Manufacturing method of decorative panel and decorative panel

Abstract

To provide a method for simply manufacturing a decorative plate which is excellent in uneven feeling.SOLUTION: Step 1: Forming a release layer 20 at a part on one surface side of a first base material 10. An area where the release layer is formed in one surface of the first base material is represented by A1, and an area where the release layer is not formed is represented by A2. A first laminate 100 is obtained by forming a resin layer 30 in the second region. As the first base material, a water-soluble base material or a water-permeable base material is used. Step 2: A second laminate 300 is obtained by overlapping a second base material 200 containing a resin-impregnated base material impregnated with an uncured thermosetting resin on a surface on a side opposite to the side having the release layer of the first laminate. Step 3: Infiltrating a part of the uncured thermosetting resin into a resin layer of the second area by hot pressing the second laminate in the state where both surfaces of the second laminate are sandwiched between mirror surface plates. Step 4: Taking out the second laminate of the mirror surface plates, and a decorative plate is obtained.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a decorative board and a decorative board. [Background technology]

[0002] Decorative laminates excellent in strength, hardness, heat resistance, etc. are sometimes laminated on the surfaces of furniture such as tables and counters, and residential building materials such as walls and floors. Examples of such decorative laminates include thermosetting resin decorative laminates such as high-pressure melamine resin decorative laminates, low-pressure melamine resin decorative laminates, diallyl phthalate resin decorative laminates, polyester decorative laminates, guanamine resin decorative laminates, and phenolic resin decorative laminates.

[0003] Decorative boards such as thermosetting resin decorative boards are required to have a design that conveys a sense of luxury. For example, a textured surface is formed on the surface of the decorative board to impart a visual three-dimensional effect to the decorative board, thereby imparting a sense of luxury to the decorative board. As a decorative board having an uneven surface, an embossed decorative board has been proposed (see, for example, Patent Documents 1 and 2).

[0004] However, the embossing treatments described in Patent Documents 1 and 2 require an embossing plate for each pattern, which increases costs and makes manufacturing difficult. Also, the decorative boards described in Patent Documents 1 and 2 have the problem that it is difficult to synchronize the embossed uneven shape with the pattern, making it difficult to impart a sophisticated design.

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

[0006] [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] International Publication No. 2016 / 148091 DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0007] The decorative board of Patent Document 3 comprises a paper substrate, a release layer containing a cured product of an ionizing radiation-curable resin provided on a portion of the surface of the paper substrate, and a surface layer containing a cured product of a melamine resin provided on the remaining portion of the surface of the paper substrate. The decorative board of Patent Document 3 is manufactured by a method including the steps of providing a release layer on a portion of the surface of the paper substrate, impregnating the paper substrate with an uncured product of melamine resin and coating the release layer with the uncured product of melamine resin, and then heating to thermally cure the uncured product of melamine resin, and peeling off the cured resin layer covering the release layer. As a result, the decorative board of Patent Document 3 has an elevation difference between areas with and without the release layer, forming an uneven surface. The method for producing a decorative board in Patent Document 3 includes a step of obtaining a laminate including a paper substrate, a release layer, and a cured melamine resin layer, and then peeling the cured resin layer covering the release layer from the laminate. The method for producing a decorative board in Patent Document 3 has a problem in that the releasability in the step of peeling the cured resin layer covering the release layer varies depending on the material of the paper substrate. If the releasability varies, it becomes difficult to stabilize the quality of the resulting decorative board. Furthermore, even if the paper substrate is changed, the releasability can be adjusted by changing the material of the other layers that make up the decorative board or by changing the production conditions, but this adjustment requires a great deal of effort.

[0008] The present disclosure has been made under these circumstances, and has an object to provide a method for easily manufacturing a decorative board with an excellent textured appearance, and a decorative board with an excellent textured appearance. [Means for solving the problem]

[0009] In order to solve the above problems, the present disclosure provides the following decorative boards and methods for manufacturing decorative boards [1] and [2]. [1] A method for producing a decorative board, comprising the following steps 1 to 4: Step 1: A release layer is formed on a portion of one surface of a first substrate. Within the one surface of the first substrate, the region where the release layer is formed is designated as a first region, and the region where the release layer is not formed is designated as a second region. A resin layer is formed in the second region on the one surface of the first substrate, thereby obtaining a first laminate having the first substrate, the release layer, and the resin layer. A water-soluble or water-permeable substrate is used as the first substrate. Step 2: A second laminate is obtained by overlaying a second substrate including a resin-impregnated substrate impregnated with an uncured thermosetting resin on the surface of the first laminate opposite to the side having the release layer. Step 3: By sandwiching both sides of the second laminate between mirrored plates and hot pressing, a portion of the uncured thermosetting resin is made to penetrate the first base material, and the portion of the uncured thermosetting resin that has penetrated the first base material is made to soak into the resin layer in the second region. Step 4: The second laminate is removed from between the mirror plates to obtain a decorative board. [2] A decorative laminate having one or more layers on a substrate, The decorative board has a first region and a second region within a surface thereof, A decorative board that satisfies the following conditions 1 and 2, when the outermost surface of the decorative board having one or more layers is defined as the first surface. <Condition 1> When the refractive index of the resin contained in the layer corresponding to the first region among the layers constituting the first surface is defined as n1 and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2, n1≠n2. <Condition 2> With respect to the elevation of the first surface, the difference in elevation between the location corresponding to the first region and the location corresponding to the second region is more than 1.0 μm and not more than 5.0 μm. [Effects of the Invention]

[0010] According to the present disclosure, a decorative board with an excellent textured appearance can be easily manufactured. Also, according to the present disclosure, a decorative board with an excellent textured appearance can be provided. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic perspective view showing one embodiment of a decorative board according to the present disclosure. [Figure 2] 1 is a schematic cross-sectional view showing one embodiment of a decorative board according to the present disclosure. [Figure 3] 1 is a schematic cross-sectional view showing one embodiment of a state in which a first laminate is obtained in the method for producing a decorative board of the present disclosure. [Figure 4] FIG. 2 is a schematic cross-sectional view showing one embodiment of the state in which a second laminate is obtained in the method for producing a decorative board of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] [Decorative panel] The decorative board of the present disclosure has one or more layers on a substrate, has a first region and a second region within the surface of the decorative board, and satisfies the following conditions 1 and 2 when the outermost surface of the decorative board on the side having one or more layers is defined as the first surface. <Condition 1> When the refractive index of the resin contained in the layer corresponding to the first region among the layers constituting the first surface is defined as n1 and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2, n1≠n2. <Condition 2> With respect to the elevation of the first surface, the difference in elevation between the location corresponding to the first region and the location corresponding to the second region is more than 1.0 μm and not more than 5.0 μm.

[0013] Fig. 1 is a schematic perspective view showing one embodiment of a decorative board of the present disclosure, and Fig. 2 is a schematic cross-sectional view showing one embodiment of a decorative board of the present disclosure. The decorative board 500 in Figs. 1 and 2 has a layer 90 on a substrate 80. The decorative board 500 in Figs. 1 and 2 also has a first region A1 and a second region A2 within its surface. In Fig. 1, the symbol S1 indicates the outermost surface of the decorative board on the side having one or more layers. In Fig. 2, the area corresponding to the first region A1 has a release layer 20, a primer layer 30, and a first pattern layer 41 as the layer 90. In Fig. 2, the area corresponding to the second region A2 has a primer layer 30 and a second pattern layer 42 as the layer 90. In Fig. 2, the symbol h indicates the difference in elevation between the elevation of the first surface at the area corresponding to the first region and the elevation of the first surface at the area corresponding to the second region.

[0014] The shape of the decorative board of the present disclosure is not particularly limited. Examples of the shape of the decorative board include a flat plate shape, a shape with a curved surface, a three-dimensional shape, etc. In order to simplify the production of the decorative board, it is preferable that the shape of the decorative board is a flat plate shape.

