Cosmetic material and its manufacturing method

Abstract

To provide a decorative material that can impart an excellent three-dimensional effect and has a good expression of natural objects.SOLUTION: A decorative material comprises a plurality of independent concavities (A) on a first main surface side and a groove-shaped parallel concavity-convexity pattern group (B) arranged at least partially in a location where the plurality of independent concavities (A) do not exist. When defining the average depth of the plurality of independent concavities (A) as XA and the average depth of the concavities in the groove-shaped parallel concavity-convexity pattern group (B) as XB, XB<XA is satisfied.SELECTED DRAWING: Figure 4

Description

[Technical Field]

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

[0002] Decorative materials are widely used to decorate interior and exterior materials such as furniture and fixtures, and in recent years, there has been a demand for materials that can impart a three-dimensional effect to enhance the decorative effect. As such decorative materials, there have been proposed materials that form regions with different glossiness within the surface of the decorative material, thereby imparting a three-dimensional effect through the contrast of glossiness.

[0003] Means for imparting a three-dimensional effect by contrasting glossiness include partially exposing a matte layer, partially forming unevenness by embossing, partially forming a glittering ink layer, and combinations of the above-mentioned means (Patent Documents 1 to 3). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-62081 [Patent Document 2] Japanese Patent Application Publication No. 7-314630 [Patent Document 3] Japanese Patent Application Publication No. 2018-122575 DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0005] The decorative material of Patent Document 1 has a glossy layer partially formed on a matte layer formed on the entire surface, and the contrast between the exposed matte layer (low gloss area) and the glossy layer (high gloss area) creates a three-dimensional effect. However, the decorative material of Patent Document 1 has a problem in that the three-dimensional effect is insufficient and the exposed matte layer is easily soiled. Furthermore, the decorative material of Patent Document 1 does not have anisotropic gloss, so it gives a strong artificial impression and is insufficient in terms of design when trying to express natural objects such as wood grain.

[0006] The decorative material of Patent Document 2 is partially embossed to form concaves and convexes, which can impart a three-dimensional effect by contrasting concaves (low gloss areas) with flat areas (high gloss areas). However, like the decorative material of Patent Document 1, the decorative material of Patent Document 2 has the problem of insufficient design when it is desired to represent natural objects.

[0007] The decorative material of Patent Document 3 can impart a three-dimensional effect by contrasting an area having a matte layer (low gloss area) with an area having a pearlescent pigment adjacent to the matte layer (high gloss area). However, like the decorative material of Patent Document 1, the decorative material of Patent Document 3 also suffers from problems such as insufficient three-dimensional effect, the matte layer area being easily soiled, and insufficient design potential when attempting to represent natural objects. Furthermore, the decorative material of Patent Document 3 requires the use of relatively costly materials such as pearlescent pigments and metal flakes.

[0008] An object of the present invention is to provide a cosmetic material that can impart an excellent three-dimensional effect and that can effectively express natural objects, and a method for producing the cosmetic material. [Means for solving the problem]

[0009] In order to solve the above problems, the present inventors provide the following [1] to

[11] . [1] A decorative material, comprising: a first main surface of the decorative material having a plurality of independent recesses (A) and a group of groove-like parallel concave-convex patterns (B) arranged at least in a portion where the plurality of independent recesses (A) are not present; and an average depth of the plurality of independent recesses (A) is XA The average depth of the recesses of the groove-like parallel uneven patterns (B) is X B When we define B <X A A cosmetic material that satisfies the above requirements. [2] X A is 40 to 150 μm, and B The decorative material according to the above [1], wherein the particle size is 5 to 100 μm. [3] X A -X B The decorative material according to the above [1] or [2], wherein the particle size is 20 μm or more. [4] The average width of the plurality of independent recesses (A) is Y A The average width of the recesses of the groove-like parallel uneven patterns (B) is Y B1 The average width of the convex portions of the groove-shaped parallel concave-convex patterns (B) is Y B2 When Y is defined as A is 150 to 500 μm, and the Y B1 is 10 to 200 μm, and the Y B2 The decorative material according to any one of the above [1] to [3], wherein the particle size is 10 to 250 μm. [5] The extension direction of the independent recesses (A) is D A The stretching direction of the groove-shaped parallel uneven patterns (B) is D B When we define A and D B The decorative material according to any one of the above [1] to [4], wherein and are non-parallel. [6] D above A and the aforementioned D B The decorative material according to [5] above, wherein the angle between the surface and the surface is 5 to 70 degrees. [7] The decorative material according to any one of the above [1] to [6], wherein each of the groove-like parallel uneven patterns constituting the group of groove-like parallel uneven patterns (B) has a wavy shape in a plan view. [8] The decorative material according to any one of the above [1] to [7], wherein the shape of the recess (A) in plan view is one or more selected from the group consisting of vessels, wood, and knots of wood. [9] The decorative material according to any one of the above [1] to [8], wherein a colorant is filled in at least a portion of the depth direction of the plurality of independent recesses (A).

[10] The decorative material according to [9] above, which satisfies either of the following conditions (i) and (ii): (i) At least a part of the recesses in the groove-like parallel uneven patterns (B) in the depth direction is not filled with colorant. (ii) A colorant is filled in at least a part of the depth direction of the recesses of the group of groove-like parallel uneven patterns (B), and the filling amount of the colorant per unit area is W B The amount of colorant per unit area filled in at least a portion of the independent recesses (A) in the depth direction is W A When we define W B <W A Satisfy the relationship.

[11] A method for producing a decorative material, comprising the following steps (1) to (2): (1) A process for obtaining the decorative material according to any one of the above [1] to [8] by embossing a single layer of a substrate selected from a plastic film or a composite of a plastic film and paper, or a laminate including the substrate, with an embossing block. (2) A step of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in (1) above, and then scraping off the filler ink. [Effects of the Invention]

[0010] The decorative material of the present invention can impart an excellent three-dimensional effect and has excellent natural object expression, thereby achieving extremely good design properties. Furthermore, the manufacturing method of the decorative material of the present invention can easily manufacture a decorative material having the above-mentioned effects. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a plan view of a first main surface side showing one embodiment of a decorative material of the present invention. [Figure 2] FIG. 2 is an enlarged plan view of the circular portion surrounded by the dashed line in FIG. [Figure 3] 1 is an image in which the elevation of the decorative material of Example 1 was measured from the first main surface side, and the measured elevation is expressed in shades of gray. [Figure 4]2 is a cross-sectional view taken along a line AA' in FIG. 1 and parallel to the z-axis in FIG. [Figure 5] FIG. 10 is a plan view illustrating one step of calculating the average depth (XA) of a plurality of independent recesses (A). [Figure 6] FIG. 2 is a diagram showing a flow of one embodiment of a process for forming an uneven shape on the first main surface of the decorative material of the present invention. [Figure 7] FIG. 7 is a diagram showing a scene in a step of producing a plate by a laser, which is an example of step S14 in FIG. 6. DETAILED DESCRIPTION OF THE INVENTION

[0012] [Decorative materials] The decorative material of the present invention has, on the first main surface side, a plurality of independent recesses (A) and a group of groove-like parallel uneven patterns (B) arranged in at least a part of the area where the plurality of recesses (A) are not present, and the average depth of the plurality of independent recesses (A) is X A The average depth of the recesses of the groove-like parallel uneven patterns (B) is X B When we define B <X A The relationship is as follows:

[0013] <First main surface of decorative material> Fig. 1 is a plan view of the first main surface side showing one embodiment of a decorative material 100 of the present invention. As shown in Fig. 1, the decorative material 100 of the present invention has, on the first main surface side, a plurality of independent recesses (A) 10 and a group of groove-like parallel uneven patterns (B) 20 arranged in locations where the plurality of recesses (A) 10 are not present. In Fig. 1, the group of groove-like parallel uneven patterns (B) 20 is made up of groove-like uneven patterns 20a, 20b, ..., and 20l, and each groove-like uneven pattern is parallel. Fig. 2 is an enlarged plan view of the circular portion surrounded by the dashed line in Fig. 1. As shown in Fig. 2, the group of groove-like parallel uneven patterns (B) 20 is composed of recesses 21 and protrusions 22 surrounded by the recesses 21. In this specification, the term "parallel" in the group of groove-shaped parallel concave-convex patterns means that adjacent concaves are parallel when the decorative material is viewed in a plane. Furthermore, the term "parallel" in the group of groove-shaped parallel concave-convex patterns is not limited to being completely parallel, but also includes being approximately parallel. "Approximately parallel" means that when tangents are drawn to the edges of a pair of adjacent concaves, the angle formed by the two tangents is within 7.0 degrees, preferably within 5.0 degrees, and more preferably within 3.0 degrees.

