer may contain a foaming agent, and the volume may expand when the foaming agent foams.

[0012] In the decorative paper impregnated with the above cosmetic resin, the foaming agent may have a particle size of 15 μm or more and 250 μm or less after foaming.

[0013] In the decorative paper impregnated with the above cosmetic resin, the foamed resin layer may be formed by printing with the printing plate having a plurality of cells with a hexagonal cell shape.

[0014] The resin-impregnated decorative board of the present invention includes any one of the resin-impregnated decorative papers described above and a base material adhered to the lower side of the resin-impregnated decorative paper.

[0015] The method for manufacturing the resin-impregnated decorative paper of the present invention includes a pattern printing step of printing a pattern layer on the upper side of the base paper, a foamed resin printing step of partially printing a foamed resin layer on the upper side of the pattern layer to form a decorative sheet, and a resin impregnation step of impregnating the decorative sheet with an impregnating resin. In the foamed resin printing step, the foamed resin layer is printed with a printing plate having a line number of 10 L / cm or more and 50 L / cm or less, a cell interval of 2 μm or more and 20 μm or less, and a plate depth of 40 μm or more and 120 μm or less.

[0016] In the method for manufacturing the above resin-impregnated decorative paper, a heating step of foaming the foamed resin layer may be provided after the resin impregnation step.

[0017] The method for manufacturing the resin-impregnated decorative board of the present invention includes the method for manufacturing any one of the resin-impregnated decorative papers described above and a pressing step of adhering a base material to the lower side of the resin-impregnated decorative paper.

Advantages of the Invention

[0018] According to the present invention, it is possible to provide a resin-impregnated decorative paper, a resin-impregnated decorative board, and a method for manufacturing a resin-impregnated decorative paper and a resin-impregnated decorative board, which have improved touch, scratch resistance, and stain resistance.

Brief Description of the Drawings

[0019]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0020] An embodiment of the present invention will be described with reference to the drawings.

[0021] FIG. 1 is a cross-sectional view schematically showing a resin-impregnated decorative paper 10 according to this embodiment. FIG. 2 is a cross-sectional view schematically showing a resin-impregnated decorative board 100 according to this embodiment.

[0022] In this embodiment, as shown in FIGS. 1 and 2, the thickness direction of the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 is defined as the "vertical direction V", the side where the base material 20 is provided in the resin-impregnated decorative board 100 is defined as the "lower side LO" in the vertical direction V, and the side opposite to the lower side LO is defined as the "upper side UP" in the vertical direction V.

[0023] The resin-impregnated decorative board 100 includes a resin-impregnated decorative paper 10 and a base material 20.

[0024] The base material 20 is a layer provided on the lower side LO of the resin-impregnated decorative paper 10. As the base material 20, a particle board or a medium density fiberboard (MDF) or the like can be adopted. As the base material 20, a metal-based plate-like member such as aluminum or stainless steel, or a composite board in which a metal such as aluminum is attached to both sides of a core material made of a resin such as polyethylene may be adopted.

[0025] The resin-impregnated decorative paper 10 includes a decorative sheet 10a and an impregnated resin 10b. The resin-impregnated decorative paper 10 is formed by drying the decorative sheet 10a impregnated with the impregnated resin 10b.

[0026] By impregnating the decorative sheet 10a with the impregnating resin 10b, the impregnating resin 10b penetrates into the interior of the decorative sheet 10a and covers the surface. By drying the decorative sheet 10a impregnated with the impregnating resin 10b, the impregnating resin 10b cures. As a result, the resin-impregnated decorative paper 10 has excellent properties such as high surface hardness, stain resistance, abrasion resistance, heat resistance, and water resistance.

[0027] The impregnating resin 10b is a known thermosetting resin used for resin-impregnated decorative boards. As the impregnating resin 10b, it is preferable to employ a melamine resin having high strength and excellent stain resistance, abrasion resistance, heat resistance, and water resistance.

[0028] The decorative sheet 10a includes a foamed resin layer 1, a pattern layer 2, and a base paper 3.

[0029] The base paper 3 is a layer provided on the lower side LO of the decorative sheet 10a. The base paper 3 is a known fibrous sheet capable of being impregnated with the impregnating resin 10b. As the base paper 3, titanium paper, tissue paper, or the like can be employed. As the base paper 3, it is preferable to employ titanium paper having excellent concealability so as not to transmit the color and texture of the base material 20 after adhesion to the base material 20.