[0015] The decorative board of the present disclosure must satisfy conditions 1 and 2 when the outermost surface on the side having one or more layers is defined as the first surface.

[0016] <Condition 1> Condition 1 stipulates that when the refractive index of the resin contained in the layer corresponding to the first region among the layers constituting the first surface is defined as n1 and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2, n1 ≠ n2.

[0017] By satisfying condition 1, a difference in surface reflectance between the first region and the second region can be created, resulting in a contrast between the first and second regions. This contrast can improve the texture of the surface of the decorative board even if the elevation difference between the first and second regions is not sufficient.

[0018] The magnitude relationship between n1 and n2 may be such that n1 is larger, or n2 may be larger. Regardless of which of n1 and n2 is larger, a difference in brightness based on the difference in reflectance can be generated between the first region and the second region, thereby improving the textured appearance of the decorative panel surface. In another preferred embodiment, the refractive index of the region at a higher elevation than the first or second region is increased, which makes the region at a higher elevation appear higher, and makes it easier to achieve a more favorable uneven surface appearance for the decorative panel.

[0019] To improve the texture of the surface of the decorative board, it is preferable to increase the difference between n1 and n2. |n1-n2| is preferably 0.02 or more, more preferably 0.05 or more, more preferably 0.07 or more, more preferably 0.10 or more, and more preferably 0.12 or more. In order to increase the degree of freedom in the combination of the resin constituting the first region and the resin constituting the second region, and to make it easier to maintain the practical strength of the decorative panel, |n1-n2| is preferably 0.20 or less, more preferably 0.18 or less, and even more preferably 0.16 or less. n1 and n2 can be determined, for example, by the method described in the Examples. In this specification, unless otherwise specified, the refractive index difference refers to the refractive index at a wavelength of 589 nm.

[0020] The values ​​of n1 and n2 can be adjusted by the type of resin contained in the layer that corresponds to the first region among the layers that make up the first surface, and the type of resin contained in the layer that corresponds to the second region among the layers that make up the first surface. In the manufacturing method of the decorative board of the present disclosure, described later, a portion of the uncured thermosetting resin that has penetrated the first substrate penetrates into the resin layer in the second region. Therefore, the layer that corresponds to the second region among the layers that make up the first surface contains uncured thermosetting resin. Meanwhile, in the first region, the release layer inhibits penetration of the uncured thermosetting resin that has penetrated the first substrate. Therefore, the layer that corresponds to the first region among the layers that make up the first surface contains almost no uncured thermosetting resin. In this way, a difference is created between n1 and n2 in the manufacturing method of the decorative board of the present disclosure, described later.

[0021] The reason why a difference occurs between the surface reflectance of the first region and the surface reflectance of the second region when Condition 1 is satisfied will be explained below.

[0022] When the refractive index of air is n0 and the angle of incidence of light from air to the surface of the first region is φ0, the surface reflectance R1 of the first region can be expressed by the following formulas 1' and 1'' from n0, n1, and φ0. R1 P , R1 S are the reflectance for the P-polarized light component and the reflectance for the S-polarized light component, respectively. R1 P =tan 2 {φ0-sin -1 (n0sinφ0 / n1)} / tan 2 {φ0+sin -1 (n0sinφ0 / n1)} [Formula 1'] R1 S =sin 2 (φ0-sin -1 (n0sinφ0 / n1)) / sin 2 (φ0+sin -1 (n0sinφ0 / n1)) [Formula 1'']

[0023] The above formula is well known in the field of optics and is described in, for example, the following documents. "Science Library Physics = 9 Optics" September 30, 1980, first edition, second printing, published by Science Publishing Co., Ltd., pages 20-29

[0024] Similarly, if the incident angle of light from the air to the surface of the second region is φ0, the surface reflectance R1 of the second region can be expressed by the following formulas 2' and 2'' using n0, n2, and φ0. R2 P , R2 S are the reflectance for the P-polarized light component and the reflectance for the S-polarized light component, respectively. R2 P =tan 2 {φ0-sin -1 (n0sinφ0 / n2)} / tan 2 {φ0+sin -1 (n0sinφ0 / n2)} [Formula 2'] R2S = sin 2 (φ0 - sin -1 (n0sinφ0 / n2)) / sin 2 (φ0 + sin -1 (n0sinφ0 / n2)) [Equation 2’’]

[0025] When the incident angle φ0 of light to the first region and the second region is 0 degrees, the distinction between P-polarized light and S-polarized light disappears, and the reflectance of the first region and the reflectance of the second region can be expressed by the following Equation 1’’’ and Equation 2’’’.

[0026] The reflectance R1 of light on the surface of the first region = (n1 - n0) / (n1 + n0) [Equation 1’’’] The reflectance R2 of light on the surface of the second region = (n2 - n0) / (n2 + n0) [Equation 2’’’]

[0027] Since the refractive index of air is approximately 1, approximating n0 = 1, [Equation 1’’’] and [Equation 2’’’] can be further approximated by the following Equation 1A and Equation 2A. The reflectance R1 of light on the surface of the first region = (n1 - 1) / (n1 + 1) [Equation 1A] The reflectance R2 of light on the surface of the second region = (n2 - 1) / (n2 + 1) [Equation 2A]

[0028] As is clear from the above equations, when n1 < n2, R1 < R2, and when n1 > n2, R1 > R2.

[0029] <Condition 2> In Condition 2, regarding the elevation of the first surface, it is defined that the elevation difference between the elevation of the portion corresponding to the first region and the elevation of the portion corresponding to the second region is more than 1.0 μm and 5.0 μm or less.

[0030] If the elevation of the surface of the decorative board is too uniform, the decorative board is likely to be felt like an artificial object. Therefore, in Condition 2, by setting the elevation difference to more than 1.0 μm, the artificial object feeling can be suppressed and it can be easily felt like a natural object. If there is too much difference in elevation on the surface of the decorative board, the appearance of the unevenness based on the refractive index difference in condition 1 may be impaired. Therefore, in condition 2, by setting the elevation difference to 5.0 μm or less, the unevenness of the surface of the decorative board can be improved. Furthermore, if the difference in elevation on the surface of the decorative sheet is too great, dirt tends to accumulate in the recesses on the surface of the decorative sheet, which tends to reduce the stain resistance. Therefore, in condition 2, it is preferable to set the difference in elevation to 5.0 μm or less, as this makes it easier to improve the stain resistance. The difference in elevation in condition 2 is preferably 1.5 μm or more and 4.5 μm or less, and more preferably 2.0 μm or more and 4.0 μm or less.

[0031] In this specification, "altitude" refers to the thickness direction of the decorative board. In Figures 1 and 2, the z direction corresponds to the thickness direction of the decorative board. In Figure 2, the symbol h indicates the altitude difference under Condition 2. The difference between the elevation of the first region and the elevation of the second region can be determined, for example, by the method described in the Examples.

[0032] The elevation of the first region may be higher than that of the second region, or the elevation of the second region may be higher. Regardless of whether the elevation of the first region or the elevation of the second region is higher, by satisfying conditions 1 and 2, the texture of the surface of the decorative board can be improved. The elevation difference in condition 2 can be adjusted by the difference between the total thickness of the layers formed in the first region and the total thickness of the layers formed in the second region.

[0033] <Arrangement of the first and second areas> The first and second regions may be arranged arbitrarily within the surface of the decorative sheet, but it is preferable that the areas and patterns of both regions are as follows, for example.

[0034] -area- On the first surface of the decorative board, the area of ​​the first region is defined as S1, and the area of ​​the second region is defined as S2. The ratio of S1 and S2 to the first surface of the decorative board can be adjusted depending on the desired design. The ratio of the total area of ​​S1 and S2 to the total area of ​​the first surface is preferably 80% or more, more preferably 90% or more, and most preferably 100%, in order to improve the texture.