[0014] Figure 3 is a plan view showing the elevation of the decorative material of Example 1 measured from the first main surface side, with the measured elevation expressed in shades. In Figure 3, lighter shades indicate higher elevations, and darker shades indicate lower elevations. In Figure 3, the elongated, high-density areas extending in the vertical direction are recesses (A). Multiple independent recesses (A) exist within the surface of the decorative material in Figure 3. In Figure 3, the low-density areas extending diagonally downward to the right are groups of groove-like parallel uneven patterns (B). Groups of groove-like parallel uneven patterns (B) are located in areas where multiple independent recesses (A) do not exist. 4 is a cross-sectional view taken along a line AA' in FIG. 1 and parallel to the z-axis in FIG.

[0015] The portion of the first main surface of the decorative material having the recess (A) has an average depth X A Since the depth of the groove-like parallel concave-convex pattern (B) is so deep that light incident on the concave portion is easily scattered and attenuated by multiple reflections, the concave portion (B) appears dark. On the other hand, in the concave portion (B), multiple reflections do not occur in the convex portion, and the concave portion (B) has an average depth of X B Since the grooves are shallower and there is less multiple reflection, the area having the groove-shaped parallel uneven pattern group (B) appears brighter than the recesses (A). Furthermore, the brightness of the area having the groove-shaped parallel uneven pattern group (B) differs when viewed from the direction in which the grooves extend and when viewed from a direction perpendicular to the direction in which the grooves extend. This is because there is less multiple reflection of light incident on the recesses when viewed from the direction in which the grooves extend. As described above, the decorative material of the present invention has a plurality of independent recesses (A) and a group of groove-like parallel concave-convex patterns (B), and B <X ASince the relationship is satisfied, the area having the group of groove-shaped parallel concave-convex patterns (B) can be visually perceived as relatively brighter than the area having the concave portions (A), and a three-dimensional effect can be imparted by the contrast in brightness. Furthermore, since the group of groove-shaped parallel concave-convex patterns (B) can be imparted with anisotropy in brightness, natural objects can be well expressed.

[0016] The ratio of the area occupied by the recesses (A) (total area of ​​a plurality of independent recesses (A)) to the total area of ​​the first main surface is preferably 20 to 50%, more preferably 30 to 40%.

[0017] <<Depth>> Average depth X of multiple independent recesses (A) A can be calculated, for example, by the following steps A1 to A3. A1: For each recess (A), height data in the direction across each recess (A) is measured at five randomly selected locations to obtain five cross-sectional curves with height data. If the planar shape of the recess (A) is an elongated shape extending in any direction, height data is measured in a direction perpendicular to the extension direction of the recess (A). For example, if the planar shape is the recess (A) shown in Figure 5, height data is measured at five locations a to e in the dotted line direction, which is a direction perpendicular to the extension direction of the recess (A) (the vertical direction in Figure 5). A2: From the height data measured in A1, the maximum depth of each measurement point is extracted, and the average value of the maximum depths at the five points is taken as the average depth of each recess (A). A3: Average the average depth of each recess (A) calculated in A2 to obtain X A Calculate.

[0018] For example, in Figure 4, the average depth of the left recess (A) (average of the maximum depths at five locations) is X A-1 The average depth of the recess (A) on the right side (average of the maximum depth of the five locations) is X A-2 In this case, the average depth of the independent recesses (A) is X A can be calculated using the following formula: Average depth of recess (A) X A =(X A-1 +X A-2) / 2

[0019] The average depth of the groove-like parallel uneven pattern group (B) is X B can be calculated using B1 to B3 below. B1: For each recess in the group of groove-like parallel uneven patterns (B) present within the plane of the decorative sheet, height data in the direction crossing each recess is measured at five randomly selected locations, and five cross-sectional curves with height data are obtained. The measurement direction at each measurement location is perpendicular to the extension direction of the recess. Note that, in order to simultaneously measure the width of the convex portions of the group of groove-like parallel uneven patterns (B), it is preferable to use a cross-sectional curve crossing the convex portions. B2: From the height data measured in B1, extract the maximum depth of each measurement point, and use the average value of the maximum depths at the five points as the average depth of each recess. B3: Average the average depth of each recess calculated in B2 to obtain X B Calculate.

[0020] For example, in Figure 4, the average depth of the nth recess from the left (the average of the five maximum depths) is X B1-n In FIG. 4, there are nine recesses in the group of groove-like parallel concave-convex patterns (B) (20d to 20l in FIG. 4), so the average depth X of the recesses in the group of groove-like parallel concave-convex patterns (B) is B can be calculated using the following formula: Average depth X of the groove-like parallel uneven pattern group (B) B =(X B1-1 +X B1-2 +X B1-3 +X B1-4 +X B1-5 +X B1-6 +X B1-7 +X B1-8 +X B1-9 ) / 9

[0021] The average depth (X) of multiple independent recesses (A) A ) is preferably 40 to 150 μm, more preferably 45 to 120 μm, and even more preferably 50 to 100 μm. A By making X 40 μm or more, it is possible to easily reduce the brightness of the area having the recess (A). ABy setting the thickness to 150 μm or less, it is possible to reproduce a realistic design in which the darkness of the recesses (A) and the brightness of the groove-like parallel uneven patterns (B) are well harmonized. The average depth of the groove-like parallel uneven patterns (B) (X B ) is preferably 5 to 100 μm, more preferably 10 to 70 μm, and even more preferably 15 to 60 μm. B By making X 5 μm or more, it is possible to easily impart anisotropy to the lightness. B By making X 100 μm or less, it is possible to easily increase the contrast in brightness between the independent recesses (A) and the group of groove-like parallel uneven patterns (B). Note that, from the viewpoint of making it difficult for a colorant to fill the recesses of the groove-like parallel uneven pattern (B) when performing the wiping step described later, X B It is preferable that the thickness is 60 μm or less.

[0022] Also, X A -X B is preferably 20 μm or more, more preferably 30 μm or more, and even more preferably 40 μm or more. A -X B By making X 20 μm or more, it is possible to easily increase the contrast in brightness between the independent recesses (A) and the group of groove-like parallel concave-convex patterns (B). A -X B By making the thickness 20 μm or more, when the wiping step described later is performed, a large amount of colorant is filled into the recesses (A), while the amount of colorant filled into the recesses of the groove-like parallel uneven pattern (B) is reduced, thereby making it possible to achieve better contrast.

[0023] <<Width and length>> In addition, the decorative material of the present invention has an average width of the recessed portion (A) of Y A , the average width of the recesses of the groove-like parallel uneven pattern group (B) is Y B1 , the average width of the convex part of the groove-like parallel uneven pattern group (B) is Y B2 When we define Y A , Y B1 and Y B2is preferably in the following range: The convex portions of the group of groove-like parallel concave-convex patterns (B) refer to those located between the concave portions of the group of groove-like parallel concave-convex patterns (B).