[0030] The pattern layer 2 is a layer provided on the upper side UP of the base paper 3. The pattern layer 2 is formed, for example, by performing printing such as wood grain, stone grain, or sand grain.

[0031] As the printing method of the pattern layer 2, for example, known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be employed. For the pattern layer 2, known printing inks suitable for the printing method employed can be employed.

[0032] The foamed resin layer 1 is a layer provided on the upper side UP of the pattern layer 2. The foamed resin layer 1 includes a resin 1a for the foamed resin layer and a foaming agent 1b. The foamed resin layer 1 is a layer for imparting a three-dimensional effect to the upper surface 2s on the upper side UP of the pattern layer 2 and is printed at an arbitrary position on the upper surface 2s on the upper side UP of the pattern layer 2.

[0033] The foamed resin layer 1 is partially provided on the upper side UP of the pattern layer 2. The foamed resin layer 1 is preferably arranged at a position synchronized with the pattern of the pattern layer 2.

[0034] The resin 1a for the foamed resin layer is a printing ink containing a foaming agent 1b. As a printing method for the foamed resin layer 1, for example, known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be adopted. For the resin 1a for the foamed resin layer, a known printing ink suitable for the adopted printing method can be adopted.

[0035] The foaming agent 1b is a thermally expandable microcapsule. The thermally expandable microcapsule used for the foaming agent 1b is a resin capsule containing a foaming component such as a hydrocarbon, and expands in volume by being heated. As the resin forming the thermally expandable microcapsule used for the foaming agent 1b, an epoxy resin, a casein resin, an acrylic resin, or the like can be adopted.

[0036] When the foaming agent 1b foams, the volume of the foamed resin layer 1 expands. When the volume of the foamed resin layer 1 expands, an uneven shape is formed on the upper surface 2s of the pattern layer 2, and a tactile sensation is imparted to the surface (upper surface UP) of the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100. FIG. 1 shows the resin-impregnated decorative paper 10 before foaming the foamed resin layer 1. FIG. 2 shows the resin-impregnated decorative board 100 after foaming the foamed resin layer 1.

[0037] The particle size after foaming of the foaming agent 1b is preferably 15 μm or more and 250 μm or less, and more preferably 100 μm or more and 200 μm or less. When the particle size after foaming of the foaming agent is small, there is a risk that the tactile sensation imparted to the surface of the resin-impregnated decorative paper and the resin-impregnated decorative board by the foaming of the foaming agent becomes weak. When the particle size after foaming of the foaming agent is large, there is a risk that the scratch resistance and stain resistance on the surface of the resin-impregnated decorative paper and the resin-impregnated decorative board decrease.

[0038] The foaming start temperature of the foaming agent 1b is preferably 150°C or higher and 220°C or lower. In the resin-impregnated decorative board 100, for example, the base material 20 is adhered to the lower side LO of the resin-impregnated decorative paper 10 by heat and pressure molding. The foaming agent 1b foams and its volume expands due to the heat during heat and pressure molding.

[0039] If the foaming start temperature of the foaming agent is low, when the resin-impregnated decorative paper and the base material are adhered by heat and pressure molding, the foaming of the foaming agent starts at an early stage of the heat and pressure molding, and the time for pressurization after the foaming of the foaming agent becomes long, resulting in the foamed resin layer being crushed, and there is a risk that the tactile sensation on the surface of the resin-impregnated decorative paper and the resin-impregnated decorative board becomes weak. If the foaming start temperature of the foaming agent is high, the foaming agent may not be sufficiently foamed during heating, and there is a risk that the tactile sensation on the surface of the resin-impregnated decorative paper and the resin-impregnated decorative board becomes weak.

[0040] FIG. 3 is a front view schematically showing a printing plate P for printing the foamed resin layer 1 on the resin-impregnated decorative paper 10. FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 3.

[0041] The printing plate P is a printing plate for printing the foamed resin layer 1 on the upper side UP of the pattern layer 2, and is, for example, a gravure plate. For example, the printing plate P is a cylindrical gravure roll, and a plurality of cells C are provided on the outer peripheral surface of the gravure roll.

