Cosmetic material and method for producing the same

Abstract

To provide a decorative material having visual three-dimensionality and excellent abrasion resistance.SOLUTION: A decorative material in which the material has a first region and a second region within a plane surface, the surface of the first region has a lower elevation than the surface of the second region, the decorative material of a place corresponding to the first region has a first cured product layer whose surface has releasability on one face of a substrate A, the decorative material of a place corresponding to the second region has a second cured product layer on one face of the substrate A, the first cured product layer and the second cured product layer are formed on the same face side of the substrate A, at least on a part of the opposite side of a side having the first cured product layer and the second cured product layer of the substrate A has a decorative layer, and the substrate A is a resin-impregnated paper having light permeability.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a cosmetic material and a method for producing a cosmetic material. [Background technology]

[0002] Conventionally, decorative materials have been used for the surfaces of tables, counters, walls, floors, etc., by impregnating a porous substrate such as titanium paper with an uncured liquid of melamine resin and curing the impregnated resin by a heat press. The decorative materials may further be laminated with phenol core paper, etc., as necessary. Such decorative materials impregnated and cured with melamine resin exhibit physical properties such as strength, hardness, and heat resistance.

[0003] Such decorative materials are required to have a design that gives off a sense of luxury, and a visual three-dimensional effect is imparted by forming an uneven shape on the surface. As a decorative material having an uneven surface, there has been proposed a decorative material that is embossed using an embossing plate (a textured mirror plate) with an uneven surface formed thereon (see, for example, Patent Documents 1 and 2).

[0004] However, when imparting a desired design of a concave-convex pattern to the surface of the decorative material described in Patent Documents 1 and 2, an embossing plate is required for each pattern, which is costly and difficult to manufacture. In addition, it is difficult to harmonize the concave-convex shape with the pattern of the base, making it difficult to impart a high level of design.

[0005] On the other hand, a decorative material disclosed in Patent Document 3 has been proposed as a decorative material having an uneven surface shape without using an embossing plate. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2015-193209 A [Patent Document 2] JP 2017-87544 A [Patent Document 3] International Publication No. 2016 / 148091 DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0007] The decorative material of Patent Document 3 comprises a paper base material, a release layer containing a cured product of an ionizing radiation curable resin provided on a part of the surface of the paper base material, and a surface layer containing a cured product of a melamine resin provided on the remaining part of the surface of the paper base material. The decorative board of Patent Document 3 is manufactured by a method including a step of providing a release layer on a part of the surface of the paper base material, a step of impregnating the paper base material with an uncured product of melamine resin and coating the release layer with the uncured product of melamine resin, and then heating to thermally cure the uncured product of melamine resin, and a step of peeling off the cured resin film coating the release layer. As a result, the decorative material of Patent Document 3 has an elevation difference between the area with the release layer and the area without the release layer, and a surface uneven shape is formed. The decorative material of Patent Document 3 does not use an embossed plate, and therefore solves the problems of Patent Documents 1 and 2. However, when the decorative material of Patent Document 3 is used in places where a high level of wear resistance is required, such as tables, there have been many cases where the design deteriorates over time. [Means for solving the problem]

[0008] As a result of intensive research, the inventors have found that the decorative material of Patent Document 3 has a reduced design quality because it is not possible to suppress wear of the decorative layer after wear of the release layer containing a cured product of an ionizing radiation curable resin and the surface layer containing a cured product of a melamine resin. As a result of further intensive research, the present inventors have completed a decorative material that has a visual three-dimensional effect and can dramatically improve abrasion resistance.

[0009] The present invention aims to provide the following [1] to [3]. [1] A decorative material having a first region and a second region in a plane, the surface of the first region being at a lower elevation than the surface of the second region, the decorative material in a portion corresponding to the first region having a first hardened material layer having a releasable surface on one side of a substrate A, the decorative material in a portion corresponding to the second region having a second hardened material layer on one side of the substrate A, the first hardened material layer and the second hardened material layer being formed on the same side of the substrate A, and the substrate A having a decorative layer on at least a portion of the side opposite to the side having the first hardened material layer and the second hardened material layer, and the substrate A is a resin-impregnated paper having optical transparency.

[0010] [2] A method for producing a decorative material, comprising the following steps (A1) to (A7): (A1) A step of preparing paper that will serve as the base for substrate A. (A2) A step of forming a laminate A having a first cured material layer having a releasable surface on at least a portion of one side of a paper and a decorative layer on the other side. (A3) A step of impregnating the laminate A with a curable resin composition to impregnate paper with the curable resin composition to obtain a substrate A which is a resin-impregnated paper having optical transparency, and forming an uncured curable resin composition layer on the entire surface of the side of the laminate A having the first cured material layer to obtain a laminate B. (A4) A step of obtaining a laminate C by disposing a release film on the uncured curable resin composition layer side of the laminate B. (A5) A step of hot pressing both sides of the laminate C between mirror-finished plates to form a second cured material layer by curing the uncured curable resin composition layer. (A6) A step of removing the laminate C from between the mirror plates. (A7) A process in which, when peeling and removing the release film from the laminate C, the second cured material layer on the first cured material layer of the second cured material layer is removed together with the release film to form a first region, and a second region is formed in which the second cured material layer formed in an area not having a first region forming layer remains.

[0011] [3] A method for producing a decorative material, comprising the following steps (B1) to (B9): (B1) A step of preparing paper that will serve as the base for substrate A. (B2) A step of obtaining a laminate D by forming a first cured product layer having a releasable surface on at least a portion of one side of the paper. (B3) A step of forming a decorative layer on at least a portion of one surface of the base material B to obtain a laminate E. (B4) A step of laminating the surface of the laminate D opposite to the first cured material layer and the surface of the laminate E on the decorative layer side to obtain a laminate F. (B5) A step of impregnating the laminate F with a curable resin composition to impregnate paper with the curable resin composition, thereby obtaining a substrate A which is a resin-impregnated paper having optical transparency, and forming an uncured curable resin composition layer on the entire surface of the side of the laminate F having the first cured material layer, thereby obtaining a laminate G. (B6) A step of obtaining a laminate H by disposing a release film on the uncured curable resin composition layer side of the laminate G. (B7) A step of hot pressing the laminate H while sandwiching both sides between mirror-finished plates to form a second cured material layer by curing the uncured curable resin composition layer. (B8) A step of removing the laminate H from between the mirror plates. (B9) A process for removing the release film from the laminate H, removing the second cured material layer on the first cured material layer together with the release film to form a first region, and forming a second region in which the second cured material layer remains in an area not having a first region forming layer. Effect of the Invention

[0012] According to the present invention, it is possible to provide a decorative material that has a visual three-dimensional effect and is also excellent in abrasion resistance. [Brief description of the drawings]

[0013] [Figure 1] 1 is a cross-sectional view showing one embodiment of a decorative material of the present invention. [Diagram 2] FIG. 4 is a cross-sectional view showing another embodiment of the decorative material of the present invention. [Diagram 3]FIG. 2 is a cross-sectional view showing one step of the method for producing the decorative material of the present invention. [Figure 4] FIG. 2 is a cross-sectional view showing one step of the method for producing the decorative material of the present invention. [Diagram 5] FIG. 2 is a cross-sectional view showing one step of the method for producing the decorative material of the present invention. [Figure 6] FIG. 2 is a cross-sectional view showing one step of the method for producing the decorative material of the present invention. [Figure 7] FIG. 2 is a cross-sectional view showing one step of the method for producing the decorative material of the present invention. [Figure 8] FIG. 2 is a cross-sectional view showing one step of the method for producing the decorative material of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] [Cosmetic materials] The decorative material of the present invention has a first region and a second region in a plane, the surface of the first region is at a lower elevation than the surface of the second region, the decorative material in a portion corresponding to the first region has a first hardened material layer having a releasable surface on one side of the substrate A, and the decorative material in a portion corresponding to the second region has a second hardened material layer on one side of the substrate A, the first hardened material layer and the second hardened material layer being formed on the same side of the substrate A, and the substrate A has a decorative layer on at least a portion of the side opposite to the side having the first hardened material layer and the second hardened material layer, and the substrate A is a resin-impregnated paper having optical transparency.

[0015] 1 and 2 are cross-sectional views showing an embodiment of a decorative material 100 of the present invention. The decorative material 100 in Figures 1 and 2 has a first region R1 and a second region R2 in a plane (in the XY plane in the figures). The surface of the first region R1 is at a lower elevation than the surface of the second region R2. In addition, when the entire surface of the decorative material 100 in a plane is considered as a universal set, the first region R1 and the second region R2 of the decorative material 100 in Figures 1 and 2 are in a complementary relationship with each other. 1 and 2 has a first hardened material layer 21, the surface of which has releasability, on the substrate A (10) in a location corresponding to the first region R1. Also, the decorative material 100 in Fig. 1 and 2 has a second hardened material layer 22 on the substrate A (10) in a location corresponding to the second region R2. Also, in the decorative material 100 in Fig. 1 and 2, the first hardened material layer 21 and the second hardened material layer 22 are formed on the same side of the substrate A (10) (the positive side in the z-axis direction of the substrate A in the figures). 1 and 2 has a decorative layer 30 on the side opposite to the side of the base material A (10) having the first cured material layer 21 and the second cured material layer 22 (the negative side in the z-axis direction of the base material A in the figures). The decorative layer 30 in Figs. 1 and 2 has a first decorative layer 31 that is in phase with the first region R1 and a second decorative layer 32 that is in phase with the second region R2. As shown in Figs. 1 and 2, the first decorative layer 31 and the second decorative layer 32 are preferably in phase with the first region R1 and the second region R2, respectively, but may be non-in phase. The decorative material 100 in FIG. 2 also has a base material B (50) and a reinforcing layer 60 on the surface of the decorative layer 30 opposite the base material A (10). 1 and 2, t1 indicates the thickness of the first hardened material layer 32, and t2 indicates the thickness of the second hardened material layer 22. In addition, in FIG.

