Decorative material and method for producing decorative material

Abstract

The present disclosure provides a decorative material comprising a decorative material body and a surface layer. The surface layer includes at least a first protective layer. The surface of the decorative material on the surface layer side satisfies conditions of: a color difference ∆E between a color measured under geometric condition a (45°c : 0°) in accordance with JIS Z 8722:2009 and a color measured under geometric condition c (de : 8°) in accordance with JIS Z 8722:2009 being 3.0 or less; and a gloss value difference ∆G between a 75° gloss value and a 60° gloss value measured in accordance with JIS Z 8741:1997 being 5.0 or less.

Description

Cosmetic material and method for manufacturing cosmetic material

[0001] This disclosure relates to cosmetic materials and methods for manufacturing cosmetic materials.

[0002] Conventionally, so-called decorative materials have been used to decorate the surfaces of interior and exterior building components, fixtures, furniture, and interior and exterior vehicle components. One example of such decorative material is resin-impregnated decorative laminate. Resin-impregnated decorative laminate can be obtained, for example, by laminating a decorative sheet impregnated with a curable resin and a release film opposite each other, and then curing the curable resin by heat pressing.

[0003] Furthermore, Patent Document 1 discloses another method for manufacturing resin-impregnated decorative laminates, in which a transfer sheet containing a transfer layer and a release support is laminated onto a decorative sheet impregnated with a curable resin, and after hot pressing, the release support is peeled off to transfer only the transfer layer onto the surface of the laminate.

[0004] Japanese Patent Publication No. 2023-108981

[0005] In recent years, low gloss is sometimes required for cosmetic materials in order to improve the visibility of the design. To achieve low gloss, a method can be considered in which a film having a matte layer containing a matting agent, a film with a matting agent kneaded into it, or a film with a sandblasted surface is used as the release film or the release support to form an uneven surface on the cosmetic material.

[0006] However, while the decorative materials obtained by these methods have low gloss, the color may appear different from the original design depending on the viewing angle due to the influence of reflected light. For example, some light may be strongly reflected in a particular direction, causing the material to appear whitish. Therefore, there is room for further improvement in the visibility of the design.

[0007] This disclosure is made in view of the above circumstances and primarily aims to provide a decorative material with excellent design visibility.

[0008] This disclosure provides a decorative material having a decorative material body and a surface layer, wherein the surface layer has at least a first protective layer, and the surface of the decorative material on the surface layer side satisfies the following conditions: the color difference ΔE between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009 is 3.0 or less, and the difference ΔG between the gloss values ​​of the 75° gloss value and the 60° gloss value measured under JIS Z 8741:1997 is 5.0 or less.

[0009] Furthermore, this disclosure provides a method for manufacturing a cosmetic material, comprising: a transfer sheet preparation step of preparing a transfer sheet comprising a release support and a transfer layer including at least the first protective layer; a laminate formation step of forming a laminate in which the cosmetic material body and the transfer layer of the transfer sheet are arranged to face each other; and a peeling step of peeling the release support from the transfer sheet from the laminate.

[0010] This disclosure offers the advantage of providing a decorative material with excellent design visibility.

[0011] This is a schematic cross-sectional view illustrating a decorative material in this disclosure. This is a schematic cross-sectional view illustrating a transfer sheet used in the manufacture of the decorative material in this disclosure. This is a schematic cross-sectional view illustrating a method for manufacturing the decorative material in this disclosure. This is an example of a microscopic image of the uneven surface of the release support of the transfer sheet in this disclosure. This is a schematic cross-sectional view illustrating a decorative material (resin-impregnated decorative board) in this disclosure. This is a schematic cross-sectional view illustrating a method for manufacturing the conventional method for manufacturing a resin-impregnated decorative board. These are the ΔE and ΔG results for each color of resin-impregnated decorative boards in Example 2 and Comparative Examples 2 to 4. These are the ΔE results for each resin-impregnated decorative board obtained in Example 3.

[0012] The embodiments will be described below with reference to the drawings, etc. However, this disclosure can be implemented in many different ways and is not limited to the embodiments described below. In addition, the drawings may schematically represent the width, thickness, and shape of each part compared to the actual form in order to make the explanation clearer, but this is merely an example and should not be interpreted as limiting.

[0013] In this specification, when describing a manner in which one member is placed on another member, the term "above" or "below" includes, unless otherwise specified, both cases: when the other member is placed directly above or directly below the member so as to be in contact with it, and when the other member is placed above or below the member via yet another member. Similarly, in this specification, when describing a manner in which one member is placed on the surface of a member, the term "on the surface" includes, unless otherwise specified, both cases: when the other member is placed directly above or directly below the member so as to be in contact with it, and when the other member is placed above or below the member via yet another member.

[0014] The cosmetic material and the method for manufacturing the cosmetic material described herein will be explained in detail below.

[0015] A. Decorative material The decorative material in this disclosure is a decorative material having a decorative material body and a surface layer, wherein the surface layer has at least a first protective layer, and the surface of the decorative material on the surface layer side satisfies the following conditions: the color difference ΔE between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009 is 3.0 or less, and the difference ΔG between the gloss values ​​of the 75° gloss value and the 60° gloss value measured under JIS Z 8741:1997 is 5.0 or less.

[0016] Figures 1(a) and 1(b) are schematic cross-sectional views illustrating decorative materials in this disclosure. As shown in Figure 1(a), the decorative material 10 in this disclosure comprises a decorative material body 1 and a surface layer 2. The surface layer 2 may have an adhesion layer 21 and a first protective layer 22 in that order from the decorative material body 1 side. As shown in Figure 1(b), the surface layer 2 may have a second protective layer 23 between the adhesion layer 21 and the first protective layer 22. Also, as shown in Figure 1(c), the surface layer 2 may have a decorative layer 24. The decorative layer 24 is arranged, for example, between the adhesion layer 21 and the second protective layer 23. On the other hand, although not specifically shown, the surface layer does not have an adhesion layer.

[0017] Figure 2 is a schematic cross-sectional view illustrating a transfer sheet used in manufacturing a cosmetic material according to this disclosure. As shown in Figure 2, the transfer sheet 50 has a release support 3 and a transfer layer 20. The surface layer 2 shown in Figure 1(a) may be, for example, the transfer layer 20 in the transfer sheet 50 shown in Figure 2. As shown in Figure 2, the release support 3 has, for example, a resin film 31 and an uneven layer 32 disposed on one side of the resin film 31.

[0018] Figure 3 is a schematic cross-sectional view illustrating a method for manufacturing a decorative material according to this disclosure. First, as shown in Figure 3(a), a transfer sheet 50 is prepared (transfer sheet preparation step). Next, as shown in Figure 3(b), a laminate 55 is obtained in which the decorative material body 1 and the transfer layer 20 of the transfer sheet 50 are arranged facing each other (laminated body formation step). Next, as shown in Figure 3(c), the release support 3 on the transfer sheet 50 is peeled off the laminate 55 (peeling step). This allows, for example, the decorative material body 1, the adhesion layer 21 and the first protective layer 22 to be separated in the thickness direction D Ｔ In this way, a decorative material 10 having the elements in this order is obtained. In Figure 3, the transfer layer 20 has an adhesion layer 21. On the other hand, as will be described later, in this disclosure, the transfer layer in the transfer sheet does not have an adhesion layer, and an adhesion layer may be formed on at least one of the transfer layer side surface of the decorative material body and the decorative material body side surface of the transfer layer after the transfer sheet has been prepared and before the laminate formation process.

[0019] In this disclosure, as shown in Figure 1, the surface S1 on the surface layer 2 side of the decorative material 10 has a color difference ΔE between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009, and the difference ΔG between the gloss values ​​of the 75° gloss value and the 60° gloss value measured under JIS Z 8741:1997 is within a predetermined range. In this specification, "surface S1 on the surface layer 2 side of the decorative material 10" refers to the surface of the decorative material 10 located on the surface layer 2 side when the decorative material body 1 is used as a reference.

[0020] Light reflected from the surface of a decorative material consists of specular reflection and diffuse reflection. The color measured under geometric condition a (45°c:0°) is the color due to diffuse reflection when light is irradiated from one direction. The color measured under geometric condition c (de:8°) is the color due to diffuse reflection when light is irradiated uniformly from multiple directions. When these color differences ΔE are within the above range, it means that the difference in intensity of diffuse reflection depending on the direction of incident light is small. Also, when the difference in gloss value ΔG is within the above range, it means that the difference in intensity of specular reflection depending on the direction of incident light is small. When the color difference ΔE is within the predetermined range and the difference in gloss value ΔG is within the predetermined range, the color change due to the reflected light (specular reflection and diffuse reflection) is small regardless of the angle of incident light, and the design change is small from any angle, resulting in a decorative material with good design visibility. Furthermore, in this disclosure, by using both the color difference ΔE and the difference in gloss value ΔG as indicators, the visibility of the design can be evaluated without being affected by the color of the decorative material.

[0021] Furthermore, the decorative material in this disclosure has a first protective layer as its surface layer. Therefore, the surface properties of the decorative material (e.g., scratch resistance, abrasion resistance, etc.) can be improved. In addition, the decorative material in this disclosure may have a transfer layer transferred from a transfer sheet comprising a release support and a transfer layer as its surface layer, and the surface layer may also have an adhesion layer. This makes it possible to easily leave the transfer layer on the decorative material body side during the peeling step in the manufacturing process of the decorative material in which the release support is peeled off, thus reducing the likelihood of peeling defects.

[0022] In conventional methods of forming a specific surface shape on the surface of a decorative material using a shaping sheet, when peeling off the shaping sheet, areas with strong adhesion between the shaping sheet and the decorative material may be pulled off by either the decorative material or the shaping sheet, resulting in shape damage. For example, the cured resin layer described later may peel off together with the shaping sheet, or a portion of the surface of the shaping layer on the shaping sheet may peel off and remain on the decorative material side. In this case, it becomes difficult to adjust the surface shape of the decorative material. On the other hand, the decorative material in this disclosure, as described above, is less prone to peeling defects. Therefore, it is easier to adjust the surface shape of the surface layer, and it is easier to obtain a specific surface shape in which ΔE and ΔG are within the above range.

