Decorative material, laminate, and method for manufacturing decorative material

Abstract

To provide a decorative material having a design excellent in touch and visual effect. [Solution] A decorative material having a textured region on a substrate, the textured region containing a plurality of particles having a particle size of 5 μm or more and 60 μm or less, and composed of a plurality of independent raised regions and gap regions between the raised regions, and when the textured region is viewed in a plane, the average diameter of the circumscribed circle of the raised regions is 100 μm or more and 500 μm or less.

Description

[Technical Field]

[0001] The present disclosure relates to a decorative material, a laminate, and a method for manufacturing 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 on which a textured surface has been formed have been proposed (for example, Patent Documents 1 and 2). Also, decorative materials have been proposed in which a textured pattern has been imparted to the surface of a substrate by build-up printing (for example, Patent Document 3).

[0004] Patent Document 4 discloses a decorative steel sheet having an improved design by partially providing a pattern layer made of a resin material containing resin beads on a steel sheet substrate. Patent Document 5 discloses a decorative material in which a patterned printed layer made of a particle-containing resin is provided on a substrate. The decorative material of Patent Document 5 has a textured pattern formed by convex portions, which are areas where the patterned printed layer is provided, and concave portions, where no patterned printed layer is provided, thereby giving the surface an excellent tactile feel. [Prior art documents] [Patent documents]

[0005] [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 [Patent Document 4] Japanese Patent Application Laid-Open No. 2006-123373 [Patent Document 5] Japanese Patent Application Laid-Open No. 2016-215423 DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0006] However, as described in Patent Documents 1 and 2, when a textured pattern is created by embossing, an embossing plate is required for each pattern, which increases costs and makes manufacturing difficult. Furthermore, the textured pattern is large, making it difficult to achieve a tactile feel that matches the underlying design. Furthermore, with embossing, it is difficult to harmonize the textured shape with the underlying design, making it difficult to create a sophisticated design.

[0007] In the build-up printing described in Patent Document 3, the thickness of the printed pattern is almost uniform, so only a monotonous feel is obtained. Furthermore, the method in Patent Document 3 can only form a visually monotonous pattern, making it difficult to obtain a decorative material with a luxurious feel.

[0008] Although the decorative materials described in Patent Documents 4 and 5 have a better feel than embossed or overlaid printed materials, further improvement in the feel has been desired.

[0009] In view of the above problems, the present disclosure aims to provide a decorative material having a design with excellent tactile and visual effects. [Means for solving the problem]

[0010] In order to solve the above problems, the present disclosure provides the following [1] to

[18] . [1] A substrate having a textured region thereon; the texture region includes a plurality of particles having a particle diameter of 5 μm or more and 60 μm or less, and is composed of a plurality of independent convex regions and gap regions between the convex regions; A decorative material in which, when the texture region is viewed in plan, the average diameter of the circumscribed circle of the convex region is 100 μm or more and 500 μm or less. [2] The decorative material according to [1], wherein the area ratio of the convex regions in the texture region is 20% or more and 70% or less within a 1 cm square area. [3] The average diameter of the circumscribed circles of a pair of adjacent convex regions is 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 The decorative material according to [1] or [2], which satisfies a viscosity of ≦6.0. [4] The decorative material according to any one of [1] to [3], wherein the shortest distance between adjacent convex regions is 50 μm or more and 120 μm or less. [5] The decorative material according to any one of [1] to [4], wherein the average height of the convex regions is 10 μm or more and 60 μm or less. [6] The decorative material according to any one of [1] to [5], wherein the convex regions are irregular. [7] A decorative material according to any one of [1] to [6], which has a raised layer on at least a portion of the substrate, and has the textured region on the surface of the decorative material on the side having the raised layer. [8] A decorative material according to any one of [1] to [7], wherein the area ratio of the textured region within the surface of the decorative material is 10% or more and 90% or less. [9] The decorative material according to any one of [1] to [8], wherein the area ratio of the gap region in the texture region is 30% or more and 80% or less within a 1 cm square area.

[10] The decorative material according to any one of [1] to [9], wherein the substrate is a metal substrate.

[11] The decorative material according to any one of [1] to

[10] , which has a surface coating layer on the outermost surface of the side of the decorative material having the textured region.

[12] The decorative material according to any one of [1] to

[11] , wherein the convex regions further contain glittering particles.

[13] A decorative material, The decorative material is a metal substrate made of metal having a first surface and a second surface; a design layer having a first surface and a second surface, the design layer including a resin binder and a colorant, the design layer being disposed so that the second surface side of the design layer faces the first surface side of the metal substrate; a particle group including particles having a particle diameter of 5 μm or more and 60 μm or less, the particle group being arranged on the first surface side of the design layer; Equipped with The surface of the decorative material has a textured area that has a texture and feel different from the second surface of the metal substrate, the textured region has projections and recesses; the irregularities include a first convex region, a second convex region located at a position separated from the first convex region, and a gap region located between the first convex region and the second convex region; the first convex region and the second convex region are raised toward the surface of the decorative material due to the presence of the particle groups; Cosmetic materials.

[14] A laminate comprising an adherend and the decorative material according to any one of [1] to

[13] laminated on the adherend.

[15] A method for producing a decorative material, comprising the step of forming a textured region on a substrate, the texture region is composed of convex regions that are independent of each other and gap regions between the convex regions, each of the raised regions includes a plurality of particles having a particle size of 5 μm or more and 60 μm or less; A method for producing a decorative material, wherein, when the texture region is viewed in plan, the average diameter of a circumscribed circle of the convex region is 100 μm or more and 500 μm or less.

[16] The method for producing a decorative material according to

[15] , wherein the textured region is formed by applying an ink for a raised layer onto the substrate and drying it.

[17] The method for producing a decorative material according to

[15] , wherein the textured area is formed by transferring a transfer layer of a transfer sheet having a transfer layer on a release layer onto the substrate.