[0024] Y A The thickness is preferably 150 to 500 μm, more preferably 170 to 450 μm, and even more preferably 200 to 400 μm. Y A By making Y 150 μm or more, it becomes easier to recognize each recess (A) as an independent region. A By making Y 150 μm or more, it becomes easier to fill a large amount of colorant into the recesses (A) when performing the wiping step described later. A By making the thickness 500 μm or less, light incident on the recesses (A) is more likely to be multiple-reflected, and the recesses (A) can be more easily viewed as dark.

[0025] Y B1 is preferably 10 to 200 μm, more preferably 15 to 150 μm, and even more preferably 20 to 100 μm. B1 By making Y 10 μm or more, it is possible to make the reflected light from the recesses of the groove-like parallel uneven patterns (B) more easily visible to the human eye, and in turn, it is possible to make it easier to impart anisotropy to the lightness. B1 By making Y 200 μm or less, it is possible to easily increase the difference in brightness between when viewed from the extending direction of the grooves and when viewed from a direction perpendicular to the extending direction of the grooves, and it is possible to easily impart anisotropy to the brightness. B1 By making the distance 200 μm or less, it becomes difficult for the colorant to fill into the recesses of the group of groove-like parallel uneven patterns (B) when performing the wiping step described below.

[0026] Y B2 is preferably 10 to 250 μm, more preferably 20 to 200 μm, and further preferably 40 to 180 μm. B2 By making the thickness of the groove-shaped parallel uneven patterns (B) 10 μm or more, it is possible to easily increase the brightness of the area having the groove-shaped parallel uneven patterns (B).B2 By setting the distance to 200 μm or less, it is possible to prevent the reflection from the convex parts of the group of groove-like parallel uneven patterns (B) from becoming too strong, and to make it easier to recognize the anisotropy of brightness based on the concave parts of the group of groove-like parallel uneven patterns (B).

[0027] In order to improve the three-dimensional effect and the expression of natural objects, A , Y B1 and Y B2 It is preferable that Y satisfies either of the following formulas (1) and (2), and more preferable that Y satisfies either of the following formulas (1) and (2). Furthermore, when either of the following formulas (1) and (2) is satisfied, it is more preferable that Y satisfies either of the following formulas (3) and (4). Furthermore, when either of the following formulas (1) and (2) is satisfied, it is more preferable that Y satisfies either of the following formulas (3) and (4). B1 / Y A It is more preferable that Y in formula (4) is 0.20 or more and 0.40 or less. B2 / Y A is more preferably 0.20 or more and 0.60 or less. Y B1 <Y A (1) Y B2 <Y A (2) 0.06≦Y B1 / Y A ≦0.40 (3) 0.10≦Y B2 / Y A ≦1.00 (4)

[0028] Average width Y of multiple independent recesses (A) A can be calculated using C1 to C2 below. C1: From the five cross-sectional curves measured in A1 above, the width of the recess (A) at each measurement point is calculated, and the average value of the widths at the five points is taken as the average width of each recess (A). C2: The average width of each recess (A) calculated in C1 above is averaged to obtain Y A Calculate.

[0029] For example, in Figure 4, the average width of the left recess (A) (average of the widths at five locations) is YA-1 The average width of the recess (A) on the right side (average of the widths at five points) is Y A-2 When the average width Y of the independent recesses (A) is A can be calculated using the following formula: Average width Y of recess (A) A =(Y A-1 +Y A-2 ) / 2

[0030] Average width Y of the groove-like parallel uneven pattern group (B) B1 can be calculated using D1 to D2 below. D1: From the five cross-sectional curves measured in B1 above, calculate the width of the recess at each measurement point, and use the average value of the widths at the five points as the average width of each recess. D2: The average width of each recess calculated in D1 above is averaged to obtain Y B1 Calculate.

[0031] For example, in Figure 4, the average width of the recess located at the nth position from the left (average of the widths of five recesses) is Y B1-n In FIG. 4, there are nine recesses in the group of groove-like parallel concave-convex patterns (B) (20d to 20l in FIG. 4), so the average width Y B1 can be calculated using the following formula: Average width Y of the groove-like parallel uneven pattern group (B) B1 =(Y B1-1 +Y B1-2 +Y B1-3 +Y B1-4 +Y B1-5 +Y B1-6 +Y B1-7 +Y B1-8 +Y B1-9 ) / 9

[0032] Average width Y of the convex part of the groove-like parallel uneven pattern group (B) B2 can be calculated using E1 to E2 below. Note that the convex portions of the group of groove-like parallel concave-convex patterns (B) refer to those located between the concave portions of the group of groove-like parallel concave-convex patterns (B). E1: From the five cross-sectional curves measured in B1 above, calculate the width of the convex portion at each measurement point, and use the average value of the widths at the five points as the average width of each convex portion. E2: Average the average width of each convex part calculated in E1 above to obtain Y B2 Calculate.

[0033] For example, in Figure 4, the average width of the nth convex part from the left (average of the widths of five parts) is Y B2-n In FIG. 4, there are six convex portions of the groove-like parallel concave-convex pattern group (B), so the average width Y B2 can be calculated using the following formula: Average width Y of the convex part of the groove-like parallel uneven pattern group (B) B2 =(Y B2-1 +Y B2-2 +Y B2-3 +Y B2-4 +Y B2-5 +Y B2-6 ) / 6

[0034] The length of the independent recesses (A) is not particularly limited, and the range of the preferred length cannot be generalized because it varies depending on the design to be expressed. For example, if the design to be expressed by the entire decorative sheet is a wood pattern, the average length (L A ) is preferably 2 to 50 mm, more preferably 5 to 30 mm. The average length of the recesses (A) can be calculated as the average value of the lengths of the individual recesses (A). The length of each recess (A) means the maximum distance between any two points within each recess (A).

[0035] The length of each groove-shaped uneven pattern that makes up the group of groove-shaped parallel uneven patterns (B) is not particularly limited, but as shown in Figure 1, it is preferably a length that roughly crosses from any end of the decorative sheet to the other end (excluding the area where the recess (A) is present, and if necessary, also excluding the area near the recess (A)).

[0036] <<Examples of planar shapes>> The shape of the recess (A) in plan view is not particularly limited, and various patterns can be mentioned. When the design expressed by the entire decorative sheet is a wood pattern, the shape of the recesses (A) in plan view preferably forms one or more patterns selected from vessels, wood grain and knots. Vessels are cylindrical cells that serve as water passageways, and the arrangement of these tiny vessels creates what appears to the human eye as a dark pattern along the arrangement. Autumn wood refers to the narrow, dark-colored parts that form from summer to autumn. The wide-grained parts that form from spring to summer are called spring wood, and the alternation of spring wood and autumn wood forms the annual rings of wood. Knots are traces of branches embedded in the trunk, and are circular or nearly oval in shape, and darker in color than the surrounding tissue.

[0037] Furthermore, when the design to be expressed by the entire decorative sheet is a stone pattern such as travertine, the shape of the recesses (A) in plan view is preferably a concave recess. Furthermore, when the design to be expressed by the entire decorative sheet is a tile pattern or brick pattern, the shape of the recesses (A) in plan view is preferably a joint pattern. Furthermore, when the design to be expressed by the entire decorative sheet is a fabric pattern, the shape of the recesses (A) in plan view is preferably the recesses of fabric. Furthermore, when the design to be expressed by the entire decorative sheet is a leather pattern, the shape of the recesses (A) in plan view is preferably a wrinkled pattern.