[0023] I. Physical Properties 1. Color Difference ΔE The surface of the surface layer side of the decorative material in this disclosure has a color difference ΔE of 3.0 or less between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009. The color difference ΔE may be 2.5 or less, 2.0 or less, 1.6 or less, 1.5 or less, 1.0 or less, or 0.5 or less. On the other hand, the above color difference ΔE may be, for example, 0.1 or more, or 0.2 or more.

[0024] The method for measuring and calculating the color difference ΔE is as follows. First, using a spectrophotometer, L is measured on the surface of the surface layer of the decorative material under geometric condition a (45°c:0°). ＊ a ＊ and b ＊ The following is measured. Specifically, light (D65 light source) is shone from an angle of 45°±2° to the normal to the surface of the surface layer of the decorative material, and reflected light with an angle of 0°±5° to the normal to the surface of the surface layer of the decorative material is received. Similarly, L is measured with respect to the surface of the surface layer of the decorative material under geometric condition c (de: 8°). ＊ a ＊ and b ＊Measure it. Specifically, irradiate light evenly from all directions with respect to the normal line of the surface on the surface layer side of the cosmetic material, and receive the reflected light at 8° ± 5° with respect to the normal line direction of the surface on the surface layer side of the cosmetic material. The position of the light trap is -8 degrees with respect to the normal line direction of the surface on the surface layer side of the cosmetic material. As the spectrophotometer used for the measurement under geometric condition a, "Multi-Angle Spectrophotometer MA68II (manufactured by X-Rite)" can be used. As the spectrophotometer used for the measurement under geometric condition c, "Spectrophotometer CM-3700A (manufactured by Konica Minolta)" can be used. Regarding the measurement environment, the temperature is 25°C and the humidity is 60% RH.

[0025] The L measured under geometric condition a ＊ , a ＊ and b ＊ are respectively denoted as L1 ＊ , a1 ＊ and b1 ＊ And the L measured under geometric condition c ＊ , a ＊ and b ＊ are respectively denoted as L2 ＊ , a2 ＊ and b2 ＊ Note that the "L ＊ a ＊ b ＊ color system" means the color system standardized by the CIE (International Commission on Illumination) and adopted by JIS Z 8781-4:2013. Also, in the L ＊ a ＊ b ＊ color system, the lightness is represented by L ＊ , and the chromaticity indicating the hue and saturation is represented by a ＊ , b ＊ .

[0026] The color difference ΔE is the value calculated by substituting the measured values into the following formula. Color difference ΔE = ((L1 ＊ - L2 ＊ ) ２ + (a1 ＊ - a2 ＊ ) ２ + (b1 ＊ - b₂ ＊ ) ２ ) １／２

[0027] Specifically, the color difference ΔE is determined by the following procedure. First, the measurement sample of the decorative material is divided into nine 30mm square grids (3x3). For each grid, the measurement area of ​​the spectrophotometer is positioned at the center of the grid, and the color is measured according to geometric conditions a and c to calculate ΔE. This process is performed for all grids, and the arithmetic mean of ΔE is adopted.

[0028] 2. Difference in Gloss Values ​​In the decorative material described herein, the difference in gloss values ​​ΔG between the 75° gloss value and the 60° gloss value, measured according to JIS Z 8741:1994, with respect to the surface of the surface layer, is usually 5.0 or less. The above difference in gloss values ​​ΔG may be 4.0 or less, 3.5 or less, or 3.2 or less. On the other hand, the above difference in gloss values ​​may be, for example, 1.0 or more, or 2.0 or more.

[0029] In this specification, the 75° gloss value refers to the 75° specular gloss as defined in "Method 2" of JIS Z 8741:1997. The 60° gloss value refers to the 60° specular gloss as defined in "Method 3" of JIS Z 8741:1997. The 60° gloss value and the 75° gloss value are measured using a gloss meter. For example, a micro-gloss gloss meter manufactured by BYK-Gardner may be used as the gloss meter. The difference ΔG between the measured 75° gloss value G75° and the 60° gloss value G60° is calculated as ΔG = G75° - G60°.

[0030] Specifically, the difference in gloss values ​​ΔG is calculated using the following procedure. First, the measurement sample of the decorative material is divided into nine 30mm square grids (3x3). For each grid, the G75° and G60° values ​​are measured so that the center of the gloss meter's measurement area is at the center of the grid, and ΔG is calculated. This process is performed for all grids, and the arithmetic mean of ΔG is adopted.

[0031] 3. Surface Properties The decorative material in this disclosure has a surface shape on the surface layer side such that ΔE and ΔG are within the above range. The surface on the surface layer side preferably has a wrinkle structure. The wrinkle structure exhibits a matte effect. The wrinkle structure preferably has an uneven shape due to irregular wrinkles. In this disclosure, the wrinkle structure on the surface on the surface layer side may be referred to as the first wrinkle structure. The uneven shape due to irregular wrinkles in the first wrinkle structure is, for example, an inverted shape of the uneven shape due to irregular wrinkles in the second wrinkle structure of the uneven layer in the transfer sheet described later. It is preferable that the surface on the surface layer side has a wrinkle structure and that the wrinkle structure has the surface properties (Ra, RSm, and Rz) described later. Furthermore, it is preferable that the variation σ1 of Ra, the variation σ2 of RSm, and the variation σ3 of Rz are within the ranges described later. This is because the above-mentioned ΔE and ΔG can be easily adjusted to the above-mentioned ranges. Hereafter, a surface shape in which ΔE and ΔG are within the above-mentioned ranges may be referred to as a specific surface shape.

[0032] (1) Ra (arithmetic mean roughness) As a surface property of the wrinkle structure, Ra (arithmetic mean roughness), which is a parameter in the height direction of the contour curve as defined in JIS B0601:2013, is preferably 0.3 μm or more, more preferably 0.4 μm or more, and even more preferably 0.5 μm or more. On the other hand, the above Ra (arithmetic mean roughness) is preferably 1.5 μm or less, more preferably 1.2 μm or less, and even more preferably 1.0 μm or less.

[0033] Ra (arithmetic mean roughness) is one of the parameters in the height direction of the contour curve, and is the average value of the height difference from the average surface in the contour curve over a reference length. The larger the Ra (arithmetic mean roughness) value, the greater the height difference tends to be in the convex parts and correspondingly in the concave parts of the wrinkle structure of the surface shape. Ra (arithmetic mean roughness) is a value measured by a shape analysis laser microscope, and the "VK-X1000 (manufactured by Keyence Corporation)" can be used as the shape analysis laser microscope.

[0034] In this specification, the cutoff value for measuring Ra (arithmetic mean roughness) is 0.8 mm. Furthermore, in this specification, the above Ra (arithmetic mean roughness) is the average value of measurements taken at any 10 locations.

[0035] The variation (standard deviation) σ1 of Ra is preferably 0.20 μm or less, more preferably 0.15 μm or less, and particularly preferably 0.10 μm or less. When the variation σ1 of Ra is within the above range, the surface wrinkle shape is uniform and the variation is small, so light is reflected evenly in all directions. Therefore, visibility is improved. On the other hand, the variation σ1 of Ra may be, for example, 0.03 μm or more, or 0.05 μm or more.

[0036] (2) RSm (average length of curved elements) As a surface property of the wrinkled structure, RSm (average length of curved elements), which is a lateral parameter of the contour curve as defined in JIS B0601:2013, is preferably 50 μm or less, more preferably 45 μm or less, and even more preferably 40 μm or less. On the other hand, the above RSm (average length of curved elements) is preferably 10 μm or more, more preferably 15 μm or more, and even more preferably 20 μm or more.

[0037] RSm (average length of curve elements) is a lateral parameter of the contour curve, and is the average length of the contour curve elements at a reference length. A smaller RSm indicates a tendency for the vertices of convex parts in the wrinkle structure of the surface shape to be more densely packed. RSm (average length of curve elements) is a value measured by a shape analysis laser microscope, and the "VK-X1000 (manufactured by Keyence Corporation)" can be used as the shape analysis laser microscope.

[0038] In this specification, the cutoff value for measuring RSm (average length of the curved element) is 0.8 mm. Furthermore, in this specification, RSm (average length of the curved element) is the average value of measurements taken at any 10 locations.

[0039] The variation (standard deviation) σ² of RSm is preferably 5.0 μm or less, more preferably 4.0 μm or less, and particularly preferably 3.5 μm or less. When the variation σ² of RSm is within the above range, the surface wrinkle shape is uniform and the variation is small, so light is reflected evenly in all directions. Therefore, visibility is improved. On the other hand, the variation σ² of RSm may be, for example, 1.0 μm or more, or 2.0 μm or more.

[0040] (3) Rz (average length of curved elements) As a surface property of the wrinkle structure, Rz (maximum height) as specified in JIS B0601:2013 is, for example, 10.0 μm or less, may be 9.0 μm or less, or 8.0 μm or less. On the other hand, the above Rz (maximum height) is, for example, 2.0 μm or more, may be 3.0 μm or more, or 4.0 μm or more.

[0041] Rz (maximum height) is one of the peak and height parameters of the contour curve, and is the sum of the height of the highest peak and the depth of the deepest valley in the contour curve at a given length. A larger Rz (maximum height) value indicates the presence of large (high) convex parts relative to the valleys (concave parts), and suggests a tendency for many such convex parts to be present. Rz (maximum height) is a value measured by a shape analysis laser microscope, and the "VK-X1000 (manufactured by Keyence Corporation)" can be used as the shape analysis laser microscope.

[0042] In this specification, the cutoff value for measuring Rz (maximum height) is 0.8 mm. Furthermore, in this specification, Rz (maximum height) is the average value of measurements taken at any 10 locations.

