Cosmetic materials

Abstract

To provide a decorative material having a design excellent in visual effects.SOLUTION: A decorative material has a texture region in which a plurality of mutually independent projections 20 are aggregated, wherein the projections 20 contains resin binders 23 and brilliant flaky particles 21.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a decorative material. [Background technology]

[0002] Decorative materials are widely used for the surface decoration of building interiors, building materials, furniture, fittings, fixtures, vehicles, home appliances, bathroom products such as modular baths, kitchen products, etc. Such decorative materials include paper or resin sheets printed with a pattern and attached to a substrate, and materials in which a pattern is printed on the surface of a metal plate such as a steel plate.

[0003] The decorative material may further have an uneven pattern on the surface, thereby imparting a texture (tactile feel) that matches the design and a luxurious design. As decorative materials having a textured surface, decorative materials that are embossed using an embossing plate with a textured surface have been proposed (e.g., Patent Documents 1 and 2). Also, decorative materials have been proposed in which a textured pattern is imparted to the surface of a substrate by build-up printing (e.g., Patent Document 3). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-193209 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-87544 [Patent Document 3] Special Publication No. 63-17613 DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0005] However, as described in Patent Documents 1 and 2, when applying a relief pattern design by embossing, an embossing plate is required for each pattern, which results in problems of high cost and difficulty in manufacturing. In addition, the relief pattern is large, making it difficult to harmonize the relief shape with the underlying design, which makes it difficult to apply a sophisticated design.

[0006] The method of Patent Document 3 only allows for the formation of visually monotonous patterns, making it difficult to obtain a decorative material with a three-dimensional or deep feel.

[0007] In view of the above problems, an object of the present invention is to provide a decorative material having a design with excellent visual effects. [Means for solving the problem]

[0008] In order to solve the above problems, the present invention provides the following [1] to [4]. [1] A decorative material having a textured region on a substrate, in which a plurality of independent protrusions are aggregated, the protrusions containing a resin binder and glittering flake particles. [2] The decorative material according to [1], wherein the convex portions further contain an organic filler having a particle size of 5 μm or more and 60 μm or less. [3] The decorative material according to [1] or [2], wherein the convex portions further contain an inorganic filler. [4] The decorative material according to any one of [1] to [3], wherein the glittering flake particles are particles in which a coating layer of metal or metal oxide is formed on a flake-shaped glass base. [Effects of the Invention]

[0009] According to the present invention, a decorative material having a design with excellent visual effects can be obtained. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a perspective view of a decorative material according to one embodiment of the present invention. [Figure 2]2 is an enlarged schematic plan view of a region indicated by the symbol R in FIG. 1. [Figure 3] 1 is a schematic cross-sectional view of a portion of a decorative material according to one embodiment of the present invention where a textured region is provided. [Figure 4] FIG. 2 is a diagram for explaining the definitions of "circumscribing circle of a convex portion," "diameter of a circumscribing circle," and "distance between the centers of a pair of adjacent circumscribing circles" in the present invention. [Figure 5] 1 is a photograph showing the appearance of the decorative material of Example 1. [Figure 6] 1 is a photograph showing the appearance of the decorative material of Example 2. [Figure 7] 1 is a micrograph of a textured region in the decorative material of Example 1. [Figure 8] 1 is a micrograph of a textured region in the decorative material of Comparative Example 1. [Figure 9] 1 is a photomicrograph of a textured region in the decorative material of Comparative Example 2. DETAILED DESCRIPTION OF THE INVENTION

[0011] The decorative material of the present invention will be described in detail below. In this specification, the expression "AA to BB" as a numerical range means "not less than AA and not more than BB."

[0012] The decorative material of the present invention has a textured region on a substrate, in which a plurality of protrusions independent of one another are aggregated, and the protrusions contain a resin binder and glittering flake particles.

[0013] 1 is a perspective view of a cosmetic material according to one embodiment of the present invention. When viewed from the front side of the cosmetic material 1, a pattern (design) is visible. When viewed from above, the cosmetic material 1 has a texture region 10 on the base material on the front side. Texture region 10 may be provided over the entire surface of decorative material 1, or may be provided only partially. In the present invention, areas that are not texture region 10 are referred to as other regions 11. Texture region 10 and other regions can be distinguished, for example, by the area ratio of the convex region described below. The area ratio of the textured region within the plane of the decorative material is not particularly limited. In order to provide contrast between the textured region and other regions, the area ratio of the textured region within the plane of the decorative material is preferably 10% to 90%, more preferably 20% to 80%, and even more preferably 30% to 70%. When the textured region 10 is provided partially, the textured region 10 may be formed to have a pattern (for example, a striped pattern, a checkered pattern, a pattern combining geometric shapes such as squares, triangles, circles, and lines, or an amorphous pattern as described below) that corresponds to the design of the decorative material 1. Alternatively, the textured region 10 may be formed as a pattern that is synchronized with at least a portion of the design pattern of the design layer described below. In a cross section of the decorative material cut in the thickness direction (see Figure 3), a layer consisting of multiple protrusions that constitute the texture region is present on at least a portion of the substrate. In this specification, such a layer consisting of multiple protrusions may be referred to as a "raised layer." In other words, when the texture region is viewed from the Y-axis direction, which is perpendicular to the thickness direction of the decorative material, the raised layer is recognized as a layer consisting of protrusions (Figure 3).

[0014] In this specification, the term "plan view" means viewing the decorative material of the present invention in a planar direction from the surface side (front side) on which the textured region is provided. For example, in the XYZ coordinate system shown in Figures 1 to 4, the XY plane represented by the X-axis direction and the Y-axis direction is approximately parallel to the surface of the substrate, and the "plan view" corresponds to viewing the surface of the substrate from the Z-axis direction, which is the thickness direction of the decorative material.

[0015] [Texture area] Figure 2 is a schematic plan view of an enlarged region R in Figure 1. That is, Figure 2 is a view of the texture region observed from the Z-axis direction of the XYZ coordinate system. A surface such as that shown in Figure 2 can be observed using a microscope such as an optical microscope or a scanning electron microscope. The textured area can impart a tactile feel to the surface of the cosmetic material.

[0016] As shown in FIG. 2, the texture region is a collection of multiple protrusions 20 that are independent of one another. Within the texture region, there are gaps between the protrusions. That is, the texture region of the decorative material of the present invention is a collection of multiple protrusions 20 that are independent of one another by the gaps. The protrusions 20 are so-called "island-like regions (island portions)" that have a closed curved outline with protrusions and recesses in a planar view. FIG. 2 shows a collection of irregular protrusions 20 that have a closed curved outline with protrusions and recesses in a planar view. The regions between the protrusions 20 that form the gaps are so-called "sea portions," where the transparent base layer or pattern layer described below is exposed. The presence of the sea portions between the island portions allows the protrusions 20 to exist independently of one another. The structure in FIG. 2 that has island portions and sea portions is also called a sea-island structure. In addition, in the structure in FIG. 2, the "sea-island structure" can also be called a "phase-separated structure," the "island portions" can also be called a "continuous phase," and the "sea portions" can also be called an "isolated phase." The above-mentioned "island portion" is defined as a region having a height of 10 or more when the height is measured across the entire texture region, with the maximum height being 100 and the minimum height being 0. The above-mentioned "sea portion" is defined as a region having a height of less than 10. It is preferable that the other regions 11 have no protrusions.

[0017] The protrusions 20 may be either irregular or regular in shape, but the protrusions 20 are preferably irregular in shape in order to enhance the texture of a natural object. In the present invention, the "irregularly shaped convex portion" can also be expressed as a shape having any of the following characteristics. (1) In a plan view, the shapes of the multiple convex portions are not all congruent, but two or more types of convex portions with different shapes and sizes are mixed together. All of the convex portions in the texture region may have different shapes and sizes, or two or more congruent or similar convex portions may be included. (2) When viewed in plan, the shape of the multiple convex parts is different from relatively simple shapes such as regular polygons, circles, ellipses, cardioids, etc. For example, the contours of the convex parts have complex shapes that need to be approximated by a combination of complex functions such as polynomials or infinite series. (3) A form that has the characteristics of both (1) and (2).

