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

Abstract

To provide decorative paper and a decorative plate excellent in designability and processing suitability in a step of impregnating an impregnation resin, and to provide a method of producing the decorative paper and the decorative plate.SOLUTION: Decorative paper 10 includes: a raw fabric layer 1; a pattern-printed layer 2 provided on an upper side UP of the raw fabric layer 1; coated portions 3a provided on the upper side UP of the pattern-printed layer 2 and coated over a coating range A1; uncoated micropores 3b; and a highly designed resin layer 3 in which the area ratio of the coated portions 3a to the pattern-printed layer 2 is 5% or more and 60% or less.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to decorative paper and decorative boards, and methods for making decorative paper and decorative boards. [Background technology]

[0002] Conventionally, decorative boards made by impregnating decorative paper with a thermosetting resin such as melamine resin and then curing the impregnated thermosetting resin have high surface hardness and excellent stain resistance, abrasion resistance, heat resistance, water resistance, etc. Therefore, decorative boards made by impregnating decorative paper with a thermosetting resin are used as surface materials for furniture such as desks or for fixtures such as store counters. In addition, some decorative papers and decorative boards have the gloss of the surface resin layer adjusted with a matting agent or the like to give the surface of the decorative paper and decorative board a visual three-dimensional effect.

[0003] Gloss-adjusted decorative paper and a decorative board in which the decorative paper is impregnated with resin are described in Patent Document 1. The decorative paper for resin-impregnated decorative boards and the resin-impregnated decorative board described in Patent Document 1 include base paper, a picture pattern layer formed by printing a picture pattern on the base paper, and a liquid-repellent cured film provided on the picture pattern layer. The liquid-repellent cured film is composed of a first liquid-repellent cured film that covers the entire picture pattern layer and a second liquid-repellent cured film that is provided on a portion of the first liquid-repellent cured film. The first liquid-repellent cured film and the second liquid-repellent cured film have different glosses (lusters), so the decorative paper for resin-impregnated decorative boards and the resin-impregnated decorative board described in Patent Document 1 have excellent designability due to the gloss adjustment.

[0004] However, in the decorative paper for resin-impregnated decorative boards and resin-impregnated decorative boards described in Patent Document 1, there is a risk that the liquid-repellent cured film will penetrate into the base paper. As a result, the impregnation of the impregnating resin into the decorative paper will be poor, and the time required for the process of impregnating the decorative paper with the impregnating resin will increase, which may result in poor processability. Furthermore, to improve processability in the process of impregnating the impregnating resin, it is necessary to reduce the amount of the liquid-repellent cured film applied to reduce the amount of the liquid-repellent cured film that penetrates into the base paper, which reduces the degree of freedom in the area in which the liquid-repellent cured film is arranged, and there is a risk that the design will be poor.

[0005] Furthermore, the decorative sheet and decorative board comprising said decorative sheet described in Patent Document 2 comprise a decorative layer provided on a paper substrate, a release layer provided on the decorative layer and formed in accordance with the area of the decorative layer's pattern that is desired to have a low gloss, and a high-gloss surface layer formed in an area adjacent to the release layer. As a result, the difference in gloss between the release layer and the surface layer creates a design with adjusted gloss. The surface layer is formed from a melamine resin that is impregnated into the decorative sheet and cured.

[0006] Furthermore, the decorative sheet and decorative board including said decorative sheet described in Patent Document 2 have a coating layer between the surface layer and release layer and the decorative layer, and the coating layer prevents the release layer from penetrating into the paper substrate, thereby maintaining design. However, there is a risk that the coating layer may inhibit not only the penetration of the release layer into the paper substrate, but also the impregnation of the impregnation resin, which may result in an increase in the time required for the process of impregnating the decorative paper with the impregnation resin and a risk of poor processing suitability. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 2018-176484 [Patent Document 2] Japanese Patent Application Publication No. 2019-64120 Summary of the Invention [Problem to be solved by the invention]

[0008] In light of the above circumstances, the present invention aims to provide decorative paper and decorative boards that are excellent in design and processability in the process of impregnating with an impregnating resin, as well as methods for manufacturing decorative paper and decorative boards. [Means for solving the problem]

[0009] In order to solve the above problems, the present invention proposes the following means. The decorative paper of the present invention comprises a base fabric layer, a picture-printed layer provided on the upper side of the base fabric layer, and a highly designed resin layer provided on the upper side of the picture-printed layer, the highly designed resin layer having a coated portion coated in a coating range and uncoated micropores, the area ratio of the coated portion to the picture-printed layer being 5% or more and 60% or less. The coating area in which the high-design resin layer is placed is set partially in multiple areas relative to the picture printed layer, the width of the micropores is smaller than the distance between adjacent high-design resin layers, the micropores are capable of allowing the impregnating resin to penetrate inside, and are formed by printing.