[0043] The variation (standard deviation) σ3 of Rz is preferably 4.0 μm or less, more preferably 3.0 μm or less, and particularly preferably 2.0 μm or less. When the variation σ3 of Rz is within the above range, the surface wrinkle shape is uniform and the variation is small, so light is reflected evenly in all directions. Therefore, visibility is improved. On the other hand, the variation σ3 of Rz may be, for example, 0.5 μm or more, and may also be 1.0 μm or more.

[0044] II. Layer Structure 1. Surface Layer The decorative material in this disclosure has a surface layer disposed on the decorative material body. The surface layer has at least a first protective layer. The surface layer is, for example, a transfer layer transferred from a transfer sheet. The surface of the surface layer opposite to the decorative material body is preferably, for example, the "surface S1 on the surface layer 2 side of the decorative material 10" as shown in Figure 1.

[0045] The surface layer contributes to improving the surface properties of the decorative material (e.g., scratch resistance, abrasion resistance, etc.). The surface layer may have an adhesion layer and a first protective layer in that order from the decorative material body side. The surface layer may also have a second protective layer on the decorative material body side, relative to the first protective layer. Furthermore, the surface layer may have a second protective layer between the adhesion layer and the first protective layer. In this disclosure, it is preferable that the first protective layer contains a weather-resistant agent. Furthermore, if the surface layer has a second protective layer, it is preferable that both the first and second protective layers contain a weather-resistant agent.

[0046] (1) The first protective layer decorative material preferably has the first protective layer as its outermost layer. That is, the surface of the first protective layer opposite to the decorative material body is preferably the "surface S1 on the surface layer 2 side of the decorative material 10", as shown in Figure 1, for example.

[0047] (a) Resin The first protective layer in this disclosure contains, for example, a cured product (crosslinked structure) of a curable resin. In this disclosure, the curable resin in the first protective layer may be referred to as curable resin X. The proportion of cured product of curable resin X is, for example, 70% by mass or more, may be 90% by mass or more, may be 95% by mass or more, or may be 100% by mass, based on the total resin components constituting the first protective layer.

[0048] Examples of curable resins X include ionizing radiation-curable resins and thermosetting resins. Among these, ionizing radiation-curable resins are preferred from the viewpoint of improving scratch resistance and weather resistance. Ionizing radiation-curable resins are compositions containing compounds having ionizing radiation-curable functional groups (hereinafter also referred to as "ionizing radiation-curable compounds"), and they harden when exposed to ionizing radiation. Examples of ionizing radiation-curable resins include electron beam-curable resins and ultraviolet-curable resins. Among these, electron beam-curable resins are preferred because they do not require polymerization initiators, have less odor, and are less prone to discoloration. Electron beam-curable resins also have the advantage of being less prone to curing defects caused by weathering agents and having a higher crosslink density.

[0049] Ionizing radiation-curable functional groups are groups that crosslink and harden upon irradiation with ionizing radiation. Examples include functional groups having ethylenic double bonds, such as (meth)acryloyl groups, vinyl groups, and allyl groups. Other examples of ionizing radiation-curable functional groups include epoxy groups and oxetanyl groups. A (meth)acryloyl group refers to either an acryloyl group or a metacloyl group. A (meth)acrylate refers to either an acrylate or a methacrylate.

[0050] The number of functional groups in the ionizing radiation-curable compound is preferably 2 to 20, more preferably 2 to 18, and even more preferably 2 to 15.

[0051] Ionizing radiation refers to electromagnetic waves or charged particle beams that possess energy quanta capable of polymerizing or bridging molecules. Examples of ionizing radiation include electron beams (EB) and ultraviolet (UV). Other examples of ionizing radiation include electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

[0052] Ionizing radiation-curable resins preferably contain at least urethane (meth)acrylate as an ionizing radiation-curable compound. (Meth)acrylate refers to acrylate or methacrylate. In addition to urethane (meth)acrylate, ionizing radiation-curable resins may further contain at least one of the following as an ionizing radiation-curable compound: epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, polycarbonate (meth)acrylate, or acrylic (meth)acrylate.

[0053] The ionizing radiation-curable resin preferably contains caprolactone-based urethane (meth)acrylate as the urethane (meth)acrylate. Alternatively, the ionizing radiation-curable resin may contain both caprolactone-based urethane (meth)acrylate and urethane (meth)acrylate that has not been modified with caprolactone. In this case, the content of caprolactone-based urethane (meth)acrylate in the first protective layer is M. ＣＬＵＡ The content of caprolactone-unmodified urethane (meth)acrylate is M ＵＡ Let's assume that. M ＵＡ and M ＣＬＵＡ M for the sum ＣＬＵＡ The mass ratio (M ＣＬＵＡ / (M ＵＡ +M ＣＬＵＡ For example, the amount of the active ingredient may be 10% by mass or more and 90% by mass or less, and may also be 20% by mass or more and 80% by mass or less, or 30% by mass or more and 70% by mass or less.

[0054] When the ionizing radiation-curable compound contains caprolactone-based urethane (meth)acrylate, the number of functional groups of the caprolactone-based urethane (meth)acrylate is preferably 2 to 9, and more preferably 2 to 5. Furthermore, when the ionizing radiation-curable compound contains caprolactone-based urethane (meth)acrylate, the number of functional groups of the caprolactone-based urethane acrylate is preferably 2 to 4, and more preferably 2 to 3. By keeping the number of functional groups of the caprolactone-based urethane acrylate within the above range, it is possible to improve, for example, the processing characteristics of the transfer sheet and the scratch resistance and weather resistance of the surface protective layer.

[0055] Caprolactone-based urethane (meth)acrylates can usually be obtained by reacting a caprolactone-based polyol with an organic isocyanate and a hydroxy(meth)acrylate. One synthesis method involves reacting a polycaprolactone-based polyol with an organic polyisocyanate to produce a polyurethane prepolymer containing -NCO groups (isocyanate groups) at both ends, and then reacting it with a hydroxy(meth)acrylate.

[0056] As caprolactone-based polyols, commercially available ones can be used, preferably those having two hydroxyl groups and a number-average molecular weight of preferably 500 to 3000, more preferably 750 to 2000. In addition, polyols other than caprolactone-based polyols, such as ethylene glycol, diethylene glycol, 1,4-butanediol, and 1,6-hexanediol, can be used in any proportion or in combination of one or more types. As organic polyisocyanates, diisocyanates having two isocyanate groups are preferred, and from the viewpoint of suppressing yellowing, isophorone diisocyanate, hexamethylene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, trimethylhexamethylene diisocyanate, etc. are preferred. As hydroxy(meth)acrylates, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, caprolactone-modified 2-hydroxyethyl acrylate, etc. are preferred.

[0057] When using a caprolactone-based polyol, it is preferable that the caprolactone-based urethane (meth)acrylate is a caprolactone diol-based urethane (meth)acrylate. A caprolactone diol-based urethane (meth)acrylate refers to a urethane (meth)acrylate among caprolactone-based urethane (meth)acrylates in which the terminal end is diethylene glycol. By using a caprolactone diol-based urethane (meth)acrylate, cracking and whitening of the first protective layer can be suppressed.

[0058] The number-average molecular weight of the ionizing radiation-curable compound is, for example, 1,000 to 10,000, and may also be 2,000 to 10,000. The number-average molecular weight is measured by GPC analysis and converted to the average molecular weight in terms of standard polystyrene.

[0059] For example, if the ionizing radiation-curable compound is an ultraviolet-curable compound, the ionizing radiation-curable resin preferably contains at least one of a photopolymerization initiator and a photopolymerization accelerator. Examples of photopolymerization initiators include acetophenone, benzophenone, α-hydroxyalkylphenone, Michler ketone, benzoin, benzyldimethyl ketal, benzoyl benzoate, α-acyloxime ester, acylphosphine oxide, and thioxanthones. Examples of photopolymerization accelerators include isoamyl p-dimethylaminobenzoate and ethyl p-dimethylaminobenzoate.

[0060] Furthermore, the curable resin X may be a thermosetting resin. Details regarding the thermosetting resin are the same as those described in the second protective layer section below.

[0061] (b) Weather-resistant agent The first protective layer preferably contains a weather-resistant agent. For example, if the decorative material in this disclosure is a resin-impregnated decorative panel, the cured resin layer described later is prone to deterioration such as discoloration and embrittlement due to ultraviolet rays. Therefore, by containing a weather-resistant agent in the first protective layer, the deterioration of the cured resin layer can be suppressed.

[0062] Examples of weather-resistant agents include ultraviolet absorbers and light stabilizers. The first protective layer preferably contains at least one of the ultraviolet absorbers and light stabilizers. The first protective layer may contain one or more ultraviolet absorbers. Similarly, the first protective layer may contain one or more light stabilizers.

[0063] Examples of UV absorbers included in the first protective layer include organic UV absorbers such as triazine-based UV absorbers, benzotriazole-based UV absorbers, benzophenone-based UV absorbers, oxybenzophenone-based UV absorbers, salicylate-based UV absorbers, and cyano(meth)acrylate-based UV absorbers, as well as inorganic UV absorbers such as titanium dioxide, cerium oxide, and zinc oxide. Among these, triazine-based UV absorbers are more preferred.

[0064] Examples of triazine-based UV absorbers include hydroxyphenyltriazine-based UV absorbers. Examples of hydroxyphenyltriazine-based UV absorbers include 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2,4-bis[2-hydroxy-4-butoxyphenyl]-6-(2,4-dibutoxyphenyl)-1,3,5-triazine. Examples include azine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-(2'-ethyl)hexyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2-(4,6-diphenyl-1,3,5-triazine-2-yl)-5[2-(2-ethylhexanoyloxy)ethoxy]phenol.

[0065] The amount of ultraviolet absorber contained in the first protective layer is, for example, 0.5 parts by mass or more and 10 parts by mass or less per 100 parts by mass of resin component, and may be 0.8 parts by mass or more and 8 parts by mass or 1 part by mass or more and 5 parts by mass. If the amount of ultraviolet absorber is too high, there is a possibility that the ultraviolet absorber will bleed out, and if the amount of ultraviolet absorber is too low, there is a possibility that sufficient ultraviolet absorption performance cannot be obtained.

