Matte items

Abstract

The present invention provides a matte article with excellent visibility and texture, and a soft touch, exhibiting superior matte effect. The matte article of the present invention has at least a portion of its surface having a Spc (arithmetic mean curvature of the apex of the protrusion) greater than 4000 mm as specified in JIS B0601:2013. -1 Surface shapes whose Rsm (average length of curve elements) as specified in JIS B0601:2013 does not reach 30 μm.

Description

[Technical Field]

[0001] This invention relates to a matte article. [Previous Technology]

[0002] Previously, decorative materials or decorative sheets were used as items for decorating and protecting the surfaces of various building components, such as interior components (walls, ceilings, floors, etc.), exterior components (exterior walls, eaves, roofs, fences, etc.), window frames, doors, door frames, handrails, baseboards, ceiling trims, decorative strips, etc., as well as general furniture (multi-drawer cabinets, shelves, tables, etc.), kitchen furniture (dining tables, sinks, etc.), and cabinets for home appliances and OA (Office Automation) equipment, and interior or exterior components of vehicles. Furthermore, decorative materials, for example, those with a surface layer possessing the desired function, were used.

[0003] For decorative materials used in such applications, methods to enhance texture by employing matte effects (fading effects) are widely used to improve their design. For example, Patent Document 1 discloses a decorative sheet having a pattern layer and a masking layer on one side of a substrate sheet and a gloss adjustment layer (fading layer, gloss layer) on the other side. The decorative sheet in Patent Document 1 achieves a design effect that highlights the pattern layer and masking layer by utilizing the difference in gloss between the fading layer and the gloss layer of the gloss adjustment layer. In its embodiment, the fading layer, applied to the entire surface, uses a fading ink, which is obtained by adding 10 parts by weight of spherical alumina and 40 parts by weight of calcium carbonate, totaling 50 parts by weight of matting agent, to every 100 parts by weight of resin components.

[0004] Furthermore, Patent Document 2 discloses a decorative material having a printed layer and a transparent resin layer sequentially on a substrate, and having an embossed pattern applied to the outermost surface of the transparent resin layer. (Prior Art Documents, Patent Documents)

[0005] Patent Document 1: Japanese Patent Application Publication No. 2000-062081; Patent Document 2: Japanese Patent Application Publication No. 2011-073207 [Summary of the Invention]

[0006] [The problem the invention aims to solve]

[0007] As a method to enhance texture through matting effect (fading effect), the following methods can be mainly cited: as in Patent Document 1 above, a matting agent (also called "fading agent") is used to obtain a matting effect through its own light diffusion effect; as in Patent Document 2 above, an uneven shape is formed on the outermost surface by performing embossing. However, when using a matting agent as in Patent Document 1, in order to make the matting effect better, it is necessary to increase the amount used. However, as the amount used increases, the matting agent will peel off from the coating film and damage the coating film, thereby reducing scratch resistance. Furthermore, due to the change in gloss caused by the peeling off of the matting agent, scratches are easily noticeable. Alternatively, contaminants may penetrate into the tiny gaps at the interface between the matting agent and the resin, and then the contaminants may be adsorbed onto the matting agent itself, resulting in reduced stain resistance. For the above reasons, the surface properties tend to decrease. On the other hand, if the amount used is reduced to suppress the decrease in surface properties, the matting effect tends to decrease, indicating a conflict between surface properties and matting effect. Therefore, the matting effect obtained by using matting agents has its limits. Furthermore, in cases where embossing is used, as in Patent Document 2, the production of the embossing plate is extremely time-consuming and not easy, requiring the plate to be made one by one according to the desired pattern. Therefore, this method is not considered to be able to adequately meet the diverse needs of customers.

[0008] Furthermore, customer needs are diverse and multifaceted, requiring not only the visual matte finish as described above, but also tactile feedback. For example, when using a matte agent as described in Patent Document 1, the outline of the matte agent becomes visible on the surface of the decorative sheet due to increased usage, resulting in a slightly rough surface feel, or a "rough" feel. Similarly, when using embossing as described in Patent Document 2, the tactile feedback is generated by the uneven shape of the embossed surface. However, in both cases, the tactile feedback is not adequately addressed, resulting in a lack of sufficient tactile feedback. That is, it is not considered that previous decorative sheets and materials can simultaneously possess excellent matte finish and tactile feedback. In this invention, the focus is particularly on a "soft touch" (a soft feel).

[0009] The objective of this invention is to provide a matte article with excellent visibility, texture, and soft touch (soft feel) while exhibiting superior matte finish. [Technical Means for Solving the Problem]

[0010] To solve the above problems, the present invention provides the following matte articles. [1] A matte article having at least a portion of its surface having a surface shape in which the Spc (arithmetic mean curvature of the apex of the protrusion) as specified in JIS B0601:2013 is greater than 4000 mm-1 and the Rsm (mean length of the curve element) as specified in JIS B0601:2013 is less than 30 μm. [2] The matte article as described in [1], wherein the height parameter of the profile curve as specified in JIS B0601:2013, i.e., Rz (maximum height), of the surface shape is 12.5 μm or less. [3] The matte article as described in [1] or [2], wherein the parameter Ra (arithmetic mean roughness) of the height direction of the profile curve as specified in JIS B0601:2013 of the surface shape is 2.0 μm or less.

[0011] [4] The matte article described in any one of [1] to [3] has a matte layer, and the surface shape is formed by the surface of the matte layer. [5] The matte article described in [4] has a surface of the matte layer forming the surface shape having an uneven shape composed of irregular wrinkles. [6] The matte article described in [5] includes a plurality of protrusions formed by a plurality of linear protrusions and a recess formed by the plurality of linear protrusions.

[0012] [7] The matte article described in any one of [4] to [6], wherein the matte layer contains a hardened resin composition comprising a resin and a wrinkle-forming stabilizer, wherein the wrinkle-forming stabilizer has an average particle size with an upper limit of the smaller of 100% or less of the thickness of the matte layer and 30 μm or less, and comprises at least 0.5 parts by mass relative to 100 parts by mass of the resin. [8] The matte article described in any one of [1] to [7] has a substrate. [9] The matte article described in [8], wherein the substrate is in sheet form.

[0013]

[10] The matte article as described in [8] or [9], wherein the matte layer is provided over the entire surface of one side of the substrate.

[11] The matte article as described in any one of [1] to

[10] , wherein the 60° gloss value of the surface shape is 10.0 or less. [Effects of the Invention]

[0014] According to the present invention, a matte article with excellent visibility and texture and excellent soft touch (soft feel) can be provided.

Implementation Method

[0016] [Matte Articles] Hereinafter, embodiments of the present invention (hereinafter sometimes referred to as "this embodiment") will be described. Furthermore, in this specification, the values ​​referred to by "above", "below" and "~" in relation to the description of numerical ranges are numerical values ​​that can be arbitrarily combined, and the numerical values ​​in the embodiments are numerical values ​​that can be used at the upper and lower limits of the numerical range.

[0017] The matte article of this embodiment is characterized in that at least a portion of its surface has a surface shape in which the Spc (arithmetic mean curvature of the apex of the protrusion) as specified in JIS B0601:2013 is greater than 4000 mm-1 and the Rsm (average length of the curve element) as specified in JIS B0601:2013 is less than 30 μm.

[0018] [Regarding Surface Shape] The description begins with the surface shape (hereinafter also referred to simply as "surface shape") of at least a portion of the surface of the matte article of this embodiment. The surface shape requires that the Spc (arithmetic mean curvature of the apex of the protrusion) as specified in JIS B0601:2013 is greater than 4000 mm⁻¹, and the Rsm (mean length of the curve element) as specified in JIS B0601:2013 is less than 30 μm. By having such a surface shape, due to the light diffusion caused by the surface shape, the matte article of this embodiment exhibits excellent visibility and texture of the matte effect (hereinafter, these are sometimes collectively referred to as "matte effect"), and the tactile feel (hand feel) especially exhibits a "soft touch" (soft hand feel). "Soft touch" is a sensory expression, but "soft touch" in this specification generally includes all tactile sensations that feel "soft". Specifically, unlike the cool or rough feel often found in previous resin decorative pieces, this refers to the feel felt when touching a smooth, dry surface with the fingertip. Examples of fabrics with a "soft feel" include high-grade paper (not coated paper), Oxford cloth made with fine yarn of 60-120 count (from fine to very fine), baby skin fabric, silk, Tencel (lyocell), synthetic fibers such as Promix, rayon, and cupro, chemical fibers such as regenerated fibers, or fabrics made by applying a peach-skin-like finish (a thin napping process that resembles the skin of a peach).

[0019] (Spc (Arithmetic Mean Curvature of Protrusion Vertex)) Spc (Arithmetic Mean Curvature of Protrusion Vertex) is one of the three-dimensional surface property parameters specified in JIS B0601:2013. It is the average curvature (average sharpness) of the tip of the mountain peak, calculated from the arithmetic mean of the radii of curvature of the peaks (protrusion vertices) of the parts classified as mountains (convexities) in the shape image contained in the reference region. Therefore, Spc is the reciprocal of the radius (mm) (mm-1).

[0020] The larger the value of Spc, the greater the curvature of the tip of the ridge (1a in Figure 1) (the smaller its reciprocal radius of curvature, and the sharper the shape of the tip). On the other hand, the smaller the value of Spc, the smaller the curvature of the apex of the protrusion (1b in Figure 1) (the larger its reciprocal radius of curvature, and the blunter the shape of the tip). That is, the smaller the Spc, the more curved the protrusion, the closer it is to a plane, and thus, the greater the brightness. Therefore, if a surface shape with a larger Spc (a surface shape with a sharp apex of the protrusion) is chosen to suppress brightness by focusing only on the value of Spc, the scattering of light on the surface becomes stronger, and the brightness is reduced. A surface shape with a smaller Spc has a softer feel because the apex of the protrusion is curved. On the other hand, if the value of Spc is increased, the curvature of the protrusion is lost, the soft feel is damaged, but the matting effect is improved. Therefore, if the Spc is small, i.e., below 4000 mm⁻¹ (radius of curvature above 0.25 mm), the desired matte finish cannot be achieved. However, if the Spc is increased, i.e., greater than 4000 mm⁻¹ (radius of curvature below 0.25 mm), the softness decreases. Thus, it can be said that the matte finish and the softness are conflicting. In this invention, by setting the Rsm within a specific range, in addition to the Spc, both the matte finish and the softness can be achieved.

[0021] Due to its relationship with Rsm (average length of curve elements) described below, from the viewpoint of improving matting effect and soft touch, Spc is preferably 4200 mm⁻¹ or more, more preferably 4300 mm⁻¹ or more, more preferably 4400 mm⁻¹ or more, with an upper limit preferably 7000 mm⁻¹ or less, more preferably 6500 mm⁻¹ or less, more preferably 6000 mm⁻¹ or less, and even more preferably 5700 mm⁻¹ or less. In this specification, the critical value for measuring Spc is 0.8 mm.

[0022] Regarding the measurement of Spc, Spc is a measurement value obtained by measuring a rectangle (1024 μm × 768 μm) of any part of the surface shape of a matte article using a shape analysis laser microscope. The measurement conditions can be adjusted appropriately, for example, the measurement can be performed under the conditions described in the examples. Furthermore, Rsm (average length of curve element), Rz (maximum height), and Ra (arithmetic mean roughness) can also be measured in the same way.

[0023] (Rsm (Average Length of Curve Element)) Rsm (Average Length of Curve Element) is the lateral parameter of the profile curve in the three-dimensional surface property parameters specified in JIS B0601:2013, and is the average length of the profile curve element at the reference length. The smaller Rsm is, the more protrusions (2a and 2b in Figure 2) are included in the reference length. As a result, the surface shape with a smaller Rsm has a denser presence of protrusion vertices, so when touching the surface with a finger, for example, the contact area with the finger increases, thus resulting in a better soft touch. Thus, if Rsm is large, that is, above 30 μm, the desired soft touch cannot be obtained, but if Rsm is reduced, even if it does not reach 30 μm, a good soft touch can be obtained.

[0024] In the matte article of this embodiment, the density of the protrusions is increased by reducing Rsm. By increasing Spc, the matte effect is improved, and by further reducing Rsm, the soft touch is improved. The relationship between Spc and Rsm is more specifically as follows. As mentioned above, by increasing Spc, a matte effect can be obtained, but the touch is rough, and thus a soft touch cannot be obtained. In this invention, by increasing Spc and further reducing Rsm, a high level of both matte effect and soft touch can be achieved. By increasing Spc, the surface shape has sharp protrusions, but the more Rsm is reduced, the denser these protrusions become, thereby eliminating unevenness at the contact point with the fingertip, thus improving the soft touch. Thus, it is believed that an excellent matte effect can be obtained, while the soft touch is improved, achieving a high level of both matte effect and soft touch.

[0025] Due to the aforementioned relationship with Spc, from the viewpoint of improving the matte finish and soft touch, Rsm is preferably 29.5 μm or less, more preferably 29.0 μm or less, and even more preferably 28.5 μm or less. The lower limit is preferably 10.0 μm or more, more preferably 12.0 μm or more, and even more preferably 13.5 μm or more. By setting the lower limit value within the above range, the planar shape exhibits a matte finish, and manufacturing is not too difficult, which is preferable. Furthermore, the critical value for Rsm measured in this specification is 0.8 mm.

[0026] (Wrinkles) The surface shape of the matte article of this embodiment is preferably to have minute wrinkles as seen in the top view of Figure 3 below. Regarding the surface shape of the matte article of this embodiment, Spc (arithmetic mean curvature of the protrusion apex) and Rsm (average length of the curve element), and preferably Rz (maximum height) and Ra (arithmetic mean roughness) are easily within a specific range due to the presence of these minute wrinkles. On the other hand, these minute wrinkles are easily formed by having Spc (arithmetic mean curvature of the protrusion apex) and Rsm (average length of the curve element) within a specific range, and preferably Rz (maximum height) and Ra (arithmetic mean roughness) within a specific range. Thus, it can be said that Spc (arithmetic mean curvature of the protrusion apex) and Rsm (average length of the curve element) are inextricably linked to the minute wrinkles. Moreover, this surface shape enhances both the soft touch (soft feel) and the matte finish.

