Decorative sheet and decorative board

Abstract

This decorative sheet comprises: a print base material layer; a design pattern layer provided on the upper side of the print base material layer; a first surface protective layer that is provided on the upper side of the design pattern layer and that contains a spherical filler having an average particle size of 3.0-7.0 µm; and a second surface protective layer that is partially provided on the upper side of the first surface protective layer and that contains a spherical filler having an average particle size of 3.0-7.0 µm.

Description

Decorative sheets and boards

[0001] This disclosure relates to decorative sheets and decorative boards. This application claims priority based on Japanese Patent Application No. 2024-018388 filed in Japan on February 9, 2024, Japanese Patent Application No. 2025-002765 filed in Japan on January 8, 2025, and Japanese Patent Application No. 2025-002649 filed in Japan on January 8, 2025, the contents of which are incorporated herein by reference.

[0002] BACKGROUND ART Conventionally, decorative sheets and decorative boards have been used for the surface decoration of interior materials and fixtures in buildings such as houses, building materials such as fittings, furniture, fixtures, housing equipment, home appliances, and the like.

[0003] There is a demand for decorative sheets and boards that have a wood grain pattern and a low gloss design, reproducing a design similar to that of a real wood grain veneer decorative board. With low-gloss decorative sheets and boards that reproduce a design similar to that of a veneer decorative board, scratches on the surface can cause a change in gloss, potentially reducing the design. In particular, decorative sheets and boards with low-gloss designs are prone to gloss changes due to scratches. Therefore, decorative sheets and boards that reproduce a low-gloss design similar to that of a veneer decorative board are required to have excellent scratch resistance.

[0004] Decorative sheets and boards with improved scratch resistance include those described in Patent Document 1. The decorative sheet and board described in Patent Document 1 have a picture pattern layer, a first surface protective layer, and a second surface protective layer laminated in this order on a sheet substrate. The decorative sheet and board described in Patent Document 1 aim to improve scratch resistance by including spherical fillers with an average particle size of 3.0 μm or more and 7.0 μm or less in the first surface protective layer.

[0005] Japanese Patent Application Publication No. 2017-165030

[0006] However, in decorative sheets and decorative boards such as those described in Patent Document 1, which contain spherical fillers with an average particle size of 3.0 μm or more and 7.0 μm or less in the first surface protective layer, if the second surface protective layer is scratched, the gloss of the second surface protective layer may change, resulting in a reduction in design.

[0007] Furthermore, decorative sheets and boards that reproduce designs similar to those of veneer decorative boards are required to have not only the appearance but also a feel similar to that of veneer decorative boards.Decorative sheets and boards with low-gloss wood grain designs have excellent scratch resistance and, by being given a feel similar to that of veneer decorative boards, can achieve a feel similar to that of veneer decorative boards while stably maintaining a design similar to that of veneer decorative boards.

[0008] In light of the above circumstances, an object of the present disclosure is to provide a decorative sheet and decorative board with improved scratch resistance.

[0009] A decorative sheet according to a first aspect of the present disclosure comprises a printing substrate layer, a picture pattern layer provided on the upper side of the printing substrate layer, a first surface protective layer provided on the upper side of the picture pattern layer and containing spherical filler having an average particle size of 3.0 μm or more and 7.0 μm or less, and a second surface protective layer partially provided on the upper side of the first surface protective layer and containing spherical filler having an average particle size of 3.0 μm or more and 7.0 μm or less.

[0010] According to a second aspect of the present disclosure, in the decorative sheet according to the first aspect, the 60-degree reflected gloss of the upper surface may be 3.0 or more and 4.0 or less.

[0011] According to a third aspect of the present disclosure, in the decorative sheet according to the first aspect, the first surface protective layer may contain a mixture of a thermosetting resin and an ultraviolet-curable resin, an ultraviolet-curable resin, or an ionizing radiation-curable resin.

[0012] According to a fourth aspect of the present disclosure, in the decorative sheet according to the first aspect, the second surface protective layer may contain a mixture of a thermosetting resin and an ultraviolet-curable resin, an ultraviolet-curable resin, or an ionizing radiation-curable resin.

[0013] According to a fifth aspect of the present disclosure, in the decorative sheet according to the first aspect, the second surface protective layer may be provided in a position that is in harmony with the pattern of the picture pattern layer.

[0014] According to a sixth aspect of the present disclosure, the decorative sheet according to the first aspect may further comprise a base colored layer provided on the upper side of the printing substrate layer and on the lower side of the picture pattern layer.

[0015] According to a seventh aspect of the present disclosure, in the decorative sheet relating to the first aspect, at least a portion of the plurality of second surface protective layers partially provided on the upper side of the first surface protective layer may contain spherical organic fillers having an average particle size of 30 μm or more and 40 μm or less, and the first surface protective layer and the second surface protective layer may contain a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin.

[0016] According to an eighth aspect of the present disclosure, in the decorative sheet according to the seventh aspect, the 60-degree reflected gloss of the upper surface may be 3.0 or more and 4.0 or less.

[0017] According to a ninth aspect of the present disclosure, in the decorative sheet according to the seventh aspect, the second surface protective layer may be provided in a position that is in harmony with the pattern of the picture pattern layer.

[0018] According to a tenth aspect of the present disclosure, the decorative sheet according to the seventh aspect may further comprise a base colored layer provided on the upper side of the printing substrate layer and on the lower side of the picture pattern layer.

[0019] According to an eleventh aspect of the present disclosure, in the decorative sheet relating to the seventh aspect, at least a portion of the plurality of second surface protective layers may have thin film portions and thick film portions having different heights in the vertical direction, and the spherical organic filler may be arranged in the thick film portions, which have a height greater than that of the thin film portions.

[0020] According to a twelfth aspect of the present disclosure, in the decorative sheet according to the seventh aspect, the first surface protective layer and the second surface protective layer may contain amorphous silica.

[0021] A decorative board according to a thirteenth aspect of the present disclosure comprises a decorative sheet according to any one of the first to twelfth aspects and a decorative board substrate provided below the decorative sheet.

[0022] According to the decorative sheet and decorative board of the present disclosure, it is possible to provide a decorative sheet and decorative board with improved scratch resistance.

[0023] 1 is a cross-sectional view schematically showing a decorative board according to a first embodiment of the present disclosure; FIG. 2 is a cross-sectional view schematically showing a decorative board according to a second embodiment of the present disclosure; FIG. 3 is a cross-sectional view schematically showing a decorative board according to a third embodiment of the present disclosure.

[0024] First Embodiment A first embodiment of the present disclosure will be described with reference to the drawings. Fig. 1 is a cross-sectional view schematically showing a decorative board 100 according to this embodiment.

[0025] In this embodiment, as shown in Figure 1, the thickness direction of the decorative board 100 is defined as the "vertical direction V", the side of the decorative board 100 on which the decorative board substrate 20 is provided is defined as the "lower side LO" in the vertical direction V, and the side opposite the lower side LO is defined as the "upper side UP" in the vertical direction V.

[0026] The decorative board 100 comprises a decorative sheet 10 and a decorative board substrate 20 .

[0027] The decorative board substrate 20 is a layer provided on the lower side LO of the decorative board 100. Particle board, medium-density fiberboard (MDF), or the like can be used as the decorative board substrate 20. As the decorative board substrate 20, a metal plate-like member such as aluminum or stainless steel, or a composite board in which metal such as aluminum is attached to both sides of a core material made of resin such as polyethylene, may also be used.

[0028] The decorative sheet 10 comprises a printing substrate layer 1 , a base colored layer 2 , a picture design layer 3 , a first surface protective layer 4 , and a second surface protective layer 5 .