[0016] In this specification, the term "plane" refers to a surface viewed vertically from the side of base material A having the first hardened material layer and the second hardened material layer, when base material A of the decorative material is used as a reference, and means the xy plane in Figures 1 and 2. In addition, in this specification, "altitude" refers to the thickness direction of the decorative material, and refers to the z direction in Figures 1 and 2. Note that a specific location (specific surface, specific position, etc.) having a high (or low) altitude means that the value of the z coordinate in the thickness direction of the specific location is relatively large (or small). In Figure 1, the higher the specific location is in the figure, the higher the altitude, and the lower the specific location is in the figure, the lower the altitude. In this specification, the term "synchronization" includes, of course, a state in which the two target patterns are completely matched and overlapped in shape and position when the decorative material is viewed in a plan view, but is not strictly limited to this state, and is a concept that allows for misalignment of shape and position as long as it is within a range that does not cause discomfort in the external design and does not impair quality. Examples of the two target patterns include a combination of the first decorative layer 31 and the first region R1, and a combination of the second decorative layer 31 and the second region R2.

[0017] In this specification, the term "curable resin" refers to a cured product obtained by curing an uncured curable resin. Similarly, the term "thermosetting resin" refers to a cured product obtained by curing an uncured thermosetting resin, and the term "ionizing radiation curable resin" refers to a cured product obtained by curing an uncured ionizing radiation curable resin. In this specification, the terms "curable resin composition," "thermosetting resin composition," and "ionizing radiation curable resin composition" mean that the composition is uncured, unless otherwise specified.

[0018] <Base material A> The substrate A is a resin-impregnated paper having optical transparency, and is located between the first cured product layer, the second cured product layer, and the decorative layer. In the decorative material of the present invention, even if the first cured product layer and the second cured product layer are worn, the decorative layer is protected by the base material A, so that the wear resistance can be dramatically improved.

[0019] The base material A only needs to have light transparency to such an extent that the decorative layer can be visually recognized. The substrate A preferably has a total light transmittance according to JIS K7361-1:1997 of 40% or more, and more preferably 50% or more. Also, the haze of the base material A itself may generally vary depending on the location within the plane of the decorative material 100. The haze of the base material A can be 10% or more and 96% or less. The haze of the base material A is preferably 20% or more, more preferably 30% or more, as the lower limit value. Also, as the upper limit value of the haze of the base material A, it is more preferably 90% or less, and even more preferably 60% or less. In this specification, the haze means the haze of JIS K7136:2000.

[0020] The total light transmittance or haze of the base material A may be the same or different within the plane of the base material A. For example, the total light transmittance or haze may be the same or different between the location having the first cured product layer of the base material A and the location having the second cured product layer of the base material A.

[0021] In order to impart contrast to the first region R1 which is the location having the first cured product layer and the second region R2 which is the location having the second cured product layer, and enhance the design property of the decorative material, it is preferable that the values of the total light transmittance or haze are different between the location having the first cured product layer of the base material A and the location having the second cured product layer of the base material A.

[0022] Also, when defining the haze of the location having the first cured product layer of the base material A as Hz1 and the haze of the location having the second cured product layer of the base material A as Hz2, it is preferable to satisfy the relationship of Hz2 < Hz1. By adopting such a configuration, it is possible to impart a contrast in luster to the first region which is the location having the first cured product layer and the second region which is the location having the second cured product layer, and enhance the design property of the decorative material. Also, by satisfying the relationship of Hz2 < Hz1, the first region can be made to look more recessed and it is easier to enhance the visual three-dimensional effect. In particular, in the configuration satisfying the relationship of Hz2 < Hz1, when the base material A contains a colorant, a color tone is added to the luster, so that the contrast between the two regions becomes clearer, the pattern becomes clearer, and the design property can be further enhanced. Hz1 - Hz2 is preferably 1% or more and 30% or less, and more preferably 5% or more and 20% or less.

[0023] In order to provide a visual contrast between the first region R1, which is a portion having the first cured material layer, and the second region R2, which is a portion having the second cured material layer, and to enhance the design of the decorative material, when the decorative material 100 is observed from the side of the first cured material layer 21, it is preferable that the color tone of the first region R1 is more opaque than the color tone of the second region R2. More opaque means higher brightness. Specifically, when defined by the brightness of the Munsell color system, the difference (V1-V2) between the brightness V1 in the first region R1 and the brightness V2 in the second region R2 is preferably 2 or more, more preferably 4 or more. In addition, it is preferable that the saturation of the first region R1 is lower than that of the second region R2. In this case, the difference (C2-C1) between the saturation C1 in the first region R1 and the saturation C2 in the second region R2 is preferably 2 to 6, more preferably 2 to 4. That is, the relationship between the color tone of the first region R1 and the color tone of the second region R2 includes the following forms (1) to (3). In order to provide a visual contrast between the regions R1 and R2 and to enhance the design of the decorative material, form (1) or (2) is preferred, and form (2) is more preferred. (1) V1>V2 and C1=C2 (2) V1>V2 and C1 <C2 (3) V1>V2 and C1>C2 In order for the color tone of the first region R1 to be visually perceived as more opaque than the color tone of the second region R2 when the decorative material 100 is observed from the side of the first cured material layer 21, it is preferable that the following relationship (4) is satisfied, and it is more preferable that the following relationships (4) and (5) are satisfied. When the following relationship (4) is satisfied, the difference between the haze of the first region R1 of the laminate B and the haze of the second region R2 of the laminate B is preferably 1% or more and 30% or less, and more preferably 5% or more and 20% or less. The layer structure of the laminate B is described in the manufacturing method of the decorative material described below. (4) Haze of the first region R1 of the laminate B>Haze of the second region R2 of the laminate B (5) Total light transmittance of the first region R1 of the laminate B ≠ Total light transmittance of the second region R2 of the laminate B

[0024] The substrate A (resin-impregnated paper having optical transparency) can be obtained, for example, by impregnating a base paper with a resin. In this case, the optical transparency of the substrate A can be increased and the haze can be reduced by bringing the refractive index of the fibers constituting the paper closer to that of the resin and by sufficiently filling the gaps between the fibers with the resin. That is, even if the base paper itself is opaque, a resin-impregnated paper having optical transparency (substrate A) can be obtained by sufficiently impregnating the paper with a resin having a similar refractive index. In addition, the optical transmittance and haze can be adjusted by controlling the amount of resin impregnated into the base paper. Furthermore, by providing areas with different amounts of impregnated resin within the plane of the base paper, areas with different optical transmittance and haze values ​​can be provided within the plane of the substrate A. The substrate A may be a laminate of resin-impregnated papers having optical transparency. A laminate of resin-impregnated papers having optical transparency can be obtained by impregnating a plurality of base papers in a stacked state with a resin.

[0025] In order to make it easier for the color tone of the first region R1 to be cloudy compared to the color tone of the second region R2, it is preferable to impregnate the paper with a curable resin composition from the side of the first cured material layer 21 in step A3 described later. As a result, in the inside of the paper, in the paper directly below the first cured material layer 21 corresponding to the first region R1, resin impregnation is inhibited by the first cured material layer 21, and air is likely to remain between the constituent fibers of the paper. Then, due to the refractive index difference between the paper constituent fibers and air, the light incident on the first region R1 is scattered, and the first region R1 is more likely to be cloudy than the second region R2. In addition, in the paper directly below the first cured material layer 21 corresponding to the first region R1, the resin forming the first cured material layer and the fibers are contained, and further, a small amount of impregnated resin is contained, so that the refractive index difference between these three materials can also be a cause of cloudiness. On the other hand, in the second region R2 (region where the first hardened material layer 21 is not formed), the impregnating resin fills the gaps between the fibers constituting the paper without being hindered. The refractive index difference between the impregnating resin and the fibers constituting the paper is smaller than the refractive index difference between air and the fibers constituting the paper. As a result, the amount of scattering of light incident on the second region R2 is smaller than that of the first region R1, and the degree of cloudiness of the second region R2 is smaller than that of the first region R1.

[0026] The base paper for substrate A has a basis weight of 20 g / m 2 More than 100g / m 2 It is preferable that the thickness is 25 g / m or less. 2 More than 80g / m 2 More preferably, it is 30 g / m or less. 2 More than 60g / m 2 It is more preferable that the base material A is a laminate of resin-impregnated papers having optical transparency, and each of the multiple base papers preferably has a basis weight within the above range. The basis weight of the base paper is 20g / m 2 By setting the weight of the paper to 100 g / m or more, the impregnated resin can be easily bound by the paper fibers. 2 By setting the following, it is possible to easily impregnate the paper with the resin. In addition, when multiple papers are used as the base and paper of the substrate A, the total basis weight of the multiple papers is set to 200 g / m from the viewpoint of visibility of the decorative layer. 2 It is preferable that:

[0027] Examples of the base paper for the substrate A include papers made from cellulosic pulp, such as wood pulp fiber paper containing a large amount of α-cellulose, Manila hemp valve fiber paper, linter paper, and cotton fiber paper. Non-cellulosic resin fibers such as vinylon and acrylic resin may be mixed into these papers as necessary. In order to ensure sufficient light transmittance after resin impregnation, it is preferable that the base paper does not contain any opacifying pigments, such as titanium white and carbon black, or that only a small amount is added.

[0028] The paper that serves as the base of base material A may contain a colorant. That is, base material A may contain a colorant. By base material A containing a colorant, the design property of the decorative material can be further enhanced. In particular, as described above, in a configuration satisfying the relationship of Hz2 < Hz1, it is preferable for base material A to contain a colorant.

[0029] Examples of the colorant include inorganic pigments such as lead yellow, titanium yellow, rose pink, cadmium red, ultramarine blue, cobalt blue, etc., organic pigments such as quinacridone red, isoindolinone yellow, nickel - azo complex, phthalocyanine blue, etc., or dyes and the like.

[0030] The resin impregnated in base material A includes a thermoplastic resin and a curable resin, and a curable resin is preferable from the viewpoint of abrasion resistance. In this specification, "the resin impregnated in base material A" and "the resin impregnated in base material B" may be referred to as "the impregnated resin of base material A" and "the impregnated resin of base material B". With respect to the total amount of the impregnated resin of base material A, the curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, still more preferably 90% by mass or more, and even more preferably 100% by mass. Examples of the curable resin include a thermosetting resin and a radiation - curable resin, and a thermosetting resin is preferable from the viewpoint of handleability.