[18] The method for producing a decorative material according to any one of

[15] to

[17] , wherein the substrate is a metal substrate. [Effects of the Invention]

[0011] According to the present disclosure, a decorative material having a design with excellent tactile and visual effects can be obtained. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a perspective view of a decorative material according to one specific example of this embodiment. [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 specific example of this embodiment where a textured region is provided. [Figure 4] 10A and 10B are diagrams for explaining the definitions of the "circumscribing circle of a convex region," the "diameter of the circumscribing circle," and the "distance between the centers of a pair of adjacent circumscribing circles" in this embodiment. [Figure 5] FIG. 10 is a diagram for explaining the definition of "adjacent convex regions" in this embodiment. [Figure 6] 1 is a micrograph of a textured region in the decorative material of Example 1. [Figure 7] 1 is a micrograph of a textured region in the decorative material of Example 4. [Figure 8] 1 is a micrograph of a textured region in the decorative material of Comparative Example 1. [Figure 9] 10 is a schematic cross-sectional view of a portion of a decorative material according to another specific example of this embodiment where a textured region is provided. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] [Decorative materials] The decorative material of this embodiment has a textured region on a substrate, the textured region containing a plurality of particles having a particle size of 5 μm or more and 60 μm or less, and being composed of a plurality of mutually independent convex regions and gap regions between the convex regions, and when the textured region is viewed in a plane, the average diameter of the circumscribed circle of the convex regions is 100 μm or more and 500 μm or less.

[0014] FIG. 1 is a perspective view of a cosmetic material according to one specific example of this embodiment. When viewed from the front side of the cosmetic material 1, a picture pattern is visible. Furthermore, the cosmetic material 1 has a visible texture region 10 on the substrate on the front side. The texture region 10 does not need to be provided over the entire surface of the cosmetic material 1, and may be provided partially. When the texture region 10 is provided partially, in this embodiment, the region that is not a texture region is referred to as "other region 11." The texture region 10 and other regions can be distinguished, for example, by the area ratio of the convex region described below. The textured area 10 is preferably provided in a pattern that is synchronized with at least a part of the design, thereby providing a three-dimensional tactile sensation that corresponds to the design. 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%. The decorative material may have a raised layer on at least a portion of the substrate, and may have a textured area on the surface of the decorative material on the side having the raised layer (FIG. 3).

[0015] In this embodiment, "plan view" means viewing the decorative material of this embodiment 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 Figure 1, the plane represented by the X-axis direction and the Y-axis direction approximately coincides with the surface of the base material, and "plan view" corresponds to viewing the surface of the base material from the Z-axis direction.

[0016] [Texture area] Figure 2 is an enlarged plan view of the region indicated by the symbol R in Figure 1. Figure 2 is a diagram of the textured 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. In other words, Figure 2 shows the microstructure of the textured region. The textured area can impart a tactile feel to the surface of the cosmetic material.

[0017] As shown in FIG. 2, the decorative material of this embodiment comprises a collection of multiple raised regions 20 that are independent of one another by gaps. The raised regions 20 are so-called "island-like regions (island portions)" that have a closed curved outline in a plan view. FIG. 2 shows a collection of irregular raised regions 20 that have a closed curved outline with protrusions and depressions in a plan view. The regions between the multiple raised regions 20 are referred to as gap regions 30 in this embodiment. The gap regions 30 are so-called "sea portions" where the protective layer or pattern layer described below is exposed. The presence of the sea portions between the island portions allows the raised regions 20 to exist independently of one another. The structure of FIG. 2 that has island portions and sea portions is also called a sea-island structure. In addition, in the structure of FIG. 2, the "sea-island structure" can also be referred to as a "phase-separated structure," the "island portions" as a "continuous phase," and the "sea portions" as an "isolated phase." The above-mentioned "convex region" 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 "gap region" is defined as a region having a height of less than 10.

[0018] The raised region 20 may be either irregular or regular in shape, but is preferably irregular in shape to enhance the texture of a natural object. The "irregularly shaped raised region" can also be expressed as a shape having any of the following characteristics. (1) When viewed in a plane, the shapes of the multiple convex regions are not all congruent, but two or more types of congruent regions with different shapes and sizes are mixed together. All of the convex regions in the texture region may have different shapes and sizes, or two or more congruent or similar convex regions may be included. (2) When viewed in a plane, the shape of the multiple convex regions is different from relatively monotonous shapes such as a regular polygon, circle, ellipse, cardioid (heart shape), etc. For example, the contour of the convex region has a complex shape that needs to be approximated by a combination of complex functions such as polynomials or infinite series. (3) A shape that has the characteristics of both (1) and (2). In this embodiment, "regular shape" refers to a relatively monotonous shape when viewed in a plane, such as a regular polygon, circle, ellipse, cardioid (heart shape), etc. "Regular convex region" refers to a case where multiple convex regions all have a congruent shape when viewed in a plane.

[0019] Each of the raised regions 20 contains a plurality of particles 21 having a particle size of 5 μm or more and 60 μm or less, which are present within the raised region 20 in an aggregated state within the plane and also in an aggregated state in the thickness direction. When the raised region 20 is viewed from above, as shown by symbol A in FIG. 2, there may also be raised regions 20 in which two or more particles having a particle size of 5 μm or more and 60 μm or less are not aggregated (for example, a region in which only one particle is present within a continuous resin island). Although such regions are not referred to as "raised regions" in this embodiment, their presence is permitted to the extent that they do not impede the effects and problem-solving that this embodiment is intended to achieve.

[0020] Fig. 3 is a schematic cross-sectional view of a portion of a decorative material according to one specific example of this embodiment where a textured region 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. In the textured region of the decorative material 1 of this embodiment, a primer layer 3, a base coat layer 4, a design layer 5, a protective layer 6, a raised layer 7, 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 having the raised layer. It is preferable that substantially no raised layer is provided in other regions.