[0029] The printing substrate layer 1 is a layer provided on the lower side LO of the decorative sheet 10. In the decorative board 100, the printing substrate layer 1 is provided on the upper side UP of the substrate 20 for decorative board.

[0030] The printing substrate layer 1 is a sheet-like layer made of a known material that can be printed on. As the printing substrate layer 1, a fibrous sheet such as tissue paper or titanium paper can be used.

[0031] Resin-impregnated paper, resin-mixed paper, reinforced inter-paper paper, bleached or unbleached kraft paper, linter paper, fine paper, coated paper, inorganic paper, flame-retardant paper, paperboard, Japanese paper, etc. may be used as the printing substrate layer 1. Resin sheets such as polyethylene, polypropylene, or polyvinyl chloride, woven or nonwoven fabrics, etc. may also be used as the printing substrate layer 1.

[0032] A moisture-proof sheet may be used as the printing substrate layer 1. For example, moisture-proof paper comprising two paper substrates and a moisture-proof resin layer disposed between the two paper substrates in the up-down direction V can be used as the printing substrate layer 1 to impart moisture-proof properties to the printing substrate layer 1.

[0033] The paper base material of the moisture-proof paper can be, for example, a reinforced paper containing resin between cellulose fibers. The moisture-proof resin layer of the moisture-proof paper is a layer made of a moisture-proof resin that does not allow water vapor to pass through. The moisture-proof resin that forms the moisture-proof resin layer of the moisture-proof paper can be, for example, a thermoplastic resin such as an olefin resin.

[0034] The base color layer 2 is a layer provided on the upper side UP of the printing substrate layer 1. The base color layer 2 is a layer that provides base coloring for the picture pattern layer 3 and concealing properties to prevent the color and texture of the printing substrate layer 1 and the decorative board substrate 20 from penetrating through to the surface of the decorative sheet 10 and the decorative board 100.

[0035] Nitrocellulose-based printing inks or the like can be used for the base colored layer 2. As a printing method for the base colored layer 2, known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, and inkjet printing can be used.

[0036] The picture pattern layer 3 is a layer provided on the upper side UP of the base colored layer 2. The picture pattern layer 3 is formed by printing a picture pattern such as wood grain, stone grain, or sand grain on the upper side UP of the base colored layer 2.

[0037] A known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be used as a printing method for the picture pattern layer 3. A known printing ink suitable for the printing method to be used can be used for the picture pattern layer 3.

[0038] The first surface protective layer 4 is a layer provided on the upper side UP of the picture / pattern pattern layer 3. The first surface protective layer 4 can be made of a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, an ionizing radiation-curing resin, or the like. By using these materials as the resin forming the first surface protective layer 4, the scratch resistance of the surface 10s of the decorative sheet 10 can be improved. The surface 10s of the decorative sheet 10 refers to the surface of the upper side UP of the decorative sheet 10. It is preferable to use a transparent or translucent material for the first surface protective layer 4 that is transparent or translucent enough to allow the pattern of the picture / pattern pattern layer 3 to be seen through.

[0039] The first surface protective layer 4 is a sheet-like layer that covers the entire picture pattern layer 3. As shown in Fig. 1, the first surface protective layer 4 includes first particle portions (spherical fillers) 4a.

[0040] The first particle 4a has an average particle size of 3.0 μm or more and 7.0 μm or less. The average particle size of the first particle 4a is preferably 5.0 μm. The first particle 4a is, for example, a filler of an inorganic compound such as a silicone resin.

[0041] Using an inorganic compound filler as the first particle portions 4 a is preferable in terms of hardness compared to using an organic compound filler, and an improvement in the hardness of the first surface protective layer 4 can be expected.

[0042] It is preferable that the particle diameter of the first particle portions 4 a is approximately the same as the thickness in the vertical direction V of the first surface protective layer 4. By using first particle portions 4 a having approximately the same particle diameter as the thickness of the first surface protective layer 4, the scratch resistance of the first surface protective layer 4 can be further improved.

[0043] It is preferable to use a transparent or semi-transparent material for the first particle portion 4 a so that the design of the design pattern layer 3 can be seen through the first surface protective layer 4 .

[0044] The difference between the maximum particle size and the minimum particle size in the particle size distribution of the first particle portions 4 a is 8 μm or less, and preferably 3 μm or less. The first particle portions 4 a contained in the first surface protective layer 4 preferably cover 40% to 80% of the first surface protective layer 4, and more preferably cover the first surface protective layer 4 so as to leave almost no gaps.

[0045] The first surface protective layer 4 can be formed by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing.

[0046] When the first surface protective layer 4 containing the first particle parts 4a is printed on the upper side UP of the picture pattern layer 3, it is preferable to employ intaglio printing such as gravure printing. The first surface protective layer 4 may also be formed using a known coating device.

[0047] The second surface protective layer 5 is a layer provided on the upper side UP of the first surface protective layer 4. The decorative sheet 10 comprises a plurality of second surface protective layers 5 partially provided on the upper side UP of the first surface protective layer 4. The second surface protective layers 5 partially provided on the upper side UP of the first surface protective layer 4 are preferably provided in positions that are in harmony with the pattern of the picture pattern layer 3.

[0048] It is preferable to use a transparent or semi-transparent material for the second surface protective layer 5 so that the design of the picture pattern layer 3 can be seen through the first surface protective layer 4. A mixture of a thermosetting resin and an ultraviolet curing resin, an ultraviolet curing resin, an ionizing radiation curing resin, or the like can be used for the second surface protective layer 5. By using these materials as the resin for forming the second surface protective layer 5, the scratch resistance of the surface 10s of the decorative sheet 10 can be improved.

[0049] As shown in FIG. 1, the second surface protective layer 5 includes second particle portions (spherical fillers) 5a.

[0050] The second particle portions 5a have an average particle size of 3.0 μm or more and 7.0 μm or less, and preferably 5.0 μm. The second particle portions 5a are, for example, a filler of an inorganic compound such as a silicone resin.

[0051] The use of an inorganic compound filler as the second particle portion 5 a is preferable in terms of hardness compared to the use of an organic compound filler, and an improvement in the hardness of the second surface protective layer 5 can be expected.

[0052] It is preferable that the particle diameter of the second particle portions 5 a is approximately the same as the thickness in the vertical direction V of the second surface protective layer 5. By using second particle portions 5 a having approximately the same particle diameter as the thickness of the second surface protective layer 5, the scratch resistance of the second surface protective layer 5 can be further improved.

[0053] It is preferable to use a transparent or semi-transparent material for the second particle portion 5 a so that the design of the design pattern layer 3 can be seen through the first surface protective layer 4 and the second surface protective layer 5 .

[0054] The difference between the maximum particle size and the minimum particle size in the particle size distribution of the second particle portions 5 a is 8 μm or less, and preferably 3 μm or less. The second particle portions 5 a contained in the second surface protective layer 5 preferably cover 40% to 80% of the second surface protective layer 5, and more preferably cover the second surface protective layer 5 so as to leave almost no gaps.

[0055] The second surface protective layer 5 can be formed by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing.

[0056] When the second surface protective layer 5 containing the second particle parts 5 a is printed on the upper side UP of the first surface protective layer 4, it is preferable to employ intaglio printing such as gravure printing. The second surface protective layer 5 may also be formed using a known coating device.