[0018] [Convex part] Each of the protrusions 20 contains glittering flake particles 21 inside. The number of glittering flake particles contained in one protrusion 20 is not particularly limited. On the other hand, it is preferable that the above-mentioned "sea portion (gap)" does not substantially contain glittering flake particles. Here, "substantially not contained" means that the glittering flake particles are contained in an area of ​​the sea portion of 500 μm 2 This means that there are three or fewer glittering flake particles per particle.

[0019] Each of the protrusions 20 preferably contains a plurality of organic fillers 22 therein. The organic fillers 22 are preferably present in the protrusions 20 in a state of aggregation in the plane or in the thickness direction, and more preferably present in the protrusions 20 in a state of aggregation both in the plane and in the thickness direction. When the protrusions 20 are viewed from above, in addition to those in which two or more organic fillers are aggregated, there may also be, for example, those in which only one particle is present within a continuous resin island portion.

[0020] Fig. 3 is a schematic cross-sectional view of a portion of a decorative material according to one embodiment of the present invention where a textured region 10 is provided. That is, Fig. 3 is a schematic cross-sectional view of the textured region of the decorative material illustrated in Fig. 1 when cut in the Z-axis direction, which is the thickness direction of the decorative material. In the textured region of the decorative material 1 of Fig. 3, a primer layer 3, a base coat layer 4, a design layer 5, a transparent foundation layer 6, a raised layer 7 (these layers viewed from above are the textured region 10), and a surface coat layer 8 are provided in this order on a substrate 2. The raised layer 7 forms a textured region on the surface of the decorative material on the side where the raised layer is provided. It is preferable that substantially no raised layer is provided in other regions.

[0021] As shown schematically in Fig. 3, in a decorative material 1 according to one embodiment of the present invention, glittering flake particles 21 and organic filler 22 in protrusions 20 are present on a transparent base layer 6 (or design layer 5), and the glittering flake particles 21 and organic filler 22 are coated with a binder resin 23. In the decorative material 1 of Fig. 3, the coating with binder resin is thin, so the surfaces of the protrusions 20 have an uneven shape that roughly follows the surface shapes of the glittering flake particles and organic filler. That is, the textured region of the decorative material 1 of Fig. 3 includes unevenness (relatively large unevenness) caused by the multiple protrusions 20 arranged in a pattern, and unevenness (relatively small unevenness) caused by the glittering flake particles 21 and organic filler 22 on the surfaces of the individual protrusions 20.

[0022] In the decorative material 1 of the present invention, glittering flake particles are contained in the convex portions and are substantially absent in the sea portion (gaps). This means that the glittering flake particles are unevenly distributed in the microstructure. Therefore, when observing the textured region, the glittering flake particles can enhance the sense of brilliance compared to when the glittering flake particles are dispersed uniformly, and the contrast in brilliance between the convex portions and the sea portion (gaps) in the textured region can be increased. Furthermore, the contrast in brilliance between the textured region and other regions can be increased. Furthermore, the use of glittering flake particles allows for a design in which changes in brilliance can be perceived when the decorative material is observed from different angles. The change in brilliance due to the change in angle can be made extremely complex due to diffusion by the slopes of the convex portions, thereby significantly enhancing the visual effect. Furthermore, as described above, the unevenness of the convex surface creates a difference in gloss between the convex portions and areas without convex portions, resulting in a so-called gloss-matt effect. Therefore, the decorative material 1 of the present invention can express an excellent visual effect, i.e., a design with a sense of three-dimensionality and depth. Furthermore, the unevenness caused by the protrusions 20 and the unevenness on the surface of the protrusions 20 can provide an excellent tactile sensation. In particular, by providing the texture region 10 in a pattern that is in sync with at least a portion of the design pattern of the design layer described below, it is possible to obtain a beautiful appearance and a texture that feels good to the touch that corresponds to the design pattern.

[0023] From the viewpoint of obtaining excellent visual effects and tactile sensations, the average height of the protrusions 20 is preferably 10 μm to 60 μm, more preferably 15 μm to 45 μm, and even more preferably 25 μm to 35 μm.

[0024] Since the protrusions 20 may be of an irregular or regular shape, in the present invention the size of the protrusions 20 is represented by the diameter of the circumscribing circle when viewed in plan (when viewed from the surface). Figure 4 is an enlarged plan view schematic diagram of the texture region, and is the same as Figure 2. The circumscribing circle of the protrusion 20-1 is the circle indicated by the symbol C1. The diameter of the circumscribing circle C1 is indicated by the arrow indicated by the symbol d1. Similarly, the circumscribing circle of the protrusion 20-2 is the circle indicated by the symbol C2. The diameter of the circumscribing circle C2 is indicated by the arrow indicated by the symbol d2. The average diameter of the circumscribing circles of the protrusions 20 in the entire texture region is defined as the "average diameter d." In the present invention, the average diameter d of the circumscribed circle of the protrusions 20 is preferably 100 μm to 500 μm. When the average diameter d is 100 μm or more, the visual effect described above is easily achieved, and a satisfactory tactile sensation can be obtained. By setting the average diameter d to 500 μm or less, the protrusions become less visible. The average diameter d is preferably 150 μm to 350 μm, and more preferably 200 μm to 250 μm.

[0025] If the protrusions 20 are spaced far apart, the desired visual effect and sufficient tactile sensation may not be achieved. For this reason, it is preferable that the protrusions 20 are relatively densely packed within the texture region. From the viewpoint of visual effect and tactile feel, in the cosmetic material of the present invention, the area ratio of the protrusions 20 in the texture region is preferably 20% to 70% within a 1 cm square area. The 1 cm square is a rule that takes into consideration the contact area of ​​a finger when touching the cosmetic material. The area ratio is preferably 20% to 70%, more preferably 30% to 60%, and even more preferably 40% to 50%. The area ratio of the protrusions is a value obtained by image analysis of an optical microscope photograph (300x magnification), and is the average value obtained by measuring 10 points within the texture region.

[0026] The decorative material of the present embodiment may have other regions (regions other than the texture region). It is preferable that the texture region and the other regions have different textures and glosses. In order to distinguish the tactile sensation between the textured region and other regions, the area ratio of the convex regions in other regions is preferably less than 20% of a 1 cm square area, more preferably 10% or less, more preferably 5% or less, more preferably 3% or less, more preferably 1% or less, and more preferably 0%. The area ratio of the convex region is a value obtained by image analysis of an optical microscope photograph (magnification: 300 times), and is the average value of measurements taken at 10 points in the other regions. Furthermore, in order to distinguish the tactile sensation between the textured region and the other regions, it is preferable that the other regions contain substantially no particles with a particle size of 5 μm or more. When the other regions are viewed in plan, the area ratio of particles with a particle size of 5 μm or more is preferably 3% or less, more preferably 1% or less, more preferably 0.3% or less, and even more preferably 0%. Furthermore, when the 60-degree specular gloss of the textured region is defined as G60A and the 60-degree specular gloss of the other regions is defined as G60B, the ratio G60A / G60B is preferably 0.8 or less, more preferably 0.6 or less, and even more preferably 0.5 or less. By setting G60A / G60B to the above-mentioned value, it becomes easier to distinguish the gloss of the textured region from that of the other regions. The 60-degree specular glosses G60A and G60B are the average values ​​of measurements taken at 10 locations.

