Decorative material and method for manufacturing decorative material

Abstract

To provide a decorative material that has a plurality of grooves and ink-containing filling parts inside the grooves, wherein the decorative material is less prone to a deterioration of texture.SOLUTION: A decorative material includes a substrate layer and a surface protective layer. The substrate layer has a plurality of grooves on a surface at the surface protective layer side. At least some of the grooves include colorant-containing filling parts inside the grooves. Of the grooves, grooves extending in a direction within a range of ±10 degrees from a direction perpendicular to a predetermined direction are defined as perpendicular grooves, wherein the perpendicular grooves have an arithmetical average height of bottoms of the grooves being 4.0 μm or more on average.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a decorative material and a method for manufacturing the decorative material.

Background Art

[0002] Decorative materials are used, for example, to decorate interior and exterior materials such as furniture, fixtures, and wall surfaces. Among decorative materials, there are those having a plurality of grooves and filled with ink inside the grooves in order to impart a predetermined texture. A decorative material filled with ink inside the grooves can be produced, for example, by undergoing a process of "placing an ink for a filling portion containing a coloring agent on the surface having the grooves of the decorative material and then scraping the ink for the filling portion in a predetermined direction". In the present specification, the above-described process may be referred to as "scraping" or "wiping". When an ink for a filling portion containing a coloring agent is placed on the surface having the grooves of the decorative material, a part of the grooves is filled with the ink. And when scraping the ink, excess ink is removed and the ink can be pushed into a part of the grooves.

[0003] As decorative materials produced through scraping, for example, the decorative materials of Patent Documents 1 and 2 have been proposed.

Prior Art Documents

Patent Documents

[0004] [[ID=三十]]

Patent Document 1

Patent Document 2

Disclosure of the Invention

Problems to be Solved by the Invention

[0005] In the decorative materials described in Patent Documents 1 and 2, ink sometimes failed to fill grooves extending perpendicular to the scraping direction. As a result, the areas where ink was not filled were noticeable, and the texture of the decorative materials described in Patent Documents 1 and 2 was unsatisfactory. Furthermore, depending on the design of the decorative material, the direction in which the grooves extend may be biased in a predetermined direction. Thus, in decorative materials where the direction of the grooves is biased in a predetermined direction, the aforementioned texture problem was serious.

[0006] This disclosure aims to provide a decorative material having multiple grooves and a filling portion containing ink inside the grooves that can suppress a deterioration in texture. Furthermore, this disclosure aims to provide a method for easily manufacturing a decorative material having multiple grooves and a filling portion containing ink inside the grooves that can suppress a deterioration in texture. [Means for solving the problem]

[0007] To address the above issues, this disclosure provides the following [1] to [4]. [1] A decorative material having a base layer and a surface protective layer, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When we define a groove extending in a direction within a range of ±10 degrees perpendicular to a predetermined direction as a vertical groove, The aforementioned vertical grooves are decorative material in which the average arithmetic mean height of the groove bottoms is 4.0 μm or more. [2] A decorative material having a base layer and a surface protective layer, The aforementioned decorative material has a rectangular shape in plan view, with a longitudinal direction and a transverse direction. The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, the grooves extending in the range of ±10 degrees from the longitudinal direction are defined as longitudinal grooves, The aforementioned longitudinal grooves are decorative material in which the average arithmetic mean height of the groove bottoms is 4.0 μm or more. [3] A decorative material having a base layer and a surface protective layer, The aforementioned decorative material is in roll form, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, grooves extending in a direction within ±10 degrees of the width direction of the roll of the decorative material are defined as grooves in the width direction, The aforementioned grooves in the width direction are decorative materials in which the average of the arithmetic mean heights of the groove bottoms is 4.0 μm or more. [4] A method for manufacturing a cosmetic material, comprising the following steps 1 to 4. Step 1: A step in which the base material layer is molded with an embossing plate to form multiple grooves. In Step 1, when grooves extending in a direction within ±10 degrees perpendicular to the scraping direction of Step 3 are defined as vertical grooves, the average of the arithmetic mean heights of the bottom of these vertical grooves is set to be 4.0 μm or more. Step 2: Applying a filler ink containing a coloring agent to the side of the base layer that has been molded with an embossing plate. Step 3: A step of scraping off ink for the filling portion in a predetermined direction, and forming a filling portion containing a coloring agent inside at least some of the grooves. Step 4: A step to form a surface protective layer on the side of the base material layer that has been molded with an embossing plate. [Effects of the Invention]

[0008] This disclosure provides a method for producing a decorative material having multiple grooves and a filling portion containing ink inside the grooves, which can suppress a deterioration in the texture of the decorative material. Furthermore, this disclosure provides a method for producing a decorative material having multiple grooves and a filling portion containing ink inside the grooves, which can easily produce a decorative material with suppressed deterioration in texture. [Brief explanation of the drawing]

[0009] [Figure 1] This is a cross-sectional view showing one embodiment of the cosmetic material of the present disclosure. [Figure 2] This is a diagram for explaining the height direction of the filling portion in the groove. [Figure 3] This is a plan view showing an embodiment of the planar shape of the grooves in the base material layer. [Figure 4] This is a diagram for explaining a method of calculating the depth, width, and length of the grooves. [Figure 5] This is a plan view showing an embodiment of the convex portion disposed at the bottom of the groove. [Figure 6] This is a cross-sectional view showing an embodiment of the convex portion disposed at the bottom of the groove.

Mode for Carrying Out the Invention

[0010] [Cosmetic Material (First Cosmetic Material)] The first cosmetic material included in the present disclosure has a base material layer and a surface protection layer, the base material layer has a plurality of grooves on the surface on the side of the surface protection layer, at least some of the grooves have a filling portion containing a coloring agent inside the groove, when grooves extending in a direction within a range of ± 10 degrees in the vertical direction with respect to a predetermined direction are defined as vertical grooves, the vertical grooves are those in which the average of the arithmetic mean height at the bottom of the groove is 4.0 μm or more.

[0011] FIG. 1 is a cross-sectional view showing an embodiment of the cosmetic material 100 of the present disclosure. The cosmetic material 100 in FIG. 1 has a base material layer 10 and a surface protection layer 40. In FIG. 1, the base material layer 10 has a plurality of grooves 21 on the surface on the side of the surface protection layer 40. In FIG. 1, at least some of the grooves 21 have a filling portion 22 containing a coloring agent inside the groove. In FIG. 1, the base material layer 10 is a multi-layer base material layer having a transparent resin layer 11, an adhesive layer 12, a decorative layer 13, and a colored base material 14 in this order. The cosmetic material 100 in FIG. 1 has a primer layer 30 between the base material layer 10 and the surface protection layer 40. FIGS. 1 to 6 are diagrams common to the first to third cosmetic materials of the present disclosure.

[0012] <Base material layer> The base layer of the first decorative material must have a plurality of grooves on the surface facing the protective layer. At least some of the grooves must have a filler portion containing a coloring agent inside. When grooves extending in a direction within ±10 degrees perpendicular to a predetermined direction are defined as vertical grooves, the average of the arithmetic mean heights of the bottom of the vertical grooves must be 4.0 μm or more.

[0013] In this specification, "arithmetic mean height" means the arithmetic mean height as defined in ISO 25178-2:2012. In this specification, "arithmetic mean height" may be referred to as "Sa".