[0057] The surface 10s of the decorative sheet 10 preferably has a 60-degree reflected gloss of 3.0 or more and 4.0 or less. In this embodiment, the reflected gloss refers to the specular gloss defined in JIS Z 8741. The 60-degree reflected gloss refers to the 60-degree specular gloss in the above-mentioned JIS standard, and indicates the gloss of light reflected from the surface 10s of the decorative sheet 10 at an incident angle of 60 degrees. The gloss of reflected light can be measured using a measuring instrument such as a surface gloss meter.

[0058] By setting the 60-degree reflected gloss to 3.0 or more and 4.0 or less, the decorative sheet 10 and the decorative board 100 can have a low-gloss design, and can have a design similar to that of a real wood-grain sliced ​​veneer decorative board.

[0059] One method for adjusting the gloss of the surface 10s of the decorative sheet 10 is to add a matting agent to the first surface protective layer 4 or the second surface protective layer 5. In this embodiment, the 60-degree reflected gloss of the surface 10s of the decorative sheet 10 is adjusted to 3.0 or more and 4.0 or less by adding amorphous silica with an average particle size of 4 μm to the first surface protective layer 4 and the second surface protective layer 5.

[0060] In this embodiment, the first surface protective layer 4 has a lower gloss than the second surface protective layer 5. For example, by adding a larger amount of amorphous silica to the first surface protective layer 4 than to the second surface protective layer 5, the gloss of the first surface protective layer 4 can be made lower than that of the second surface protective layer 5. The gloss of the surface 10s of the decorative sheet 10 may also be adjusted by using a low-gloss resin material as the resin forming the first surface protective layer 4 or the second surface protective layer 5.

[0061] As described above, the first surface protective layer 4 and the second surface protective layer 5 contain the spherical fillers 4a, 5a having an average particle size of 3.0 μm or more and 7.0 μm or less, and therefore have excellent scratch resistance.

[0062] Therefore, the decorative sheet 10 and decorative board 100, which have a low-gloss design similar to that of a real wood-grain sliced ​​veneer decorative board, are less susceptible to scratches on the surface 10s of the decorative sheet 10, and gloss changes caused by scratches on the surface 10s of the decorative sheet 10 can be suppressed. As a result, the decorative sheet 10 and decorative board 100 can maintain a low-gloss design on the surface 10s of the decorative sheet 10.

[0063] The decorative sheet 10 and decorative board 100 of this embodiment comprise a printing substrate layer 1, a picture pattern layer 3 provided on the upper side UP of the printing substrate layer 1, a first surface protective layer 4 provided on the upper side UP of the picture pattern layer 3 and containing spherical filler 4a having an average particle size of 3.0 μm or more and 7.0 μm or less, and a second surface protective layer 5 partially provided on the upper side UP of the first surface protective layer 4 and containing spherical filler 5a having an average particle size of 3.0 μm or more and 7.0 μm or less.

[0064] As a result, it is possible to provide a decorative sheet 10 and a decorative board 100 with improved scratch resistance.

[0065] Although the first embodiment of the present disclosure has been described above in detail with reference to the drawings, the specific configuration is not limited to this embodiment and includes design modifications and the like within the scope of the present disclosure. Furthermore, the components shown in the first embodiment described above and the modified examples shown below can be configured by appropriately combining them.

[0066] (Variation 1) In the first embodiment, the decorative sheet 10 and the decorative board 100 include the base colored layer 2, but the form of the decorative sheet and the decorative board is not limited to this. The decorative sheet and the decorative board do not necessarily have to include the base colored layer 2.

[0067] When the base coloring and concealing properties provided by the base coloring layer 2 are not required, the decorative sheet and decorative board do not need to have the base coloring layer 2. When the decorative sheet and decorative board do not have the base coloring layer 2, the picture pattern layer 3 is provided on the upper side UP of the printing substrate layer 1.

[0068] The first embodiment of the present disclosure will be described in detail below with reference to examples, but the first embodiment of the present disclosure is not limited to the following examples.

[0069] (Example 1) As the printing substrate layer 1, a basis weight of 45 g / m ２ A thin paper of the above formula was prepared. On the upper side UP of the printing substrate layer 1, a base coloring layer 2, which serves both as a base coloring and to provide hiding properties, and a picture pattern layer 3, which has a wood grain pattern and a vessel pattern, were printed in this order using a nitrocellulose-based gravure printing ink.

[0070] The upper side UP of the picture pattern layer 3 is coated with a coating amount of 3.0 g / m after drying. ２ The mixture of the thermosetting resin and the ultraviolet curing resin was applied so as to form the first surface protective layer 4. The first surface protective layer 4 contained first particle parts 4a having an average particle size of 5.0 μm.

[0071] A second surface protective layer 5 made of a mixture of a thermosetting resin and an ultraviolet curing resin was applied by gravure onto the upper side UP of the first surface protective layer 4, thereby obtaining the decorative sheet 10 of Example 1.

[0072] Second particle portions 5a having an average particle size of 5.0 μm were contained in the second surface protective layer 5. Furthermore, amorphous silica was added to the first surface protective layer 4 and the second surface protective layer 5, and the 60-degree reflected gloss on the surface 10s of the decorative sheet 10 was adjusted to be 3.0 or more and 4.0 or less.

[0073] Example 2 A decorative sheet 10 of Example 2 was obtained in the same manner as in Example 1, except that the first surface protective layer 4 contained first particle parts 4a having an average particle size of 3.0 μm.

[0074] Example 3 A decorative sheet 10 of Example 3 was obtained in the same manner as in Example 1, except that the first surface protective layer 4 contained first particle parts 4a having an average particle size of 4.0 μm.

[0075] Example 4 A decorative sheet 10 of Example 4 was obtained in the same manner as in Example 1, except that the first surface protective layer 4 contained first particle parts 4a having an average particle size of 6.0 μm.

[0076] Example 5 A decorative sheet 10 of Example 5 was obtained in the same manner as in Example 1, except that the first surface protective layer 4 contained first particle parts 4a having an average particle size of 7.0 μm.

[0077] Example 6 A decorative sheet 10 of Example 6 was obtained in the same manner as in Example 1, except that the second surface protective layer 5 contained second particle portions 5a having an average particle size of 3.0 μm.

[0078] Example 7 A decorative sheet 10 of Example 7 was obtained in the same manner as in Example 1, except that the second surface protective layer 5 contained second particle portions 5a having an average particle size of 4.0 μm.

[0079] Example 8 A decorative sheet 10 of Example 8 was obtained in the same manner as in Example 1, except that the second surface protective layer 5 contained second particle portions 5a having an average particle size of 6.0 μm.

[0080] Example 9 A decorative sheet 10 of Example 9 was obtained in the same manner as in Example 1, except that the second surface protective layer 5 contained second particle portions 5a having an average particle size of 7.0 μm.

[0081] Comparative Example 1 A decorative sheet of Comparative Example 1 was obtained in the same manner as in Example 1, except that the second surface protective layer did not contain the second particle portion.

[0082] Comparative Example 2 A decorative sheet of Comparative Example 2 was obtained in the same manner as in Example 1, except that the first surface protective layer did not contain the first particle portion.

[0083] (Comparative Example 3) A decorative sheet of Comparative Example 3 was obtained in the same manner as in Example 1, except that the first surface protective layer did not contain the first particle portion and the second surface protective layer did not contain the second particle portion.

[0084] Comparative Example 4 A decorative sheet of Comparative Example 4 was obtained in the same manner as in Example 1, except that the second surface protective layer contained second particle portions having an average particle size of 2.0 μm.

[0085] Comparative Example 5 A decorative sheet of Comparative Example 5 was obtained in the same manner as in Example 1, except that the second surface protective layer contained second particle portions having an average particle size of 8.0 μm.

