Decorative paper and decorative panels

Abstract

To provide decorative paper and decorative panels that have a matte resin layer containing silica and possess sufficient design appeal. [Solution] The decorative paper 10 comprises a base layer 1, a pattern printing layer 2 provided on the upper side UP of the base layer 1, a high-design protective layer 3 partially provided on the upper side UP of the pattern printing layer 2, and a high-design resin layer 4 provided on the upper side UP of the high-design protective layer 3 and positioned in a position synchronized with the high-design protective layer 3, wherein the high-design resin layer 4 contains silica in a content ratio greater than 10% and less than 30%.

Description

Technical Field

[0001] The present invention relates to decorative papers and decorative boards.

Background Art

[0002] Conventionally, there has been a decorative board in which a decorative paper is impregnated with a thermosetting resin such as a melamine resin and the impregnated thermosetting resin is cured. Such a decorative board has a high surface hardness and is excellent in stain resistance, abrasion resistance, heat resistance, water resistance, etc., and is therefore used, for example, as a surface material for furniture such as desks or as a surface material for fixtures such as store counters.

[0003] In addition, in order to impart a visual three-dimensional effect to the surfaces of decorative papers and decorative boards, there are decorative papers and decorative boards in which the gloss of the resin layer on the surface is adjusted with a matting agent or the like. For example, by laminating a matte resin layer containing a matting agent such as silica and a layer having a higher gloss than the matte resin layer, a gloss-matte feeling can be imparted to the decorative paper and the decorative board, and a decorative paper and a decorative board having excellent design properties can be realized. In the case of a decorative board impregnated with an impregnating resin such as a melamine resin, for example, a gloss-matte feeling is imparted by the difference in gloss between the matte resin layer provided in the decorative paper and the impregnating resin impregnated in the decorative paper.

[0004] As a decorative paper with gloss adjustment and a decorative board obtained by impregnating the decorative paper with a resin, there are a decorative paper for a resin-impregnated decorative board and a resin-impregnated decorative board described in Patent Document 1. The decorative paper for a resin-impregnated decorative board and the resin-impregnated decorative board described in Patent Document 1 include a base paper, a pattern layer formed by printing a pattern on the base paper, and a liquid-repellent cured film provided on the pattern layer. The liquid-repellent cured film consists of a first liquid-repellent cured film covering the entire pattern layer and a second liquid-repellent cured film provided on a part of the first liquid-repellent cured film, and the first liquid-repellent cured film and the second liquid-repellent cured film have different glosses.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

[0006] However, when forming a matte resin layer containing silica for the purpose of adjusting the gloss of decorative paper and decorative panels, if the silica content in the matte resin layer is too low, a sufficient glossy-matte finish cannot be obtained, and the decorative paper and decorative panels may not be given sufficient aesthetic appeal. On the other hand, if the silica content in the matte resin layer is too high, whitening may occur on the surface of the decorative paper, which may reduce the aesthetic appeal of the decorative paper and decorative panels.

[0007] Furthermore, if the silica content in the matte resin layer is too high, there are concerns about a decrease in surface properties such as scratch resistance, abrasion resistance, and stain resistance, as well as a decrease in the impregnation of the impregnating resin and a decrease in printability.

[0008] Based on the above circumstances, the present invention aims to provide decorative paper and decorative panels that have a matte resin layer containing silica and have sufficient design appeal. [Means for solving the problem]

[0009] To solve the above problems, this invention proposes the following means. The decorative paper of the present invention comprises a base layer, a pattern printing layer provided on the upper side of the base layer, a high-design protective layer partially provided on the upper side of the pattern printing layer, and a high-design resin layer provided on the upper side of the high-design protective layer and positioned in a manner synchronized with the high-design protective layer, wherein the high-design resin layer contains silica in a content ratio greater than 10% and less than 30%.

[0010] In the decorative paper described above, the high-design resin layer may contain a silicone additive.

[0011] In the decorative paper described above, the high-design resin layer may be positioned in a location that is synchronized with the pattern of the pattern printed layer.

[0012] In the decorative paper described above, the high-design resin layer may include a thermosetting resin, an ionizing radiation-curable resin, or an ultraviolet-curable resin.

[0013] The decorative panel of the present invention comprises any of the decorative papers described above, and an impregnating resin that has been impregnated into the decorative paper and hardened.

[0014] In the decorative panel described above, the surface may have a first region covered with the impregnating resin and a second region where the high-design resin layer is exposed.

[0015] In the decorative panel described above, the 60-degree reflective gloss of the first region may be between 2 and 20. [Effects of the Invention]

[0016] The present invention provides decorative paper and decorative panels that have a silica-containing matte resin layer and possess sufficient design appeal. [Brief explanation of the drawing]

[0017] [Figure 1] This is a schematic cross-sectional view showing the structure of the decorative panel according to this embodiment. [Figure 2] This is a schematic cross-sectional view showing the structure of the decorative paper according to this embodiment. [Figure 3] This is a schematic cross-sectional view showing the pressing process in the manufacturing method of the decorative panel. [Figure 4] This is a schematic cross-sectional view showing the mold release process in the manufacturing method of the decorative laminate. [Modes for carrying out the invention]

[0018] One embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view schematically showing the configuration of the decorative board 100 according to the present embodiment. FIG. 2 is a cross-sectional view schematically showing the configuration of the decorative paper 10 according to the present embodiment.