[0035] The ratio of S1 to S2 [S1 / S2] can be adjusted depending on the desired design, but in order to achieve a better sense of unevenness, it is preferably 0.10 or more and 9.00 or less, more preferably 0.25 or more and 4.00 or less, and even more preferably 0.40 or more and 2.50 or less.

[0036] -Pattern, pattern- In order to enhance the design, it is preferable that a predetermined pattern be formed by the two regions, the first region and the second region. Examples of the predetermined pattern include wood grain patterns, marquetry patterns, stone patterns, tile patterns, fabric patterns, leather patterns, sand grain patterns, geometric patterns, etc. For example, by using a wood grain conduit pattern as the pattern of the first region and a wood grain pattern as the pattern of the second region, a wood grain pattern can be formed by combining the patterns of the two regions. In order to enhance the design of the pattern, it is preferable that the first region or the second region has a pattern layer, and it is more preferable that the first region and the second region have a pattern layer.

[0037] There are no particular limitations on the width and length of the first and second regions, and they may be determined appropriately depending on the design.

[0038] <Layer configuration> The decorative laminate of the present disclosure has one or more layers on a substrate. It is preferable that the one or more layers have different layer structures in the first region and the second region. Examples of the layer structure of the first region include X1 to X8 below. Examples of the layer structure of the second region include Y1 to Y3 below. The following X1 to X8 and the following Y1 to Y3 can be combined, respectively. However, the layer structures of the first region and the second region are not limited to the following layer structures. -Embodiment of Layer Configuration of First Region- X1: Single layer release layer X2: A layer structure having a release layer and a pattern layer in this order from the substrate side. X3: A layer structure having a release layer and a primer layer in this order from the substrate side. X4: A layer structure having a release layer, a primer layer, and a pattern layer in this order from the substrate side. X5: A layer structure having a primer layer and a release layer in this order from the substrate side. X6: A layer structure having a primer layer, a release layer, and a pattern layer in this order from the substrate side. X7: A layer structure having a primer layer, a release layer and another primer layer in this order from the substrate side. X8: Layer structure having, from the substrate side, a primer layer, a release layer, a primer layer, and a pattern layer in this order. -Embodiment of Layer Configuration of Second Region- Y1: Single layer structure of the picture layer Y2: Single layer primer layer Y3: A layer structure having a primer layer and a pattern layer in this order from the substrate side.

[0039] 《First area》 The first region preferably has a release layer. When the first region has two or more layers, the release layer is preferably located closest to the substrate. A primer layer may be provided between the substrate and the release layer to enhance adhesion. The release layer can prevent the uncured thermosetting resin contained in the substrate from seeping in during the manufacturing process of the decorative laminate. Therefore, by having a release layer in the first region, the uncured thermosetting resin is prevented from seeping into the first region, while the uncured thermosetting resin is more likely to seep into the second region. This allows the resin composition contained in the layer corresponding to the first region and the resin composition contained in the layer corresponding to the second region to be different from each other, making it easier to satisfy condition 1.

[0040] -Release layer- The release layer preferably contains a cured product of an ionizing radiation curable resin composition. When the release layer contains a cured product of the ionizing radiation curable resin composition, it becomes easier to prevent the uncured thermosetting resin from seeping into the first region, and condition 1 can be more easily satisfied.

[0041] The proportion of the cured product of the ionizing radiation curable resin composition relative to the total solid content of the release layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and even more preferably 95% by mass or more.

[0042] 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 undergoes crosslinking and curing 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. Furthermore, the ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules, and typically includes ultraviolet (UV) rays or electron beams (EB), but also includes other types of electromagnetic waves such as X-rays and gamma rays, as well as charged particle beams such as alpha rays and ion beams.

[0043] The ionizing radiation curable compound can be appropriately selected from polymerizable monomers and polymerizable oligomers that are commonly used as ionizing radiation curable compounds.

[0044] 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. From the viewpoint of obtaining design properties with a higher texture and better surface properties, acrylate monomers having an acryloyl group are preferred.

[0045] In order to obtain a design with a higher quality texture and better surface properties, the number of functional groups in the polyfunctional (meth)acrylate is preferably 2 or more, and the upper limit is preferably 8 or less, more preferably 6 or less, even more preferably 4 or less, and particularly preferably 3 or less. These polyfunctional (meth)acrylates may be used alone or in combination of two or more types.

[0046] Preferred examples of the polymerizable monomer include bifunctional (meth)acrylates such as ethylene glycol di(meth)acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate; and trifunctional or higher (meth)acrylates such as trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and isocyanuric acid-modified tri(meth)acrylate. Among these, in order to obtain a design with a higher quality texture and better surface properties, dipentaerythritol-based polymerizable monomers such as dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate are preferred, dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate are more preferred, and it is particularly preferred to use dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate in combination.

[0047] 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. Examples include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, acrylic (meth)acrylate oligomers, polycaprolactone urethane (meth)acrylate oligomers, and polycaprolactone diol urethane (meth)acrylate.

[0048] In order to obtain a design with a higher quality texture and better surface properties, the number of functional groups of the polymerizable oligomer is preferably 2 or more, and the upper limit is preferably 8 or less, more preferably 6 or less, even more preferably 4 or less, and particularly preferably 3 or less.

[0049] The weight-average molecular weight of the polymerizable oligomer is preferably 500 or more, more preferably 1,000 or more, in order to achieve a design with a higher texture and better surface properties, and to facilitate the formation of a release layer, and the upper limit is preferably 80,000 or less, more preferably 50,000 or less. In this specification, the weight-average molecular weight is the average molecular weight measured by GPC analysis and converted into standard polystyrene.

[0050] When the ionizing radiation curable resin composition is of an ultraviolet curable type, the ionizing radiation curable resin composition preferably contains a photopolymerization initiator.

[0051] The release layer preferably contains a reactive release agent such as a reactive silicone compound or a reactive fluorine compound. When the release layer contains a reactive release agent, it is possible to more easily prevent the uncured thermosetting resin from seeping into the first region, making it easier to satisfy condition 1. Among reactive release agents, a reactive silicone compound is preferred.

[0052] The reactive silicone compound may have a polysiloxane structure as a basic structure and further have at least one reactive functional group, which is preferably an ionizing radiation-curable functional group.

[0053] The reactive silicone compound is preferably a modified silicone oil having an organic group introduced into at least one of its side chains and terminals, and more preferably a modified silicone oil having an organic group introduced into both terminals. From the viewpoint of achieving a more sophisticated design, preferred examples of the organic group include reactive functional groups such as (meth)acrylic groups, amino groups, epoxy groups, mercapto groups, carbinol groups, phenol groups, and carboxyl groups, and non-reactive functional groups such as polyether groups, aralkyl groups, fluoroalkyl groups, alkyl groups, fatty acid amide groups, and phenyl groups. Among these, reactive functional groups are preferred, and (meth)acrylic groups are particularly preferred, i.e., (meth)acrylic-modified silicone oils are particularly preferred. Furthermore, these organic groups may have substituents such as nitrogen atoms, sulfur atoms, hydroxyl groups, and alkyl groups.

[0054] The content of the reactive release agent is preferably 0.1% by mass or more and 5% by mass or less, more preferably 0.5% by mass or more and 3% by mass or less, and even more preferably 0.8% by mass or more and 2% by mass or less, based on the total amount of the resin components forming the release layer. When the content of the reactive release agent is within the above range, the effect of adding the reactive release agent can be efficiently obtained.

[0055] The release layer may contain fillers such as inorganic fillers and organic fillers.

[0056] The release layer may further contain additives such as an ultraviolet absorber, a light stabilizer, an infrared absorber, an antistatic agent, a leveling agent, and an antifoaming agent.

[0057] Since no release layer is formed in the second region, the thickness of the release layer has a large effect on the height difference in condition 2. For this reason, it is preferable to adjust the thickness of the release layer within a range that satisfies condition 2. The thickness of the release layer is preferably 0.5 μm or more and 7.0 μm or less, more preferably 1.1 μm or more and 6.0 μm or less, and even more preferably 1.5 μm or more and 5.0 μm or less.