[0021] As shown schematically in FIG. 3 , in the decorative material 1 of this embodiment, the particles of the raised regions 20 are present on the protective layer 6 (or the design layer 5), and the particles 21 are coated with a binder resin 22. In this embodiment, because the resin coating is thin, the surface of the raised regions 20 has an uneven shape that roughly follows the surface shape of the particles. That is, the texture region has unevenness (relatively large unevenness) caused by the multiple raised regions 20 arranged in a pattern, and unevenness (relatively small unevenness) caused by the particles 21 on the surface of each raised region 20. The combination of these two types of unevenness provides an excellent tactile sensation. Furthermore, in FIG. 3 , the texture region has gap regions between the raised regions 20. These gap regions and the aforementioned large unevenness create a contrast between weak and strong tactile sensations, providing an excellent tactile sensation. Compared to the cases in which only raised regions are provided over the entire texture region, as in Patent Documents 4 and 5, the decorative material of this embodiment provides an excellent tactile sensation. Furthermore, when the decorative material has other regions, it is possible to create a difference in gloss between the textured region where the convex regions exist and the other regions where the convex regions do not exist. Furthermore, even within the textured region, there is a difference in gloss between the minute regions of the convex regions and the gap regions. As a result, a superior visual effect (the so-called gloss matte effect) can be achieved, even compared to Patent Documents 4 and 5.

[0022] From the viewpoint of obtaining an excellent tactile feel, the average height of the raised regions 20 is preferably 10 μm or more and 60 μm or less, more preferably 15 μm or more and 45 μm or less, and even more preferably 20 μm or more and 35 μm or less.

[0023] Since the convex region 20 has an irregular or regular shape, the size of the convex region 20 is expressed by the diameter of the circumscribing circle when viewed in a plane (when viewed from the surface). Figure 4 is an enlarged planar schematic diagram of the texture region, and is the same as Figure 2. The circumscribing circle of the convex region 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 convex region 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 convex regions 20 in the entire texture region is defined as the "average diameter d." In this embodiment, the average diameter d of the circumscribed circle of the raised region 20 is 100 μm or more and 500 μm or less. If the average diameter d is less than 100 μm, a sufficient tactile feel cannot be obtained. On the other hand, if the average diameter d is more than 500 μm, the tactile feel will be poor and the raised region will be visible, making it impossible to obtain a luxurious design. The average diameter d is preferably 150 μm or more and 350 μm or less, and more preferably 200 μm or more and 250 μm or less.

[0024] If the raised regions 20 are spaced apart, a sufficient tactile sensation may not be obtained. In other words, it is preferable that the raised regions 20 are somewhat densely packed within the texture region. From the viewpoint of tactile feel, in the cosmetic material of this embodiment, the area ratio of the raised regions 20 in the texture region is preferably 20% to 70% in a 1 cm square range. The 1 cm square is a rule that takes into account the contact area of ​​a finger when touching the cosmetic material. This area ratio is more preferably 25% to 60%, and even more preferably 30% to 50%. The remainder of the raised regions 20 in the texture region becomes gap regions. The area ratio of the gap regions in the texture region is preferably 30% to 80% in a 1 cm square range, more preferably 40% to 75%, and even more preferably 50% to 70%.

[0025] 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 texture region and 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.

[0026] Furthermore, from the viewpoint of tactile sensation, in the decorative material of this embodiment, the average diameter of the circumscribed circles of a pair of adjacent convex regions 20 in the entire texture region 10 when viewed in plan is 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 ave The diameters of the circumscribing circles of a pair of adjacent convex regions 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 convex regions is large, and indicates that the convex regions 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 D / d is, the denser the convex regions are. ave When D / d is less than 1, the overlapping area between adjacent convex regions becomes large depending on the shape of the convex regions when viewed in a plane. ave If D / d is 0, the convex regions will overlap and become one region geometrically. In order for the two convex regions to be independent of each other by the gap, D / d ave The lower limit is preferably 0.5 as described above. D / d aveIt is more preferable that the number of pairs of adjacent convex regions that satisfy the above range accounts for 95% or more of all combinations.

[0027] Furthermore, the shortest distance between adjacent raised regions is preferably from 50 μm to 120 μm, more preferably from 60 μm to 110 μm, and even more preferably from 70 μm to 100 μm. When the shortest distance is within the above range, the raised regions are densely packed within the texture region, providing a good tactile feel.

[0028] Here, "adjacent convex regions" is defined as follows: Fig. 5 shows the result of determining the centers B of the circumscribing circles of the convex region 20 and the island portion A not considered to be convex regions for the enlarged planar schematic diagram of the texture region shown in Fig. 2, and then performing Voronoi tessellation on the texture region based on the centers B. Voronoi tessellation refers to determining the perpendicular bisectors between adjacent kernel points for multiple kernel points distributed within a plane, and dividing the plane into cellular regions using the obtained perpendicular bisectors. In this embodiment, the center B of the circumscribing circle of each convex region 20 is used as a "mother point" to divide the texture region into cellular regions by Voronoi division. Then, when two cellular regions corresponding to arbitrarily extracted convex regions have a common boundary line (Voronoi boundary), it is defined that "the convex regions are adjacent to each other."

[0029] The raised regions 20 can be formed, for example, using an ink (raised region ink) made of a resin composition containing particles and a binder resin. The "raised region ink" is sometimes referred to as the "raised layer ink." When the raised regions are formed using the raised region ink (raised layer ink), gap regions are simultaneously formed between the raised regions. Preferred examples of binder resins for the convex region 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.

[0030] Examples of particles contained in the convex regions 20 include organic fillers such as acrylic resin, urethane resin, nylon resin, polypropylene resin, and urea-based resin. Acrylic resin is particularly preferred because it has good heat resistance, the particles are less likely to be buried in the lower layer after the baking step and therefore tend to maintain their height, and the particles tend to aggregate, making it easier for the average diameter of the circumscribed circle of the convex regions to fall within the above-mentioned range. The particle size of the particles 21 is 5 μm or more and 60 μm or less. Particles smaller than 5 μm do not provide a satisfactory tactile feel. The particles are preferably 10 μm or more, more preferably 30 μm or more. Particles larger than 60 μm tend to fall off easily, resulting in a poor tactile feel in the textured region. In particular, when forming raised regions by gravure printing, the particles are unable to enter the cells of the plate, or the number of particles that enter is reduced, making it difficult to obtain the desired tactile feel. The particle size is preferably 50 μm or less, more preferably 40 μm or less. 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.