[0086] Comparative Example 6 A decorative sheet of Comparative Example 6 was obtained in the same manner as in Example 1, except that the first surface protective layer contained first particle portions having an average particle size of 2.0 μm.

[0087] Comparative Example 7 A decorative sheet of Comparative Example 7 was obtained in the same manner as in Example 1, except that the first surface protective layer contained first particle portions having an average particle size of 8.0 μm.

[0088] (Comparative Example 8) The decorative sheet of Comparative Example 8 was obtained in the same manner as in Example 1, except that the second surface protective layer did not contain the second particle portion and the 60-degree reflective gloss on the surface of the decorative sheet was adjusted to be 6.0 or more and 8.0 or less.

[0089] (Test 1) A scratch resistance evaluation test was conducted on the decorative sheets of Examples 1 to 9 and Comparative Examples 1 to 8. In the scratch resistance evaluation test, a scratch resistance test was conducted on the surface of the decorative sheet using a Martindale abrasion tester, and the presence or absence of scratches on the surface of the decorative sheet after the test was evaluated.

[0090] In the scratch resistance test using a Martindale abrasion tester, the test load was set to 6.0 N, the abrasion pieces were Scotch-Brite 7447 (manufactured by 3M Japan Ltd.), and the test cycle was set to 160 times.

[0091] The evaluation criteria were divided into two stages, with a rating of ◯ being considered a pass. ◯ (Good): No noticeable scratches on the surface of the decorative sheet. × (Poor): Noticeable scratches on the surface of the decorative sheet.

[0092] (Test 2) A gloss change evaluation test was conducted on the decorative sheets of Examples 1 to 9 and Comparative Examples 1 to 8. In the gloss change evaluation test, the presence or absence of gloss change on the surface of the decorative sheet after the scratch resistance test using the Martindale abrasion tester in Test 1 was evaluated.

[0093] The evaluation criteria were divided into two stages, with a rating of ◯ being considered a pass. ◯ (Good): No noticeable change in gloss on the surface of the decorative sheet. × (Poor): There was a noticeable change in gloss on the surface of the decorative sheet.

[0094] (Test 3) A design evaluation test was conducted on the decorative sheets of Examples 1 to 9 and Comparative Examples 1 to 8. In the design evaluation test, a sensory evaluation was conducted focusing on whether the gloss of the surface of the decorative sheet was comparable to that of a real wood grain sliced ​​veneer decorative board.

[0095] The evaluation criteria were divided into two stages, with a rating of ◯ being considered a pass. ◯ (Good): The glossiness of the surface of the decorative sheet was comparable to that of the veneer decorative board. × (Poor): The glossiness of the surface of the decorative sheet was different from that of the veneer decorative board.

[0096] (Test Results) The results of Tests 1-3 are shown in Table 1. Table 1 also shows the average particle size of the first particle portions contained in the first surface protective layer and the average particle size of the second particle portions contained in the second surface protective layer in Examples 1-9 and Comparative Examples 1-8. In the average particle sizes of the first particle portions and the second particle portions shown in Table 1, "-" indicates that the respective surface protective layer (first surface protective layer, second surface protective layer) does not contain the respective particle portion (first particle portion, second particle portion).

[0097] The decorative sheets 10 of Examples 1-9 showed good results in all tests. That is, the decorative sheets 10 of Examples 1-9 have a low-gloss design comparable to that of the targeted sliced ​​veneer decorative board, and are decorative sheets with excellent scratch resistance and suppressed gloss changes on the surface 10s of the decorative sheet 10.

[0098] The decorative sheet of Comparative Example 1, in which the second surface protective layer did not contain the second particle portion, showed a change in gloss in Test 2 and was rejected.

[0099] The decorative sheet of Comparative Example 2, in which the first surface protective layer did not contain the first particle portion, failed both Test 1 and Test 2.

[0100] The decorative sheet of Comparative Example 3, in which the first surface protective layer did not contain the first particle portion and the second surface protective layer did not contain the second particle portion, failed both Test 1 and Test 2.

[0101] The decorative sheet of Comparative Example 4, in which the average particle size of the second particle portion contained in the second surface protective layer was less than 3.0 μm, failed Test 2.

[0102] The decorative sheet of Comparative Example 5, in which the average particle size of the second particle portion contained in the second surface protective layer was greater than 7.0 μm, failed Test 2.

[0103] The decorative sheet of Comparative Example 6, in which the average particle size of the first particle portion contained in the first surface protective layer was less than 3.0 μm, failed both Tests 1 and 2.

[0104] The decorative sheet of Comparative Example 7, in which the average particle size of the first particle portion contained in the first surface protective layer was greater than 7.0 μm, failed both Tests 1 and 2.

[0105] The decorative sheet of Comparative Example 2, in which the second surface protective layer did not contain the second particle portion and the 60-degree reflected gloss on the surface of the decorative sheet was 6.0 or more and 8.0 or less, failed Test 3 because there was a discrepancy between the gloss on the surface of the decorative sheet and the gloss of the target veneer decorative board.

[0106]

[0107] Second Embodiment A second embodiment of the present disclosure will be described with reference to the drawings. Fig. 2 is a cross-sectional view schematically showing a decorative board 200 according to this embodiment. The decorative board 200 includes a decorative sheet 30 and a decorative board substrate 40.

[0108] In this embodiment, as shown in Figure 2, the thickness direction of the decorative board 200 is defined as the "vertical direction V", the side of the decorative board 200 on which the decorative board substrate 40 is provided is defined as the "lower side LO" in the vertical direction V, and the side opposite the lower side LO is defined as the "upper side UP" in the vertical direction V.

[0109] The decorative board substrate 40 is a layer provided on the lower side LO of the decorative board 200. Particle board, medium-density fiberboard (MDF), or the like can be used as the decorative board substrate 40. The decorative board substrate 40 may also be a metal plate-like member such as aluminum or stainless steel, or a composite board in which metal such as aluminum is attached to both sides of a core material made of resin such as polyethylene.

[0110] The decorative sheet 30 comprises a printing substrate layer 11 , a base colored layer 12 , a picture design layer 13 , a first surface protective layer 14 , and a second surface protective layer 15 .

[0111] The printing substrate layer 11 is a layer provided on the lower side LO of the decorative sheet 30. In the decorative board 200, the printing substrate layer 11 is provided on the upper side UP of the decorative board substrate 40. The printing substrate layer 11 is a sheet-like layer made of a known material that can be printed on. A fibrous sheet such as tissue paper or titanium paper can be used as the printing substrate layer 11.

[0112] Resin-impregnated paper, resin-mixed paper, reinforced inter-paper paper, bleached or unbleached kraft paper, linter paper, fine paper, coated paper, inorganic paper, flame-retardant paper, paperboard, Japanese paper, etc. may be used as the printing substrate layer 11. Resin sheets such as polyethylene, polypropylene, or polyvinyl chloride, woven fabric, nonwoven fabric, etc. may also be used as the printing substrate layer 11.

[0113] A moisture-proof sheet may be used as the printing substrate layer 11. For example, moisture-proof paper including two paper substrates and a moisture-proof resin layer disposed between the two paper substrates in the up-down direction V may be used as the printing substrate layer 11, thereby imparting moisture-proof properties to the printing substrate layer 11.

[0114] The paper base material of the moisture-proof paper can be, for example, a reinforced paper containing resin between cellulose fibers. The moisture-proof resin layer of the moisture-proof paper is a layer made of a moisture-proof resin that does not allow water vapor to pass through. The moisture-proof resin that forms the moisture-proof resin layer of the moisture-proof paper can be, for example, a thermoplastic resin such as an olefin resin.