[0058] -Primer layer- The first region may have a primer layer. The primer layer is preferably located on the opposite side of the release layer from the substrate. When the first region further has a design layer, it preferably has the release layer, primer layer, and design layer in this order from the substrate side. The primer layer is formed, for example, to improve the adhesion between the release layer and the design layer. In order to improve the adhesion between the substrate and the release layer, a primer layer may be formed between the substrate and the release layer.

[0059] Examples of resin materials for forming the primer layer include urethane resin, polyester resin, acrylic resin, acrylic urethane resin, and vinyl chloride-vinyl acetate copolymer resin.

[0060] To improve adhesion, the primer layer preferably does not substantially contain a cured product of the ionizing radiation-curable resin composition. Furthermore, by not substantially containing a cured product of the ionizing radiation-curable resin composition, it becomes easier to allow the uncured thermosetting resin to penetrate into the primer layer in the second region, making it easier to satisfy condition 1. In this specification, "the primer layer is substantially free of the cured product of the ionizing radiation-curable resin composition" means that the proportion of the cured product of the ionizing radiation-curable resin composition relative to the total solid content of the primer layer is 1% by mass or less, preferably 0.1% by mass or less, more preferably 0.01% by mass or less, and even more preferably no cured product at all.

[0061] The thickness of the primer layer is preferably 0.1 μm or more and 10 μm or less, more preferably 0.3 μm or more and 5 μm or less, and even more preferably 0.5 μm or more and 3 μm or less.

[0062] -Picture layer- The first region may have a design layer. The design layer is preferably located on the opposite side of the release layer from the substrate. When the first region further has a primer layer, it preferably has the release layer, primer layer, and design layer in this order from the substrate side. In this specification, the design layer in the first region may be referred to as the first design layer, and the design layer in the second region may be referred to as the second design layer.

[0063] To enhance the design, it is preferable that the pattern of the first design layer be synchronized with the pattern of the release layer. For example, if the gravure printing plate forming the release layer and the gravure printing plate forming the first design layer have the same pattern, it is possible to easily synchronize the release layer and the first design layer. It is preferable that the pattern of the second design layer be a pattern complementary to the pattern of the release layer.

[0064] The design layer can be formed, for example, by printing using a design layer ink containing a colorant and a binder resin.

[0065] Examples of colorants include inorganic pigments such as carbon black, iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; luster pigments such as pearl pigments, metal particles, and metal flakes; organic pigments such as quinacridone red, isoindolinone yellow, nickel-azo complexes, and phthalocyanine blue; and dyes. Examples of binder resins include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymer resins, polyvinyl butyral resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, cellulose derivatives, and rubber resins.

[0066] It is preferable that the design layer is substantially free of a cured product of the ionizing radiation curable resin composition. By not including a cured product of the ionizing radiation curable resin composition in the design layer, it becomes easier to allow the uncured thermosetting resin to penetrate into the design layer in the second region, making it easier to satisfy condition 1. In this specification, "the design layer is substantially free of the cured product of the ionizing radiation curable resin composition" means that the proportion of the cured product of the ionizing radiation curable resin composition relative to the total solid content of the design layer is 1% by mass or less, preferably 0.1% by mass or less, more preferably 0.01% by mass or less, and even more preferably completely free.

[0067] The thickness of the pattern layer can be adjusted appropriately within the range of about 0.1 μm to 20 μm, taking into consideration the desired design.

[0068] 《Second area》 The second region preferably has at least one selected from a primer layer and a design layer. Because the second region does not have a release layer, the uncured thermosetting resin can easily penetrate the primer layer and the design layer in the second region. Therefore, among the layers constituting the first surface, the resin composition contained in the layer corresponding to the first region can be made different from the resin composition contained in the layer corresponding to the second region, making it easier to satisfy condition 1.

[0069] The layer configuration of the second region may be a single layer configuration of a design layer, a single layer configuration of a primer layer, or a laminated configuration having a primer layer and a design layer in this order from the substrate side. The embodiment of the design layer in the second region and the embodiment of the primer layer in the second region are the same as the embodiment of the design layer in the first region and the embodiment of the primer layer in the first region. The design layer and primer layer of the second region preferably contain a cured product of the thermosetting resin contained in the base material.

[0070] <Base material> The substrate is preferably one that can be impregnated with uncured thermosetting resin during the manufacturing process of the decorative board. Examples of the substrate include paper substrates, fiber substrates, and resin substrates. Among these, paper substrates and fiber substrates, which are easily impregnated with resin, are preferred, and paper substrates are more preferred.

[0071] Examples of paper substrates include kraft paper, titanium paper, linter paper, resin-impregnated paper, tissue paper, and Japanese paper. Examples of the fiber substrate include nonwoven fabrics and woven fabrics, and examples thereof include fiber substrates made of inorganic fibers such as glass fibers, alumina fibers, silica fibers, and carbon fibers, fiber substrates made of organic fibers of various synthetic resins such as polyester resins, acrylic resins, polyethylene resins, and polypropylene resins, and composites of these.

[0072] The thickness of the substrate is preferably 10 μm or more and 200 μm or less, more preferably 20 μm or more and 150 μm or less, and even more preferably 30 μm or more and 120 μm or less, in terms of impregnation with the uncured thermosetting resin, mechanical strength, and handleability. When a paper substrate is used as the substrate, the basis weight is 20 g / m or less for the same purpose. 2 More than 150g / m 2 Preferably less than 30 g / m 2 More than 100g / m 2 The following is the result.

[0073] In a preferred embodiment of the decorative board of the present disclosure, the substrate is impregnated with an uncured thermosetting resin during the manufacturing process of the decorative board, resulting in a resin-impregnated substrate. During the manufacturing process of the decorative board, some of the thermosetting resin remains in the substrate and hardens, while the other thermosetting resin penetrates into the primer layer or the pattern layer and hardens. This creates a refractive index difference between the first and second regions of the decorative board of the present disclosure, making it easier to achieve high design potential and improve mechanical strength.

[0074] Preferred examples of the curable resin to be impregnated into the substrate include melamine resin, urea resin, melamine-urea resin, guanamine resin, diallyl phthalate resin, polyester resin, phenol resin, epoxy resin, aminoalkyd resin, silicon resin, and polysiloxane resin. Among these, thermosetting resins such as melamine resin, urea resin, melamine-urea resin, guanamine resin, and sulfonamide resin are preferred. Furthermore, among thermosetting resins, melamine resin, melamine-urea resin, and phenol resin are preferred, with melamine resin being particularly preferred.

[0075] When using a melamine resin as the curable resin, the difference in the penetration of the melamine resin between the first region and the second region can be evaluated by the following method. Among the layers constituting the first surface, the content of the triazine skeleton contained in the layer corresponding to the first region is defined as TA1, and the content of the triazine skeleton contained in the layer corresponding to the second region is defined as T2. If TA1 < T2, it can be said that more melamine resin has penetrated into the layer corresponding to the second region among the layers constituting the first surface. Even when using a resin other than the melamine resin as the curable resin, by quantitatively analyzing the content of the skeleton peculiar to the resin, the difference in the penetration of the curable resin between the first region and the second region can be evaluated. The uncured thermosetting resin described above is preferably a cured product of the thermosetting resin at the time of completion of the decorative board.

[0076] <Core layer> The decorative board of the present disclosure may have a core layer on the side opposite to one or more layers of the base material in order to increase the strength of the decorative board.

[0077] Examples of the core layer include a fiber base material or a paper base material impregnated with an uncured resin composition containing an uncured product of a thermosetting resin. Examples of the types of the fiber base material and the paper base material used for the core layer include those exemplified as the base material described above. The basis weight of the fiber base material and the paper base material used for the core layer is preferably 100 g / m 2 to 300 g / m 2 or less, more preferably 150 g / m 2 to 250 g / m 2 or less. Examples of the thermosetting resin for the core layer include the same ones as those exemplified as the thermosetting resin to be impregnated into the base material. Among the thermosetting resins, a phenol resin is preferable. That is, as the core layer, a phenol resin-impregnated paper is preferable.