[0014] The first decorative material of this disclosure can have a good texture by making the average Sa at the bottom of the vertical grooves equal to or greater than a predetermined value. The reason why the first decorative material of this disclosure can have a good texture will be explained below. First, the filling portion formed inside the groove has two directions: one in which the height is uneven, and another in which the height is uniform. In this specification, the direction in which the height of the filling portion is uneven is referred to as the "predetermined direction." Also, in this specification, the direction in which the height of the filling portion is uniform is referred to as the "direction perpendicular to the predetermined direction." "Height of the filling portion" refers to the position of the filling portion in the thickness direction of the decorative material. In other words, "height of the filling portion" may differ from the thickness of the filling portion. "Uneven filling height" means that the difference in filling height is 5 μm or more. If there are multiple directions in which the difference in filling height is 5 μm or more, the direction in which the difference in filling height per unit length is largest should be considered the direction in which "uneven filling height". In the direction in which "uniform filling height", it is preferable that the difference in filling height is less than 5 μm, and more preferably 3 μm or less.

[0015] Decorative materials exhibiting both uneven filling heights and uniform filling heights can be observed, for example, in decorative materials manufactured through scraping. That is, when a filling ink containing a coloring agent is placed on the grooved surface of a decorative material, and then the filling ink is scraped off in a predetermined direction, the filling height tends to be uneven in the scraping direction, while the filling height tends to be uniform in the direction perpendicular to the scraping direction. The above will be further explained using Figure 2. Consider the case where ink is placed on the surface of the decorative material in Figure 2(a) and the ink is scraped off in the Y-Y' direction. In this case, the Y-Y' direction, which is aligned with the scraping direction, tends to result in uneven filling heights, as shown in the cross-sectional view of Figure 2(b). On the other hand, the X-X' direction, which is perpendicular to the scraping direction, tends to result in uniform filling heights, as shown in the cross-sectional view of Figure 2(c). Therefore, in this disclosure, "a predetermined direction" can also be interpreted as meaning "the scraping direction." Furthermore, in this disclosure, "a direction perpendicular to the predetermined direction" can also be interpreted as meaning "a direction perpendicular to the scraping direction." Furthermore, among the grooves in the base material layer, those extending approximately perpendicular to the scraping direction are less likely to be filled with ink. This is because, during scraping, the ink is easily scraped out of these grooves. Therefore, in the first decorative material of this disclosure, the "grooves extending in a direction within a range of ±10 degrees perpendicular to a predetermined direction" can be said to specify "grooves that are less likely to be filled with ink when scraped (≒ grooves extending at ±10 degrees perpendicular to the scraping direction)." Grooves that are not filled with ink (grooves without a filled section) tend to have a lower texture because the gloss from reflected light at the bottom of the groove is more noticeable. The first decorative material of this disclosure has an average Sa of 4.0 μm or more at the bottom of the vertical grooves. Therefore, even if the vertical grooves are not filled with ink, the first decorative material of this disclosure can suppress the appearance of gloss by scattering the reflected light at the bottom of the grooves, thereby suppressing a decrease in texture.

[0016] The average Sa at the bottom of the vertical grooves is preferably 4.5 μm or more, more preferably 5.0 μm or more, and even more preferably 5.5 μm or more. If the average of Sa is too large, the difference in brightness between the grooved areas and the areas outside the grooves may decrease. For this reason, the average of Sa is preferably 10.0 μm or less, and more preferably 8.0 μm or less. In this specification, the average Sa at the bottom of the groove can be measured by the method described later.

[0017] Grooves in directions other than the vertical tend to form filler portions. Therefore, if all grooves are in directions other than the vertical, the problem of reduced texture is less likely to occur. However, if all grooves are in directions other than the vertical, the design freedom is limited, and furthermore, the absence of grooves in a specific direction creates an unnatural appearance, making it difficult to obtain a decorative material with a high texture. Furthermore, it is thought that the deterioration of texture can be suppressed by adjusting the shape of the vertical grooves to a shape that facilitates the formation of filler within the grooves, changing the ink used for the filler, or changing the scraping conditions. However, with these methods, the shape of the vertical grooves is limited or the ink material is changed, so the desired texture may not be obtained. On the other hand, the decorative material of this disclosure is less likely to cause the aforementioned defects, making it easier to obtain a decorative material with a high texture.

[0018] For grooves other than those oriented vertically, it is preferable that the average Sa at the bottom of the groove is within the above range.

[0019] <<Groove shape, etc.>> The shape and other characteristics of the grooves in the base layer are not particularly limited. The embodiments of the grooves will be described below.

[0020] The planar shape of the groove is not particularly limited, and various patterns can be used. When the design expressed by the entire decorative material is a wood grain pattern, it is preferable that the planar shape of the grooves form one or more patterns selected from burnt cedar cracks, vessels, autumn wood, and knots. "Burnt cedar cracks" refers to cracks that are formed perpendicular to the grain direction when the surface of a cedar board is charred to form a carbon layer. When the overall design of the decorative material is a stone pattern such as travertine, it is preferable that the groove's shape in plan view be a recessed area. Figure 3 shows one embodiment of the plan view shape of the groove 21 in the base layer 10.

[0021] The direction in which each groove extends represents the direction in which the distance between any two points within that groove is maximized. For example, in the case of the groove in Figure 4, the direction D1 in which the groove extends is the direction connecting points A and B. The length of each groove represents the length that maximizes the distance between any two points within that groove. In the case of the groove in Figure 4, the distance between point A and point B is the length of the groove.

[0022] With respect to individual grooves, the groove width is not particularly limited, but is preferably 150 μm or more and 1000 μm or less, more preferably 175 μm or more and 900 μm or less, and even more preferably 200 μm or more and 800 μm or less. With respect to individual grooves, the groove depth is not limited, but is preferably 10 μm or more and 100 μm or less, more preferably 20 μm or more and 95 μm or less, and even more preferably 30 μm or more and 90 μm or less. With respect to individual grooves, the length of the groove is not limited, but is preferably between 1 mm and 100 mm, more preferably between 2 mm and 80 mm, and even more preferably between 3 mm and 50 mm.

[0023] The depth of each groove can be calculated, for example, in steps A1 to A2 below. A1: For each groove, height data in the direction transverse to the groove is measured at five randomly selected locations, and five cross-sectional curves with height data are obtained. The height data is measured in a direction perpendicular to D1, which is the direction in which the groove extends. For example, for a groove whose plan view shape is as shown in Figure 4, height data is measured at five locations a to e in the direction of the dotted line, which is perpendicular to the groove's extension direction D1. From the height data measured in A2:A1, the maximum depth at each measurement point is extracted, and the average of the five maximum depths is taken as the average depth of each groove.

[0024] The width of each groove can be calculated, for example, using B1 below. B1: Calculate the width of the groove at each measurement point from the five cross-sectional curves measured in A1 above. Then, take the average of the widths at the five points and use that as the width of each individual groove.

[0025] The average of the arithmetic mean heights at the bottom of vertical grooves can be calculated, for example, using C1 to C3 below. C1: Extract any 10 grooves from the vertical grooves. C2: Measure the arithmetic mean height of the bottom of each of the 10 extracted grooves. The measurement area shall be 500 μm × 150 μm. If multiple measurement areas can be secured in each groove without overlapping, measure multiple arithmetic mean heights. However, a maximum of 5 measurement areas are required. From the measurement results of C3:C2, the average of the arithmetic mean heights of each groove is calculated. This average is then defined as the Sa of each groove. Furthermore, the Sa of the 10 extracted grooves is averaged to obtain the "average of the arithmetic mean heights of the groove bottoms in the vertical direction."

[0026] Groove height data and cross-sectional curves can be obtained, for example, by photographing the surface of the substrate layer facing the protective layer with a laser microscope and analyzing the image. An example of a laser microscope is the VK-X1000 3D shape measuring instrument manufactured by Keyence Corporation, and an example of an analysis application is the "Shape Measurement Laser Microscope VK-X100 / X200 Series Analysis Application," which is software included with the measuring instrument.

[0027] Of all the grooves present in the substrate layer, the proportion of grooves extending in a direction perpendicular to a predetermined direction within a range of ±40 degrees is preferably 80% or more, more preferably 90% or more, even more preferably 97% or more, and most preferably 100%, based on the number of grooves, in order to further enhance the texture. The fact that the direction of the grooves in the base layer is as described above means that the direction in which the grooves extend is biased in a predetermined direction. Thus, the decorative material of this disclosure is preferable in that it is easy to achieve a good texture even when the direction of the grooves is biased in a predetermined direction.