[0115] The base coloring layer 12 is a layer provided on the upper side UP of the printing substrate layer 11. The base coloring layer 12 is a layer that provides base coloring for the picture pattern layer 13 and concealing properties to prevent the color and texture of the printing substrate layer 11 and the decorative board substrate 40 from penetrating through to the surfaces of the decorative sheet 30 and the decorative board 200.

[0116] Nitrocellulose-based printing ink or the like can be used for the base colored layer 12. As a printing method for the base colored layer 12, for example, known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, and inkjet printing can be used.

[0117] The picture pattern layer 13 is a layer provided on the upper side UP of the base color layer 12. The picture pattern layer 13 is formed by printing a picture pattern such as wood grain, stone grain, or sand grain on the upper side UP of the base color layer 12.

[0118] A known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be used as a printing method for the picture pattern layer 13. A known printing ink suitable for the printing method to be used can be used for the picture pattern layer 13.

[0119] The first surface protective layer 14 is a layer provided on the upper side UP of the picture / pattern pattern layer 13. The first surface protective layer 14 can be made of a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, an ionizing radiation-curing resin, or the like. By using these materials as the resin forming the first surface protective layer 14, the scratch resistance of the surface 30s of the decorative sheet 30 can be improved. The surface 30s of the decorative sheet 30 refers to the surface of the upper side UP of the decorative sheet 30. It is also preferable to use a transparent or translucent material for the first surface protective layer 14 that is transparent or translucent enough to allow the pattern of the picture / pattern pattern layer 13 to be seen through.

[0120] The first surface protective layer 14 is a sheet-like layer that covers the entire picture / pattern layer 13. Strictly speaking, the first surface protective layer 14 does not need to cover the entire picture / pattern layer 13. As shown in Fig. 2, the first surface protective layer 14 includes first particle portions (spherical fillers) 14a.

[0121] The first particle portions 14a have an average particle size of 3.0 μm or more and 7.0 μm or less. The average particle size of the first particle portions 14a is preferably 5.0 μm. The first particle portions 14a are an inorganic compound filler containing, for example, silica particles or silicone resin.

[0122] The use of an inorganic compound filler as the first particle portions 14a is preferable in terms of hardness compared to the use of an organic compound filler, and is expected to improve the hardness of the first surface protective layer 14. It is preferable to use a transparent or semi-transparent material for the first particle portions 14a to the extent that the design of the picture pattern layer 13 can be seen through the first surface protective layer 14.

[0123] The difference between the maximum particle size and the minimum particle size in the particle size distribution of the first particle portions 14a is 8 μm or less, and preferably 3 μm or less. The first particle portions 14a contained in the first surface protective layer 14 preferably cover 40% to 80% of the first surface protective layer 14, and more preferably cover the first surface protective layer 14 so as to leave almost no gaps.

[0124] The first surface protective layer 14 can be formed by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing. When the first surface protective layer 14 containing the first particle portions 14a is printed on the upper side UP of the picture pattern layer 13, it is preferable to use intaglio printing such as gravure printing. The first surface protective layer 14 may also be formed using a known coating device.

[0125] The second surface protective layer 15 is a layer provided on the upper side UP of the first surface protective layer 14. The decorative sheet 30 has a plurality of second surface protective layers 15 partially provided on the upper side UP of the first surface protective layer 14. The second surface protective layers 15 partially provided on the upper side UP of the first surface protective layer 14 are preferably provided in positions that are in harmony with the pattern of the picture pattern layer 13.

[0126] It is preferable to use a transparent or translucent material for the second surface protective layer 15 so that the design of the picture pattern layer 13 can be seen through the first surface protective layer 14. A mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin can be used for the second surface protective layer 15. By using these materials as the resin that forms the second surface protective layer 15, the scratch resistance of the surface 30s of the decorative sheet 30 can be improved. As shown in FIG. 2 , the second surface protective layer 15 includes second particle portions (spherical fillers) 15a and third particle portions (spherical organic fillers) 15b.

[0127] The second particle portions 15a have an average particle size of 3.0 μm or more and 7.0 μm or less. The average particle size of the second particle portions 15a is preferably 5.0 μm. The second particle portions 15a are, for example, an inorganic compound filler containing silica particles, silicone resin, or the like.

[0128] The use of an inorganic compound filler as the second particle portions 15a is preferable in terms of hardness compared to the use of an organic compound filler, and is expected to improve the hardness of the second surface protective layer 15. It is preferable to use a transparent or semi-transparent material for the second particle portions 15a so that the design of the picture pattern layer 13 can be seen through the first surface protective layer 14 and the second surface protective layer 15.

[0129] The difference between the maximum particle size and the minimum particle size in the particle size distribution of the second particle portions 15a is 8 μm or less, and preferably 3 μm or less. The second particle portions 15a contained in the second surface protective layer 15 preferably cover 40% to 80% of the second surface protective layer 15.

[0130] The average particle size of the third particle portion 15b is 30 μm or more and 40 μm or less. The average particle size of the third particle portion 15b is preferably 35.0 μm. The third particle portion 15b is, for example, a filler of an organic compound containing acrylic particles or the like.

[0131] By including the third particle portion 15b having an average particle size of 30 μm or more and 40 μm or less in the second surface protective layer 15, it is possible to impart a pleasant feel to the surface 30s of the decorative sheet 30.

[0132] By imparting a texture to the surface 30s of the decorative sheet 30 with the third particle portions 15b, it is possible to realize a decorative sheet 30 having a texture similar to that of a real wood grain veneer decorative board. For example, by having the picture pattern layer 13 have a wood grain pattern and arranging the second surface protective layer 15 including the third particle portions 15b in the duct parts of the wood grain pattern, it is possible to realize a decorative sheet 30 that reproduces the texture of the duct parts of the veneer decorative board.

[0133] Furthermore, by using an organic compound filler for the third particle portion 15b, even if the third particle portion 15b falls off from the second surface protective layer 15 due to the application of external force to the second surface protective layer 15, the surface 30s of the decorative sheet 30 can be prevented from being damaged by the third particle portion 15b.

[0134] The third particle portions 15b may be contained in at least some of the plurality of second surface protective layers 15 included in the decorative sheet 30. By disposing a second surface protective layer 15 including the third particle portions 15b and a second surface protective layer 15 not including the third particle portions 15b on the upper side UP of the first surface protective layer 14, the strength of the feel can be adjusted depending on the presence or absence of the third particle portions 15b, and a decorative sheet 30 having a feel closer to that of a real wood grain sliced ​​veneer decorative board can be realized.

[0135] The second surface protective layer 15 can be formed by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing. When the second surface protective layer 15 containing the mixture of the second particle portion 15a and the third particle portion 15b is printed on the upper side UP of the first surface protective layer 14, it is preferable to use intaglio printing such as gravure printing. The second surface protective layer 15 may also be formed using a known coating device.

[0136] The surface 30s of the decorative sheet 30 preferably has a 60-degree reflected gloss of 3.0 or more and 4.0 or less. In this embodiment, the reflected gloss refers to the specular gloss defined in JIS Z 8741. The 60-degree reflected gloss refers to the 60-degree specular gloss in the above-mentioned JIS standard, and indicates the gloss of light reflected from the surface 30s of the decorative sheet 30 at an incident angle of 60 degrees. The gloss of reflected light can be measured using a measuring instrument such as a surface gloss meter.

[0137] By setting the 60-degree reflected gloss of the surface 30s of the decorative sheet 30 to 3.0 or more and 4.0 or less, the decorative sheet 30 and the decorative board 200 can have a low-gloss design, and can have a design similar to that of a real wood-grain veneer decorative board.