[0078] Examples of the phenol resin-impregnated paper include, for example, a basis weight of 150 g / m 2 to 250 g / m2 Examples of such a product include those produced by impregnating the following kraft paper with a phenolic resin to an impregnation rate of 20% to 60% and drying the impregnated paper at 100°C to 140°C.

[0079] <Water-soluble or water-permeable substrate> The decorative laminate of the present disclosure may have a water-soluble or water-permeable substrate between the substrate and one or more layers. The water-soluble or water-permeable substrate serves as a support when forming, for example, a release layer, a primer layer, and a pattern layer. Furthermore, the water-soluble or water-permeable substrate can allow the uncured thermosetting resin contained in the substrate to permeate. Therefore, even if a water-soluble or water-permeable substrate is present between the substrate and one or more layers, Condition 1 can be satisfied. In addition, to facilitate permeation through the water-soluble or water-permeable substrate, the uncured thermosetting resin is preferably dispersed in a liquid containing water.

[0080] Among the water-soluble substrates and the water-permeable substrates, the water-soluble substrates are preferred in that they have less color and therefore do not affect the design formed by the design layer.

[0081] -Water-soluble base material- The water-soluble substrate can be any substrate that is water-soluble or water-swellable, and is capable of permeating an aqueous dispersion of an uncured thermosetting resin by dissolving or swelling in water.

[0082] Examples of resins that constitute the water-soluble base material include various water-soluble resins such as polyvinyl alcohol resin, dextrin, gelatin, glue, casein, shellac, gum arabic, starch, protein, polyacrylic acid amide, sodium polyacrylate, polyvinyl methyl ether, methyl vinyl ether-maleic anhydride copolymer, vinyl acetate-itaconic acid copolymer, polyvinylpyrrolidone, acetyl cellulose, acetyl butyl cellulose, carboxymethyl cellulose, methyl cellulose, hydroxyethyl cellulose, and sodium alginate. These resins may be used alone or in combination of two or more. The water-soluble base material may contain a rubber component such as mannan, xanthan gum, or guar gum added to the water-soluble resin.

[0083] Among the above-mentioned resins, polyvinyl alcohol is preferred. That is, the water-soluble substrate is preferably a polyvinyl alcohol film. The polyvinyl alcohol film may contain additives such as starch and rubber. The strength, solubility in water, and permeability of the uncured thermosetting resin of the polyvinyl alcohol film can be adjusted by changing the degree of polymerization and saponification of the polyvinyl alcohol and the amount of additives added.

[0084] The thickness of the water-soluble base material is preferably 10 μm or more and 100 μm or less, more preferably 20 μm or more and 60 μm or less, and even more preferably 30 μm or more and 50 μm or less. When the thickness of the water-soluble base material is 10 μm or more, the uniformity of the film is good and production stability is high.When the thickness of the water-soluble base material is 100 μm or less, the uncured thermosetting resin can easily permeate through the film.

[0085] After the production of the decorative board is completed, the state and composition of the water-soluble substrate may differ from the original composition. For example, after the production of the decorative board is completed, the water-soluble substrate may contain a cured product of the thermosetting resin contained in the substrate. Furthermore, after the production of the decorative board is completed, some of the water-soluble resin constituting the water-soluble substrate may have soaked into the pattern layer and primer layer of the second region.

[0086] -Water permeable base material- The water-permeable substrate is preferably one that can transmit the aqueous dispersion of the uncured thermosetting resin, and examples thereof include paper and fiber, with paper being preferred because it is easy to improve the suitability for coating.

[0087] The paper used as the water-permeable substrate has a basis weight of 20 g / m 2 More than 100g / m 2 Preferably, it is 25 g / m or less.2 More than 80g / m 2 More preferably, it is 30 g / m or less. 2 More than 60g / m 2 It is even more preferable that: Paper basis weight: 20 g / m 2 By setting the basis weight of the paper to 100 g / m or more, it is possible to improve the coating suitability. 2 By setting the temperature as follows, it is possible to easily improve the permeability of the aqueous dispersion of the uncured thermosetting resin.

[0088] After the production of the decorative board is completed, the state and composition of the water-permeable substrate may differ from the initial composition. For example, after the production of the decorative board is completed, the water-permeable substrate may contain a cured product of the thermosetting resin contained in the substrate.

[0089] <Adherent material> The decorative board of the present disclosure may be laminated and integrated with an adherend. The adherend is preferably located on the opposite side of the substrate from the one or more layers. Examples of the adherend include wood boards, cement boards, ceramic boards, metal boards, resin boards, and FRP boards.

[0090] <Application> The decorative board of the present disclosure has an excellent texture. Furthermore, the decorative board of the present disclosure is also easily stain-resistant. Therefore, the decorative board of the present disclosure can be used as it is, or after being molded, for interior and exterior building materials such as countertops, desk tops, furniture, kitchen cabinets, and doors.

[0091] [Manufacturing method of decorative panels] The method for producing a decorative board of the present disclosure includes the following steps 1 to 4. Step 1: A release layer is formed on a portion of one surface of a first substrate. Within the one surface of the first substrate, the region where the release layer is formed is designated as a first region, and the region where the release layer is not formed is designated as a second region. A resin layer is formed in the second region on the one surface of the first substrate, thereby obtaining a first laminate having the first substrate, the release layer, and the resin layer. A water-soluble or water-permeable substrate is used as the first substrate. Step 2: A second laminate is obtained by overlaying a second substrate including a resin-impregnated substrate impregnated with an uncured thermosetting resin on the surface of the first laminate opposite to the side having the release layer. Step 3: By sandwiching both sides of the second laminate between mirrored plates and hot pressing, a portion of the uncured thermosetting resin is made to penetrate the first base material, and the portion of the uncured thermosetting resin that has penetrated the first base material is made to soak into the resin layer in the second region. Step 4: The second laminate is removed from between the mirror plates to obtain a decorative board.

[0092] Steps 1 to 4 will be described below with reference to FIGS.

[0093] <Process 1> In step 1, a release layer 20 is formed on a portion of one surface of a first substrate 10. Within the one surface of the first substrate, the region where the release layer is formed is referred to as a first region, and the region where the release layer is not formed is referred to as a second region. In Figures 3 and 4, symbol A1 corresponds to the first region, and symbol A2 corresponds to the second region.

[0094] In step 1, the embodiment of the relationship between the first region and the second region is the same as the embodiment of the relationship between the first region and the second region in the decorative board described above. As described above, the embodiment of the relationship between the first region and the second region includes the arrangement, area ratio, etc. of the first region and the second region.

[0095] The embodiment of the release layer formed in step 1 is the same as the embodiment of the release layer in the decorative sheet described above. For example, the release layer formed in step 1 preferably contains a cured product of an ionizing radiation curable resin composition. The ionizing radiation curable resin composition of the release layer is preferably cured at least before starting step 3, and more preferably cured immediately after applying the ink for the release layer in step 1.

[0096] The release layer can be formed by applying a release layer ink containing the components constituting the release layer to the first substrate, and drying and curing it as necessary. Examples of the application method include general-purpose application methods such as gravure coating, bar coating, roll coating, reverse roll coating, and comma coating. In step 1, the release layer is preferably formed before the resin layer. In order to improve the adhesion between the first substrate and the release layer, a primer layer may be formed on the first substrate before forming the release layer. In this case, the primer layer may be formed only in the first region, but it is preferable to form it in both the first and second regions.

[0097] Furthermore, in step 1, a resin layer is formed in the second region on the one surface side of the first substrate 10. The resin layer may be formed only in the second region, or may be formed in the second region and the first region. When forming a resin layer in the first region, it is preferable that the resin layer be formed on the release layer in the first region. In other words, when forming a resin layer in the first region, it is preferable that the resin layer be formed on the side of the release layer opposite the first substrate. 3 and 4, the primer layer 30 and the design layer 40 correspond to the resin layer. In Fig. 3 and 4, the resin layer is formed in the second region and the first region.