[0010] In the decorative paper, the highly-designed resin layer may contain a thermosetting resin, an ultraviolet-curable resin, or an ionizing radiation-curable resin.

[0011] In the decorative paper, the area ratio of the highly-designed resin layer in the coated portion to the picture-printed layer may be 10% or more and 40% or less.

[0012] In the decorative paper, the highly-designed resin layer may be arranged in harmony with the pattern of the pattern-printed layer.

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

[0014] The method for manufacturing decorative paper of the present invention includes a pattern printing step of forming a pattern printed layer, and a highly decorative resin coating step of forming a highly decorative resin layer in which the area ratio of the coated portion to the pattern printed layer is 5% or more and 60% or less. The high-design resin coating process places the high-design resin layer in multiple coating areas that are set partially on the picture printing layer, and in the coating area, the high-design resin layer is not coated, and micropores into which the impregnating resin can penetrate are formed by printing, and the width of the micropores is smaller than the distance between adjacent high-design resin layers.

[0015] In the above-mentioned decorative paper manufacturing method, the high-design resin coating process may form a high-design resin layer in which the area ratio of the coated portion of the high-design resin layer to the picture printed layer is 10% or more and 40% or less.

[0016] The method for manufacturing a decorative board of the present invention comprises any of the methods for manufacturing decorative paper described above, a resin impregnation step of impregnating the decorative paper with an impregnation resin, and a pressing step of curing the impregnation resin. [Effects of the Invention]

[0017] According to the decorative paper and decorative board, and the manufacturing method for decorative paper and decorative board of the present invention, it is possible to provide decorative paper and decorative board, and the manufacturing method for decorative paper and decorative board, which have excellent design properties and processing suitability in the process of impregnating with impregnating resin. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a cross-sectional view schematically illustrating the configuration of decorative paper according to the present embodiment. [Figure 2] 1 is a cross-sectional view schematically illustrating a configuration of a decorative board according to an embodiment of the present invention. [Figure 3] 3 is a flowchart showing a method for manufacturing the decorative board. DETAILED DESCRIPTION OF THE INVENTION

[0019] An embodiment of the present invention will be described with reference to FIGS.

[0020] Fig. 1(a) is a cross-sectional view schematically showing the configuration of decorative paper 10 according to this embodiment. Fig. 1(b) is a cross-sectional view showing an enlarged view of a coated area A1 in Fig. 1(a) where a highly-designed resin layer 3, described later, is coated. Fig. 2(a) is a cross-sectional view schematically showing the configuration of a decorative board 100 in which decorative paper 10 is impregnated with an impregnating resin 4. Fig. 2(b) is a cross-sectional view showing an enlarged view of a coated area A1 in Fig. 2(a) where a highly-designed resin layer 3, described later, is coated.

[0021] In this embodiment, as shown in Figures 1 and 2, the thickness direction of the decorative paper 10 and the decorative board 100 is defined as the "vertical direction V," the side on which the raw fabric layer 1 of the decorative paper 10 is provided is defined as the "lower side LO" in the vertical direction V, and the side opposite the lower side LO is defined as the "upper side UP" in the vertical direction V.

[0022] The decorative board 100 comprises decorative paper 10 and an impregnating resin 4. The decorative board 100 is formed by impregnating the decorative paper 10 with the impregnating resin 4 and then curing the impregnated resin 4. By impregnating the decorative paper 10 with the impregnating resin 4, the impregnating resin 4 penetrates into the decorative paper 10 and hardens. The decorative board 100 that has been impregnated with and hardened the impregnating resin 4 has excellent properties such as high surface hardness, stain resistance, abrasion resistance, heat resistance, and water resistance.