[0019] In the present embodiment, as shown in FIGS. 1 and 2, the thickness direction of the decorative paper 10 and the decorative board 100 is defined as the "vertical direction V", the side on which the original web layer 1 of the decorative paper 10 is provided 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. Further, the plate surface direction of the decorative board 100 is defined as the "width direction C". Here, the "plate surface direction (width direction C)" of the decorative board 100 indicates a direction orthogonal to the vertical direction V. For example, when the vertical direction V indicates the vertical direction, the plate surface direction (width direction C) indicates the horizontal direction.

[0020] [Decorative board 100] The decorative board 100 includes the decorative paper 10 and the impregnated resin 20. The decorative board 100 is formed by impregnating the decorative paper 10 with the impregnated resin 20 and curing the impregnated resin 20. By impregnating the decorative paper 10 with the impregnated resin 20, the impregnated resin 20 penetrates into the interior of the decorative paper 10 and cures.

[0021] In the decorative board 100, as shown in FIG. 1, the impregnated resin 20 covers at least a part of the surface of the decorative paper 10 and cures. The decorative board 100 impregnated with and cured with the impregnated resin 20 has excellent properties such as high surface hardness, solvent resistance, stain resistance, abrasion resistance, heat resistance, and water resistance.

[0022] [Decorative paper 10] The decorative paper 10 includes an original web layer 1, a pattern printing layer 2, a high-design protection layer 3, and a high-design resin layer (mat resin layer) 4.

[0023] [Original web layer 1] The base layer 1 is a layer provided on the lower LO of the decorative paper 10. The base layer 1 is a known fibrous sheet that can be impregnated with the impregnation resin 20. For example, titanium paper, tissue paper, fine paper, unbleached kraft paper, or bleached kraft paper can be used as the base layer 1. It is preferable to use titanium paper as the base layer 1, as it has excellent printability and resin impregnation properties. There are no restrictions on the thickness of the base layer 1, and generally, a basis weight of 20 g / m² is used. 2 More than 200g / m 2 The following will be used.

[0024] [Image Printing Layer 2] The pattern printing layer 2 is a layer provided on the upper side UP of the base material layer 1, and is formed by printing, for example, wood grain, stone pattern, or sand pattern. Known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing can be used to print the pattern printing layer 2.

[0025] For the pattern printing layer 2, any known printing ink suitable for the printing method used can be employed, but it is preferable to use a water-based ink. Compared to oil-based inks, water-based inks are more compatible with the aqueous solution of the impregnating resin 20, allowing for rapid and uniform impregnation of the decorative paper 10 with the impregnating resin 20. Furthermore, by integrating with the impregnating resin 20, the water-based ink can achieve excellent strength.

[0026] It is preferable to use a water-based ink for the pattern printing layer 2 in which the binder resin mainly consists of casein or emulsion resin. Binder resins mainly consisting of casein or emulsion resin have the property of becoming poorly water-soluble after going through a drying process after printing the ink, and in the process of impregnating with the impregnation resin 20, they are difficult to redissolve in the aqueous solution of the impregnation resin 20, so as not to damage the pattern of the pattern printing layer 2, and it is possible to suppress contamination of the dissolved pattern printing layer 2 with the impregnation resin 20.

[0027] Examples of emulsion resins that can be used in the binder resin include acrylic, vinyl acetate, styrene, and urethane types. In addition to casein or emulsion resin, binder resins that also contain water-soluble resins such as polyvinyl alcohol or polyacrylamide, polysaccharides, or water-soluble polymers such as cellulose derivatives may be used to improve ink stability.

[0028] As shown in Figures 1 and 2, in this embodiment, the pattern printing layer 2 comprises a pattern body layer 2a and an accent ink layer 2b. The pattern body layer 2a is a layer that covers the entire surface of the base material layer 1 in the pattern printing layer 2. However, the pattern body layer 2a does not need to strictly cover the entire surface of the base material layer 1.

[0029] The emphasis ink layer 2b is a layer partially provided on the upper side UP of the main pattern layer 2a. The emphasis ink layer 2b is positioned, for example, in a location that is synchronized with the pattern on the pattern printing layer 2. For example, if the pattern printing layer 2 has a wood grain pattern, by positioning the emphasis ink layer 2b in a location that is synchronized with the pores of the wood grain pattern, a visual three-dimensional effect can be added to the pores of the wood grain pattern.

[0030] [High-design protective layer 3] The high-design protective layer 3 is a layer partially provided on the upper side UP of the pattern printing layer 2. It is preferable that the high-design protective layer 3 be made of a material that is transparent or semi-transparent enough to allow the pattern of the pattern printing layer 2 to be seen through. While the material of the high-design protective layer 3 is not limited, it is preferable to use a thermosetting resin. Examples of resins used for the high-design protective layer 3 include casein resin and urethane resin.