[0031] The particle content 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 region 20. When the particle content is within the above range, the particles tend to aggregate together. This provides an excellent tactile feel, an excellent visual effect, and a three-dimensional design. On the other hand, from the viewpoints of reliably binding the particles with the binder resin to prevent them from falling off, and improving the fluidity of the resin composition to facilitate the forming process, the particle content 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.

[0032] The convex region 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 or more and 20 μm or less, more preferably 2 μm or more and 10 μm or less, and even more preferably 3 μm or more and 7 μm or less. The size of the inorganic filler is preferably selected taking into consideration the particle size and the like so as not to affect the tactile feel of the particles. The content of the inorganic filler is preferably 1 part by mass or more and 40 parts by mass or less, more preferably 2 parts by mass or more and 30 parts by mass or less, and even more preferably 3 parts by mass or more and 25 parts by mass or less, relative to 100 parts by mass of the binder resin constituting the convex region 20. In this way, by including an inorganic filler in addition to the above particles, the difference in gloss between the textured region and the other regions can be increased, making it easier to impart a luxurious design to the decorative material.

[0033] The ink for the raised area (the 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 viscosity of the ink will be low, and even if particle aggregates are formed, there will be a shortage of resin, making it difficult to form raised regions and obtaining a good tactile feel. On the other hand, if a solvent with a high viscosity coefficient is used, the viscosity of the ink will be high, which tends to deteriorate the coatability. Furthermore, when the raised regions are formed by gravure printing, individual cells may be formed independently, or particles may be buried in the resin, making it difficult to obtain a good tactile feel. Furthermore, if the evaporation rate of the solvent is too slow, it will be difficult to form large raised regions and obtain a good 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 a good 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 suitable viscosity coefficients 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).

[0034] The raised region 20 may further contain glittering particles. The glittering particles in the raised region 20 can enhance the design of the decorative material. In particular, when a metal substrate is used as the substrate, the effect of the glittering particles can be further enhanced by the reflection of the metal substrate. Examples of glittering particles include one or more selected from metallic pigments made of metal flakes or powder, pearlescent pigments using a glass substrate or mica substrate, and other pearlescent pigments such as glass flakes, metal-coated glass flakes whose surfaces are coated with a thin metal film, phosphorescent pigments, and hologram glitter. Among glittering particles, flake-shaped glittering particles such as pearlescent pigments, glass flakes, metal-coated glass flakes, and metal flakes are preferred. Of these, pearlescent pigments are preferred, and pearlescent pigments using a glass substrate are particularly preferred.

[0035] The glittering particles may have an average particle size of 5 μm or more, preferably 20 μm or more. The glittering particles may have an average particle size of 80 μm or less, preferably 60 μm or less. The average particle size is measured by laser diffraction. When the glittering particles are non-spherical, such as flake-shaped, the maximum length of the glittering particles is preferably within the range described below. The maximum length of the flat portion is preferably 5 μm or more and 90 μm or less, and more preferably 10 μm or more and 60 μm or less. The aspect ratio (maximum length / thickness) of the maximum length to thickness of the flat portion of the flake-shaped glittering particles is preferably 10 or more and 180 or less. The length of the flake-shaped glittering particles means the maximum length in the planar direction when the particles are observed under a microscope. The thickness of the flake-shaped glittering particles is determined by dividing a cross-sectional image of the particle 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.

[0036] Specifically, pearlescent pigments using a glass substrate are particles in which a metal oxide coating layer is formed on a flake-shaped glass substrate. Examples of glass substrates include glass flakes and glass flakes. Examples of metal oxides in the coating layer include titanium oxide and iron oxide. The color of the pigment can be varied by changing the material and film thickness of the coating layer. The glass pigment blended into the ink may be of one type or multiple types.

[0037] 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 this embodiment, the pearl pigment may be any of a white pearl pigment, an interference pearl pigment, and a colored pearl pigment.

[0038] 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 thin metal coating layer is formed on the surface of a flake-shaped or scale-shaped glass substrate. Examples of glasses constituting 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.

[0039] The content of the glittering 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 particles and increasing the contrast between areas where the glittering 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.

[0040] From the viewpoint of improving weather resistance, the raised region 20 preferably contains a weather resistance agent such as an ultraviolet absorber or a light stabilizer.

[0041] Each layer 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.

[0042] 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, polyethylene 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.

[0043] Examples of metal substrates include pure metals consisting of a single metal element such as aluminum, iron, copper, titanium, etc., and alloys containing one or more of these metals such as carbon steel, stainless steel, duralumin, brass, bronze, etc. Substrates that have been plated with these metals can also be used. Metal substrates are preferred because they have excellent heat resistance and are resistant to deformation during high-temperature heating processes (drying after base coat layer formation and final baking process) in the manufacturing method described below. Because of the aforementioned properties, metal substrates can easily maintain the shape of the textured region. Furthermore, when the convex region 20 contains glittering particles, using a metal substrate can further enhance the effect of the glittering particles due to the reflection of the metal substrate.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] Examples of wood-based substrates include wooden veneers, plywood, laminated wood, particle board, and medium density fiberboard (MDF).

[0048] 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 0.2 mm or more and 5 mm or less, and more preferably 0.4 mm or more and 3 mm or less.

[0049] [Primer layer] The primer layer 3 is provided as needed 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.

[0050] 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.

[0051] 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.

[0052] 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). The type of binder resin can be selected taking into consideration the material of the substrate 2 and the material of the binder resin of the later-described pattern layer 5. For example, as will be explained in the manufacturing method later, in a decorative material using a metal plate as the substrate, when baking is performed after the formation of the pattern layer 5, it is preferable to select an ester-based resin (such as an alkyd resin, an epoxy resin, or a urethane resin) as the binder resin of the primer layer.

