Method for manufacturing decorative board and transfer sheet used in said manufacturing method

Abstract

To provide a method for simply manufacturing a decorative plate which is excellent in uneven feeling.SOLUTION: A method for manufacturing a decorative plate includes the following steps. Step 1: Forming a release layer at a part on one surface side of a water-soluble base material as a first base material. An area where the release layer is formed in one surface of the first base material is represented by a first region, and an area where the release layer is not formed is represented by a second region. A first laminate having the first base material, the release layer and the resin layer is obtained by forming a resin layer in the second region on the one surface side of the first base material. Step 2: A second laminate is obtained by overlapping a second base material containing a resin-impregnated base material impregnated with an uncured thermosetting resin on a surface on 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 then the water-soluble base material as the first base material is removed using a liquid containing water.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a decorative board and a transfer sheet used in the manufacturing method. [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 aims to provide a method for easily producing a decorative board with an excellent textured appearance, and a transfer sheet to be used in the production method. [Means for solving the problem]

[0009] In order to solve the above problems, the present disclosure provides the following methods for producing decorative panels and transfer sheets [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 water-soluble substrate, which is 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. 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 having the release layer. Step 3: The second laminate is sandwiched between mirrored plates on both sides and heat-pressed to cause a portion of the uncured thermosetting resin to soak into the resin layer in the second region. Step 4: After the second laminate is removed from between the mirror plates, the water-soluble base material, which is the first base material, is removed using a liquid containing water. [2] A transfer sheet having a release layer on a portion of one side of a water-soluble substrate, and a resin layer on the one side of the water-soluble substrate that does not have the release layer. [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 transfer sheet suitable for manufacturing 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 obtained by a decorative board manufacturing method of the present disclosure. [Figure 2] 1 is a schematic cross-sectional view showing one embodiment of a decorative board obtained by a decorative board manufacturing method of 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] [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 water-soluble substrate, which is 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. 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 having the release layer. Step 3: The second laminate is sandwiched between mirrored plates on both sides and heat-pressed to cause a portion of the uncured thermosetting resin to soak into the resin layer in the second region. Step 4: After the second laminate is removed from between the mirror plates, the water-soluble base material, which is the first base material, is removed using a liquid containing water.

[0013] To facilitate understanding of the method for producing a decorative board according to the present disclosure, first, an overview of the decorative board obtained by the method for producing a decorative board according to the present disclosure will be described. Fig. 1 is a schematic perspective view showing one embodiment of a decorative board obtained by the decorative board manufacturing method of the present disclosure. Fig. 2 is a schematic cross-sectional view showing one embodiment of a decorative board obtained by the decorative board manufacturing method of the present disclosure. 1 and 2, the reference symbol S1 indicates the outermost surface of the decorative board on the side of the first laminate 100. However, in FIG. 1, layers constituting the decorative board, such as the first laminate, are omitted. 1 and 2 has a first region A1 and a second region A2 within its surface. The first region A1 is a region where a release layer is formed in step 1, and the second region A2 is a region where a release layer is not formed in step 1. The decorative board 500 in Fig. 2 has, in the first region, a first pattern layer 41, a primer layer 30, and a release layer 20, in this order, from the second substrate 200 side. The decorative board 500 in Fig. 2 has, in the second region, a first pattern layer 42 and a primer layer 30, in this order, from the second substrate 200 side.

[0014] By setting the refractive index of the resin contained in the layer corresponding to the first region and the refractive index of the resin contained in the layer corresponding to the second region, which are among the layers constituting the outermost surface of the decorative board, to different values, a difference in surface reflectance can be created between the first region and the second region. This creates a contrast between the first and second regions. This contrast can then improve the textured appearance of the surface of the decorative board even if the elevation difference between the first and second regions is insufficient. The decorative board obtained by the decorative board manufacturing method of the present disclosure easily satisfies the refractive index relationship described above, and therefore can easily achieve a good textured surface.

[0015] The shape of the decorative board obtained by the decorative board manufacturing method 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 further simplify the manufacturing method of the decorative board of the present disclosure, it is preferable that the shape of the decorative board is a flat plate shape.

[0016] Steps 1 to 4 will be described below with reference to FIGS.

[0017] <Process 1> In step 1, a release layer 20 is formed on a portion of one surface of a water-soluble substrate 11, which is a first substrate 10. Within the one surface of the first substrate, a region where a release layer is formed is referred to as a first region, and a region where a release layer is not formed is referred to as a second region. In Figures 2 to 4, symbol A1 corresponds to the first region, and symbol A2 corresponds to the second region.