[0031] As a method for forming the high-design protective layer 3, known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing can be employed. Furthermore, the high-design protective layer 3 may be formed using known coating equipment.

[0032] In this embodiment, the high-design protective layer 3 is positioned in a location synchronized with the pattern on the pattern printing layer 2. Specifically, the high-design protective layer 3 is positioned in a location corresponding to the accent ink layer 2b on the pattern printing layer 2.

[0033] [High-design resin layer (matte resin layer) 4] The high-design resin layer (matte resin layer) 4 is a layer provided on the upper side UP of the high-design protective layer 3. It is preferable that the high-design resin layer 4 be made of a material that is transparent or semi-transparent enough to allow the design of the design printing layer 2 to be seen through the high-design protective layer 3.

[0034] As the high-design resin layer 4, thermosetting resins, ionizing radiation-curable resins, ultraviolet-curable resins, or mixtures thereof can be used. For example, as the high-design resin layer 4, thermosetting resins such as melamine resins, epoxy resins, urea resins, phenolic resins, unsaturated polyester resins, diallyl phthalate resins, benzoguanamine resins, urethane resins, amino alkyd resins, and silicone resins can be used, as well as ionizing radiation-curable resins such as (meth)acrylate resins and unsaturated polyester resins. The high-design resin layer 4 preferably contains a silicone additive as a release agent to make the impregnating resin 20 easier to repel.

[0035] As a method for forming the high-design resin layer 4, known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing can be employed. Alternatively, the high-design resin layer 4 may be formed using a known coating apparatus.

[0036] In this embodiment, the high-design resin layer 4 is positioned in a location synchronized with the high-design protective layer 3, as shown in Figures 1 and 2. As described above, the high-design protective layer 3 in this embodiment is positioned in a location synchronized with the pattern of the pattern printing layer 2. That is, in this embodiment, the high-design resin layer 4 and the high-design protective layer 3 are positioned in a location synchronized with the pattern of the pattern printing layer 2.

[0037] The coating area of ​​the high-design protective layer 3 is preferably 0.5 times or more and 1.5 times or less than the coating area of ​​the high-design resin layer 4. Here, the coating area refers to the area in a plan view on the decorative paper 10, as seen from above (UP).

[0038] Furthermore, it is not necessary for all of the resin forming the high-design resin layer 4 to be located on the upper side UP of the high-design protective layer 3; the high-design resin layer 4 only requires that at least a portion of the resin forming the high-design resin layer 4 be located on the upper side UP of the high-design protective layer 3.

[0039] For example, when the coating area of ​​the high-design protective layer 3 is less than 1 times the coating area of ​​the high-design resin layer 4, that is, when the coating area of ​​the high-design resin layer 4 is larger than the coating area of ​​the high-design protective layer 3, a portion of the high-design resin layer 4 is positioned above the pattern printing layer 2.

[0040] The coating area of ​​the high-design protective layer 3 shown in Figures 1 and 2 is greater than 1 times the coating area of ​​the high-design resin layer 4. In other words, in the decorative paper 10 shown in Figures 1 and 2, the coating area of ​​the high-design resin layer 4 is smaller than the coating area of ​​the high-design protective layer 3.

[0041] Since the high-design resin layer 4 is provided on the upper side UP of the high-design protective layer 3, it is less likely to seep into the base material layer 1. In other words, the high-design protective layer 3 suppresses the seeping of the high-design resin layer 4 into the base material layer 1. Therefore, it is possible to prevent the area of ​​the high-design resin layer 4 formed on the upper side UP of the high-design protective layer 3 from becoming smaller than the desired area due to seeping, thereby suppressing a decrease in design quality.

[0042] Even when the coating area of ​​the high-design protective layer 3 is smaller than the coating area of ​​the high-design resin layer 4, at least a portion of the high-design resin layer 4 is provided on the upper side UP of the high-design protective layer 3. Therefore, the high-design protective layer 3 can suppress the high-design resin layer 4 from seeping into the base material layer 1.

[0043] The high-design protective layer 3 is synchronized with the pattern of the pattern printing layer 2 and is partially provided on the upper side UP of the pattern printing layer 2, so it does not hinder the sufficient impregnation of the decorative paper 10 by the impregnation resin 20. In the width direction C of the decorative paper 10, the high-design protective layer 3 is divided into multiple sections and arranged. On the upper surface of the pattern printing layer 2, gaps (micropores) into which the impregnation resin 20 can penetrate are formed between adjacent high-design protective layers 3.

[0044] This allows the decorative paper 10 to be sufficiently impregnated with the impregnation resin 20. By sufficiently impregnating the decorative paper 10 with the impregnation resin 20, the decorative panel 100 can have excellent solvent resistance.