[0028] Of the grooves extending in a direction within ±40 degrees perpendicular to a predetermined direction, the proportion of grooves extending in a direction within ±10 degrees perpendicular to a predetermined direction is preferably 50% to 95%, and more preferably 70% to 90%.

[0029] When a predetermined direction is used as a reference, the standard deviation σ of the direction of all grooves present in the base layer is preferably between 1 degree and 20 degrees, more preferably between 2 degrees and 15 degrees, and even more preferably between 3 degrees and 10 degrees. By setting the standard deviation σ of the groove direction within the above range, the texture can be further enhanced, and it becomes easier to impart the appearance of natural materials.

[0030] The ratio of the area where grooves are formed to the total area of ​​the base material layer is preferably 40% to 90%, more preferably 50% to 80%, and even more preferably 60% to 70%.

[0031] To facilitate achieving a Sa of 4.0 μm or more, the bottom of the groove preferably has a convex portion and / or a concave portion, and more preferably a convex portion. Figure 5 is a plan view showing one embodiment of a convex portion located at the bottom of a groove, and Figure 6 is a cross-sectional view showing one embodiment of a convex portion located at the bottom of a groove. It is preferable that not only vertical grooves but also grooves in directions other than vertical have a convex portion and / or a concave portion at the bottom.

[0032] At the bottom of the groove, the convex and / or concave portions may be arranged regularly, but it is preferable that they be arranged randomly in order to further enhance the texture and make it easier to give the appearance of a natural object.

[0033] Assuming that the height of the protrusion or the depth of the recess is smaller than the depth of the groove, it is preferably 5 μm to 30 μm, more preferably 6 μm to 27 μm, and even more preferably 7 μm to 25 μm. The height of the protrusion refers to the maximum height of the protrusion relative to the bottom of the groove. The depth of the recess refers to the maximum depth of the recess relative to the bottom of the groove. Assuming that the height of the protrusion or the maximum diameter of the recess is narrower than the width of the groove, it is preferably 10 μm to 300 μm, more preferably 20 μm to 250 μm, and even more preferably 30 μm to 200 μm. The maximum diameter of the protrusion means the length at which the distance between any two points on the bottom surface of the protrusion is maximized. The maximum diameter of the recess means the length at which the distance between any two points on the opening of the recess is maximized.

[0034] The height of the protrusions, the depth of the recesses, and the maximum diameter of the recesses can be obtained by photographing the surface of the substrate layer facing the protective layer with a laser microscope and analyzing the image.

[0035] The ratio of the height of the protrusion or the depth of the recess to the depth of the groove is preferably 0.05 or more and 0.50 or less, more preferably 0.07 or more and 0.40 or less, and even more preferably 0.10 or more and 0.37 or less. By setting the ratio within the above range, it is possible to more easily suppress the deterioration of the texture of the decorative material.

[0036] <<Method for forming grooves>> Grooves in the substrate layer can be formed, for example, by molding the substrate layer with an embossing plate. The embossing plate can be made, for example, by engraving a metal roll with laser light. The grooves in the substrate layer are formed by the raised regions of the embossing plate. By having finer raised and / or recessed portions than the raised portions of the embossing plate, raised and / or recessed portions can be formed at the bottom of the grooves in the substrate layer. Even finer raised and / or recessed portions than the raised portions can be formed, for example, by engraving with laser light. A method for engraving metal rolls with laser light is described, for example, in international publication number WO2020 / 203737.

[0037] The temperature and pressure used when forming with an embossing plate should be adjusted as appropriate depending on the material of the base layer. If the base material and transparent resin layer of the base layer are polyolefin, the temperature should be between 140°C and 180°C, and the pressure should be 10 kg / cm². 2 More than 50kg / cm 2 The following applies: Typical methods of patterning using embossing plates include the following: First, the embossing plate is pressed onto the softened base layer to create the pattern on the surface of the embossing plate. Then, the base layer is solidified by cooling or other means to fix the pattern formed on the base layer. After that, the base layer with the pattern formed on it is released from the embossing plate.

[0038] <<Layer structure of the base material layer>> The base layer may be a single layer or a multilayer structure with multiple layers stacked together. Examples of the layer configurations of the base layer include (1) to (10) below. In (1) to (10) below, " / " indicates the interface between layers. In the base layers of (1) to (10) below, it is preferable to arrange the layers listed on the left toward the surface protective layer. (1) Single layer of substrate (2) Decorative layer / base material (3) Substrate / Decorative layer (4) Transparent resin layer / base material (5) Transparent resin layer / decorative layer / substrate (6) Transparent resin layer / substrate / decorative layer (7) Transparent resin layer / adhesive layer / base material (8) Transparent resin layer / adhesive layer / decorative layer / substrate (9) Transparent resin layer / decorative layer / adhesive layer / substrate (10) Transparent resin layer / adhesive layer / substrate / decorative layer

[0039] -Base material- The material of the base material is not particularly limited, but a plastic film or a composite of a plastic film and paper is preferred due to the ease with which grooves can be formed by embossing or other processes.

[0040] Specific examples of resins that make up plastic films include polyolefin resins such as polyethylene and polypropylene, vinyl resins such as vinyl chloride resin, vinylidene chloride resin, polyvinyl alcohol, and ethylene-vinyl alcohol copolymer, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, acrylic resins such as polymethyl methacrylate, polymethyl acrylate, and polyethyl methacrylate, polystyrene, acrylonitrile-butadiene-styrene copolymer (ABS resin), cellulose triacetate, and polycarbonate. Among these, polyolefin resins, vinyl chloride resins, polyester resins, and acrylic resins are preferred because they have excellent printability and moldability.

[0041] The base material may be a transparent base material or a colored base material. Furthermore, the base material may be a laminated base material formed by stacking multiple base materials. In the case of the layer configuration of the base material layer as described in (6) and (10) above, it is preferable to use a transparent base material in order to allow the decorative layer to be visible through the base material.

[0042] There are no particular restrictions on the thickness of the substrate, but it is preferably 20 μm to 200 μm, more preferably 40 μm to 160 μm, and even more preferably 40 μm to 100 μm.

[0043] To improve adhesion with the layer provided on the substrate, one or both sides may be treated with an easy-adhesion treatment such as a physical treatment or a chemical surface treatment.

[0044] —Decorative layer— The base layer may have a decorative layer to improve the aesthetic appeal of the decorative material. The decorative layer may be, for example, a colored layer that covers the entire surface (a so-called solid colored layer), a patterned layer with various designs, or a combination of these.

[0045] The patterns that can be added by the decorative layer are not particularly limited, but examples include wood grain patterns, stone grain patterns, etc. By forming these patterns with the decorative layer, the texture based on the grooves and filler areas can be further emphasized.

[0046] The decorative layer can be formed, for example, by applying and drying a decorative layer ink containing a coloring agent such as a pigment or dye and a binder resin. The decorative layer ink may optionally contain additives such as extender pigments, antioxidants, plasticizers, catalysts, curing agents, UV absorbers, and light stabilizers. The colorants and binder resins for the decorative layer are not particularly limited, and the same as those exemplified in the ink for the filling section described later can be used.

[0047] The thickness of the decorative layer is preferably 0.1 μm to 20 μm, more preferably 0.5 μm to 10 μm, and even more preferably 1.0 μm to 5.0 μm.

[0048] -Transparent resin layer- The base layer may have a transparent resin layer to increase its strength. Examples of resins that make up the transparent resin layer include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylic resins, and vinyl chloride resins. Among these, polyolefin resins are preferred from the viewpoint of processability. Furthermore, the transparent resin layer may be a mixture of these example resins, or it may be a laminate of layers consisting of one or more of these example resins.