[0031] From the viewpoints of the adhesion between base material A and the second cured product layer and the manufacturing efficiency, the impregnated resin of base material A is preferably of the same type as the resin of the second cured product layer. Further, when base material B described later is impregnated with a resin, from the viewpoint of manufacturing efficiency, the resin impregnated into the paper is preferably of the same type as the impregnated resin of base material B. When forming the first cured product layer on base material A, a small amount of the resin component constituting the first cured product layer or a small amount of the resin component constituting the penetration - preventing layer penetrates into base material A. That is, the impregnated resin of base material A contains a small amount of the resin component constituting the first cured product layer or a small amount of the resin component constituting the penetration - preventing layer.

[0032] As the thermosetting resin, which is a suitable embodiment of the impregnating resin of the base material A, from the viewpoint of further improving the texture of the decorative material and improving the mechanical strength of the decorative material, preferred are melamine resin, urea resin, melamine-urea resin, guanamine resin, diallyl phthalate resin, polyester resin, phenol resin, epoxy resin, aminoalkyd resin, silicon resin, polysiloxane resin, etc., and among these, preferred are thermosetting resins such as melamine resin, urea resin, melamine-urea resin, guanamine resin, sulfonamide resin, etc. Furthermore, among the thermosetting resins, preferred are melamine resin, melamine-urea resin, and phenol resin, and particularly preferred is melamine resin.

[0033] Means for impregnating paper with resin include a method of preparing a composition containing a resin (uncured curable resin in the case of a curable resin) and impregnating the base paper with the resin composition (for example, steps (A3) and (B5) described below). Of the resin compositions impregnated into the paper, the thermosetting resin composition is heated at an appropriate time to be cured through a crosslinking reaction, a polymerization reaction, or the like, to become a cured thermosetting resin (for example, steps (A5) and (B7) described below). In steps (A2) and (B2) described later, the resin constituting the first cured material layer is cured in the steps (A2) and (B2). The region of the base material A having the first cured material layer is less likely to be impregnated with the resin in steps (A3) and (B5) than the other regions of the base material A. Therefore, the portion of the base material A having the first cured material layer and the portion of the base material A having the second cured material layer have different degrees of impregnation with the resin, and the total light transmittance or haze value of the two portions can be easily made different.

[0034] The thickness of the base material A is preferably 80 μm or more and 360 μm or less, and more preferably 80 μm or more and 200 μm or less. By making the thickness of the base material A 80 μm or more, it is possible to easily improve the abrasion resistance, and by making the thickness of the base material A 360 μm or less, it is possible to easily ensure the visibility of the decorative layer.

[0035] <Decorative layer> The decorative material of the present invention has a decorative layer on at least a part of the side of the substrate A opposite to the side having the first cured product layer and the second cured product layer. Since the decorative material of the present invention has the decorative layer at the above-mentioned position, the decorative layer is less susceptible to wear, and the wear resistance of the decorative material can be dramatically improved.

[0036] The decorative layer can be formed, for example, by printing with a decorative layer ink containing a colorant and a binder resin. The pattern of the decorative layer is not particularly limited.

[0037] The decorative layer preferably has at least one of a first decorative layer formed on at least a part of the area corresponding to the first region and a second decorative layer formed on at least a part of the area corresponding to the second region, and more preferably has both. The first decorative layer is preferably formed in accordance with the first region, and the second decorative layer is preferably formed in accordance with the second region. The first decorative layer and the second decorative layer will be described in detail later.

[0038] Examples of embodiments of the decorative layer are shown in A to K below. A) A configuration in which the first decorative layer is synchronized in all first regions. (a) A configuration in which the first decorative layer is present in all of the first regions, but the first regions and the first decorative layer are not synchronized, and the printing is misaligned. (c) A configuration in which, among a plurality of first regions, some of the first regions have a first decorative layer, while other first regions do not have a first decorative layer. (e) A configuration in which the second decorative layer is synchronized in all second regions. E) A configuration in which the second decorative layer is present in all second regions, but the second regions and the second decorative layer are not synchronized, resulting in misaligned printing. (c) A configuration in which, among a plurality of second regions, some of the second regions have a second decorative layer, while other second regions do not have a second decorative layer. (g) A configuration having only a first decorative layer and not a second decorative layer. (k) A configuration having only a second decorative layer. I) A structure having a first decorative layer and a second decorative layer.

[0039] <area> The decorative material of the present invention has, within a plane, a first region R1 and a second region R2. In addition, in the decorative material of the present invention, the elevation of the surface of the first region is lower than the elevation of the surface of the second region, so that the first region is visually perceived as being recessed compared to the second region, thereby imparting a three-dimensional effect. The elevation of the surface of the first region can be adjusted by the total thickness of the layers formed on the first region of the substrate A. The elevation of the surface of the second region can be adjusted by the total thickness of the layers formed on the second region of the substrate A.

[0040] When the area of ​​the first region R1 of the decorative material is defined as S1 and the area of ​​the second region is defined as S2, S2 / S1 is preferably 0.1 or more and 20 or less, and more preferably 0.5 or more and 10 or less. By making S2 / S1 0.1 or more, it becomes easier to impregnate the paper that is the base of the substrate A with resin in post-processing (for example, steps A3 and B5 described below). Also, by making S2 / S1 20 or less, the balance between the proportion of areas that are visible as recessed and areas that are visible as raised can be kept within an appropriate range, making it easier to improve the design.

[0041] 《First area》 The first region is an area that is visually perceived as being recessed compared to the second region. The first region has a first cured material layer having a releasable surface on a substrate A. In order to easily increase the elevation difference between the surface of the first region and the surface of the second region, a permeation prevention layer, which will be described later, may be provided between the substrate A and the first cured material layer.

[0042] The first region preferably has a roughened surface. By roughening the surface of the first region, the first region is more likely to appear recessed, which makes it easier to achieve a better three-dimensional effect.

[0043] -First cured material layer- The first cured product layer has a surface with releasability. Since the first cured material layer has a releasable surface, the second cured material layer on the first cured material layer is almost entirely peeled off. It is preferable that the second cured material layer on the first cured material layer is completely peeled off from the viewpoint of improving the three-dimensional effect due to the surface unevenness, but there are many cases where the second cured material layer cannot be completely peeled off from the first cured material layer. Therefore, a small amount of the second cured material layer may remain on the first cured material layer as long as it does not impair the effects of the present invention.

[0044] The first cured product layer is a layer formed from a curable resin, more specifically, a layer formed from a cured product of an uncured curable resin composition. As the curable resin, from the viewpoint of obtaining a design with a higher texture and more excellent surface properties, a thermosetting resin or an ionizing radiation curable resin is preferably used, and from the viewpoint of abrasion resistance, an ionizing radiation curable resin is more preferable. That is, the first cured product layer preferably contains an ionizing radiation curable resin.

[0045] The first cured product layer may contain a thermoplastic resin, but preferably contains a curable resin as a main component. Based on the total amount of resin in the first cured material layer, the curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and even more preferably 100% by mass.

[0046] As the thermosetting resin for the first cured material layer, for example, those exemplified as the thermosetting resin capable of being impregnated into the base material A can be mentioned.

[0047] The ionizing radiation curable resin is a resin that crosslinks and hardens by irradiation with ionizing radiation, and has an ionizing radiation curable functional group. Here, the ionizing radiation curable functional group is a group that crosslinks and hardens by irradiation with ionizing radiation, and preferred examples include functional groups having an ethylenic double bond such as (meth)acryloyl group, vinyl group, and allyl group. In addition, the ionizing radiation means electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules, and generally includes ultraviolet rays (UV) or electron beams (EB), but also includes electromagnetic waves such as X-rays and gamma rays, charged particle beams such as alpha rays, and ion beams. Specifically, the ionizing radiation curable resin can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation curable resins.

[0048] As the polymerizable monomer, a (meth)acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferable, and among them, a polyfunctional (meth)acrylate monomer is preferable. Here, "(meth)acrylate" means "acrylate or methacrylate". Examples of polyfunctional (meth)acrylate monomers include (meth)acrylate monomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the functional group. From the viewpoint of obtaining a design with a higher texture and better surface properties, acrylate monomers having an acryloyl group are preferred. From the viewpoint of obtaining a design with a higher quality texture and more excellent surface properties, the number of functional groups of the (meth)acrylate monomer is preferably 2 or more, more preferably 3 or more, and even more preferably 4 or more, and the upper limit is preferably 8 or less, more preferably 6 or less. These polyfunctional (meth)acrylate monomers may be used alone or in combination of two or more kinds. The ionizing radiation curable resin of the first cured product layer is preferably a polyfunctional (meth)acrylate monomer, from the viewpoint of increasing the crosslink density and improving the scratch resistance.

[0049] Preferred examples of such polymerizable monomers include bifunctional (meth)acrylates such as ethylene glycol di(meth)acrylate, bisphenol A tetraethoxy diacrylate, bisphenol A tetrapropoxy diacrylate, and 1,6-hexanediol diacrylate; and trifunctional or higher (meth)acrylates such as trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and isocyanuric acid-modified tri(meth)acrylate. Among these, from the viewpoint of obtaining a design with a higher quality texture and more excellent surface characteristics, dipentaerythritol-based polymerizable monomers such as dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate are preferred, dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate are more preferred, and it is particularly preferred to use dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate in combination.

[0050] Examples of the polymerizable oligomer include (meth)acrylate oligomers having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth)acryloyl group as the functional group. Examples of the polymerizable oligomer include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, acrylic (meth)acrylate oligomers, polycaprolactone urethane (meth)acrylate oligomers, polycaprolactone diol urethane (meth)acrylates, etc.

[0051] In order to obtain a design with a higher quality texture and better surface properties, the number of functional groups of these polymerizable oligomers is preferably 2 or more, more preferably 3 or more, and the upper limit is preferably 8 or less, more preferably 6 or less.