[0045] By partially providing the high-design protective layer 3 on the upper side UP of the pattern printing layer 2 and providing the high-design resin layer 4 in coordination with the high-design protective layer 3, the decorative paper 10 can achieve both excellent design and impregnation properties. Furthermore, the decorative board 100 formed by impregnating the decorative paper 10, which has excellent design and impregnation properties, with the impregnation resin 20 can achieve both excellent design and solvent resistance.

[0046] In this embodiment, the high-design resin layer 4, which is positioned in the same location as the high-design protective layer 3, is divided into multiple sections and arranged in the width direction C of the decorative paper 10. On the surface of the decorative paper 10 (upper side UP), gaps (micropores) into which the impregnating resin 20 can penetrate are formed between adjacent high-design resin layers 4.

[0047] The micropores formed between adjacent high-design protective layers 3 and the micropores formed between adjacent high-design resin layers 4 are in communication in the vertical direction V. In the decorative panel 100, the impregnating resin 20 is placed in the micropores (impregnation holes) that are in communication with the micropores formed between adjacent high-design protective layers 3 and the micropores formed between adjacent high-design resin layers 4.

[0048] The high-design resin layer 4 contains silica. Silica is added to the high-design resin layer 4 as a matting agent to impart a low-gloss, matte finish. The silica content in the high-design resin layer 4 is greater than 10% and less than 30%.

[0049] By increasing the silica content in the high-design resin layer 4 to more than 10%, a sufficient matte finish can be imparted to the high-design resin layer 4. Furthermore, by keeping the silica content in the high-design resin layer 4 below 30%, whitening of the high-design resin layer 4 can be suppressed, thereby preventing a decrease in the aesthetic appeal of the decorative paper 10 and decorative panel 100 due to whitening.

[0050] Furthermore, by limiting the silica content in the high-design resin layer 4 to less than 30%, the decorative paper 10 and decorative panel 100 can be given excellent surface properties (scratch resistance, abrasion resistance, and stain resistance).

[0051] Furthermore, by keeping the silica content in the high-design resin layer 4 below 30%, a decrease in printability and impregnation properties can be suppressed in the decorative paper 10. Printability refers to the degree of variation in design that occurs between the area printed immediately after the start of printing and the area printed immediately before the end of printing when the decorative paper 10 is continuously produced by a printing roll or the like.

[0052] If the silica content in the high-design resin layer 4 is 30% or more, for example, the particle size distribution of the silica added to the resin forming the high-design resin layer 4 can cause variations in the design, as the particle size of the silica in the high-design resin layer 4 printed immediately after the start of printing differs from the particle size of the silica in the high-design resin layer 4 printed immediately before the end of printing.

[0053] By setting the silica content in the high-design resin layer 4 to less than 30%, the decorative paper 10 exhibits excellent printability, resulting in less variation in design between areas printed immediately after the start of printing and areas printed immediately before the end of printing, thus stably maintaining excellent design quality.

[0054] Furthermore, impregnation refers to the performance related to how easily the impregnation resin 20 can penetrate the decorative paper 10. By setting the silica content in the high-design resin layer 4 to less than 30%, the decorative paper 10 exhibits excellent impregnation properties, allowing the impregnation resin 20 to penetrate rapidly.

[0055] [Impregnation resin 20] The impregnation resin 20 is impregnated into the decorative paper 10 as an aqueous impregnation solution dissolved or dispersed in water. The impregnation resin 20 is a known thermosetting resin used in resin-impregnated decorative boards. As the impregnation resin 20, melamine resins, epoxy resins, diallyl phthalate resins, benzoguanamine resins, urethane resins, alkyd resins, unsaturated polyester resins, phenolic resins, or urea resins can be used. It is preferable to use melamine resin as the impregnation resin 20, as it has high strength and excellent solvent resistance, stain resistance, abrasion resistance, heat resistance, and water resistance.

[0056] [Method for manufacturing decorative paper 10 and decorative board 100] Next, a method for manufacturing decorative paper 10 and decorative panels 100 using a decorative panel manufacturing system will be described. A decorative panel manufacturing system refers to a system that manufactures decorative paper 10 and decorative panels 100.

[0057] [Image printing process] First, the decorative laminate manufacturing system performs a pattern printing process. In the pattern printing process, the decorative laminate manufacturing system prints a pattern on the upper side UP of the base layer 1 to form a pattern printing layer 2.

[0058] [Protective layer printing process] Next, the decorative laminate manufacturing system performs a protective layer printing process. In the protective layer printing process, the decorative laminate manufacturing system forms a high-design protective layer 3 on the upper side UP of the pattern printing layer 2. At this time, the high-design protective layer 3 is formed partially on the upper side UP of the pattern printing layer 2. Specifically, the high-design protective layer 3 is positioned in a location that is synchronized with the pattern on the pattern printing layer 2.

[0059] [Surface resin layer printing process] Next, the decorative laminate manufacturing system performs a surface resin layer printing process. In the surface resin layer printing process, the decorative laminate manufacturing system forms a high-design resin layer 4 on the upper side UP of the high-design protective layer 3 to obtain decorative paper 10.