[0038] The planar shape of each groove-like uneven pattern constituting the group of groove-like parallel uneven patterns (B) is not particularly limited, and various patterns can be mentioned, but a wavy shape as shown in FIG. 1 is preferred. By making the planar shape of the groove-shaped uneven pattern wavy, the brightness of the area having the group of groove-shaped parallel uneven patterns (B) changes along the wave shape. As a result, the brightness contrast between the recesses (A) and the group of groove-shaped parallel uneven patterns (B) is not uniform at each location on the surface of the decorative sheet, improving the representation of natural objects. Furthermore, the distribution of the brightness contrast described above changes as the direction of light incidence changes or the viewer moves, resulting in extremely good design properties. The wavelength (period) and wave height of the wavy pattern are not particularly limited, and the wavelength (period) can be adjusted appropriately within the range of about 1 to 100 mm, and the wave height can be adjusted appropriately within the range of about 1 to 20 mm.

[0039] <<Stretching direction>> The decorative material of the present invention has a plurality of independent recesses (A) extending in the direction D. A The stretching direction of the groove-shaped parallel uneven pattern group (B) is D B When we define A and D B It is preferable that the and are not parallel. A and D B and are not parallel, and the ink scraping direction in the wiping process described later is D A By carrying out the process in a direction parallel to the groove-shaped parallel uneven pattern (B), a large amount of colorant is filled into the recesses (A), while the amount of colorant filled into the recesses of the groove-shaped parallel uneven pattern (B) is reduced, thereby achieving better contrast.

[0040] The extension direction (D A ) means the average direction of the stretching directions of the individual recesses (A). The stretching direction of each recess (A) means the direction in which the distance between any two points in each recess (A) is the maximum. For example, in the case of the recess (A) in FIG. 5, the direction connecting the two points A and B is the stretching direction D. A This becomes: The stretching direction of the groove-like parallel uneven pattern group (B) (D B ) means the average direction of the extension directions of the individual recesses. The extension direction of each recess means the direction of a straight line connecting the start point and end point of each recess.

[0041] D A and D B The angle formed by the above is preferably 5 to 70 degrees, more preferably 7 to 50 degrees, and even more preferably 10 to 40 degrees. By setting the angle to 5 degrees or more, the ink scraping direction in the wiping process described later can be set to D A By carrying out the process in a direction parallel to the direction of the groove-shaped parallel concave-convex pattern (B), a large amount of colorant is filled in the concave portion (A), while the amount of colorant filled in the concave portion of the groove-shaped parallel concave-convex pattern (B) is reduced, thereby improving the contrast. A When wiping in a direction parallel to the group of groove-like parallel concave-convex patterns (B), it is possible to easily prevent the scraping blade from getting caught on the group of groove-like parallel concave-convex patterns (B).

[0042] <<Coloring agent>> As shown in Figure 4, the decorative material of the present invention preferably has a colorant 30 filled in at least a portion of the depth direction of a plurality of independent recesses (A). This configuration can improve the design of the decorative material. Furthermore, by using a dark-colored colorant as the colorant, the recesses (A) can be made darker, thereby increasing the brightness contrast within the surface of the decorative material. "Dark colors" refer to colors with low brightness and low saturation that give a dark impression, such as dark gray, dark green, navy blue, black, dark purple, crimson, and brown.

[0043] One method for filling the colorant into at least a portion of the depth of the recesses (A) is to apply a filling ink containing a colorant and a binder resin to the first main surface of the decorative material, and then scrape off the ink with a scraping blade such as a doctor blade. In this case, the amount of colorant filled into the recesses (A) can be adjusted by adjusting the material of the blade, the angle at which the blade is applied, the viscosity of the ink, etc.

[0044] Examples of colorants include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue; and dyes. Examples of binder resins for filling inks include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral, alkyd resins, petroleum-based resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, and rubber-based resins.

[0045] The decorative material of the present invention, in which a colorant is filled in at least a portion of the depth direction of a plurality of independent recesses (A), preferably further satisfies either of the following conditions (i) and (ii). (i) At least a part of the recesses in the groove-like parallel uneven patterns (B) in the depth direction is not filled with colorant. (ii) A colorant is filled in at least a part of the depth direction of the recesses of the group of groove-like parallel uneven patterns (B), and the filling amount of the colorant per unit area is W B The amount of colorant per unit area filled in at least a portion of the independent recesses (A) in the depth direction is W A When we define W B <W A Satisfy the relationship.

[0046] By satisfying either of the above conditions (i) or (ii), a contrast based on the difference in the amount of colorant is generated between the recesses (A) and the recesses constituting the group of groove-like parallel uneven patterns (B), thereby improving the design. Furthermore, by using a dark colorant as the colorant, the brightness contrast between the recesses (A) and the recesses constituting the group of groove-like parallel uneven patterns (B) is increased, thereby making the three-dimensional effect more prominent. In this specification, W A means the average amount of colorant filled per unit area of ​​each recess (A), and W B means the average amount of colorant filled per unit area of ​​each recess constituting the group of groove-like parallel concave-convex patterns (B).

[0047] To make it easier to meet either of the above conditions (i) and (ii), X A , X B , X A -X B , Y A , Y B1 and Y B2 The range of, and D A and D B It is preferable that at least one embodiment selected from the above relationships be the preferred embodiment described above.

[0048] <Second main surface> The shape of the surface (second main surface) opposite to the first main surface of the decorative material is not particularly limited, and may be smooth or may have irregularities.

[0049] <Layer structure of decorative material> The decorative material of the present invention may have the following laminated structures (1) to (8): " / " indicates the interface of layers, and the surface of the layer located on the left side indicates the first main surface of the decorative material. (1) Single layer of substrate (2) Decorative layer / substrate (3) Surface protection layer / decorative layer / substrate (4) Transparent resin layer / decorative layer / substrate (5) Surface protection layer / transparent resin layer / decorative layer / substrate (6) Surface protection layer / primer layer / transparent resin layer / decorative layer / substrate (7) Surface protection layer / base material / decorative layer (8) Surface protection layer / primer layer / substrate / decorative layer

[0050] <<Base material>> The decorative material preferably includes a substrate. The material of the substrate is not particularly limited, but is preferably a plastic film or a composite of a plastic film and paper, in consideration of the ease of forming a plurality of independent recesses (A) and a group of groove-like parallel concave-convex patterns (B) by embossing.

[0051] Specific examples of resins constituting plastic films include polyolefin resins such as polyethylene and polypropylene, vinyl resins such as vinyl chloride resin, vinylidene chloride resin, polyvinyl alcohol and ethylene-vinyl alcohol copolymer, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, acrylic resins such as polymethyl methacrylate, polymethyl acrylate and polyethyl methacrylate, polystyrene, acrylonitrile-butadiene-styrene copolymer (ABS resin), cellulose triacetate, polycarbonate, etc. Among these, polyolefin resins, vinyl chloride resin, polyester resin, and acrylic resin are preferred from the viewpoints of various physical properties such as weather resistance and water resistance, printability, moldability, cost, etc.

[0052] The substrate may be a transparent substrate or a colored substrate. The substrate may also be a laminated substrate in which multiple substrates are laminated. When the decorative material has a laminated structure as described above in (7) and (8), a transparent substrate is used so that the decorative layer can be seen through the substrate.

[0053] The thickness of the substrate is not particularly limited, but is preferably 20 to 200 μm, more preferably 40 to 160 μm, and even more preferably 40 to 100 μm.

[0054] The substrate may be subjected to an adhesion-facilitating treatment such as a physical treatment or a chemical surface treatment on one or both sides thereof in order to improve adhesion to a layer provided on the substrate.

[0055] <<Decorative layer>> From the viewpoint of improving the design, the decorative sheet preferably has a decorative layer at any location on the decorative sheet. The decorative layer is preferably formed on the side closer to the substrate from the viewpoint of improving the weather resistance of the decorative layer. However, if the substrate is transparent, the decorative layer may be located on the inner layer side (opposite the first main surface) of the substrate, as in the above-mentioned layer configurations (7) and (8).