[0049] Examples of polyolefin resins for the transparent resin layer include polyethylene (low density, medium density, high density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, and ethylene-propylene-butene copolymer. Among these, polyethylene (low density, medium density, high density), polypropylene, ethylene-propylene copolymer, and propylene-butene copolymer are preferred, with polypropylene being more preferred.

[0050] The transparent resin layer may contain additives such as UV absorbers, light stabilizers, and colorants. If the transparent resin layer contains a UV absorber, the UV absorber is preferably a triazine compound, and more preferably a hydroxyphenyltriazine compound.

[0051] The thickness of the transparent resin layer is preferably 20 μm to 150 μm, more preferably 40 μm to 120 μm, and even more preferably 60 μm to 100 μm, from the viewpoint of balancing scratch resistance, processability, and weather resistance.

[0052] -Adhesive layer- The substrate layer may have an adhesive layer to improve interlayer adhesion. The adhesive layer can be made from a general-purpose adhesive such as a urethane-based adhesive, acrylic-based adhesive, epoxy-based adhesive, or rubber-based adhesive. Among these adhesives, a urethane-based adhesive is preferred in terms of adhesive strength. Examples of urethane-based adhesives include adhesives that utilize a two-component curing urethane resin containing various polyol compounds such as polyether polyols, polyester polyols, and acrylic polyols, and a curing agent such as an isocyanate compound.

[0053] The thickness of the adhesive layer is preferably 0.1 μm to 30 μm, more preferably 1 μm to 15 μm, and even more preferably 2 μm to 10 μm.

[0054] The shape of the surface of the substrate layer opposite to the surface protective layer is not particularly limited; it may be smooth or grooved.

[0055] <Filling section> At least some of the grooves must have a filler portion containing a coloring agent inside the groove. Having a filler portion inside the groove can enhance the texture of the decorative material.

[0056] Of the grooves, the proportion of grooves with a filling portion is preferably 85% or more, more preferably 90% or more, and even more preferably 95% or more, based on the number of grooves. However, as mentioned above, if the proportion of grooves with a filling portion is made to be extremely high, the shape of the grooves may be limited or the ink material may have to be changed. Furthermore, the decorative material of this disclosure can suppress a decrease in texture even if there are grooves without a filling portion. For this reason, the proportion of grooves with a filling portion is preferably 99% or less, based on the number of grooves.

[0057] One method for forming a filler portion containing a coloring agent in a groove is to apply a filler ink containing a coloring agent and a binder resin to the grooved side of the base layer, and then scrape off the ink with a scraping blade such as a doctor blade. In this case, the amount of ink filled into the groove can be adjusted by adjusting the material of the blade and the angle at which the blade is applied. To make it easier to push the ink into the groove, it is preferable that the blade be made of a soft material. Similarly, to make it easier to push the ink into the groove, it is preferable that the angle of the blade relative to the base layer be tilted toward the direction of travel of the base layer.

[0058] Examples of colorants include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, lead yellow, titanium yellow, red iron oxide, cadmium red, ultramarine, and cobalt blue; organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue; and dyes. The coloring agent content is preferably 1 part by mass or more and 90 parts by mass or less, and more preferably 2 parts by mass or more and 50 parts by mass or less, per 100 parts by mass of binder resin.

[0059] The color of the coloring agent is not particularly limited, but dark coloring agents are preferred. Dark coloring agents can darken the grooves, thereby increasing the contrast in brightness within the surface of the decorative material. Dark colors refer to low-brightness, low-chroma colors that give a dark impression, such as dark gray, dark green, navy blue, black, dark purple, maroon, and brown. When dark-colored colorants are used as coloring agents, grooves without filling tend to become more noticeable. However, since the Sa at the bottom of the grooves in the decorative material of this disclosure is within a predetermined range, even when dark-colored colorants are used, the noticeable appearance of grooves without filling can be suppressed.

[0060] Examples of binder resins include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral, alkyd resins, petroleum-based resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, and rubber-based resins.

[0061] The filling portion may contain a matting agent to further enhance the texture. When the filling portion contains a matting agent, the difference between grooves with the filling portion and grooves without the filling portion becomes more noticeable. However, since the Sa at the bottom of the grooves of the decorative material of this disclosure is within a predetermined range, even if the filling portion contains a matting agent, the noticeable difference between grooves without the filling portion and those without it can be suppressed.

[0062] Examples of matting agents include inorganic particles such as silica, calcium carbonate, titanium dioxide, and barium sulfate; and organic particles such as acrylic beads and styrene beads. The average particle size of the matting agent is preferably 1 μm or more and 20 μm or less. In this specification, the average particle size refers to the mass-average value d50 obtained by particle size distribution measurement using laser diffraction. The matting agent content is preferably 1 to 30 parts by mass, and more preferably 2 to 20 parts by mass, per 100 parts by mass of binder resin.

[0063] The filling portion preferably contains at least one of an ultraviolet absorber and a light stabilizer in order to help maintain its texture over a long period of time. Examples of UV absorbers include inorganic UV absorbers and organic UV absorbers. As inorganic ultraviolet absorbers, titanium dioxide, cerium oxide, zinc oxide, etc., with an average particle size of 5 nm to 120 nm, can be preferably used. Examples of organic UV absorbers include benzotriazole compounds, triazine compounds, and benzophenone compounds. The amount of ultraviolet absorber is preferably 1 part by mass or more and 50 parts by mass or less, and more preferably 10 parts by mass or more and 40 parts by mass or less, per 100 parts by mass of binder resin. Examples of light stabilizers include hindered amine-based light stabilizers. The content of the light stabilizer is preferably 1 to 50 parts by mass, and more preferably 10 to 40 parts by mass, per 100 parts by mass of the binder resin.

[0064] <Surface protective layer> The decorative material has a surface protective layer. The surface protective layer preferably contains a cured product of a curable resin composition in order to improve the scratch resistance of the decorative material.

[0065] Examples of curable resin compositions include thermosetting resin compositions containing thermosetting resins, ionizing radiation-curable resin compositions containing ionizing radiation-curable resins, and mixtures thereof. Among these, ionizing radiation-curable resin compositions are preferred because they increase the crosslinking density of the surface protective layer and improve surface properties such as scratch resistance. Furthermore, electron beam-curable resin compositions are more preferred among ionizing radiation-curable resin compositions because they can be applied without solvents and are easy to handle.

[0066] A thermosetting resin composition is a composition containing at least a thermosetting resin, which hardens upon heating. Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. A curing agent is added to these curable resins as needed in the thermosetting resin composition.

[0067] An ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). The ionizing radiation-curable functional group is a group that crosslinks and hardens upon irradiation with ionizing radiation, and preferred examples include functional groups having an ethylenically double bond, such as a (meth)acryloyl group, a vinyl group, or an allyl group. In this specification, a (meth)acryloyl group refers to an acryloyl group or a metacloyl group. In this specification, a (meth)acrylate refers to an acrylate or a methacrylate. Ionizing radiation refers to electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing or bridging molecules. While ultraviolet (UV) or electron beams (EB) are commonly used, the term also includes other electromagnetic waves such as X-rays and gamma rays, as well as charged particle beams such as alpha rays and ion beams. Specifically, the ionizing radiation-curable compound can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation-curable resins.

[0068] As polymerizable monomers, (meth)acrylate monomers having a radical polymerizable unsaturated group in the molecule are preferred, and among these, polyfunctional (meth)acrylate monomers are 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 one (meth)acryloyl group as such functional group.