[0018] 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. 2 to 4, the primer layer 30 and the design layer 40 correspond to the resin layer. In Fig. 2 to 4, the resin layer is formed in the second region and the first region.

[0019] 《First base material (water-soluble base material)》 In the method for producing a decorative board of the present disclosure, a water-soluble substrate is used as the first substrate. The water-soluble substrate serves as a support when the release layer and the resin layer are formed. The water-soluble substrate is removed with a solution containing water in step 4. Any water-soluble substrate that is water-soluble or water-swellable can be removed in step 4. The water-soluble substrate can be removed, for example, by rinsing with water or by combining rinsing with brushing.

[0020] 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.

[0021] 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 of the polyvinyl alcohol film, ease of removal in step 4, and other properties can be adjusted by changing the degree of polymerization and degree of saponification of the polyvinyl alcohol, the amount of additives added, and other properties.

[0022] 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 removal work in step 4 can be made easier.

[0023] 《Release layer》 The release layer preferably contains a cured product of an ionizing radiation curable resin composition. By including a cured product of the ionizing radiation curable resin composition in the release layer, it is possible to easily prevent the uncured thermosetting resin from seeping into the release layer. Therefore, among the layers constituting the outermost surface of the decorative sheet, the layer corresponding to the first region contains almost no uncured thermosetting resin. Meanwhile, among the layers constituting the outermost surface of the decorative sheet, the layer corresponding to the second region contains uncured thermosetting resin. Therefore, it is easy to make the refractive index of the resin contained in the layer corresponding to the first region different from the refractive index of the resin contained in the layer corresponding to the second region. Of the layers constituting the outermost surface of the decorative board, the layer corresponding to the first region is preferably a release layer.

[0024] 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.

[0025] 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.

[0026] The ionizing radiation curable compound can be appropriately selected from polymerizable monomers and polymerizable oligomers that are commonly used as ionizing radiation curable compounds.

[0027] 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.

[0028] 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.

[0029] 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 functional (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.

[0030] 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.

[0031] In order to obtain a design with a higher quality texture and better surface properties, the number of functional groups in 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.

[0032] 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.

[0033] When the ionizing radiation curable resin composition is of an ultraviolet curable type, the ionizing radiation curable resin composition preferably contains a photopolymerization initiator.

[0034] The release layer preferably contains a reactive release agent such as a reactive silicone compound or a reactive fluorine compound. By containing a reactive release agent in the release layer, it is possible to more easily prevent the uncured thermosetting resin from seeping into the release layer. Among reactive release agents, a reactive silicone compound is preferred.

[0035] 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.

[0036] 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 organic groups introduced at both terminals. From the viewpoint of obtaining a more textured design, the organic group is preferably a reactive functional group such as a (meth)acrylic group, an amino group, an epoxy group, a mercapto group, a carbinol group, a phenol group, a carboxyl group, etc., or a non-reactive group functional group such as a polyether group, an aralkyl group, a fluoroalkyl group, an alkyl group, a fatty acid amide group, a phenyl group, etc. Among them, a reactive functional group is preferred, and a (meth)acrylic group is particularly preferred, that is, a (meth)acrylic-modified silicone oil is particularly preferred. Further, these organic groups may have substituents such as a nitrogen atom, a sulfur atom, a hydroxyl group, an alkyl group, etc.

[0037] 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 still more preferably 0.8% by mass or more and 2% by mass or less with respect to 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 addition effect of the reactive release agent can be obtained efficiently.

[0038] The release layer may contain fillers such as inorganic fillers and organic fillers. When the refractive index relationship described later is n1 < n2, by containing a filler in the release layer, it is easier to improve the unevenness feeling better.

[0039] 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. <0000​​​​​​​​

[0042] 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.

[0043] <Resin layer> 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, the resin layer is formed on the release layer in the first region. In other words, when forming a resin layer in the first region, the resin layer is formed on the side of the release layer opposite the first substrate. 2 to 4, the primer layer 30 and the design layer 40 correspond to the resin layer. In Fig. 2 to 4, the resin layer is formed in the second region and the first region.

[0044] 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.

[0045] 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.

[0046] -Primer layer- The primer layer is formed, for example, to improve the adhesion between the release layer and the pattern layer. Note that, in order to improve the adhesion between the water-soluble substrate, which is the first substrate, and the release layer, a primer layer may be formed between the substrate and the release layer.