[0027] In addition, from the viewpoint of visual effect and tactile sensation, in the decorative material of the present invention, the average diameter of the circumscribed circles of a pair of adjacent convex portions 20 in the entire texture region 10 when viewed in a plane is set to d ave When the center distance between a pair of adjacent circumscribed circles is D, 90% or more of all combinations are 0.5≦D / d ave It is preferable that the value satisfies ≦6.0. Above d aveThe diameters of the circumscribed circles of a pair of adjacent protrusions 20-1 and 20-2 are d1 and d2, respectively. ave = (d1 + d2) / 2. The center distance D is the distance between the arrows of the two-dot dashed lines. D / d ave A large D / d means that the distance between adjacent convexities is large, and indicates that the convexities are sparsely distributed. ave The upper limit of D / d is preferably 5.5, more preferably 5.0, and even more preferably 4.5. ave The smaller the D / d, the denser the convex parts. ave When D / d is less than 1, the overlapping area between adjacent convex portions becomes large when viewed in a plan view, depending on the shape of the convex portion. ave If is 0, the convex parts will overlap and become one area geometrically. In order for the two convex parts to be independent of each other by the gap, D / d ave The lower limit is preferably 0.5 as described above. D / d ave It is more preferable that the number of pairs of adjacent projections that satisfy the above range accounts for 95% or more of all combinations.

[0028] Furthermore, the shortest distance between adjacent protrusions is preferably 5 to 120 μm, more preferably 10 to 80110 μm, and even more preferably 20 to 60 μm. When the shortest distance is within the above range, the protrusions are densely packed within the texture region, making it easier to obtain a good tactile feel.

[0029] Here, "adjacent convex portions" can be defined by Voronoi tessellation of an enlarged plan view of the texture region. Voronoi tessellation is a method of dividing a plane into cellular regions by finding the perpendicular bisectors between adjacent kernel points distributed within a plane. Specifically, first, the centers of the circumscribing circles of the convex portions and the island portions not considered to be convex portions are found for an enlarged plan view of the texture region. Using the centers B of the circumscribing circles of each convex portion and island portion as "mother points," the texture region is divided into cellular regions using Voronoi division. Then, when two cellular regions corresponding to arbitrarily extracted convex portions share a common boundary line (Voronoi boundary), it is defined that "the convex portions are adjacent to each other."

[0030] The protrusions 20 can be formed using, for example, an ink (protrusion ink) made of a resin composition containing a binder resin and glittering flake particles. In this specification, the "protrusion ink" may also be referred to as the "raised layer ink." When the protrusions are formed using the protrusion ink (raised layer ink), gaps are simultaneously formed between the protrusions.

[0031] <Binder resin> Preferred examples of binder resins for the convex portion 20 include urethane-based resins, acrylic polyol-based resins, acrylic resins, ester-based resins, amide-based resins, butyral-based resins, styrene-based resins, urethane-acrylic copolymers, polycarbonate-based urethane-acrylic copolymers (urethane-acrylic copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer main chain and two or more hydroxyl groups at the terminals and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated propylene-based resins, nitrocellulose-based resins (nitrocellulose), cellulose acetate-based resins, and fluorine-based resins, and these can be used alone or in combination.

[0032] <Brilliant flake particles> Examples of glittering flake particles include pearl pigments, metal flakes, and metal-coated glass flakes, and one or more of these can be used. These particles can be blended into the ink alone or in combination. Among these, pearl pigments are preferred, and pearl pigments using a glass substrate are particularly preferred. The glittering flaky particles preferably have an average particle size of 5 μm to 100 μm, more preferably 10 μm to 80 μm, and even more preferably 20 μm to 60 μm.The glittering flaky particles preferably have an average thickness of 0.5 μm to 5 μm. The particle size refers to the diameter when the glittering flaky particles are assumed to be perfect spheres. The particle size of the glittering flaky particles is a diameter obtained by measurement using a known method such as the Stokes diameter or light scattering diameter. The thickness of the glittering flaky particles is measured using a laser light diffraction method.

[0033] The aspect ratio (maximum length / thickness) of the maximum length to thickness of the planar portion of the glittering flaky particles is preferably 10 or more and 180 or less. The length of the glittering flaky particles means the maximum length in the planar direction when the particles are observed under a microscope. The thickness of the glittering flaky particles is determined by dividing a cross-sectional image of the particles obtained by microscope observation into multiple regions of equal length in the longitudinal direction and averaging the measured thicknesses at the center of each region.

[0034] Specifically, pearl pigments using a glass substrate are particles in which a coating layer of metal oxide is formed on a flake-like glass substrate. Examples of the glass substrate include glass flakes and glass flakes. Examples of the metal oxide of the coating layer include titanium oxide and iron oxide. By changing the material and film thickness of the coating layer, the color of the pigment can be varied.

[0035] Other pearl pigments include those in which a scaly base material such as mica or aluminum is covered with a coating layer made of a metal oxide such as titanium dioxide or ferric oxide. As described above, the pearl pigment is not a metal itself but is mainly composed of a metal oxide, but is a colorant that can impart a metallic luster. In the present invention, any of white pearl pigments, interference pearl pigments, and colored pearl pigments can be used as the pearl pigment.

[0036] The length of the other pearl pigments is preferably 5 μm to 90 μm, more preferably 10 μm to 60 μm. The thickness of the other pearl pigments is preferably 0.5 μm to 50 μm, more preferably 1 μm to 30 μm. The length of the pearl pigment means the maximum length in the planar direction when the pigment is observed under a microscope. The thickness of the pearl pigment is determined by dividing a cross-sectional image of the pigment obtained under a microscope into multiple regions of equal length in the longitudinal direction and averaging the thickness measurements at the center of each region.

[0037] Examples of materials for the metal flakes include metals and alloys such as aluminum, gold, silver, brass, titanium, chromium, nickel, nickel chromium, and stainless steel. Metal-coated glass flakes are particles in which a metal coating layer is formed on the surface of a flake-shaped glass substrate. Examples of glasses that make up the glass substrate include soda glass, potash glass, phosphate glass, borosilicate glass, and lead glass. Examples of metals include metals and alloys such as aluminum, gold, silver, brass, titanium, chromium, nickel, nickel-chromium, and stainless steel. The length of the metal flakes or metal-coated glass flakes is preferably 2 to 90 μm, and more preferably 10 to 60 μm. The thickness of the metal flakes or metal-coated glass flakes is preferably 0.5 μm to 50 μm, and more preferably 1 μm to 30 μm. The length of the metal flakes or metal-coated glass flakes refers to the maximum length in the planar direction when the flakes are observed under a microscope. The thickness of the metal flakes or metal-coated glass flakes is determined by dividing a cross-sectional image of the flakes obtained by microscope observation into multiple regions of equal length in the longitudinal direction and averaging the thickness measurements at the center of each region.

[0038] The content of the glittering flaky particles is preferably 3 parts by mass or more, more preferably 10 parts by mass or more, and even more preferably 15 parts by mass or more, relative to 100 parts by mass of the binder resin, from the viewpoint of imparting a high-brightness design due to the glittering flaky particles and increasing the contrast between areas where the glittering flaky particles are present and areas where they are not. Furthermore, from the viewpoint of imparting a matte design due to the organic filler or the inorganic filler described below, the content is preferably 40 parts by mass or less, more preferably 30 parts by mass or less, and even more preferably 20 parts by mass or less, relative to 100 parts by mass of the binder resin.

[0039] There are no particular restrictions on the orientation direction of the glittering flaky particles 21 within the protrusions 20. A random orientation direction is preferable because a change in brightness can be perceived when the decorative material 1 is observed from different angles, imparting a sense of three-dimensionality and depth to the design of the decorative material 1. Inclusion of at least either organic particles or inorganic filler within the protrusions 20 makes it easier to randomize the orientation direction of the glittering flaky particles.