[0069] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least one (meth)acryloyl group as such 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, and the like. Furthermore, polymerizable oligomers include other highly hydrophobic polybutadiene (meth)acrylate oligomers having (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers having polysiloxane bonds in the main chain, aminoplast resin (meth)acrylate oligomers obtained by modifying aminoplast resins that have many reactive groups in a small molecule, or oligomers having cationic polymerizable functional groups in the molecules of novolac-type epoxy resins, bisphenol-type epoxy resins, aliphatic vinyl ethers, aromatic vinyl ethers, etc.

[0070] These polymerizable oligomers may be used individually or in combination of multiple types. From the viewpoint of improving processing characteristics, scratch resistance, and weather resistance, one or more selected from urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers are preferred, one or more selected from urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers are more preferred, and urethane (meth)acrylate oligomers are even more preferred.

[0071] Monofunctional (meth)acrylates may be used in combination with ionizing radiation-curable resin compositions for purposes such as reducing the viscosity of the ionizing radiation-curable resin composition. These monofunctional (meth)acrylates may be used individually or in combination of multiple types.

[0072] When the ionizing radiation-curable compound is an ultraviolet-curable compound, the ionizing radiation-curable resin composition preferably contains additives such as photopolymerization initiators and photopolymerization accelerators. Examples of photopolymerization initiators include one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler ketone, benzoin, benzyldimethyl ketal, benzoylbenzoate, α-acyloxime ester, thioxanthones, etc. Furthermore, photopolymerization accelerators can reduce polymerization inhibition by air during curing and accelerate the curing speed. Examples include one or more selected from p-dimethylaminobenzoate isoamyl ester, p-dimethylaminobenzoate ethyl ester, etc.

[0073] The surface protective layer may contain additives such as UV absorbers, light stabilizers, matting agents, and colorants, as needed.

[0074] From the viewpoint of balancing processing characteristics, scratch resistance, and weather resistance, the thickness of the surface protective layer is preferably 1.5 μm to 30 μm, more preferably 2 μm to 15 μm, and even more preferably 3 μm to 10 μm.

[0075] <Primer layer> A primer layer may be provided between the substrate layer and the surface protective layer to improve adhesion. The primer layer is mainly composed of a binder resin. The primer layer may also contain additives such as UV absorbers and light stabilizers.

[0076] Preferred binder resins for the primer layer include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene resins, urethane-acrylic copolymers, polycarbonate-based urethane-acrylic copolymers (urethane-acrylic copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer main chain and two or more hydroxyl groups in the terminals and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated propylene resins, nitrocellulose resins (nitrified cotton), and cellulose acetate resins. These can be used individually or in combination. The binder resin may also be obtained by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent to these resins and crosslinking and curing them. Among these, polyol-based resins such as acrylic polyol resins crosslinked and cured with an isocyanate-based curing agent are preferred, and acrylic polyol resins crosslinked and cured with an isocyanate-based curing agent are more preferred.

[0077] The thickness of the primer layer is preferably 0.5 μm to 10 μm, more preferably 0.7 μm to 8 μm, and even more preferably 1 μm to 6 μm.

[0078] <Primer layer on the back surface> The decorative material of this disclosure may have a backside primer layer on the side opposite to the surface protective layer of the base layer in order to improve the adhesion between the decorative material and various adherends. The materials used to form the backside primer layer are not particularly limited and include urethane resin, acrylic resin, polyester resin, vinyl chloride / vinyl acetate copolymer, chlorinated polypropylene resin, chlorinated polyethylene resin, and the like. The thickness of the primer layer on the back surface is preferably 0.5 μm or more and 5.0 μm or less, and more preferably 1 μm or more and 3 μm or less.

[0079] The surface protective layer, decorative layer, primer layer, adhesive layer, and backside primer layer can be formed by applying an ink containing the composition for each layer using a known method such as gravure printing, bar coating, roll coating, reverse roll coating, or comma coating, and then drying and curing it as necessary. The transparent resin layer can be formed, for example, by hot melt extrusion.

[0080] [Decorative material (second decorative material)] The second decorative material included in this disclosure is A decorative material having a base layer and a surface protective layer, The aforementioned decorative material has a rectangular shape in plan view, with a longitudinal direction and a transverse direction. The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, the grooves extending in the range of ±10 degrees from the longitudinal direction are defined as longitudinal grooves, The longitudinal grooves are characterized by having an average arithmetic mean height of the groove bottoms of 4.0 μm or more.

[0081] <Base material layer> The base layer of the second decorative material must have a plurality of grooves on the surface facing the protective layer. At least some of the grooves must have a filler portion containing a coloring agent inside. When grooves extending in a range of ±10 degrees from the longitudinal direction are defined as longitudinal grooves, the average of the arithmetic mean heights of the bottom of the longitudinal grooves must be 4.0 μm or more.

[0082] The second decorative material of this disclosure can have a good texture by making the average Sa at the bottom of the longitudinal grooves equal to or greater than a predetermined value. The reason why the second decorative material of this disclosure can have a good texture will be explained below. In decorative materials whose plan view shape is a rectangle with a longitudinal and transverse direction, it is preferable to direct the grooves so that they extend within a predetermined angle relative to the longitudinal direction in order to emphasize the texture. On the other hand, for manufacturing reasons, when filling the grooves of the aforementioned decorative material with a plan view shape with ink containing a coloring agent, the direction in which the ink is scraped off may be perpendicular to the longitudinal direction. As explained with the first decorative material, grooves in the base layer that extend approximately perpendicular to the scraping direction are difficult to fill with ink. In other words, in the second decorative material of this disclosure, the "grooves extending in a direction within ±10 degrees of the longitudinal direction" can be said to be "grooves that are less likely to be filled with ink when scraped (≒ grooves extending at ±10 degrees perpendicular to the scraping direction)." Grooves that are not filled with ink (grooves without a filled section) tend to have a lower texture because the gloss from reflected light at the bottom of the groove is more noticeable. The second decorative material of this disclosure has an average Sa of 4.0 μm or more at the bottom of the longitudinal grooves. Therefore, even if the longitudinal grooves of the second decorative material of this disclosure are not filled with ink, the gloss can be suppressed by scattering the reflected light at the bottom of the grooves, thereby suppressing a decrease in texture.

[0083] The average Sa at the bottom of the longitudinal groove is preferably 4.5 μm or more, more preferably 5.0 μm or more, and even more preferably 5.5 μm or more. If the average of Sa is too large, the difference in brightness between the grooved areas and the areas outside the grooves may decrease. For this reason, the average of Sa is preferably 10.0 μm or less, and more preferably 8.0 μm or less. For grooves other than those in the longitudinal direction, it is preferable that the average Sa at the bottom of the groove is within the above range.

[0084] Furthermore, when the ink scraping direction is perpendicular to the longitudinal direction, filling portions tend to form in grooves other than those in the longitudinal direction. For this reason, if all grooves are in directions other than the longitudinal direction, it is thought that the problem of filling rate will not occur. However, if all grooves are in directions other than the longitudinal direction, the degree of design freedom will be lacking, and furthermore, an unnatural feeling will arise due to the absence of grooves in a specific direction, making it difficult to obtain a decorative material with a high texture. Furthermore, it is thought that the deterioration of texture can be suppressed by adjusting the shape of the longitudinal grooves to a shape that facilitates the formation of filler within the grooves, changing the ink used for the filler, or changing the scraping conditions. However, with these methods, the shape of the longitudinal grooves is limited or the ink material is changed, so the desired texture may not be obtained. On the other hand, the decorative material of this disclosure is less likely to cause the aforementioned defects, making it easier to obtain a decorative material with a high texture.

[0085] <<Groove shape, etc.>> The shape of the groove in the second decorative material is not particularly limited. Unless otherwise specified, embodiments of the groove in the second decorative material are the same as embodiments of the groove in the first decorative material. Similarly, unless otherwise specified, embodiments of the protrusions and / or recesses at the bottom of the groove in the second decorative material are the same as embodiments of the protrusions and / or recesses at the bottom of the groove in the first decorative material.