[0047] Examples of resin materials for forming the primer layer include urethane resin, polyester resin, acrylic resin, acrylic urethane resin, vinyl chloride-vinyl acetate copolymer resin, and the like.

[0048] To improve adhesion, the primer layer preferably does not substantially contain a cured product of an ionizing radiation-curable resin composition. Furthermore, by substantially not containing a cured product of an ionizing radiation-curable resin composition, the primer layer can be more easily impregnated with uncured thermosetting resin. Therefore, the refractive index of the resin contained in the layer corresponding to the first region and the refractive index of the resin contained in the layer corresponding to the second region, among the layers constituting the outermost surface of the decorative sheet, can be easily made different. 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.

[0049] 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.

[0050] -Picture layer- The pattern layer is formed as needed to enhance the design of the decorative board. 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.

[0051] 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.

[0052] The design layer can be formed, for example, by printing using a design layer ink containing a colorant and a binder resin.

[0053] 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.

[0054] It is preferable that the design layer is substantially free of a cured product of an ionizing radiation curable resin composition. By not substantially containing a cured product of an ionizing radiation curable resin composition, the design layer can be easily impregnated with uncured thermosetting resin. Therefore, among the layers constituting the outermost surface of the decorative sheet, the refractive index of the resin contained in the layer corresponding to the first region and the refractive index of the resin contained in the layer corresponding to the second region can be easily made different. 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.

[0055] 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.

[0056] 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.

[0057] By the above-described step 1, a first laminate 100 having a first substrate, a release layer, and a resin layer is obtained (FIG. 3).

[0058] <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 having the release layer 20, thereby obtaining a second laminate 300.

[0059] 《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.

[0060] 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.

[0061] -Base material for resin-impregnated substrate- Examples of the substrate for the resin-impregnated 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.

[0062] 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.

[0063] The thickness of the resin-impregnated 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.

[0064] -Thermosetting resin- A portion of the thermosetting resin in the resin-impregnated substrate remains in the substrate and hardens, while the other portion penetrates into the resin layer and hardens. As a result, the decorative board obtained by the decorative board manufacturing method of the present disclosure has a refractive index difference between the first region and the second region, which makes it easier to achieve high designability and improve mechanical strength.

[0065] Examples of the curable resin include melamine resin, urea resin, melamine-urea resin, guanamine resin, diallyl phthalate resin, polyester resin, phenol resin, epoxy resin, aminoalkyd resin, silicone resin, polysiloxane resin, etc. Among these, thermosetting resins such as melamine resin, urea resin, melamine-urea resin, guanamine resin, and sulfonamide resin are preferred. Among the thermosetting resins, melamine resin, melamine-urea resin, and phenol resin are preferred, and melamine resin is particularly preferred.

[0066] When using a melamine-based resin as the curable resin, the difference in the penetration of the melamine-based resin between the first region and the second region can be evaluated by the following method. Among the layers constituting the outermost surface of the decorative board, 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 a large amount of the melamine-based resin has penetrated into the layer corresponding to the second region among the layers constituting the outermost surface of the decorative board. Even when using a resin other than the melamine-based resin as the curable resin, the difference in the penetration of the curable resin between the first region and the second region can be evaluated by quantitatively analyzing the content of the skeleton specific to the resin. The above-mentioned uncured thermosetting resin is preferably made into a cured product of the thermosetting resin at the time of completion of the decorative board.

[0067] The second base material 200 may be a laminated base material having a resin-impregnated base material 201 on a core layer 202. By having a core layer, the strength of the decorative board can be increased.

[0068] 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 of the resin-impregnated base material. 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 2or less, more preferably 150 g / m 2 More than 250g / m 2 The following is the result. The thermosetting resin for the core layer may be the same as the thermosetting resin exemplified for the resin-impregnated substrate. Among thermosetting resins, phenolic resin is preferred. That is, phenolic resin-impregnated paper is preferred for the core layer.

[0069] As the phenol resin impregnated paper, for example, a paper with a basis weight of 150 g / m 2 More than 250g / m 2 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.

[0070] <Process 3> In step 3, the second laminate is sandwiched between mirrored plates on both sides and then heat-pressed to cause a portion of the uncured thermosetting resin to soak into the resin layer in the second region.