[0056] The decorative layer may be, for example, a colored layer that covers the entire surface (a so-called solid colored layer), or a patterned layer formed by printing various patterns using ink and a printing machine, or a combination of these.

[0057] The pattern imparted by the decorative layer is not particularly limited, and examples thereof include wood patterns, stone patterns, tile patterns, brick patterns, fabric patterns, and leather patterns. By forming these patterns with the decorative layer, the effects based on the shape of the first main surface described above can be further emphasized.

[0058] The pattern of the wood is preferably formed by combining the bark portion with one or more patterns selected from vessels, fall wood and knots. The stone pattern is preferably formed by combining stone surface portions and recessed portions. The tile or brick pattern is preferably formed by combining the bare surface of the tile or brick with a joint pattern. The fabric pattern is preferably formed by combining the surface portion of the fabric with recesses in the fabric. The leather pattern is preferably formed by combining the surface of the leather with a wrinkled pattern.

[0059] The decorative layer can be formed, for example, by applying and drying a decorative layer ink containing a colorant such as a pigment or dye and a binder resin. The ink can be mixed with additives such as extender pigments, antioxidants, plasticizers, catalysts, curing agents, UV absorbers, and light stabilizers, as needed. The colorant and binder resin of the decorative layer are not particularly limited, and for example, the same as those exemplified for the filler ink can be used.

[0060] The thickness of the decorative layer may be selected appropriately depending on the desired pattern, but from the viewpoint of concealing the base color of the adherend and improving the design, it is preferably 0.1 μm or more and 20 μm or less, more preferably 0.5 μm or more and 10 μm or less, and even more preferably 1.0 μm or more and 5.0 μm or less.

[0061] <<Surface protective layer>> The decorative material may have a surface protective layer to improve scratch resistance. From the viewpoint of improving the scratch resistance of the decorative sheet, the surface protective layer preferably contains a cured product of a curable resin composition.

[0062] Examples of the curable resin composition include a thermosetting resin composition containing a thermosetting resin, an ionizing radiation curable resin composition containing an ionizing radiation curable resin, and a mixture thereof. Among them, an ionizing radiation curable resin composition is preferred from the viewpoint of increasing the crosslink density of the surface protective layer and improving surface properties such as scratch resistance. Furthermore, among ionizing radiation curable resin compositions, an electron beam curable resin composition is more preferred from the viewpoint of being able to be applied without a solvent and being easy to handle.

[0063] A thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that cures when heated. Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In a thermosetting resin composition, a curing agent is added to the curable resin as needed.

[0064] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). The ionizing radiation-curable functional group is a group that crosslinks and cures upon irradiation with ionizing radiation, and preferred examples include functional groups having an ethylenic double bond, such as a (meth)acryloyl group, a vinyl group, or an allyl group. In this specification, the term "(meth)acryloyl group" refers to an acryloyl group or a methcroyl group. In addition, in this specification, the term "(meth)acrylate" refers to an acrylate or a methacrylate. Furthermore, ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Typically, ultraviolet (UV) rays or electron beams (EB) are used, but it also includes other electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams. Specifically, the ionizing radiation curable compound can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation curable resins.

[0065] As the polymerizable monomer, a (meth)acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferred, and among them, a polyfunctional (meth)acrylate monomer is preferred. Here, "(meth)acrylate" means "acrylate or methacrylate." Examples of polyfunctional (meth)acrylate monomers include (meth)acrylate monomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the functional group.

[0066] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the functional group, such as urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers. Other polymerizable oligomers include highly hydrophobic polybutadiene (meth)acrylate oligomers having (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers having polysiloxane bonds in the main chain, aminoplast resin (meth)acrylate oligomers obtained by modifying aminoplast resins having many reactive groups in their small molecules, and oligomers having cationically polymerizable functional groups in the molecules of novolac epoxy resins, bisphenol epoxy resins, aliphatic vinyl ethers, aromatic vinyl ethers, etc.

[0067] These polymerizable oligomers may be used alone or in combination of two or more. From the viewpoint of improving processing characteristics, scratch resistance, and weather resistance, one or more selected from urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers are preferred, one or more selected from urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers are more preferred, and urethane (meth)acrylate oligomers are even more preferred.

[0068] In the ionizing radiation-curable resin composition, a monofunctional (meth)acrylate may be used in combination for the purpose of reducing the viscosity of the ionizing radiation-curable resin composition, etc. These monofunctional (meth)acrylates may be used alone or in combination of two or more kinds.

[0069] When the ionizing radiation curable compound is an ultraviolet ray curable compound, the ionizing radiation curable resin composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator. The photopolymerization initiator may be one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzil dimethyl ketal, benzoyl benzoate, α-acyloxime ester, thioxanthones, and the like. The photopolymerization accelerator can reduce polymerization inhibition caused by air during curing and increase the curing rate, and examples thereof include one or more selected from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, etc.

[0070] The surface protective layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant, if necessary.

[0071] From the viewpoint of a balance between processing characteristics, scratch resistance, and weather resistance, the thickness of the surface protective layer is preferably from 1.5 μm to 30 μm, more preferably from 2 μm to 15 μm, and even more preferably from 3 μm to 10 μm.

[0072] <<Transparent resin layer>> The decorative sheet may have a transparent resin layer from the viewpoint of increasing strength, etc. When the decorative sheet has a surface protective layer, the transparent resin layer is preferably located between the substrate and the surface protective layer. When the decorative sheet has a primer layer, the transparent resin layer is preferably located between the substrate and the primer layer. Furthermore, when the decorative sheet has a decorative layer, the transparent resin layer is preferably located between the decorative layer and the surface protective layer from the viewpoint of protecting the decorative layer.

[0073] Resins constituting the transparent resin layer include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylic resins, vinyl chloride resins, etc. Among these, polyolefin resins are preferred from the viewpoint of processability. The transparent resin layer may be a mixture of these exemplified resins, or may be a laminate of layers made of one or more of these exemplified resins.

[0074] Examples of polyolefin resins for the transparent resin layer include polyethylene (low density, medium density, high density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-propylene-butene copolymer, etc. Among these, polyethylene (low density, medium density, high density), polypropylene, ethylene-propylene copolymer, and propylene-butene copolymer are preferred, and polypropylene is more preferred.

[0075] The transparent resin layer may contain additives such as an ultraviolet absorber, a light stabilizer, a colorant, etc. When the transparent resin layer contains an ultraviolet absorber, the ultraviolet absorber is preferably a triazine-based compound, and more preferably a hydroxyphenyltriazine-based compound.

[0076] The thickness of the transparent resin layer is preferably from 20 μm to 150 μm, more preferably from 40 μm to 120 μm, and even more preferably from 60 μm to 100 μm, from the viewpoint of a balance between scratch resistance, processability, and weather resistance.

[0077] <<Primer layer>> When the decorative sheet has a surface protective layer, it preferably has a primer layer in contact with the surface of the surface protective layer facing the substrate. The primer layer improves the adhesion between the substrate and the surface protective layer (when a transparent resin layer is present, the adhesion between the transparent resin layer and the surface protective layer), making it easier to ensure long-term interlayer adhesion when exposed to the outdoors (so-called weather-resistant adhesion) and improve scratch resistance.

[0078] The primer layer is mainly composed of a binder resin, and may contain additives such as an ultraviolet absorber and a light stabilizer, if necessary.

[0079] Preferred examples of the binder resin for the primer layer include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene 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 resins, nitrocellulose resins (nitrocellulose), and cellulose acetate resins. These may be used alone or in combination. Furthermore, the binder resin may be a resin obtained by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent to the resin and crosslinking and curing it. Among these, a polyol-based resin such as an acrylic polyol resin crosslinked and cured with an isocyanate-based curing agent is preferred, and an acrylic polyol resin crosslinked and cured with an isocyanate-based curing agent is more preferred.