[0040] <Organic filler> Examples of the organic filler include acrylic resin, urethane resin, nylon resin, polypropylene resin, urea-based resin, etc. Acrylic resin is particularly preferred from the viewpoints of good heat resistance, easy maintenance of height since the organic filler is unlikely to be buried in the lower layer after the baking step, and easy formation of convex portions due to aggregation of the organic filler.

[0041] The particle size of the organic filler is preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more, from the viewpoints of imparting a gloss and matte effect to the decorative material 1 and providing a suitable tactile feel. Furthermore, the particle size of the organic filler is preferably 60 μm or less, more preferably 50 μm or less, and even more preferably 40 μm or less, from the viewpoints of preventing the filler from falling off the decorative material 1, visual effects, tactile feel, etc. In particular, when forming convex portions by gravure printing, if the organic filler is too large, it may be unable to enter the cells of the printing plate or the number of particles that enter will be reduced, making it difficult to obtain the desired visual effects and tactile feel. Therefore, it is particularly preferable to use an organic filler with the above particle size. In this specification, the particle size of each type of particle is the 50% particle size (d50: median size) when the particle size distribution measured by a dynamic light scattering method is expressed as a volume cumulative distribution.

[0042] The content of the organic filler is preferably 15 parts by mass or more, more preferably 20 parts by mass or more, and even more preferably 25 parts by mass or more, per 100 parts by mass of the binder resin constituting the convex portions 20. When the content of the organic filler is within the above range, the organic fillers aggregate together to easily form convex portions. This results in an excellent visual effect, allowing for a design that gives a sense of three-dimensionality and depth. Furthermore, it is possible to impart an excellent tactile feel to the decorative material 1. On the other hand, from the viewpoints of reliably binding the organic filler with the binder resin to prevent it from falling off, and improving the fluidity of the resin composition to facilitate the forming process, the content of the organic filler is preferably 50 parts by mass or less, more preferably 45 parts by mass or less, and even more preferably 40 parts by mass or less, per 100 parts by mass of the binder resin.

[0043] <Inorganic filler> The protrusions 20 may further contain an inorganic filler. Examples of inorganic fillers include silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, and synthetic silicates. The size of the inorganic filler is preferably 1 μm to 20 μm, more preferably 3 μm to 10 μm, and even more preferably 3 μm to 7 μm. The size of the inorganic filler is preferably selected within a range that does not impair the tactile feel provided by the organic filler. The content of the inorganic filler relative to 100 parts by mass of the binder resin constituting the convex portions 20 is preferably 1 to 40 parts by mass, more preferably 2 to 30 parts by mass, and even more preferably 3 to 25 parts by mass. By including inorganic fillers in addition to the glitter flakes, the gloss of the decorative material can be adjusted. Also, by increasing the difference in gloss between the textured area and other areas, a luxurious design can be imparted to the decorative material.

[0044] The ink for the raised portion (ink for the raised layer) may contain an organic solvent as needed. The organic solvent to be used is not particularly limited, but it is preferable to select an appropriate organic solvent taking into consideration the viscosity of the ink and the evaporation rate of the solvent. Specifically, if the viscosity coefficient of the solvent is too low, the ink viscosity will be low, resulting in a shortage of resin even when aggregates of glittering flake particles and organic filler are formed, making it difficult to form convex portions. As a result, the glittering flake particles will be scattered throughout the texture region, reducing brightness contrast and resulting in a monotonous design. Furthermore, it may be difficult to achieve the gloss / matt effect and good tactile feel achieved by the organic filler. On the other hand, using a solvent with a high viscosity coefficient increases the viscosity of the ink, which tends to deteriorate its coatability. Furthermore, when forming convex portions by gravure printing, individual cells may be formed independently, or the organic filler may be buried in the resin, making it difficult to achieve a good gloss and tactile feel. Furthermore, if the evaporation rate of the solvent is too slow, it will be difficult to form large convex portions, making it difficult to achieve a good gloss and tactile feel. For these reasons, by selecting an organic solvent with an appropriate viscosity coefficient and evaporation rate, it is possible to obtain a cosmetic material with excellent gloss and tactile feel. A single organic solvent may be used, or a mixed solvent of multiple organic solvents may be used. Specific examples of organic solvents with viscosity coefficients suitable for the present invention include xylene, cyclohexanone, toluene, methyl isobutyl ketone, butyl acetate, methoxypropyl acetate, and propylene glycol monomethyl ether propionate (methotate). An example of a solvent with a fast evaporation rate is cyclohexanone. It is particularly preferable to use a mixed solvent of xylene and cyclohexanone (a mixed solvent with a weight ratio of 1:1). The ink for raised areas (raised layer ink) is applied at a dry amount of 10 g / m 2 ~500g / m 2 It is preferable that:

[0045] From the viewpoint of improving weather resistance, the protrusions 20 preferably contain a weather resistance agent such as an ultraviolet absorber or a light stabilizer.

[0046] Each layer of the decorative material 1 other than the raised layer 7 will be described in detail below. [Base material] The substrate 2 is not particularly limited as long as it is one that is commonly used as a decorative material. For example, a resin substrate, a metal substrate, a ceramic substrate, a fibrous substrate, a wood substrate, or the like can be appropriately selected depending on the application. Each of the above substrates may be used alone, or may be a laminate of any combination. When the substrate 2 is a laminate, an adhesive layer may be further provided between each layer of the laminate.

[0047] Examples of the resin substrate include those made of various synthetic resins, such as polyethylene resin, polypropylene resin, polymethylpentene resin, polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl alcohol copolymer resin, polyethylene terephthalate resin, polybutylene terephthalate resin, ethylene glycol-naphthalate-isophthalate copolymer resin, polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, polyamide resins such as nylon 6 and nylon 66, cellulose triacetate resin, cellophane, polystyrene resin, polycarbonate resin, polyarylate resin, and polyimide resin.

[0048] Examples of metal substrates include pure metals consisting of a single metal element such as aluminum, iron, copper, or titanium, and alloys containing one or more of these metals, such as carbon steel, stainless steel, duralumin, brass, or bronze. Substrates coated with these metals by plating or other methods can also be used. Metal substrates are preferred because they have excellent heat resistance and are resistant to deformation during high-temperature heating treatments (drying after base coat layer formation and final baking treatment) in the manufacturing method described below. Furthermore, the use of a metal substrate can further enhance the effect of the glittering flake particles due to the reflection of the metal substrate.

[0049] Examples of ceramic substrates include ceramic building materials such as gypsum boards, calcium silicate boards, and wood-chip cement boards, as well as ceramics, glass, enamel, fired tiles, etc. Ceramic substrates are also preferred because they have excellent heat resistance and are resistant to deformation during high-temperature heat treatment in the manufacturing method described below.

[0050] Examples of fibrous substrates that can be used include paper substrates such as tissue paper, kraft paper, titanium paper, linter paper, paperboard, and base paper for gypsum board. These paper substrates may further contain resins such as acrylic resin, styrene butadiene rubber, melamine resin, and urethane resin (impregnated with the resin after papermaking or filled in during papermaking) to increase the strength between the fibers of the paper substrate or between other layers and the paper substrate, or to prevent fluffing. Examples of paper substrates to which resins have been added include inter-fiber reinforced paper and resin-impregnated paper. Furthermore, as the fibrous substrate, a vinyl wallpaper roll or the like having a vinyl chloride resin layer provided on the surface of a paper substrate can also be used.

[0051] In addition, fibrous substrates include woven and nonwoven fabrics made of various fibers that have an appearance and properties similar to paper, although they are different from the paper substrates described above. Examples of the various fibers include inorganic fibers such as glass fiber, asbestos fiber, potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber. Examples of the various fibers include synthetic resin fibers such as polyester fiber, acrylic fiber, and vinylon fiber. These papers are preferably laminated with a plastic substrate that has excellent shaping suitability in terms of shaping suitability for forming a textured pattern.

