Decorative paper, decorative board, and method for manufacturing decorative paper

Abstract

The present invention provides decorative paper, decorative board, and a method for manufacturing decorative paper that can obtain the same level of design and color tone as when forming a pattern using gravure printing. [Solution] The decorative paper 10 is characterized by comprising a base material 11 made of paper, a pattern ink section 12 provided only on a part of one side of the base material 11 to form a pattern, and an ink receiving section 13 provided only between the base material 11 and the pattern ink section 12 so as to be located in the entire space between the base material 11 and the pattern ink section 12, and fixing the pattern ink section 12 to the base material 11.

Description

Technical Field

[0001] The present invention relates to decorative papers, decorative boards, and a method for manufacturing decorative papers, which are used for interior and exterior finishing materials of buildings, furniture, and the like.

Background Art

[0002] Decorative papers used for interior and exterior finishing materials of buildings, furniture, and the like are provided with a pattern layer by gravure printing using paper containing titanium oxide (titanium paper) as a base material, and the surface thereof is coated with a transparent resin layer. In such decorative papers, in order to cope with small-lot and multi-variety patterns, in recent years, a pattern layer has been provided with aqueous ink for inkjet printing by inkjet printing without using a plate.

[0003] When discharging aqueous ink for inkjet printing onto titanium paper by such inkjet printing, since a large amount of ink is used so that the pattern can be printed with good color development, wrinkles are likely to occur on the titanium paper due to the influence of moisture in the ink. Therefore, after applying a treatment liquid containing calcium carbonate or the like to the titanium paper to form an ink-receiving layer on the base material, an aqueous ink for inkjet printing is inkjet-printed to form a pattern layer, so that even with a small discharge amount of ink, the pattern can be printed with good color development and the occurrence of wrinkles can be suppressed (see, for example, Patent Document 1 below).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In conventional decorative papers as described above, the color of the titanium paper substrate on which the ink-receiving layer is formed can change. Therefore, even if the same design is used for decorative paper with the design layer printed using gravure printing and decorative paper with the design layer printed using inkjet printing, there may be differences in design and color tone. In particular, when colored titanium paper is used as the substrate and the color of the substrate is used for the design, the differences in design and color tone tend to be larger.

[0006] Therefore, the present invention aims to provide decorative paper, decorative board, and a method for manufacturing decorative paper that can obtain the same level of design and color tone as when a pattern is formed by gravure printing. [Means for solving the problem]

[0007] To solve the aforementioned problems, the decorative paper according to the present invention is characterized by comprising: a base material made of paper; a pattern ink portion provided only on a part of one side of the base material to form a pattern; and an ink receiving portion provided only between the base material and the pattern ink portion so as to be located in the entire space between the base material and the pattern ink portion, and fixing the pattern ink portion to the base material.

[0008] Furthermore, in the decorative paper according to the present invention, it is preferable that the base material is titanium paper containing titanium oxide.

[0009] Furthermore, it is preferable that the decorative paper according to the present invention includes a transparent resin layer that is light-transmitting and is provided to cover one side of the base material and the pattern ink portion.

[0010] Furthermore, in the decorative paper according to the present invention, it is preferable that the transparent resin layer is made of melamine resin.

[0011] Furthermore, the decorative panel according to the present invention, which solves the aforementioned problems, is characterized by comprising the decorative paper described above and a substrate to which the other side of the base material of the decorative paper is adhered.

[0012] Furthermore, a method for manufacturing decorative paper according to the present invention, which solves the aforementioned problems, is a method for manufacturing decorative paper as described above, characterized by comprising: an ink receiving portion forming step of forming the ink receiving portion by inkjet printing a processing liquid containing the material for the ink receiving portion onto only a part of one side of the substrate; and a pattern ink portion forming step of inkjet printing an inkjet ink containing the material for the pattern ink portion onto all of the ink receiving portions to form the pattern ink portion on only a part of one side of the substrate.