[0053] 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.

[0054] From the viewpoint of improving interlayer adhesion, the thickness of the primer layer 3 is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 3 μm or more. 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.

[0055] [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. The base coat layer 4 can be colored, for example, any color. By coloring the base coat layer any color in this way, the base coat layer can function as a color base for the decorative material, thereby enhancing the design of the decorative material.

[0056] The base coat layer 4 is usually formed as an opaque layer, and serves to conceal the substrate 2 from the viewer's perspective and to impart the intended color. However, the base coat layer 4 may be formed as a semi-transparent or transparent layer, making use of the pattern and color of the substrate 2. The base coat layer can be omitted as necessary.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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 or more and 40 μm or less, and more preferably 10 μm or more and 30 μm or less.

[0061] [Picture layer] The pattern layer 5 is provided on the surface side of the base material 2 as needed, 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.

[0062] 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.

[0063] 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.

[0064] 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 fluororesins. 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. For example, as described in the manufacturing method described below, in a decorative material using a metal plate as the substrate, when baking is performed after forming a pattern layer 5, it is preferable to select a polyester-based resin as the binder resin for the pattern layer 5 in consideration of processability.

[0065] 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.

[0066] The design layer 5 may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers in order to improve weather resistance.

[0067] 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 raised region 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 silicate.

[0068] The particle size (volume average particle size) of the matting agent is preferably 1 μm or more and 15 μm or less, more preferably 3 μm or more and 10 μm or less, and even more preferably 3 μm or more and 7 μm or less. The content of the matting agent relative to 100 parts by mass of the binder resin in the design layer is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, and even more preferably 20 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, the design layer can be visually recognized as a low-gloss layer, thereby enhancing the visual effect (gloss-matt effect).

[0069] 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 20 μm or less, more preferably 10 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.

[0070] [Protective layer] The protective layer 6 is provided between the design layer 5 and the raised area 20 as needed. The protective layer 6 serves to protect the design layer 5, for example. The protective layer 6 may be provided with functions such as weather resistance, contamination resistance, and chemical resistance. The protective layer is provided as needed to provide the above-mentioned functions. The protective 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 portion of the surface.

[0071] An ink (protective layer ink) made of a resin composition containing a binder resin is used to form the protective layer 6. The protective layer ink may contain a solvent as appropriate.

[0072] 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.

[0073] The protective layer 6 preferably has a higher gloss than the raised area 20, for the purpose of improving the visual effect (gloss-matt effect) due to the difference in gloss from the raised area 20. The protective 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 or more and 20 μm or less, more preferably 3 μm or more and 10 μm or less, and even more preferably 3 μm or more and 7 μm or less.

[0074] The content of the matting agent relative to 100 parts by mass of the binder resin in the protective layer 6 is preferably 1 part by mass or more, more preferably 2 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.

[0075] The protective layer 6 may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers in order to improve weather resistance.

[0076] The thickness of the protective layer 6 may be appropriately selected depending on the desired pattern. The protective 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.

[0077] [Surface coating layer] A surface coating layer 8 may be formed as needed on the outermost surface of the decorative material 1 on the side having the textured region in order to improve durability such as weather resistance, scratch resistance, abrasion resistance, and stain resistance. When the surface coating layer is formed on the raised layer, the raised layer and the surface coating layer can form the convex regions and gap regions of the textured region.

[0078] 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.

[0079] 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.

[0080] The thickness of the surface coating layer 8 is preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 15 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 to dry and harden 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, more preferably 30 μm or less, more preferably 25 μm or less, and more preferably 20 μm or less. Furthermore, setting the upper limit of the thickness of the surface coating layer 8 within the above range is preferable in that it makes it easier to maintain the shape of the raised layer.

[0081] The decorative material of this embodiment can specifically have the following laminated structure, for example: The symbol " / " indicates the boundary between layers. (1) Base material / primer layer / base coat layer / pattern layer / protective layer / raised layer / surface coat layer (2) Base material / primer layer / base coat layer / pattern layer / protective layer / raised layer (3) Base material / primer layer / base coat layer / pattern layer / raised layer / surface coat layer

[0082] [Manufacturing method for decorative materials] The method for producing a decorative material of the present embodiment is a method for producing a decorative material including a step of forming a textured region on a substrate, the texture region is composed of convex regions that are independent of each other and gap regions between the convex regions, each of the raised regions includes a plurality of particles having a particle size of 5 μm or more and 60 μm or less; When the texture region is viewed from above, the average diameter of the circumscribed circle of the convex region is 100 μm or more and 500 μm or less.

[0083] In the above-mentioned method for producing a decorative material, the textured region can be formed, for example, by the following methods (A) and (B). (A) The textured region is formed by applying an ink for a raised layer onto the substrate and drying it. (B) The textured region is formed by transferring the transfer layer of a transfer sheet having a transfer layer on a peelable substrate onto the substrate.

[0084] In the above method (A), the ink for the raised layer can be applied and dried by any commonly used means. In the above method (B), the surface shape of the releasable substrate of the transfer sheet preferably has a shape complementary to the shape of the textured region. A transfer layer formed on a releasable substrate having such a shape can have a surface shape after transfer that is the same as the shape of the textured region.

[0085] Below, a specific example of the method for producing a decorative material of this embodiment will be further described, taking as an example a case where a metal plate is used as the substrate.

[0086] (1) Primer layer formation process The primer layer ink is applied to one surface of the metal plate (substrate). The primer layer ink is preferably applied to the entire surface of the metal plate. The application method can be roll coating, reverse coating, air spray coating, electrostatic coating, powder coating, or the like. After application, the ink is heated and dried at a temperature between 100°C and 300°C to form a primer layer.

[0087] (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.