[0052] Examples of wood-based substrates include veneers of wood such as cedar, cypress, pine, zelkova, oak, and lauan, plywood, laminated wood, particle board, and medium density fiberboard (MDF).

[0053] The thickness of the substrate 2 is not particularly limited and can be set appropriately depending on the application, required specifications, etc. For example, the thickness of the substrate 2 is preferably 0.02 mm or more and 5 mm or less, and more preferably 0.4 mm or more and 3 mm or less.

[0054] [Primer layer] The primer layer 3 is provided between the substrate 2 and the design layer 5. The primer layer 3 plays a role in ensuring good adhesion between the substrate 2 and the design layer 5.

[0055] An ink (primer layer ink) made of a resin composition containing a binder resin is used to form the primer layer 3. The primer layer ink may contain a solvent as appropriate.

[0056] Preferred examples of binder resins include urethane-based resins, acrylic polyol-based resins, acrylic resins, ester-based resins, amide-based resins, butyral-based resins, styrene-based resins, urethane-acrylic copolymers, polycarbonate-based urethane-acrylic copolymers (urethane-acrylic copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer main chain and two or more hydroxyl groups at the terminals and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated propylene-based resins, nitrocellulose-based resins (nitrocellulose), cellulose acetate-based resins, and fluorine-based resins, and these can be used alone or in combination.

[0057] In addition to the one-component curing type, various types of resins can be used, such as two-component curing types that include a curing agent such as an isocyanate compound, such as tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPID), or xylylene diisocyanate (XDI).

[0058] From the viewpoint of improving weather resistance, the primer layer 3 preferably contains a weather resistance agent such as an ultraviolet absorber or a light stabilizer.

[0059] The thickness of the primer layer 3 is preferably 1 μm or more, more preferably 2 μm or more, from the viewpoint of improving interlayer adhesion, etc. The upper limit of the thickness of the primer layer 3 is preferably 10 μm or less, more preferably 7 μm or less, and even more preferably 5 μm or less.

[0060] [Base coat layer] The base coat layer 4 is a layer that is provided between the substrate 2 and the surface coat layer 8 as needed in order to enhance the design.

[0061] The base coat layer 4 is usually formed as an opaque layer, and serves to conceal the substrate 2 from the viewer and to impart the intended color. However, the base coat layer 4 may be formed as a semi-transparent or transparent layer, and the pattern or color of the substrate 2 may be utilized.

[0062] An ink made of a resin composition (base coat layer ink) is used to form the base coat layer 4. The base coat layer ink may contain a solvent as appropriate. The resin used to form the base coat layer 4 is not particularly limited. Examples include thermoplastic resins such as fluororesin, (meth)acrylic resin, polyurethane resin, polyester resin, polyamide resin, (meth)acrylic acid ester-olefin copolymer resin, vinyl acetate chloride resin, ethylene-vinyl acetate copolymer resin (EVA resin), ionomer resin, and olefin-α-olefin copolymer resin; and curable resins such as fluororesin, epoxy resin, phenolic resin, urea resin, polyester resin, melamine resin, alkyd resin, polyimide resin, silicone resin, hydroxyl-functional acrylic resin, carboxyl-functional acrylic resin, amide-functional copolymer, and urethane resin. Here, curable resins include thermosetting resins, ionizing radiation-curable resins, and two-component curable resins.

[0063] When the base coat layer 4 is provided as a hiding layer, the base coat layer 4 contains a colorant such as a pigment in addition to the above-mentioned resin. The colorant blended into the base coat layer 4 is not particularly limited. Examples include inorganic pigments such as carbon black, iron black, titanium white, antimony white, titanium yellow, yellow iron, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolinone yellow, and phthalocyanine blue; metallic pigments consisting of scaly flakes of aluminum, brass, or the like; and pearl pigments consisting of scaly flakes of titanium dioxide-coated mica, basic lead carbonate, or the like. These colorants may be used alone or in combination of two or more.

[0064] In addition to the above components, various additives can be blended into the base coat layer 4 depending on the desired physical properties. Examples of additives include weather resistance improvers such as ultraviolet absorbers and light stabilizers, abrasion resistance improvers, polymerization inhibitors, infrared absorbers, antifoaming agents, and fillers. Furthermore, if a curable resin is used to form the base coat layer 4, a curing agent may be included. These additives can be appropriately selected from commonly used additives.

[0065] The thickness of the base coat layer 4 is not particularly limited and can be set appropriately depending on the application, required specifications, etc. For example, the thickness of the base coat layer 4 is preferably 5 μm to 40 μm, and more preferably 10 μm to 30 μm.

[0066] [Picture layer] The pattern layer 5 is provided on the surface side of the base material 2 and is a layer that imparts design to the decorative material. The pattern layer 5 may be provided over the entire surface of the base material 2 when viewed from the surface side, or may be provided on only a part of it. There are no particular limitations on the pattern of the design layer 5, and any desired pattern can be used. Examples include wood grain patterns, marble patterns (e.g., travertine marble patterns), stone patterns that imitate the surface of rock such as the cleavage plane of a granite slab, fabric patterns that imitate fabric grain or cloth-like patterns, leather (leather grain) patterns that express leather grain, tiled patterns, brickwork patterns, hairlines, linear grooves, matte finishes, sand grain patterns, letters, symbols, geometric patterns, and patterns that combine these, such as marquetry and patchwork.

[0067] The pattern layer 5 may be a single layer or a laminate of multiple layers. For example, the layer on the substrate side may be a base coat layer that is the base color, and a pattern layer that is the pattern may be laminated on the base coat layer.

[0068] An ink (ink for design layer) made of a resin composition containing a binder resin and a colorant is used to form the design layer 5. The ink may contain a solvent as appropriate.

[0069] Preferred examples of binder resins include urethane resin, acrylic polyol resin, acrylic resin, polyester resin, alkyd resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, nitrocellulose resin (nitrocellulose), cellulose acetate resin, and fluororesin. Furthermore, curable resins such as two-component curable resins containing polyol as the main component and isocyanate as the curing agent may also be used. These may be used alone or in combination.

[0070] Pigments, dyes, and combinations thereof can be used as colorants in the design layer 5. Examples of pigments include inorganic pigments such as white pigments such as titanium white, iron black, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolinone yellow, phthalocyanine blue, nickel-azo complexes, azomethine azo-based black pigments, and perylene-based black pigments; metal pigments made of scaly flakes such as aluminum or brass; and pearlescent pigments made of scaly flakes such as titanium dioxide-coated mica and basic lead carbonate.

[0071] The design layer 5 may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers in order to improve weather resistance.

[0072] The design layer 5 may contain a matting agent from the viewpoint of obtaining a visual effect due to a difference in gloss from the protrusions 20. Examples of the matting agent include organic fillers such as urethane resin, nylon resin, polypropylene resin, and urea-based resin; and inorganic fillers such as silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, and synthetic silicates.

[0073] The particle size (volume average particle size) of the matting agent is preferably 1 μm to 15 μm, more preferably 2 μm to 10 μm, and even more preferably 3 μm to 7 μm. The content of the matting agent relative to 100 parts by mass of the binder resin in the design layer is preferably 3 parts by mass or more, more preferably 10 parts by mass or more, and even more preferably 20 parts by mass or more, with the upper limit usually being 100 parts by mass or less, preferably 70 parts by mass or less, more preferably 50 parts by mass or less, and even more preferably 30 parts by mass or less. When the content of the matting agent is within the above range, the design layer can be visually recognized as a low-gloss layer, thereby enhancing the visual effect (gloss-matt effect).

[0074] The thickness of the design layer 5 may be appropriately selected depending on the desired pattern. The thickness of the design layer 5 is preferably 1 μm or more, more preferably 3 μm or more, and even more preferably 5 μm or more. The upper limit of the thickness of the design layer 5 is preferably 10 μm or less, more preferably 7 μm or less, and even more preferably 5 μm or less. When multiple design layers are formed, the total thickness of all layers is set within the above-mentioned range.