[0023] The impregnating resin 4 is a known thermosetting resin used in resin-impregnated decorative panels. Examples of resins that can be used as the impregnating resin 4 include melamine resins, epoxy resins, diallyl phthalate resins, benzoguanamine resins, urethane resins, alkyd resins, unsaturated polyester resins, phenolic resins, and urea resins. The impregnating resin 4 is dissolved or dispersed in water to form an aqueous impregnation liquid, which is then impregnated into the decorative paper 10. It is desirable to use a melamine resin as the impregnating resin 4, which has high strength and excellent stain resistance, abrasion resistance, heat resistance, and water resistance.

[0024] The decorative paper 10 comprises a base layer 1, a pattern printed layer 2, and a highly decorative resin layer 3. The raw fabric layer 1 is a layer provided on the lower side LO of the decorative paper 10. The raw fabric layer 1 is a known fibrous sheet that can be impregnated with the impregnation resin 4. For example, titanium paper, tissue paper, fine paper, unbleached kraft paper, bleached kraft paper, etc. can be used as the raw fabric layer 1. It is desirable to use titanium paper as the raw fabric layer 1, as it has excellent printability and resin impregnation suitability. There are no restrictions on the thickness of the raw fabric layer 1, and it is generally a material with a basis weight of 20 g / m 2 More than 200g / m 2 The following is used:

[0025] The pattern-printed layer 2 is a layer provided on the upper side UP of the raw fabric layer 1 and is formed, for example, by printing a wood grain, stone grain, or sand grain. The pattern-printed layer 2 has a first pattern-forming portion 2a and a second pattern-forming portion 2b. The first pattern-forming portion 2a and the second pattern-forming portion 2b form a pattern on the upper side UP of the raw fabric layer 1, for example, by using different colored pigments in the resin (ink) forming the first pattern-forming portion 2a and the resin (ink) forming the second pattern-forming portion 2b. The pattern-printed layer 2 can be printed using known printing methods such as gravure printing, offset printing, flexographic printing, silkscreen printing, and inkjet printing. Known printing inks suitable for the printing method can be used for the pattern-printed layer 2, but water-based inks are preferred. Compared to oil-based inks, water-based inks are more compatible with the aqueous solution of the impregnating resin 4, and when the impregnating resin 4 is impregnated into the decorative paper 10, the impregnation can be achieved quickly and uniformly.Furthermore, by integrating with the impregnating resin 4, the water-based inks can have excellent strength.

[0026] Furthermore, it is desirable to use a water-based ink whose binder resin is primarily made of casein or emulsion resin for the picture-printed layer 2. Binder resins whose primary component is casein or emulsion resin have the property of becoming less water-soluble when subjected to a drying process after printing the ink, and are therefore less likely to re-dissolve in the aqueous solution of the impregnating resin 4 during the process of impregnating the picture-printed layer 2, making it less likely to damage the picture pattern of the picture-printed layer 2 and preventing the impregnating resin 4 from contaminating the dissolved picture-printed layer 2.

[0027] The emulsion resin contained in the binder resin may be, for example, an acrylic, vinyl acetate, styrene, urethane, etc. In addition to casein or emulsion resin, the binder resin may also be a combination of, for example, a water-soluble resin such as polyvinyl alcohol or polyacrylamide, or a water-soluble polymer such as a polysaccharide or cellulose derivative, in order to improve the stability of the ink.

[0028] The highly-designed resin layer 3 is a layer provided on the upper side UP of the picture-printed layer 2. For the highly-designed resin layer 3, it is desirable to use a transparent or translucent material that allows the picture of the picture-printed layer 2 to be seen through. For the highly-designed resin layer 3, a thermosetting resin, an ultraviolet-curable resin, an ionizing radiation-curable resin, or a mixture thereof can be used. For example, for the highly-designed resin layer 3, a thermosetting resin such as a melamine-based resin, an epoxy-based resin, a urea-based resin, a phenol-based resin, an unsaturated polyester-based resin, a diallyl phthalate-based resin, a benzoguanamine-based resin, a urethane-based resin, an aminoalkyd-based resin, or a silicone-based resin, or an ionizing radiation-curable resin such as a (meth)acrylate-based resin or an unsaturated polyester-based resin can be used.