[0066] Examples of light stabilizers included in the first protective layer include hindered amine-based light stabilizers. Examples of hindered amine-based light stabilizers include 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, bis(2,2,6,6-pentamethyl-4-piperidinyl) sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, methyl(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, and 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidine-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine).

[0067] The amount of light stabilizer contained in the first protective layer is, for example, 1 to 10 parts by mass per 100 parts by mass of resin component, and may be 1.5 to 8 parts by mass, or 2 to 5 parts by mass. If the amount of light stabilizer is too high, bleed-out of the light stabilizer may occur, and if the amount of light stabilizer is too low, sufficient light stability may not be obtained.

[0068] (c) Other additives The first protective layer may contain additives such as silicone compounds, polymerization inhibitors, crosslinking agents, antistatic agents, adhesion improvers, antioxidants, leveling agents, thixotropic agents, coupling agents, plasticizers, antifouling agents, defoaming agents, fillers, abrasion resistant agents, antibacterial agents, antiviral agents, and antifungal agents.

[0069] (d) The first protective layer may have a single-layer structure or a multilayer structure in which multiple layers are stacked. The thickness of the first protective layer is preferably 2 μm or more, more preferably 3 μm or more, and particularly preferably 4 μm or more. When the thickness of the first protective layer is within the above range, sufficient abrasion resistance and pencil hardness (resistance to gouges) can be obtained. In addition, the specific surface shape described above can be easily obtained. On the other hand, the thickness of the first protective layer is preferably 40 μm or less, more preferably 30 μm or less, and particularly preferably 20 μm or less.

[0070] In this specification, the thickness of each layer is determined, for example, by observing the cross-section of each layer using a laser microscope and taking the arithmetic mean of the thicknesses at any three points.

[0071] The surface of the first protective layer facing the main body of the decorative material may be surface-treated to improve adhesion with other layers. Examples of surface treatments include corona discharge treatment and plasma treatment.

[0072] (2) Adhesion layer The surface layer in this disclosure may have an adhesion layer on the decorative material body side with respect to the first protective layer. The adhesion layer may constitute the surface of the surface layer on the decorative material body side. Furthermore, it is preferable that the adhesion layer is a layer that is in contact with the decorative material body among the layers that constitute the surface layer. In this case, the adhesion layer is arranged to improve the adhesion between the surface layer and the decorative material body.

[0073] When the surface layer has a second protective layer, as described later, the adhesion between the surface layer and the decorative material body tends to decrease if the second protective layer contains an ultraviolet absorber. However, by having an adhesion layer, good adhesion to the decorative material body can be achieved. Therefore, the second protective layer allows the ultraviolet absorber to exert its effect while the adhesion layer improves adhesion to the decorative material body.

[0074] The adhesion layer may be any of the following: a pressure-sensitive adhesive layer, a curing-type adhesive layer, or a heat-sensitive adhesive layer (heat-seal layer). In order to improve the adhesion between the surface layer and the decorative material body, it is preferable to select one of the following as the adhesion layer, depending on the type of decorative material body: a pressure-sensitive adhesive layer, a curing-type adhesive layer, or a heat-sensitive adhesive layer.

[0075] If the adhesion layer is a pressure-sensitive adhesive layer, it is preferable that the adhesion layer contains an adhesive. As the adhesive, acrylic, urethane, silicone, rubber, and other types of adhesives can be appropriately selected and used.

[0076] When the adhesion layer is a curing type adhesive layer, it is preferable that the adhesive layer contains a thermosetting adhesive. The thermosetting adhesive should preferably contain a composition that undergoes a chemical reaction and crosslinking upon heating. Examples include two-component curing urethane adhesives, polyester urethane adhesives, polyether urethane adhesives, acrylic adhesives, polyester adhesives, polyamide adhesives, polyvinyl acetate adhesives, epoxy adhesives, and rubber adhesives. The urethane resin constituting the two-component curing urethane adhesive is a polyurethane primarily composed of a polyol (polyhydric alcohol) with isocyanate as a crosslinking agent (curing agent).

[0077] When the adhesion layer is a heat-sensitive adhesive layer, it is preferable that the adhesive layer contains a thermoplastic resin. Examples of thermoplastic resins include acrylic resins, urethane resins, vinyl chloride resins, vinyl acetate resins, vinyl chloride-vinyl acetate copolymers, styrene-acrylic copolymers, polyester resins, amide resins, cyanoacrylate resins, epoxy resins, etc., and these can be used individually or in combination of several types. Among these, for example, it is preferable to use acrylic resin to improve the processability when forming a component using a transfer sheet and to improve the adhesion between the heat-sensitive adhesive layer and the decorative material body.

[0078] The weight-average molecular weight of the thermoplastic resin is preferably 10,000 to 200,000, preferably 50,000 to 150,000, and more preferably 80,000 to 120,000. When the weight-average molecular weight of the thermoplastic resin composition is within the above range, the coating suitability is improved, and it becomes easier to form an adhesion layer in a good condition. Furthermore, for example, when manufacturing a decorative material using a transfer sheet, it becomes easier to improve the adhesion between the adhesion layer and the decorative material body, and it becomes easier to improve the durability of the component.

[0079] The thickness of the adhesion layer varies depending on the material constituting the adhesion layer and is not particularly limited, but for example, it is 2 μm or more and 150 μm or less. The above thickness of the adhesion layer may be 3 μm or more, 5 μm or more, or 10 μm or more. On the other hand, the above thickness of the adhesion layer may be 125 μm or less, or 100 μm or less. Furthermore, for example, when the adhesion layer is a heat-sensitive adhesive layer, and good adhesion can be obtained even if the adhesion layer is relatively thin, the thickness of the adhesion layer is preferably 2 μm or more and 10 μm or less, more preferably 3 μm or more and 8 μm or less, and even more preferably 3 μm or more and 5 μm or less. On the other hand, when the adhesion layer is a pressure-sensitive adhesive layer or a curing-type adhesive layer, and good adhesion can be obtained by making the adhesion layer relatively thick, the thickness of the adhesion layer is preferably 5 μm or more and 150 μm or less, and more preferably 10 μm or more and 125 μm or less. When the thickness of the adhesion layer is within the above range, it is easier to achieve good adhesion between the surface layer and the decorative material body.

[0080] (3) Second protective layer As shown in Figure 1(b), the surface layer 2 of the decorative material 10 in this disclosure preferably has a second protective layer 23 between the first protective layer 22 and the adhesion layer 21. That is, from the decorative material body 1 side, the adhesion layer 21, the second protective layer 23 and the first protective layer 22 are in the thickness direction D Ｔ It is preferable that the layers be in this order. The second protective layer, together with the first protective layer, contributes to improving the surface properties of the decorative material. The second protective layer and the first protective layer may be arranged in direct contact or in between other layers. The second protective layer and the adhesion layer may be arranged in direct contact or in between other layers.

[0081] (a) The second protective resin layer contains, for example, a cured product (crosslinked structure) of a curable resin Y. A thermosetting resin is preferred as the curable resin Y. A thermosetting resin is a resin that hardens with heat. By containing a cured product of a thermosetting resin in the second protective layer, the adhesion between each layer constituting the surface layer is improved.

[0082] Examples of thermosetting resins include urethane (meth)acrylic resins. In addition to urethane (meth)acrylic resins, other examples of thermosetting resins include (meth)acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In this disclosure, only one type of thermosetting resin may be used, or two or more types may be used. Furthermore, the thermosetting resin composition containing the thermosetting resin may further contain a curing agent such as an isocyanate curing agent or an epoxy curing agent.

[0083] As the urethane (meth)acrylic resin, a urethane (meth)acrylic copolymer is preferred. Examples of urethane (meth)acrylic copolymers include polycarbonate-based urethane (meth)acrylic copolymers, polyester-based urethane (meth)acrylic copolymers, polyether-based urethane (meth)acrylic copolymers, and caprolactone-based urethane (meth)acrylic copolymers. Among these, polycarbonate-based urethane (meth)acrylic copolymers are more preferred. A polycarbonate-based urethane (meth)acrylic copolymer is a resin obtained by radical polymerization of a (meth)acrylic monomer to a polycarbonate-based polyurethane polymer obtained by reacting a polycarbonate diol with a (di)isocyanate.

[0084] Examples of (di)isocyanates include aromatic isocyanates such as 4,4'-diphenylmethane diisocyanate, 2,4-tole diisocyanate, 1,5-naphthalene diisocyanate, n-isocyanate phenylsulfonyl isocyanate, o-isocyanate phenylsulfonyl isocyanate, and p-isocyanate phenylsulfonyl isocyanate; aliphatic isocyanates such as 1,6-hexamethylene diisocyanate; and alicyclic isocyanates such as isophorone diisocyanate, hydrogenated xylylene diisocyanate, and hydrogenated diphenylmethane diisocyanate.

[0085] Examples of (meth)acrylic monomers include alkyl (meth)acrylate esters such as (meth)acrylic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, and isobutyl (meth)acrylate.

[0086] In a polycarbonate-based urethane (meth)acrylic copolymer, the mass ratio of the urethane component to the total of the (meth)acrylic component and the urethane component ([urethane component] / ([(meth)acrylic component] + [urethane component]) is, for example, 65% by mass or more and 95% by mass or less, and may be 70% by mass or more and 90% by mass or less. If the mass ratio of the urethane component is too high, the adhesion to the first protective layer may be reduced.

[0087] (b) Weather-resistant agent The second protective layer preferably contains a weather-resistant agent. Examples of weather-resistant agents include ultraviolet absorbers and light stabilizers. The second protective layer preferably contains at least one of an ultraviolet absorber and a light stabilizer. The preferred types and forms of the weather-resistant agent are the same as those described for the first protective layer above, so they are omitted here. In particular, the second protective layer preferably contains a triazine-based ultraviolet absorber. The second protective layer also preferably contains a hindered amine-based light stabilizer.