[0060] In this case, the high-design resin layer 4 is provided in conjunction with the high-design protective layer 3. Therefore, the high-design protective layer 3 suppresses the penetration of the high-design resin layer 4 into the base material layer 1. For example, if the high-design resin layer 4 penetrates into the base material layer 1, the gloss-matt expression of the low-gloss high-design resin layer 4 weakens, and the design quality deteriorates. In addition, variations in the degree of penetration of the high-design resin layer 4 reduce production stability.

[0061] The decorative paper 10 formed by the above-described surface resin layer printing process has excellent design and production stability because the high-design protective layer 3 suppresses the penetration of the high-design resin layer 4 into the base layer 1, thereby suppressing a decrease in design quality and production stability.

[0062] Furthermore, in the surface resin layer printing process, by forming the high-design protective layer 3 such that its coating area is 0.5 to 1.5 times that of the high-design resin layer 4, the penetration of the high-design resin layer 4 into the base material layer 1 can be further suppressed.

[0063] [Resin impregnation process] Next, the decorative panel manufacturing system performs a resin impregnation process. In the resin impregnation process, the decorative panel manufacturing system impregnates the decorative paper 10 obtained in the surface resin layer printing process with impregnation resin 20 to form impregnated decorative paper 100p (see Figure 3).

[0064] At this time, the decorative paper 10 may be impregnated with the impregnating resin 20 from the upper side UP, or from the lower side LO. Alternatively, it may be impregnated in multiple stages from either the upper side UP or the lower side LO, or it may be impregnated simultaneously from both the upper side UP and the lower side LO.

[0065] Since the high-design protective layer 3 formed in the protective layer printing process described above is partially provided on the upper side UP of the pattern printing layer 2, it does not hinder the impregnation of the decorative paper 10 with the impregnation resin 20. Therefore, the decorative paper 10 has excellent impregnation properties, and the resin impregnation process allows the decorative paper 10 to be sufficiently impregnated with the impregnation resin 20.

[0066] In the resin impregnation process, the impregnating resin 20 impregnated into the decorative paper 10 seeps into the base layer 1. The impregnating resin 20 also seeps into the aforementioned impregnation holes formed between adjacent high-design protective layers 3 and between adjacent high-design resin layers 4 on the upper side UP of the pattern printing layer 2.

[0067] [Pressing process] Next, the decorative panel manufacturing system performs a pressing process. Figure 3 is a schematic cross-sectional view showing the pressing process in the manufacturing method of the decorative panel 100. In the pressing process, the decorative panel manufacturing system sandwiches the impregnated decorative paper 100p, which was formed by impregnating the decorative paper 10 with impregnation resin 20 in the resin impregnation process described above, between press plates PM such as metal plates from the upper side UP and the lower side LO, and applies pressure and heat to the impregnated decorative paper 100p from the upper side UP and the lower side LO.

[0068] The thermosetting resin forming the impregnating resin 20 hardens when the impregnated decorative paper 100p is pressurized and heated. As a method for heating and pressurizing the impregnated decorative paper 100p, a method of pressing with a metal plate and flat-pressure pressing, or a circular pressure continuous lamination method can be employed.

[0069] Furthermore, in the pressing process, as shown in Figure 3, release paper RP is provided in the area that comes into contact with the surface 100ps of the impregnated decorative paper 100p. Specifically, on the upper side UP of the impregnated decorative paper 100p, release paper RP is provided between the press plate PM and the surface 100ps of the impregnated decorative paper 100p.

[0070] [Mold release process] Next, the decorative panel manufacturing system performs a demolding step. Figure 4 is a schematic cross-sectional view showing the demolding step in the manufacturing method of the decorative panel 100. In the demolding step, the decorative panel manufacturing system separates at least the upper UP press plate PM from the surface 100ps of the impregnated decorative paper 100p by moving it upward UP, among the press plates PM that sandwich the impregnated decorative paper 100p in the vertical direction V.

[0071] As a result, as shown in Figure 4, the impregnating resin 20 covering the high-design resin layer 4 moves upward together with the release paper RP and is removed from the upper surface of the high-design resin layer 4. The high-design resin layer 4 contains, for example, a silicone additive as a release agent. The presence of a silicone additive in the high-design resin layer 4 reduces the adhesion between the high-design resin layer 4 and the impregnating resin 20, causing the impregnating resin 20 to be repelled from the high-design resin layer 4.

[0072] The impregnating resin 20 that is not sufficiently adhered to the high-design resin layer 4 separates from the high-design resin layer 4 together with the release paper RP. As a result, a decorative panel 100 is formed on the surface 100s, with a region covered by the impregnating resin 20 (first region) and a region where the high-design resin layer 4 is exposed (second region).

[0073] Furthermore, during the release process, it is not necessary for all of the impregnating resin 20 covering the high-design resin layer 4 to be removed from the upper surface UP of the high-design resin layer 4. The upper surface UP of the high-design resin layer 4 may be slightly covered, for example, by a thin layer of impregnating resin 20 remaining on the upper surface UP of the high-design resin layer 4.