[0029] The highly-designed resin layer 3 is provided on a portion of the upper UP of the picture-printed layer 2, and is positioned in harmony with the picture of the picture-printed layer 2. In this embodiment, the highly-designed resin layer 3 is positioned so as to overlap the first picture-forming portion 2a when the decorative paper 10 and the decorative board 100 are viewed from the upper UP. For example, if the picture of the picture-printed layer 2 is wood grain and the first picture-forming portion 2a forms a duct portion of the wood grain, the highly-designed resin layer 3 is provided on the upper UP of the duct portion. By providing the highly-designed resin layer 3 in a position that is in harmony with the duct portion, a visual three-dimensional effect can be imparted to the duct portion.

[0030] A known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be used to form the highly-designed resin layer 3. The highly-designed resin layer 3 may also be formed using a known coating device.

[0031] The gloss of the highly-designed resin layer 3 may be adjusted to impart a glossy or matte finish to the decorative paper 10 and decorative board 100. One method for adjusting the gloss of the highly-designed resin layer 3 is to add a matte material to the highly-designed resin layer 3. By adding a matte material, the gloss of the highly-designed resin layer 3 can be adjusted to have a low gloss (matte finish). Alternatively, the gloss may be adjusted to have a high gloss (gloss finish) without adding a matte material.

[0032] For example, if the pattern of the pattern printed layer 2 is wood grain, adding a matte material to the highly-designed resin layer 3 provided in sync with the duct portion (first pattern forming portion 2a) to reduce gloss can impart different gloss (gloss difference) to the portion where the highly-designed resin layer 3 is located (first pattern forming portion 2a) and the portion where it is not located (second pattern forming portion 2b) on the upper UP surface of the pattern printed layer 2. As a result, the duct portion of the wood grain where the highly-designed resin layer 3 is located has a lower gloss than the portion where the highly-designed resin layer 3 is not located, making it possible to take advantage of an optical illusion and further emphasize the visual three-dimensional effect.

[0033] By imparting a three-dimensional effect with the highly-designed resin layer 3, it is possible to provide decorative paper 10 and decorative board 100 with excellent design. For example, if a three-dimensional effect is imparted to the duct portion of a wood grain pattern with the highly-designed resin layer 3, it is possible to provide decorative paper 10 and decorative board 100 that more closely resembles the appearance of natural wood.

[0034] The highly-designed resin layer 3 also includes a coated portion 3a and micropores 3b. As shown in Figures 1(b) and 2(b), the coating area A1 where the highly-designed resin layer 3 is coated includes the coated portion 3a where the resin that will actually be coated to form the highly-designed resin layer 3 is arranged, and the micropores 3b where the resin that will form the highly-designed resin layer 3 is not arranged and is not coated.

[0035] For example, when the highly-designed resin layer 3 is disposed in the duct portion (first pattern forming portion 2a) of a wood grain pattern, the area of the duct portion is the coating area A1. Typically, the coating is performed so that the resin is disposed throughout the entire coating area A1, but the highly-designed resin layer 3 has micropores 3b, which are tiny holes where no resin is disposed, as shown in FIG. 1(b). There are no restrictions on the shape of the micropores 3b; when the decorative paper 10 and the decorative board 100 are viewed from above, the micropores 3b may be dot-like or linear. Furthermore, the micropores 3b disposed within the coating area A1 may be arranged regularly or irregularly. Therefore, it is desirable to arrange the micropores 3b so as to minimize the effect on the design imparted by the highly-designed resin layer 3 to the decorative paper 10 and the decorative board 100.

[0036] In this case, the ratio (area ratio) of the area where the coated portion 3a is arranged to the area where the picture-printed layer 2 is arranged in the decorative paper 10 and the decorative board 100 is 5% or more and 60% or less. If the area ratio of the coated portion 3a to the picture-printed layer 2 is less than 5%, the amount of resin that forms the highly-designed resin layer 3 in the decorative paper 10 and the decorative board 100 will be small, resulting in inferior design. By making the area ratio 5% or more, the resin that forms the highly-designed resin layer 3 can be sufficiently arranged, allowing the decorative paper 10 and the decorative board 100 to have an excellent design.