[0052] The weight average molecular weight of the polymerizable oligomer is preferably 500 or more, more preferably 1,000 or more, and the upper limit is preferably 80,000 or less, more preferably 50,000 or less. In this specification, the weight average molecular weight is an average molecular weight measured by GPC analysis and converted into standard polystyrene.

[0053] The first cured material layer preferably contains a release agent, which allows other resins to be laminated on the surface of the first cured material layer and then peeled off, while the other resins are adhered to the second region and are not peeled off, making it easier to provide an elevation difference between the surfaces of the first region and the second region (see steps (A7) and (B9) described later).

[0054] Examples of the release agent include fluorine-based release agents and silicone-based release agents. From the viewpoint of obtaining a design with a higher quality texture, silicone-based release agents are preferred. Examples of silicone-based release agents include those having a polysiloxane structure as a basic structure, and among them, modified silicone oils in which an organic group is introduced at least in one of the side chains and the terminals of the polysiloxane skeleton are preferred, and modified silicone oils in which an organic group is introduced at both terminals are more preferred. From the viewpoint of obtaining a design with a higher texture, preferred examples of the organic group include reactive functional groups such as (meth)acrylic groups, amino groups, epoxy groups, mercapto groups, carbinol groups, phenol groups, and carboxyl groups, and non-reactive functional groups such as polyether groups, aralkyl groups, fluoroalkyl groups, alkyl groups, fatty acid amide groups, and phenyl groups. Among them, reactive functional groups are preferred, and (meth)acrylic groups are particularly preferred, that is, (meth)acrylic modified silicone oils are particularly preferred. In addition, these organic groups may have substituents such as nitrogen atoms, sulfur atoms, hydroxyl groups, and alkyl groups.

[0055] The content of the release agent is preferably 0.1 parts by mass or more and 5 parts by mass or less, more preferably 0.5 parts by mass or more and 3 parts by mass or less, and even more preferably 1 part by mass or more and 2 parts by mass or less, relative to 100 parts by mass of the curable resin that forms the first cured product layer. When the content of the release agent is within the above range, the effect of adding the release agent can be efficiently obtained.

[0056] The first cured material layer preferably contains a filler such as an inorganic filler or an organic filler, and more preferably an inorganic filler from the viewpoint of abrasion resistance. When the first cured material layer contains a filler, the reflected light of the first region is diffused, making the first region more likely to appear recessed, and making it easier to improve the three-dimensional effect of the decorative material. Examples of inorganic fillers include particles made of inorganic materials such as oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide, zinc oxide, and zirconia oxide, hydroxides such as aluminum hydroxide, magnesium hydroxide, and calcium hydroxide, carbonates such as magnesium carbonate and calcium carbonate, sulfates such as calcium sulfate and barium sulfate, and silicates such as magnesium silicate, aluminum silicate, calcium silicate, and aluminosilicate. Among these, oxides such as aluminum oxide, magnesium oxide, silica, calcium oxide, titanium oxide, and zinc oxide are preferred, and silica is particularly preferred. Organic fillers include particles of acrylic, styrene, silicone, and the like. The first cured product layer preferably does not contain any luster filler such as pearl pigments, metal particles, or metal flakes.

[0057] The average particle size of the filler is preferably 0.3 μm or more and 20 μm or less, more preferably 0.5 μm or more and 10 μm or less, from the viewpoint of making it easier to set Ra1 within the range described below. In this specification, the average particle size of the filler is a value measured as the mass average value d50 in particle size distribution measurement by a laser diffraction scattering method.

[0058] The filler content is preferably 1 part by mass or more and 50 parts by mass or less, more preferably 10 parts by mass or more and 40 parts by mass or less, still more preferably 20 parts by mass or more and 35 parts by mass or less, based on 100 parts by mass of the curable resin forming the first cured product layer, from the viewpoint of facilitating the range of Ra1 described later. When the filler content is within the above range, the addition effect of the filler can be obtained efficiently.

[0059] The thickness t1 of the first cured product layer is not particularly limited, but is usually about 0.1 μm or more and 20.0 μm or less. From the viewpoint of more easily obtaining a highly textured design, it is preferably 0.5 μm or more and 10.0 μm or less, more preferably 1.0 μm or more and 5.0 μm or less.

[0060] When the thickness of the first cured product layer is defined as t1 and the thickness of the second cured product layer is defined as t2, it is preferable to satisfy the relationship of t1 < t2. By satisfying such a relationship, it is easy to impart a three-dimensional feeling to the decorative material. t2 - t1 is preferably 1.0 μm or more and 45.0 μm or less, more preferably 2.0 μm or more and 35.0 μm or less, still more preferably 3.0 μm or more and 30.0 μm or less. By setting t2 - t1 to 1.0 μm or more, it is easy to improve the three-dimensional feeling. Also, by setting t2 - t1 to 45.0 μm or less, it is easy to stably manufacture the first region and the second region.

[0061] t1 and t2, and t0 (the thickness of the penetration prevention layer) described later are preferably calculated as the average value of the thicknesses at 20 locations. The thickness can be calculated, for example, from a cross-sectional photograph of the decorative material. Note that it is preferable to pick up 20 locations for calculating the average value so that there is no bias in the locations.

[0062] The first cured product layer can be formed, for example, by applying an ink for the first cured product layer containing the components constituting the first cured product layer to a part of the base material A, drying it, and curing it. The region where the first cured product layer is formed on the base material A becomes the first region R1.

[0063] -Penetration prevention layer- The permeation prevention layer is optionally disposed between the substrate A and the first cured product layer. By having a permeation prevention layer between the substrate A and the first cured material layer, the composition constituting the first cured material layer is prevented from permeating into the substrate A side, ensuring the thickness of the first cured material layer, which in turn makes it easier to increase the thickness of the second cured material layer and facilitates improving the abrasion resistance of the decorative material.

[0064] The permeation prevention layer is preferably formed on only a part of the substrate A, rather than on the entire substrate A. By forming the permeation prevention layer on only a part of the substrate A, rather than on the entire substrate A, it becomes easier to impregnate the paper, which is the base of the substrate A, with the resin. The permeation prevention layer is preferably formed in accordance with the first region.

[0065] The permeation-preventing layer preferably contains a curable resin. In other words, the permeation-preventing layer preferably contains a cured product of an uncured curable resin composition. In addition, the content of the curable resin is preferably 50 mass% or more of the total solid content constituting the permeation prevention layer, more preferably 70 mass% or more, even more preferably 80 mass% or more, and even more preferably 90 mass% or more. When the permeation preventing layer contains a curable resin, the permeation preventing layer can improve the sealing effect of the first cured product layer.

[0066] In order to make it difficult for the composition forming the permeation prevention layer to permeate into the substrate, the composition forming the permeation prevention layer preferably contains a thermoplastic resin. The content of the thermoplastic resin is preferably 2 parts by mass or more and 30 parts by mass or less, more preferably 5 parts by mass or more and 15 parts by mass or less, relative to 100 parts by mass of the curable resin. Examples of the thermoplastic resin include general-purpose thermoplastic resins such as acrylic resins, polyester resins, and cellulose resins.

[0067] Preferred examples of the curable resin for the permeation preventing layer include a thermosetting resin and an ionizing radiation curable resin, and an ionizing radiation curable resin is more preferred.

[0068] As the thermosetting resin for the permeation preventing layer, the same ones as those exemplified as the thermosetting resin that can be impregnated into the base material A can be used.

[0069] The ionizing radiation curable resin of the permeation preventing layer may be the same as the ionizing radiation curable resin exemplified for the first cured product layer. From the viewpoint of easily suppressing the permeation of the composition forming the permeation preventing layer into the substrate, the ionizing radiation curable resin of the permeation preventing layer is preferably a polymerizable oligomer having two or more ionizing radiation curable functional groups in the molecule.

[0070] From the viewpoint of facilitating the formation of the first cured product layer, it is preferable that the permeation preventing layer does not substantially contain a release agent. "Substantially not containing a release agent" means that the content of the release agent is less than 0.1 mass% of the total solid content of the permeation preventing layer, preferably 0.01 mass% or less, and more preferably 0 mass% (no release agent is contained).

[0071] It is preferable that the permeation preventing layer does not substantially contain a filler. "Substantially not containing a filler" means that the filler content is less than 0.1% by mass of the total solid content of the permeation preventing layer, preferably 0.01% by mass or less, and more preferably 0% by mass (no filler).

[0072] The thickness t0 of the permeation preventing layer is preferably 0.1 μm or more and 10.0 μm or less, and more preferably 0.5 μm or more and 5.0 μm or less. By setting t0 to 0.1 μm or more, it is possible to easily suppress the uncured curable resin composition contained in the ink for the first cured layer from permeating into the substrate side. Also, by setting t0 to 10.0 μm or less, it is possible to stably form a permeation prevention layer without affecting other regions.

[0073] When the thickness of the penetration prevention layer is defined as t0, the thickness of the first cured product layer is defined as t1, and the thickness of the second cured product layer is defined as t2, it is preferable to satisfy the relationship of t0 + t1 < t2. By satisfying such a relationship, it is easy to impart a three-dimensional effect to the decorative material. Preferably, t2 - (t0 + t1) is 1.0 μm or more and 45.0 μm or less, more preferably 2.0 μm or more and 35.0 μm or less, and even more preferably 3.0 μm or more and 30.0 μm or less. By setting t2 - (t0 + t1) to be 1.0 μm or more, it is easy to improve the three-dimensional effect. Also, by setting t2 - (t0 + t1) to be 45.0 μm or less, it is easy to stably manufacture the first region and the second region.

[0074] The penetration prevention layer can be formed, for example, by applying, drying, and curing an ink for a penetration prevention layer containing components constituting the penetration prevention layer to a part of the base material A.

[0075] - First decorative layer - The decorative material of the present invention preferably has a first decorative layer on at least a part of the location corresponding to the first region on the side opposite to the side having the first cured product layer and the second cured product layer of the base material A. Also, the first decorative layer is preferably formed in synchronization with the first region.