[0013] Furthermore, a method for manufacturing decorative paper according to the present invention to solve the aforementioned problems is a method for manufacturing decorative paper as described above, characterized by comprising: an ink receiving portion forming step of forming the ink receiving portion by inkjet printing a processing liquid containing the material for the ink receiving portion onto only a part of one side of the substrate; a pattern ink portion forming step of forming the pattern ink portion on only a part of one side of the substrate by inkjet printing an inkjet ink containing the material for the pattern ink portion onto all of the ink receiving portions; and a transparent resin layer forming step of applying the resin liquid containing the material for the transparent resin layer to one side of the substrate and the pattern ink portion so as to cover one side of the substrate and the pattern ink portion with the resin liquid. [Effects of the Invention]

[0014] In the decorative paper and decorative board according to the present invention, the pattern ink portion is provided on only a part of one side of the base material, and the ink receiving portion is provided only between the base material and the pattern ink portion so as to be located in the entire area between the base material and the pattern ink portion. As a result, the area where the pattern ink portion is formed and the area where the ink receiving portion is formed are exactly the same. Therefore, the ink receiving portion can reliably fix and hold the pattern ink portion while preventing the ink receiving portion from being exposed from the pattern ink portion, and the area without the pattern ink portion can be made to the color of the base material.

[0015] Therefore, with the decorative paper and decorative board according to the present invention, it is possible to obtain the same design quality and color tone as decorative paper in which the same pattern as the pattern ink portion is formed by gravure printing.

[0016] Furthermore, according to the method for manufacturing decorative paper of the present invention, since the ink receiving area and the pattern ink area are formed by inkjet printing, it is easy to make the area where the pattern ink area is formed and the area where the ink receiving area is formed the same, and it is easy to reliably manufacture the decorative paper of the present invention. [Brief explanation of the drawing]

[0017] [Figure 1] This is a cross-sectional view showing the schematic structure of the main embodiments of decorative paper and decorative panels according to the present invention. [Figure 2] This is a flowchart showing the procedure of the main embodiment of the method for manufacturing decorative paper and decorative panels according to the present invention. [Modes for carrying out the invention]

[0018] Embodiments of the decorative paper, decorative board, and method for manufacturing decorative paper according to the present invention will be described based on the drawings. It should be noted that the present invention is not limited to the embodiments described below based on the drawings, and various technical matters described in each embodiment can be combined or replaced as needed.

[0019] [Main Implementations] The main embodiments of the decorative paper, decorative board, and method for manufacturing decorative paper according to the present invention will be described with reference to Figures 1 and 2.

[0020] <Cosmetic paper> As shown in Fig. 1, a pattern ink portion 12 for forming a pattern is provided on a part of one surface (the upper surface in Fig. 1) of a base material 11 made of paper. An ink receiving portion 13 for fixing the pattern ink portion 12 to the base material 11 is provided between the base material 11 and the pattern ink portion 12. One surface (the upper surface in Fig. 1) of the base material 11 and the pattern ink portion 12 are covered with a transparent resin layer 14 having light transmissivity. In the present embodiment, the decorative paper 10 is constituted by the base material 11, the pattern ink portion 12, the ink receiving portion 13, the transparent resin layer 14, and the like.

[0021] 《Base material 11》 The base material 11 is a titanium paper obtained by incorporating titanium white (titanium oxide) into cellulose pulp. By containing titanium white (titanium oxide) inside, the concealability can be enhanced, and the variation in quality due to the difference in color tone for each substrate can be suppressed. Specifically, for example, the base material 11 can be manufactured by forming a material containing titanium white (titanium oxide) or the like on a calendared printing base paper using a fourdrinier machine or the like.

[0022] 《Pattern ink portion 12》 The pattern ink portion 12 forms a pattern and imparts design properties to the decorative paper 10, and is provided only on a part of one surface (the upper surface in Fig. 1) of the base material 11. The pattern ink portion 12 is formed on the ink receiving portion 13 by inkjet printing with an aqueous ink for inkjet (hereinafter referred to as "inkjet ink") on the ink receiving portion 13. As the inkjet ink, known ones are used. The inkjet ink is one in which a colorant is dispersed in an aqueous medium liquid. The inkjet ink can also contain various other additives.

[0023] Examples of colorants include pigments and dyes. Pigments are preferred because of their water resistance, lightfastness, and resistance to deterioration (discoloration, etc.) caused by these factors. Dyes are also preferred because, due to their very small particle size and low viscosity, the viscosity does not increase easily even if the proportion of dye components in the medium is increased, and they dissolve easily in the medium, eliminating the need to add dispersants, which are one of the factors that increase viscosity. This makes them suitable for achieving both high colorability and print flatness.

[0024] The pattern ink section 12 can be ideally formed by printing using an inkjet printer equipped with a total of four inkjet colors (CMYK): cyan (C), magenta (M), yellow (Y), and black (K). It is also possible to use five or more colors by adding other inkjet inks such as light blue.