[0075] [Transparent base layer] The transparent base layer 6 is provided between the pattern layer 5 and the protrusions 20, and serves to make the pattern layer 5 easier to see and to improve adhesion between the pattern layer 5 and the protrusions 20. The transparent base layer 6 may be provided over the entire surface of the substrate 2 when viewed from the front side, or may be provided only on a part of it.

[0076] An ink (transparent underlayer ink) made of a resin composition containing a binder resin is used to form the transparent underlayer 6. The transparent underlayer ink may contain a solvent as appropriate.

[0077] Preferred examples of binder resins include urethane resins, acrylic polyol resins, acrylic resins, polyester resins, alkyd resins, amide resins, butyral resins, styrene resins, urethane-acrylic copolymers, vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, and fluorine-based resins. Furthermore, curable resins, such as two-component curable resins containing polyol as the main component and isocyanate as the curing agent, may also be used. These may be used alone or in combination.

[0078] The transparent base layer 6 preferably has a higher gloss than the protrusions 20, for the purpose of improving the visual effect (gloss-matt effect) due to the difference in gloss from the protrusions 20. The transparent base layer 6 preferably contains a matting agent as needed. Examples of the matting agent include inorganic fillers such as silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, synthetic silicate, and silicate fine powder. The volume average particle size of the matting agent is preferably 1 μm to 20 μm, more preferably 3 μm to 10 μm, and even more preferably 3 μm to 7 μm.

[0079] The content of the matting agent relative to 100 parts by mass of the binder resin in the transparent underlayer 6 is preferably 1 part by mass or more, more preferably 3 parts by mass or more, and even more preferably 5 parts by mass or more, and the upper limit is usually 100 parts by mass or less, preferably 80 parts by mass or less, more preferably 50 parts by mass or less, and even more preferably 30 parts by mass or less. When the content of the matting agent is within the above range, an excellent visual effect (gloss matte effect) can be obtained.

[0080] The transparent underlayer 6 may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers in order to improve weather resistance.

[0081] The thickness of the transparent base layer 6 may be appropriately selected depending on the desired pattern. The transparent base layer 6 is preferably 2 μm or more, more preferably 4 μm or more, and even more preferably 6 μm or more. The upper limit of the thickness is preferably 20 μm or less, more preferably 15 μm or less, and even more preferably 10 μm or less.

[0082] [Surface coating layer] A surface coating layer 8 may be formed on the outermost surface of the decorative material 1 as needed to improve durability such as weather resistance, scratch resistance, abrasion resistance, and stain resistance, as well as design properties such as gloss. When the surface coating layer 8 is formed, the transparent base layer 6 can be omitted. If the desired durability and design properties are achieved even when the convex portions 20 are exposed on the outermost surface, the surface coating layer can be omitted. When the surface coating layer is formed on the raised layer, the raised layer and the surface coating layer can form the convex portions and gaps of the textured region.

[0083] An ink made of a resin composition (ink for surface coating layer) is used to form the surface coating layer 8. The ink for surface coating layer may contain a solvent as appropriate. The resin used to form the surface coating layer 8 is not particularly limited. Examples include thermoplastic resins such as (meth)acrylic resin, polyurethane resin, polyester resin, polyamide resin, (meth)acrylic acid ester-olefin copolymer resin, vinyl acetate chloride resin, ethylene-vinyl acetate copolymer resin (EVA resin), ionomer resin, and olefin-α-olefin copolymer resin; epoxy resin, phenol resin, urea resin, unsaturated polyester resin, melamine resin, alkyd resin, polyimide resin, silicone resin, hydroxyl-functional acrylic resin, carboxyl-functional acrylic resin, amide-functional copolymer, urethane resin, and fluororesin. These resins may be used alone or in combination of two or more.

[0084] Various additives can be blended into the surface coating layer 8 depending on the desired physical properties. Examples of additives include weather resistance improvers such as ultraviolet absorbers (benzotriazole-based ultraviolet absorbers, triazine-based ultraviolet absorbers, etc.), light stabilizers (hindered amine-based radical scavengers, etc.), abrasion resistance improvers (particles of silica, alumina, kaolinite, etc.), polymerization inhibitors, infrared absorbers, antifoaming agents, fillers, etc.

[0085] The thickness of the surface coating layer 8 is preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more in order to impart durability and gloss to the surface of the decorative material 1. On the other hand, taking into consideration the time and energy required for drying and curing the surface coating layer and the material costs, the upper limit of the thickness of the surface coating layer 8 is preferably 40 μm or less, more preferably 35 μm or less, and even more preferably 30 μm or less.

[0086] The decorative material of this embodiment can have, for example, the following layered structure: The symbol " / " indicates the boundary between layers. (1) Substrate / Primer layer / Base coat layer / Pattern layer / Transparent base layer / Raised layer / Surface coat layer (2) Base material / primer layer / base coat layer / pattern layer / transparent base layer / raised layer (3) Base material / primer layer / base coat layer / pattern layer / raised layer / surface coat layer (4) Base material / primer layer / base coat layer / pattern layer / raised layer (5) Base material / build-up layer (6) Base material / raised layer / surface coating layer (7) Base material / primer layer / build-up layer (8) Base material / primer layer / raising layer / surface coating layer (9) Base material / primer layer / pattern layer / raised layer / surface coating layer

[0087] [Manufacturing method for decorative materials] In the decorative material 1 of the present invention, each layer other than the base material is preferably formed by known coating methods. The method for producing a decorative material of the present invention will be described below using a metal plate as an example of the substrate.

[0088] (1) Primer layer formation process The primer layer ink is applied to one surface of the metal plate (substrate). This step can be omitted. The primer layer ink is preferably applied to the entire surface of the metal plate by a method such as roll coating, reverse coating, air spray coating, electrostatic coating, or powder coating. After application, the ink is dried by heating at 100 to 300°C to form a primer layer.

[0089] (2) Base coat layer formation process The base coat ink is applied onto the primer layer. This step can be omitted. The ink for the base coat layer is preferably applied to the entire surface of the primer layer. The application method may be flow coater coating, roll coating, reverse coating, air spray coating, electrostatic coating, powder coating, or the like.

[0090] After coating, the coating is dried at a heating temperature (substrate temperature) of 165 to 270° C. (preferably 200 to 250° C.), thereby forming a base coat layer. By heat-curing the base coat layer ink within the above temperature range, the layer below the protrusions 20 is prevented from being depressed in the areas where the organic filler is present during baking after the protrusions 20 are formed, making it possible to form protrusions 20 of sufficient height. Furthermore, the particles of the protrusions 20 are more likely to aggregate during heating after the protrusions 20 are formed. As a result, a decorative material with the desired visual effect and a good tactile feel can be obtained. In particular, in the case of a base coat layer made of a thermosetting polyester resin, a decorative material with an excellent tactile feel can be obtained by heating the base material to a temperature of 200°C or higher.

[0091] (3) Pattern layer formation process The ink for the design layer is applied to the base coat layer in any desired pattern. Note that this step can be omitted. As the application method, gravure printing, offset printing, flexographic printing, letterpress printing, screen printing, ink jet printing, transfer printing, etc. can be used. After coating, the ink for the design layer is dried to form the design layer.

[0092] (4) Transparent base layer formation process A transparent base layer ink is applied onto the picture layer (pattern layer). This step can be omitted. The ink for the transparent underlayer is preferably applied to the entire surface of the metal plate, and the application method can be gravure printing, offset printing, flexographic printing, letterpress printing, screen printing, or the like. After coating, the ink is dried by heating at 150 to 250°C (the temperature reached by the substrate) to form a transparent base layer.