[0037] Furthermore, when the highly-designed resin layer 3 is formed on the upper side UP of the picture-printed layer 2, some of the resin forming the highly-designed resin layer 3 penetrates and soaks into the picture-printed layer 2 and the base fabric layer 1. When the resin forming the highly-designed resin layer 3 soaks into the picture-printed layer 2 and the base fabric layer 1, the impregnation of the impregnating resin 4 into the decorative paper 10 in the decorative board 100 is hindered. When the impregnation of the impregnating resin 4 is hindered, it takes a long time to impregnate the entire decorative paper 10 with the impregnating resin 4, and the processability of the impregnation process of the impregnating resin 4 is poor.

[0038] Here, by setting the area ratio of the coated portion 3a to the picture-printed layer 2 to 60% or less, the resin forming the highly-designed resin layer 3 is prevented from seeping into the picture-printed layer 2 and the base fabric layer 1, allowing the impregnating resin 4 to sufficiently impregnate the decorative paper 10. Furthermore, as shown in Figure 2(b), the impregnating resin 4 enters the micropores 3b and can be passed through the micropores 3b to sufficiently soak into the decorative paper 10. In other words, by setting the area ratio of the coated portion 3a to the picture-printed layer 2 to 5% or more and 60% or less, it is possible to obtain decorative paper 10 and decorative board 100 that have excellent design and processability in the process of impregnating with the impregnating resin 4.

[0039] For example, in the coating area A1 where the highly-designed resin layer 3 is coated, such as the duct portion of the wood grain pattern (first pattern forming portion 2a), the amount of resin forming the highly-designed resin layer 3 is reduced by providing micropores 3b in the highly-designed resin layer 3. Therefore, in the coating area A1, the amount of resin forming the highly-designed resin layer 3 can be reduced without significantly changing the design. As a result, the impact on the design of the decorative board 100 can be minimized, and the processability in the process of impregnating the impregnating resin 4 can be improved, achieving both design and processability in the process of impregnating the impregnating resin 4.

[0040] Furthermore, the area ratio of the coated portion 3a to the picture-printed layer 2 is preferably 10% or more and 40% or less. By setting the area ratio to 10% or more, more of the resin that forms the highly-designed resin layer 3 can be provided on the upper side UP of the picture-printed layer 2, allowing the decorative paper 10 and decorative board 100 to have better design. Furthermore, by setting the area ratio to 40% or less, it is possible to further prevent the resin that forms the highly-designed resin layer 3 from seeping into the picture-printed layer 2 and the base fabric layer 1, thereby further improving processing suitability in the process of impregnating the impregnating resin 4.

[0041] Next, a method for manufacturing the decorative paper 10 and the decorative board 100 will be described. Figure 3 is a flowchart showing the steps for manufacturing the decorative paper 10 and the decorative board 100 according to this embodiment using a decorative board manufacturing system. Here, the decorative board manufacturing system is a system that carries out the manufacturing of the decorative paper 10 and the decorative board 100 according to this embodiment.

[0042] First, the decorative board manufacturing system performs step S1 (pattern printing step). In step S1, a pattern is printed on the upper side UP of the raw fabric layer 1 to form a pattern-printed layer 2.

[0043] Next, the decorative board manufacturing system performs step S2 (high-design resin coating process). In step S2, a high-design resin layer 3 is formed on the upper side UP of the picture-printed layer 2 to obtain the decorative paper 10. At this time, in the first picture-forming section 2a and the second picture-forming section 2b that form the picture of the picture-printed layer 2, the high-design resin layer 3 is formed on the upper side UP of the first picture-forming section 2a. Furthermore, the area of the coating section 3a where the resin that forms the high-design resin layer 3 is disposed (coated) is set to an area ratio of 5% to 60% of the area of the picture-printed layer 2. By providing micropores 3b where the resin that forms the high-design resin layer 3 is not disposed (coated) in the coating area A1 where the high-design resin layer 3 is desired to be disposed, the amount of resin that forms the high-design resin layer 3 can be reduced while minimizing the impact on the design imparted by the high-design resin layer 3. Furthermore, since the area ratio of the coated portion 3a to the picture-printed layer 2 is 5% or more, the highly-designed resin layer 3 can have sufficient design. As a result, the amount of resin forming the highly-designed resin layer 3 can be reduced while the design imparted by the highly-designed resin layer 3 is sufficiently maintained.