[0025] Ink receiving section 13 The ink receiving section 13 is for fixing the pattern ink section 12 to the base material 11. It is provided only between the base material 11 and the pattern ink section 12, so as to be located in all areas between the base material 11 and the pattern ink section 12, and is interposed in the gaps between the pulp fibers of the base material 11. The ink receiving section 13 is made of a mixture of, for example, binder resin, inorganic metal, additives, etc., and is white so as not to interfere with the color tone of the ink in the pattern ink section 12.

[0026] Examples of binder resins include urea-based resins, acrylic resins, ethylene vinyl acetate resins, and acrylic styrene resins. Examples of inorganic metals include silica, titania, calcium, and alumina. Examples of additives include cationic ink setting agents, surfactants, defoamers, thickeners, and water-resistant agents.

[0027] 《Transparent resin layer 14》 The transparent resin layer 14 protects the pattern ink area 12 while allowing the pattern to be seen, and is provided to cover one side of the substrate 11 (the top surface in Figure 1) and the pattern ink area 12. When heat resistance, scratch resistance, and stain resistance are required, the transparent resin layer 14 is preferably made of melamine resin. The transparent resin layer 14 is preferably 1 μm to 30 μm thick. Within this range, the function of protecting the surface can be sufficiently obtained, and the thickness can be made necessary and sufficient, thus suppressing an increase in manufacturing costs.

[0028] <Decorative panel> As shown in Figure 1, the other side (the bottom surface in Figure 1) of the base material 11 of the decorative paper 10 is bonded to the substrate 101 via an adhesive layer 102. In this embodiment, the decorative board 100 is composed of the decorative paper 10, the substrate 101, the adhesive layer 102, etc.

[0029] Circuit board 101 The substrate 101 forms the framework of the decorative panel 100, and materials such as tropical hardwood plywood, particleboard, medium-density fiberboard (MDF), and ordinary plywood are used.

[0030] 《Adhesive layer 102》 The adhesive layer 102 is for bonding the decorative paper 10 and the substrate 101, and any adhesive that can bond wood and paper materials can be used.

[0031] <Method for manufacturing decorative paper and decorative panels> The manufacturing method of the decorative paper 10 and decorative board 100 according to this embodiment will be explained with reference to Figure 2.

[0032] First, the ink receiving section 13 is formed by inkjet printing a processing liquid containing the material for the ink receiving section 13 onto only a portion of one side of the substrate 11 (ink receiving section formation step S11). At this time, the processing liquid is inkjet printed only on the areas where the inkjet ink forming the pattern ink section 12 will be inkjet printed. In other words, the ink receiving section 13 is printed in exactly the same position as the pattern ink section 12.

[0033] Next, inkjet ink containing the material for the pattern ink area 12 is inkjet printed onto all the ink receiving areas 13 to form the pattern ink area 12 on only a portion of one side of the substrate 11 (pattern ink area formation step S12). As a result, the pattern ink area 12 exists only where the ink receiving areas 13 are formed, and at the same time, the ink receiving areas 13 exist only where the pattern ink area 12 is formed.

[0034] Next, a transparent resin layer 14 is formed by applying a resin liquid containing a transparent resin material such as melamine resin to one side of the base material 11 and the pattern ink area 12, and then drying the resin liquid (transparent resin layer formation step S13). Through this process, decorative paper 10 is manufactured.

[0035] Next, an adhesive layer 102 is formed by applying an adhesive to one side of the substrate 101, and then the base material 11 of the decorative paper 10 is attached to the adhesive layer 102 to bond the decorative paper 10 to the substrate 101 (substrate bonding step S14). Through this process, the decorative panel 100 is manufactured.

[0036] <Effects> In the decorative paper 10 and decorative board 100 manufactured in this manner according to this embodiment, the area where the pattern ink portion 12 is formed and the area where the ink receiving portion 13 is formed are exactly the same. Therefore, the ink receiving portion 13 can securely fix and hold the pattern ink portion 12 while preventing the ink receiving portion 13 from being exposed from the pattern ink portion 12, and the areas without the pattern ink portion 12 can be made to the color of the base material 11.

[0037] Therefore, according to the decorative paper 10 and decorative board 100 of this embodiment, it is possible to obtain the same design quality and color tone as decorative paper in which the same pattern as the pattern ink portion 12 is formed by gravure printing.