[0088] After coating, the coating is dried at a heating temperature (substrate temperature) of 165° C. to 270° C. (preferably 200° C. to 250° C.), thereby forming a base coat layer. By heating and curing the base coat layer ink within the above temperature range, a base coat layer with sufficient hardness is formed. Therefore, baking after forming the raised layer 7 prevents the lower layer of the raised region 20 from being depressed where particles are present, making it possible to form a raised region 20 with sufficient height. Furthermore, the particles in the raised region 20 tend to aggregate during baking after forming the raised layer 7, making it easier for the average diameter of the circumscribed circle to fall within the above range. As a result, a decorative material with a good feel can be obtained. In particular, by heating the base coat layer at 200°C or higher, a decorative material with an excellent feel can be obtained. On the other hand, if the drying temperature is less than 165°C (the temperature reached by the substrate), the lower layer will be depressed, reducing the height of the raised regions 20, and a sufficient tactile feel will not be obtained.

[0089] (3) Pattern layer formation process The ink for the design layer is applied to the base coat layer in a desired pattern by gravure printing, offset printing, flexographic printing, letterpress printing, screen printing, inkjet printing, transfer printing, or the like. After coating, the ink for the design layer is dried to form the design layer.

[0090] (4) Protective layer formation process The ink for the protective layer is applied onto the design layer (pattern layer). It is preferable to apply the ink for the protective layer to the entire surface of the metal plate. 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 a temperature between 150°C and 250°C (the temperature reached by the substrate) to form a protective layer. If no protective layer is formed, this step can be omitted.

[0091] (5) Build-up layer formation process A raised layer is formed on the protective layer or the design layer in a location that will become a textured region, thereby forming a textured region that includes a plurality of raised regions and gap regions between the raised regions. Specifically, an ink for the raised area (a raised layer ink) is applied to the protective layer or the design 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 design layer, since this provides a tactile sensation that corresponds to the pattern. In this embodiment, the ink for the raised layer is preferably applied 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 integrate in part of the texture region, forming raised regions. At the same time, gap regions are formed between the raised regions. By using gravure printing, it is possible to easily form raised regions having the above-mentioned average diameter of the circumscribed circle. Among gravure printing methods, gravure offset printing is particularly preferred because it facilitates integration of adjacent inks on the blanket cylinder. In this process, the raised regions 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. In addition, by applying gravure printing, the above-mentioned area ratio, D / d ave , and the shortest distance between the convex regions can be easily satisfied.

[0092] (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 heated and dried at a temperature between 100°C and 300°C to form a surface coating layer.

[0093] (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°C or higher and 270°C or lower (preferably 200°C or higher and 250°C or lower).

[0094] [Laminate] The laminate of this embodiment comprises an adherend and the decorative material of this embodiment 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.

[0095] [Uses of decorative materials and laminates] The decorative material and laminate of this embodiment can be used, for example, as a surface decorative panel for an interior or exterior member. 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]

[0096] Next, the cosmetic material and the method for producing the cosmetic material of the present disclosure will be described in more detail using examples, but the present embodiment is not limited to these examples in any way.

[0097] [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.

[0098] <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

[0099] <Observation using an optical microscope (microscopic shape of textured area)> The textured areas of the prepared decorative materials were observed using an optical microscope (Keyence Digital Microscope VHX-2000) at magnifications of 200 to 700 times. Areas where numerous convex areas where multiple particles were aggregated were observed were given an A rating, and areas where particles were confirmed but few aggregates were observed were given a C rating.

[0100] <Calculation of area ratio> For the decorative materials of the Examples and Comparative Examples, the optical microscope images (magnification: 300x) were subjected to binarization processing. Convex regions were extracted from the binarized images, and the area ratio of the convex regions to the entire image was calculated.

[0101] <Average diameter of circumscribed circle> For the decorative materials of the Examples and Comparative Examples, the diameters of the circumscribed circles of all the convex regions that could be seen in the images after the binarization process were calculated, and the average value (average diameter) of the diameters of the obtained circumscribed circles was also calculated.

[0102] <D / d ave > For the decorative materials of the Examples and Comparative Examples, five pairs of adjacent convex regions were selected using the optical microscope images (magnification: 300x). For each pair, the average diameter d of the circumscribed circle was calculated. 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.

[0103] <Height of the convex area (average height)> For the decorative materials of the Examples and Comparative Examples, the optical microscope images (magnification: 700x) were analyzed using high-resolution depth synthesis 3D to measure the average height of the convex regions. The height of the convex regions was determined by drawing four lines passing through the center of the circumscribing circle and dividing the circumscribing circle into eight equal parts, and measuring the average height of the convex regions on these four lines from areas where no convex regions existed.

[0104] Example 1 Primer layer ink 1 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 (substrate temperature) to form a primer layer. <Ink for primer layer 1> Thermosetting polyester resin Solvent (mixture of propylene glycol monomethyl ether acetate, cyclohexanone, and Swazol #1500) Solids content: 74%

[0105] 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 Colorants (carbon black, titanium oxide (titanium white), iron oxide (red iron oxide), yellow iron oxide (pyrite)): 25 parts by weight per 100 parts by weight of resin Solvents (xylene, cyclohexanone) Solids content: 35%

[0106] 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. After drying, a wood grain design layer was formed.

[0107] An ink for a protective 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. <Ink for protective layer> Thermosetting acrylic resin Silica: 8 parts by weight per 100 parts by weight of resin Solvents (xylene, cyclohexanone)

[0108] A raised layer was formed on the protective layer in accordance with the pattern of the design layer, thereby forming a textured region on the protective layer, the textured region including a plurality of raised regions and gap regions between the raised regions. Specifically, the protective layer was coated with the following formulation of ink 1 for the raised layer by gravure printing. 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. <Ink for raised layer 1> Thermosetting acrylic resin Silica: 8 parts by weight per 100 parts by weight of resin Acrylic beads (30 μm diameter): 20 parts by weight per 100 parts by weight of resin Solvents (xylene, cyclohexanone) Solids content: 40%

[0109] 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.

[0110] Example 2 A decorative material of Example 2 was obtained in the same manner as in Example 1, except that the drying temperature of the base coat layer was changed to 180°C (the temperature reached by the substrate).