[0027] In the surface shape of the matte article, in order to set Spc (arithmetic mean curvature of the protrusion apex) and Rsm (average length of the curve element) within the above-mentioned specific numerical range, and preferably Rz (maximum height) and Ra (arithmetic mean roughness) as described above, (1) it is preferable to form a tiny wrinkle structure on the surface of the matte layer. Furthermore, it is preferable to (2) adapt the composition of the resin composition for forming the matte layer, especially the types, functional groups, molecular weights, presence or absence of a wrinkle-forming stabilizer, and the particle size and content of the wrinkle-forming agent when a wrinkle-forming stabilizer is used; (3) adapt the irradiation conditions of the resin composition for forming the matte layer, especially the wavelength of light with a wavelength of 100 nm to 380 nm that can cause the surface portion of the matte layer to harden and shrink, the cumulative light intensity, and the ultraviolet output density; and (4) adapt the type and thickness of the substrate and the thickness of the matte layer, in addition to the above. By adapting these, regarding the surface shape of the matte article of this embodiment, it is easy to set Spc (arithmetic mean curvature of the protrusion apex) and Rsm (average length of the curve element) within the above-mentioned specific numerical range, and it is preferable to set Rz (maximum height) and Ra (arithmetic mean roughness) within the specified numerical range.

[0028] (Rz (maximum height)) In this embodiment, regarding the surface shape, the lateral parameter Rz (maximum height) of the profile curve specified in JIS B0601:2013 is preferably 12.50 μm or less. Rz (maximum height) is one of the mountain and height parameters of the profile curve, and is the sum of the height of the highest mountain and the depth of the deepest valley in the profile curve at the reference length. The larger the value of Rz (maximum height), the larger (higher) convex part exists when viewed from the valley (concave part), and the existence of such convex parts tends to increase. Therefore, in the surface shape that satisfies Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curve element), if Rz (maximum height) is 12.50 μm or less, the unevenness of the height of the convex parts is also reduced, and the soft touch is improved.

[0029] From the viewpoint of improving matte finish and soft touch, Rz (maximum height) is preferably 12.0 μm or less, more preferably 11.5 μm or less, and even more preferably 11.0 μm or less. The lower limit is preferably 3.25 μm or more, more preferably 3.50 μm or more, and even more preferably 4.00 μm or more. Furthermore, the critical value for Rz (maximum height) measured in this specification is 0.8 mm.

[0030] (Ra (Arithmetic Mean Roughness)) In this embodiment, regarding the surface shape, the lateral parameter Ra (Arithmetic Mean Roughness) of the profile curve specified in JIS B0601:2013 is preferably 2.00 μm or less. Ra (Arithmetic Mean Roughness) is one of the parameters in the height direction of the profile curve, and is the average value of the height difference between the profile curve and the average surface at the reference length. The smaller the value of Ra (Arithmetic Mean Roughness), the more likely the height difference between the convex parts and the corresponding concave parts in the surface shape becomes smaller, and the shape becomes smoother and more uniform. Therefore, in the surface shapes that satisfy Spc (arithmetic mean curvature of the protrusion apex) and Rsm (mean length of the curve element) mentioned above, if Ra (arithmetic mean roughness) is 2.00 μm or less, the surface shape has more, more uniform, and smoother protrusions, thus suppressing abnormal tactile sensations, especially improving the softness of the touch. Furthermore, the matting effect is also improved. From the viewpoint of improving the matting effect and softness of the touch, Ra (arithmetic mean roughness) is preferably 1.90 μm or less, more preferably 1.80 μm or less, and even more preferably 1.75 μm or less, with a lower limit preferably 0.10 μm or more, more preferably 0.40 μm or more, and even more preferably 0.60 μm or more. Furthermore, in this specification, the critical value for measuring Ra (arithmetic mean roughness) is 0.8 mm.

[0031] [Regarding Layer Structure] As long as the matte article of this embodiment has the shape specified by the above parameters as its surface shape, the layer structure is not particularly limited, and any layer structure can be adopted. For example, as the simplest layer structure of the matte article of this embodiment, a single-layer structure as shown in FIG4 can be cited. As the article shown in FIG4, examples include articles containing a single layer, such as articles in which the above-mentioned surface shape is present on one side of a hardened layer of a resin composition, preferably a hardened layer of a hardened resin composition containing a hardened resin such as a free radiation hardening resin; or articles in which the surface shape is given by processing such as embossing on the surface of a resin molded article.

[0032] Furthermore, from the perspective of more flexibly addressing various performance requirements such as mechanical strength, post-processing suitability, and design appearance of articles to meet various needs, as well as from the perspective of manufacturing suitability and usability, an article composed of a plurality of laminated layers, as shown in Figures 5 and 6, can also be cited. This laminated body, for example, has a substrate and a hardened layer of a resin composition, which serves as a matte layer and has the aforementioned surface shape in at least a portion thereof. Hereinafter, regarding the layers constituting the matte article of this embodiment, for an article composed of a laminated body, which is one of the preferred embodiments, the layers constituting the laminated body having a substrate and a hardened layer (matte layer) having the aforementioned surface shape in at least a portion thereof will be described.

[0033] [Substrate] The shape (or form) of the substrate forming the matte article of this embodiment is not particularly limited, and various shapes such as film, sheet or plate, polyhedron, polygonal prism, cylinder, sphere, ellipsoid, etc. can be appropriately adopted. Here, film, sheet, and plate are referred to as film, sheet, and plate according to their relative thickness from thinnest to thickest, but in this specification, it is not particularly meaningful to strictly distinguish between these three, and the interpretation of the claims of this invention will not differ due to the difference between film, sheet, and plate. Therefore, in this specification, film, sheet, and plate are sometimes collectively referred to as "sheet", "sheet-like", etc. When the matte article of this embodiment is composed of a laminate, the shape of the substrate is preferably sheet-like. If the substrate is sheet-like, it is particularly easy to provide the following matte layer, thus improving manufacturing suitability, and it is easy to integrate with resin molded articles by means of bonding, thus improving post-processing suitability.

[0034] There are no particular limitations on the constituent materials of the substrate. Various materials such as resin, metal, non-metallic inorganic materials, fibrous materials, and wood-based materials can be appropriately selected according to the application. The substrate containing these various materials can be used as a single layer, or two or more substrates containing these various materials can be combined to form multiple layers. In the case of multiple layers, two or more layers of different types of materials can be laminated and integrated to complement each other and provide various functions of each layer.

[0035] When a substrate with multiple layers is used, there is a case where the laminate formed by laminating each layer constituting the multiple layers, such as a layer containing material A and a layer containing material B, is denoted as "A / B". The following are examples of preferred forms. (1) Resin / wood-based materials (2) Resin / metal (3) Resin / fibrous materials (4) Resin / non-metallic inorganic materials (5) Resin 1 / Resin 2 (e.g., "olefin resin / acrylic resin" etc., which have multiple layers containing different resins) (6) Metal / wood-based materials (7) Metal / non-metallic inorganic materials (8) Metal / fibrous materials (9) Metal 1 / Metal 2 (e.g., "copper / chromium" etc., which have multiple layers containing different metals) (10) Non-metallic inorganic materials / fibrous materials Furthermore, when the substrate has multiple layers, an adhesive layer, a bonding agent layer, and a primer layer (also called a tackifying layer or easy-to-bond layer) may be provided between the multiple layers as layers to improve the adhesion of adjacent layers.

[0036] Examples of resins that can be used as substrates include various synthetic resins and natural resins. Examples of synthetic resins include thermoplastic resins and curable resins. Considering the suitability for manufacturing matte articles, handling, and post-processing, thermoplastic resins are preferred.

[0037] Preferred thermoplastic resins include: olefin resins such as polyethylene, polypropylene, polymethylpentene, ionomers, and various olefin-based thermoplastic elastomers; vinyl chloride resins such as polyvinyl chloride, polyvinylidene chloride, and vinyl chloride-vinyl acetate copolymer; polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymer, and polyester-based thermoplastic elastomers; and poly(meth)acrylate and poly(meth)acrylate. Acrylic resins such as poly(meth)acrylate and methyl methacrylate-butyl methacrylate copolymer; polyamide resins represented by nylon 6 and nylon 66; cellulose resins such as cellulose triacetate, celluloid, and celluloid; styrene resins such as polystyrene, acrylonitrile-styrene copolymer, and acrylonitrile-butadiene-styrene copolymer (ABS resin); polyvinyl alcohol, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, polycarbonate resin, polyaryl ester resin, and polyimide resin. Natural resins, such as natural rubber, rosin, and amber, are preferred examples. Furthermore, as curable resins, thermosetting resins and radiation-cured resins, as examples of materials used in matte layers, are preferred examples.

[0038] Examples of metals that can be used as substrates include, for example: aluminum alloys such as aluminum or duralumin; iron alloys such as iron or carbon steel, stainless steel; copper alloys such as copper or brass, bronze; gold, silver, chromium, nickel, cobalt, tin, titanium, etc. Furthermore, examples of substrates containing metals include those where such metals are attached to the surface by means of plating or the like.

[0039] As non-metallic inorganic materials that can be used as substrates, for example, preferred examples include: cement, ALC (lightweight aerated concrete), gypsum, calcium silicate, wood chip cement and other non-ceramic kiln materials; ceramic kiln materials such as ceramics, earthenware, glass, enamel and other ceramic kiln materials; natural stones such as limestone (including marble), granite, and andesite, etc.

[0040] Examples of fibrous materials that can be used as substrates include, for example, thin paper, kraft paper, high-grade paper, Japanese paper, titanium paper, cotton linter paper, tracing paper, paraffin paper, parchment paper, cellophane, wallpaper backing paper, thick paper, gypsum board base paper, etc.; woven or non-woven fabrics containing polyester resin fibers, acrylic resin fibers, silk, cotton, linen and other protein or cellulose-based natural fibers, glass fibers, carbon fibers, etc. In these materials, to improve the interlayer strength between fibers of the paper substrate or with other substrates used in combination with the paper substrate, and to prevent pilling, various resins such as acrylic resin, styrene-butadiene rubber, melamine resin, and urethane resin can be added (these resins are impregnated after papermaking or filled during papermaking). Examples of resin-added paper include, for example, inter-paper reinforced paper, resin-impregnated paper, etc. Furthermore, when the substrate is made of fibrous materials such as paper, the liquid composition for forming the matte layer can penetrate into the substrate during application. This can lead to unevenness or irregularity of the substrate fibers on the surface of the matte layer, making it impossible to obtain the desired Spc and Rsm values. In such cases, it is preferable to form a known impermeable resin layer on the matte layer forming side surface of the fibrous material substrate by coating or other methods. Examples of resins for forming this impermeable resin layer include, for example, two-component curable urethane resins. Additionally, as a laminate formed by layering a fibrous material layer and a resin layer, examples of wallpaper sheets commonly used in the building materials industry include vinyl chloride resin layers, olefin resin layers, acrylic resin layers, and other resin-containing layers on the surface of wallpaper backing paper.

[0041] As a wood-based material that can be used as a substrate, examples of veneers, plywood, engineered wood, particleboard, medium-density fiberboard (MDF) of various woods such as cedar, cypress, pine, beech, oak, walnut, lauan, teak, and rubberwood are preferred.

[0042] There are no limitations on the substrate material; any substrate containing the aforementioned materials can be used, and the appropriate selection can be made according to the desired properties. From the viewpoint of improving the matte effect and soft touch, a substrate containing resin or a substrate containing fibrous materials is preferred, and a substrate containing resin is even more preferred. Among the resins, olefin resins, vinyl chloride resins, polyester resins, and acrylic resins are preferred, and olefin resins, vinyl chloride resins, and polyester resins are even more preferred. As an olefin resin, polyethylene or polypropylene is preferred; as a vinyl chloride resin, polyvinyl chloride is preferred; and as a polyester resin, polyethylene terephthalate is preferred. Furthermore, among the fibrous materials, paper is preferred. By using a substrate containing these materials, it is particularly easy to obtain the aforementioned surface shape and to improve the soft touch.

[0043] There are no particular restrictions on the shape and size of the substrate comprising a single layer or a laminate, and it can be appropriately selected considering the application, required performance, and suitability for post-processing. When using the shape of a film, sheet, or plate, thickness is a representative dimension in the design of matte articles, but there are no particular restrictions on the thickness. Considering manufacturing suitability, operational suitability, post-processing suitability, mechanical strength, and economy, a preferred thickness can be selected in the range of 10 μm to 10 cm. When using the shape of a film or sheet, a preferred thickness can be selected in the range of 20 μm to 300 μm, and when using the shape of a plate, a preferred thickness can be selected in the range of 1 mm to 2 cm.

[0044] From the viewpoint of improving the adhesion between the substrate and other layers, such as the matte layer constituting the matte article, and the adhesion between the substrate and the bonded material, such as the resin molded article of the laminated matte article, surface treatments for improving adhesion, such as oxidation, texturing, and chemical surface treatments, can be applied to at least one side of the substrate. Examples of oxidation methods include corona discharge treatment, chromating treatment, flame treatment, hot air treatment, and ozone-ultraviolet treatment. Examples of texturing methods include sandblasting and solvent treatment. These surface treatments can be appropriately selected according to the type of substrate. Based on the adhesion improvement effect obtained from the surface treatment and workability, corona discharge treatment is preferred.

[0045] The substrate may be colored or uncolored (can be transparent). When colored, there are no particular restrictions on the coloring pattern. It may be transparent or opaque (concealed). These can be chosen arbitrarily.

[0046] When the substrate is colored, the colorant may include, for example, inorganic pigments such as titanium dioxide, iron black, chrome yellow, titanium yellow, red lead, cadmium red, ultramarine, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolinone yellow, phthalocyanine blue, nickel-azo complex, methyliminoazo black pigments, and perylene black pigments; metallic pigments containing flake-like foils such as aluminum and brass; and colorants such as titanium dioxide coated with mica and pearlescent (pearl) pigments containing flake-like foils such as alkaline lead carbonate. For example, when the surface hue of the bonded material, such as a resin molded product of a laminated matte article, is uneven, and it is desired to conceal the surface hue and improve the hue stability of the decorative layer to be applied, inorganic pigments such as white pigments may be used.