[0038] Furthermore, according to the manufacturing method of the decorative paper 10 of this embodiment, since the ink receiving section 13 and the pattern ink section 12 are formed by inkjet printing, it is easy to make the location where the pattern ink section 12 is formed and the location where the ink receiving section 13 is formed the same, and it is easy to reliably manufacture the decorative paper 10 and decorative board 100 according to this embodiment.

[0039] [Other embodiments] In the embodiments described above, the case of decorative paper 10 and decorative board 100 provided with a transparent resin layer 14 was explained, but the present invention is not limited thereto. In other embodiments, for example, decorative paper and decorative board without the transparent resin layer 14 can also be used to obtain the same effects as the decorative paper 10 and decorative board 100 according to the embodiments described above. However, as in the embodiments described above, decorative paper 10 and decorative board 100 provided with a transparent resin layer 14 are highly preferable because they allow the pattern of the pattern ink area 12 to be visible while protecting the pattern ink area 12. [Examples]

[0040] Examples of decorative paper and decorative panels according to the present invention will be described in detail, but the present invention is not limited to the following embodiments described in detail.

[0041] [Preparation of test specimens, comparison specimens, and reference specimens] <Test specimen A> Using the white titanium paper shown below as the base material, an ink-receiving area was formed by inkjet printing a processing solution containing the binder resin and inorganic metal shown below onto only a portion of one side of the base material (in the same shape as the pattern in the pattern ink area) (ink-receiving area formation process). 《Base material》 • White titanium paper manufactured by Mitsubishi Paper Mills Ltd. Processing solution • Binder resin: Urea-based resin Inorganic metals: Calcium carbonate

[0042] Next, the following inkjet inks were inkjet printed onto the ink receiving section to form the pattern ink area (pattern ink area formation process). Inkjet ink • Toyo Color Co., Ltd.'s "Liojet(registered trademark) AP" series

[0043] Next, a resin liquid containing melamine resin was applied to one side of the substrate and the pattern ink area, and then heated, dried, and cured to form a transparent resin layer (transparent resin layer formation step). Through this process, test specimen A of decorative paper was prepared.

[0044] <Test specimen B> Test specimen B of decorative paper was prepared by using the same method as test specimen A, except that the colored titanium paper described below was used as the base material. 《Base material》 • Brown titanium paper manufactured by Mitsubishi Paper Mills Ltd.

[0045] <Comparative Object A1> A comparative sample of decorative paper, A1, was prepared by following the same procedure as for test sample A, except that in the ink receiving section formation process, the processing liquid was gravure printed over the entire surface of one side of the substrate to form the ink receiving section.

[0046] <Comparison B1> A comparative sample of decorative paper, sample B1, was prepared by following the same procedure as for test sample B, except that in the ink receiving section formation process, the processing liquid was gravure printed over the entire surface of one side of the substrate to form the ink receiving section.

[0047] <Comparison A2> A comparative sample of decorative paper, A2, was prepared by omitting the ink receiving section formation process, i.e., by omitting the ink receiving section, except that it was the same as test sample A.

[0048] <Comparison B2> A comparative sample of decorative paper, sample B2, was prepared by omitting the ink receiving section formation process, i.e., by omitting the ink receiving section, except that it was the same as sample B.

[0049] <Reference body A> A standard decorative paper sample A was prepared by omitting the ink receiving section formation process, that is, by omitting the ink receiving section and forming the patterned ink section by gravure printing the following gravure ink onto the substrate, except that it was the same as test sample A. Gravure Ink • "ATSK" series manufactured by Toyo Ink Co., Ltd.

[0050] <Reference body B> A reference sample B of decorative paper was prepared by making it identical to reference sample A, except that it used the same colored titanium paper as test sample B as the base material.

[0051] [Evaluation details] <Wrinkle formation> The wrinkle formation status was visually inspected for test specimens A and B, and comparison specimens A1, A2, B1, and B2. The results are shown in Table 1 below. In Table 1, "○" indicates no wrinkle formation, "△" indicates slight wrinkle formation, and "×" indicates clear wrinkle formation.