[0138] One method for adjusting the gloss of the surface 30s of the decorative sheet 30 is to add a matting agent to the first surface protective layer 14 or the second surface protective layer 15. In this embodiment, the 60-degree reflected gloss of the surface 30s of the decorative sheet 30 is adjusted to 3.0 or more and 4.0 or less by adding amorphous silica with an average particle size of 4 μm to the first surface protective layer 14 and the second surface protective layer 15.

[0139] In this embodiment, the first surface protective layer 14 has a lower gloss than the second surface protective layer 15. For example, by adding a larger amount of amorphous silica to the first surface protective layer 14 than the amount of amorphous silica to the second surface protective layer 15, the gloss of the first surface protective layer 14 can be made lower than the gloss of the second surface protective layer 15. The gloss of the surface 30s of the decorative sheet 30 may be adjusted by using a low-gloss resin material as the resin forming the first surface protective layer 14 or the second surface protective layer 15.

[0140] As described above, the first surface protective layer 14 and the second surface protective layer 15 contain spherical fillers 14a, 15a having an average particle size of 3.0 μm or more and 7.0 μm or less, and contain a mixture of a thermosetting resin and an ultraviolet-curable resin, an ultraviolet-curable resin, or an ionizing radiation-curable resin, and therefore have excellent scratch resistance.

[0141] Furthermore, since second surface protective layer 15 contains spherical organic filler 15b with an average particle size of 30 μm or more and 40 μm or less, it is possible to impart a texture similar to that of a real wood grain veneer decorative board to decorative sheet 30. As a result, decorative sheet 30 and decorative board 200 have excellent scratch resistance and a texture similar to that of a veneer decorative board.

[0142] The decorative sheet 30 and decorative board 200 of this embodiment include a printing substrate layer 11, a picture / pattern layer 13 provided on the upper side UP of the printing substrate layer 11, a first surface protective layer 14 including spherical fillers (first particle portions) 14a having an average particle size of 3.0 μm to 7.0 μm and provided on the upper side UP of the picture / pattern layer 13, and a plurality of second surface protective layers 15 including spherical fillers (second particle portions) 15a having an average particle size of 3.0 μm to 7.0 μm and partially provided on the upper side UP of the first surface protective layer 14. At least some of the plurality of second surface protective layers 15 include spherical organic fillers (third particle portions) 15b having an average particle size of 30 μm to 40 μm. The first surface protective layer 14 and the second surface protective layer 15 include a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin.

[0143] As a result, it is possible to provide a decorative sheet 30 and a decorative board 200 that have excellent scratch resistance and a feel similar to that of a sliced ​​veneer decorative board.

[0144] Third Embodiment A third embodiment of the present disclosure will be described with reference to the drawings. Fig. 3 is a cross-sectional view schematically showing a decorative board 200A according to this embodiment. In the following description, components that are common to components already described will be assigned the same reference numerals, and redundant description will be omitted.

[0145] The decorative board 200A includes a decorative sheet 30A and a decorative board substrate 40. The decorative sheet 30A includes a printing substrate layer 11, an undercoat colored layer 12, a picture design layer 13, a first surface protective layer 14, and a second surface protective layer 15A.

[0146] The second surface protective layer 15A is a layer provided on the upper side UP of the first surface protective layer 14. The decorative sheet 30A includes a plurality of second surface protective layers 15A partially provided on the upper side UP of the first surface protective layer 14. The second surface protective layers 15A partially provided on the upper side UP of the first surface protective layer 14 are preferably provided in positions that are in harmony with the pattern of the picture pattern layer 13.

[0147] The second surface protective layer 15A is preferably made of a transparent or translucent material that allows the design of the design pattern layer 13 to be seen through the first surface protective layer 14. The second surface protective layer 15A may be made of a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin. By using these materials as the resin forming the second surface protective layer 15A, the scratch resistance of the surface 30As of the decorative sheet 30A can be improved. The surface 30As of the decorative sheet 30A refers to the upper side (UP) of the decorative sheet 30A. Furthermore, as shown in FIG. 3, the second surface protective layer 15A includes a second particle portion (spherical filler) 15Aa and a third particle portion (spherical organic filler) 15Ab.

[0148] The second particle portions 15Aa have an average particle size of 3.0 μm or more and 7.0 μm or less, and preferably have an average particle size of 5.0 μm. The second particle portions 15Aa are, for example, an inorganic compound filler containing silica particles, silicone resin, or the like.

[0149] The use of an inorganic compound filler as the second particle portion 15Aa is preferable in terms of hardness compared to the use of an organic compound filler, and is expected to improve the hardness of the second surface protective layer 15 A. The second particle portion 15Aa is preferably made of a transparent or semi-transparent material that allows the design of the design pattern layer 13 to be seen through the first surface protective layer 14 and the second surface protective layer 15 A.

[0150] The difference between the maximum particle size and the minimum particle size in the particle size distribution of the second particle portions 15Aa is 8 μm or less, and preferably 3 μm or less. The second particle portions 15Aa contained in the second surface protective layer 15A preferably cover 40% to 80% of the second surface protective layer 15A.

[0151] The third particle portion 15Ab has an average particle size of 30 μm or more and 40 μm or less. The third particle portion 15Ab preferably has an average particle size of 35.0 μm. The third particle portion 15Ab is, for example, a filler of an organic compound containing acrylic particles or the like.

[0152] By including the third particle portion 15Ab having an average particle size of 30 μm or more and 40 μm or less in the second surface protective layer 15A, it is possible to impart a pleasant feel to the surface 30As of the decorative sheet 30A.

[0153] By imparting a texture to the surface 30As of the decorative sheet 30A with the third particle portion 15Ab, it is possible to realize a decorative sheet 30A having a texture similar to that of a real wood grain veneer decorative board. For example, by having the picture pattern layer 13 have a wood grain pattern and arranging the second surface protective layer 15A including the third particle portion 15Ab in the duct parts of the wood grain pattern, it is possible to realize a decorative sheet 30A that reproduces the texture of the duct parts of the veneer decorative board.

[0154] Furthermore, by using an organic compound filler for the third particle portion 15Ab, even if the third particle portion 15Ab falls off from the second surface protective layer 15A due to the application of external force to the second surface protective layer 15A, the surface 30As of the decorative sheet 30A can be prevented from being damaged by the third particle portion 15A.

[0155] Here, the second surface protective layer 15A has a thick film portion 16 and a thin film portion 17 that have different heights in the vertical direction V. In the vertical direction V, the height H1 of the thick film portion 16 is greater than the height H2 of the thin film portion 17. The height H1 of the thick film portion 16 indicates the coating thickness of the thick film portion 16. The height H2 of the thin film portion 17 indicates the coating thickness of the thin film portion 17.

[0156] In the second surface protective layer 15A, the thin film portion 17 is laminated with a substantially constant coating thickness on the upper side UP of the first surface protective layer 14. The thick film portion 16 is a portion of the second surface protective layer 15A that protrudes above the thin film portion 17 on the upper side UP.

[0157] The third particle portions 15Ab are arranged in the thick film portions 16 of the second surface protective layer 15A. The printing resin that forms the second surface protective layer 15A covers the third particle portions 15Ab, so that the thick film portions 16 are taller in the up-down direction V than the thin film portions 17 by the particle size of the third particle portions 15Ab. As a result, the thick film portions 16 protrude upward UP relative to the thin film portions 17.

[0158] The height of the second surface protective layer 15A in the vertical direction V may change gradually from the height H1 of the thick film portion 16 to the height H2 of the thin film portion 17. For example, the printing resin of the second surface protective layer 15A is pulled by the surface tension of the third particle portion 15Ab, forming a gentle slope between the thick film portion 16 and the thin film portion 17.