[0047] When coloring a resin-based substrate, any method can be used, such as adding (mixing, kneading) a colorant to the resin or applying a coating containing the resin and colorant to form a film. When coloring a substrate made of fibrous materials such as paper, woven fabric, or non-woven fabric, any method can be used, such as mixing with pulp or fibrous materials or forming a film, or a combination of these methods. When coloring a wood-based substrate, any method can be used, such as dyeing with dyes or forming a film, or a combination of these methods. When coloring a metal substrate, in addition to forming a film, an electrolytic coloring method can be used, such as forming a metal oxide film on the surface using anodizing. Furthermore, when coloring a non-metallic inorganic material substrate, any method can be used, such as forming a film or adding to the substrate, or a combination of these methods.

[0048] Additives may be formulated into the substrate as needed. When the substrate primarily utilizes resin, examples of additives include inorganic substances such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, UV absorbers, and light stabilizers. There are no particular limitations on the amount of additives; they can be appropriately set according to required characteristics, within a range that does not impede surface properties, processing characteristics, etc.

[0049] From the viewpoint of improving the weather resistance of the matte article of this embodiment, among the above-mentioned additives, it is preferable to use weather-resistant agents such as ultraviolet absorbers and light stabilizers. Examples of ultraviolet absorbers and light stabilizers that can be included in the matte layer are as follows. These weather-resistant agents such as ultraviolet absorbers and light stabilizers, as well as various other additives, can be used alone or in combination.

[0050] In this embodiment, the above-mentioned substrate can be used alone or in combination of multiple types of the above-mentioned substrate. The substrate can be obtained by combining multiple paper substrates, or by combining paper substrate with fiber substrate, paper substrate with resin substrate, fiber substrate with resin substrate, or paper substrate, fiber substrate and resin substrate. Furthermore, the resin substrate can be a single layer of the above-mentioned resin substrate, or composed of multiple layers of the same or different types of resin.

[0051] As described above, when the substrate is a film or sheet of the aforementioned resin, the thickness is preferably 20 μm or more, and preferably up to 300 μm. Considering manufacturing suitability, operational suitability, post-processing suitability, mechanical strength, and economy, it is more preferably 40 μm or more, and preferably up to 200 μm, and even more preferably 100 μm or less. Based on the same viewpoint as above, when the substrate is paper, the basis weight is generally preferably 20 to 150 g / m², and more preferably 30 to 100 g / m².

[0052] [Matte Layer] The matte layer of the matte article in this embodiment is a layer that is either a single layer or deposited on at least a portion of the substrate, and has the surface shape described above, i.e., a surface shape with Spc (arithmetic mean curvature of the apex of the protrusion) greater than 4000 mm⁻¹ and Rsm (mean length of the curve element) less than 30 μm. When the matte article has a substrate, as shown in FIG5, the matte layer is a layer provided such that the surface having the surface shape is the opposite side of the substrate side. Therefore, the matte article of this embodiment is preferably composed of having a matte layer and the surface shape being formed by the surface of the matte layer. Furthermore, from the viewpoints of mechanical strength and manufacturability, the matte layer is preferably a layer containing a cured resin composition, and more preferably a layer containing a cured resin composition containing a cured resin.

[0053] As the resin composition for forming the matte layer, from the viewpoint of obtaining a matte article with excellent matte effect and excellent soft touch, it is preferable to be a resin composition containing a resin and a wrinkle-forming stabilizer (hereinafter sometimes referred to as "resin composition for forming matte layer"). That is, in this embodiment, the matte layer is preferably a layer containing a resin and a wrinkle-forming stabilizer.

[0054] (Wrinkle Formation Stabilizer) The wrinkle formation stabilizer has the following functions: by stabilizing the formation of wrinkles on at least one surface of the matte layer, it imparts: visibility of the light effect; uniform presentation of the surface shape of the entire surface of the matte layer covering at least a portion of the surface of the matte article, and a stable matte effect that reduces unevenness in some areas of brightness (hereinafter, the expression "visibility of stable matte effect" is sometimes used as the standard); and uniformity of surface state (also known as "texture") achieved by the stable formation of wrinkles covering the entire surface of the matte layer. Moreover, the wrinkles formed on the matte layer also greatly contribute to the presentation of a soft tactile feel. In this specification, "wrinkle formation stabilization" means that by adding a wrinkle formation stabilizer, the in-plane distribution (variance σ) of the shape and geometrical properties of the wrinkles (length, width, and ratio of each protrusion) and their statistical indices (Spc, Rsm, Rz, and Ra in this case, and further, Sm, Ssk, Sku, etc., as needed) converges compared to the case without the addition. Consequently, the in-plane distribution (variance σ) of the 60° gloss value of the surface shape described below also converges. Therefore, even when the constituent materials and average particle size of the so-called "matte agent" in the prior art and the "wrinkle formation stabilizer" of this embodiment are the same, they differ in their matting mechanism (function), the structure used to achieve matte finish, and the relationship between the amount used and the gloss level of the surface. Furthermore, they also differ from "matte agents" in that they produce a soft tactile feel by forming wrinkles.

[0055] In the prior art, such as Patent Document 1, the matting agent used to achieve matting effect presents the visual appearance of matting effect through the light diffusion effect caused by the physical shape. Specifically, the matting agent generally has the difference in refractive index between the matting agent particles and the surrounding resin and air. The visual appearance of matting effect is presented by the light diffusion effect caused by the reflection and refraction interface of light corresponding to the contour shape of the particles. On the other hand, in the matting article of this embodiment, the wrinkle-forming stabilizer does not present the visual appearance of matting effect by the light diffusion caused by the reflection and refraction of light generated by the particles themselves. Instead, it stabilizes the formation of wrinkles on the surface of the matting layer by the wrinkle-forming stabilizer, and uses the light diffusion effect of the interface between the refractive index difference of the surface and air to stably impart the visual appearance and texture of matting effect to the matting article. Therefore, the wrinkle-forming stabilizer used in this embodiment differs from the visually apparent matting agent that exhibits a matting effect (even if both have the same constituent substances and average particle size) in their matting mechanisms (functions) and the structures used to produce matting. Furthermore, the relationship between the content of the "wrinkle-forming stabilizer" and the "matting agent" and the surface gloss (gloss value) also differs. When the same substance A is used as a wrinkle-forming initiator AW (W: wrinkle) and contains the wrinkle-forming initiator in a specific amount C, the 60° gloss value G60°AW(C) of the surface when wrinkles are formed on the surface is significantly lower than the 60° gloss value G60°AM(C) of the surface when substance A is used as a matting agent AM and contains the matting agent in the specific amount C, but wrinkles are not formed on the surface. That is, the following relationship holds: G60°AW(C) < G60°AM(C).

[0056] The matte layer in the matte article of this embodiment may contain an agent previously used as a matting agent. However, considering the characteristics of the invention's effect—namely, to consistently obtain an extremely superior matte effect that cannot be obtained even with the use of a matting agent, and to obtain a soft touch—it is preferable that it does not contain a matting agent. Thus, it can be considered that the matte article of this embodiment, even if it does not substantially contain the matting agent previously used to obtain the visibility of the matte effect, still possesses extremely superior visibility and texture of the matte effect. Here, "does not contain a matting agent" means not only that it does not contain a matting agent at all, but also that even if it does contain a matte agent, it does not possess the visibility of the matte effect based on the effect of the matting agent itself. Specifically, relative to 100 parts by weight of resin, the content of the matting agent is less than 15.0 parts by weight, preferably 10.0 parts by weight or less, and more preferably 3.0 parts by weight or less. Furthermore, in this application specification, based on the viewpoint of forming a protrusion due to the exposure effect as described above, "matte agent" specifically means particles having an average particle size, the lower limit of which is the smaller of 100% of the thickness of the layer containing the matte agent, i.e., the matte layer, and 30 μm.

[0057] In this embodiment, the wrinkle-forming stabilizer can be used without particular limitations, as long as it is not a matting agent and the average particle size is limited to the smaller of 100% or less of the thickness of the matting layer and 30 μm or less. From the viewpoint of improving the matting effect and soft touch, it is preferable to use at least one of two wrinkle-forming stabilizers that are distinguished by their average particle size, with the average particle size limited to the smaller of 100% or less of the thickness of the matting layer and 30 μm or less. Specifically, the two wrinkle-forming stabilizers are wrinkle-forming stabilizer 1, which has an average particle size of 1 μm or more and the smaller of 100% or less of the thickness of the matting layer and 30 μm or less as the upper limit, and wrinkle-forming stabilizer 2, which has an average particle size of less than 1 μm. In this embodiment, if at least one of the two wrinkle-forming stabilizers is used, the wrinkle formation is stable, an excellent matte effect can be consistently obtained, and a soft touch can also be obtained.

[0058] In this embodiment, wrinkle forming stabilizer 1 and wrinkle forming stabilizer 2 can be used alone, or wrinkle forming stabilizer 1 and wrinkle forming stabilizer 2 can be used together. From the viewpoint of improving the matte effect and soft touch, it is preferable to use wrinkle forming stabilizer 1 and wrinkle forming stabilizer 2 together.

[0059] As a wrinkle-forming stabilizer, for example, organic particles or inorganic particles can be used. Examples of organic substances constituting organic particles include polymethyl methacrylate, acrylic-styrene copolymer resin, melamine resin, polycarbonate, polystyrene, polyvinyl chloride resin, benzoguanamine-melamine-formaldehyde condensate, silicone, fluorinated resins, and polyester resins. Examples of inorganic substances constituting inorganic particles include silica, alumina, calcium carbonate, aluminosilicates, and barium sulfate, among which silica, which has excellent transparency, is preferred.

[0060] The shape of the wrinkle-forming stabilizer is not particularly limited. For example, spherical, polyhedral, scaly, and amorphous shapes can be cited.

[0061] The average particle size of the wrinkle-forming stabilizer 1 is 1 μm or more, and the upper limit is the smaller of 100% or less of the thickness of the matte layer and 30 μm or less. From the viewpoint of stably improving the matte effect and enhancing the soft touch, the average particle size of the wrinkle-forming stabilizer 1 is preferably 1.3 μm or more, more preferably 1.5 μm or more, and even more preferably 1.8 μm or more. Regarding the upper limit, for the thickness of the matte layer, it is preferably 90% or less of the thickness of the matte layer, more preferably 80% or less of the thickness of the matte layer, and even more preferably 70% or less of the thickness of the matte layer. Regarding the absolute value, it is preferably 20 μm or less, more preferably 10 μm or less, even more preferably 8 μm or less, and even more preferably 7 μm or less. The above upper limit can be set as the smaller value when any combination of the upper limit for the thickness of the matte layer and the upper limit for the absolute value is used. For example, the smaller of 90% or less and 20 μm or less of the matte layer thickness can be used as the upper limit, or the smaller of 90% or less and 10 μm or less of the matte layer thickness can be used as the upper limit. Furthermore, the thickness of the matte layer will be explained later.

[0062] Furthermore, the average particle size of the wrinkle-forming stabilizer 2 is less than 1 μm. From the viewpoint of stabilizing wrinkle formation, consistently improving matte finish, and enhancing softness, the average particle size of the wrinkle-forming stabilizer 2 is preferably 1 nm or more, more preferably 3 nm or more, and even more preferably 5 nm or more, with an upper limit of preferably 900 nm or less, more preferably 700 nm or less, and even more preferably 500 nm or less. In this specification, the average particle size of the wrinkle-forming stabilizer is measured as the mass average value d50 using particle size distribution determination by laser diffraction.

[0063] From the viewpoint of stabilizing the formation of wrinkles by utilizing the wrinkle-forming stabilizer, stabilizing the matte effect, and enhancing the soft touch, the content of the wrinkle-forming stabilizer (the total content of which is used when wrinkle-forming stabilizer 1 and wrinkle-forming stabilizer 2 are used together) relative to 100 parts by weight of the resin forming the matte layer is preferably 0.5 parts by weight or more, more preferably 0.75 parts by weight or more, more preferably 1.0 parts by weight or more, and more preferably 1.2 parts by weight or more. The upper limit is not particularly limited from the viewpoint of stabilizing the matte effect and enhancing the soft touch. For example, from the viewpoint of improving the productivity of decorative materials by utilizing the coatability of the resin composition for forming the matte layer, and efficiently enhancing the visibility and texture of the matte effect, it is preferably 25.0 parts by weight or less, more preferably 15.0 parts by weight or less, more preferably 10.0 parts by weight or less, more preferably 7.5 parts by weight or less, and especially preferably 6.0 parts by weight or less.

[0064] When wrinkle-forming stabilizer 1 and wrinkle-forming stabilizer 2 are used together, there is no particular limitation on the content of wrinkle-forming stabilizer 1 and wrinkle-forming stabilizer 2, as long as the total content is within the above range. The content of wrinkle-forming stabilizer 2 relative to 100 parts by weight of resin is preferably 0.1 parts by weight or more, more preferably 0.5 parts by weight or more, and even more preferably 1.0 parts by weight or more. The upper limit is preferably 10.0 parts by weight or less, more preferably 7.5 parts by weight or less, even more preferably 5.0 parts by weight or less, and even more preferably 3.5 parts by weight or less. Furthermore, regarding the mixing ratio of wrinkle-forming stabilizer 1 and wrinkle-forming stabilizer 2, when the total amount is set to 100 parts by mass, the mixing amount of wrinkle-forming stabilizer 1 is preferably 0.0 parts by mass or more than 0.95 parts by mass, more preferably 0.10 parts by mass or more than 0.90 parts by mass, further preferably 0.20 parts by mass or more than 0.80 parts by mass, and further preferably 0.30 parts by mass or more than 0.70 parts by mass.

[0065] As a wrinkle-forming stabilizer, organic particles and inorganic particles can be used as described above. The types of these particles themselves can also include those previously used as matting agents, such as the matting layer of the decorative sheet described in Patent Document 1, which uses matting agents such as spherical alumina and calcium carbonate. In order for the spherical alumina, calcium carbonate, and other matting agents to exhibit a visible matting effect due to the light diffusion effect caused by their physical shape, as described in Patent Document 1, the spherical alumina and calcium carbonate are used in a content of approximately 50 parts by weight relative to 10 parts by weight of the resin component, which is approximately 10 parts by weight of spherical alumina and 40 parts by weight of calcium carbonate. However, in this embodiment, even if the content is relatively low as described above—that is, even if the content is less than the amount required to achieve a visible matting effect due to the light diffusion effect caused by their physical shape—a matting effect far superior to that obtained by using a matting agent can be obtained, thereby also achieving a soft touch. Therefore, it can be said that even if the matte article of this embodiment does not actually contain a matting agent, wrinkles are stably formed on the surface, thereby consistently obtaining a better matte effect than when a matting agent is used, while also obtaining texture and a soft touch.