[0074] As described above, the high-design resin layer 4 contains silica in a content ratio greater than 10% and less than 30%. The high-design resin layer 4 has a low-gloss matte finish due to the silica content ratio greater than 10%. On the surface 100s of the decorative panel 100, the impregnating resin 20 has a higher gloss than the high-design resin layer 4.

[0075] On the surface 100s of the decorative panel 100, the 60-degree reflective gloss of the first region covered by the impregnating resin 20 is preferably 2 or more and 20 or less, and more preferably 2 or more and 6 or less. As described above, the high-design resin layer 4 has sufficient matteness (high matteness) by having a silica content greater than 10%. By setting the 60-degree reflective gloss of the first region covered by the impregnating resin 20 to 2 or more and 20 or less, the difference in gloss between the high-design resin layer 4 and the impregnating resin 20 can impart to the decorative panel 100 an excellent design with low gloss and a gloss-matte feel. Furthermore, by setting the 60-degree reflective gloss of the first region covered by the impregnating resin 20 to 2 or more and 6 or less, it is possible to realize a decorative panel 100 with a gloss-matte feel while having even lower gloss and an excellent design.

[0076] In this embodiment, the reflective gloss refers to the specular gloss as defined in JIS Z 8741. 60-degree reflective gloss refers to the 60-degree specular gloss as defined in the JIS standard, and represents the gloss of reflected light at an incident angle of 60 degrees on the surface 100s of the decorative panel 100. The gloss of reflected light can be measured using a measuring instrument such as a surface gloss meter.

[0077] By including silica in the high-design resin layer 4 at a concentration greater than 10%, the surface 100s of the decorative panel 100 is given a glossy-matt finish due to the matte finish provided by the high-design resin layer 4 and the glossy finish provided by the impregnating resin 20. As a result, the decorative panel 100 can have excellent design properties. The decorative panel 100 is formed by a release process, and the manufacturing process of the decorative panel 100 using the decorative panel manufacturing system is completed.

[0078] The decorative paper 10 and decorative board 100 of this embodiment include a base layer 1, a pattern printing layer 2 provided on the upper side UP of the base layer 1, a high-design protective layer 3 partially provided on the upper side UP of the pattern printing layer 2, and a high-design resin layer 4 provided on the upper side UP of the high-design protective layer 3 and positioned in a position synchronized with the high-design protective layer 3. The high-design resin layer 4 contains silica in a content ratio greater than 10% and less than 30%.

[0079] Decorative paper 10 and decorative panels 100 with this configuration can have a sufficiently matte finish due to the high-design resin layer 4 containing silica at a content ratio greater than 10%. Furthermore, by keeping the silica content in the high-design resin layer 4 below 30%, whitening of the high-design resin layer 4 can be suppressed, thereby preventing a decrease in the aesthetic appeal of the decorative paper 10 and decorative panels 100 due to whitening.

[0080] Therefore, according to the decorative paper 10 and decorative panel 100 of this embodiment, it is possible to provide decorative paper 10 and decorative panel 100 that have a silica-containing matte resin layer (high-design resin layer) 4 and have sufficient design appeal.

[0081] The decorative paper 10 and decorative board 100 can have excellent surface properties, sufficient printability, and sufficient impregnation by limiting the silica content in the high-design resin layer 4 to less than 30%.

[0082] Although one embodiment of the present invention has been described in detail above with reference to the drawings, the specific configuration is not limited to this embodiment, and design changes and the like that do not depart from the spirit of the present invention are also included. Furthermore, the components shown in the above-described embodiment and the following modifications can be combined as appropriate.

[0083] (Variation 1) In the above embodiment, the pattern printing layer 2 comprises a pattern body layer 2a and an emphasis ink layer 2b, but the configuration of the pattern printing layer is not limited thereto. The pattern printing layer does not necessarily have to include the emphasis ink layer 2b.

[0084] (Modification 2) In the above embodiment, the decorative panel 100 comprises decorative paper 10 and impregnating resin 20, but the form of the decorative panel is not limited thereto. The decorative panel may also include a core paper or base material on the lower side LO of the decorative paper 10.

[0085] As the core paper laminated on the lower LO of the decorative paper 10, for example, titanium paper, bleached kraft paper, unbleached kraft paper, glass fiber nonwoven fabric, etc. may be used. Alternatively, core paper impregnated with a thermosetting resin may be laminated on the lower LO of the decorative paper 10 and then pressurized and heated. As the thermosetting resin to be impregnated into the core paper, for example, melamine resin, epoxy resin, diallyl phthalate resin, benzoguanamine resin, urethane resin, alkyd resin, unsaturated polyester resin, phenolic resin, urea resin, etc. may be used.

[0086] Furthermore, as the base material laminated to the lower LO of the decorative paper 10, a wood-based base material such as particleboard or medium-density fiberboard (MDF), a metal plate-shaped member such as aluminum or stainless steel, or a composite board in which metal such as aluminum is attached to both sides of a core material made of resin such as polyethylene can be used. When laminating core paper or base material to the lower LO of the decorative paper 10, the lamination may be done using an adhesive. By laminating core paper or base material to the lower LO of the decorative paper 10 to form a decorative panel, any desired functions such as improved rigidity or adjustment of thickness can be given to the decorative panel.