[0088] The amount of ultraviolet absorber contained in the second protective layer is, for example, 0.1 parts by mass or more and 50 parts by mass or less per 100 parts by mass of resin component, and may be 3 parts by mass or more and 40 parts by mass or 10 parts by mass or more and 35 parts by mass or less. Furthermore, the amount of ultraviolet absorber contained in the second protective layer (per 100 parts by mass of resin component) may be greater than the amount of ultraviolet absorber contained in the first protective layer (per 100 parts by mass of resin component).

[0089] The amount of light stabilizer contained in the second protective layer is, for example, 0.1 parts by mass or more and 15 parts by mass or less per 100 parts by mass of resin component, and may be 1 part by mass or more and 15 parts by mass or 3 parts by mass or more and 10 parts by mass. Furthermore, the amount of light stabilizer contained in the second protective layer (amount per 100 parts by mass of resin component) may be greater than the amount of light stabilizer contained in the first protective layer (amount per 100 parts by mass of resin component).

[0090] The second protective layer may contain additives such as silicone compounds, polymerization inhibitors, crosslinking agents, antistatic agents, adhesion enhancers, antioxidants, leveling agents, thixotropic agents, coupling agents, plasticizers, antifouling agents, defoaming agents, fillers, and antiblocking agents.

[0091] The thickness of the second protective layer is preferably 0.1 μm to 10 μm, more preferably 0.1 μm to 5 μm. This improves, for example, the adhesion with the first protective layer.

[0092] (4) Decorative layer As shown in Figure 1(c), the surface layer of the decorative material 10 in this disclosure may have a decorative layer 24 on the decorative material body 1 side with respect to the first protective layer 22. The decorative layer may be placed between the first protective layer and the adhesive layer, or between the second protective layer and the adhesive layer. Details of the decorative layer are the same as details of the decorative layer in the decorative sheet described later.

[0093] 2. Decorative Material Body The decorative material body in this disclosure can be a conventionally known decorative material. The decorative material body may, for example, have a base and a decorative sheet. The decorative material body may also consist of, for example, a base. Furthermore, the decorative material body may not have a decorative sheet. Each component will be described below.

[0094] (1) Decorative sheet A conventionally known decorative sheet can be used. The decorative sheet may include, for example, a base layer and further include layers such as a decorative layer, a transparent resin layer, and an adhesive layer.

[0095] (a) Substrate layer The substrate layer is not particularly limited and includes, for example, a resin substrate, a glass substrate, a metal substrate, and a fiber substrate. The substrate layer may also be a porous substrate.

[0096] Examples of resins used in resin substrates include various synthetic resins and various natural resins. Examples of synthetic resins include thermoplastic resins and curable resins. Considering the suitability for manufacturing, handling, and post-processing of decorative sheets, thermoplastic resins are preferred.

[0097] Examples of metals used as the metal substrate include aluminum or aluminum alloys such as duralumin; iron or iron alloys such as carbon steel and stainless steel; copper or copper alloys such as brass and bronze; gold, silver, chromium, nickel, cobalt, tin, and titanium. The metal substrate may have a plating film or an anodic oxide film on its surface.

[0098] Examples of fibrous materials used in fibrous substrates include paper such as tissue paper, kraft paper, fine paper, Japanese paper, titanium paper, linter paper, sulfuric acid paper, paraffin paper, parchment paper, glassine paper, wallpaper backing paper, cardboard, and gypsum board base paper; and woven or nonwoven fabrics made of fibers such as polyester resin fibers, acrylic resin fibers, natural protein or cellulose fibers such as silk, cotton, and hemp, glass fibers, and carbon fibers. Various resins such as acrylic resin, styrene-butadiene rubber, melamine resin, and urethane resin may be added to the fibrous substrate. When the fibrous substrate is a paper substrate, the inter-fiber strength of the paper substrate or the interlayer strength between the paper substrate and other substrates can be improved. Furthermore, fuzzing can be suppressed. As for the method of adding resin, the resin may be impregnated after papermaking, or the resin may be filled in during papermaking. Examples of paper substrates to which resin has been added include inter-paper reinforced paper and resin-impregnated paper.

[0099] The substrate layer may contain additives as needed. In the case of a resin substrate, examples of additives include inorganic fillers, flame retardants, lubricants, foaming agents, antioxidants, UV absorbers, light stabilizers, and colorants. Various additives can be used individually or in combination. There are no particular restrictions on the amount of additives, as long as they do not impair the surface properties or processing properties, and they can be set appropriately according to the required properties.

[0100] To improve weather resistance, it is preferable to use weather-resistant agents such as ultraviolet absorbers and light stabilizers among the above-mentioned additives. The ultraviolet absorbers and light stabilizers can be the same as those used in the first protective layer described above.

[0101] The base layer may be a single layer or a laminate of two or more layers. In the case of a laminate, the base layer may consist of two or more layers of the same type of base material or two or more layers of different types of base materials.

[0102] In this disclosure, the substrate layer may also serve as the decorative layer described later.

[0103] The base layer may be transparent or opaque. If the base layer is opaque, it can serve as a decorative layer.

[0104] Furthermore, the base layer may be colored. If the base layer is colored, it can serve as a decorative layer. The manner of coloring is not particularly limited; it may be transparent coloring or opaque coloring (concealing coloring), and these can be chosen arbitrarily.

[0105] (b) Decorative layer The decorative sheet has, for example, a decorative layer on one side of the base layer. The decorative layer may be, for example, placed between the base layer and the surface layer described above. The decorative layer may be, for example, a colored layer, a patterned layer, or a metal layer. The decorative layer may also have a colored layer and a patterned layer.

[0106] The colored layer may be a so-called solid colored layer that is applied to the entire surface of the decorative sheet. The colored layer may contain a binder resin and a coloring agent. The colored layer can be formed by a coating method.

[0107] The patterns (designs) of the design layers are not particularly limited and include, for example, wood grain patterns such as annual rings and vessel grooves on the surface of wooden boards; stone patterns on the surface of stone slabs such as marble and granite; sand patterns; fabric patterns on the surface of cloth; leather grain patterns on the surface of leather; tile patterns; brick patterns; abstract patterns; floral patterns; geometric patterns; symbols; letters; figures; and combinations thereof.

[0108] The pattern layer contains, for example, a binder resin and a coloring agent. The pattern layer can be formed by a printing method.

[0109] The binder resin used for the colored layer and the patterned layer is not particularly limited and includes, for example, urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, chlorinated propylene resin, nitrocellulose resin, and cellulose acetate resin. In addition, various resins can be used, such as one-component curing resins and two-component curing resins accompanied by curing agents such as isocyanate compounds.

[0110] Examples of colorants used in the colored layer and patterned layer include pigments and dyes. Specific examples of colorants include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, lead yellow, titanium yellow, reddish-brown, cadmium red, ultramarine, cobalt blue, and manganese complex oxide; organic pigments (including dyes) such as quinacridone red, isoindolinone yellow, nickel azo complex, phthalocyanine blue, and azomethine azoblack; metallic pigments such as aluminum and brass; and pearl pigments such as titanium dioxide-coated mica and basic lead carbonate. The colored layer and patterned layer may also contain additives such as weathering agents like UV absorbers and light stabilizers, extender pigments, stabilizers, plasticizers, curing agents, and catalysts, as needed.

[0111] Examples of metal materials used for the metal layer include aluminum, chromium, tin, and indium. The metal layer can be formed by vapor deposition.

[0112] The thickness of the decorative layer is appropriately selected according to the desired design and type of decorative layer. For example, the thickness of the decorative layer may be 0.5 μm or more and 20 μm or less, 1 μm or more and 10 μm or less, or 2 μm or more and 5 μm or less.

[0113] (c) Other layers The decorative sheet may have other layers in addition to the base layer and the decorative layer. Examples of other layers include a transparent resin layer, an adhesive layer, a separator layer, and a primer layer.

[0114] (2) The substrate may be a solid substrate or a porous substrate. The substrate may also be a wood-based member. Examples of wood-based members include wood fiberboard. Examples of wood fiberboard include wood veneer, wood plywood, laminated wood, particleboard, and MDF (medium-density fiberboard). Examples of wood materials for the wood-based member include cedar, cypress, pine, lauan, and other types of wood.

[0115] The substrate may be a metal component. Examples of metals that can be used for the metal component include iron, aluminum, copper, and alloys containing one or more of these metals. The adherend may be a ceramic component such as glass or porcelain, or a non-ceramic component such as gypsum, cement, ALC (autoclaved lightweight concrete), or calcium silicate.

[0116] The substrate may be a non-combustible substrate. Preferably, the non-combustible substrate meets the criteria for non-combustible materials under the Building Standards Act in the heat generation test based on ISO 5660-1. Specifically, when the amount of heat generated during heating is measured using a cone calorimeter, and the heating time that satisfies all of the following conditions (i) to (iii) is measured, a non-combustible material is one whose heating time is 20 minutes or more. (i) Total heat generation is 8 MJ / m³ ２ (ii) The maximum heating rate is 200 kW / m² for more than 10 seconds continuously. ２ (iii) No cracks or holes that penetrate to the back surface which are harmful from a fire-retardant standpoint.

[0117] Examples of non-combustible substrates include fiber-reinforced cement board, gypsum board, concrete, brick, ceramic tile, mortar, and plaster. Among these, fiber-reinforced cement board is preferred because, in addition to being non-combustible, it is also excellent in durability, water resistance, and lightness. Fiber-reinforced cement board is specified in JIS A 5430:2018 and is classified into slate, calcium silicate board, and slag gypsum board. Slate is a product made mainly from cement, fibers, and admixtures, and is further classified into corrugated slate and slate board (flexible board). On the other hand, calcium silicate board is a product made mainly from calcareous raw materials, silicate raw materials, fibers, and admixtures. Slag gypsum board is a product made mainly from slag, gypsum, fibers, and admixtures.