[0071] In step 3, a portion of the uncured thermosetting resin extruded from the resin-impregnated substrate penetrates into the resin layer in the second region. If the first region has a resin layer, the uncured thermosetting resin also penetrates into the resin layer in the first region. On the other hand, in step 3, the uncured thermosetting resin extruded from the resin-impregnated substrate hardly penetrates into the release layer in the first region. Therefore, in the decorative board obtained by the decorative board manufacturing method of the present disclosure, the refractive index of the resin contained in the layer corresponding to the first region and the refractive index of the resin contained in the layer corresponding to the second region, among the layers constituting the outermost surface of the decorative board, are set to different values, thereby creating a difference in the surface reflectance between the first region and the second region. This difference in brightness can create a good textured appearance on the surface of the decorative board, even if the elevation difference between the first region and the second region is insufficient.

[0072] 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 resin layer of the first region, and the second substrate.

[0073] 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 water-soluble base material in the second region is suppressed, and the penetration of the uncured thermosetting resin into the release layer in the first region is also 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.

[0074] <Step 4> In step 4, the second laminate is removed from between the mirror plates, and then the water-soluble base material, which is the first base material, is removed using a liquid containing water.

[0075] The water-soluble base material that is the first base material can be removed, for example, by rinsing with water or by combining rinsing with brushing.

[0076] The decorative board obtained by the decorative board manufacturing method of the present disclosure preferably satisfies the following refractive index difference and altitude difference.

[0077] <Refractive index difference> The outermost surface on the side of the first laminate of the decorative panel is defined as the first surface. When the refractive index of the resin contained in the layer corresponding to the first region is defined as n1 and the refractive index of the resin contained in the layer corresponding to the second region is defined as n2 among the layers constituting the first surface, it is preferable that n1 ≠ n2.

[0078] By setting n1 ≠ n2, a difference can be caused between the surface reflectance of the first region and the surface reflectance of the second region, so that a brightness difference can be caused between the first region and the second region. And due to this brightness difference, even if the height difference between the first region and the second region is not sufficient, the unevenness on the surface of the decorative panel can be improved.

[0079] Regarding the magnitude relationship between n1 and n2, n1 may be larger or n2 may be larger. Whichever of n1 and n2 is larger, a brightness difference based on the reflectance difference can be caused between the first region and the second region, so that the unevenness on the surface of the decorative panel can be improved. When n1 < n2, by containing a filler in the release layer, it is easier to further improve the unevenness.

[0080] In order to better improve the unevenness on the surface of the decorative panel, 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, still more preferably 0.07 or more, still more preferably 0.10 or more, and still more preferably 0.12 or more. In order to increase the degree of freedom of the combination of the resin constituting the first region and the resin constituting the second region, and to easily maintain the practical strength of the decorative panel, |n1 - n2| is preferably 0.20 or less, more preferably 0.18 or less, and still more preferably 0.16 or less. n1 and n2 can be determined by, for example, the method described in the examples. In this specification, unless otherwise specified, the refractive index difference means the refractive index at a wavelength of 589 nm.

[0081] The values ​​of n1 and n2 can be adjusted by 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. In the manufacturing method of the decorative board of the present disclosure, a portion of the uncured thermosetting resin is allowed to soak into the resin layer of the second region, while in the first region, the release layer inhibits the soaking of the uncured thermosetting resin, thereby creating a difference between n1 and n2.

[0082] The reason why a difference between n1 and n2 results in a difference between the surface reflectance of the first region and the surface reflectance of the second region will be explained below.

[0083] 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'']

[0084] 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

[0085] 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. R2P , R2 S are the reflectance with respect to the P-polarized component and the reflectance with respect to the S-polarized component, respectively. R2 P = tan 2 {φ0 - sin -1 (n0sinφ0 / n2)} / tan 2 {φ0 + sin -1 (n0sinφ0 / n2)} [Equation 2’] R2 S = sin 2 (φ0 - sin -1 (n0sinφ0 / n2)) / sin 2 (φ0 + sin -1 (n0sinφ0 / n2)) [Equation 2’’]

[0086] When the angle of incidence φ0 of light to the first region and the second region is 0 degree, 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’’’.

[0087] 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’’’]

[0088] Since the refractive index of air is approximately 1, when approximated as 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]

[0089] As is clear from the above equations, when n1 < n2, R1 < R2, and when n1 > n2, R1 > R2.

[0090] 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 is allowed to soak into the resin layer in the second region, while in the first region, the release layer inhibits the soaking of the uncured thermosetting resin, thereby creating a difference between n1 and n2.

[0091] <Elevation difference> The outermost surface of the decorative sheet facing 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 portion corresponding to the first region and the portion corresponding to the second region is 1.0 μm or less.