[0159] Since the second surface protective layer 15A has a thick film portion 16 and a thin film portion 17 that have different heights in the vertical direction V, the decorative sheet 30A and the decorative board 200A can be given a visual three-dimensional effect and a three-dimensional effect through touch.

[0160] The thick film portion 16 may be formed in at least some of the plurality of second surface protective layers 15A of the decorative sheet 30A. That is, at least some of the plurality of second surface protective layers 15A of the decorative sheet 30A may be formed with a substantially constant coating thickness without having thick film portions 16 and thin film portions 17 that differ in height in the up-down direction V.

[0161] The third particle portions 15b arranged in the thick film portions 16 may be contained in at least some of the second surface protective layers 15A included in the decorative sheet 30A. For example, the third particle portions 15b may not be contained in the second surface protective layers 15A that do not have the thick film portions 16.

[0162] By arranging a second surface protective layer 15A including the third particle portion 15Ab and a second surface protective layer 15A not including the third particle portion 15Ab on the upper side UP of the first surface protective layer 14, the strength of the feel can be adjusted depending on the presence or absence of the third particle portion 15Ab, and a decorative sheet 30A having a feel closer to that of a genuine wood grain veneer decorative board can be realized.

[0163] The second surface protective layer 15A can be formed by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing. When the second surface protective layer 15A containing the mixture of the second particle portion 15Aa and the third particle portion 15Ab is printed on the upper side UP of the first surface protective layer 14, it is preferable to use intaglio printing such as gravure printing. The second surface protective layer 15A may also be formed using a known coating device.

[0164] The thick film portion 16 may be formed in a position of the second surface protective layer 15A where the third particle portion 15Ab is not disposed. In the grooves into which the printing resin of the gravure plate used to print the second surface protective layer 15A is poured, a greater amount of printing resin flows into deeper grooves than into shallower grooves. As a result, in the second surface protective layer 15A, the deeper grooves of the gravure plate are higher in height than the shallower grooves. In other words, by varying the depth of the gravure plate grooves, a second surface protective layer 15A having thick film portions 16 and thin film portions 17 with different heights in the vertical direction V can be formed without disposing the third particle portion 15Ab. As described above, at least some of the multiple second surface protective layers 15A provided in the decorative sheet 30A contain the third particle portion 15Ab.

[0165] The surface 30As of the decorative sheet 30A preferably has a 60-degree reflected gloss of 3.0 or more and 4.0 or less. In this embodiment, the reflected gloss refers to the specular gloss defined in JIS Z 8741. The 60-degree reflected gloss refers to the 60-degree specular gloss in the above-mentioned JIS standard, and indicates the gloss of light reflected from the surface 30As of the decorative sheet 30A at an incident angle of 60 degrees. The gloss of reflected light can be measured using a measuring instrument such as a surface gloss meter.

[0166] By setting the 60-degree reflected gloss of the surface 30As of the decorative sheet 30A to 3.0 or more and 4.0 or less, the decorative sheet 30A and the decorative board 200A can have a low-gloss design, and can have a design similar to that of a real wood-grain veneer decorative board.

[0167] One method for adjusting the gloss of the surface 30As of the decorative sheet 30A is to add a matting agent to the first surface protective layer 14 or the second surface protective layer 15A. In this embodiment, the 60-degree reflected gloss of the surface 30As of the decorative sheet 30A is adjusted to 3.0 or more and 4.0 or less by adding amorphous silica with an average particle size of 4 μm to the first surface protective layer 14 and the second surface protective layer 15A.

[0168] In this embodiment, the first surface protective layer 14 has a lower gloss than the second surface protective layer 15 A. For example, by adding a larger amount of amorphous silica to the first surface protective layer 14 than to the second surface protective layer 15 A, the gloss of the first surface protective layer 14 can be made lower than that of the second surface protective layer 15 A. The gloss of the surface 30As of the decorative sheet 30A may be adjusted by using a low-gloss resin material as the resin forming the first surface protective layer 14 or the second surface protective layer 15A.

[0169] As described above, the first surface protective layer 14 and the second surface protective layer 15A contain spherical fillers 14a, 15Aa with an average particle size of 3.0 μm or more and 7.0 μm or less, and contain a mixture of a thermosetting resin and an ultraviolet-curable resin, an ultraviolet-curable resin, or an ionizing radiation-curable resin, and therefore have excellent scratch resistance.

[0170] Furthermore, since second surface protective layer 15A contains spherical organic filler 15Ab with an average particle size of 30 μm or more and 40 μm or less, decorative sheet 30A can be given a texture similar to that of a real wood-grain veneer decorative board, thereby providing decorative sheet 30A and decorative board 200A with excellent scratch resistance and a texture similar to that of a veneer decorative board.

[0171] The second surface protective layer 15A also has a thick film portion 16 and a thin film portion 17. The spherical organic filler 15Ab is disposed in the thick film portion 16, which has a height in the vertical direction V greater than that of the thin film portion 17. This allows the decorative sheet 30A and the decorative board 200A to have a three-dimensional effect both visually and tactilely.

[0172] Although the second and third embodiments of the present disclosure have been described above in detail with reference to the drawings, the specific configurations are not limited to these embodiments and include design modifications within the scope of the present disclosure. Furthermore, the components shown in the second and third embodiments described above and the modified examples shown below can be configured in any suitable combination.

[0173] (Variation 2) In the second and third embodiments, the decorative sheets 30, 30A and the decorative boards 200, 200A are provided with a base colored layer 12, but the configuration of the decorative sheets and decorative boards is not limited to this. The decorative sheets and decorative boards do not necessarily have to include a base colored layer 12.

[0174] When the base coloring layer 12 does not need to provide base coloring and hiding properties, the decorative sheet and decorative board do not need to have the base coloring layer 12. When the decorative sheet and decorative board do not have the base coloring layer 12, the picture pattern layer 13 is provided on the upper side UP of the printing substrate layer 11.

[0175] The second and third embodiments of the present disclosure will be described in detail below with reference to examples, but the second and third embodiments of the present disclosure are not limited to the following examples.

[0176] (Example 10) As the printing substrate layer 11, a basis weight of 45 g / m ２ A thin paper sheet having the above structure was prepared. On the upper side UP of the printing substrate layer 11, a base coloring layer 12, which serves both as a base coloring and as a concealing layer, and a picture pattern layer 13, which has a wood grain pattern and a vessel pattern, were printed in this order using a nitrocellulose-based gravure printing ink.

[0177] The upper side UP of the picture pattern layer 13 is coated with a coating amount of 3.0 g / m after drying. ２A mixture of a thermosetting resin and an ultraviolet-curable resin was applied so as to form a first surface protective layer 14. The first surface protective layer 14 contained first particle portions (spherical filler) 14a having an average particle size of 5.0 μm.

[0178] A second surface protective layer 15 made of a mixture of a thermosetting resin and an ultraviolet-curing resin was applied by gravure to the upper side UP of the first surface protective layer 14, thereby obtaining a decorative sheet 30 of Example 10. The second surface protective layer 15 contained second particle portions (spherical filler) 15a having an average particle size of 5.0 μm and third particle portions (spherical organic filler) 15b having an average particle size of 35 μm.

[0179] Furthermore, amorphous silica was added to the first surface protective layer 14 and the second surface protective layer 15, and the 60-degree reflected gloss on the surface 30s of the decorative sheet 30 was adjusted to be 3.0 or more and 4.0 or less.