[0066] (Surface Shape of the Matte Layer) The matte layer in the matte article of this embodiment has the aforementioned surface shape, preferably a layer containing a hardened resin composition for forming a matte layer containing a specific amount of a wrinkle-forming stabilizer. As mentioned above, by stabilizing the formation of wrinkles on the surface of the matte layer, the layer stably exhibits a matte effect and a soft feel by utilizing the light diffusion effect caused by the shape of the wrinkles. FIG3 is a schematic diagram from a top view of one embodiment of the matte article of this embodiment, and is a schematic diagram of the surface of the matte article obtained in the embodiment. In FIG3, it is shown that wrinkles are formed on the surface of the matte article of this embodiment, i.e., the surface of the matte layer. Here, "top view" means viewing the surface of the matte article from the positive Z-axis in the XYZ coordinate system shown in FIG4 to 6.

[0067] There are no particular limitations on the wrinkles present on at least one surface of the matte layer, as long as the surface shape described above is formed, that is, a surface shape having Spc and Rsm within the specific numerical range described above, and preferably also having Rz and Ra within the specific numerical range described above. Since it has the surface shape by presenting wrinkles, it forms a stabilizer by wrinkles, thus forming a stable matte effect and also presenting a soft touch. Regarding wrinkles, from the viewpoint of presenting the surface shape described above, improving the matte effect, and improving the soft touch, at least one surface of the matte layer preferably has a concave-convex shape composed of irregular wrinkles. The irregular wrinkles preferably include a plurality of protrusions formed by a plurality of protrusions and a concave portion formed by a plurality of protrusions surrounding a plurality of protrusions. The protrusions are preferably protrusions with lines. In this specification, "a protrusion of a line" (hereinafter also referred to as "a line protrusion") means that the ratio of the length to the width (length / width) of the protrusion is 3 or more, preferably 5 or more, and even more preferably 10 or more. The method for determining the length and width is as described below. In this embodiment, a more preferred irregular fold includes a plurality of protrusions formed by a plurality of line protrusions and a recess formed by the plurality of line protrusions surrounding it.

[0068] As a pattern related to these wrinkles, the pattern shown in FIG3 can be cited as an example. FIG3 also shows the following: the surface of the matte article, i.e., the surface of the matte layer, has irregular wrinkles when viewed from above; the irregular wrinkles are formed by a plurality of protrusions 2 formed by a plurality of curved line protrusions and a recess 3 formed by the plurality of protrusions (the plurality of protrusions 2); and at least a portion of the curved plurality of protrusions 2 is formed by a respective meandering line protrusion, and the meandering recess 3 is formed by the meandering line protrusion. The matte article of this embodiment stably presents a matte effect and also presents a soft touch due to the stable formation of the wrinkles shown in FIG3.

[0069] Here, "curved" means a portion in which the extension direction of a protrusion 2 having one or more continuous lines in a top view is reversed from one side to the other. Examples of a portion in which the extension direction is reversed from one side to the other include forms such as those where, when the width of the top-view shape of the protrusion 2 is ignored (and the width is considered 0), it is approximated by a continuous curve, and thus has a point of inversion. Also, examples include forms where, when the width of the top-view shape of the protrusion 2 is ignored and approximated by a straight line, it is approximated by a V-shaped broken line or the two sides of a triangle sandwiching one vertex.

[0070] Furthermore, "winding" refers to a portion of a protrusion 2 with at least two continuous lines in a top view where the direction of extension is reversed from one side to the other (hereinafter also referred to as "reversed portion"), and where the protrusion 2 with lines alternately reverses the direction of extension of the two adjacent protrusions 2 as it travels in its extension direction. For example, a portion approximated by the Roman letter "S" can be given when the width of the top view shape of the protrusion 2 with lines is ignored and approximated by a continuous curve. Also, a portion approximated by the Roman letter "W" can be given when the width of the top view shape of the protrusion 2 with lines is ignored and approximated by a straight line.

[0071] In this specification, "irregular" means a shape that cannot be considered to have a fixed regularity, and a so-called pattern that cannot be considered to be arranged in a fixed regularity. Typical examples of non-irregular shapes (regular shapes) include shapes such as a so-called "lenticular lens," which is formed by arranging a plurality of cylindrical unit lenses adjacent to each other in a direction orthogonal to their length direction, or a shape arranged in a fixed periodicity in a specific direction. Therefore, the irregular wrinkles in this embodiment include: a protrusion whose shape itself is not formed in a fixed regularity such as periodicity, thus being irregular; a plurality of protrusions formed by a plurality of protrusions whose shapes are not formed and arranged in a fixed regularity, thus being irregular; and the shape of the concave portion surrounded by such a plurality of protrusions is also irregular. In the matte article of this embodiment, as long as any one of the following is irregular: the shape of a single protrusion (a raised portion), the shape and arrangement of each of the plurality of protrusions (a plurality of raised portions), or the shape of the recess surrounded by the plurality of protrusions, a matte effect achieved by irregular wrinkles and a soft touch can be obtained. However, it is preferable that all of them are irregular. The matte article of this embodiment, by having irregular wrinkles, enhances the visibility and texture of its matte effect, consistently presents an extremely excellent matte effect, and exhibits a soft touch.

[0072] As described above, the matte layer has wrinkles, i.e., an uneven shape, on at least one surface. Regarding the convex and concave parts in the uneven shape, for example, by using the brightness difference of the surface image of the decorative material of this embodiment, the darkest part of the density distribution image is set as gray level 255, and the lightest part of the density distribution image is set as gray level 0. For gray levels 0 to 255, binarization processing is performed, and gray levels 0 to 127 are set as concave parts, and gray levels 128 to 255 are set as convex parts for differentiation.

[0073] Preferably, the surface of the matte article in this embodiment has irregular wrinkles formed in at least a portion of it, and more preferably, irregular wrinkles are formed throughout the entire surface. The location of the wrinkles is not particularly limited, as long as it is on the surface of the matte article. For example, it is not limited to the portion corresponding to the drawing (on the drawing) as described below. As long as it is at least a portion of the surface, a matte effect and soft feel achieved by the formation of wrinkles will be presented. For example, in the case where the decorative layer has irregular wrinkles formed in a portion, if the wrinkles are formed in the portion of the decorative layer corresponding to the drawing (e.g., on the drawing), the drawing is considered to be a more matte area than the surrounding area, thus enhancing the design. Furthermore, preferably, as shown in FIG3, it has a plurality of protrusions formed by a plurality of irregular but somewhat homogeneous protrusions, and a recess surrounded by the protrusions. Therefore, a shape with a highly varied width within a single protrusion (protrusion) is unlikely to achieve the aforementioned surface shape. Such a shape cannot be considered superior in terms of both visual appeal and texture for achieving a matte finish, nor can it be considered superior in terms of achieving a soft tactile feel. Regarding the shapes of protrusions (protrusions) and concave portions forming irregular wrinkles, specific shapes that offer advantages in consistently enhancing both the matte finish and the soft tactile feel will be explained below. By having wrinkles with the following shapes, the aforementioned surface shape is easily achieved, thereby enhancing both the matte finish and the soft tactile feel.

[0074] Regarding the shape of the wrinkles formed on at least one surface of the matte layer, the height of the protrusion (height of the raised portion) is preferably 0.5 μm or more, more preferably 1 μm or more, and even more preferably 2 μm or more, with an upper limit of about 10 μm or less. Furthermore, the width of the protrusion is preferably 0.1 μm or more, more preferably 0.3 μm or more, even more preferably 0.5 μm or more, with an upper limit of about 10 μm or less, even more preferably 4 μm or less, and even more preferably 3 μm or less. If the height and width of the protrusion are within the above ranges, it is easy to achieve the above surface shape. Due to the relationship with the concave portion, the matte effect is stably improved, and the soft touch is enhanced. Here, the above dimensions of the protrusion are the average value of any 10 protrusions (raised portions) of any 10 parts (100 μm square area × 10 parts) of the matte article of this embodiment, i.e., a total of 100 protrusions. Furthermore, as shown in Figure 3, the width of a single protrusion (protrusion) is not uniform, varying in width. Therefore, the width of a single protrusion (protrusion) is set as the average of the widths of any five parts of that protrusion (protrusion). The height of the protrusion (protrusion) is determined in the same way.

[0075] The depth of the recess is preferably 0.5 μm or more, more preferably 1 μm or more, and even more preferably 2 μm or more, with an upper limit of approximately 10 μm or less. Furthermore, the width of the recess is preferably 0.1 μm or more, more preferably 0.2 μm or more, even more preferably 0.3 μm or more, with an upper limit of approximately 10 μm or less, even more preferably 3 μm or less, and even more preferably 2 μm or less. If the depth and width of the recess are within the above ranges, it is easy to achieve the aforementioned surface shape. Due to its relationship with the convex portion, the matte finish is stably improved, and the soft touch is enhanced. Here, the dimensions of the recess are determined in the same manner as the dimensions of the convex portion.

[0076] The distance from the top of the convex portion to the bottom of the concave portion (the height difference between the convex and concave portions) is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 4 μm or more, with an upper limit of preferably 20 μm or less, more preferably 8 μm or less, and even more preferably 7 μm or less. If this distance is within the above range, it is easier to achieve the above-mentioned surface shape, the matting effect is stably improved, and the soft touch is enhanced. Here, the size of the concave portion is determined in the same way as the size of the convex portion.

[0077] The occupancy ratio of the protrusion is preferably 15% or more, more preferably 20% or more, and even more preferably 30% or more, with an upper limit of preferably 80% or less, more preferably 70% or less, and even more preferably 60% or less. If the occupancy ratio of the protrusion is within the above range, it is easy to achieve the above surface shape. Due to the relationship with the occupancy ratio of the concave portion surrounded by the protrusion, the matte effect is stably improved, and the soft touch is enhanced. Here, the occupancy ratio of the protrusion is the average of the occupancy ratios of the protrusions in any 10 portions (100 μm square area × 10 portions) of the matte article of this embodiment.

[0078] The protrusions and recesses may have portions that are substantially in the same direction and substantially the same width. From the viewpoint of improving the matte finish and enhancing the soft touch, their length is preferably shorter. Specifically, the continuous length of protrusions and recesses that are substantially in the same direction and substantially the same width is preferably 95 μm or less, more preferably 80 μm or less, and even more preferably 70 μm or less. The lower limit is preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 15 μm or more. If the length is within the above range, the wrinkles become more irregular, thereby stably improving the matte finish and enhancing the soft touch. Here, in any 10 portions (100 portions in total) of any 10 portions (100 μm square area × 10 portions) of the matte article of this embodiment, the above conditions are preferably satisfied by 80% or more, more preferably 85% or more, even more preferably 90% or more, and even more preferably 95% or more. Furthermore, the word "approximately" in "approximately the same" in this specification means generally the same and has no derived meaning. In the case of direction, it means a difference within ±3°, and in the case of width, it means a difference within ±5%.

[0079] Furthermore, the number of protrusions (raised portions) in the 100 μm square area is preferably 10 or more, more preferably 20 or more, and even more preferably 30 or more, with an upper limit of 200 or less, more preferably 100 or less, and even more preferably 70 or less. If the number of protrusions is within the above range, the matte finish is stably improved, and the soft touch is enhanced. The number of protrusions is the average number of protrusions in 10 parts (100 μm square area × 10 parts) of the matte article of this embodiment.

[0080] Figure 4 is a cross-sectional view showing one embodiment of the matte article of this embodiment. It is a cross-sectional view obtained by cutting the matte article 10 with a plane parallel to its thickness direction (Z direction in this figure). As for the shape of the concave portion, it can be, for example, an acute angle as shown in Figure 4 3a, a semicircle or a semi-ellipse as shown in 3b, or a combination thereof. Also, it can be a shape with a convex portion and a concave portion as shown in Figure 4 3c. On the other hand, as for the shape of the convex portion, as shown in Figures 4 2c and 2d, the width can be wide or narrow, but it is in the shape of a semicircle or a semi-ellipse.

[0081] There is no particular limitation on the thickness of the matte layer. The aforementioned wrinkles can be formed to a degree that stably presents a matte effect and a soft feel. Taking into account ease of manufacture, the thickness is typically 1 μm or more, preferably 2 μm or more, more preferably 3 μm or more, further preferably 4 μm or more, further preferably 5 μm or more, with an upper limit preferably 300 μm or less, more preferably 200 μm or less, further preferably 150 μm or less, and further preferably 100 μm or less. In this specification, regarding the thickness of the matte layer, a cross-section of the matte article is photographed using a scanning electron microscope (SEM), and the thickness is measured at 20 locations in the resulting image. The average value of the 20 locations is taken. Furthermore, the accelerating voltage of the SEM is set to 3 kV, and the magnification is set according to the thickness. The thickness of other layers is also determined in the same way.

[0082] The matte layer is a layer that has the aforementioned surface shape over its entire surface. In this embodiment, the matte article has a surface shape on at least a portion of its surface. Therefore, the matte layer can be disposed on at least a portion of the surface of the matte article, or it can be disposed over its entire surface. When the matte article of this embodiment has the aforementioned substrate and matte layer, the matte layer can be disposed on at least a portion of the surface of the substrate, or it can be disposed over its entire surface. If the matte layer is disposed in a portion of the matte article that is visible and touchable by the user, that is, if the aforementioned surface shape is disposed in a portion of the matte article that is visible and touchable by the user, the effects of the invention, namely, a matte effect and a soft touch, can be obtained.

[0083] Furthermore, when the substrate is in the shape of a film, sheet, or plate, the matte layer can also be provided on the part of the matte article that needs to be seen and touched by the user. It can be provided on at least a part of one side or on the entire side. From the point of view of improving the matte effect and soft touch, it is preferable to provide it on the entire side as shown in Figures 4 to 6.