[0086] Of all the grooves present in the substrate layer, the proportion of grooves extending in the longitudinal direction within a range of ±40 degrees is preferably 80% or more, more preferably 90% or more, even more preferably 97% or more, and most preferably 100%, based on the number of grooves, in order to further enhance the texture. The fact that the groove direction of the base layer is as described above means that the direction in which the grooves extend is biased towards the longitudinal direction. Thus, the second decorative material of this disclosure is preferable in that it is easy to achieve a good texture even when the groove direction is biased towards the longitudinal direction.

[0087] Of the grooves extending in the longitudinal direction ±40 degrees, the proportion of grooves extending in the longitudinal direction ±10 degrees is preferably 50% to 95%, and more preferably 70% to 90%.

[0088] When the longitudinal direction is used as a reference, the standard deviation σ of the direction of all grooves present in the base layer is preferably between 1 degree and 20 degrees, more preferably between 2 degrees and 15 degrees, and even more preferably between 3 degrees and 10 degrees. By setting the standard deviation σ of the groove direction within the above range, the texture can be further enhanced, and it becomes easier to impart the appearance of natural materials.

[0089] To facilitate achieving a Sa of 4.0 μm or more, it is preferable that the bottom of the groove has a convex portion and / or a concave portion, and more preferably a convex portion. It is preferable that not only the longitudinal grooves but also grooves in directions other than the longitudinal direction have a convex portion and / or a concave portion at the bottom.

[0090] With respect to the second decorative material of this disclosure, the groove formation method, filling portion, layer structure of the base material layer, surface protective layer, decorative layer, transparent resin layer, primer layer and back surface primer layer are the same as those of the first decorative material unless otherwise specified.

[0091] [Decorative material (third decorative material)] The third decorative material included in this disclosure is A decorative material having a base layer and a surface protective layer, The aforementioned decorative material is in roll form, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, grooves extending in a direction within ±10 degrees of the width direction of the roll of the decorative material are defined as grooves in the width direction, The grooves in the width direction are such that the average of the arithmetic mean heights at the bottom of the grooves is 4.0 μm or more.

[0092] <Base material layer> The base layer of the third decorative material must have a plurality of grooves on the surface facing the protective layer. At least some of the grooves must have a filler portion containing a coloring agent inside. When grooves extending in a range of ±10 degrees in the width direction are defined as grooves in the width direction, the average of the arithmetic mean heights of the bottom of the grooves in the width direction must be 4.0 μm or more.

[0093] The third decorative material of this disclosure can have a good texture by making the average Sa at the bottom of the grooves in the width direction equal to or greater than a predetermined value. The reason why the third decorative material of this disclosure can have a good texture will be explained below. Roll-shaped decorative materials may have patterns formed by decorative layers. Typically, the patterns on roll-shaped decorative materials are formed so that they connect along the length of the roll. The length of the roll is perpendicular to the width of the roll. Furthermore, the length of the roll is the direction in which the roll is moved during the manufacturing process of the decorative material. Therefore, in roll-shaped decorative materials, to emphasize the texture by distinguishing it from the pattern direction, it is preferable that the direction in which the grooves extend be within a predetermined angle relative to the width of the roll. On the other hand, when filling the grooves of a roll-shaped decorative material with ink containing a coloring agent, for manufacturing reasons, the direction in which the ink is scraped is perpendicular to the width of the roll. As explained with the first decorative material, grooves in the base layer that extend approximately perpendicular to the scraping direction are difficult to fill with ink. In other words, in the third decorative material of this disclosure, the "grooves extending in a direction within a range of ±10 degrees in the width direction" can be said to be "grooves that are less likely to be filled with ink when scraped (≒ grooves extending at ±10 degrees perpendicular to the scraping direction)." Grooves that are not filled with ink (grooves without a filled section) tend to have a lower texture because the gloss from reflected light at the bottom of the groove is more noticeable. The third decorative material of this disclosure has an average Sa of 4.0 μm or more at the bottom of the grooves in the width direction. Therefore, even if the grooves in the width direction are not filled with ink, the third decorative material of this disclosure can suppress the appearance of gloss by scattering the reflected light at the bottom of the grooves, thereby suppressing a decrease in texture.

[0094] The average Sa at the bottom of the grooves in the width direction is preferably 4.5 μm or more, more preferably 5.0 μm or more, and even more preferably 5.5 μm or more. If the average of Sa is too large, the difference in brightness between the grooved areas and the areas outside the grooves may decrease. For this reason, the average of Sa is preferably 10.0 μm or less, and more preferably 8.0 μm or less. For grooves other than those in the width direction, it is preferable that the average Sa at the bottom of the groove is within the above range.

[0095] Furthermore, for grooves in directions other than the width direction, a filling portion is easily formed within the groove. Therefore, if all grooves are in directions other than the width direction, it is thought that the problem of filling rate will not occur. However, if all grooves are in directions other than the width direction, the degree of design freedom will be lacking, and furthermore, an unnatural feeling will arise due to the absence of grooves in a specific direction, making it difficult to obtain a decorative material with a high texture. Furthermore, it is thought that the deterioration of texture can be suppressed by adjusting the shape of the grooves in the width direction to a shape that facilitates the formation of a filling portion within the groove, changing the ink used for the filling portion, or changing the scraping conditions. However, with these methods, the shape of the grooves in the width direction is limited, or the ink material is changed, so the desired texture may not be obtained. On the other hand, the decorative material of this disclosure is less likely to cause the aforementioned defects, making it easier to obtain a decorative material with a high texture.

[0096] <<Groove shape, etc.>> The shape of the groove in the third decorative material is not particularly limited. Unless otherwise specified, embodiments of the groove in the third decorative material are the same as embodiments of the groove in the first decorative material. Similarly, unless otherwise specified, embodiments of the protrusions and / or recesses at the bottom of the groove in the third decorative material are the same as embodiments of the protrusions and / or recesses at the bottom of the groove in the first decorative material.

[0097] Of all the grooves present in the substrate layer, the proportion of grooves extending in a direction perpendicular to the width direction within a range of ±40 degrees is preferably 80% or more, more preferably 90% or more, even more preferably 97% or more, and most preferably 100%, based on the number of grooves, in order to further enhance the texture. The fact that the groove direction of the base layer is as described above means that the direction in which the grooves extend is biased towards the width direction. Thus, the third decorative material of this disclosure is preferable in that it is easy to achieve a good texture even when the groove direction is biased towards the width direction.

[0098] Of the grooves extending in a range of ±40 degrees in the width direction, the proportion of grooves extending in a range of ±10 degrees in the width direction is preferably 50% to 95%, and more preferably 70% to 90%.

[0099] When the width direction is used as the reference, the standard deviation σ of the direction of all grooves present in the base layer is preferably between 1 degree and 20 degrees, more preferably between 2 degrees and 15 degrees, and even more preferably between 3 degrees and 10 degrees. By setting the standard deviation σ of the groove direction within the above range, the texture can be further enhanced, and it becomes easier to impart the appearance of natural materials.

[0100] To facilitate achieving a Sa of 4.0 μm or more, it is preferable that the bottom of the groove has a convex portion and / or a concave portion, and more preferably a convex portion. It is preferable that not only grooves in the width direction, but also grooves in directions other than the width direction, have a convex portion and / or a concave portion at the bottom.

[0101] With respect to the third decorative material of this disclosure, the groove formation method, filling portion, layer structure of the base material layer, surface protective layer, decorative layer, transparent resin layer, primer layer and back surface primer layer are the same as those of the first decorative material unless otherwise specified.

[0102] <Uses of decorative materials> The decorative material disclosed herein can be used as is or as a laminate bonded to a substrate for various applications. Various applications include interior materials for buildings such as walls, ceilings, and floors; building fixtures such as window frames, doors, and handrails; furniture; casings for home appliances and office equipment; and exterior materials such as entrance doors. Examples of substrates include wood-based boards, gypsum-based boards, cement boards, fiber cement boards, ceramic boards, iron plates, metal plates, resin plates, FRP plates, etc.