[0044] Next, the decorative board manufacturing system performs step S3 (resin impregnation step). In step S3, the decorative paper 10 obtained in step S2 is impregnated with the impregnating resin 4. At this time, the decorative paper 10 may be impregnated with the impregnating resin 4 from the upper side UP, or from the lower side LO. Also, the impregnation may be performed multiple times from the upper side UP or the lower side LO, or the impregnation may be performed simultaneously from the upper side UP and the lower side LO.

[0045] In step S2, the highly-designed resin layer 3 is formed so that the area of the coated portion 3a is 60% or less of the area of the picture-printed layer 2, thereby preventing the resin forming the highly-designed resin layer 3 from seeping into the picture-printed layer 2 and the base fabric layer 1, and allowing the impregnating resin 4 to be sufficiently impregnated into the decorative paper 10 in step S3.

[0046] Next, the decorative board manufacturing system performs step S4 (pressing process). In step S4, the decorative paper 10 impregnated with the impregnating resin 4 in step S3 is sandwiched between press plates such as metal plates from the upper side UP and the lower side LO, and the decorative paper 10 is pressurized and heated from the upper side UP and the lower side LO. The thermosetting resin that forms the impregnating resin 4 hardens by the pressure and heat, forming the decorative board 100. Methods that can be used to heat and pressurize the decorative paper 10 include a flat pressure press method in contact with a metal plate and a circular pressure continuous lamination method.

[0047] The decorative board 100 obtained in step S4 has an area ratio of the coated portion 3a to the picture printed layer 2 of 5% or more and 60% or less, and therefore has excellent design properties and processability in the process of impregnating with the impregnating resin 4 (resin impregnation process S3).

[0048] According to the decorative paper 10 and decorative board 100 of this embodiment and the manufacturing method of the decorative paper 10 and decorative board 100, the high-design resin layer 3 provided on the upper side UP of the picture-printed layer 2 has, in the coating area A1 where the high-design resin layer 3 is arranged, a coated portion 3a in which the resin that forms the high-design resin layer 3 is arranged, and micropores 3b in which no resin is arranged, and the area ratio of the coated portion 3a to the picture-printed layer 2 is 5% or more and 60% or less.

[0049] Therefore, the amount of resin forming the highly-designed resin layer 3 can be reduced while fully maintaining the design imparted by the highly-designed resin layer 3, and therefore the resin forming the highly-designed resin layer 3 can be prevented from seeping into the picture-printed layer 2 and the raw fabric layer 1 provided on the lower side LO of the picture-printed layer 2 while minimizing the impact on the design imparted by the highly-designed resin layer 3. As a result, it is possible to provide decorative paper 10 and decorative board 100, as well as a method for manufacturing decorative paper 10 and decorative board 100, that have excellent design and processability in the step of impregnating with impregnating resin 4 (resin impregnation step S3).

[0050] Although one embodiment of the present invention has been described above in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and design modifications and the like are also included within the scope of the present invention. Furthermore, the components shown in the above-described embodiment and the following modified examples can be appropriately combined to form a configuration.

[0051] (Variation 1) In the above embodiment, the decorative board 100 comprises the decorative paper 10 and the impregnated resin 4, but the form of the decorative board is not limited to this. The decorative board may also comprise a core paper or substrate on the lower side LO of the decorative paper 10.

[0052] For example, titanium paper, bleached kraft paper, unbleached kraft paper, glass fiber nonwoven fabric, etc. can be used as the core paper to be laminated on the lower LO of the decorative paper 10. Alternatively, core paper impregnated with a thermosetting resin can be laminated on the lower LO of the decorative paper 10 and then pressurized and heated. For example, melamine-based resin, epoxy-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, alkyd-based resin, unsaturated polyester-based resin, phenol-based resin, urea-based resin, etc. can be used as the thermosetting resin to be impregnated into the core paper.