[0087] The present invention will be described in detail with reference to the following examples. The present invention is not limited to the following examples.

[0088] (Example 1) As for the base material layer 1, the basis weight is 80 g / m². 2 Titanium paper was prepared. A patterned printing layer 2 with a design was formed on the upper side UP of the base layer 1. Furthermore, a high-design protective layer 3 that matches the design of the patterned printing layer 2 was formed on the upper side UP of the patterned printing layer 2.

[0089] A high-design resin layer 4, which is in harmony with the pattern of the pattern printing layer 2, was formed on the upper side UP of the high-design protective layer 3 to obtain the decorative paper 10 of Example 1. At this time, the high-design resin layer 4 contained silica at a content ratio of 15%.

[0090] Furthermore, the coating area of ​​the high-design protective layer 3 was set to be between 0.5 and 1.5 times the coating area of ​​the high-design resin layer 4. In addition, a liquid-repellent silicone additive was added to the high-design resin layer 4. The high-design resin layer 4 was applied using a gravure printing plate at a rate of 6 g per square meter (including solvent).

[0091] Impregnated decorative paper 100p was formed by impregnating decorative paper 10 with melamine resin as the impregnation resin 20. The impregnated decorative paper 100p was then sandwiched between press plates PM in the vertical direction V, and pressure and heat were applied to cure the impregnation resin 20. At this time, a release paper RP was placed between the surface 100ps of the impregnated decorative paper 100p and the press plate PM.

[0092] By moving the press plate PM and release paper RP to the upper side UP, a decorative panel 100 of Example 1 was obtained in which a first region covered by the impregnating resin 20 and a second region in which the high-design resin layer 4 was exposed were formed on the surface 100s. The 60-degree reflective gloss of the first region covered by the impregnating resin 20 on the surface 100s of the decorative panel 100 was between 2 and 6.

[0093] (Example 2) The decorative paper 10 and decorative panel 100 of Example 2 were obtained by the same method as in Example 1, except that the silica content in the high-design resin layer 4 was set to 20%.

[0094] (Example 3) The decorative paper 10 and decorative panel 100 of Example 3 were obtained by the same method as in Example 1, except that the silica content in the high-design resin layer 4 was set to 25%.

[0095] (Comparative Example 1) The decorative paper and decorative panel of Comparative Example 1 were obtained by the same method as in Example 1, except that the silica content in the high-design resin layer was 10%.

[0096] (Comparative Example 2) The decorative paper and decorative panel of Comparative Example 2 were obtained by the same method as in Example 1, except that the silica content in the high-design resin layer was 30%.

[0097] (Comparative Example 3) The decorative paper and decorative panel of Comparative Example 3 were obtained by the same method as in Example 1, except that the silica content in the high-design resin layer was 40%.

[0098] (Test 1) The decorative panels of Examples 1-3 and Comparative Examples 1-3 underwent a first-stage design evaluation test. In the first-stage design evaluation test, 10 testers conducted a sensory evaluation of the design of the decorative panels, focusing on the degree of design appeal based on the gloss-matt finish of the panels. In the first-stage design evaluation test, a good design appearance is one that gives a greater sense of gloss-matt finish.

[0099] The evaluation criteria were set at three levels. ○ (Good): Seven or more people rated the design as having a good appearance. △(Fair): Five to six people rated the design as having a good appearance. × (Poor): Four or fewer people rated the design as having a good appearance.

[0100] (Exam 2) A second design evaluation test was conducted on the decorative laminates of Examples 1-3 and Comparative Examples 1-3. In the second design evaluation test, 10 testers conducted a sensory evaluation of the design of the decorative laminates, focusing on the degree of design appeal based on the whitening state of the laminate surface. In the second design evaluation test, a good design appearance was defined as an appearance with less whitening occurring on the surface of the decorative laminate.

[0101] The evaluation criteria were set at three levels. ○ (Good): Seven or more people rated the design as having a good appearance. △(Fair): Five to six people rated the design as having a good appearance. × (Poor): Four or fewer people rated the design as having a good appearance.

[0102] (Exam 3) Printability evaluation tests were conducted on the decorative papers of Examples 1-3 and Comparative Examples 1-3. In the printability evaluation tests, 10,000 m of each decorative paper was formed by printing, and 10 testers conducted sensory tests on the design of each decorative paper after printing, focusing on the degree of variation in the design of the decorative paper. In the printability evaluation tests, a good design appearance is defined as the appearance in which there is little difference in design between the area printed immediately after the start of printing and the area printed immediately before the end of printing.

[0103] The evaluation criteria were set at three levels. ○ (Good): Seven or more people rated the design as having a good appearance. △(Fair): Five to six people rated the design as having a good appearance. × (Poor): Four or fewer people rated the design as having a good appearance.