[0076] The first decorative layer 31 may be formed in an arbitrary pattern within the first region. The arbitrary pattern varies depending on the design desired for the entire decorative material. For example, when the design to be applied to the entire decorative material is a wood pattern, the first decorative layer 31 is preferably formed with one or more patterns selected from vessels, spring wood, and knots, which are parts that form recesses in a wooden board. In other words, the first region is preferably formed with one or more patterns selected from vessels, spring wood, and knots of wood. Vessels are cylindrical cells that serve as a passage for moisture, and when the wood is sawn into a board, the arrangement of tiny vessels forms groove-like recesses along the arrangement and appears to the human eye to have a dark pattern. Spring wood is a part that is formed from spring to summer with a wide grain width and a light color. The part that is formed from summer to autumn with a narrow grain width is called autumn wood, and the spring wood and autumn wood are alternately repeated to form the annual rings of wood. Knots are traces of branches that have been incorporated into the trunk, have a circular or elliptical shape, and have a darker color than the surrounding tissue. In addition, when the design to be imparted to the entire decorative material is a stone pattern such as travertine, it is preferable that the first decorative layer 31 has a recessed pattern. In other words, it is preferable that the first region is formed with a stone recessed pattern. In addition, when the design to be imparted to the entire decorative material is a tile pattern or a brick pattern, it is preferable that the first decorative layer 31 has a joint pattern. In other words, it is preferable that the first region is formed with a tile or brick joint pattern. By providing the design by the first decorative layer 31 as described above, the first region R1 is more likely to appear recessed, and the visual three-dimensional effect can be improved.

[0077] The first decorative layer can be formed, for example, by printing using a first decorative layer ink that contains a colorant and a binder resin.

[0078] Examples of the colorant for the first decorative layer include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, cobalt blue, etc., organic pigments such as quinacridone red, isoindolinone yellow, nickel-azo complex, phthalocyanine blue, etc., or dyes, etc. It is preferable that the colorant for the first decorative layer does not contain luster pigments such as pearl pigments, metal particles, and metal flakes. The binder resin of the first decorative layer is not particularly limited, and examples thereof include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymer resins, polyvinyl butyral resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, cellulose derivatives, rubber resins, and the like.

[0079] The thickness of the first decorative layer can be appropriately adjusted within the range of about 0.1 μm or more and 20 μm or less, taking into consideration the desired design.

[0080] -Surface shape- The arithmetic mean roughness Ra (Ra1) of the surface of the first region according to JIS B0601:1994 at a cutoff value of 0.8 mm is preferably 1.0 μm or more and 5.0 μm or less, and more preferably 1.0 μm or more and 3.0 μm or less. By making Ra1 1.0 μm or more, it is possible to make the first region appear concave. Also, by making Ra1 5.0 μm or less, it is possible to prevent the first region from appearing whitish, and it is possible to easily improve the design.

[0081] Ra1 can be adjusted, for example, by the surface shape of the substrate A, or the particle size and amount of the inorganic filler in the first cured product layer.

[0082] 《Second area》 The second region is a region that is visually recognized as being higher than the first region. The second region has a second cured product layer on substrate A.

[0083] -Second cured material layer- The second cured product layer is a layer formed from a curable resin, more specifically, a layer formed from a cured product of an uncured curable resin composition.

[0084] As the curable resin of the second cured material layer, from the viewpoint of obtaining a design with a higher texture, a thermosetting resin or an ionizing radiation curable resin is preferably mentioned, and a thermosetting resin is more preferable. That is, the second cured material layer preferably contains a thermosetting resin. By using a thermosetting resin, a design with a higher texture can be obtained, and the adhesion to the substrate A is improved, and a superior mechanical strength can be obtained. Examples of the thermosetting resin include the same ones as those exemplified as the thermosetting resin that can be impregnated into the substrate A. Among them, melamine resin, urea resin, melamine-urea resin, diallyl phthalate resin, guanamine resin and sulfonamide resin are preferred, melamine resin, melamine-urea resin and phenol resin are more preferred, and melamine resin is even more preferred. Examples of the ionizing radiation curable resin include the same resins as those exemplified for the first cured product layer.

[0085] From the viewpoints of adhesion between the substrate A and the second cured material layer and production efficiency, the curable resin of the second cured material layer is preferably the same as the impregnating resin of the substrate A. In addition, when the substrate B described below is impregnated with a curable resin, from the viewpoints of production efficiency, the curable resin of the second cured material layer is preferably the same as the impregnating resin of the substrate B.

[0086] The second cured product layer may contain a thermoplastic resin, but preferably contains a curable resin as a main component. Based on the total amount of resin in the second cured material layer, the curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and even more preferably 100% by mass.

[0087] From the viewpoint of reducing diffusion, it is preferable that the second cured material layer contains substantially no filler. "Substantially no filler" means that the filler content is 0.1% by mass or less of the total solid content of the second cured material layer, preferably 0.01% by mass or less, and more preferably 0% by mass.

[0088] The thickness t2 of the second cured product layer is usually about 1 μm or more and 50 μm or less, preferably 3 μm or more and 40 μm or less, and more preferably 5 μm or more and 30 μm or less.

[0089] -Second decorative layer- The second decorative layer can be formed, for example, by printing using a second decorative layer ink that contains a colorant and a binder resin. Examples of the colorant and binder resin of the second decorative layer include the colorants and binder resins exemplified for the first decorative layer described below.

[0090] The second decorative layer may be formed, for example, in any desired pattern on the substrate. The arbitrary pattern varies depending on the design to be imparted. For example, when a wood grain pattern is to be imparted to the entire decorative material, the arbitrary pattern is preferably a wood grain pattern (part other than the vessel groove pattern and / or knot pattern) that is a relatively convex part on the wooden board, particularly autumn wood, when a stone pattern such as travertine is to be imparted to the entire decorative material, a pattern other than the concave parts is preferable, and when a tile or brick pattern is to be imparted to the entire decorative material, a tile or brick part is preferable.

[0091] The thickness of the second decorative layer can be appropriately adjusted within the range of about 0.1 μm or more and 20 μm or less, taking into consideration the desired design.

[0092] -Surface shape- The arithmetic mean roughness Ra (Ra2) of the surface of the second region according to JIS B0601:1994 at a cutoff value of 0.8 mm is preferably 2.0 μm or less, and more preferably 0.5 μm or more and 1.5 μm or less.

[0093] <Base material B> The decorative material of the present invention may have a substrate B on the surface opposite to the substrate A of the decorative layer. The substrate B is preferably selected from a paper substrate and a fiber substrate, and more preferably a paper substrate. The paper substrate and the fiber substrate can be impregnated with a curable resin to easily increase the adhesion between the substrate A and the reinforcing layer described later. Furthermore, if a material having a concealing property is used as the base material B, it is possible to prevent the color of the reinforcing layer, which will be described later, from showing through. Furthermore, by using a paper substrate or fiber substrate impregnated with a curable resin as substrate B, improvements in the mechanical strength and scratch resistance of the decorative material can be expected. As the substrate B, metal plates such as aluminum plates and iron plates, non-metallic inorganic plates such as calcium silicate plates, ceramic plates and cement plates, wood plates, resin plates, etc. can also be used.

[0094] Examples of paper substrates include kraft paper, titanium paper, linter paper, resin-impregnated paper, tissue paper, and Japanese paper. Examples of the fiber substrate include a fiber substrate made of inorganic fibers such as glass fibers, alumina fibers, silica fibers, and carbon fibers, a fiber substrate made of organic fibers of various synthetic resins such as polyester resin, acrylic resin, polyethylene resin, and polypropylene resin, and a composite of these. The fiber substrate may be a nonwoven fabric or a woven fabric. The substrate B may be a laminate of two or more substrates selected from the paper substrates and the fiber substrates.

[0095] The thickness of the base material B is not particularly limited and may be appropriately selected depending on the desired performance. From the viewpoints of ensuring mechanical properties and ease of handling, the thickness is usually about 10 μm to 150 μm, preferably 20 μm to 120 μm, and more preferably 30 μm to 100 μm. When a paper base material is used as the base material B, the basis weight is usually 20 g / m 2 More than 150g / m 2 About 30 g / m or less, preferably 30 g / m 2 More than 100g / m 2 The following is the result.

[0096] The substrate B is preferably impregnated with a curable resin. This configuration can improve the mechanical strength of the decorative material, and in turn can increase the pencil hardness of the surface of the decorative material, making the surface of the decorative material less susceptible to scratches. As the curable resin, a curable resin such as a thermosetting resin or an ionizing radiation curable resin can be used, and a thermosetting resin is preferable from the viewpoint of handling. That is, the base material B preferably contains a curable resin, and more preferably contains a thermosetting resin.

[0097] Examples of the thermosetting resin to be impregnated into the base material B include the same resins as those exemplified as the impregnating resin for the base material A. Among them, melamine resin, urea resin, melamine-urea resin, guanamine resin and sulfonamide resin are preferred, melamine resin, melamine-urea resin and phenol resin are more preferred, and phenol resin and melamine resin are even more preferred.

[0098] As a means for impregnating the base material B with a thermosetting resin, a method may be used in which an uncured thermosetting resin composition is prepared and the base material is impregnated with the resin composition (for example, steps (A3) and (B5) described below). The impregnated composition is heated at an appropriate time to be cured by a crosslinking reaction, a polymerization reaction or the like, to become a cured thermosetting resin (for example, steps (A5) and (B7) described below).

[0099] The impregnating resin of the base material B may contain a thermoplastic resin, but preferably contains a curable resin as the main component. Based on the total amount of the impregnated resin in the substrate B, the curable resin is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and even more preferably 100% by mass.

[0100] The total light transmittance of the substrate B according to JIS K7361-1:1997 is preferably 20% or less, more preferably 15% or less, even more preferably 12% or less, and even more preferably 10% or less. By setting the total light transmittance of the substrate B within this range, the substrate B acts as a base and can improve the visibility of the decorative layer. In addition, by setting the total light transmittance of the substrate B within this range, the concealing property of the substrate B is improved, and it is easy to suppress the color of the reinforcing layer described later from showing through.

[0101] <Reinforcing layer> For the purpose of improving mechanical properties, the decorative material may have a reinforcing layer on the surface of the decorative layer opposite the substrate A. When the decorative material has substrate B, the reinforcing layer is preferably disposed on the surface of substrate B opposite the decorative layer.