[0111] Example 3 Primer layer ink 2 having the following formulation was applied to the entire surface of a steel plate (SGCC-QM, size 800 mm × 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 (substrate temperature) to form a primer layer. <Primer layer ink 2> Thermosetting polyester resin Solvent (mixture of propylene glycol monomethyl ether acetate, cyclohexanone, and Swazol #1500) ·Solid content: 74% by mass

[0112] The base coat layer ink 2 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 2> 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

[0113] 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 stone-grain design layer.

[0114] The entire surface of the design layer was coated with protective layer ink 2 having the following formulation by gravure offset printing so that the film thickness after drying would be 2 μm. <Protective layer ink 2> Thermosetting acrylic resin: 100 parts by weight Silica: 8 parts by weight Solvents (xylene, cyclohexanone)

[0115] A raised layer was formed on the entire surface of the protective layer, thereby forming a textured region on the protective layer, the textured region including a plurality of raised regions and gap regions between the raised regions. Specifically, the entire surface of the protective layer was coated with the following ink 2 for the raised layer by gravure printing. 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 plate material to a laser beam, and then etching the metal plate material to form the desired cell pattern. <Ink for raised layer 2> Thermosetting acrylic resin: 100 parts by weight Shiny flat 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

[0116] 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 3.

[0117] Example 4 Primer layer ink 3 having the following formulation was applied to the entire surface of an aluminum plate (A3004PH32, size 1220 mm × 2440 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 (substrate temperature) to form a primer layer. <Primer layer ink 3> Thermosetting polyester resin Solvents (propylene glycol monomethyl ether acetate, cyclohexanone, Swazol 1500) ·Solid content: 34% by mass

[0118] The base coat layer ink 3 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 3> Thermosetting polyester resin Solvents (xylene, cyclohexanone) ·Solid content: 35% by mass

[0119] 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 stone-grain design layer.

[0120] A raised layer was formed on the design layer in accordance with the pattern of the design layer, thereby forming a textured region including a plurality of raised regions and gap regions between the raised regions. Specifically, the raised layer ink 3 having the following formulation was applied to the design layer by gravure printing. 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. <Ink for raised layer 3> Thermosetting acrylic resin Silica: 8 parts by weight per 100 parts by weight of resin Acrylic beads (30 μm diameter): 20 parts by weight per 100 parts by weight of resin Solvents (xylene, cyclohexanone) Solids content: 40%

[0121] The ink for the surface coating layer having the following formulation was applied to the entire surface of the raised layer and the exposed pattern layer using a flow coater so that the film thickness after drying would be 18 μm. Then, the coating was baked at 220°C (the temperature reached by the substrate). This produced the decorative material of Example 4. <Ink for surface coating layer> Thermosetting acrylic resin Solvents (xylene, cyclohexanone) Solids content: 40%

[0122] Comparative Example 1 A decorative material of Comparative Example 1 was obtained in the same manner as in Example 1, except that the drying temperature of the ink for the base coat layer was set to 160°C (temperature reached by the substrate) and the ink for the raised layer was formulated as follows. <Ink for the raised layer of Comparative Example 1> Thermosetting acrylic resin Silica: 12 parts by weight per 100 parts by weight of resin Nylon beads (20 μm diameter): 12 parts by weight per 100 parts by weight of resin Solvents (xylene, cyclohexanone) Solids content: 40%

[0123] [Table 1]

[0124] 6 and 7 show micrographs of the textured regions of Examples 1 and 4. FIG. 8 shows a micrograph of the textured region of Comparative Example 1. In Example 1, it was confirmed that raised regions formed by aggregation of particles in the texture region were densely formed, and gap regions existed between the raised regions, as shown in Figure 6. Because a texture region with such a fine shape was formed, the decorative material of Example 1 provided an excellent feel to the touch. As shown in Figure 7, it was confirmed that in Example 4 as well, raised areas formed by particle aggregation in the textured area were densely formed. Furthermore, in Example 4, a surface coating layer was formed on the raised layer, and a good tactile feel was obtained. This is because heating after the base coating layer formation formed a base coating layer with sufficient hardness, allowing raised areas of sufficient height to be formed densely. Comparing Example 1 and Example 2, it can be seen that by heating the base coat layer at a higher temperature, it is possible to form convex regions of sufficient height, resulting in an excellent feel. On the other hand, in Comparative Example 1, as shown in Figure 8, almost no particle aggregation was observed and the particles were sparsely dispersed. The average height was also lower than in the Examples. From this, it is thought that the hardness of the base coat layer was insufficient and the particles caused depressions in the layer below the convex regions, making it impossible to form convex regions with sufficient height.

[0125] [Decorative materials] Another decorative material included in this embodiment (hereinafter referred to as "decorative material 100") includes a metal substrate made of metal and having a first surface and a second surface; a design layer having a first surface and a second surface and including a resin binder and a colorant, the design layer being arranged so that the second surface side of the design layer faces the first surface side of the metal substrate; and a particle group including particles having a particle diameter of 5 μm to 60 μm and arranged on the first surface side of the design layer, the surface of the decorative material including a textured region having a texture and feel different from that of the second surface of the metal substrate, the textured region having irregularities, the irregularities including a first convex region, a second convex region located at a position away from the first convex region, and a gap region located between the first convex region and the second convex region, Convex The region and the second convex region are raised on the surface side of the decorative material due to the presence of the particle groups.