[0042] The cell C in the printing plate P is a concave depression into which the printing ink for forming the foamed resin layer 1 flows. That is, the foamed resin layer resin 1a containing the foaming agent 1b flows into the plurality of cells C provided in the printing plate P. The cell C is a depression in which the surface of the printing plate P is concave, and is formed, for example, by performing etching on the outer peripheral surface of a metal cylinder forming the printing plate P.

[0043] The cell shape of the cell C is, for example, hexagonal as shown in FIG. 3. As shown in FIG. 3, a plurality of hexagonal cells C are arranged adjacent to each other to form a printing plate P for printing the foamed resin layer 1.

[0044] In the printing plate P, the number of lines of the cells C is 10 L / cm or more and 50 L / cm or less. The number of lines of the cells C is preferably 30 L / cm. The number of lines of the cells C indicates the number of cells C per centimeter on the printing surface of the printing plate P.

[0045] In the printing plate P, the cell pitch Cs is 2 μm or more and 20 μm or less. The cell pitch Cs is preferably 10 μm.

[0046] As shown in FIG. 3, the cell pitch Cs indicates the interval between two adjacent cells C. For example, as shown in FIG. 4, the cell pitch Cs indicates the thickness of the wall portion disposed between two adjacent cells C.

[0047] The wall portion disposed between two adjacent cells C is a wall body that separates two adjacent cells C. Further, the thickness of the wall portion indicates the thickness in the direction (layout direction) in which two adjacent cells C are arranged.

[0048] In the printing plate P, the plate depth Cd of the cells C is 40 μm or more and 120 μm or less. As shown in FIG. 4, the plate depth Cd of the cells C indicates the depth of the cells C in which the surface (printing surface) of the printing plate P is recessed. When the printing plate P is a cylindrical gravure roll, the plate depth Cd of the cells C is the dimension in the radial direction of the gravure roll.

[0049] When a printing plate having a number of lines greater than 50 L / cm, a cell pitch greater than 20 μm, or a plate depth less than 40 μm is used, the height difference in the concavo-convex shape formed by the foamed resin layer becomes insufficient, and the touch feeling is inferior.

[0050] When a printing plate having a number of lines less than 10 L / cm, a cell pitch less than 2 μm, or a plate depth greater than 120 μm is used, the height difference in the concavo-convex shape formed by the foamed resin layer becomes excessively large, and the scratch resistance and stain resistance are inferior.

[0051] By printing the foamed resin layer 1 with a printing plate P having a line count of 50 L / cm or less and 10 L / cm or more, a cell pitch Cs of 20 μm or less and 2 μm or more, and a plate depth Cd of 120 μm or less and 40 μm or more, the surfaces of the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 in which the foamed resin layer 1 has foamed to form an uneven shape can have a sufficient touch feeling, excellent scratch resistance, and stain resistance.

[0052] Next, a manufacturing method for manufacturing the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 using a resin-impregnated decorative board manufacturing system will be described. Here, the resin-impregnated decorative board manufacturing system is a system that executes the manufacturing of the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 according to the present embodiment.

[0053] First, the resin-impregnated decorative board manufacturing system performs a pattern printing process. In the pattern printing process, the resin-impregnated decorative board manufacturing system forms a pattern layer 2 on the upper side UP of the base paper 3 by printing.

[0054] Next, the resin-impregnated decorative board manufacturing system performs a foamed resin printing process. In the foamed resin printing process, the resin-impregnated decorative board manufacturing system prints a foamed resin layer 1 formed of a resin 1a for a foamed resin layer in which a foaming agent 1b is mixed on the surface 2s on the upper side UP of the pattern layer 2. As a result, a decorative sheet 10a including the base paper 3, the pattern layer 2, and the foamed resin layer 1 is formed.

[0055] In the foamed resin printing process, the printing plate P for printing the foamed resin layer 1 is a printing plate having a line count of 50 L / cm or less and 10 L / cm or more, a cell pitch Cs of 20 μm or less and 2 μm or more, and a plate depth Cd of 120 μm or less and 40 μm or more.

[0056] Next, the resin-impregnated decorative board manufacturing system performs a resin impregnation process. In the resin impregnation process, the resin-impregnated decorative board manufacturing system impregnates the decorative sheet 10a with an impregnating resin 10b and then dries it in an oven to form the resin-impregnated decorative paper 10.