[0118] The thickness of the non-combustible substrate varies depending on the application of the decorative material and is not particularly limited. For example, when the decorative material is used as an exterior wall material, the thickness of the non-combustible substrate may be, for example, 3 mm or more and 30 mm or less, 5 mm or more and 25 mm or less, or 7 mm or more and 12 mm or less. Also, for example, when the decorative material is used as a partition plate installed at the boundary between adjacent units on the balcony of an apartment building, the partition plate is required to be able to be destroyed in an emergency. In such cases where destructibility is required for the decorative material, the thickness of the non-combustible substrate may be 1 mm or more and 15 mm or less, 2 mm or more and 12 mm or less, or 3 mm or more and 10 mm or less.

[0119] The substrate may be a resin component. Examples of resins used for the resin component include acrylic resin, polyester resin, polystyrene resin, polyolefin resin such as polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) resin, phenolic resin, vinyl chloride resin, cellulose resin, and rubber.

[0120] (3) Preferred form When the decorative material in this disclosure is a resin-impregnated decorative board, as shown in Figure 5, the decorative material body 1 has, for example, a porous substrate 11 containing a cured product of a curable resin α. Preferably, the decorative material body 1 has a core paper 15 containing a cured product of a curable resin α on the side of the porous substrate 11 opposite to the surface layer 2 side. The decorative material body 1 may also have a design layer 12 on the surface of the porous substrate 11 facing the surface layer 2. In this disclosure, the decorative layer may be referred to as the design layer for convenience. On the other hand, although not specifically shown, the porous substrate 11 may also serve as the design layer (coloring layer) 12. A cured resin layer 13 containing a cured product of a curable resin α may be present in at least one of the spaces between the porous substrate 11 and the surface layer 2, and between the porous substrate 11 and the core material 15.

[0121] The porous substrate, design layer, core material, curable resin α, and cured resin layer in the case where the decorative material in this disclosure is a resin-impregnated decorative panel will be described later.

[0122] Furthermore, the decorative material in this disclosure does not have to be a resin-impregnated decorative panel. For example, the decorative material body 1 shown in Figures 1(a) to (c) may be a non-combustible substrate. In addition, various substrates other than the non-combustible substrate described above can be used.

[0123] 3. Transfer Sheet The transfer sheet in this disclosure comprises a release support and a transfer layer disposed on one side of the release support. The transfer layer has at least a first protective layer. Also, as shown in Figure 2, the transfer layer 20 has the first protective layer 22 and the adhesion layer 21 in the thickness direction D from the release support 3 side. Ｔ They may be present in this order.

[0124] (1) Release support The release support serves as a support for transferring the transfer layer to the main body of the cosmetic material. The release support has a textured layer and a resin film that supports the textured layer. In this disclosure, the release support also functions as a component for forming the transfer layer. The release support and the first protective layer may be arranged in direct contact or arranged via other layers.

[0125] (a) Resin film Examples of resins contained in the resin film include ester resins, olefin resins, styrene resins, vinyl resins, (meth)acrylic resins, amide resins, imide resins, and carbonate resins.

[0126] The resin film preferably contains an ester resin or an olefin resin. Examples of ester resins include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and polyethylene terephthalate-isophthalate copolymer. Among these, PET or PBT are preferred, with PET being more preferred, from the viewpoint of being less susceptible to thermal shrinkage during the manufacture of the transfer sheet and shrinkage due to irradiation with ionizing radiation.

[0127] Examples of olefin resins include polyethylene, polypropylene, polybutene, ethylene-propylene copolymer, and ethylene-propylene-butene copolymer. Among these, polypropylene is preferred from the viewpoint of being less susceptible to thermal shrinkage during the manufacture of the transfer sheet and shrinkage due to irradiation with ionizing radiation.

[0128] The resin film may be a stretched film or an unstretched film. The stretching ratio in the mechanical direction (MD) of the stretched film is, for example, 5 times or more and 30 times or less. The stretching ratio in the width direction (TD) of the stretched film is, for example, 5 times or more and 30 times or less. The thickness of the resin film is, for example, 10 μm or more and 200 μm or less, may be 15 μm or more and 150 μm or less, or 20 μm or more and 100 μm or less.

[0129] (b) In the uneven layer release support, it is preferable that the surface of the uneven layer opposite to the resin film has a surface shape having a second wrinkle structure.

[0130] The second wrinkle structure preferably has an uneven shape due to irregular wrinkles. The irregular wrinkles preferably have multiple protrusions formed by multiple projections and recesses formed by being surrounded by multiple projections.

[0131] Furthermore, the projection is preferably linear. In this specification, "linear projection" means that the ratio of the length to the width of the projection (length / width) is 3 or more, preferably 5 or more, and more preferably 10 or more. The method for determining the length and width of the projection is as described below. Hereinafter, linear projections may be referred to as linear projections.

[0132] A specific embodiment of the second wrinkle structure is, for example, the embodiment shown in Figure 4. Figure 4 also shows that the surface shape of the surface opposite to the resin film of the uneven layer has irregular wrinkles in a plan view; the irregular wrinkles have multiple protrusions formed by multiple curved linear protrusions and recesses formed by being surrounded by multiple protrusions (multiple convex parts); at least a portion of the multiple curved protrusions are each formed by meandering linear protrusions, and meandering recesses are formed surrounded by the meandering linear protrusions.

[0133] Here, "curvature" means that, in a plan view, a continuous line has one or more points where the direction of extension of the convex part of the line reverses from one side to the other. Hereafter, the points where the direction of extension of the convex part of a continuous line reverses from one side to the other may be referred to as reversed portions. An example of a reversed portion is a form that has an inflection point when the width of the plan view shape of the convex part of the line is ignored (when the width is considered to be 0) and it is approximated by a continuous curve. Another example of a reversed portion is a form that has a portion that is approximated by a V-shaped polyline or two sides enclosing one vertex of a triangle when the width of the plan view shape of the convex part of the line is ignored and it is approximated by a straight line.

[0134] Furthermore, "serpentine" means that, in a plan view, it has two or more inverted sections, and when the convex part of the line is moved in the direction of its extension, there are sections where the direction of extension of the convex part of the line alternately reverses in the opposite direction at two adjacent inverted sections. For example, when the width of the plan view shape of the convex part of the line is ignored and it is approximated by a continuous curve, it has a portion that is approximated by the Roman letter "S". Another example is when the width of the plan view shape of the convex part of the line is ignored and it is approximated by a straight line, it has a portion that is approximated by the Roman letter "W".

[0135] In this specification, "irregular" means that the shape does not follow a certain rule, nor is it arranged according to a certain rule, and is not so-called patterned. Typical examples of non-irregular shapes (regular shapes) include, for example, a so-called lenticular lens in which multiple cylindrical unit lenses are arranged adjacent to each other in a direction perpendicular to its longitudinal direction, and other shapes that are arranged with a certain periodicity in a specific direction. Therefore, in this disclosure, the irregular wrinkles that a wrinkle structure forming the surface shape of a surface layer may have include: the shape of a single protrusion itself is not a shape formed according to a certain rule such as periodicity, but is irregular; the shapes of multiple convex parts formed by multiple protrusions are not formed and arranged according to a certain rule, but are irregular; and the shape of the concave part surrounded by such multiple protrusions is also irregular.

[0136] In the wrinkle structure that forms the surface shape, if the shape of a single protrusion (single convex part), the shape and arrangement of multiple protrusions (multiple convex parts), or the shape of the recesses surrounded by multiple protrusions is irregular, the surface of the release support on the transfer layer (surface layer) is more likely to take on a specific surface shape, improving the visibility of the decorative material's design. For the same reason, it is more preferable that all of these are irregular.

[0137] As described above, the surface opposite to the resin film of the uneven layer has a wrinkled structure and is substantially uneven. The convex and concave parts of the uneven shape are defined based on the midpoint of the height distribution in the uneven shape, with areas exceeding this midpoint being defined as convex parts and areas below this midpoint being defined as concave parts. For example, by using the density difference (i.e., brightness difference) of an image with a density that corresponds 1:1 to the height of the uneven layer surface, the darkest part of the density distribution image can be set to 255 and the lightest part of the density distribution image to 0, and then the areas from 0 to 255 can be divided into concave parts (0 to 127) and convex parts (128 to 255) by binarization. In this case, the midpoint of density relative to the midpoint of height is 127.

[0138] Furthermore, as shown in Figure 4, for example, it is preferable that the wrinkle structure has multiple convex portions formed by multiple irregular but somewhat homogeneous protrusions, and recessed portions surrounded by the convex portions.

[0139] The shape of the recess may be acute, semicircular, or semielliptical in cross-sectional view, or a combination thereof. Furthermore, the shape of the recess may be such that a single convex portion has a recess in part in cross-sectional view.

[0140] On the other hand, the shape of the convex portion can be semicircular or semielliptical in cross-sectional view, although its width may vary.

[0141] The height of the protrusion (the height of the projection) is preferably 0.5 μm or more, more preferably 1 μm or more, and even more preferably 2 μm or more. The height of the protrusion is also, for example, about 10 μm or less. The width of the protrusion is preferably 0.1 μm or more, more preferably 0.3 μm or more, and even more preferably 0.5 μm or more. The width of the protrusion is also, for example, preferably 10 μm or less, more preferably 4 μm or less, and even more preferably 3 μm or less.

[0142] 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. The depth of the recess is also, for example, about 10 μm or less. The width of the recess is preferably 0.1 μm or more, more preferably 0.2 μm or more, and even more preferably 0.3 μm or more. The width of the recess is also, for example, preferably 10 μm or less, more preferably 3 μm or less, and even more preferably 2 μm or less. When the depth and width of the recess are within the above ranges, the surface of the release support side of the transfer layer (surface layer) tends to take on a specific surface shape in relation to the convex portion, improving the visibility of the design of the decorative material.