[0103] [Method of manufacturing decorative materials] The method for manufacturing the cosmetic material described herein includes the following steps 1 to 4. Step 1: A step in which the base material layer is molded with an embossing plate to form multiple grooves. In Step 1, when grooves extending in a direction within ±10 degrees perpendicular to the scraping direction of Step 3 are defined as vertical grooves, the average of the arithmetic mean heights of the bottom of these vertical grooves is set to be 4.0 μm or more. Step 2: Applying a filler ink containing a coloring agent to the side of the base layer that has been molded with an embossing plate. Step 3: A step of scraping off ink for the filling portion in a predetermined direction, and forming a filling portion containing a coloring agent inside at least some of the grooves. Step 4: A step to form a surface protective layer on the side of the base material layer that has been molded with an embossing plate.

[0104] <Process 1> Step 1 is the process of forming multiple grooves by shaping the base layer with an embossing plate. In step 1, grooves are formed such that, with respect to grooves extending in a direction within ±10 degrees perpendicular to the scraping direction of step 3, the average of the arithmetic mean heights of the bottom of the grooves is 4.0 μm or more.

[0105] The width of the groove, the depth of the groove, and the arithmetic mean height of the groove bottom are generally determined by the shape of the embossing plate. For this reason, it is preferable that the embossing plate has a shape such that the arithmetic mean height of the groove bottom of the molded base layer fits within a predetermined range. To facilitate control of the shape of the embossing plate, it is preferable to manufacture the embossing plate by engraving a metal roll with laser light.

[0106] The embossing conditions in step 1 are not particularly limited. Examples of embossing conditions include a temperature of 140°C to 180°C and a pressure of 10 kg / cm². 2 More than 50kg / cm 2 The following are listed below.

[0107] <Process 2> Step 2 is the process of applying a filling ink containing a coloring agent to the side of the base layer that has been molded with an embossing plate. In step 2, some of the grooves are filled with ink. The ink for the filling section preferably contains a binder resin and a solvent in addition to a colorant.

[0108] <Process 3> Step 3 is a step of scraping off the ink for the filling portion in a predetermined direction and forming a filling portion containing a coloring agent inside at least some of the grooves. Step 3, the scraping process, removes excess ink and also allows ink to be pushed into some of the grooves.

[0109] As a means of scraping off the ink, it is preferable to use a scraping blade such as a doctor blade. The angle of the blade relative to the substrate layer is preferably 3 degrees to 45 degrees, more preferably 5 degrees to 30 degrees, with respect to the direction perpendicular to the substrate layer. A positive value indicates an inclination toward the direction of travel of the substrate layer, while a negative value indicates an inclination toward the opposite direction of travel of the substrate layer. The blade material can be metal, rubber, or resin, with metal being preferred among these. The pressure applied to the substrate layer by the blade can be adjusted as appropriate, within a range that does not cause streaks or unevenness in the ink.

[0110] In step 3, it is preferable to place a roll with a circular cross-section on the side opposite to the side where the blade for scraping the base material layer is located. Examples of materials for the roll include metal, rubber, and resin.

[0111] It is preferable to have a step of curing the binder resin of the ink for the filling part during step 3, or after the completion of step 3 and before the start of step 4.

[0112] <Step 4> Step 4 is the process of forming a surface protective layer on the side of the base material layer that has been molded with an embossing plate. The surface protective layer can be formed, for example, by applying an ink containing the components that make up the surface protective layer using a general-purpose coating means to form a coating film, and then drying and curing the coating film as needed.

[0113] If a primer layer is present between the substrate layer and the surface protective layer, it is preferable to form the primer layer between step 3 and step 4.

[0114] This disclosure provides, for example, the following [1] to

[10] . [1] A decorative material having a base layer and a surface protective layer, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When we define a groove extending in a direction within a range of ±10 degrees perpendicular to a predetermined direction as a vertical groove, The aforementioned vertical grooves are decorative material in which the average arithmetic mean height of the groove bottoms is 4.0 μm or more. [2] The decorative material according to [1], wherein the vertical grooves have an average arithmetic mean height of the bottom of the grooves of 4.0 μm or more and 10.0 μm or less. [3] The decorative material according to [1] or [2], wherein the vertical groove has a convex portion and / or a concave portion at the bottom of the groove. [4] The decorative material according to [3], wherein the ratio of the height of the protrusion or the depth of the recess to the depth of the vertical groove is 0.05 or more and 0.50 or less. [5] The decorative material according to any one of [1] to [4], wherein the filling portion contains a matting agent. [6] The cosmetic material according to any one of [1] to [5], wherein the filling portion contains at least one of an ultraviolet absorber and a light stabilizer. [7] A decorative material according to any one of [1] to [6], having a primer layer between the base material layer and the surface protective layer. [8] A decorative material having a base layer and a surface protective layer, The aforementioned decorative material has a rectangular shape in plan view, with a longitudinal direction and a transverse direction. The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, the grooves extending in the range of ±10 degrees from the longitudinal direction are defined as longitudinal grooves, The aforementioned longitudinal grooves are decorative material in which the average arithmetic mean height of the groove bottoms is 4.0 μm or more. [9] A decorative material having a base layer and a surface protective layer, The aforementioned decorative material is in roll form, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, grooves extending in a direction within ±10 degrees of the width direction of the roll of the decorative material are defined as grooves in the width direction, The aforementioned grooves in the width direction are decorative materials in which the average of the arithmetic mean heights of the groove bottoms is 4.0 μm or more.

[10] A method for manufacturing a cosmetic material, comprising the following steps 1 to 4. Step 1: A step in which the base material layer is molded with an embossing plate to form multiple grooves. In Step 1, when grooves extending in a direction within ±10 degrees perpendicular to the scraping direction of Step 3 are defined as vertical grooves, the average of the arithmetic mean heights of the bottom of these vertical grooves is set to be 4.0 μm or more. Step 2: Applying a filler ink containing a coloring agent to the side of the base layer that has been molded with an embossing plate. Step 3: A step of scraping off ink for the filling portion in a predetermined direction, and forming a filling portion containing a coloring agent inside at least some of the grooves. Step 4: A step to form a surface protective layer on the side of the base material layer that has been molded with an embossing plate. [Examples]

[0115] Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited in any way by these examples. Unless otherwise specified, "parts" are based on mass.

[0116] 1. Measurement and evaluation 1-1. Measurement of groove shape and measurement of Sa at the bottom of the groove For the base layers constituting the decorative materials of the examples and comparative examples, 10 grooves were selected from the vertical grooves. For the 10 grooves, the groove width, groove depth, groove length, and arithmetic mean height of the groove bottom were measured and the average values ​​were calculated in accordance with the description in the main text of the specification. The average values ​​for the 10 grooves are shown in Table 1. Furthermore, for the base layers constituting the decorative materials of the examples, the height of the protrusions at the bottom of the grooves and the maximum diameter of the protrusions at the bottom of the grooves were calculated. Since the base layers constituting the decorative materials of the comparative examples did not have protrusions at the bottom of the grooves, the height of the protrusions and the maximum diameter of the protrusions were not measured. The above measurements were performed by photographing the surface of the substrate layer facing the protective layer using a laser microscope and then analyzing the results. The laser microscope used was the Keyence VK-X1000 3D shape measuring instrument. The analysis application used was the "Shape Measurement Laser Microscope VK-X100 / X200 Series Analysis Application," which is software included with the measuring instrument. When calculating the arithmetic mean height, the groove was observed using a 5x lens, and the measurement area was set to 500 μm × 150 μm.