[0084] (Resin) As the resin for forming the matte layer, a resin composition for forming the matte layer containing the aforementioned wrinkle-forming stabilizer in a predetermined amount is formed and then cured to become a cured material, thereby constituting the matte layer. Ionizing radiation-cured resins can be cited as examples of such resins. As shown in Figures 4-6, the matte layer is the outermost layer of the matte article of this embodiment. Therefore, in addition to a resin that easily forms wrinkles using a wrinkle-forming stabilizer, from the viewpoint of improving the usability of the matte article, a resin that easily exhibits surface properties such as processing characteristics, stain resistance, scratch resistance, and weather resistance is preferred. Ionizing radiation-cured resins are preferred from these views. Since the content of the wrinkle-forming stabilizer contained in the matte layer of the matte article of this embodiment is extremely small, the properties of the resin forming the matte layer are more directly manifested as its surface properties.

[0085] Ionizing radiation-curing resin is a resin having ionizing radiation-curing functional groups, which are groups that undergo cross-linking and curing upon irradiation by ionizing radiation. Examples of preferred ionizing radiation-curing resins include functional groups with vinyl double bonds such as (meth)acrylic, vinyl, and allyl. Furthermore, in this specification, (meth)acrylic represents acrylonitrile or methacrylic. Also, in this specification, (meth)acrylate represents acrylate or methacrylate. Furthermore, ionizing radiation refers to electromagnetic waves or charged particle beams containing energy quanta capable of polymerizing and / or cross-linking molecules. Ultraviolet (UV) or electron beams (EB) are commonly used, and also include electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

[0086] Examples of ionizing radiation-curing resins include electron beam-curing resins and ultraviolet-curing resins. From the perspectives of stabilizing wrinkle formation using wrinkle-forming stabilizers, steadily improving matting effects, and enhancing softness, ultraviolet-curing resins are preferred. Specifically, ionizing radiation-curing resins can be appropriately selected from polymeric monomers and polymeric oligomers that are conventionally used as ionizing radiation-curing resins.

[0087] As a polymerizable monomer, it is preferably a (meth)acrylate monomer having a free radical polymerizable unsaturated group in the molecule, and more preferably a multifunctional (meth)acrylate monomer. Here, "(meth)acrylate" means "acrylate or methacrylate". Examples of multifunctional (meth)acrylate monomers include (meth)acrylate monomers having two or more free radiation-curing functional groups in the molecule and having at least a (meth)acrylic group as such a functional group.

[0088] From the perspective of stabilizing wrinkle formation, steadily improving matte finish, enhancing softness, and thereby improving post-processing properties, scratch resistance, and weather resistance, the functional group number of the multifunctional (meth)acrylate monomer is preferably 2 to 8, more preferably 2 to 6. Furthermore, with the aforementioned functional group number, it is particularly easy to obtain the aforementioned surface shape and to enhance the softness. These multifunctional (meth)acrylates can be used alone or in combination.

[0089] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more free radiation-curing functional groups in the molecule, with at least one (meth)acrylic group as such a functional group. Examples include 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. Furthermore, as polymerizable oligomers, they also include polybutadiene (meth)acrylate oligomers with high hydrophobicity having (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers having polysiloxane bonds in the main chain, amine plastic resin (meth)acrylate oligomers obtained by modifying amine plastic resins with more reactive groups in smaller molecules, and oligomers with cationic polymerizable functional groups in molecules such as phenolic varnish-type epoxy resins, bisphenol-type epoxy resins, aliphatic vinyl ethers, and aromatic vinyl ethers.

[0090] These polymeric oligomers can be used alone or in combination. From the viewpoints of stabilizing wrinkle formation, steadily improving matte finish, enhancing softness, and thereby improving post-processing properties, scratch resistance, and weather resistance, it is preferable to use 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; more preferably, urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers; and even more preferably, urethane (meth)acrylate oligomers.

[0091] From the perspective of stabilizing wrinkle formation, steadily improving matte finish, enhancing softness, and thereby improving surface properties such as processing characteristics, scratch resistance, and weather resistance, the functional group of these polymeric oligomers is preferably 2 to 8, more preferably 6 or less, and even more preferably 4 or less. Furthermore, based on the same viewpoints as above, the weight-average molecular weight of these polymeric oligomers is preferably 2,500 to 7,500, more preferably 3,000 to 7,000, and even more preferably 3,500 to 6,000. Here, the weight-average molecular weight is the average molecular weight obtained by GPC (Gel Permeation Chromatography) analysis and converted to standard polystyrene.

[0092] In this embodiment, the resin used to form the matte layer is preferably a combination of the aforementioned polymeric oligomer and polymeric monomer. In this case, the polymeric oligomer is preferably a multifunctional urethane (meth)acrylate oligomer, more preferably a multifunctional urethane acrylate oligomer, and the polymeric monomer is preferably a multifunctional polymeric monomer, more preferably a multifunctional (meth)acrylate monomer, and even more preferably a multifunctional acrylate monomer. This stabilizes the formation of wrinkles, steadily improves the matte effect, enhances the soft touch, and further improves surface properties such as processing characteristics, scratch resistance, and weather resistance. When used in combination, based on the same viewpoint as above, the content of the polymeric oligomer relative to 100 parts by mass of the total polymeric oligomer and polymeric monomer is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, further preferably 55 parts by mass or more, further preferably 60 parts by mass or more, with a maximum of 90 parts by mass or less, more preferably 80 parts by mass or less, further preferably 70 parts by mass or less. Furthermore, polymeric oligomers can also be used in combination, preferably by combining two polymeric oligomers with different functional groups. In this case, the content of the polymeric oligomer with the larger functional group relative to 100 parts by mass of the total polymeric oligomer is preferably 50 parts by mass or more, more preferably 55 parts by mass or more, further preferably 60 parts by mass or more, further preferably 65 parts by mass or more.

[0093] (Resin Composition) The matte layer is preferably a cured product containing a resin composition comprising the aforementioned wrinkle-forming stabilizer in a specified amount, wherein the resin composition preferably comprises the aforementioned resin and the aforementioned wrinkle-forming stabilizer in a specified amount. In this embodiment, the resin composition may contain other components besides the aforementioned wrinkle-forming stabilizer and resin, depending on desired properties. The resin composition for forming the matte layer may contain monofunctional (meth)acrylates for purposes such as reducing its viscosity. These monofunctional (meth)acrylates may be used alone or in combination.

[0094] Furthermore, when the above-mentioned resin is an ultraviolet-curable resin that is cured by ultraviolet light, it is preferable to include additives such as photopolymerization initiators and photopolymerization accelerators. By including such additives, the resin can be cured even when using ultraviolet light (even without using ionizing radiation), and surface properties that are beneficial to practical use can be obtained. Examples of photopolymerization initiators include one or more selected from acetophenone, benzophenone, α-hydroxyalkyl benzophenone, milchnerone, benzoin, benzodiazepine dimethyl ketal, benzoylbenzoate, α-acyl oxime ester, and 9-oxosulfuron derivatives. Furthermore, the photopolymerization accelerator is one that can reduce polymerization inhibition caused by air during curing and increase the curing speed; for example, examples include one or more selected from isoamyl p-dimethylaminobenzoate and ethyl p-dimethylaminobenzoate.

[0095] Since the matte layer is the outermost layer that can be applied to the matte article of this embodiment, it is preferably a weather-resistant layer, and preferably contains various weather-resistant agents such as ultraviolet absorbers and light stabilizers. There are no particular limitations on the ultraviolet absorber; it can be a common ultraviolet absorber used in decorative materials and decorative sheets, such as benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, triterpenoid-based ultraviolet absorbers, and hydroxyphenyl triterpenoid-based ultraviolet absorbers. There are also no particular limitations on the light stabilizer; it can be a common light stabilizer used in decorative materials and decorative sheets, such as hindered amine-based light stabilizers such as piperidine sebacate. Furthermore, these ultraviolet absorbers and light stabilizers can be reactive functional groups with vinyl double bonds, such as (meth)acrylic, vinyl, or allyl groups in their molecules. These weather-resistant agents, such as ultraviolet absorbers and light stabilizers, can be used alone or in combination.

[0096] [60° Gloss Value] The matte article of this embodiment is an article with excellent visibility and texture due to its matte effect. In this specification, "matte" means that the gloss is not easily visible. Since it varies depending on the color tone, pattern, etc. of the article, it cannot be generalized. For example, if the 60° gloss value is 20.0 or less, preferably around 10.0 or less, it is generally considered to be "matte". Therefore, for matte articles, such as those in black and other dark colors ("dark colors" refers to low brightness, such as the L* value in the CIE (International Commission on Illumination) L*a*b* colorimetric system measured according to JIS Z8781-4:2013, which is usually around 40 or less, preferably 30 or less), even with the use of matting agents, it is possible to obtain excellent matting effect visibility with a 60° gloss value of 20.0 or less, preferably 10.0 or less. However, due to the use of a large amount of matting agent, streaks and unevenness are generated during layer formation, making it difficult to manufacture and reducing surface properties. Furthermore, for matte articles with hues other than black and other dark colors, even with the use of matting agents, the 60° gloss value also has a lower limit. Similar to matte articles in black, it is not easy to obtain matte articles with excellent surface properties and excellent matting effect visibility and texture. This trend becomes more pronounced as the 60° gloss value decreases.

[0097] In the matte article of this embodiment, two wrinkle-forming stabilizers having a specified average particle size are used in combination, and their content is set to a small amount as described above. This not only stably obtains excellent visibility and texture of matte effect, but also achieves a soft touch. Furthermore, by suppressing the amount of wrinkle-forming stabilizer used to a very small amount, the significant increase in viscosity of the resin composition can be suppressed. As a result, layer formation becomes easier, and depending on the characteristics of the resin used for the matte layer, it naturally possesses excellent surface properties such as stain resistance, scratch resistance, and weather resistance.

[0098] As described above, the matte article of this embodiment varies depending on the hue and therefore cannot be uniformly defined. For example, in the case of black and other dark colors, if the 60° gloss value of the matte layer side is 10.0 or less, and further 7.5 or less, 5.0 or less, 4.0 or less, 3.6 or less, or 2.0 or less, then extremely excellent visibility of the matte effect can be achieved. Furthermore, matte articles with hues other than black and other dark colors can also have the above-mentioned 60° gloss value. The 60° gloss value of the matte article of this embodiment on the matte layer side is substantially the same as the 60° gloss value of the surface of the outermost layer forming the matte article, unless other layers are further present; otherwise, it is the 60° gloss value of the surface of the matte layer. In cases where other layers are further disposed on the surface side than the matte layer, the 60° gloss value refers to the 60° gloss value of those other layers. However, the specific 60° gloss value of the matte article in this embodiment is essentially due to the composition of the matte layer. In this specification, the 60° gloss value on the matte layer side is the 60° specular gloss measured according to JIS K 5600-4-7:1999, which is the average value of any 10 measurements taken from the matte layer side using a gloss meter or the like.

[0099] [Other Layers] In addition to the matte layer and substrate described above, the matte article of this embodiment may have other layers as needed, such as a base coat, a transparent resin layer, a decorative layer, and an adhesive layer. A cross-sectional view of one embodiment of the matte article of this embodiment having such layers is shown in Figures 5 and 6. The soft touch view is a cross-sectional view of one embodiment of the matte article of this embodiment, which is a cross-sectional view obtained by cutting the matte article 10 with a plane parallel to its thickness direction (Z direction in this figure). The matte decorative material 10 shown in Figure 5 has a substrate 12 and a matte layer 11 in sequence, and the matte article 10 shown in Figure 6 has a substrate 12, a decorative layer 13, an adhesive layer 14, a transparent resin layer 15, a base coat 16, and a matte layer 11 in sequence.

[0100] (Undercoat) When the matte article of this embodiment comprises, for example, a plurality of layers, an undercoat may be provided to improve the interlayer adhesion of the plurality of layers. When the matte article of this embodiment has layers other than the matte layer, for example, when it has a matte layer and a substrate, an undercoat may be provided between the matte layer and the substrate to improve the interlayer adhesion. When an undercoat is formed on the release layer, it is preferable to perform a surface treatment on the release layer, and corona irradiation is preferable as the surface treatment.

[0101] The base coating mainly contains adhesive resin, and may contain additives such as ultraviolet absorbers and light stabilizers as needed.

[0102] Preferred adhesive resins include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyraldehyde resins, styrene resins, urethane-acrylic acid copolymers, polycarbonate-based urethane-acrylic acid copolymers (derived from polymers (polycarbonate polyols) whose polymer backbone has carbonate bonds and whose terminal and side chains have two or more hydroxyl groups), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic acid copolymer resins, chlorinated propylene resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, etc. These can be used alone or in combination. Furthermore, the adhesive resin can also be obtained by adding isocyanate-based curing agents, epoxy-based curing agents, etc., to these resins for cross-linking and curing. Of these, the one obtained by cross-linking and curing polyol resins such as acrylic polyol resins using an isocyanate-based curing agent is preferred, and the one obtained by cross-linking and curing acrylic polyol resins using an isocyanate-based curing agent is even more preferred.

[0103] The thickness of the base coating is preferably 0.1 μm to 10 μm, more preferably 1 μm to 8 μm, and even more preferably 1.5 μm to 6 μm.

[0104] In order to improve the adhesion of the matte article to the bonded material such as the resin molded article on which the article is laminated, when the substrate is also provided on the opposite side of at least one surface of the matte layer with wrinkles, a base coating (also called "back base coating") may be provided on the opposite side of the substrate where the matte layer is provided.

[0105] (Transparent Resin Layer) In order to improve its strength, and in the case where a decorative layer is present as described below, a transparent resin layer may be provided for the protection of the decorative layer. In the case where a substrate is present, the transparent resin layer may be disposed between the substrate and the matte layer; in the case where a decorative layer is present, the transparent resin layer may be disposed between the decorative layer and the matte layer to protect the decorative layer.

[0106] Examples of resins constituting the transparent resin layer include polyolefin resins, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene resins (hereinafter also referred to as "ABS resins"), acrylic resins, and vinyl chloride resins. Among these, polyolefin resins and vinyl chloride resins are preferred from the viewpoint of post-processing suitability. Furthermore, two or more of these various resins can be laminated or mixed for use.