[0057] Next, the resin-impregnated decorative board manufacturing system performs a heating and pressing process.

[0058] The heating and pressing process includes a heating process of heating and foaming the foamed resin layer 1, and a pressing process of adhering the base material 20 to the lower side LO of the resin-impregnated decorative paper 10.

[0059] The above-mentioned heating process and pressing process may be performed simultaneously. For example, in the heating and pressing process, the resin-impregnated decorative board manufacturing system adheres the base material 20 to the lower side LO of the resin-impregnated decorative paper 10 by heating and pressing molding to form the resin-impregnated decorative board 100.

[0060] The foamed resin layer 1 starts to foam by reaching the foaming start temperature by heating for heating and pressing molding to adhere the resin-impregnated decorative paper 10 and the base material 20, and forms an uneven shape on the surface 2s on the upper side UP of the pattern layer 2.

[0061] As the heating and pressing molding method for adhering the resin-impregnated decorative paper 10 and the base material 20, a heating and pressing molding method known as a hot pressure bonding method for decorative boards can be adopted. For example, as the heating and pressing molding method, there are a method of heating and flat-pressing the resin-impregnated decorative paper 10 and the base material 20 facing each other in the vertical direction V with a flat press plate for hot pressure bonding, and a method of continuously heating and pressing with a rotary circular pressure endless belt sandwiching the resin-impregnated decorative paper 10 and the base material 20 facing each other in the vertical direction V for hot pressure bonding.

[0062] According to the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 of the present embodiment, it includes a decorative sheet 10a and an impregnated resin 10b impregnated in the decorative sheet 10a. The decorative sheet 10a includes a base paper 3, a pattern layer 2 provided on the upper side UP of the base paper 3, and a foamed resin layer 1 partially provided by printing on the upper side UP of the pattern layer 2.

[0063] The foamed resin layer 1 is formed by being printed by a printing plate P having a line number of 10 L / cm or more and 50 L / cm or less, a cell interval Cs of 2 μm or more and 20 μm or less, and a plate depth Cd of 40 μm or more and 120 μm or less, and expands in volume by foaming.

[0064] As a result, the foamed resin layer 1 can form an uneven shape on the surfaces of the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 that can achieve both sufficient touch feeling, excellent scratch resistance, and stain resistance, and it is possible to provide the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 with improved touch feeling, scratch resistance, and stain resistance, as well as a method for manufacturing the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100.

[0065] As described above, one embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and design changes and the like within the scope not departing from the gist of the present invention are also included. In addition, the components shown in the above-described one embodiment and the modified examples shown below can be configured by appropriately combining them.

[0066] (Modification Example 1) In the above embodiment, the decorative sheet 10a includes the foamed resin layer 1, the pattern layer 2, and the base paper 3. However, the form of the decorative sheet is not limited to this. The decorative sheet may include a layer having a conduit expression or the like for visually imparting a three-dimensional effect, a blocking layer for preventing the foamed resin layer 1 or the pattern layer 2 from penetrating into the base paper 3, and the like.

[0067] (Modification Example 2) In the above embodiment, the foamed resin layer 1 contains the foaming agent 1b which is a thermally expandable microcapsule. However, the form of the foamed resin layer is not limited to this. The foamed resin layer may be a thermally decomposable chemical foaming agent.

[0068] (Modification Example 3) In the above embodiment, the heating step for foaming the foamed resin layer 1 is performed when the resin-impregnated decorative paper 10 and the base material 20 are heated and pressure-molded. However, the step for foaming the foamed resin layer is not limited to this. The step for foaming the foamed resin layer may be performed before or after adhering the resin-impregnated decorative paper and the base material.

[0069] (Modification Example 4) In the above embodiment, the resin-impregnated decorative paper 10 and the base material 20 are adhered by heat and pressure molding, but the adhesion method between the resin-impregnated decorative paper and the base material is not limited to this. The adhesion method between the resin-impregnated decorative paper and the base material may also be an adhesion method without applying heat.

[0070] (Modification Example 5) In the above embodiment, the cell shape of the cells C in the printing plate P for printing the foamed resin layer 1 is hexagonal, but the cell shape in the printing plate for printing the foamed resin layer is not limited to this. The cell shape in the printing plate for printing the foamed resin layer may be a diamond shape, a trapezoid shape, a circular shape, an elliptical shape, etc., or may be a cell shape such as a slanted line type or a tortoise shell type.