[0053] The substrate to be laminated on the lower LO of the decorative paper 10 can be a wood substrate such as particle board or medium density fiberboard (MDF), a metal plate-like member such as aluminum or stainless steel, or a composite board in which a metal such as aluminum is attached to both sides of a core material made of a resin such as polyethylene. When a core paper or substrate is laminated on the lower LO of the decorative paper 10, it may be laminated using an adhesive. By laminating a core paper or substrate on the lower LO of the decorative paper 10 to form a decorative board, desired functions such as improved rigidity and adjustable thickness can be imparted to the decorative board.

[0054] (Variation 2) In the above embodiment, the highly-designed resin layer 3 is provided on the upper side UP of the first pattern forming section 2a, but the form of the highly-designed resin layer 3 is not limited to this. The highly-designed resin layer may be provided on the upper side UP of the second pattern forming section 2b, and does not have to be positioned in a position that is synchronized with the pattern of the pattern-printed layer 2. For example, if the pattern of the pattern-printed layer 2 is a stone-grain pattern, even if the highly-designed resin layer is not positioned in a position that is synchronized with the pattern, the thickness and low gloss of the highly-designed resin layer in the vertical direction can give the decorative paper 10 an irregular three-dimensional effect, thereby achieving a more realistic stone-grain pattern.

[0055] The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.

[0056] Example 1 Base layer 1: 80g / m 2 Titanium paper was prepared. A pattern-printed layer 2 having a pattern was formed on the upper side UP of the raw sheet layer 1, and a urethane-based ultraviolet-curing resin was formed as a highly-designed resin layer 3 at a position synchronized with the pattern on the upper side UP of the pattern-printed layer 2. At this time, the area ratio of the coated portion 3a to the pattern-printed layer 2 in the highly-designed resin layer 3 was set to 30%. The micropores 3b in the highly-designed resin layer 3 were dot-shaped. The ultraviolet-curing resin that forms the highly-designed resin layer 3 was cured by ultraviolet irradiation, and the decorative paper 10 of Example 1 was formed.

[0057] Example 2 The decorative paper 10 of Example 2 was formed in the same manner as in Example 1, except that the area ratio of the coated portion 3a to the picture-printed layer 2 was set to 40%.

[0058] Example 3 The decorative paper 10 of Example 3 was formed in the same manner as in Example 1, except that the area ratio of the coated portion 3a to the picture-printed layer 2 was set to 50%.

[0059] Example 4 The decorative paper 10 of Example 4 was formed in the same manner as in Example 1, except that the area ratio of the coated portion 3a to the picture-printed layer 2 was set to 60%.

[0060] Example 5 The decorative paper 10 of Example 5 was formed in the same manner as in Example 1, except that the area ratio of the coated portion 3a to the picture-printed layer 2 was set to 5%.

[0061] Example 6 The decorative paper 10 of Example 6 was formed in the same manner as in Example 1, except that the area ratio of the coated portion 3a to the picture-printed layer 2 was set to 10%.

[0062] Example 7 The decorative paper 10 of Example 7 was formed in the same manner as in Example 1, except that a thermosetting resin was used as the highly decorative resin layer 3.

[0063] Example 8 The decorative paper 10 of Example 8 was formed in the same manner as in Example 1, except that an electron beam curable resin was used as the highly decorative resin layer 3.

[0064] (Comparative Example 1) The decorative paper of Comparative Example 1 was formed in the same manner as in Example 1, except that the area ratio of the coated portion to the picture printed layer was 70%.

[0065] (Comparative Example 2) The decorative paper of Comparative Example 2 was produced in the same manner as in Example 1, except that a coating layer as described in Example 1 of Patent Document 2 was formed between the picture-printed layer and the highly-designed resin layer.

[0066] (Test 1) A design evaluation test was conducted on the decorative papers of Examples 1-8 and Comparative Examples 1-2. In the design evaluation test, 10 testers conducted a sensory test on the design of the decorative paper, and evaluated the appearance of the design, focusing on the effect on the design of the micropores in the highly designed resin layer. The evaluation criteria were three levels, and anything other than × was considered a pass. ◎ (Excellent): Between 7 and 10 people rated the design as good in appearance. ◯ (Good): Between 1 and 6 people rated the design as good in appearance. × (Poor): 0 people rated the design as looking good.