[0107] The transparency of the resin layer is sufficient to allow the substrate to be viewed from the transparent resin layer. Furthermore, in the case of a decorative layer, the transparency is sufficient to allow the decorative layer to be viewed. In addition to colorless transparency, it can also be colored transparency and semi-transparent. That is, in this invention, "transparency" means that in addition to colorless transparency, it also includes colored transparency and semi-transparent.

[0108] The transparent resin layer may contain weather-resistant agents such as ultraviolet absorbers and light stabilizers, as well as additives such as colorants. The thickness of the transparent resin layer, based on the viewpoint of protecting the decorative layer and considering post-processing suitability, is preferably 20 μm to 150 μm, more preferably 40 μm to 120 μm, and even more preferably 60 μm to 100 μm.

[0109] (Decorative Layer) From the viewpoint of enhancing design, the matte article of this embodiment may have a decorative layer. The decorative layer may be disposed on the side opposite to the at least one side of the matte layer that has wrinkles. In the case of having a substrate, the decorative layer may be disposed between the substrate and the matte layer. Furthermore, in the case of having a transparent resin layer, the decorative layer may be disposed in the order of decorative layer, transparent resin layer and matte layer.

[0110] The decorative layer may be, for example, a coloring layer covering the entire surface (a so-called pure coloring layer, "13a" in Figure 6), or a pattern layer formed by printing various patterns using ink and a printing press ("13b" in Figure 6). Also, as shown in Figure 6, it may be obtained by combining a pure coloring layer and a pattern layer.

[0111] There are no particular restrictions on the pattern (pattern) of the pattern layer. Any pattern that meets the requirements can be used. For example, wood grain patterns such as annual rings or duct grooves on the surface of wood panels, stone grain patterns on the surface of marble, granite and other stone slabs, fabric patterns on the surface of cloth, leather grain patterns on the surface of leather, geometric patterns, text, graphics, and combinations thereof.

[0112] As an ink used in the decorative layer, it is obtained by appropriately mixing pigments, dyes, colorants, extender pigments, solvents, stabilizers, plasticizers, catalysts, hardeners, ultraviolet absorbers, light stabilizers, etc., into an adhesive resin. There are no particular limitations on the adhesive resin used in the decorative layer; examples include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyraldehyde resins, styrene resins, urethane-acrylic acid copolymers, vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic acid copolymer resins, chlorinated propylene resins, nitrocellulose resins, cellulose acetate resins, etc. Furthermore, various types of resins can be used, such as one-component curing resins and two-component curing resins containing isocyanate compounds or other hardeners.

[0113] The colorant is preferably a pigment with excellent opacity and weather resistance. The pigment may be the same as those exemplified as pigments that can be used on the substrate. The content of the colorant relative to 100 parts by weight of the resin constituting the decorative layer is preferably 5 parts by weight or more and 90 parts by weight, more preferably 15 parts by weight or more and 80 parts by weight, and even more preferably 30 parts by weight or more and 70 parts by weight.

[0114] The decorative layer may contain UV absorbers, light stabilizers and other weather-resistant agents, colorants and other additives. The thickness of the decorative layer can be appropriately selected according to the required pattern. From the point of view of concealing the natural color of the bonded material and improving the design, it is preferably 0.5 μm to 20 μm, more preferably 1 μm to 10 μm, and even more preferably 2 μm to 5 μm.

[0115] (Adhesive) In the case where the matte article of this embodiment has a substrate and a transparent resin layer, an adhesive layer may be provided between the substrate and the transparent resin layer to improve the adhesion between the two layers. When a decorative layer is further provided between the substrate and the transparent resin layer, the positional relationship between the adhesive layer and the decorative layer is not particularly limited. Specifically, the decorative layer, the adhesive layer, and the transparent resin layer may be provided sequentially from the side closest to the substrate, or the adhesive layer, the decorative layer, and the transparent resin layer may be provided sequentially from the side closest to the substrate.

[0116] The adhesive layer may include, for example, urethane adhesives, acrylic adhesives, epoxy adhesives, rubber adhesives, and the like. Among these adhesives, urethane adhesives are preferred in terms of adhesion. Examples of urethane adhesives include, for instance, adhesives obtained using various polyol compounds such as polyether polyols, polyester polyols, and acrylic polyols, and two-component curing urethane resins containing curing agents such as isocyanate compounds.

[0117] The thickness of the adhesive layer is preferably 0.1 μm or more and 30 μm or less from the point of view of efficiently obtaining the required adhesion force, more preferably 1 μm or more and 15 μm or less, and even more preferably 2 μm or more and 10 μm or less.

[0118] The matte article of this embodiment may have a substrate containing a non-transparent material or a decorative layer. Therefore, the total light transmittance of the matte article of this embodiment can be relatively low. Specifically, the total light transmittance of the matte article of this embodiment, measured according to JIS K7361-1:1997, is preferably 20% or less, more preferably 15% or less, and even more preferably 10% or less. In this specification, the total light transmittance of the matte article is the total light transmittance measured according to JIS K7361-1:1997, which is the average value of measurements taken at any 10 locations.

[0119] [Method for Manufacturing Matte Articles] The first method for manufacturing matte articles according to this embodiment is characterized by including a matte layer forming step, which involves irradiating a layer of a resin composition for forming a matte layer, comprising a resin and a wrinkle-forming stabilizer, with light of a wavelength of at least 100 nm and less than 380 nm to form a matte layer. By this first manufacturing method, a matte article, as shown in Figures 5 and 6, can be manufactured having a multi-layered structure, such as a laminate, having a substrate and a hardened layer of a resin composition having the aforementioned surface shape at least a portion thereof, serving as a matte layer. For example, if the resin composition for forming a matte layer is coated onto a substrate, a layer of the resin composition is formed on the substrate, and the aforementioned irradiation is performed to form a matte layer, a matte article having a substrate and a matte layer can be manufactured. This method is a manufacturing method suitable for the following situations: by making a matte article have the above-mentioned surface shape by means of a matte layer (making the matte article have the above-mentioned surface shape on the surface of the matte layer side), a matte article with a matte effect of 20.0 or less, 10.0 or less, and even lower at 60° on the matte layer side and a soft touch is manufactured.

[0120] The matte article of the present embodiment can be easily obtained by the manufacturing method of the matte article of the present embodiment. Specifically, when the matte layer is formed, a resin composition for matte forming, which contains a wrinkle forming stabilizer for forming the matte layer, is irradiated with ultraviolet light of a short wavelength of at least 100 nm to 380 nm. This forms wrinkles on at least one surface of the matte layer, thereby giving the matte article (matte layer) a matte effect and a soft feel.

[0121] The details of the mechanism by which wrinkles are formed on at least one surface of the matte layer by irradiating the resin composition used to form the matte layer with such short-wavelength ultraviolet light, thereby presenting a matte effect and a soft touch, are not yet clear, but it is speculated that the following mechanism is used.

[0122] It is believed that if a coating layer obtained by applying a resin composition for forming a matte layer to a specified thickness is irradiated with short-wavelength ultraviolet light, the energy of the ultraviolet light only penetrates to the surface portion and does not reach the lower layers of the surface portion. As a result, only the surface portion of the resin composition begins to harden, and thus only the surface undergoes hardening and shrinkage, thereby forming wrinkles. Thus, it is believed that the formation of wrinkles occurs when the resin composition for forming the matte layer is hardened by irradiation with short-wavelength ultraviolet light only at a certain thickness from the surface of the resin composition for forming the matte layer. Furthermore, according to the comparison of the following examples and comparative examples, in the case where no wrinkle-forming stabilizer is included, the formation of wrinkles becomes unstable, the visibility and texture of the matte effect are not stably and fully presented throughout the entire surface of the matte layer, and the soft touch is not sufficiently presented. Therefore, it is impossible to explain the stable presentation of the matte effect and the soft touch by hardening only the surface portion with short-wavelength ultraviolet light. In other words, in order for the matte article of this embodiment to exhibit a matte effect and a soft feel by stably having wrinkles, a wrinkle-forming stabilizer must be included. It is believed that, considering that a stable matte effect and soft feel resulting from the formation of wrinkles cannot be obtained without the inclusion of a wrinkle-forming stabilizer, the wrinkle-forming stabilizer has a core function of inducing wrinkle formation. Centered on this core, the resin on the surface portion of the resin composition accumulates, the convex portion (protrusion) of the wrinkle is formed, and the concave portion is formed along with the formation of the convex portion (protrusion). As a result, the formation of wrinkles is stable, and a stable matte effect and soft feel are presented.

[0123] The wrinkle-forming stabilizer and the resin composition for forming a matte layer containing the wrinkle-forming stabilizer used in the manufacturing method of this embodiment are the same as those described above as wrinkle-forming stabilizers and resin compositions for forming a matte layer that can be used in the matte decorative material of this embodiment.

[0124] In the manufacturing method of this embodiment, the resin composition for forming the matte layer is irradiated with light of a wavelength of at least 100 nm and less than 380 nm. By this irradiation, as described above, the energy of the ultraviolet light only penetrates to the surface portion and does not reach the layers below the surface. Therefore, only the surface portion of the resin composition begins to harden, and only the surface undergoes hardening and shrinkage. This stabilizes the formation of wrinkles, and the surface layer of the resin composition becomes a hardened material, constituting a matte layer. Furthermore, thereafter, hardening proceeds in the depth direction away from the deeper portion near the surface where hardening is slower. The layer of the resin composition becomes a hardened material, thus forming a matte layer that is hardened throughout the entire thickness of the resin composition and has wrinkles on the surface exhibiting a light-diffusing effect and a soft tactile feel. From the viewpoint of promoting hardening to this deeper portion, it is preferable, as described below, to perform further irradiation treatment after irradiation with light of a wavelength of 100 nm and less than 380 nm.

[0125] Preferably, the light with a wavelength of at least 100 nm and less than 380 nm is "excimer light," which includes light in the ultraviolet wavelength region from an excited-state dimer, i.e., an excimer, formed by discharging a gas or a mixture of such gases, such as halides of rare gases obtained from rare gases such as Ar, Kr, Xe, and Ne, and halogens such as F, Cl, I, and Br. Regarding the wavelength of the excimer light and the excimer as the light source, wavelengths of light radiated from an excimer of Ar2 with wavelengths of 126 nm (hereinafter referred to as "126 nm (Ar2)"), 146 nm (Kr2), 157 nm (F2), 172 nm (Xe2), 193 nm (ArF), 222 nm (KrCl), 247 nm (KrF), 308 nm (XeCl), and 351 nm (XeF) are preferred. As an excimer laser, either spontaneously emitted light or laser light with high coherence (interferometry) utilizing stimulated emission can be used; spontaneously emitted light is usually sufficient. Furthermore, the discharge lamp emitting this light (ultraviolet light) is also called an "excimer lamp." Excimer lasers are characterized by a single wavelength peak and a narrower half-maximum width at half-maximum (FWHM) than typical ultraviolet light (such as that emitted from metal halide lamps and mercury lamps). Using this type of excimer laser stabilizes wrinkle formation, consistently enhances extinction effects, and improves the softness of the touch.

[0126] From the viewpoint of stabilizing the formation of wrinkles, steadily improving the matting effect, and enhancing the soft touch, the wavelength is preferably 120 nm or more, more preferably 140 nm or more, even more preferably 150 nm or more, even more preferably 155 nm or more, with an upper limit of preferably 320 nm or less, even more preferably 300 nm or less, even more preferably 250 nm or less, even more preferably 200 nm or less, and most preferably 172 nm (Xe2). Thus, it can also be said that in this embodiment, from the viewpoint of steadily improving the matting effect and enhancing the soft touch, it is preferable to use a shorter wavelength of light, more preferably medium-wavelength ultraviolet light (wavelength: 280-320 nm), short-wavelength ultraviolet light (wavelength: 280 nm or less), and even more preferably short-wavelength ultraviolet light.

[0127] In this embodiment, the cumulative light intensity of the aforementioned wavelength light is preferably 1 mJ / cm² or more, more preferably 10 mJ / cm² or more, and even more preferably 30 mJ / cm² or more, and even more preferably 50 mJ / cm² or more, based on the viewpoints of stabilizing wrinkle formation, steadily improving the extinction effect, and enhancing the soft touch. Furthermore, there is no particular upper limit; from a productive viewpoints such as reducing the number of lamps required for wavelength light irradiation and improving production efficiency, the upper limit is preferably 1,000 mJ / cm² or less, more preferably 500 mJ / cm² or less, and even more preferably 300 mJ / cm² or less. Based on the same viewpoints as above, the ultraviolet output density is preferably 0.001 W / cm² or more, more preferably 0.01 W / cm² or more, and even more preferably 0.03 W / cm², with an upper limit preferably 10 W / cm² or less, more preferably 5 W / cm² or less, and even more preferably 3 W / cm² or less. Furthermore, the oxygen concentration when irradiated with light of the aforementioned wavelength is preferably lower, preferably below 1,000 ppm, more preferably below 750 ppm, further preferably below 500 ppm, and even more preferably below 300 ppm.

[0128] In the matte layer formation step of the method for manufacturing a matte article according to this embodiment, in addition to irradiation with light of a wavelength of at least 100 nm to 380 nm as described above, other treatments that help to harden the resin composition for matte layer formation can be performed. For example, based on the viewpoint of stabilizing the formation of wrinkles caused by the difference in the degree of hardening between the aforementioned surface portion and the deeper portion away from the surface in the depth direction, and promoting hardening to the deeper portion, for example, the resin composition for matte layer formation can be pre-hardened by irradiation with light of a wavelength of more than 380 nm, preferably around 385 nm to 400 nm, and then irradiated with light of a wavelength of 100 nm to 380 nm or less. Alternatively, after irradiation with light of a wavelength of 100 nm to 380 nm or less, post-hardening can be performed to further harden the resin composition. Whether to use pre-hardening or post-hardening can be appropriately determined according to the desired properties of the matte layer (e.g., processing characteristics, surface characteristics such as stain resistance). Furthermore, while the aforementioned wavelengths of light belong to the ultraviolet range, they are not limited to ultraviolet light; other ionizing radiation, such as electron beams, can also be used. For example, in post-curing, from the viewpoint of improving the surface properties of the matting layer, electron beams can be used more effectively.