[0080] The thickness of the primer layer is preferably 0.5 μm or more and 10 μm or less, more preferably 0.7 μm or more and 8 μm or less, and even more preferably 1 μm or more and 6 μm or less.

[0081] <<Other layers>> The decorative material of the present invention may have other layers such as an adhesive layer and a backside primer layer.

[0082] When the decorative sheet has a transparent resin layer, it is preferable to form an adhesive layer between the substrate and the transparent resin layer in order to improve the adhesion between the two layers. When a decorative layer is further provided between the substrate and the transparent resin layer, the positional relationship between the adhesive layer and the decorative layer is not particularly limited. Specifically, the decorative layer, adhesive layer, and transparent resin layer may be provided in this order from the side closest to the substrate, or the adhesive layer, decorative layer, and transparent resin layer may be provided in this order from the side closest to the substrate.

[0083] The adhesive layer can be made of a general-purpose adhesive such as a urethane adhesive, an acrylic adhesive, an epoxy adhesive, a rubber adhesive, etc. Among these adhesives, a urethane adhesive is preferred in terms of adhesive strength. Examples of urethane adhesives include adhesives that utilize two-component curing urethane resins containing various polyol compounds such as polyether polyol, polyester polyol, and acrylic polyol, and a curing agent such as an isocyanate compound.

[0084] The thickness of the adhesive layer is preferably 0.1 μm or more and 30 μm or less, more preferably 1 μm or more and 15 μm or less, and even more preferably 2 μm or more and 10 μm or less.

[0085] The back surface primer layer is a layer formed on the surface of the decorative material opposite to the first main surface, for the purpose of improving the adhesion between the decorative material and various adherends.

[0086] The material used to form the back primer layer is not particularly limited, and examples include urethane resin, acrylic resin, polyester resin, vinyl chloride / vinyl acetate copolymer, chlorinated polypropylene resin, chlorinated polyethylene resin, etc., and may be selected appropriately depending on the material of the adherend. The thickness of the back primer layer is preferably 0.5 to 5.0 μm, and more preferably 1 to 3 μm.

[0087] The decorative layer, surface protective layer, primer layer, adhesive layer and back primer layer described above can be formed by applying an ink containing a composition for forming each layer by a known method such as gravure printing, bar coating, roll coating, reverse roll coating or comma coating, and then drying and curing the applied ink as necessary. The transparent resin layer can be formed by, for example, hot melt extrusion.

[0088] <Uses of decorative materials> The decorative material of the present invention can be used for various purposes as it is, or as a laminate attached to an adherend, or after the decorative material or laminate is subjected to a predetermined molding process or the like. Various applications include interior materials for buildings such as walls, ceilings, and floors; fixtures such as window frames, doors, and handrails; furniture; housings for home appliances and office automation equipment; and exterior materials for entrance doors.

[0089] Examples of substrates include wood boards such as wood veneer, wood plywood, particle board, MDF (medium density fiberboard), and laminated lumber; gypsum boards such as gypsum boards and gypsum slag boards; cement boards such as calcium silicate boards, asbestos slate boards, lightweight foam concrete boards, and hollow extruded cement boards; fiber cement boards such as pulp cement boards, asbestos cement boards, and wood chip cement boards; ceramic boards such as pottery, porcelain, earthenware, glass, and enamel; metal boards such as iron boards, galvanized steel boards, polyvinyl chloride sol-coated steel boards, aluminum boards, and copper boards; polyolefin resin boards, acrylic resin boards, and ABS resin boards. thermoplastic resin plates such as polycarbonate plates; thermosetting resin plates such as phenolic resin plates, urea resin plates, unsaturated polyester resin plates, polyurethane resin plates, epoxy resin plates, and melamine resin plates; and so-called FRP plates formed by impregnating and curing resins such as phenolic resins, urea resins, unsaturated polyester resins, polyurethane resins, epoxy resins, melamine resins, and diallyl phthalate resins into glass fiber nonwoven fabrics, cloth, paper, and other various fibrous substrates. These may be used alone, or two or more of these may be laminated together to form a composite substrate.

[0090] <Method of forming the first principal surface> The plurality of independent concave portions (A) and the groove-shaped parallel concavo-convex pattern group (B) on the first main surface can be formed, for example, by shaping with an embossing plate engraved by a laser.

[0091] The shaping by an embossing plate engraved by a laser can be carried out, for example, in the steps (S11 to S15) of FIG. 6. Hereinafter, each step will be described.

[0092] <<S11: Creation of density distribution data for concave portion (A)>> In the density distribution data creation step (step S11), a density distribution image that is the basis of the pattern of the plurality of independent concave portions (A) to be expressed on the surface of the decorative material is acquired, and this is used as density distribution data. As an example of the density distribution image, an image in which only the vessel pattern of the wood grain is expressed can be cited.

[0093] The density distribution image acquired in step S11 is preferably a two-dimensional density pattern that does not have height information. Examples of such density patterns include photographs, paintings, printed materials, etc. Also, a three-dimensional image having height information may be used, but in that case, it is preferable to use only the information based on the density in two dimensions when viewed in plan, excluding the height information.

[0094] In step S11, for the obtained density distribution image, a density value D(x, y) is obtained for each two-dimensional coordinate (x, y) to obtain density distribution data. The two-dimensional coordinate (x, y) is not particularly limited, but it is preferable to correspond to the coordinates on the surface of a plate (in this embodiment, an embossing plate in the shape of a metal roll) described later. Also, the specific expression of the density value D is not particularly limited, but for example, the darkest part of the density distribution image is set to 255, the lightest part is set to 0, and the values between them are evenly divided by integers to express the density value in 256 gradations. As described above, a set of data of density values D expressed in 256 gradations at each coordinate (x, y) is obtained, and this is used as density distribution data.

[0095] As described above, the density distribution data is preferably digital data. Therefore, when the original density distribution image is not digital data, it is digitized by using a method of reading a two-dimensional image such as the original manuscript itself or a photograph of the manuscript with a scanner and performing AD conversion. Also, when the pattern has been designed from the beginning using digital data with CAD or the like, the digital data can be used.

[0096] The means for creating the density distribution data is not particularly limited. For example, using the graphic design drawing software "Photoshop" manufactured by Adobe Systems, density distribution data with a resolution of 2540 dpi and 8-bit density gradation (256 gradations) in TIF format can be created.

[0097] <<S12: Conversion of Density Distribution Data to Depth Data>> In the conversion process to depth data (Process S12), the density value D(x, y) of the density distribution data of the recess (A) obtained in Process S11 is converted to the depth F(x, y) for each coordinate (x, y) to obtain depth data. This depth data is depth data corresponding to the concavities and convexities of a plurality of independent recesses (A). Therefore, the shape of a plurality of independent recesses (A) is determined by this process. Here, the conversion of the density value D(x, y) to the depth F(x, y) is performed based on a predetermined rule. Thereby, the density distribution and the depth distribution are associated with each other, and a unique texture based on the density distribution image can be obtained in the surface pattern of the decorative material.

[0098] One example is that in Process S11, the darkest part in the density distribution image is set as gradation 255, and in Process S12, this is set to a depth of 300 μm. On the other hand, in Process S11, the lightest part in the density distribution image is set as gradation 0, and in Process S12, this is set as the reference (depth 0 μm). Then, for gradations 0 to 255 in Process S11, 0 μm to 300 μm are proportionally distributed and assigned to the depths in Process S12. Therefore, according to this example, the thinnest part in the concentration distribution image becomes the reference (depth 0 μm), and it becomes deeper as it gets denser, with a depth of 300 μm at the densest part.