[0180] Comparative Example 9 A decorative sheet of Comparative Example 9 was obtained in the same manner as in Example 10, except that the second surface protective layer did not contain the third particle portion (spherical organic filler).

[0181] Comparative Example 10 A decorative sheet of Comparative Example 10 was obtained in the same manner as in Example 10, except that an inorganic filler having an average particle size of 35 μm was used as the third particle portion contained in the second surface protective layer.

[0182] Comparative Example 11 A decorative sheet of Comparative Example 11 was obtained in the same manner as in Example 10, except that an organic filler having an average particle size of 20 μm was used as the third particle portion contained in the second surface protective layer.

[0183] A decorative sheet of Comparative Example 12 was obtained in the same manner as in Example 10, except that a thermosetting resin was used as the resin forming the first surface protective layer and the second surface protective layer. In Comparative Example 12, the first surface protective layer contained the first particle portion as in Example 10, and the second surface protective layer contained the second particle portion and the third particle portion as in Example 10.

[0184] (Test 4) A scratch resistance evaluation test was conducted on the decorative sheets of Example 10 and Comparative Examples 9 to 12. In the scratch resistance evaluation test, a scratch resistance test was conducted on the surface of the decorative sheet using a Martindale abrasion tester, and the presence or absence of scratches on the surface of the decorative sheet after the test was evaluated.

[0185] In the scratch resistance test using a Martindale abrasion tester, the test load was set to 6.0 N, the abrasion pieces were Scotch-Brite 7447 (manufactured by 3M Japan Ltd.), and the test cycle was set to 160 times.

[0186] The evaluation criteria were divided into two stages, with a rating of ◯ being considered a pass. ◯ (Good): No noticeable scratches on the surface of the decorative sheet. × (Poor): Noticeable scratches on the surface of the decorative sheet.

[0187] (Test 5) A gloss change evaluation test was conducted on the decorative sheets of Example 10 and Comparative Examples 9 to 12. In the gloss change evaluation test, the presence or absence of gloss change on the surface of the decorative sheet after the scratch resistance test using the Martindale abrasion tester in Test 4 was evaluated.

[0188] The evaluation criteria were divided into two stages, with a rating of ◯ being considered a pass. ◯ (Good): No noticeable change in gloss on the surface of the decorative sheet. × (Poor): There was a noticeable change in gloss on the surface of the decorative sheet.

[0189] (Test 6) A tactile evaluation test was conducted on the decorative sheets of Example 10 and Comparative Examples 9 to 12. In the tactile evaluation test, a sensory evaluation was conducted focusing on whether the tactile feel of the surface of the decorative sheet was comparable to that of a real wood-grain sliced ​​veneer decorative board.

[0190] The evaluation criteria were divided into two stages, with a rating of ◯ being considered a pass. ◯ (Good): The feel of the surface of the decorative sheet was similar to that of a veneer decorative board. × (Poor): The feel of the surface of the decorative sheet was different from that of a veneer decorative board.

[0191] (Test Results) The results of Tests 4 to 6 are shown in Table 2.

[0192] The decorative sheet 30 of Example 10 showed good results in all tests. That is, the decorative sheet 30 of Example 10 has excellent scratch resistance and a feel similar to that of a veneer decorative board. Furthermore, the decorative sheet 30 of Example 10 is a decorative sheet in which changes in gloss on the surface 30s of the decorative sheet 30 are suppressed.

[0193] The decorative sheet of Comparative Example 9, in which the second surface protective layer did not contain the third particle portion, failed Test 6 because the feel was weaker than the feel of the sliced ​​veneer decorative board.

[0194] The decorative sheet of Comparative Example 10, which used an inorganic filler as the third particle portion contained in the second surface protective layer, failed Tests 4 and 5. When the decorative sheet of Comparative Example 10 underwent an abrasion test using a Martindale abrasion tester, the inorganic filler, which constituted the third particle portion, fell off, and the fallen hard inorganic filler rubbed against the surface of the decorative sheet, causing scratches and changes in gloss.

[0195] The decorative sheet of Comparative Example 11, in which the average particle size of the third particle portion contained in the second surface protective layer was less than 30 μm, had a weaker feel than the feel of the sliced ​​veneer decorative board in Test 6 and failed.

[0196] The decorative sheet of Comparative Example 12, which used a thermosetting resin as the resin forming the first surface protective layer and the second surface protective layer, failed Tests 4 and 5. During the abrasion test using the Martindale abrasion tester, the decorative sheet of Comparative Example 12 suffered scratches and changes in gloss in the first surface protective layer and the second surface protective layer formed of the thermosetting resin.

[0197]

[0198] 100, 200, 200A Decorative board 10, 30, 30A Decorative sheet 1, 11 Printing substrate layer 2, 12 Undercoat colored layer 3, 13 Picture pattern layer 4, 14 First surface protective layer 4a, 14a First particle portion (spherical filler) 5, 15, 15A Second surface protective layer 5a, 15a, 15Aa Second particle portion (spherical filler) 15b, 15Ab Third particle portion (spherical organic filler) 16 Thick film portion 17 Thin film portion 10s, 30s, 30As Surface of decorative sheet 20, 40 Base material for decorative board V Vertical direction UP Upper side LO Lower side

Claims

1. A decorative sheet comprising: a printing substrate layer; a picture pattern layer provided on the upper side of the printing substrate layer; a first surface protective layer provided on the upper side of the picture pattern layer and containing spherical filler having an average particle size of 3.0 μm or more and 7.0 μm or less; and a second surface protective layer provided partially on the upper side of the first surface protective layer and containing spherical filler having an average particle size of 3.0 μm or more and 7.0 μm or less.

2. The decorative sheet according to claim 1, wherein the 60-degree reflected gloss on the upper surface is 3.0 or more and 4.0 or less.

3. The decorative sheet according to claim 1, wherein the first surface protective layer comprises a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin.

4. The decorative sheet according to claim 1, wherein the second surface protective layer comprises a mixture of a thermosetting resin and an ultraviolet-curing resin, an ultraviolet-curing resin, or an ionizing radiation-curing resin.

5. The decorative sheet according to claim 1, wherein the second surface protective layer is provided in a position that is in sync with the pattern of the picture design layer.

6. The decorative sheet according to claim 1, further comprising a base colored layer provided on the upper side of said printing substrate layer and below said picture pattern layer.

7. The decorative sheet according to claim 1, wherein at least some of the plurality of second surface protective layers partially disposed on the upper side of the first surface protective layer contain spherical organic fillers having an average particle size of 30 μm or more and 40 μm or less, and the first surface protective layer and the second surface protective layer contain a mixture of a thermosetting resin and an ultraviolet curing resin, an ultraviolet curing resin, or an ionizing radiation curing resin.

8. The decorative sheet according to claim 7, wherein the 60-degree reflected gloss on the upper surface is 3.0 or more and 4.0 or less.

9. The decorative sheet according to claim 7, wherein the second surface protective layer is provided in a position that is in sync with the pattern of the picture design layer.

10. The decorative sheet according to claim 7, further comprising a base coloring layer provided on the upper side of said printing substrate layer and below said picture pattern layer.

11. The decorative sheet according to claim 7, wherein at least some of the plurality of second surface protective layers have thin film portions and thick film portions that are different in height in the vertical direction, and the spherical organic filler is disposed in the thick film portions that are taller than the thin film portions.

12. The decorative sheet according to claim 7, wherein the first surface protective layer and the second surface protective layer contain amorphous silica.

13. A decorative board comprising: a decorative sheet according to any one of claims 1 to 12; and a decorative board substrate provided below the decorative sheet.

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