[0126] Fig. 9 is a schematic cross-sectional view of a portion of a decorative material A according to one specific example of the present embodiment where a textured region is provided. As shown in Fig. 9, the decorative material A (1) comprises, in this order, a "metal substrate (2) made of metal and having a first surface (2a) and a second surface (2b)," a "pattern layer (5) having a first surface (5a) and a second surface (5b) and containing a resin binder and a colorant, the pattern layer (5) being arranged so that the second surface (5b) of the pattern layer faces the first surface (2a) of the metal substrate," and a "particle group including particles (21) having a particle diameter of 5 μm or more and 60 μm or less, the particle group being arranged on the first surface (5a) side of the pattern layer." The surface of the decorative material A(1) has a textured area whose texture and feel are different from those of the second surface (2b) of the metal substrate, and the textured area has irregularities (7), and the irregularities (7) have a first convex area (20a), a second convex area (20b) located at a position away from the first convex area, and a gap area located between the first convex area and the second convex area. The decorative material A(1) also has a textured area whose texture and feel are different from those of the second surface (2b) of the metal substrate, and the textured area has irregularities (7), and the irregularities (7) have a first convex area (20a), a second convex area (20b) located at a position away from the first convex area, and a gap area located between the first convex area and the second convex area. Convex The region (20a) and the second convex region (20b) are raised toward the surface of the decorative material due to the presence of the particle groups.

[0127] As shown in Figure 9, decorative material A may have a configuration other than a metal substrate, a pattern layer, and particle groups. For example, decorative material A may have a primer layer 3 and a base coat layer 4 between the metal substrate and the pattern layer. Decorative material A may also have a protective layer 6 between the pattern layer and the particle groups. Decorative material A may also have a surface coat layer 8 on the side of the particle groups opposite the pattern layer.

[0128] The decorative material A in FIG. 9 is made up of two sets of first Convex As shown in FIG. 9, the decorative material A has a plurality of first convex regions (20a) and a second convex region (20b). Convex It is preferable that the first convex region (20a) and the second convex region (20b) are provided. Convex It is preferable that the region (20a) and the second convex region (20b) contain a plurality of particles with a particle size of 5 μm or more and 60 μm or less.

[0129] Cosmetic material A is the first Convex The surface of the region (20a) and the second convex region (20b) may have second irregularities having a width or height smaller than the first irregularities. Convex In the case of FIG. 9, the surface coating layer 8 is present on the surface of the particle 21, but since the surface coating layer is thin, the first Convex The surfaces of the region (20a) and the second convex region (20b) are formed with small irregularities that roughly follow the surface shape of the particles. The specific embodiments of each region, each layer, and each material that make up the cosmetic material A are the same as those of the cosmetic material 1 of this embodiment described above. [Explanation of symbols]

[0130] 1,100 cosmetic materials 2 Base material 3 Primer layer 4 Base Coat Layer 5. Picture layer 6 Protective layer 7 Raised layer 8 Surface coating layer 10 Texture Area 11 Other Areas 20 Convex region 21 particles 22 Binder resin 30 Interstitial area

Claims

1. having a textured region on the substrate; the texture region includes a plurality of organic fillers in the form of particles having a particle diameter of 5 μm or more and 60 μm or less, and is composed of a plurality of convex regions that are independent of each other and gap regions between the convex regions; A decorative material, wherein, when the texture region is viewed in plan, the average diameter of the circumscribed circle of the convex region is 100 μm or more and 260 μm or less.

2. The decorative material according to claim 1 , wherein the area ratio of the convex regions in the texture region is 20% to 70% within a 1 cm square area.

3. The average diameter of the circumscribed circles of a pair of adjacent convex regions is defined as 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 3. The decorative material according to claim 1 or 2, wherein the viscosity satisfies ≦6.

0.

4. 4. The decorative material according to claim 1, wherein the shortest distance between adjacent raised regions is 50 μm or more and 120 μm or less.

5. 5. The decorative material according to claim 1, wherein the average height of the convex regions is 10 μm or more and 60 μm or less.

6. The decorative material according to any one of claims 1 to 5, wherein the raised regions are irregular in shape.

7. The decorative material according to claim 1 , wherein the decorative material has a raised layer on at least a portion of the substrate, and the textured region is on a surface of the decorative material on the side having the raised layer.

8. 8. The decorative material according to claim 1, wherein the area ratio of the textured region within the surface of the decorative material is 10% or more and 90% or less.

9. 9. The decorative material according to claim 1, wherein the area ratio of the gap region in the texture region is 30% to 80% within a 1 cm square area.

10. The decorative material according to any one of claims 1 to 9, wherein the substrate is a metal substrate.

11. The decorative material according to claim 1 , further comprising a surface coating layer on the outermost surface of the decorative material on the side having the textured region.

12. The decorative material according to claim 1 , wherein the convex regions further contain glittering particles.

13. A cosmetic material, The decorative material is a metal substrate made of a metal having a first surface and a second surface; a design layer having a first surface and a second surface, the design layer including a resin binder and a colorant, the design layer being disposed so that the second surface side of the design layer faces the first surface side of the metal substrate; a particle group including an organic filler as particles having a particle diameter of 5 μm or more and 60 μm or less, the particle group being arranged on the first surface side of the design layer; Equipped with the surface of the decorative material has a textured area that has a texture and feel different from the second surface of the metal substrate; the textured region has projections and recesses; the irregularities include a first convex region, a second convex region located at a position separated from the first convex region, and a gap region located between the first convex region and the second convex region; the shortest distance between the first convex region and the second convex region is 50 μm or more and 120 μm or less; the first convex region and the second convex region are raised toward the surface side of the decorative material due to the presence of the particle groups; Cosmetic materials.

14. A laminate comprising an adherend and the decorative material according to any one of claims 1 to 13 laminated on the adherend.

15. A method for manufacturing a decorative material, comprising a step of forming a textured region on a substrate, the texture region is composed of convex regions that are independent of each other and gap regions between the convex regions, each of the convex regions includes a plurality of organic fillers as particles having a particle size of 5 μm or more and 60 μm or less; A method for producing a decorative material, wherein, when the texture region is viewed in plan, the average diameter of a circumscribed circle of the convex region is 100 μm or more and 260 μm or less.

16. The method for producing a decorative material according to claim 15, wherein the textured region is formed by applying an ink for a raised layer onto the substrate and drying the applied ink.

17. The method for producing a decorative material according to claim 15, wherein the textured region is formed by transferring a transfer layer of a transfer sheet having a transfer layer on a release layer onto the substrate.

18. The method for producing a decorative material according to any one of claims 15 to 17, wherein the substrate is a metal substrate.

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