[0071] The present invention will be described in detail with reference to the following examples. The present invention is not limited to the following examples.

[0072] (Example 1) Titanium paper was prepared as the base paper 3, and the pattern layer 2 was printed on the upper side UP of the base paper 3 by gravure printing.

[0073] The foamed resin layer 1 was printed on the upper side UP of the pattern layer 2 to form the decorative sheet 10a. At this time, the foamed resin layer 1 was printed using a printing plate P having a line number of 30 L / cm, a cell interval Cs of 10 μm, and a plate depth Cd of 40 μm.

[0074] The decorative sheet 10a was impregnated with a melamine resin as the impregnating resin 10b and dried in an oven to form the resin-impregnated decorative paper 10. The base material 20 was adhered to the lower side LO of the resin-impregnated decorative paper 10 by heat and pressure molding to obtain the resin-impregnated decorative board 100 of Example 1. In the hot press in the heat and pressure molding, a flat plate was used.

[0075] (Example 2) The resin-impregnated decorative board 100 of Example 2 was obtained in the same manner as in Example 1, except that the plate depth Cd in the printing plate P for printing the foamed resin layer 1 was set to 60 μm.

[0076] (Example 3) A resin-impregnated decorative board 100 of Example 3 was obtained in the same manner as in Example 1, except that the plate depth Cd of the printing plate P for printing the foamed resin layer 1 was 80 μm.

[0077] (Example 4) A resin-impregnated decorative board 100 of Example 4 was obtained in the same manner as in Example 1, except that the plate depth Cd of the printing plate P for printing the foamed resin layer 1 was 100 μm.

[0078] (Example 5) A resin-impregnated decorative board 100 of Example 5 was obtained in the same manner as in Example 1, except that the plate depth Cd of the printing plate P for printing the foamed resin layer 1 was 120 μm.

[0079] (Example 6) A resin-impregnated decorative board 100 of Example 6 was obtained in the same manner as in Example 1, except that in the printing plate P for printing the foamed resin layer 1, the line number was 10 L / cm and the plate depth Cd was 90 μm.

[0080] (Comparative Example 1) A resin-impregnated decorative board of Comparative Example 1 was obtained in the same manner as in Example 1, except that the plate depth of the printing plate for printing the foamed resin layer was 20 μm.

[0081] (Comparative Example 2) A resin-impregnated decorative board of Comparative Example 2 was obtained in the same manner as in Example 1, except that the plate depth of the printing plate for printing the foamed resin layer was 140 μm.

[0082] (Test 1) A scratch resistance test was carried out on the resin-impregnated decorative boards of Examples 1-6 and Comparative Examples 1-2. In the scratch resistance test, a coin scratching test was carried out on the surface of the resin-containing decorative board, and the way of scratching in the foamed resin layer was evaluated.

[0083] The evaluation criteria were divided into three levels, and those other than × were considered qualified. 〇(Excellent): There are no scratches in the foamed resin layer. △(Good): There are inconspicuous scratches in the foamed resin layer. ×(Poor): The foamed resin layer has scratches.

[0084] (Test 2) The stain resistance test was carried out on the resin-impregnated decorative boards of Examples 1-6 and Comparative Examples 1-2. In the stain resistance test, the surfaces of the resin-containing decorative boards were coated with black crayon and red ink, and after 1 hour, they were wiped off with alcohol, and the degree of residue after wiping was evaluated.

[0085] The evaluation criteria were divided into three levels, and those other than × were considered qualified. 〇(Excellent): The residue after wiping is less than 30%. △(Good): The residue after wiping is 30% or more and less than 70%. ×(Poor): The residue after wiping is 70% or more and 100% or less.

[0086] (Test 3) The tactile evaluation test was carried out on the resin-impregnated decorative boards of Examples 1-6 and Comparative Examples 1-2. In the tactile evaluation test, a sensory test on the tactile sensation of the surface of the resin-containing decorative board was carried out by 10 testers, and the degree of tactile sensation was evaluated.

[0087] The evaluation criteria were divided into three levels, and those other than × were considered qualified. 〇(Excellent): 7 or more and 10 or fewer people evaluated that the tactile sensation was good. △(Good): 1 or more and 6 or fewer people evaluated that the tactile sensation was good. ×(Poor): 0 people evaluated that the tactile sensation was good.