[0143] The distance from the top of the convex portion to the bottom of the concave portion (the height difference between the convex portion and the concave portion) is, for example, preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 4 μm or more. Alternatively, the above distance is, for example, preferably 20 μm or less, more preferably 8 μm or less, and even more preferably 7 μm or less. When the above distance is within the above range, the surface of the transfer layer (surface layer) on the release support side tends to take on a specific surface shape, improving the visibility of the design of the decorative material.

[0144] Here, the dimensions of the protrusions are the average value of 10 arbitrary protrusions (projections) in 10 arbitrary locations (100 μm square areas × 10 locations) on the surface of the uneven layer, i.e., a total of 100 protrusions. Also, as shown in Figure 4, the width of each protrusion (projection) is not uniform but varies; therefore, the width of each protrusion (projection) is the average value of the widths of 5 arbitrary locations on that protrusion (projection). The same applies to the height of each protrusion (projection).

[0145] Furthermore, the dimensions of the recessed portion are determined in the same way as the dimensions of the convex portion described above.

[0146] The proportion of the protrusions is preferably 15% or more, more preferably 20% or more, and even more preferably 30% or more. Alternatively, the proportion of the protrusions is preferably 80% or less, more preferably 70% or less, and even more preferably 60% or less. When the proportion of the protrusions is within the above range, the surface of the release support on the release support side of the transfer layer (surface layer) tends to take on a specific surface shape in relation to the proportion of the recesses surrounded by the protrusions, improving the visibility of the design of the decorative material.

[0147] Here, the occupancy rate of the protrusions is the average value of the occupancy rate of the protrusions in any 10 locations (100 μm square regions × 10 locations) of the uneven layer.

[0148] The convex and concave portions may have locations that are substantially in the same direction and substantially the same width, but it is preferable that the length of such locations be short. When the length is short, the surface of the transfer layer (surface layer) on the release support side tends to take on a specific surface shape, improving the visibility of the design of the decorative material. Specifically, the length of continuous convex and concave portions 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. Also, the length is, for example, preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 15 μm or more. When the length is within the above range, the wrinkles become more irregular, so the surface of the transfer layer (surface layer) on the release support side tends to take on a specific surface shape, improving the visibility of the design of the decorative material.

[0149] Here, it is preferable that 80% or more of any 10 protrusions and recesses (i.e., a total of 100 protrusions and recesses) in any 10 locations (100 μm square areas × 10 locations) of the decorative material satisfy the above conditions, more preferably 85% or more, even more preferably 90% or more, and even more preferably 95% or more.

[0150] In this specification, "approximately identical" means roughly the same, without branching, with approximately identical direction being within ±3° and approximately identical width being within ±5%.

[0151] Furthermore, the number of protrusions (projections) in a 100 μm square area is preferably 10 or more, more preferably 20 or more, and even more preferably 30 or more. The number of protrusions is preferably 200 or less, more preferably 100 or less, and even more preferably 70 or less. When the number of protrusions is within the above range, the surface of the release support side of the transfer layer (surface layer) tends to take on a specific surface shape, improving the visibility of the design of the decorative material.

[0152] Here, the number of protrusions in a 100 μm square region is the average number of protrusions in 10 locations on the surface layer (100 μm square region × 10 locations).

[0153] The uneven layer preferably contains a cured product of an ionizing radiation-curable resin, as it easily forms a specific surface shape. An ionizing radiation-curable resin is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). Examples of ionizing radiation-curable resins include electron beam-curable resins and ultraviolet-curable resins. Among these, ultraviolet-curable resins are preferred.

[0154] Specifically, the ionizing radiation-curable compound can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation-curable compounds.

[0155] As polymerizable monomers, (meth)acrylate monomers having a radical polymerizable unsaturated group in the molecule are preferred, and among these, polyfunctional (meth)acrylate monomers are preferred. Examples of polyfunctional (meth)acrylate monomers include (meth)acrylate monomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as one of the ionizing radiation-curable functional groups.

[0156] To stabilize wrinkle formation, the number of functional groups in the polyfunctional (meth)acrylate monomer is preferably 2 to 8, and more preferably 2 to 6. Furthermore, this number of functional groups makes it easier to obtain a wrinkled structure. These polyfunctional (meth)acrylates may be used individually or in combination of multiple types.

[0157] Polymerizable monomers can be used individually or in combination of multiple types, and it is preferable to use two or more polymerizable monomers in combination. When using two or more polymerizable monomers in combination, a combination of a monofunctional monomer and a polyfunctional monomer, a combination of two or more polyfunctional monomers, and a combination of two polyfunctional monomers are preferred.

[0158] When using polyfunctional monomers, the number of functional groups is preferably two or more. Furthermore, the number of functional groups is preferably eight or less, more preferably six or less, and even more preferably four or less.

[0159] When monofunctional monomers and polyfunctional monomers are used in combination, the number of functional groups in the polyfunctional monomer is most preferably two or less. In other words, it is most preferable for the polyfunctional monomer to have two functional groups. Furthermore, in this case, it is preferable that both the monofunctional monomer and the polyfunctional monomer be (meth)acrylate monomers.

[0160] Furthermore, when using two or more polyfunctional monomers, it is most preferable to combine a monomer with two functional groups and a monomer with four functional groups. In this case, the polyfunctional monomer is preferably a (meth)acrylate monomer.

[0161] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as one of the ionizing radiation-curable functional groups. Examples include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, acrylic (meth)acrylate oligomers, and the like.

[0162] Furthermore, polymerizable oligomers include other highly hydrophobic polybutadiene (meth)acrylate oligomers having (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers having polysiloxane bonds in the main chain, aminoplast resin (meth)acrylate oligomers obtained by modifying aminoplast resins that have many reactive groups in a small molecule, and oligomers having cationic polymerizable functional groups in the molecules of novolac-type epoxy resins, bisphenol-type epoxy resins, aliphatic vinyl ethers, aromatic vinyl ethers, etc.

[0163] To form the uneven layer having the surface shape described above, urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers are preferred, urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers are more preferred, and urethane (meth)acrylate oligomers are even more preferred.

[0164] Polymerizable oligomers can be used individually or in combination of multiple types, and it is preferable to use one type of polymerizable oligomer alone.

[0165] In order to form an uneven layer having the surface shape described above, the number of functional groups of the polymerizable oligomer is preferably 2 to 8, more preferably 2 to 6, and even more preferably 2 to 4. Also, for the same purpose as above, the weight-average molecular weight of the polymerizable oligomer is preferably 2,500 to 7,500, more preferably 3,000 to 7,000, and even more preferably 3,500 to 6,000.

[0166] Here, the weight-average molecular weight is the average molecular weight measured by GPC analysis and converted to standard polystyrene.

[0167] As the ionizing radiation-curable compound, it is preferable to use a combination of a polymerizable oligomer and a polymerizable monomer. In this case, the polymerizable oligomer is preferably a polyfunctional urethane (meth)acrylate oligomer, and more preferably a polyfunctional urethane acrylate oligomer. Furthermore, the polymerizable monomer is preferably a polyfunctional polymerizable monomer, more preferably a polyfunctional (meth)acrylate monomer, and even more preferably a polyfunctional acrylate monomer.

[0168] When polymerizable oligomers and polymerizable monomers are used in combination, the content of polymerizable oligomers per 100 parts by mass of the total of polymerizable oligomers and polymerizable monomers is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, even more preferably 55 parts by mass or more, and even more preferably 60 parts by mass or more. Furthermore, the content of the polymerizable oligomers is preferably 90 parts by mass or less, more preferably 80 parts by mass or less, and even more preferably 70 parts by mass or less.

[0169] Furthermore, polymerizable oligomers can be used in combination, and it is preferable to use two polymerizable oligomers with different numbers of functional groups in combination. In this case, the content of the polymerizable oligomer with a larger number of functional groups relative to 100 parts by mass of the total amount of polymerizable oligomers is preferably 50 parts by mass or more, more preferably 55 parts by mass or more, even more preferably 60 parts by mass or more, and even more preferably 65 parts by mass or more.

[0170] The uneven layer in this disclosure may or may not contain a wrinkle-forming stabilizer. If the resin is an ultraviolet-curable resin, the resin composition may contain a photopolymerization initiator, a photopolymerization accelerator, etc.

[0171] The wrinkle-forming stabilizer stabilizes wrinkle formation on at least one surface of the uneven layer, thereby enabling uniform visibility of the matte effect across the entire surface of the uneven layer and reducing localized unevenness in gloss. It provides stable visibility of the matte effect (hereinafter, expressions such as "stable visibility of the matte effect" or similar expressions may be used), and uniformity of the surface condition (also referred to as "texture") due to the stable formation of wrinkles across the entire surface of the uneven layer. By including the wrinkle-forming stabilizer in the uneven layer, stable visibility of the matte effect and uniformity of the surface condition can also be provided to the surface of the transfer layer on the release support side.

[0172] In this specification, "wrinkle formation stabilization" means that the in-plane distribution (dispersion σ) of the wrinkle shape and its geometric characteristics (length, width, and ratio of individual protrusions), and the surface properties of the wrinkle (Ra, RSm, Rz, etc.) converges more when a wrinkle formation stabilizer is added compared to when no stabilizer is added.

[0173] Therefore, even if the constituent materials and average particle size are the same, the so-called "matting agent" in the prior art and the "wrinkle-forming stabilizer" in this embodiment will differ in their matting mechanisms (actions), the structure for producing the matting effect, and the relationship between the amount used and the degree of surface gloss (gloss value).

[0174] In conventional technology, matting agents (also called matting agents) used to suppress light reflection and reduce gloss exert their own matting effect due to the light diffusion effect caused by their physical shape. Specifically, particles generally referred to as matting agents generally have a refractive index difference between the particle and the surrounding resin and air, and exert a matting effect through the reflection of light rays corresponding to the contour shape of the particle and the light diffusion effect due to the refractive interface.