[0102] The reinforcing layer may be a sheet impregnated with a thermosetting resin. The types of fiber substrate and paper substrate used in the thermosetting resin-impregnated sheet are not particularly limited as long as they are the same as those exemplified as the fiber substrate and paper substrate of the substrate B, and the basis weight is preferably 100 g / m 2 More than 300g / m 2 Less than 150 g / m 2 More than 250g / m 2 The thermosetting resin is not particularly limited as long as it can be impregnated into the substrate in the form of a thermosetting resin composition, and a phenolic resin is preferred. That is, the reinforcing layer is preferably a phenolic resin-impregnated paper. As the phenol resin impregnated paper, for example, a paper with a basis weight of 150 g / m 2 More than 250g / m 2 The following craft paper is preferably impregnated with phenol resin to an impregnation rate of about 20% to 60%, and then dried at about 100° C. to 140° C. The reinforcing layer may be made of metal plates such as aluminum plates and iron plates, non-metallic inorganic plates such as calcium silicate plates, ceramic plates and cement plates, wood plates, resin plates, etc.

[0103] The reinforcing layer has a total light transmittance according to JIS K7361-1:1997 of preferably 20% or less, more preferably 15% or less, even more preferably 12% or less, and even more preferably 10% or less. By setting the total light transmittance of the reinforcing layer within this range, the reinforcing layer acts as a base and can improve the visibility of the decorative layer.

[0104] <Primer layer, adhesive layer> In the decorative material of the present invention, a primer layer or an adhesive layer can be provided between each layer in order to improve the adhesion between the layers. Examples of the resin material for forming the primer layer include urethane resin, polyester resin, acrylic resin, acrylic urethane resin, vinyl chloride-vinyl acetate copolymer resin, and the like. The adhesive constituting the adhesive layer may be a general-purpose pressure-sensitive adhesive, heat-sensitive adhesive, or curable adhesive (such as a heat-curable adhesive, a light-curable adhesive, or a two-part curable adhesive). From the viewpoint of efficiently obtaining excellent adhesion, the thickness of the primer layer and the adhesive layer is usually about 0.1 μm or more and 15 μm or less, and preferably 1 μm or more and 10 μm or less.

[0105] <Adherent material> The decorative material of the present invention may be integrated by laminating an adherend. It is preferable that the adherend is disposed as the outermost layer on the side having the decorative layer with respect to the base material A as a reference.

[0106] Examples of the substrate include wood boards such as veneer, wood plywood, particle board, MDF (medium density fiberboard), and laminated lumber; gypsum-based boards such as gypsum boards and gypsum slag boards; cement boards such as calcium silicate boards, asbestos slate boards, lightweight foamed concrete boards, and hollow extruded cement boards; fiber cement boards such as pulp cement boards, asbestos cement boards, and wood chip cement boards; ceramic boards such as pottery, porcelain, earthenware, glass, and enamel; metal boards such as iron boards, galvanized steel boards, polyvinyl chloride sol-coated steel boards, aluminum boards, and copper boards; polyolefin boards such as gypsum-based boards and gypsum-based boards; Examples of the adhesive include thermoplastic resin plates such as acrylic resin plates, ABS plates, and polycarbonate plates; thermosetting resin plates such as phenolic resin plates, urea resin plates, unsaturated polyester resin plates, polyurethane resin plates, epoxy resin plates, and melamine resin plates; and so-called FRP plates in which resins such as phenolic resins, urea resins, unsaturated polyester resins, polyurethane resins, epoxy resins, melamine resins, and diallyl phthalate resins are impregnated and cured into glass fiber nonwoven fabrics, cloth, paper, and other various fibrous substrates to form composites. These may be used alone as the adhesive, or two or more of these may be laminated together to form a composite substrate.

[0107] The method of laminating the substrate and various adherends is not particularly limited, and for example, a method of attaching a sheet to an adherend using an adhesive can be adopted. The adhesive may be appropriately selected from known adhesives depending on the type of adherend. Examples of the adhesive include polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ionomer, butadiene-acrylonitrile rubber, neoprene rubber, natural rubber, etc.

[0108] <Application> The decorative material of the present invention is used, for example, for tops of various counters and desks, furniture, cabinets for kitchen products, building materials for homes such as doors, etc. Among these, members including horizontal surfaces such as tops used for counters and desks are preferred in that they are required to have a visual three-dimensional effect and to have abrasion resistance since they are rubbed by various items such as clothing, cleaning supplies, and watches, and therefore the effects of the decorative plate of the present invention can be easily exhibited.

[0109] [Manufacturing method of decorative materials] The decorative material of the present invention can be produced, for example, by steps including the following (A1) to (A7). (A1) A step of preparing paper that will serve as the base for substrate A. (A2) A step of forming a laminate A having a first cured material layer having a releasable surface on at least a portion of one side of a paper and a decorative layer on the other side. (A3) A step of impregnating the laminate A with a curable resin composition to impregnate paper with the curable resin composition to obtain a substrate A which is a resin-impregnated paper having optical transparency, and forming an uncured curable resin composition layer on the entire surface of the side of the laminate A having the first cured material layer to obtain a laminate B. (A4) A step of obtaining a laminate C by disposing a release film on the uncured curable resin composition layer side of the laminate B. (A5) A step of hot pressing both sides of the laminate C between mirror-finished plates to form a second cured material layer by curing the uncured curable resin composition layer. (A6) A step of removing the laminate C from between the mirror plates. (A7) A process in which, when peeling and removing the release film from the laminate C, the second cured material layer on the first cured material layer of the second cured material layer is removed together with the release film to form a first region, and a second region is formed in which the second cured material layer formed in an area not having a first region forming layer remains.

[0110] Although not shown, in the first region R1, when removing the second cured material layer 22 directly on the first cured material layer 21, only the second cured material layer 22 near the surface of the first cured material layer 21 may be left so that the surface becomes a rough thin film. By doing so, the surface of the concave portion of the first region R1 becomes rough and has a lower gloss than the surface of the surrounding second region, so that the three-dimensional effect formed by both regions R1 and R2 can be emphasized.

[0111] Step (A1) is a step of preparing paper that will be the base of the substrate A.

[0112] Step (A2) is a step of forming a laminate A (71) having a first hardened material layer 21 having a releasable surface on at least a portion of one side of paper 10a and a decorative layer 30 on the other side (FIG. 3). Either the first hardened material layer 21 or the decorative layer 30 may be formed first. The area where the first cured material layer 21 is formed becomes the first region R1 of the decorative material. It is preferable that the curable resin composition used to form the first cured material layer is cured at this stage.

[0113] When the decorative material has a substrate B, in step (A2), it is preferable to dispose the substrate B on the surface of the decorative layer opposite to the substrate A. In other words, when the decorative material has the substrate B, it is preferable that the laminate A1 contains the substrate B.

[0114] When the decorative material 100 has a permeation prevention layer 41, it is preferable to have a step of forming the permeation prevention layer between steps (A1) and (A2). When the ink for forming the permeation prevention layer contains a curable resin composition, it is preferable to cure it at this stage.

[0115] Step (A3) is a step of impregnating the laminate A with a curable resin composition, impregnating the paper with the curable resin composition, and obtaining a substrate A (10) which is a resin-impregnated paper having optical transparency, and forming an uncured curable resin composition layer (22a) on the entire surface of the side of the laminate A having the first cured product layer, thereby obtaining a laminate B (72) (FIG. 4).

[0116] In the step (A3), it is preferable that the curable resin composition contained in the laminate B (72) is dried.

[0117] The step (A4) is a step of obtaining a laminate C (73) by disposing a release film 80 on the uncured curable resin composition layer 22a side of the laminate B (FIG. 5).

[0118] The release film 80 serves to remove the second cured product layer on the first cured product layer with a release surface among the second cured product layers obtained by curing the uncured curable resin composition layer 22a in the processes (A7) and (B9) described below. That is, when the adhesive force between the release film and the second cured product layer is x1, and the adhesive force between the second cured product layer and the layer located on the substrate A side of the cured product layer (the first cured product layer in the case of the first region and the substrate A in the case of the second region) is x2, as long as the relationship x1 > x2 in the first region and x1 < x2 in the second region is satisfied, the material of the release film 80 is not particularly limited.

[0119] Examples of the release film 80 include single layers of sheets of various resins such as polyester resins such as polyethylene terephthalate and polybutylene terephthalate; polyolefin resins such as polyethylene and polypropylene; acrylic resins; or those in which a resin layer is formed on these resin sheets.

[0120] When the decorative material has a reinforcing layer, in the process (A4), it is preferable to dispose the reinforcing layer on the surface opposite to the substrate A of the decorative layer. That is, when the decorative material has a reinforcing layer, it is preferable that the laminate C includes the reinforcing layer.

[0121] The process (A5) is a process of thermally pressing the laminate C (73) with both sides of the laminate C (73) sandwiched between mirror plates to form the second cured product layer 22 formed by curing the uncured curable resin composition layer 22a. During the process (A5), the curable resin composition impregnated in the substrate A and the substrate B can also be cured.

[0122] The conditions for thermal pressing may be appropriately adjusted according to the type of thermosetting resin used, and there is no particular limitation. Usually, the temperature condition is 100°C or higher and 200°C or lower, the pressure is 0.1 MPa or higher and 9.8 MPa or lower, and the time is 10 seconds to 120 minutes.

[0123] The process (A6) is a process of taking out the laminate C from between the mirror plates. Step (A7) is a step in which, when the release film is peeled off and removed from the laminate C, the second cured material layer on the first cured material layer of the second cured material layer is removed together with the release film to form a first region, and a second region is formed in which the second cured material layer formed in the area not having the first region forming layer remains (Figure 1). In step (A7), the second cured material layer on the first cured material layer is removed while the second cured material layer remains on the second region, so that after step (A7), the surface of the first region has a lower elevation than the surface of the second region.