[0104] (Exam 4) An impregnation evaluation test was conducted on the decorative paper of Examples 1-3 and Comparative Examples 1-3. In the impregnation evaluation test, decorative paper cut into 5 cm squares was floated in liquid melamine resin with the side containing the high-design resin layer facing downwards, and the time taken for the melamine resin to permeate the entire surface on the side containing the base layer was evaluated.

[0105] The evaluation criteria were set at three levels. 〇(Good): Less than 20 seconds. △(Fair): 21 seconds or more and 30 seconds or less. × (Poor): 31 seconds or more.

[0106] (comprehensive evaluation) Based on the results of Test 1-4, an overall evaluation of the decorative paper and decorative panels of Example 1-3 and Comparative Example 1-3 was conducted.

[0107] The evaluation criteria consisted of two levels, with a circle (〇) indicating a passing grade. ○ (Good): "All evaluations in Tests 1-4 were ○," or "There were no × evaluations in Tests 1-4, and two or more ○ evaluations." × (Poor): "One or more evaluations were × in Tests 1-4," or "More than half of Tests 1-4 received a △ evaluation."

[0108] (Test results and overall evaluation results) Table 1 shows the results of Test 1-4 and the overall evaluation results. The decorative paper 10 and decorative panel 100 of Example 1-3, in which the silica content of the high-design resin layer 4 was greater than 10% but less than 30%, passed the overall evaluation.

[0109] In Example 1, the decorative panel 100, in which the silica content of the high-design resin layer 4 was 15%, performed worse in Test 1 compared to the decorative panel 100 of Example 2, in which the silica content of the high-design resin layer 4 was 20%, but the overall evaluation was satisfactory.

[0110] In Example 3, the decorative panel 100, in which the silica content of the high-design resin layer 4 was 25%, performed worse in Test 2 compared to the decorative panel 100 of Example 2, in which the silica content of the high-design resin layer 4 was 20%, but the overall evaluation was satisfactory.

[0111] Comparative Example 1, a decorative panel with a silica content of 10% in the high-design resin layer, received a failing grade in Test 1. As a result, both the decorative paper and decorative panel of Comparative Example 1 failed the overall evaluation. Compared to Examples 1-3, Comparative Example 1 did not exhibit a matte finish due to its lower silica content in the high-design resin layer.

[0112] Comparative Example 2, a decorative panel with a silica content of 30% in the high-design resin layer, received a failing grade (×) in Test 2 and a moderate grade (△) in Tests 3-4. As a result, the decorative paper and decorative panel of Comparative Example 2 failed the overall evaluation. Compared to Examples 1-3, Comparative Example 2 had a higher silica content in the high-design resin layer, resulting in whitening and an overall whitish appearance, as well as poor production stability and inconsistent design finish. Furthermore, compared to Examples 1-3, Comparative Example 2 had poor impregnation properties with the impregnation resin due to its higher silica content in the high-design resin layer.

[0113] Comparative Example 3, a decorative panel with a silica content of 40% in the high-design resin layer, received a failing grade (×) in Tests 2-3 and a moderate grade (△) in Test 4. As a result, the decorative paper and decorative panel of Comparative Example 3 failed the overall evaluation. Compared to Examples 1-3, Comparative Example 3 had a higher silica content in the high-design resin layer, resulting in whitening and an overall whitish appearance, as well as poor production stability and inconsistent design finish. Furthermore, compared to Examples 1-3, Comparative Example 3 had poor impregnation properties with the impregnation resin due to its higher silica content in the high-design resin layer.

[0114] [Table 1] [Explanation of Symbols]

[0115] 100 decorative panels 10 Cosmetic paper 1. Anti-nuclear layer 2. Pattern printing layer 3. High-design protective layer 4. High-design resin layer (matte resin layer) 20 Impregnating resin V vertical direction UP upper side LO (lower side)

Claims

1. The nuclear franc and, A pattern printing layer provided on the upper side of the aforementioned base material layer, A high-design protective layer is partially provided on the upper side of the pattern printing layer, A high-design resin layer is provided on the upper side of the high-design protective layer and positioned in a manner consistent with the high-design protective layer, Equipped with, The aforementioned high-design resin layer contains silica in a content ratio greater than 10% and less than 30%. Cosmetic paper.

2. The aforementioned high-design resin layer contains a silicone additive. The decorative paper according to claim 1.

3. The aforementioned high-design resin layer is positioned in a location that is synchronized with the pattern of the pattern printed layer. The decorative paper according to claim 2.

4. The aforementioned high-design resin layer includes a thermosetting resin, an ionizing radiation-curing resin, or an ultraviolet-curing resin. The decorative paper according to claim 3.

5. A decorative paper according to any one of claims 1 to 4, The impregnated resin that has been impregnated and hardened into the aforementioned decorative paper, Equipped with, Decorative panel.

6. The surface is formed with a first region covered by the impregnating resin and a second region where the high-design resin layer is exposed. The decorative panel according to claim 5.

7. The 60-degree reflected gloss of the first region is between 2 and 20. The decorative panel according to claim 6.

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