[0098] The ratio of the area of ​​the resin layer formed in the second region to the total area of ​​the second region (area of ​​the resin layer formed in the second region / total area of ​​the second region) is preferably 0.80 or more, more preferably 0.90 or more, even more preferably 0.95 or more, and most preferably 1.00.

[0099] In step 1, it is preferable to form at least one resin layer selected from a primer layer and a design layer. When a primer layer and a design layer are formed as the resin layer, it is preferable to form the primer layer and the design layer in this order from the first substrate side.

[0100] The embodiments of the primer layer and the design layer formed in step 1 are the same as those of the primer layer and the design layer in the decorative board described above. Resin layers such as the primer layer and the design layer can be formed by applying an ink containing the components constituting each layer, followed by drying and curing as necessary. Coating methods include general-purpose coating methods such as gravure coating, bar coating, roll coating, reverse roll coating, and comma coating.

[0101] In step 1, a water-soluble substrate or a water-permeable substrate is used as the first substrate. The water-soluble substrate or the water-permeable substrate serves as a support when forming the release layer and the resin layer in step 1. In addition, the water-soluble substrate or the water-permeable substrate has the property of allowing a portion of the uncured thermosetting resin to pass through in step 3.

[0102] The embodiments of the water-soluble substrate or water-permeable substrate used in step 1 are the same as those of the water-soluble substrate or water-permeable substrate in the decorative board described above. Some embodiments of the water-soluble substrate or water-permeable substrate used in step 1 will be explained below for completeness.

[0103] In step 1, among water-soluble substrates and water-permeable substrates, water-soluble substrates are preferred because they have less color and therefore are less likely to affect the design formed by the pattern layer. Furthermore, among water-soluble substrates, polyvinyl alcohol film is preferred.

[0104] Examples of the water-permeable substrate include paper and fiber, with paper being preferred because it is easy to make the substrate suitable for coating.

[0105] The paper used as the water-permeable substrate has a basis weight of 20 g / m 2 More than 100g / m2 Preferably, it is 25 g / m or less. 2 More than 80g / m 2 More preferably, it is 30 g / m or less. 2 More than 60g / m 2 It is even more preferable that:

[0106] By the above-described step 1, a first laminate 100 having a first substrate, a release layer, and a resin layer is obtained.

[0107] <Process 2> In step 2, as shown in FIG. 4, a second substrate 200 including a resin-impregnated substrate 201 impregnated with an uncured thermosetting resin is superimposed on the side of the first laminate 100 opposite to the side having the release layer 20, thereby obtaining a second laminate 300.

[0108] 《Second base material》 The second substrate includes a resin-impregnated substrate impregnated with an uncured thermosetting resin. Examples of resin-impregnated substrates impregnated with an uncured thermosetting resin include substrates that are easily impregnated with a resin, such as paper substrates and fiber substrates, impregnated with an uncured thermosetting resin. The resin-impregnated substrate can be obtained by, for example, immersing a substrate that is easily impregnated with a resin, such as a paper substrate or fiber substrate, in a composition containing an uncured thermosetting resin.

[0109] The composition containing the uncured thermosetting resin may contain components other than the uncured thermosetting resin. Examples of components other than the uncured thermosetting resin include additives such as ultraviolet absorbers and light stabilizers, thermoplastic resins, solvents, and water. The composition containing the uncured thermosetting resin preferably contains water. That is, the composition containing the uncured thermosetting resin is preferably an aqueous dispersion of the uncured thermosetting resin. The curable resin preferably accounts for 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and even more preferably 100% by mass of the total resin amount of the composition containing the uncured thermosetting resin. The uncured thermosetting resin is preferably cured by the time the decorative board is completed. For example, the uncured thermosetting resin can be cured by Step 3 described below.

[0110] The paper substrate and fiber substrate that are the materials for the second substrate are similar to the paper substrate and fiber substrate that can be impregnated with uncured thermosetting resin, as exemplified above in the substrate of the decorative board of the present disclosure. The embodiment of the uncured thermosetting resin that is the material of the second substrate is the same as the embodiment of the uncured thermosetting resin that is impregnated into the substrate exemplified in the substrate of the decorative board of the present disclosure described above.

[0111] The second substrate 200 may be a laminated substrate having a resin-impregnated substrate 201 on a core layer 202 . The embodiment of the core layer, which is the material of the second substrate, is the same as the embodiment of the core layer exemplified in the decorative board of the present disclosure described above.

[0112] <Process 3> In step 3, the second laminate is sandwiched between mirrored plates and heat-pressed to allow a portion of the uncured thermosetting resin to penetrate the first substrate, and also allows a portion of the uncured thermosetting resin that has penetrated the first substrate to soak into the resin layer in the second region.

[0113] In step 3, first, a portion of the uncured thermosetting resin is extruded from the resin-impregnated substrate. Then, a portion of the uncured thermosetting resin that has permeated the first substrate soaks into the resin layer in the second region. On the other hand, in step 3, the uncured thermosetting resin that has permeated the first substrate hardly soaks into the release layer in the first region. Therefore, the decorative board obtained by the decorative board manufacturing method of the present disclosure can create a refractive index difference on the surface of the decorative board, and can improve the texture of the surface of the decorative board.

[0114] The uncured thermosetting resin can be cured during step 3. The cured thermosetting resin is contained in, for example, the resin layer of the second region, the first substrate, or the second substrate.

[0115] The pressure of the heat press is 10 kg / cm 2 More than 300kg / cm 2 It is preferable that the resistance is 50 kg / cm or less. 2 More than 200kg / cm 2 More preferably, it is 80 kg / cm or less. 2 More than 150kg / cm 2 By performing heat pressing within this range, the uncured thermosetting resin penetrates into the resin layer in the second region, and the penetration of the uncured thermosetting resin into the release layer in the first region is suppressed, making it easier to create a refractive index difference between the first region and the second region. To obtain excellent mechanical strength, the heat pressing temperature is preferably 10°C or higher and 300°C or lower, more preferably 80°C or higher and 200°C or lower, and even more preferably 100°C or higher and 180°C or lower. The heat pressing time can be adjusted as appropriate depending on the thickness of the decorative sheet and the type of uncured thermosetting resin, and is, for example, preferably from 1 minute to 60 minutes, more preferably from 5 minutes to 30 minutes, and even more preferably from 8 minutes to 20 minutes.

[0116] After step 3 is completed, the state and composition of the water-soluble substrate may differ from the initial composition. For example, the water-soluble substrate after step 3 may contain a cured product of the thermosetting resin contained in the resin-impregnated substrate. Furthermore, after step 3 is completed, some of the water-soluble resin constituting the water-soluble substrate may have soaked into the pattern layer and primer layer of the second region. The state and composition of the water-permeable substrate may differ from the initial composition after completion of step 3. For example, the water-permeable substrate after completion of step 3 may contain a cured product of the thermosetting resin contained in the resin-impregnated substrate.

[0117] <Step 4> In step 4, the second laminate is removed from between the mirror plates to obtain a decorative board.

[0118] The decorative board obtained by the decorative board manufacturing method of the present disclosure preferably satisfies the following refractive index difference and altitude difference.

[0119] <Refractive index difference> The outermost surface of the decorative sheet facing the first laminate is defined as the first surface. When the refractive index of the resin contained in the layer corresponding to the first region among the layers constituting the first surface is defined as n1 and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2, it is preferable that n1 ≠ n2.

[0120] By making n1≠n2, a difference in surface reflectance between the first region and the second region can be created, resulting in a contrast between the first and second regions. This contrast can improve the texture of the surface of the decorative board even if the elevation difference between the first and second regions is not sufficient.