[0093] (5) Build-up layer formation process A raised layer is formed in a portion of the decorative material that will become a textured region. The raised layer forms a textured region having a plurality of independent protrusions, and further forms gaps between the protrusions. Specifically, a raised portion ink (raised layer ink) is applied onto the transparent base layer or the pattern layer. The raised layer ink may be applied to the entire surface of the metal plate, or may be applied to only a portion of the metal plate. It is particularly preferable to apply the ink in accordance with the pattern of the pattern layer, as this provides a beautiful appearance and a tactile feel that corresponds to the pattern. In the present invention, the application of the ink for the raised layer is preferably carried out by gravure printing. The gravure printing plate has a plurality of cells on its surface. Immediately after printing, the cellular inks printed on the substrate side from each cell are independent of each other, but during the process from printing to drying, the cellular inks randomly merge in part of the texture region to form convex portions. Among gravure printing methods, gravure offset printing is particularly preferred because it facilitates the integration of adjacent inks on the blanket cylinder. In this process, the convex portions may be formed in a single printing pass, or may be formed by multiple printing passes. Furthermore, by including an organic solvent with an appropriate viscosity coefficient and evaporation rate in the raised layer ink, adjacent cellular ink particles are more likely to integrate. However, if the ink viscosity is too low, the aforementioned integration is less likely to occur, so it is preferable to set the particle content within the above range and select the solvent as described above.

[0094] (6) Surface coating layer formation process The ink for the surface coating layer is applied onto the raised layer. Note that this step can be omitted. The ink for the surface coating layer is preferably applied to the entire surface of the decorative material. Application methods that can be used include flow coater coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. After application, the ink is dried by heating at 100 to 300°C to form a surface coating layer.

[0095] (7) Baking process After forming the raised layer or the surface coating layer, baking is carried out at a heating temperature (substrate temperature) of 150 to 270°C (preferably 200 to 250°C).

[0096] [Laminate] The laminate of the present invention comprises an adherend and the decorative material of the present invention described above laminated on the adherend. The adherend and the decorative material are preferably fixed together with an adhesive layer, rivets, or the like. The adherend can be appropriately selected depending on the application of the laminate, and examples of the adherend include metal members, wood members, ceramic members, and resin members.

[0097] [Uses of decorative materials and laminates] The decorative material and laminate of the present invention can be used, for example, as a surface decorative sheet for interior or exterior components. Examples of interior materials include surface materials for interior building materials such as walls, floors, and ceilings; surface materials for interior fittings such as partitions, doors, window frames, handrails, trim, and modular baths; interior materials for vehicles such as automobiles and trains; and surface materials for home appliances. Examples of outer layer members include surface materials for exterior building components such as roofs, walls, floors, balcony screens, eaves, and ceilings; surface materials for exterior fittings such as entrance doors, doors, window frames, handrails, trim, and moldings; and exterior materials for vehicles such as automobiles and trains. [Example]

[0098] Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to these examples in any way.

[0099] [Measurement and Evaluation] The decorative materials prepared in the examples and comparative examples were subjected to the following measurements and evaluations. The results are shown in Table 1.

[0100] <Appearance observation> The appearance of the decorative materials of the Examples and Comparative Examples was observed.

[0101] <Visual Effects Evaluation> The visual effects of the cosmetic materials of the Examples and Comparative Examples were evaluated in terms of brightness and three-dimensionality. Twenty subjects evaluated the materials, giving 2 points for a visual effect that was perceived as excellent, 1 point for a visual effect that was perceived as insufficient but noticeable, and 0 point for a visual effect that was poor. The average scores were calculated and the materials were evaluated according to the following criteria based on the average scores obtained. A: Average score of 1.5 or above B: Average score is 1.2 or more but less than 1.5 C: Average score is less than 1.2

[0102] <Observation using an optical microscope (microscopic shape of textured area)> The textured region of the prepared decorative material was observed using an optical microscope (Keyence Digital Microscope VHX-2000) at a magnification of 200 to 700 times.

[0103] <Calculation of area ratio> The decorative materials of the Examples and Comparative Examples were binarized using the optical microscope images (magnification: 300x). Convex portions were extracted from the binarized images, and the area ratio of the convex portions to the entire image was calculated.

[0104] <Average diameter of circumscribed circle> For the decorative materials of the Examples and Comparative Examples, the diameters of the circumscribing circles of all the convex portions that could be seen in the images after binarization were calculated, and the average value (average diameter) of the diameters of the obtained circumscribing circles was calculated.

[0105] <D / d ave > For the decorative materials of the Examples and Comparative Examples, five pairs of adjacent convex portions were selected using the optical microscope images (magnification: 300x). For each pair, the average diameter of the circumscribed circle, d ave Calculate the distance D between the centers of the circumscribed circles, and calculate D / d ave Furthermore, the obtained D / d ave The average value was calculated.

[0106] <Height of the convex part (average height)> For the decorative materials of the Examples and Comparative Examples, the optical microscope images (magnification: 700x) were analyzed using high-resolution depth stacking 3D to measure the average height of the convex portions. Four lines were drawn passing through the center of the circumscribing circle to divide the circumscribing circle into eight equal parts, and the height of the convex portions on these four lines was taken as the average height from an area where no convex portions existed.

[0107] <Tactile sensation> The textured areas of the prepared cosmetic materials were checked by touch. Twenty subjects evaluated the texture, assigning a score of 2 for a strong sense of unevenness, 1 for a sense of unevenness, and 0 for a sense of almost no unevenness, and the average score was calculated. The average scores were used to evaluate the textured areas according to the following criteria: A: Average score of 1.5 or above B: Average score is 1.2 or more but less than 1.5 C: Average score is less than 1.2

[0108] Example 1 The primer layer ink having the following formulation was applied to the entire surface of a steel plate (SGCC-QM, size 800 mm x 2000 mm, thickness 0.6 mm) by roll coating so that the film thickness after drying would be 2 μm. It was then dried at 230°C (the temperature reached by the substrate) to form a primer layer. <Ink for primer layer> Thermosetting polyester resin Dilution solvent ·Solid content: 74% by mass

[0109] The ink for the base coat layer having the following formulation was applied to the entire surface of the primer layer using a curtain flow coater so that the film thickness after drying would be 22 μm, and then dried at 210°C (the temperature reached by the substrate) to form a base coat layer. <Base coat ink> Thermosetting polyester resin: 100 parts by weight Colorants (carbon black, titanium oxide (titanium white), iron oxide (red iron oxide), yellow iron oxide (pyrite)): 25 parts by weight Solvents (xylene, cyclohexanone) ·Solid content: 35% by mass

[0110] A design layer with a predetermined pattern was formed on the base coat layer. Specifically, a design layer ink containing a thermosetting polyester resin and a colorant was applied to the entire surface of the base coat layer by gravure printing so that the film thickness after drying would be 1 μm. This formed a stone-grain design layer.

[0111] An ink for a transparent undercoat layer having the following formulation was applied to the entire surface of the design layer by gravure offset printing so that the film thickness after drying would be 2 μm. <Transparent base layer ink> Thermosetting acrylic resin: 100 parts by weight Silica: 8 parts by weight Solvents (xylene, cyclohexanone)

[0112] The entire surface of the transparent base layer was coated with the following ink 1 for the raised layer by gravure printing, and then dried (amount of ink applied after drying: 200 g / m2 ), a raised layer was formed. This formed a textured region with a plurality of independent convex portions on the transparent base layer. A diagonal gravure printing cylinder was used for printing. The gravure printing cylinder was made by a method in which a photosensitive resist film on the surface of a metal printing plate was exposed to a laser beam, and then the metal printing plate was corroded to form the desired cell pattern.