[0099] <<S13: Conversion to height data and superposition of data of groove-shaped concavo-convex pattern group (B)>> In the process of converting to height data (process S13), the depth F(x, y) of a plurality of independent concave portions (A) obtained in process S12 is converted to the height H1(x1, y1) for producing a corresponding plate to obtain depth data. That is, the height H1(x1, y1) for forming an uneven pattern that is the complementary shape of the concave portion (A) having the depth F(x, y) on the surface of the plate is created. Here, the height H2(x2, y2) for forming an uneven pattern that is complementary to the unevenness of the groove-shaped uneven pattern group (B) having predetermined depth data on the surface of the plate is superimposed on the height H1(x1, y1). The result of superimposing the height H2(x2, y2) on the height H1(x1, y1) is defined as the height H3(x3, y3). If unevenness is formed on the surface of the plate according to this height data H3(x3, y3), the unevenness on the surface of the decorative material shaped by this plate will conform to the height data of the first main surface.

[0100] In this embodiment, when converting the depth F(x, y) to the height H(x, y), the conversion is performed so that it is inverse with the same scale. That is, if "depth" is represented as negative and "height" as positive, then F(x, y) = -H(x, y). However, it is not limited to this, and if necessary for expression, the depth F(x, y) may be converted to the height H(x, y) by multiplying by a predetermined coefficient α. For example, it may be converted as F(x, y) = αH(x, y). Here, α can be either positive or negative. According to this, it is possible to manufacture a plurality of types of decorative materials that give different impressions from the same height data by simply changing α.

[0101] <<S14: Plate production>> In the plate preparation step (S14), a plate with a textured surface is prepared using the height data for the height H3 (x3, y3) obtained in step S13. Here, an embossed plate made with a metal roll is used as an example. More specifically, the embossed plate is prepared as follows.

[0102] First, a metal roll 50, which will eventually become the embossing plate 50, is prepared as shown in Fig. 7. The metal roll 50 may be, for example, a hollow iron cylinder having a rotary drive shaft 51 at both axial ends, the surface of which is plated with a copper layer. The surface of the metal roll 50 is preferably roughened by grinding with a grindstone or the like to prevent a decrease in engraving efficiency due to specular reflection of the engraving laser light.

[0103] Then, as shown schematically in FIG. 7, a laser beam direct engraving machine is used to engrave the surface of the prepared metal roll 50 based on the height data for each coordinate created in step S13. The metal roll 50 is driven by an electric motor via its rotary drive shaft 51, and rotates around the rotary drive shaft 51 as a central axis. At this time, the surface of the metal roll 50 is scanned with light L emitted from a laser head 52. An example of the laser light L is a fiber laser beam with an oscillation wavelength of 1024 nm, a spot diameter of 10 μm, and an output of 360 W. When the surface of the metal roll is scanned with laser light L, the laser light is switched on and off (switching between irradiation and non-irradiation) for each coordinate (x, y) according to the height H3 (x3, y3) created in step S13, and a depression is formed at the irradiation position by evaporating the metal with a single laser light irradiation (the depressions in the plate correspond to the protrusions in the decorative material. Therefore, the higher the coordinate, the fewer times the laser should be irradiated). Under the laser conditions exemplified above, a depression 10 μm deep is formed with a single laser light irradiation. The scanning of the metal roll surface with the laser light is repeated, for example, about 10 times. In order to prevent the evaporated metal from turning into powder and remaining on or adhering to the surface of the metal roll 50, it is preferable to perform the laser light irradiation while spraying the engraving liquid T from the engraving liquid outlet 53 onto the laser light irradiated area on the surface of the metal roll. Thus, by finely engraving the surface of the metal roll 50 with a laser, a metal roll having a shape capable of forming the surface shape of the first main surface can be obtained.

[0104] After engraving the unevenness in this way, it is preferable to wash the engraving liquid and then perform electrolytic polishing to remove the metal residue adhering to the surface of the metal roll 20. And, in order to improve the durability, it is preferable to perform plating treatment such as hard chrome plating on the surface of the metal roll 20. The thickness of the plating layer is usually about 10 μm.

[0105] Through the above steps S11 to S14, a plate 50 (a molding die for a decorative material, an embossing plate in this embodiment) having a shape complementary to the uneven shape of the first main surface of the decorative material can be obtained.

[0106] <<S15: Shaping>> In the shaping step (S15), using the plate (embossing plate) produced in steps S11 to S14, embossing is performed on the decorative material before forming the first main surface to produce the decorative material. The embossing can be performed by any appropriate known method and is not particularly limited. The temperature and pressure during embossing may be appropriately adjusted according to the material of the decorative material. If the base material and the transparent resin layer of the decorative material are polyolefin, it is 140 to 180 °C, 10 to 50 kg / cm 2 or so. Typical methods of embossing are as follows, for example. First, an embossing plate is pressed against the surface of the softened resin base material to form the uneven pattern on the surface of the embossing plate on the surface of the base material. Then, the resin base material is solidified by cooling or light irradiation to fix the uneven pattern on the resin base material. After that, the resin with the uneven pattern formed is released from the embossing plate.

[0107] [Method for manufacturing a decorative material] The method for manufacturing a decorative material of the present invention includes the following steps (1) to (2). (1) A step of shaping a single layer of a substrate selected from a plastic film or a composite of a plastic film and paper, or a laminate including the substrate, with an embossing block to obtain the decorative material of the present invention described above. (2) A step of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in (1) above, and then scraping off the filler ink.

[0108] The decorative material obtained through the above steps (1) and (2) has the colorant filled into at least a portion of the recess (A) in the depth direction, which can improve the design of the decorative material. In particular, X regarding the first main surface of the decorative material obtained in step (1) A , X B , X A -X B , Y A , Y B1 and Y B2 The range of, and D A and D B By selecting at least one embodiment selected from the above-mentioned relationship as the preferred embodiment, the colorant loading amount of the cosmetic material obtained in step (2) satisfies either of the above-mentioned conditions (i) and (ii), the contrast in brightness between the recesses (A) and the recesses constituting the group of groove-shaped parallel uneven patterns (B) becomes higher, and a cosmetic material with a more pronounced three-dimensional effect can be obtained.

[0109] The embossing conditions in step (1) are not particularly limited, and examples thereof include the conditions described in step S15 above.

[0110] Furthermore, the step (2) preferably includes the following steps (2-1) to (2-3). (2-1) A step of placing the decorative material obtained in step (1) along at least a portion of the surface of a roll having a circular cross section, with the first main surface of the decorative material facing away from the roll. (2-2) A step of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in step (1). (2-3) A step of pressing a blade against the first main surface of the decorative material and scraping off the filler ink adhering to the first main surface.

[0111] In step (2-1), the roll material may be metal, rubber, resin, or the like, among which rubber and resin are preferred, and rubber is more preferred. By using a roll material with cushioning properties such as rubber or resin, it is possible to easily prevent the colorant from remaining excessively in the recesses. Furthermore, by using a roll material with cushioning properties such as rubber or resin, it is possible to easily satisfy either of the above conditions (i) or (ii).

[0112] The filling ink in step (2-2) preferably contains a colorant and a binder resin, and optionally a solvent. The higher the viscosity of the filling ink, the more difficult it is to scrape out the ink from the recesses. The lower the viscosity of the filling ink, the more easily the ink from the recesses is scraped out. Therefore, it is preferable to adjust the viscosity of the filling ink appropriately depending on the desired filling amount. It is preferable that the colorant for the filler ink is a dark color.