[0124] Moreover, the decorative material of the present invention can be produced, for example, by a process including the following (B1) to (B9). (B1) A step of preparing paper that will serve as the base for substrate A. (B2) A step of obtaining a laminate D by forming a first cured product layer having a releasable surface on at least a portion of one side of the paper. (B3) A step of forming a decorative layer on at least a portion of one surface of the base material B to obtain a laminate E. (B4) A step of laminating the surface of the laminate D opposite to the first cured material layer and the surface of the laminate E on the decorative layer side to obtain a laminate F. (B5) A step of impregnating the laminate F with a curable resin composition to impregnate paper with the curable resin composition, thereby obtaining a substrate A which is a resin-impregnated paper having optical transparency, and forming an uncured curable resin composition layer on the entire surface of the side of the laminate F having the first cured material layer, thereby obtaining a laminate G. (B6) A step of obtaining a laminate H by disposing a release film on the uncured curable resin composition layer side of the laminate G. (B7) A step of hot pressing the laminate H while sandwiching both sides between mirror-finished plates to form a second cured material layer by curing the uncured curable resin composition layer. (B8) A step of removing the laminate H from between the mirror plates. (B9) A process for removing the release film from the laminate H, removing the second cured material layer on the first cured material layer together with the release film to form a first region, and forming a second region in which the second cured material layer remains in an area not having a first region forming layer.

[0125] Step (B1) is a step of preparing paper that will serve as the base of the substrate A.

[0126] Step (B2) is a step of obtaining a laminate D having a first cured product layer having a releasable surface formed on at least a part of one side of paper. Step (B3) is a step of forming a decorative layer on at least a part of one surface of the base material B to obtain a laminate E.

[0127] Either step (B2) or step (B3) may be carried out first. The area where the first cured material layer 21 is formed in step (B2) becomes the first region R1 of the decorative material. It is preferable that the curable resin composition used to form the first cured material layer is cured at this stage.

[0128] When the decorative material 100 has a permeation prevention layer 41, it is preferable to have a step of forming the permeation prevention layer between steps (B1) and (B2). When the ink for forming the permeation prevention layer contains a curable resin composition, it is preferable to cure it at this stage.

[0129] Step (B4) is a step of obtaining a laminate F (76) by laminating the surface of the laminate D (74) opposite the first hardened material layer 21 and the surface of the laminate E (75) facing the decorative layer 30 (Figure 6).

[0130] Step (B5) is a step of impregnating the laminate F with a curable resin composition, impregnating the paper with the curable resin composition, and obtaining a substrate A (10) which is a resin-impregnated paper having optical transparency, and forming an uncured curable resin composition layer (22a) on the entire surface of the side of the laminate F having the first cured product layer, thereby obtaining a laminate G (77) (FIG. 7).

[0131] When the substrate B is a paper substrate or a fiber substrate, the substrate B can also be impregnated with the curable resin composition in step (B5).

[0132] The step (B6) is a step of obtaining a laminate H (78) by disposing a release film 80 on the uncured curable resin composition layer 22a side of the laminate G (FIG. 8).

[0133] The release film 80 in step (B6) may be the same as the release film 80 in step (A4).

[0134] When the decorative material has a reinforcing layer, in step (B6), it is preferable to dispose the reinforcing layer on the surface of the base material B opposite to the decorative layer. In other words, when the decorative material has a reinforcing layer, it is preferable that the laminate H includes the reinforcing layer.

[0135] Step (B7) is a step of hot pressing the laminate H (78) with both sides of the laminate H (78) sandwiched between mirror plates to form a second cured material layer 22 by curing the uncured curable resin composition layer 22a. During the step (B7), the curable resin compositions impregnated in the substrate A and the substrate B can also be cured.

[0136] The conditions for the heat press can be adjusted appropriately depending on the type of thermosetting resin used, and are not particularly limited, but typically the temperature is 100°C or higher and 200°C or lower, the pressure is 0.1 MPa or higher and 9.8 MPa or lower, and the time is 10 seconds to 120 minutes.

[0137] The step (B8) is a step of removing the laminate H from between the mirror plates. Step (B9) is a step in which, when the release film is peeled off and removed from the laminate H, the second cured material layer on the first cured material layer of the second cured material layer is removed together with the release film to form a first region, and a second region is formed in which the second cured material layer formed in the area not having the first region forming layer remains (Figure 2). In step (B9), the second cured material layer on the first cured material layer is removed while the second cured material layer remains on the second region, so that after step (B9), the surface of the first region has a lower elevation than the surface of the second region. EXAMPLES

[0138] The present invention will now be described in more detail with reference to examples, but the present invention is not limited to these examples in any way.

[0139] 1. Evaluation 1-1.Abrasion resistance The abrasion resistance of the decorative materials obtained in the examples and comparative examples was evaluated in accordance with "6.2 Abrasion Resistance Method B" of JIS K6902:2008 using a product name "Rotary Abrasion Tester" manufactured by Toyo Seiki Seisakusho Co., Ltd. The abrasive paper "Product No.: S-42, 3M company" conforming to JIS R6252 was used as the abrasive. The rotation speed of the turntable when the printed pattern of the decorative material began to be worn away, and the rotation speed of the turntable when the printed pattern of the decorative material was completely worn away and no longer visible are shown in Table 1. The higher the rotation speed, the better the abrasion resistance.

[0140] 1-2. Three-dimensional effect The cosmetic materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting to determine whether or not they had a three-dimensional effect. The results are shown in Table 1. A: More than 18 people answered that it has a highly three-dimensional design. B: The number of people who answered that the design has a high degree of three-dimensionality was between 11 and 17. C: Between 6 and 10 people answered that the design had a high degree of three-dimensionality. D: Five or fewer people answered that the design had a high degree of three-dimensionality.

[0141] 1-3. Clarity of design The decorative materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting for clarity of design, with color contrast as the evaluation point. The results are shown in Table 1. A+: 19 or more people answered that the design was clear. A-: Between 17 and 18 people answered that the design was clear. B+: 14 to 16 people answered that the design was clear. B-: 11 to 13 people answered that the design was clear. C: Fewer than 10 people answered that the design was clear.

[0142] 2. Preparation of cosmetic materials [Example 1] Paper containing no coloring agents (KJ Tokushu Shi Co., Ltd., product number: OLP-38, basis weight: 42 g / m 2 A 3 μm thick first decorative layer (vascular portion of the wood grain) and a second decorative layer (bark portion of the wood grain) were formed on one side of the sheet using printing ink (Ode SPTI, manufactured by DIC Graphics Inc.) by gravure printing. Next, the following curable resin composition for forming a first cured material layer was printed on the other side of the paper, and cured by irradiating with an electron beam (applied voltage: 165 KeV, 3 Mrad (30 kGy)) to obtain a laminate A having a first cured material layer with a thickness t1 of 2.0 μm. Next, the laminate A was impregnated with the following curable resin composition for forming a second cured material layer and dried to obtain a substrate A which is a resin-impregnated paper having optical transparency, and a laminate B in which an uncured curable resin composition layer was formed on the entire surface of the side of the laminate A on which the first cured material layer was formed (the amount of the cured resin composition when dried was 80 g / m 2 The total light transmittance of the substrate A was 40% or more throughout the entire surface, and the haze was 96% or less. The Hz1-Hz2 in the specification was approximately 10%. [Hz1-Hz2 was calculated as follows. First, the above paper (KJ Tokushuushi Co., Ltd., product number: OLP-38, basis weight: 42 g / m 2 The haze of the resin-impregnated paper obtained by impregnating the same paper with a curable resin composition for forming a second cured product layer and drying the paper was regarded as Hz2. Hz1-Hz2 was calculated from Hz1 and Hz2.] Next, the following release film was laminated on the surface of the laminate B having the uncured curable resin composition layer, and a reinforcing layer (a 245 g / m2 basis weight obtained by impregnating craft paper with a liquid uncured resin composition made of a phenol resin) was laminated on the decorative layer side of the laminate B. 2 A laminate C was obtained by laminating three sheets of phenol resin-impregnated core paper (Ohta Core, manufactured by Ohta Sangyo Co., Ltd.). Next, both sides of the laminate C are sandwiched between mirror-finished plates, and a heat press is used to mold the laminate at a molding temperature of 150°C and a molding pressure of 100 kg / cm. 2 The laminate was heated and pressurized for 10 minutes at 30° C. The molding resulted in a second cured layer formed by curing the uncured curable resin composition layer. The molding also resulted in the uncured curable resin composition impregnated in the base material A being cured. After molding, the laminate C was taken out from between the two mirror plates, and the release film was peeled off from the laminate C to obtain the decorative board of Example 1. When the release film was peeled off from the laminate C, the second cured material layer on the first cured material layer was removed together with the release film, forming a concave first region. Also, a second region in which the second cured material layer remained was formed in a portion not having the first cured material layer. The decorative material of Example 1 had a thickness t1 of 2.0 μm and a thickness t2 of 5 μm. Furthermore, the ratio (S2 / S1) of the area S1 of the first region to the area S2 of the second region was approximately 4.0.

[0143] <Curable resin composition for forming first cured material layer> The following components were stirred for 1 hour at 2000 rpm using a process homogenizer (manufactured by SMT Corporation, "PH91") to obtain a resin composition. ·Ionizing radiation curable resin 60 parts by mass (Mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate, trade name "Aronix M400" manufactured by Toagosei Co., Ltd.) Silicone release agent 0.9 parts by weight (Organopolysiloxane modified with methacryloyloxyalkyl at both ends, product name "X-22-164B" manufactured by Shin-Etsu Chemical Co., Ltd.) Silane coupling treated silica 18 parts by weight (Average particle size 3.0μm) Methyl ethyl ketone 40 parts by weight

[0144] <Curable resin composition for forming second cured material layer> Melamine formaldehyde resin 60 parts by weight ·Water 35 parts by mass 5 mass of isopropyl alcohol

[0145] <Preparation of release film> The following ionizing radiation curable resin composition was applied to the adhesive surface of a 100 μm thick polyethylene terephthalate film (Toyobo Co., Ltd.'s product name "Lumirror S34") and cured by irradiation with an electron beam (applied voltage: 165 KeV, 5 Mrad (50 kGy)) to form a 5 μm thick cured layer, and a release film was obtained.