[0129] In the manufacturing method of this embodiment, the matte layer can be formed by irradiating a coating layer (uncured resin layer) obtained by coating a resin composition for forming a matte layer using known methods such as gravure printing, rod coating, roller coating, reverse roller coating, and corner wheel coating with light of a wavelength of at least 100 nm and less than 380 nm.

[0130] Furthermore, the matte article obtained by the manufacturing method of this embodiment may have other layers besides the substrate described above as layers that can be used in the matte article of this embodiment, such as a transparent resin layer. For example, the decorative layer, adhesive layer, and primer layer may be formed by applying a coating liquid containing the composition forming each layer using the methods known above, and then drying and curing as needed. Furthermore, when forming a transparent resin layer, a resin film for forming the transparent resin layer may be formed by dry lamination or the like.

[0131] Among the matte articles of this embodiment, the matte article comprising a single layer, as shown in FIG4, such as a hardened material comprising a resin composition and having the aforementioned surface shape on one side of its surface, can be manufactured by the following second manufacturing method. The second manufacturing method is characterized by comprising the following steps: a step of coating a resin composition for forming matte articles comprising a resin and a wrinkle-forming stabilizer onto the release layer of a support sheet having a release layer, thereby forming a coating layer; a step of irradiating the coating layer with light of a wavelength of at least 100 nm and less than 380 nm; and a step of peeling off the support sheet.

[0132] The support sheet can be appropriately selected from the examples of those that can be used as substrates mentioned above. For example, a substrate containing fibrous materials, preferably high-grade paper, can be used. After the resin composition is made into a matte article, the support sheet can be easily peeled off from the matte article, making the operation easy and more economical.

[0133] The release layer is a layer provided to facilitate the peeling of the support sheet from the matte article after the resin composition has been made into a matte article. Examples of release layers with excellent peelability include acrylic resins, vinyl chloride-vinyl acetate, olefin resins, silicone resins, fluororesins, and various resins modified by silicone or fluorine, and waxes may be mixed as needed. Examples of waxes include, for example, microcrystalline wax, carnauba wax, paraffin wax, Fischer-Tropsch wax, various low molecular weight polyethylenes, wood wax, beeswax, cetacean wax, insect wax, lanolin wax, shellac wax, candelilla wax, petrolatum, partially modified waxes, fatty acid esters, fatty acid amides, and other waxes.

[0134] The resin composition for forming matte articles, which includes resin and wrinkle-forming stabilizer, may be used in the resin and wrinkle-forming stabilizer that are exemplified by the user in the resin composition for forming matte layers. Furthermore, the content of the wrinkle-forming stabilizer, etc., is also the same as in the resin composition for forming matte layers.

[0135] The coating of the resin composition for forming a matte article can be performed in the same manner as the coating of the resin composition for forming a matte layer described above. Furthermore, the method of irradiating the coating layer with light of a wavelength of at least 100 nm and less than 380 nm is also the same as the irradiation of the resin composition layer for forming the matte layer. The thickness of the coating layer is directly the thickness of the resulting matte article. The thickness of the coating layer can be determined according to the desired thickness and is not particularly limited, and can be selected from the widest range of the thickness of the substrate, from 1 μm to 10 cm. Considering manufacturing suitability and operational suitability, the thickness of the coating layer is preferably 3 μm or more, more preferably 5 μm or more, and preferably less than 300 μm, more preferably less than 200 μm.

[0136] Furthermore, before forming the coating layer of the resin composition for forming a matte article, a decorative layer may be provided to enhance design. Therefore, in the case of a single layer as shown in FIG. 3, the matte article can further have a decorative layer. The decorative layer may be configured to have the same structure as the decorative layer described above as a layer that a matte article having a substrate and a matte layer can have.

[0137] By irradiating the coating layer of the resin composition for forming a matte article with light of the aforementioned wavelength, similar to the aforementioned matte layer, only the surface undergoes hardening shrinkage, thereby stabilizing the formation of wrinkles. The surface layer of the resin composition becomes a hardened object with the aforementioned surface shape. Hardening proceeds in the depth direction away from the deeper portion of the surface layer where hardening is slower, and the resin composition as a whole hardens, thereby becoming a matte article with the aforementioned surface shape on at least a portion of its surface. Furthermore, regarding irradiation, in order to promote hardening to the deeper portion, post-hardening or pre-hardening can be performed.

[0138] After irradiating the coating layer of the resin composition for forming the matte article with light of the specified wavelength as described above, the support sheet is peeled off, thereby obtaining a matte article having the surface shape described above on at least a portion of its surface.

[0139] Furthermore, among the matte articles of this embodiment, the matte article comprising a single layer, as shown in FIG4, having at least a portion of the surface of a resin article such as a resin molded article having the aforementioned surface shape, can be manufactured by the following third manufacturing method. The third manufacturing method is characterized by having a step of using an embossing plate, a shaping sheet, or the like to perform embossing processing on at least a portion of the surface of the resin molded article to impart the aforementioned surface shape.

[0140] There are no particular restrictions on the embossing plate or the shaping sheet; any material capable of imparting the aforementioned surface shape may be used. The surface shape of the embossing plate or the shaping sheet must be the opposite of the surface shape shaped by it. Specifically, regarding the shape of the concave portion of the shaping sheet that is a convex portion in the shaped surface shape, the absolute value of the surface shape's Spc must be greater than 4000 mm⁻¹, and the Rsm of the shaping sheet must not exceed 30 μm. Furthermore, the values ​​related to the surface shape of the shaping sheet and the matte article are ultimately theoretical values, and slight errors are naturally possible.

[0141] Furthermore, as a matte article of this embodiment, examples include high-pressure melamine resin decorative panels, low-pressure melamine resin decorative panels, diallyl phthalate (DAP) resin decorative panels, polyester decorative panels, guanidine resin decorative panels, phenolic resin decorative panels, and other thermosetting resin decorative panels. Thermosetting resin decorative panels are those obtained by impregnating a liquid, uncured material containing fibrous materials such as paper or fiber into a woven or non-woven fabric with thermosetting resin, using this material as a substrate, and subjecting the substrate to, for example, pressure molding or heat-press molding under conditions of heating temperature: 100–200°C, pressure: 0.1–9.8 MPa, and molding time: 10 seconds–120 minutes. The fibrous material is as described above as a substrate that can be used as a matte article. When performing pressure forming or heat-press forming, the substrate is arranged in a manner that stacks the above-mentioned embossing plate and shaping sheet to form a decorative panel as a matte article having the above-mentioned surface shape.

[0142] In this case, the thermosetting resin used to impregnate the substrate may include, for example, melamine resin, urea resin, melamine-urea resin, guanidine resin, diallyl phthalate resin, polyester resin, phenolic resin, epoxy resin, amino alkyd resin, silicone resin, polysiloxane resin, etc., and more preferably, thermosetting resins such as melamine resin, urea resin, melamine-urea resin, guanidine resin, sulfonamide resin, etc., among which melamine resin, melamine-urea resin, and phenolic resin are preferred, and melamine resin is even more preferred.

[0143] (Application) The matte article of this embodiment can be used as a decorative component as described below.

[0144] Furthermore, the matte article of this embodiment can also be used as a shaping sheet. When used as a shaping sheet, it can be used as an embossing plate or shaping sheet for embossing processing in the second and third manufacturing methods described above, thereby obtaining the above-mentioned single-layer article and thermosetting resin decorative panel. The surface shape of the object to be shaped (including the single-layer article, thermosetting resin decorative panel, etc.) is the opposite of the surface shape of the shaping sheet (the matte article of this embodiment) described above.

[0145] [Decorative Component] The matte article of this embodiment can be used directly as a decorative component, or it can be used as a decorative component in combination with an adhered layer or composite. Whether it is used directly as a decorative component or in combination with an adhered layer or composite can be determined according to the requirements. When the matte article of this embodiment is used as a decorative component, the matte article preferably has a decorative layer.

[0146] When a substrate is present, the decorative component comprises both the substrate and the matte article of this embodiment. Specifically, it is laminated with the opposite side of the substrate to be decorated and the side of the matte article that forms wrinkles to achieve a matte effect and a soft feel. Furthermore, when a substrate is present, considering the ease of lamination, the matte article of this embodiment is preferably in the form of a film or sheet.

[0147] On the other hand, regarding the matte article of this embodiment, the single-layer article shown in FIG. 4 is suitable for direct use as a decorative component, and the matte article having the aforementioned surface shape on at least a portion of the surface of a resin article such as a resin molded article is particularly preferred. When the matte article of this embodiment is used directly as a decorative component, it is preferable to use it as a decorative component constituting the surface of, for example, buildings, various furniture, vehicles, and household appliances. Furthermore, among the single-layer articles shown in FIG. 4, the matte article containing a hardened resin composition for forming matte articles obtained by the second manufacturing method described above can be used directly as a decorative component, and can also be used in combination depending on the thickness and the bonding material.

[0148] (Bonus material) Examples of bonding materials include: various materials such as flat panels, curved panels, etc.; three-dimensional objects such as cylinders and polygonal columns; sheets (or films), etc. For example, examples include: wood components such as wood veneers, plywood, engineered wood, particleboard, MDF (medium-density fiberboard), and other wood fiberboards containing various types of wood such as cedar, cypress, pine, and lauan; metal components such as sheets, three-dimensional articles, or plates containing metals such as iron, aluminum, copper, and alloys containing one or more of these metals; kiln components such as sheets or three-dimensional articles containing non-ceramic kiln materials such as glass, ceramics, gypsum, cement, ALC (lightweight aerated concrete), and calcium silicate; and resin components such as sheets, three-dimensional articles, and sheets containing resins such as acrylic resin, polyester resin, polystyrene resin, polyolefin resins such as polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) resin, phenolic resin, vinyl chloride resin, cellulose resin, and rubber. Furthermore, these components can be used individually or in combination.

[0149] The adhesive material may be appropriately selected from the above according to the application. When the application is for interior components of buildings such as walls, ceilings, and floors, or exterior components such as exterior walls, roofs, eaves, ceilings, fences, and doors, window frames, doors, handrails, baseboards, ceiling trims, and decorative strips, it is preferable to include at least one component selected from wood components, metal components, and resin components. When the application is for exterior components such as entrance doors, window frames, and doors, it is preferable to include at least one component selected from metal components and resin components.

[0150] The thickness of the adhesive can be appropriately selected according to the application and material, preferably 0.1 mm to 100 mm, more preferably 0.3 mm to 5 mm, and even more preferably 0.5 mm to 3 mm.

[0151] (Adhesive layer) In order to obtain excellent adhesion, the substrate and the matte article are preferably bonded together via an adhesive layer.

[0152] There are no particular limitations on the adhesive used for the adhesive layer, and known adhesives can be used, which can be appropriately selected according to the application. For example, preferred adhesives include moisture-curing adhesives, anaerobic-curing adhesives, dry-curing adhesives, UV-curing adhesives, heat-sensitive adhesives (e.g., hot-melt adhesives), pressure-sensitive adhesives, etc.

[0153] Examples of resins used in these adhesives include acrylic resins, carbamate resins, vinyl chloride resins, vinyl acetate resins, vinyl chloride-vinyl acetate copolymers, styrene-acrylic acid copolymers, polyester resins, amide resins, cyanoacrylate resins, and epoxy resins. These can be used alone or in combination. Two-component curing carbamate adhesives and ester adhesives using isocyanate compounds as curing agents can also be used. Furthermore, adhesives can also be used in the adhesive layer. Various adhesives, such as acrylic, carbamate, silicone, and rubber adhesives, can be appropriately selected as adhesives.

[0154] There is no particular limitation on the thickness of the adhesive layer. From the point of view of obtaining excellent adhesion, it is preferably 1 μm or more and 100 μm or less, more preferably 5 μm or more and 50 μm or less, and even more preferably 10 μm or more and 30 μm or less.

[0155] (Manufacturing Method of Decorative Component) The decorative component can be manufactured by laminating the matte article of this embodiment with a substrate. This step is the lamination of the substrate with the matte article of this embodiment. The surface of the substrate to be decorated is laminated to the opposite side of the matte layer of the matte article of this embodiment, which forms wrinkles to present a matte effect and a soft touch. Furthermore, when the matte article of this embodiment has a substrate, the surface of the substrate to be decorated is laminated to the substrate side. As a method for laminating the substrate with the matte article, for example, a lamination method can be used to laminate the matte article onto a sheet-like substrate by applying pressure with an adhesive layer and a pressure roller.

[0156] When using a hot melt adhesive (thermal adhesive) as the adhesive, the heating temperature also depends on the type of resin constituting the adhesive, preferably between 160°C and 200°C. When using a reactive hot melt adhesive, it is preferably between 100°C and 130°C. Furthermore, in the case of vacuum forming, heating is generally performed simultaneously, and the heating temperature is preferably between 80°C and 130°C, more preferably between 90°C and 120°C.

[0157] The decorative components obtained by the above operation can be cut arbitrarily, and the surface or wood cut edges can be grooved, chamfered, or otherwise decorated using cutting machines such as grooving machines and cutting machines. Furthermore, these decorative components are well used for various purposes, such as interior components for buildings such as walls, ceilings, and floors; exterior components for exterior walls, eaves, ceilings, roofs, fences, etc.; window frames, doors, door frames, handrails, baseboards, ceiling trims, decorative strips, etc.; general furniture such as multi-drawer cabinets, shelves, and tables; kitchen furniture such as dining tables and sinks; or surface decorative panels for cabinets of home appliances and OA equipment; and interior and exterior components for vehicles. Furthermore, in addition to the decorative components used in buildings, etc., as described above, the matte article of this embodiment can be used directly as a standalone unit, or in a laminated, composite, or combined form with other materials (adhesive materials), for packaging materials, anti-glare films for displays, whiteboards or blackboards, credit cards, debit cards, phone cards, various cards such as various identification documents, keys for various keyboards, transparent panels (window glass, etc.) for windows, doors, partitions, artificial leather, etc. In these applications, it is generally preferred to have the matte article of this embodiment, which presents a matte effect and a soft touch, placed on the outermost surface; however, other application forms can be used depending on the purpose and intended use. [Example]

[0158] Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to these examples at all.