[0117] 1-2.Texture The surface texture of the cosmetic materials obtained in the examples and comparative examples was evaluated. Twenty randomly selected adults evaluated the materials according to the following criteria. The results are shown in Table 1. AA: More than 18 people said they didn't mind the grooves that didn't have filling sections and that the texture was good. A: 15 to 17 people said they didn't mind the grooves that didn't have filling sections and that the texture was good. B: 11 to 14 people said they didn't mind the grooves that didn't have filling sections and that the texture was good. C: Fewer than 10 people answered that they did not mind the grooves without filling areas and that the texture was good.

[0118] 2. Creation of the embossing plate Embossing plates 1 and 2 were created. Embossing plates 1 and 2 were both manufactured by engraving an iron roll plated with a copper layer on its surface using a laser beam, and then hard chrome plating the surface. Embossing plate 1 was irradiated with laser light in the raised areas of the embossing plate to form recesses finer than the raised areas. Embossing plate 2 was not irradiated with laser light in the raised areas of the embossing plate with the aim of forming recesses finer than the raised areas. The raised areas of the embossing plate correspond to the areas where grooves are formed in the substrate layer. The fine recess areas formed in the raised areas of the embossing plate correspond to the areas where raised areas are formed at the bottom of the grooves.

[0119] 3. Preparation of decorative materials [Example 1] On a colored substrate (a 60 μm thick white polypropylene film), a pattern layer of wood grain grooves was formed using black ink and a pattern layer of wood grain outside the wood grain areas was formed using brownish-red ink by gravure multicolor printing, creating a wood grain decorative layer with a total thickness of 1 μm. Next, an adhesive layer (polyester resin, thickness: 5 μm) was formed on the decorative layer. Then, a transparent resin layer (transparent polypropylene resin sheet, thickness: 80 μm) was laminated on the adhesive layer using an extrusion lamination method to obtain a base layer having a colored base material, a decorative layer, an adhesive layer, and a transparent resin layer in this order. Next, the transparent resin layer was heated to soften it, and an embossing process was performed on the transparent resin layer side using the embossing plate 1 prepared in "2" above, thereby forming multiple grooves on the transparent resin layer side. Next, a dark brown filler ink was placed on the transparent resin layer side, and then a doctor blade was pressed perpendicular to the substrate layer to scrape off the filler ink, remove excess ink, and push the ink into the grooves. The ink was then dried and cured. The filler ink contains a copolymer resin of acrylic and urethane as a binder resin, carbon black, quinacridone and isoindolinone as pigments, and ultraviolet absorbers, light stabilizers, silica, anti-settlement agents and dispersants as additives. Next, corona discharge treatment was applied to the transparent resin layer side, and then the following primer layer composition was applied to the transparent resin layer and dried to form a primer layer with a thickness of 4 μm. <Composition for primer layer> A composition obtained by mixing 100 parts by mass of composition X (a composition obtained by mixing a polycarbonate-based urethane-acrylic copolymer and an acrylic polyol with hexamethylene diisocyanate in a mass ratio of 100:5) with a diluent.

[0120] Next, the surface protection layer composition described below was applied to the primer layer, and the surface protection layer composition was crosslinked and cured by irradiation with an electron beam to form a surface protection layer with a thickness of 5 μm, thereby obtaining the decorative material of Example 1.

[0121] <Composition for surface protective layer> ·Ionizing radiation curable resin composition 100 parts (Trifunctional urethane acrylate oligomer with a weight-average molecular weight of 4000) • Matting agent 15 parts (Silica with an average particle size of 6 μm)

[0122] [Comparative Example 1] A decorative material for Comparative Example 1 was obtained in the same manner as in Example 1, except that embossing plate 1 was changed to embossing plate 2. The percentage of grooves in the base layer of Comparative Example 1 that had filled portions was approximately the same as the percentage of grooves in the base layer of Example 1 that had filled portions, both at 50%.

[0123] [Table 1]

[0124] From the results in Table 1, it can be confirmed that the decorative material of Example 1, which has multiple grooves and a filling portion containing ink inside the grooves, can suppress the deterioration of texture. On the other hand, in Comparative Example 1, the Sa at the bottom of the vertical grooves of the decorative material was less than 4.0 μm, resulting in noticeable reflected light at the bottom and a reduced texture. Furthermore, the bottom of the vertical grooves in the decorative material of Comparative Example 1 is not perfectly smooth. The first reason is that when the raised areas of the embossed plate are formed with laser light, slight steps are formed in the raised areas. The second reason is that even if the tops of the raised areas of the embossed plate are smooth, slight steps are formed within the grooves during the embossing process. [Explanation of Symbols]

[0125] 10: Base material layer 11: Transparent resin layer 12: Adhesive layer 13: Decorative layer 14: Colored base material 21: Groove 22: Filling section 23: Convex part 30: Primer layer 40: Surface protective layer 100: Decorative materials

Claims

1. A decorative material having a base layer and a surface protective layer, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, grooves extending in a direction within a range of ±10 degrees perpendicular to a predetermined direction are defined as vertical grooves, The aforementioned vertical grooves have an average arithmetic mean height of 4.0 μm or more at the bottom of the grooves. A decorative material in which the predetermined direction is the direction in which the height of the filling portion is uneven.

2. The decorative material according to claim 1, wherein the vertical grooves have an average arithmetic mean height of the bottom of the grooves of 4.0 μm or more and 10.0 μm or less.

3. The decorative material according to claim 1 or 2, wherein the vertical groove has a convex portion and / or a concave portion at the bottom of the groove.

4. The decorative material according to claim 3, wherein the ratio of the height of the protrusion or the depth of the recess to the depth of the vertical groove is 0.05 or more and 0.50 or less.

5. The decorative material according to any one of claims 1 to 4, wherein the filling portion contains a matting agent.

6. The cosmetic material according to any one of claims 1 to 5, wherein the filling portion contains at least one of an ultraviolet absorber and a light stabilizer.

7. The decorative material according to any one of claims 1 to 6, wherein a primer layer is provided between the base material layer and the surface protective layer.

8. A decorative material having a base layer and a surface protective layer, The aforementioned decorative material has a rectangular shape in plan view, with a longitudinal direction and a transverse direction. The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, the grooves extending in the range of ±10 degrees from the longitudinal direction are defined as longitudinal grooves, The longitudinal grooves have an average arithmetic mean height of 4.0 μm or more at the bottom of the grooves. A decorative material in which the direction perpendicular to the longitudinal direction is the direction in which the height of the filling portion is uneven.

9. A decorative material having a base layer and a surface protective layer, The aforementioned decorative material is in roll form, The substrate layer has a plurality of grooves on the surface facing the surface protection layer, At least some of the grooves have a filling portion containing a coloring agent inside the groove, When, among the grooves mentioned above, grooves extending in a range of ±10 degrees in the width direction of the roll of the decorative material are defined as grooves in the width direction, The grooves in the width direction have an average arithmetic mean height of 4.0 μm or more at the bottom of the grooves. A decorative material wherein the direction perpendicular to the width direction of the roll of the decorative material is the direction in which the height of the filling portion is uneven.

10. A method for manufacturing cosmetic materials, comprising the following steps 1 to 4. Step 1: A step in which a base material layer is molded with an embossing plate to form multiple grooves. In Step 1, when grooves extending in a direction within ±10 degrees perpendicular to the scraping direction of Step 3 are defined as vertical grooves, the average of the arithmetic mean heights of the bottom of the vertical grooves is set to be 4.0 μm or more. Step 2: A step in which an ink containing a coloring agent is applied to the side of the base layer that has been molded with an embossing plate. Step 3: A step of scraping off ink for the filling portion in a predetermined direction, and forming a filling portion containing a coloring agent inside at least some of the grooves. The predetermined direction is the direction in which the height of the filled portion is uneven. Step 4: A step to form a surface protective layer on the side of the base material layer that has been molded with an embossing plate.

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