[0052] <Design> The aesthetic appearance of test specimen A and comparative specimens A1 and A2 was visually confirmed in comparison with standard specimen A. The aesthetic appearance of test specimen B and comparative specimens B1 and B2 was visually confirmed in comparison with standard specimen B. The results are shown in Table 1 below. In Table 1, "○" indicates that the aesthetic appearance was equivalent to that of the standard specimen, "△" indicates that there was a slight decrease in aesthetic appearance compared to the standard specimen, and "×" indicates that there was a clear decrease in aesthetic appearance compared to the standard specimen.

[0053] <Color tone> Test specimens A and B, comparator specimens A1, A2, B1, B2, and reference specimens A and B were irradiated with light from a D50 light source (color temperature 5003K) as defined by the International Commission on Illumination (CIE). Using an X-Rite® eXact spectrodensitometer manufactured by X-Rite Corporation, USA, the color difference dE00 between test specimen A and comparator specimens A1 and A2 and reference specimen A, and the color difference dE00 between test specimen B and comparator specimens B1 and B2 and reference specimen B were determined based on the color difference formula defined in CIE DE2000, and the color tone was confirmed. The results are shown in Table 1 below. In Table 1, "○" indicates that the color difference dE00 was less than 1.0, "△" indicates that the color difference dE00 was 1.0 or more and less than 2.0, and "×" indicates that the color difference dE00 was 2.0 or more.

[0054] [Evaluation Results] The evaluation results are shown in Table 1 below.

[0055] [Table 1]

[0056] As can be seen from Table 1, wrinkles appeared in comparison samples A2 and B2, which lacked an ink receiving section. Furthermore, in comparison samples A1 and B1, which had an ink receiving section throughout, the design quality was reduced and the color tone differed compared to the standard samples A and B, which were printed using gravure printing. In particular, the design quality reduction and color tone difference were greater in comparison sample B1, which used a colored substrate, than in comparison sample A1, which used a white substrate.

[0057] In contrast, test specimens A and B according to the present invention achieved the same design and color tone as standard specimens A and B produced by gravure printing, while preventing the occurrence of wrinkles.

[0058] These results confirm the effectiveness of the decorative paper and decorative board according to the present invention. [Industrial applicability]

[0059] The present invention provides decorative paper, decorative panels, and a method for manufacturing decorative paper that can obtain design quality and color tone equivalent to that obtained when forming patterns by gravure printing, and therefore can be used very effectively in various industries, including the construction industry. [Explanation of Symbols]

[0060] 10 Cosmetic paper 11 Base material 12. Ink portion of the design 13 Ink Receiving Department 14 Transparent resin layer 100 decorative panels 101 circuit board 102 Adhesive layer

Claims

1. A base material made of paper, A pattern ink portion is provided on only a part of one side of the aforementioned substrate to form a pattern, An ink receiving section is provided only between the substrate and the pattern ink section so as to be located in all areas between the substrate and the pattern ink section, and fixes the pattern ink section to the substrate; A decorative paper characterized by having the following features.

2. The substrate is titanium paper containing titanium oxide. The decorative paper according to feature 1.

3. The substrate is provided with a light-transmitting transparent resin layer that covers one side and the pattern ink portion. The decorative paper according to feature 1.

4. The transparent resin layer is made of melamine resin. The decorative paper according to feature 3.

5. A decorative paper according to any one of claims 1 to 4, The other side of the base material of the decorative paper is bonded to a substrate, A decorative panel characterized by having the following features.

6. A method for manufacturing decorative paper according to claim 1 or 2, An ink receiving portion forming step, wherein a processing liquid containing the material for the ink receiving portion is inkjet printed onto only a portion of one side of the substrate to form the ink receiving portion; A pattern ink portion forming step, wherein an inkjet ink containing the material for the pattern ink portion is inkjet printed onto all of the ink receiving portions to form the pattern ink portion on only a part of one side of the substrate, A method for manufacturing decorative paper, characterized by performing the following steps.

7. A method for manufacturing decorative paper according to claim 3 or 4, An ink receiving portion forming step, wherein a processing liquid containing the material for the ink receiving portion is inkjet printed onto only a portion of one side of the substrate to form the ink receiving portion; A pattern ink portion forming step, wherein an inkjet ink containing the material for the pattern ink portion is inkjet printed onto all of the ink receiving portions to form the pattern ink portion on only a part of one side of the substrate, A transparent resin layer forming step involves applying the resin liquid containing the material for the transparent resin layer to one side of the substrate and the pattern ink area so as to cover the substrate with the resin liquid, A method for manufacturing decorative paper, characterized by performing the following steps.

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