[0088] (Test 4) The design evaluation test was carried out on the resin-impregnated decorative boards of Examples 1-6 and Comparative Examples 1-2. In the design evaluation test, a sensory test on the design of the surface of the resin-containing decorative board was carried out by 10 testers, and the degree of design was evaluated.

[0089] The evaluation criteria were divided into three levels, and those other than × were considered qualified. 〇(Excellent): 7 or more and 10 or fewer people evaluated that the design was good. △(Good): One or more and six or fewer people evaluated the design as good. ×(Poor): Zero people evaluated the design as good.

[0090] (Test Results) The results of Tests 1 - 4 are shown in Table 1.

[0091] The resin - impregnated decorative boards 100 of Examples 1 - 6, which include a foamed resin layer 1 printed by a printing plate P having a line count of 10 L / cm or more and 50 L / cm or less, a cell pitch Cs of 2 μm or more and 20 μm or less, and a plate depth Cd of 40 μm or more and 120 μm or less, showed good results in all tests. That is, the resin - impregnated decorative boards 100 of Examples 1 - 6 have sufficient touch, excellent scratch resistance, and stain resistance.

[0092] The resin - impregnated decorative board of Comparative Example 1, which includes a foamed resin layer printed by a printing plate with a plate depth of less than 40 μm for the cells, was inferior in touch and design in Tests 3 - 4 and was unqualified.

[0093] The resin - impregnated decorative board of Comparative Example 2, which includes a foamed resin layer printed by a printing plate with a plate depth of more than 120 μm for the cells, was inferior in scratch resistance and stain resistance in Tests 1 - 2 and was unqualified.

[0094]

Table 1

Explanation of Symbols

[0095] 100 Resin - impregnated decorative board 10 Resin - impregnated decorative paper 10a Decorative sheet 10b Impregnated resin 1 Foamed resin layer 1a Resin for foamed resin layer 1b Foaming agent 2 Pattern layer 2s Upper surface of pattern layer 3 Base paper 20 Substrate P Printed plate C Cell Cs Cell spacing Cd Plate depth V Vertical direction UP Upper side LO Lower side

Claims

1. A decorative sheet comprising a base paper, a pattern layer provided on the upper side of the base paper, and a foamed resin layer partially provided by printing on the upper side of the pattern layer, an impregnated resin impregnated in the decorative sheet, comprising, the foamed resin layer, is formed by printing with a printing plate having a line number of 10 L / cm or more and 50 L / cm or less, a cell interval of 2 μm or more and 20 μm or less, and a plate depth of 40 μm or more and 120 μm or less, and expands in volume by foaming, resin-impregnated decorative paper.

2. The foamed resin layer contains a foaming agent, and the volume expands when the foaming agent foams, The resin-impregnated decorative paper according to claim 1.

3. The foaming agent has a particle size of 15 μm or more and 250 μm or less after foaming, The resin-impregnated decorative paper according to claim 2.

4. The foamed resin layer is formed by printing with a printing plate having a plurality of cells with a hexagonal cell shape, The resin-impregnated decorative paper according to claim 1.

5. The resin-impregnated decorative paper according to any one of claims 1 to 4, and a base material adhered to the lower side of the resin-impregnated decorative paper, comprising, resin-impregnated decorative board.

6. A pattern printing step of printing a pattern layer on the upper side of the base paper, a foamed resin printing step of partially printing a foamed resin layer on the upper side of the pattern layer to form a decorative sheet, a resin impregnation step of impregnating the decorative sheet with an impregnating resin, comprising, in the foamed resin printing step, the foamed resin layer is printed with a printing plate having a line number of 10 L / cm or more and 50 L / cm or less, a cell interval of 2 μm or more and 20 μm or less, and a plate depth of 40 μm or more and 120 μm or less, Method for manufacturing resin-impregnated decorative paper.

7. After the resin impregnation step, a heating step of foaming the foamed resin layer is provided, The method for manufacturing resin-impregnated decorative paper according to claim 6.

8. The method for manufacturing resin-impregnated decorative paper according to claim 6 or claim 7, and a pressing step of adhering a base material to the lower side of the resin-impregnated decorative paper, comprising, Method for manufacturing resin-impregnated decorative board.

Images