[0121] The embodiment of the magnitude relationship between n1 and n2 in the manufacturing method for a decorative board of the present disclosure is the same as the embodiment of the magnitude relationship between n1 and n2 in the decorative board of the present disclosure. For example, the lower limit of |n1-n2| is preferably 0.02 or more, and the upper limit is preferably 0.20 or less.

[0122] The values ​​of n1 and n2 can be adjusted by adjusting the type of resin contained in the layer corresponding to the first region and the type of resin contained in the layer corresponding to the second region, among the layers constituting the first surface. In the method for manufacturing a decorative board of the present disclosure, a portion of the uncured thermosetting resin that has permeated the first substrate is allowed to soak into the resin layer in the second region, while in the first region, the release layer inhibits the permeation of the uncured thermosetting resin that has permeated the first substrate, thereby creating a difference between n1 and n2.

[0123] <Elevation difference> The outermost surface of the decorative sheet on the side of the first laminate is defined as the first surface. With regard to the elevation of the first surface, it is preferable that the difference in elevation between the location corresponding to the first region and the location corresponding to the second region is more than 1.0 μm and not more than 5.0 μm.

[0124] If the elevation of the surface of the decorative board is too uniform, the decorative board will tend to feel like an artificial object. Therefore, by making the elevation difference more than 1.0 μm, the artificial feeling can be suppressed and the decorative board will tend to feel like a natural object. If the difference in elevation on the surface of the decorative board is too great, the appearance of the texture due to the difference in refractive index on the surface of the decorative board may be impaired. Therefore, by keeping the difference in elevation to 5.0 μm or less, the texture of the surface of the decorative board can be improved. Furthermore, if the difference in elevation on the surface of the decorative sheet is too great, dirt tends to accumulate in the recesses on the surface of the decorative sheet, which tends to reduce the stain resistance. Therefore, it is preferable to set the difference in elevation to 5.0 μm or less, as this makes it easier to improve the stain resistance. The difference in elevation is preferably 1.5 μm or more and 4.5 μm or less, and more preferably 2.0 μm or more and 4.0 μm or less.

[0125] The elevation of the location corresponding to the first area and the elevation of the location corresponding to the second area may be higher in either case. The above-mentioned difference in elevation can be adjusted by the difference between the total thickness of the release layer and resin layer formed in the first region and the total thickness of the resin layer formed in the second region. In FIG. 4, the symbol h indicates the above-mentioned difference in altitude.

[0126] The method for manufacturing a decorative board according to the present disclosure makes it possible to easily manufacture a decorative board with a good textured appearance. The conventional manufacturing method for decorative boards disclosed in Patent Document 3 requires a step of peeling off the release film, but the manufacturing method for decorative boards disclosed herein does not require this peeling step. When peeling off the release film, the releasability varies depending on the material of the layers that make up the decorative board. For this reason, the manufacturing method disclosed in Patent Document 3 required changing the manufacturing conditions to obtain appropriate releasability each time the material was changed. Furthermore, with the manufacturing method disclosed in Patent Document 3, when a specific material that makes up the decorative board was changed, other materials sometimes had to be changed to obtain appropriate releasability. Furthermore, the manufacturing method disclosed in Patent Document 3 has the problem that the release film becomes waste, which is not good for the environment. On the other hand, the method for manufacturing a decorative board according to the present disclosure does not require a peeling step, and therefore can suppress the problems caused by peeling as described above. [Example]

[0127] Next, the present disclosure will be described in more detail by way of examples, but the present disclosure is not limited to these examples in any way.

[0128] 1. Measurement and Evaluation The decorative boards obtained in the examples and comparative examples were measured and evaluated for the following items: The measurement and evaluation were carried out in an environment of a temperature of 23°C ± 5°C and a relative humidity of 40% to 65%.

[0129] 1-1. Refractive index Among the layers constituting the first surface of the decorative panel, n1, which is the refractive index of the resin contained in the layer corresponding to the first region, and n2, which is the refractive index of the resin contained in the layer corresponding to the second region, were measured in accordance with Method B (Becke method by liquid immersion) of JIS K 7142:2014.

[0130] 1-2. Uneven feeling The decorative panels 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 sense of unevenness. Evaluation was made according to the following criteria. A: More than 18 people answered that it has a highly three-dimensional design. B: Between 11 and 17 people answered that the design has a high degree of three-dimensionality. C: Between 6 and 10 people answered that the design has a high degree of three-dimensionality. D: Five or fewer people answered that the design has a high degree of three-dimensionality.

[0131] 1-3.Elevation difference For the first surface of the decorative panel, the elevation of the location corresponding to the first region and the elevation of the location corresponding to the second region were measured. Measurements were taken at 10 locations in each region, and the average value of the 10 locations was used as the elevation of each region. The elevation difference was calculated by subtracting the elevation of the location corresponding to the second region from the elevation of the location corresponding to the first region.

[0132] 1-4. Stain resistance A straight line was written on the surface of each of the decorative panels obtained in the examples and comparative examples using a black oil-based pen (Teranishi Chemical Industry Co., Ltd. magic ink, product number: ML-T1) conforming to JIS S60377. After leaving it for 5 minutes, the decorative panel was wiped dry, and the degree of the writing remaining on the surface was visually evaluated according to the following criteria. A: No handwritten traces were found. B: Some traces of writing were found, but to a degree that would not cause any problems in practical use. C: Handwriting was found.

[0133] 2. Preparation of ink for release layer An ink for the release layer was prepared by stirring 60 parts by mass of an ionizing radiation curable monomer (Aronix M400, manufactured by Toagosei Co., Ltd.), 0.9 parts by mass of a reactive silicone (X-22-164B, manufactured by Shin-Etsu Chemical Co., Ltd.), and 40 parts by mass of methyl ethyl ketone (Maruzen Petrochemical Co., Ltd.) at 2000 rpm for 1 hour using a process homogenizer PH91 (manufactured by SMT Corporation).

[0134] 3. Manufacture of decorative panels [Example 1] As the first substrate, a water-soluble film (polyvinyl alcohol film, Mitsubishi Chemical Corporation, trade name: Hi-Selon C-300, thickness 40 μm) was prepared. The release layer ink described above in "2" was applied to a portion of one side of the water-soluble film by gravure coating and cured by electron beam irradiation of 3 Mrad at an acceleration voltage of 165 kV to form a release layer with a thickness of 3 μm. The release layer had a pattern in which independent portions with a width of 30 μm and a length of 50 mm were randomly arranged. The area where the release layer was formed was the first area, and the area where the release layer was not formed was the second area. Next, a primer layer ink containing an acrylic urethane resin was applied onto the first and second regions and dried to form a primer layer having a thickness of 1 μm. Next, a first design layer ink containing an acrylic resin and a colorant was applied to the area corresponding to the first region on the primer layer and dried to form a 3 μm thick first design layer. Furthermore, a second design layer ink containing an acrylic resin and a colorant was applied to the area corresponding to the second region on the primer layer and dried to form a 3 μm thick second design layer. The first and second design layers form a wood grain pattern. Through the above steps, a first laminate having a first substrate (water-soluble film), a release layer, and a resin layer (primer layer and design layer) was obtained.

[0135] Next, using an impregnation device, the substrate (titanium paper base paper for building materials, product name "PM-67P" manufactured by KJ Specialty Paper Co., Ltd., basis weight: 80 g / m 2 The uncured composition was impregnated at a rate of 80 g / m². 2 The ratio of water to water (when dry) was then adjusted. The resin-impregnated paper was then obtained by drying. The drying was completed when the surface of the resin-impregnated paper became no longer viscous. In other words, moisture was left inside the resin-impregnated paper. Next, the resin-impregnated paper and the core layer described below were laminated together to obtain a second substrate including the core layer and the resin-impregnated paper. <Liquid uncured composition of thermosetting resin> Melamine formaldehyde resin 60 parts by weight ·Water 35 parts by mass Isopropyl alcohol 5 parts by weight <Core layer> A paper sheet with a basis weight of 245 g / m2 obtained by impregnating kraft paper with a liquid uncured resin composition made of phenolic resin. 2 It is made by stacking two sheets of phenolic resin-impregnated core paper (Ota Core, manufactured by Ota Sangyo Co., Ltd.).