[0146] <<Ionizing radiation curable resin composition>> ·Ionizing radiation curable resin 100 parts by mass (Trimethylolpropane triacrylate modified with ethylene bottom oxide, trade name "Aronix M350" manufactured by Toagosei Co., Ltd.) Silicone release agent 2 parts by weight (Organopolysiloxane modified with methacryloyloxyalkyl at both ends, product name "X-22-164B" manufactured by Shin-Etsu Chemical Co., Ltd.) Silica particles: 8 parts by weight (Product name: "Silisia 450" manufactured by Fuji Silysia Chemical Co., Ltd., average particle size: 5.2 μm) Ethyl acetate 50 parts by weight

[0147] [Example 2] In Example 1, the "paper without coloring agent" was replaced with "orange colored paper (paper with the same composition as KJ Specialty Paper's product number "OLP-38" except for the inclusion of a coloring agent, basis weight: 42 g / m 2A cosmetic material of Example 2 was obtained in the same manner as in Example 1, except that the above-mentioned "Haze Hz1-Hz2" was changed to "Haze Hz1-Hz2" in Example 2. In Example 2, the total light transmittance of the substrate A was 40% or more throughout the entire surface, and the haze was 96% or less. In addition, Hz1-Hz2 in the main text of the specification was approximately 10%.

[0148] [Comparative Example 1] Base material (titanium paper base paper for building materials, product name "PM-67P" manufactured by KJ Specialty Paper Co., Ltd., basis weight: 80g / m 2 A first decorative layer (vascular portion of the wood grain) and a second decorative layer (wood grain surface portion) having a thickness of 3 μm were formed on one side of a board (thickness: 100 μm) by gravure printing using printing ink (Ode SPTI, manufactured by DIC Graphics Inc.). Next, the above-mentioned curable resin composition for forming the first cured material layer was printed on the decorative layer, and cured by irradiating with an electron beam (applied voltage: 165 KeV, 3 Mrad (30 kGy)), to obtain a laminate A' having a first cured material layer with a thickness t1 of 2.0 μm. Next, the laminate A' was impregnated with the above-mentioned curable resin composition for forming the second cured material layer and dried to obtain a laminate B' in which an uncured curable resin composition layer was formed on the entire surface of the side of the laminate A' having the first cured material layer (the amount of the cured resin composition when dried was 80 g / m 2 (impregnated so that Next, the release film was laminated on the surface of the laminate B' having the uncured curable resin composition layer, and a reinforcing layer (a layer having a basis weight of 245 g / m2 obtained by impregnating craft paper with a liquid uncured resin composition made of a phenol resin) was laminated on the surface of the laminate B' on the substrate side. 2 A laminate C' was obtained by laminating three sheets of phenol resin-impregnated core paper (Ohta Core, manufactured by Ohta Sangyo Co., Ltd.). Next, both sides of the laminate C' are sandwiched between mirror-finished plates, and a heat press is used to mold the laminate at a molding temperature of 150°C and a molding pressure of 100 kg / cm. 2The laminate was heated and pressurized for 10 minutes at 30° C. The molding process resulted in a second cured layer formed by curing the uncured curable resin composition layer. The molding process also resulted in the uncured curable resin composition impregnated in the substrate being cured. After molding, the laminate C' was taken out from between the two mirror plates, and the release film was peeled off from the laminate C' to obtain the decorative board of Comparative Example 1. When the release film was peeled off from the laminate C', the second cured material layer on the first cured material layer was removed together with the release film, forming a concave first region. Also, a second region in which the second cured material layer remained was formed in a portion not having the first cured material layer. The decorative material of Comparative Example 1 had a thickness t1 of 2.0 μm and a thickness t2 of 5 μm. The ratio (S2 / S1) of the area S1 of the first region to the area S2 of the second region was approximately 5.0. The decorative material of Comparative Example 1 did not have a substrate between the first and second cured material layers and the decorative layer, and had the decorative layer directly below the first and second cured material layers.

[0149] [Comparative Example 2] Except for not forming a first cured product layer, a decorative material of Comparative Example 2 was obtained in the same manner as in Example 1. The decorative material of Comparative Example 2 has a second cured product layer with an average thickness of 40 μm over the entire surface of the side opposite the decorative layer of the base material A, does not have a first region or a second region, and has no three-dimensional effect.

[0150] [Table 1]

[0151] From the results in Table 1, it can be confirmed that the decorative materials of the Examples have a visual three-dimensional effect and are excellent in abrasion resistance. In addition, among the Examples, it can be confirmed that the decorative material of Example 2, in which the base material A contains a coloring agent, has a clear design and is excellent in design. [Explanation of symbols]

[0152] 10: Base material A 21: First cured material layer 22: Second cured material layer 22a: Curable resin composition layer 30:Decorative layer 31: First decorative layer 32: Second decorative layer 41: Penetration prevention layer 50: Base material B 60: Reinforcement layer 71: Laminate A 72: Laminate B 73: Laminate C 74: Laminate D 75: Laminate E 76: Laminate F 77: Laminate G 78: Laminate H 80: Release film 100: Cosmetic materials

Claims

1. A cosmetic material comprising: The decorative material has a first region and a second region in a plane, a surface of the first region is lower in elevation than a surface of the second region; The decorative material in the area corresponding to the first region has a first cured material layer having a releasable surface on one side of a substrate A, The decorative material in the area corresponding to the second region has a second cured material layer on one surface of the base material A, the first cured material layer and the second cured material layer are formed on the same side of the substrate A, a decorative layer is provided on at least a part of the substrate A on a side opposite to the side on which the first cured material layer and the second cured material layer are provided, The decorative material, wherein the substrate A is a resin-impregnated paper having optical transparency.

2. The decorative material according to claim 1 , wherein the resin impregnated in the base material A contains a thermosetting resin.

3. The decorative material according to claim 1 or 2, wherein the base material A contains a colorant.

4. The decorative material according to any one of claims 1 to 3, wherein, when the decorative material is observed from the first cured material layer side, the first region has a higher brightness than the second region.

5. The decorative material according to any one of claims 1 to 4, wherein when the haze of a portion of the base material A having the first cured material layer is defined as Hz1 and the haze of a portion of the base material A having the second cured material layer is defined as Hz2, a relationship of Hz2 < Hz1 is satisfied.

6. The decorative material according to any one of claims 1 to 5, wherein the first cured material layer contains an ionizing radiation curable resin.

7. The decorative material according to any one of claims 1 to 6, wherein the first cured material layer contains a release agent.

8. The decorative material according to any one of claims 1 to 7, wherein the second cured material layer comprises a thermosetting resin.

9. The decorative material according to any one of claims 1 to 8, wherein when the thickness of the first cured material layer is defined as t1 and the thickness of the second cured material layer is defined as t2, the relationship of t1 < t2 is satisfied.

10. The decorative material according to any one of claims 1 to 9, wherein the decorative layer comprises at least one of a first decorative layer formed on at least a portion of the area corresponding to the first region, and a second decorative layer formed on at least a portion of the area corresponding to the second region.

11. The decorative material according to any one of claims 1 to 10, further comprising a permeation-preventing layer between the substrate A and the first cured material layer.

12. The decorative material according to claim 11, wherein when the thickness of the permeation prevention layer is defined as t0, the thickness of the first hardened material layer is defined as t1, and the thickness of the second hardened material layer is defined as t2, the relationship of t0 + t1 < t2 is satisfied.

13. The decorative material according to any one of claims 1 to 12, further comprising a substrate B on the surface of the decorative layer opposite to the substrate A.

14. The decorative material according to claim 13 , wherein the substrate B comprises a thermosetting resin.

15. A method for producing a decorative material, comprising the following steps (A1) to (A7): (A1) A step of preparing paper that will serve as the base of the substrate A. (A2) A first cured material layer having a releasable surface is formed on at least a part of one side of the paper. and forming a laminate A having a decorative layer on the other surface. (A3) impregnating the laminate A with a curable resin composition, and impregnating paper with the curable resin composition; A substrate A is obtained which is a resin-impregnated paper having optical transparency, and a first cured material layer of the laminate A is A step of forming an uncured curable resin composition layer on the entire surface of the side having the cured resin composition to obtain a laminate B. (A4) A release film is placed on the uncured curable resin composition layer side of the laminate B. A step of obtaining a laminate C. (A5) Both sides of the laminate C are sandwiched between mirror plates and hot pressed to remove the uncured curable resin. A step of forming a second cured layer by curing the resin composition layer. (A6) A step of removing the laminate C from between the mirror plates. (A7) When the release film is peeled off and removed from the laminate C, Also, the second cured material layer on the first cured material layer is removed to form a first region. and a second cured material layer formed in a portion not having the first region forming layer remains. A process for forming a region.

16. A method for producing a decorative material, comprising the following steps (B1) to (B9): (B1) A step of preparing paper that will serve as the base of the substrate A. (B2) A first cured material layer having a releasable surface is formed on at least a portion of one side of the paper. A process for obtaining a laminate D comprising the above steps. (B3) A step of forming a decorative layer on at least a part of one surface of the substrate B to obtain a laminate E. About. (B4) The surface of the laminate D opposite to the first cured material layer and the surface of the laminate E on the decorative layer side A step of obtaining a laminate F by laminating the above. (B5) impregnating the laminate F with a curable resin composition, and impregnating paper with the curable resin composition; A substrate A is obtained which is a resin-impregnated paper having optical transparency, and a first cured material layer of the laminate F is obtained. A step of forming an uncured curable resin composition layer on the entire surface of the side having the cured resin composition to obtain a laminate G. (B6) A release film is placed on the uncured curable resin composition layer side of the laminate G. A process for obtaining a laminate H. (B7) Both sides of the laminate H are sandwiched between mirror plates and hot pressed to remove the uncured curable resin. A step of forming a second cured layer by curing the resin composition layer. (B8) A step of removing the laminate H from between the mirror plates. (B9) When peeling and removing the release film from the laminate H, Also, the second cured material layer on the first cured material layer is removed to form a first region. and a second cured material layer formed in a portion not having the first region forming layer remains. A process for forming a region.

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