[0113] In the step (2-3), it is preferable to use a scraping blade such as a doctor blade as a means for scraping off the filler ink. In this case, the direction in which the ink is scraped off is D A Approximately equal to (D A It is preferable to set the angle within ±10 degrees, preferably within ±5 degrees, and more preferably within ±3 degrees relative to the angle. The angle of the blade relative to the first main surface of the decorative material is preferably approximately perpendicular. "Approximately perpendicular" means an angle in the range of 90±10 degrees, preferably 90±5 degrees, and more preferably 90±3 degrees. Note that an angle tilted toward the direction of travel of the decorative material is designated as positive, and an angle tilted away from the direction of travel of the decorative material is designated as negative. The blade may be made of metal, rubber, resin, or the like, with metal being preferred.

[0114] In step (2-3), the pressure with which the blade is applied to the decorative material can be adjusted as appropriate within a range that does not cause streaks or unevenness in the ink. [Example]

[0115] The present invention will now be described in more detail with reference to examples, but the present invention is not limited to these examples. In addition, "parts" are by mass unless otherwise specified.

[0116] 1. Evaluation 1-1. Three-dimensional effect The cosmetic materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting to determine whether or not they gave a three-dimensional effect. AA: 18 or more people answered that the three-dimensional effect was good. A: 15 to 17 people answered that the three-dimensional effect was good. B: 11 to 14 people answered that the three-dimensional effect was good. C: Fewer than 10 people answered that the three-dimensional effect was good.

[0117] 1-2.Natural texture The cosmetic materials obtained in the Examples and Comparative Examples were visually evaluated by 20 random adults under fluorescent lighting to determine whether or not they had a natural texture. AA: More than 18 people answered that it has a natural texture. A: 15 to 17 people answered that it has a natural texture. B: 11 to 14 people answered that it has a natural texture. C: Fewer than 10 people answered that it has a natural texture.

[0118] 2. Making an embossing plate An embossed plate A having a hard chrome-plated surface was produced in accordance with steps S11 to S14 of the specification. Embossed plates B to C were produced in the same manner as plate A, except that the shapes of the recesses (A) and the group of groove-like parallel uneven patterns (B) were changed as shown in Table 1. Embossed plates D to E were produced in the same manner as plate A, except that the group of groove-like parallel uneven patterns (B) was not formed and the shape of the recesses (A) was changed as shown in Table 1.

[0119] 3. Preparation of decorative materials [Example 1] A pattern layer of vessel groove pattern printed in black ink and a pattern layer of wood grain pattern excluding vessel part printed in brown ink were formed on a colored substrate (white polypropylene film with a thickness of 60 μm) by gravure multicolor printing, forming a wood pattern decorative layer with a total thickness of 1 μm. Next, an adhesive layer (polyester resin, thickness: 5 μm) was formed on the decorative layer, and then a transparent resin layer (transparent polypropylene resin sheet, thickness: 80 μm) was laminated on the adhesive layer by extrusion lamination. Next, the transparent resin layer was heated to a softened state, and embossed from the surface on the transparent resin layer side using the embossing plate A prepared in "2" above, to form a concave-convex shape on the surface on the transparent resin layer side (the surface on the first principal surface side). The measured values ​​of the concave-convex shape are shown in Table 1. Furthermore, after applying a dark brown filler ink to the surface on the transparent resin layer side (the surface on the first main surface side), a doctor blade was pressed perpendicularly against the first main surface to scrape off the filler ink, thereby obtaining the decorative material of Example 1. The filler ink was scraped off in the direction of D A The same direction as

[0120] [Examples 2 to 3] The decorative materials of Examples 2 and 3 were obtained in the same manner as in Example 1, except that the embossing plate A was changed to embossing plates B and C.

[0121] [Comparative Examples 1 to 2] Decorative materials of Comparative Examples 1 and 2 were obtained in the same manner as in Example 1, except that embossing plate A was changed to embossing plates D and E.

[0122] [Table 1]

[0123] As shown in Table 1, the decorative materials of the examples can impart an excellent three-dimensional effect and are excellent in expressing natural objects, so it can be confirmed that they have extremely good design properties. [Explanation of symbols]

[0124] 10: Recess (A) 20: Grooved uneven pattern group (B) 20a, 20b, 20c, 20d, 20e, 20f, 20g, 20h, 20i, 20j, 20k, 20l: Grooved uneven pattern 30: Coloring agent 100: Cosmetic materials 50: Plate (embossed plate, metal roll) 51: Rotating drive shaft 52: Laser Head 53: Engraving liquid outlet

Claims

1. A decorative material, the first main surface of the decorative material having a plurality of independent recesses (A) and a group of groove-like parallel uneven patterns (B) arranged in at least a portion of an area where the plurality of independent recesses (A) are not present, the first main surface is located on the outermost surface, The average depth of the plurality of independent recesses (A) is X Ａ The average depth of the recesses of the groove-like parallel uneven patterns (B) is X Ｂ When we define Ｂ <X Ａ Fulfilling the relationship, A decorative material that satisfies at least one of the following formulas (1) and (2), when the average width of the independent recesses (A) is defined as Y A , the average width of the recesses of the group of groove-shaped parallel uneven patterns (B) is defined as Y B1 , and the average width of the convex portions of the group of groove-shaped parallel uneven patterns (B) is defined as Y B2 . Y B1 < Y ​​A (1) Y B2 < Y A (2)

2. A cosmetic material as described in claim 1, which, when satisfying either of the formula (1) and the formula (2), further satisfies either of the following formulas (3) and (4). 0.06≦Y B1 / Y A ≦0.40 (3) 0.10≦Y B2 / Y A ≦1.00 (4)

3. A cosmetic material as described in claim 1, which, when satisfying the formula (1) and the formula (2), further satisfies the following formulas (3) and (4). 0.06≦Y B1 / Y A ≦0.40 (3) 0.10≦Y B2 / Y A ≦1.00 (4) 4. The cosmetic material according to claim 1, wherein X A is 40 to 150 μm and X B is 5 to 100 μm.

5. The decorative material according to claim 1, wherein X A -X B is 20 μm or more.

6. The cosmetic material according to claim 1, wherein Y A is 150 to 500 μm, Y B1 is 10 to 200 μm, and Y B2 is 10 to 250 μm.

7. A decorative material according to any one of claims 1 to 6, wherein when the extension direction of the independent recesses (A) is defined as D A and the extension direction of the group of groove-like parallel uneven patterns (B) is defined as D B , D A and D B are non-parallel.

8. The decorative material according to claim 7, wherein the angle between D A and D B is 5 to 70 degrees.

9. A decorative material described in any one of claims 1 to 8, wherein each of the groove-shaped parallel uneven patterns constituting the group of groove-shaped parallel uneven patterns (B) has a wavy shape when viewed in a plane.

10. A decorative material described in any one of claims 1 to 9, wherein the planar shape of the recess (A) is one or more selected from wood vessels, fall wood, and knots.

11. A cosmetic material described in any one of claims 1 to 10, wherein a colorant is filled in at least a portion of the depth direction of the independent plurality of recesses (A).

12. A cosmetic material as described in claim 11, which satisfies either of the following conditions (i) and (ii). (i) At least a part of the recesses in the groove-like parallel uneven patterns (B) in the depth direction is not filled with colorant. (ii) A colorant is filled into at least a portion of the recesses of the group of groove-like parallel uneven patterns (B) in the depth direction, and when the filling amount of the colorant per unit area is defined as W B and the filling amount of the colorant per unit area filled into at least a portion of the independent plurality of recesses (A) in the depth direction is defined as WA, the relationship W B < WA is satisfied.

13. A method for manufacturing a cosmetic material, comprising the following steps (1) to (2): (1) A process for obtaining the decorative material according to any one of claims 1 to 10 by shaping a single layer of a substrate selected from a plastic film or a composite of a plastic film and paper, or a laminate including the substrate, using an embossing plate. (2) A step of applying a filler ink containing a colorant and a binder resin to the first main surface side of the decorative material obtained in (1), and then scraping off the filler ink.

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