[0067] (Test 2) An impregnation evaluation test was conducted on the decorative papers of Examples 1-8 and Comparative Examples 1-2. In the impregnation evaluation test, decorative papers cut into 5 cm squares were floated in liquid melamine resin with the side on which the highly-designed resin layer was laminated facing downwards, and the time required for the melamine resin to penetrate the entire surface on which the raw paper layer was laminated was evaluated. The evaluation criteria were three levels, and anything other than × was considered a pass. ◎(Excellent): Less than 20 seconds. 〇 (Good): More than 20 seconds but less than 45 seconds. ×(Poor): More than 45 seconds.

[0068] (Test 3) A surface property evaluation test was conducted on the decorative papers of Examples 1-8 and Comparative Examples 1-2. In the surface property evaluation test, the decorative paper was impregnated with melamine resin as the impregnating resin, and then pressed and heated in a high-pressure press to form a decorative board. A cotton ball soaked in methyl ethyl ketone (MEK) was passed back and forth 10 times against the side of the formed decorative board on which the high-design resin layer was laminated, and the degree of removal of the pattern in the pattern printed layer was evaluated. The evaluation criteria were three levels, and anything other than × was considered a pass. ◎(Excellent): No image loss. Good: There is some color transfer to the cotton, but the pattern on the decorative board does not fade. × (Poor): The pattern on the decorative panel is noticeably faded.

[0069] (Test results) The results of Tests 1-3 are shown in Table 1. Examples 1-8, in which the area ratio of the coated portion to the picture-printed layer was 5% or more and 60% or less, showed good results in all tests. Comparative Example 1, in which the area ratio of the coated portion to the picture-printed layer was 70%, and Comparative Example 2, which had a coating layer, failed Tests 2-3. Furthermore, Examples 1-2 and 6-8, in which the area ratio of the coated portion to the picture-printed layer was 10% or more and 40% or less, showed even better results.

[0070] [Table 1] [Explanation of symbols]

[0071] 100 decorative panels 10 decorative paper 1. Original fabric layer 2. Picture printing layer 3. Highly designed resin layer 3a Coating Department 3b Micropore 4 Impregnating resin A1 Coating range S1 Picture printing process S2 Highly designed resin coating process S3 Resin impregnation process S4 Pressing process V vertical direction UP upper side LO lower side

Claims

1. The original opposition layer, A pattern printed layer provided on the upper side of the raw fabric layer; a highly designed resin layer provided above the picture printed layer, having a coated portion coated within a coating range and uncoated micropores, the area ratio of the coated portion to the picture printed layer being 5% or more and 60% or less; Equipped with The coating area in which the highly-designed resin layer is arranged is set partially in a plurality of areas with respect to the picture print layer, The width of the micropores is smaller than the distance between adjacent highly-designed resin layers, The micropores are Impregnating resin can penetrate inside, Formed by printing, Decorative paper.

2. The highly-designed resin layer contains a thermosetting resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin. The decorative paper according to claim 1.

3. The area ratio of the highly-designed resin layer to the picture printed layer in the coated portion is 10% or more and 40% or less. The decorative paper according to claim 2.

4. The highly-designed resin layer is arranged in synchronization with the pattern of the pattern printed layer. The decorative paper according to claim 3.

5. The decorative paper according to any one of claims 1 to 4, the impregnating resin impregnated into the decorative paper and cured; Equipped with Decorative panel.

6. a pattern printing step of forming a pattern printing layer; a highly-designed resin coating step of forming a highly-designed resin layer having an area ratio of the coated portion to the picture printed layer of 5% to 60%; Equipped with The highly-designed resin coating process includes: The highly-designed resin layer is disposed in a plurality of coating areas partially set on the picture print layer, In the coating area, the highly-designed resin layer is not coated, and micropores into which the impregnating resin can penetrate are formed by printing; The width of the micropores is smaller than the distance between adjacent highly-designed resin layers. A method for manufacturing decorative paper.

7. The highly-designed resin coating process forms the highly-designed resin layer such that the area ratio of the coated portion of the highly-designed resin layer to the picture printed layer is 10% or more and 40% or less. The method for producing decorative paper according to claim 6.

8. A method for producing decorative paper according to claim 6 or 7; a resin impregnation step of impregnating the decorative paper with the impregnation resin; a pressing step for hardening the impregnated resin; Equipped with A method for manufacturing decorative panels.

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