[0136] Next, the surface of the first laminate opposite to the side having the release layer was placed on the surface of the second substrate on the resin-impregnated paper side, thereby obtaining a second laminate.

[0137] The second laminate was sandwiched between two mirror-finished plates and pressed at a pressure of 100 kg / cm using a heat press. 2The mixture was heat molded at a molding temperature of 150°C for 10 minutes. During this process, some of the uncured thermosetting resin permeated the water-soluble film, and some of the uncured thermosetting resin that permeated the water-soluble film soaked into the primer layer and second pattern layer in the second region. In the first region, the release layer suppresses the permeation of the uncured thermosetting resin, so almost no uncured thermosetting resin permeated into the primer layer and first pattern layer in the second region. After this step was completed, most of the thermosetting resin had been cured. Next, the second laminate was taken out from between the mirror plates to obtain the decorative board of Example 1.

[0138] [Comparative Example 1] Base material (titanium paper base paper for building materials, product name "PM-67P" manufactured by KJ Specialty Paper Co., Ltd., basis weight: 80 g / m 2 A 3 μm thick first decorative layer (the vessel part of the wood grain) and a 3 μm thick second decorative layer (the bare part of the wood grain) were formed on the 100 μm thick wooden board (a 100 μm thick wooden board) by gravure printing using printing ink (Ode SPTI, manufactured by DIC Graphics Corporation). Next, the following curable resin composition 1 for forming the first cured material layer was printed on the first decorative layer, and cured by irradiating with an electron beam (applied voltage: 165 KeV, 3 Mrad (30 kGy)), to obtain a laminate A having a first cured material layer with a thickness t1 of 15.0 μm. Next, the laminate A was impregnated with the following curable resin composition for forming a second cured product layer, and dried to obtain a laminate B (the amount of the cured resin composition when dried was 80 g / m 2 (impregnated so that Next, the following release film was laminated on the surface of the laminate B opposite to the substrate (the surface having the uncured second cured product layer), and a reinforcing layer (a layer of 245 g / m2 obtained by impregnating kraft paper with a liquid uncured resin composition consisting of a phenolic resin) was laminated on the surface of the laminate B facing the substrate. 2 A laminate C was obtained by laminating three sheets of phenol resin-impregnated core paper (Ohta Core, manufactured by Ohta Sangyo Co., Ltd.). Next, both sides of the laminate C were sandwiched between mirror plates (the mirror plate was placed on the reinforcing layer side and the embossed plate was placed on the release film side), and the laminate was pressed using a heat press at a molding temperature of 150°C and a molding pressure of 100 kg / cm. 2 After molding, the laminate C was removed from between the two mirror plates, and the release film was peeled off from the laminate C, thereby obtaining the decorative board of Comparative Example 1. When the release film was peeled off from the laminate C, the second cured material layer on the first cured material layer was removed together with the release film, forming a first concave region. Furthermore, the second cured material layer remained in the area where the first cured material layer was not present, forming a second convex region.

[0139] Comparative Example 2 Except for not forming the first cured product layer, the decorative board of Comparative Example 2 was obtained in the same manner as Comparative Example 1. The decorative board of Comparative Example 2 has a second cured product layer of uniform thickness over the entire surface of the first decorative layer and the second decorative layer of the substrate, with no distinction between the first region and the second region.

[0140] [Table 1]

[0141] In the method for producing a decorative board in Example 1, a decorative board with an excellent textured appearance could be produced in a simple manner. On the other hand, the decorative board manufacturing method of Comparative Example 1 produced a decorative board with excellent texture, but because it included a peeling step, it was difficult to adjust the manufacturing conditions to obtain appropriate peelability, and it could not be said that the decorative board could be easily manufactured. The decorative board manufacturing method of Comparative Example 2 did not have a region with different refractive index differences on the surface of the obtained decorative board, so the texture was poor. [Explanation of symbols]

[0142] 10 First base material 11 Water-soluble base material 20 Release layer 30 primer layer 40 Picture layer 41 First pattern layer 42 Second pattern layer 100 First laminate 200 Second base material 201 Resin-impregnated substrate 202 Core layer 300 Second laminate 80 Base material 90 layers 500 decorative panels A1 1st area A2 2nd area S1 1st surface

Claims

1. A method for manufacturing a decorative board, comprising the following steps 1 to 4: Step 1: A release layer containing a cured product of an ionizing radiation curable resin composition is formed on a portion of one surface of a first substrate. A region on the one surface of the first substrate where the release layer is formed is referred to as a first region, and a region on the one surface of the first substrate where the release layer is not formed is referred to as a second region. A resin layer is formed in the second region on the one surface of the first substrate, thereby obtaining a first laminate having the first substrate, the release layer, and the resin layer. The first base material is a water-soluble base material. Step 2: A second laminate is obtained by superposing a second substrate including a resin-impregnated substrate impregnated with an uncured thermosetting resin on the surface of the first laminate opposite to the side having the release layer. Step 3: By sandwiching both sides of the second laminate between mirrored plates and hot pressing, a portion of the uncured thermosetting resin is made to penetrate the first substrate, and the portion of the uncured thermosetting resin that has penetrated the first substrate is made to soak into the resin layer in the second region. Step 4: The second laminate is removed from between the mirror plates to obtain a decorative board.

2. The method for manufacturing a decorative board according to claim 1 , wherein in step 1, the resin layer is also formed on the release layer in the first region.

3. The method for producing a decorative board according to claim 1 or 2, wherein in step 1, at least one selected from a primer layer and a pattern layer is formed as the resin layer.

4. 4. The method for producing a decorative board according to claim 1, wherein the water-soluble substrate is a polyvinyl alcohol film.

5. 5. The method for producing a decorative board according to claim 1, wherein the second substrate in step 2 is a laminated substrate having the resin-impregnated substrate on a core layer.

6. The outermost surface of the decorative board on the side of the first laminate is defined as a first surface. A method for manufacturing a decorative panel according to any one of claims 1 to 5, wherein the refractive index of the resin contained in the layer corresponding to the first region among the layers constituting the first surface is defined as n1, and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2, and n1 ≠ n2.

7. The method for producing a decorative board according to claim 6, wherein |n1-n2| is 0.02 or more and 0.20 or less.

8. The outermost surface of the decorative board on the side of the first laminate is defined as a first surface. The method for manufacturing a decorative board according to any one of claims 1 to 7, wherein the elevation difference between the elevation of the first surface at the location corresponding to the first region and the elevation of the location corresponding to the second region is greater than 1.0 μm and less than 5.0 μm.

9. A decorative board having one or more layers on a substrate, the decorative board having a water-soluble substrate between the substrate and the one or more layers, The decorative board has a first region and a second region within a surface thereof, A decorative board that satisfies the following conditions 1 and 2, when the outermost surface of the decorative board having one or more layers is defined as a first surface. <Condition 1> When the refractive index of the resin contained in the layer corresponding to the first region among the layers constituting the first surface is defined as n1 and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2, n1≠n2. <Condition 2> With respect to the elevation of the first surface, the difference in elevation between the location corresponding to the first region and the location corresponding to the second region is greater than 1.0 μm and not more than 5.0 μm.

10. The decorative board according to claim 9, wherein in the condition 1, |n1-n2| is 0.02 or more and 0.20 or less.

11. 11. The decorative board according to claim 9 or 10, wherein the one or more layers include a release layer containing a cured product of an ionizing radiation curable resin composition in a location corresponding to the first region, and at least one selected from a primer layer and a pattern layer in a location corresponding to the second region.

12. The decorative board according to claim 11, further comprising at least one selected from a primer layer and a design layer on the side of the release layer opposite to the substrate.

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