[0092] 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 1.0 μm or less, it is easier to achieve a good texture on the surface of the decorative board. 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. For this reason, it is preferable to set the difference in elevation to 1.0 μm or less, as this makes it easier to improve the stain resistance. The difference in elevation is more preferably 0.8 μm or less, which is the maximum wavelength of visible light, even more preferably 0.6 μm or less, and even more preferably 0.4 μm or less, which is the minimum wavelength of visible light.

[0093] In the method for producing a decorative board of the present disclosure, the first base material that functions as a support for the first laminate is removed, making it easier to reduce the elevation difference.

[0094] 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. 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.

[0095] <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.

[0096] -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.

[0097] 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.

[0098] -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.

[0099] 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.

[0100] 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.

[0101] <Adherent material> The decorative board obtained by the method for producing a decorative board of the present disclosure may be laminated and integrated with an adherend for use. 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.

[0102] <Application> The decorative board obtained by the decorative board manufacturing method of the present disclosure has an excellent texture. Furthermore, the decorative board obtained by the decorative board manufacturing method of the present disclosure is also likely to have good stain resistance. Therefore, the decorative board of the present disclosure can be used as it is, or after being subjected to molding or other processing, as interior and exterior materials for buildings, such as counter and desk tops; furniture; kitchen cabinets; doors; and the like.

[0103] [Transfer sheet] The transfer sheet of the present disclosure has a release layer on a portion of one side of a water-soluble substrate, and a resin layer on the one side of the water-soluble substrate that does not have the release layer. The transfer sheet of the present disclosure can be used, for example, as the first laminate in the method for producing a decorative board of the present disclosure.

[0104] The transfer sheet of the present disclosure can be embodied in the same manner as the first laminate used in the method for producing a decorative board of the present disclosure described above. For example, the transfer sheet of the present disclosure preferably further includes a resin layer on the release layer opposite the water-soluble substrate. Furthermore, in the transfer sheet of the present disclosure, the resin layer is preferably at least one selected from a primer layer and a design layer. Furthermore, in the transfer sheet of the present disclosure, the release layer preferably includes a cured product of an ionizing radiation-curable resin composition. [Example]

[0105] 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.

[0106] 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%.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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).

[0112] 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.

[0113] 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.).

[0114] Next, the surface of the first laminate having the release layer was placed on the surface of the second substrate having the resin-impregnated paper, thereby obtaining a second laminate.

[0115] The second laminate was sandwiched between two mirror-finished plates and pressed at a pressure of 100 kg / cm using a heat press. 2 The mixture was heat molded at a molding temperature of 150°C for 10 minutes. During this process, some of the uncured thermosetting resin extruded from the resin-impregnated paper soaked into the resin layers in the second and first regions, whereas almost none of the uncured thermosetting resin extruded from the resin-impregnated paper soaked into the release layer in the first region. After this step was completed, most of the thermosetting resin had been cured. Next, the second laminate was removed from between the mirror plates, and the water-soluble base material serving as the first base material was then washed away with water, thereby obtaining the decorative board of Example 1.

[0116] [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.

[0117] 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.

[0118] [Table 1]

[0119] 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]

[0120] 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 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 water-soluble substrate, which is 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. 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 having the release layer. Step 3: The second laminate is sandwiched between mirrored plates on both sides and heat-pressed to cause a portion of the uncured thermosetting resin to soak into the resin layer in the second region. Step 4: After the second laminate is removed from between the mirror plates, the water-soluble base material, which is the first base material, is removed using a liquid containing water.

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. A method for manufacturing a decorative panel according to any one of claims 1 to 7, wherein the difference in elevation between the elevation of the portion corresponding to the first region and the elevation of the portion corresponding to the second region is 1.0 μm or less.

9. A water-soluble substrate has a release layer on a part of one surface side thereof, and the one surface side of the water-soluble substrate is a resin layer is provided in a portion where the release layer is not provided, the release layer comprises a cured product of an ionizing radiation curable resin composition, a ratio of the cured product of the ionizing radiation curable resin composition to the total solid content of the release layer is 50% by mass or more, the resin layer is at least one selected from a primer layer and a design layer, a ratio of the cured product of the ionizing radiation curable resin composition to the total solid content of the primer layer is 1 mass% or less, A transfer sheet, wherein 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 mass % or less.

10. The transfer sheet according to claim 9 , further comprising the resin layer on the release layer opposite to the water-soluble substrate.

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