[0113] <Ink for raised layer 1> Thermosetting acrylic resin: 100 parts by weight Shiny flake particles (glass flakes, 2025PSTM manufactured by Nippon Sheet Glass Co., Ltd.): 7 parts by mass Silica: 20 parts by weight Acrylic beads (30 μm diameter): 20 parts by weight Solvents (butyl carbitol, xylene, cyclohexanone) ·Solid content: 40% by mass

[0114] After the raised layer was formed, baking was carried out under the condition of 220° C. (the temperature reached by the substrate), thereby obtaining the decorative material of Example 1.

[0115] Example 2 The entire surface of an aluminum plate (A3004PH32, size 800 mm × 2000 mm, thickness 2 mm) was coated by roll coating with the same ink for the primer layer as in Example 1 so that the film thickness after drying would be 2 μm. The resulting coating was then dried at 230°C (the temperature reached by the substrate) to form a primer layer.

[0116] The entire surface of the primer layer was coated with the base coat layer ink having the same formulation as in Example 1 using a curtain flow coater so that the film thickness after drying would be 22 μm, and then dried at 210°C (the temperature reached by the substrate) to form a base coat layer.

[0117] A design layer with a predetermined pattern was formed on the base coat layer. A design layer ink containing a thermosetting polyester resin and a colorant was applied to the entire surface of the base coat layer by gravure printing so that the film thickness after drying would be 1 μm. This formed a striped design layer.

[0118] On the pattern layer, the ink 1 for the raised layer is applied in stripes by gravure printing and dried (amount of ink applied after drying: 250 g / m 2 ), a raised layer was formed. This resulted in a textured region with a plurality of independent convex portions on the design layer. A diagonal gravure printing cylinder was used for printing. The gravure printing cylinder was made by exposing a photosensitive resist film on the surface of a metal printing plate to a laser beam, and then etching the metal printing plate to form the desired cell pattern.

[0119] The ink for the surface coating layer having the following formulation was applied using a flow coater to the areas with and without the raised layer (i.e., over the entire surface of the aluminum plate) so that the film thickness after drying would be 18 μm. It was then baked at 220°C (the temperature reached by the substrate) to form the raised layer and the surface coating layer. This produced the decorative material of Example 2. <Ink for surface coating layer> Thermosetting polyester resin Solvents (xylene, cyclohexanone) ·Solid content: 35% by mass

[0120] Comparative Example 1 Using the same formulation and process as in Example 1, layers from the primer layer to the transparent undercoat layer were formed on the entire surface of a steel plate (SGCC-QM, size 800 mm×2000 mm, thickness 0.6 mm). Thereafter, the ink 2 for the raised layer having the following formulation was applied to the entire surface of the transparent base layer by gravure printing and dried (amount of ink applied after drying: 300 g / m 2 Thereafter, the substrate was baked at 220°C (the temperature reached by the substrate) to form a raised layer, thereby obtaining a decorative material of Comparative Example 1. <Ink for raised areas 2> Thermosetting acrylic resin: 100 parts by weight Silica: 8 parts by weight Solvents (xylene, cyclohexanone)

[0121] <Comparative Example 2> Using the same formulation and process as in Example 1, layers from the primer layer to the transparent undercoat layer were formed on the entire surface of a steel plate (SGCC-QM, size 800 mm×2000 mm, thickness 0.6 mm). Thereafter, the ink 3 for the raised layer having the following formulation was applied by gravure printing and dried (amount of application after drying: 250 g / m 2 ) For printing, a diagonal gravure printing cylinder was used. The gravure printing cylinder was made by exposing the photosensitive resist film on the surface of a metal printing plate to a laser beam, and then etching the metal printing plate to form the desired cell pattern. The printing plate was then baked at 220°C (the temperature reached by the substrate) to form a raised layer, and the decorative material of Comparative Example 2 was obtained. <Ink for raised areas 3> Thermosetting acrylic resin: 100 parts by weight Silica: 8 parts by weight Acrylic beads (30 μm diameter): 20 parts by weight Solvents (butyl carbitol, xylene, cyclohexanone) ·Solid content: 40% by mass

[0122] Figures 5 and 6 show photographs of the appearance of the decorative materials of Examples 1 and 2. Figures 7 to 9 show micrographs (magnification: 300x) of the texture regions of the decorative materials of Example 1 and Comparative Examples 1 and 2. Table 1 shows the evaluation results for the decorative materials of each Example and Comparative Example.

[0123] [Table 1]

[0124] The decorative material of Example 1 appeared to have a pattern in which areas of high brightness due to the accumulation of glittering flake particles were randomly arranged. As a result, there was a strong sense of contrast between the areas of high brightness (the convex areas within the textured region) and other areas (the sea areas within the textured region). Furthermore, the design showed a change in brightness of the patterned areas when the viewing angle was changed. As a result, the decorative material of Example 1 was able to express a design with a three-dimensional feel and a luxurious impression. The decorative material of Example 2 had a large difference in brightness between the textured area (the patterned area created by the convex portions) and the other areas (other areas), and the change in brightness of the patterned area was noticeable when the angle was changed. Within the textured area, a contrast was noticeable between the areas with high brightness created by the glittering flaky particles and the other areas. Furthermore, areas other than the bright spots created by the glittering flaky particles had a subdued luster and a moist texture. As a result, the decorative material of Example 2 was able to express a design with a three-dimensional feel as a whole. Furthermore, the decorative materials of Examples 1 and 2 were both evaluated as having an excellent feel to the touch. As shown in Figure 7, it was confirmed that the convex portions were densely formed in Example 1. Furthermore, the glittering flake particles were unevenly distributed within the convex portions (island portions), and almost no glittering flake particles were observed in areas other than the convex portions (sea portion). It is believed that the presence of such a fine structure caused the convex portions to appear to have high brightness and the sea portion to appear to have low brightness, resulting in the brightness contrast described above.

[0125] In the decorative material of Comparative Example 1, no difference in brightness or glossiness was perceived between the textured region and other regions. Because the decorative material of Comparative Example 1 did not contain glittering flake particles, a glossy design was not expressed. Although the decorative material of Comparative Example 1 was able to express a matte design, the design gave a flat impression. In the decorative material of Comparative Example 1, the textured region did not have a tactile sensation. As shown in FIG. 8, in Comparative Example 1, although some protrusions were observed, they were smaller than those in Example 1.

[0126] The cosmetic material of Comparative Example 2 had a noticeable difference in glossiness between the textured area and other areas, but because it did not contain glittering flake particles, it was unable to express a design with a sense of brightness compared to Examples 1 and 2. The cosmetic material of Comparative Example 2 contained acrylic beads, so it was possible to obtain a tactile sensation equivalent to that of Examples 1 and 2. As shown in FIG. 9, it was confirmed that in Comparative Example 2, protrusions formed by aggregation of particles were formed densely. [Explanation of symbols]

[0127] 1. Cosmetic materials 2 Base material 3 Primer layer 4 Base Coat Layer 5. Picture layer 6 Transparent base layer 7 Raised layer 8 Surface coating layer 10 Texture Area 20 Convex part 21. Glittering flake particles 22 Organic Filler 23 Binder resin

Claims

1. A decorative material having a textured region on a substrate, the textured region comprising a collection of a plurality of protrusions that are independent of each other, an area ratio of the convex portions in the texture region is 20% to 50% within a 1 cm square area; The area ratio of the texture region within the surface of the decorative material is 10% or more and 90% or less, the convex portions contain a resin binder and glittering flake particles, The decorative material, wherein the average diameter of the circumscribed circle of the convex portion is 100 μm to 250 μm.

2. The decorative material according to claim 1 , wherein the convex portions further contain an organic filler having a particle size of 5 μm or more and 60 μm or less.

3. The decorative material according to claim 1 or 2, wherein the convex portions further contain an inorganic filler.

4. The decorative material according to any one of claims 1 to 3, wherein when the 60-degree specular gloss of the texture region is defined as G60A and the 60-degree specular gloss of other regions other than the texture region is defined as G60B, G60A / G60B is 0.8 or less.

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