[0159] (Measurement of Surface Shape) Regarding the Spc (arithmetic mean curvature of the protrusion apex), Rsm (average length of the curve element), Rz (maximum height), and Ra (arithmetic mean roughness) of the articles obtained in the Examples and Comparative Examples, for a rectangle (1024 μm × 768 μm) of any part of the surface shape of the article, measurements were performed using a shape-resolving laser microscope ("VK-X150 (control unit) / VK-X160 (measurement unit)", manufactured by KEYENCE Co., Ltd.), under the following conditions: objective lens: 50x, laser wavelength: 658 nm, measurement mode: surface shape mode, measurement interval: 0.13 μm, measurement quality: high-speed mode. Furthermore, the critical values ​​for Rsm (average length of the curve element), Rz (maximum height), and Ra (arithmetic mean roughness) were set to 0.8 mm.

[0160] (Evaluation method: 60° gloss value) For the articles obtained in the examples and comparative examples, the 60° specular gloss was measured using a gloss meter ("micro-gross", manufactured by BYK Gardner Co., Ltd.) in accordance with K 5600-4-7:1999.

[0161] (Evaluation of Texture (Uniformity of Surface Condition)) For the articles obtained in the Examples and Comparative Examples, any 20 adults evaluated the texture (uniformity of surface condition) of the surface according to the following criteria: A: 18 or more people evaluated that the surface condition is uniform and the visibility of the matte effect is high. B: 15 to 17 people evaluated that the surface condition is uniform and the visibility of the matte effect is high. C: 14 or fewer people evaluated that the surface condition is uniform and the visibility of the matte effect is high. A and B are considered acceptable.

[0162] (Evaluation of Softness) For the articles obtained in the Examples and Comparative Examples, Oxford cloth made from 80-count cotton yarn was used as the benchmark for softness. Any 20 adults evaluated the surface feel according to the following criteria: A: 18 or more people rated the feel as close to the benchmark, indicating a soft feel. B: 15 to 17 people rated the feel as close to the benchmark, indicating a soft feel. C: 14 or fewer people rated the feel as close to the benchmark, indicating a soft feel. A and B were considered acceptable.

[0163] [Example 1] (Preparation of resin composition for matte layer formation) 60 parts by weight of polyfunctional urethane acrylate oligomer (functionality: 4), 30 parts by weight of polyfunctional acrylate monomer (difunctional), and 10 parts by weight of monofunctional acrylate monomer were mixed, and 3 parts by weight of wrinkle forming stabilizer (silicon oxide particles, average particle size: 5 nm) and 0.8 parts by weight of photopolymerization initiator (benzophenone-based) were added to obtain a resin composition (resin A) for matte layer formation. (Manufacturing of Matte Articles) A ​​PET (polyethylene terephthalate) sheet (COSMOSHINE (registered trademark) A4160 (50 μm) manufactured by Toyobo Co., Ltd.) is used as a substrate. The resin composition (resin A) for forming the matte layer is coated onto the easy-to-adhere surface of the substrate by gravure coating (coating amount: 18 μm (drying)). Then, ultraviolet light (wavelength: 395 nm, ultraviolet light intensity: 0.6 W / cm2) is irradiated using a UV irradiation device containing an LED (light-emitting diode). Next, ultraviolet light (wavelength: 172 nm (Xe2), ultraviolet output density: 1 W / cm, cumulative light intensity: 10-100 mJ / cm2, nitrogen atmosphere (oxygen concentration below 200 ppm)) is irradiated using an excimer light irradiation device. Then, high-pressure mercury lamp is used for irradiation (ultraviolet output density: 200 W / cm) to form a matte layer on the substrate, thereby obtaining a matte article having a substrate and a matte layer. For the obtained matte articles, Spc (arithmetic mean curvature of the apex of the protrusion), Rsm (mean length of the curve element), and 60° gloss value were measured to evaluate the texture (uniformity of surface condition) and softness. These results are presented in Table 1.

[0164] [Examples 2 and 3] The coating amount of the resin composition (resin A) for forming the matte layer and the substrate were set as shown in Table 1. Otherwise, the process was the same as in Example 1 to obtain the matte article of Example 2. The coating amount of the resin composition for forming the matte layer was set as shown in Table 1. A polypropylene sheet (PP, thickness: 100 μm) subjected to corona discharge treatment was used as the substrate. The resin composition for forming the base layer (urethane resin, coating amount: 2 μm (when dry)) was coated on one side of the substrate. The resin composition for forming the matte layer was then coated on the base layer. Otherwise, the process was the same as in Example 1 to obtain the matte article of Example 3.

[0165] [Example 4] In Example 1, a PET sheet (COSMOSHINE (registered trademark) A4160 (50 μm) manufactured by Toyobo Co., Ltd.) was used as a substrate. After applying a coloring layer (thickness: 3 μm (when dry)) to the easy-to-adhere surface of the substrate, the above-mentioned resin composition (resin A) for forming the matte layer was applied to the coloring layer. Otherwise, the process was carried out in the same way to obtain a matte article.

[0166] For the matte articles obtained in Examples 2 to 4, Spc (arithmetic mean curvature of the protrusion apex), Rsm (mean length of the curve element), and 60° gloss value were measured to evaluate the texture (uniformity of surface state) and the softness of the surface. These results are shown in Table 1.

[0167] [Comparative Example 1] A colored paper base paper for building materials (thickness: 30 μm) was used as a substrate. A colored layer (thickness: 3 μm (when dry)) was applied to one side of the substrate. Then, the resin composition (resin A) for forming the above-mentioned matte layer (coating amount: 5 μm (when dry)) was applied to the colored layer. Otherwise, the process was carried out in the same manner as in Example 1 to obtain the matte article of Comparative Example 1.

[0168] [Comparative Example 2] In Example 2, ultraviolet light was irradiated without using a UV irradiation device containing LEDs. Otherwise, the same procedure was performed to obtain the matte article of Comparative Example 2.

[0169] [Comparative Example 3] In Example 1, a matte layer forming resin composition (resin B) was obtained by mixing 60 parts by mass of a polyfunctional urethane acrylate oligomer (functionality: 7), 30 parts by mass of a polyfunctional acrylate monomer (difunctional), and 10 parts by mass of a monofunctional monomer, and adding 15 parts by mass of a wrinkle-forming stabilizer (silicon oxide particles, average particle size: 5 nm) and 0.8 parts by mass of a photopolymerization initiator (benzophenone-based), instead of the matte layer forming resin composition (resin A). Otherwise, the same procedure was performed to obtain the matte article of Comparative Example 3.

[0170] [Comparative Example 4] In Example 2, the resin composition (resin B) for forming the matte layer obtained in Comparative Example 3 was used instead of the resin composition (resin A) for forming the matte layer. Otherwise, the same procedure was performed to obtain the matte article of Comparative Example 4.

[0171] [Comparative Example 5] In Example 2, a resin composition (resin C) for forming a matte layer was obtained by mixing 60 parts by mass of a polyfunctional urethane acrylate oligomer (functionality: 4), 30 parts by mass of a polyfunctional acrylate monomer (difunctional), and 10 parts by mass of a monofunctional acrylate monomer, and adding 40 parts by mass of a matting agent (silicon oxide particles, average particle size: 7 μm), 3 parts by mass of a wrinkle-forming stabilizer (silicon oxide particles, average particle size: 5 nm), and 0.8 parts by mass of a photopolymerization initiator (benzophenone-based), instead of the resin composition (resin A) for forming a matte layer. Otherwise, the same procedure was performed to obtain the matte article of Comparative Example 5.

[0172] For the matte articles obtained in Comparative Examples 1 to 5, Spc (arithmetic mean curvature of the protrusion apex), Rsm (mean length of the curve element), and 60° gloss value were measured to evaluate the texture (uniformity of surface state) and softness. These results are shown in Table 1. Figures 7 to 14 are microscopic images of the matte articles obtained in Examples 1 to 3 and Comparative Examples 1 to 5.

[0173] [Table 1] Table 1 Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Comparative Example 5 resin A A A A A A B B A Matting agent (parts by weight) 0 0 0 0 0 0 0 0 40 Coating amount (μm) 18 5 5 18 5 5 18 5 5 substrate PET PET PP PET Paper PET PET PET PET LED-UV Irradiation Irradiation Irradiation Irradiation Irradiation - Irradiation Irradiation Irradiation Spc(mm -1 ) 5251 4599 5466 5367 4335 2193 2396 1773 3721 Rsm(μm) 14.3 17.1 28.2 15.2 37.8 47.5 44.4 52 58.1 Rz(μm) 4.5 4.6 8.9 4.5 9.4 12.6 12.9 12.8 5.8 Ra(μm) 0.9 0.8 1.5 0.8 1.5 1.9 1.6 1.4 0.8 60 gloss level 1.9 1.9 1.6 1.9 1.3 2.9 4.9 5.4 5.8 Texture A A A A A C C C C Soft touch A A A A C C C C C

[0174] The resin in Table 1 refers to the resin composition used for forming the matte layer. According to the results in Table 1, it is confirmed that the matte article of this embodiment has a 60° gloss value of 1.6 to 1.9 on the matte layer side. The matte article of this embodiment has excellent visibility of the matte effect and excellent texture. In addition, it is also confirmed that the matte article of this embodiment has excellent soft touch. On the other hand, it is known that although the matte article of Comparative Example 1 with an Rsm of 30 μm or more has excellent 60° gloss value and texture, it cannot obtain a soft touch. It is known that the matte articles of Comparative Examples 2 to 4 with an Rsm of 30 μm or more and an Spc of 4000 mm-1 or less have a 60° gloss value of 2.9 to 5.4. The texture is further worse than that of the matte article of Comparative Example 1, and it also cannot obtain a soft touch. It can be seen that the matte article of Comparative Example 5, which uses a resin composition for forming a matte layer containing a matting agent, also exhibits poor 60° gloss value, texture, and softness, similar to Comparative Examples 2-4. [Industrial Applicability]

[0175] The matte article of this embodiment has excellent visibility and texture due to its excellent matte effect and soft touch, and is therefore well used for various purposes, such as interior components of buildings such as walls, ceilings, and floors; exterior components such as exterior walls, eaves, ceilings, roofs, fences, and railings; window frames, doors, door frames, handrails, baseboards, ceiling trims, decorative strips, and other door and window or decorative components; as well as general furniture such as multi-drawer cabinets, shelves, and tables; kitchen furniture such as dining tables and sinks; or surface decoration of cabinets for home appliances, OA equipment, etc. Decorative components for various components such as panels, interior and exterior components of vehicles, and, in addition to the decorative components used in buildings, etc., the matte articles of this embodiment are well used as packaging materials, anti-glare films for displays, whiteboards or blackboards, credit cards, debit cards, phone cards, various cards such as various certificates, keys for various keyboards, transparent panels (window glass, etc.) for windows, doors, partitions, etc., and artificial leather, etc. [Simplified Explanation of the Diagram]

[0015] Figure 1 is a schematic diagram illustrating the surface shape of the matte article of the present invention. Figure 2 is a schematic diagram illustrating the surface shape of the matte article of the present invention. Figure 3 is a top view schematic diagram showing one embodiment of the matte article of the present invention. Figure 4 is a cross-sectional view showing one embodiment of the matte article of the present invention. Figure 5 is a cross-sectional view showing one embodiment of the matte article of the present invention. Figure 6 is a cross-sectional view showing one embodiment of the matte article of the present invention. Figure 7 is an optical microscope image of the surface of the matte article obtained in Example 1. Figure 8 is an optical microscope image of the surface of the matte article obtained in Example 2. Figure 9 is an optical microscope image of the surface of the matte article obtained in Example 3. Figure 10 is an optical microscope image of the surface of the matte article obtained in Comparative Example 1. Figure 11 is an optical microscope image of the surface of the matte article obtained in Comparative Example 2. Figure 12 is an optical microscope image of the surface of the matte article obtained in Comparative Example 3. Figure 13 is an optical microscope image of the surface of the matte article obtained in Comparative Example 4. Figure 14 is an optical microscope image of the surface of the matte article obtained in Comparative Example 5.

Claims

1. A matte article having at least a portion of its surface having a surface shape in which Spc (arithmetic mean curvature of the apex of the protrusion) is greater than 4000 mm⁻¹ and Rsm (mean length of the curve element) as specified in JIS B0601:2013 is less than 30 μm, wherein the Spc (arithmetic mean curvature of the apex of the protrusion) is the average curvature (average sharpness) of the tip of the mountain peak obtained by the arithmetic mean of the radii of curvature of the mountain peaks (protrusion apex) of the parts classified as mountains (protrusions) in a shape image contained in a reference region.

2. For the matte article of claim 1, wherein the contour curve and height parameter Rz (maximum height) of the surface shape as specified in JIS B0601:2013 are 12.5 μm or less.

3. For matte articles as requested in item 1 or 2, the parameter Ra (arithmetic mean roughness) of the height direction of the profile curve as specified in JIS B0601:2013 for the surface shape described above is 2.0 μm or less.

4. The matte article of claim 1 or 2, having a matte layer, and the surface shape being formed by the surface of the matte layer.

5. The matte article of claim 4, wherein the surface of the matte layer forming the above-mentioned surface shape has an uneven shape composed of irregular folds.

6. The matte article of claim 5, wherein the irregular wrinkles comprise a plurality of protrusions formed by a plurality of linear protrusions and a recess formed by the plurality of linear protrusions.

7. The matte article of claim 4, wherein the matte layer contains a hardened resin composition comprising a resin and a wrinkle-forming stabilizer, wherein the wrinkle-forming stabilizer has an average particle size with an upper limit of the smaller of 100% or less of the thickness of the matte layer and 30 μm or less, and comprises at least 0.5 parts by mass relative to 100 parts by mass of the resin.

8. Matte articles as claimed in item 1 or 2, which have a substrate.

9. The matte article as claimed in item 8, wherein the substrate is in sheet form.

10. The matte article of claim 4 further has a substrate, and the matte layer is provided on the entire surface of one side of the substrate.

11. The matte article of claim 1 or 2, wherein the gloss value at 60° of the aforementioned surface shape is 10.0 or less.

Images