[0175] On the other hand, wrinkle-forming stabilizers do not produce a matting effect through light diffusion caused by the reflection and refraction of light rays by the particles themselves, but rather by stabilizing the formation of wrinkles on the surface of the uneven layer due to the wrinkle-forming stabilizer, thereby imparting a matting effect through the light diffusion effect at the refractive index difference interface between the surface and the air. Therefore, the wrinkle-forming stabilizers used in this disclosure differ from matting agents that produce a matting effect on their own (even if the constituent materials and average particle sizes of both are the same or similar), in terms of the mechanisms (operations) of light reflection suppression and matting, and the structures for producing light reflection suppression and matting.

[0176] Furthermore, "wrinkle-forming stabilizers" and "matting agents" differ in their relationship to the amount contained and the surface gloss value. When the same substance A is used as a wrinkle-forming initiator AW (W: wrinkle), and this is included in a specific amount C to form wrinkles on the surface, the 60° gloss value G of the surface is... ６０° ＡＷ (C) is the 60° gloss value G of the surface when substance A is used as a simple matting agent AM and is included in a specific amount C, but no wrinkles are formed on the surface. ６０° ＡＭ It is clearly lower than (C). That is, the following relationship holds: G ６０° ＡＷ (C) < G ６０° ＡＭ (C)

[0177] As a wrinkle-forming stabilizer, it is not a matting agent, and specifically, any substance whose average particle size is limited to 100% or less of the thickness of the uneven layer or 30 μm or less, whichever is smaller, can be used without particular restriction.

[0178] Here, the average particle size of wrinkle-forming stabilizers and the like refers to the average particle size (arithmetic mean diameter) measured for 100 randomly selected non-aggregated particles, observed using a scanning electron microscope (SEM) to observe the cross-section in the thickness direction of the uneven layer under conditions of an acceleration voltage of 3.0 kV and a magnification of 50,000x. The particle size is the value measured by the distance between two parallel lines that maximize the distance between the two lines when the cross-section of the particle is sandwiched between them.

[0179] As wrinkle-forming stabilizers, for example, organic particles and inorganic particles can be used. Examples of organic materials constituting organic particles include polymethyl methacrylate, acrylic-styrene copolymer resin, melamine resin, polycarbonate, polystyrene, polyvinyl chloride resin, benzoguanamine-melamine-formaldehyde condensate, silicone, fluorine-based resin, and polyester-based resin. Examples of inorganic materials constituting inorganic particles include silica, alumina, calcium carbonate, aluminosilicate, and barium sulfate. To improve the strength of the uneven layer, it is preferable to use inorganic particles.

[0180] The shape of the wrinkle-forming stabilizer is not particularly limited, but examples include spherical, polyhedral, flaky, and amorphous forms.

[0181] The average particle size of the wrinkle-forming stabilizer is 1 μm or more, and is limited to the smaller of 100% or less of the thickness of the uneven layer and 30 μm or less. To stably impart a matting effect to the transfer layer, the average particle size of the wrinkle-forming stabilizer is preferably 1.3 μm or more, more preferably 1.5 μm or more, and even more preferably 1.8 μm or more. Furthermore, the average particle size of the wrinkle-forming stabilizer is preferably 90% or less of the thickness of the uneven layer, more preferably 80% or less, and even more preferably 70% or less. In terms of absolute value, the average particle size of the wrinkle-forming stabilizer 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 average particle size of the wrinkle-forming stabilizer may be set to the smaller of any combination of the upper limit relative to the thickness of the uneven layer and the upper limit in absolute value. For example, the upper limit may be set to the smaller of 90% or less of the thickness of the uneven layer and 20 μm or less, or it may be set to the smaller of 90% or less of the thickness of the uneven layer and 10 μm or less. The thickness of the uneven layer will be discussed later.

[0182] In order to stabilize wrinkle formation by the wrinkle-forming stabilizer and to stably impart a matte effect to the transfer layer, the content of the wrinkle-forming stabilizer is preferably 0.5 parts by mass or more, more preferably 0.75 parts by mass or more, even more preferably 1.0 part by mass or more, and even more preferably 1.2 parts by mass or more, per 100 parts by mass of resin. Furthermore, the upper limit of the content of the above wrinkle-forming stabilizer is not particularly limited in order to improve the stable matte effect, but for example, in order to improve the coatability of the resin composition and efficiently improve the matte effect, it is preferably 25.0 parts by mass or less, more preferably 15.0 parts by mass or less, even more preferably 10.0 parts by mass or less, particularly preferably 7.5 parts by mass or less, and most preferably 6.0 parts by mass or less, per 100 parts by mass of resin.

[0183] The uneven layer may or may not contain a release agent. By having the surface of the uneven layer opposite to the resin film side have the second wrinkled structure described above, good release properties can be achieved even without containing a release agent. Examples of the release agent include silicone-based release agents such as silicone oil, wax-based release agents such as polyolefin wax, and fluorine-based release agents.

[0184] The thickness of the uneven layer is not particularly limited, but is usually 1 μm or more, preferably 2 μm or more, more preferably 3 μm or more, even more preferably 4 μm or more, and especially preferably 5 μm or more. Alternatively, the thickness of the uneven layer is preferably 300 μm or less, more preferably 200 μm or less, even more preferably 150 μm or less, and especially preferably 100 μm or less. Here, the thickness of the uneven layer is determined by measuring the thickness at 20 points on an image taken using a scanning electron microscope (SEM) on the cross-section of the sheet, and taking the average value of the 20 points.

[0185] (c) Method for producing a release support As a method for producing a release support, for example, a resin composition for forming an uneven layer is applied to one side of a resin film to form a coating layer, and the coating layer is cured by irradiation with ionizing radiation to form an uneven layer. The resin composition for forming an uneven layer includes the above-mentioned ionizing radiation-curable resin.

[0186] Examples of known methods for applying the resin composition for forming the uneven layer include gravure printing, bar coating, roll coating, reverse roll coating, and comma coating. If the resin composition for forming the uneven layer contains a solvent, the solvent may be dried after applying the first resin composition.

[0187] Next, the coated layer is cured by irradiation with ionizing radiation to form an uneven layer capable of forming a surface layer having a specific surface shape. For the irradiation treatment, it is preferable to perform at least the following irradiation treatments in this order: (i) Irradiation with a first wavelength of light between 100 nm and less than 200 nm; (ii) Irradiation with at least one of an electron beam and a second wavelength of light between 200 nm and 400 nm.

[0188] By performing the irradiation treatments described in (i) and (ii) above, the uneven layer is more likely to take on the surface shape described above. First, when the irradiation treatment with low-wavelength (short-wavelength) ultraviolet light described in (i) above is performed, the energy of the ultraviolet light penetrates only to the surface portion, and the energy does not reach the layers below it. As a result, only the surface portion of the coated layer begins to harden, and it is thought that only the surface hardens and shrinks, forming a wrinkle structure. Thus, it is thought that the formation of the wrinkle structure occurs when only a certain thickness direction from the surface of the coated layer hardens due to irradiation with low-wavelength (short-wavelength) ultraviolet light.

[0189] Next, by irradiating with at least one of the electron beam and ultraviolet light of high wavelength (long wavelength) of 200 nm to 400 nm as described in (ii) above, the wrinkle structure formed on the surface of the coated layer can be maintained while promoting hardening from the near-surface portion where hardening progresses slowly to the deeper portion in the depth direction.

[0190] Although the coating layer can become cured throughout its entire thickness by the irradiation treatment described in (i) above, the curing state is further improved by combining it with the irradiation treatment described in (ii) above. As a result, a wrinkled structure appears on the surface of the coating layer.

[0191] In the irradiation process described in (i) above, the first wavelength light of 100 nm or more and less than 200 nm is preferably "excimer light" which includes light in the ultraviolet wavelength range from gases such as noble gases like Ar, Kr, Xe, Ne, halides of noble gases such as F, Cl, I, Br, or dimers of excited states formed by the discharge of mixed gases thereon, i.e., excimers. The wavelength of the excimer light and the excimer that serves as the light source are preferably Ar ２ Light with a wavelength of 126 nm radiated from the excimer (hereinafter referred to as "126 nm (Ar ２ It is abbreviated as ) ), 146 nm (Kr ２ ), 157 nm (F ２ ), 172 nm (Xe ２ Wavelengths such as 193 nm (ArF) can be preferably used. Both spontaneous emission light and highly coherent laser light produced by stimulated emission can be used as excimer light, but spontaneous emission light is usually sufficient. These discharge lamps that emit this light (ultraviolet light) are also called "excimer lamps."

[0192] Excimer light is characterized by a single wavelength peak and a narrower full width at half maximum compared to ordinary ultraviolet light (e.g., ultraviolet light emitted from metal halide lamps, mercury lamps, etc.). By using such excimer light, it becomes easier to induce wrinkle structures, and the uneven layer tends to take on the surface shape described above.

[0193] For the same reasons as above, the wavelength of the first wavelength light is preferably 120 nm or more, more preferably 140 nm or more, even more preferably 150 nm or more, and even more preferably 155 nm or more. Also, the wavelength of the first wavelength light is less than 200 nm, and particularly preferably 172 nm (Xe ２ Therefore, in order to easily induce wrinkle structures, it is preferable to use light with lower wavelengths (shorter wavelengths), and among low-wavelength (short-wavelength) ultraviolet light (wavelength: 280 nm or less), low-wavelength (short-wavelength) ultraviolet light in the region of less than 200 nm is preferable.

[0194] The integrated light intensity of the first wavelength light is preferably 1 mJ / cm².２ The above is a comfortable 2 mJ / cm². ２ More preferably 5 mJ / cm ２ That concludes the explanation. Furthermore, there is no particular upper limit to the integrated light intensity of the first wavelength light. Considering the reduction in the number of lamps required for irradiation with the first wavelength light and the improvement of productivity such as production efficiency, the integrated light intensity of the first wavelength light is preferably 1,000 mJ / cm². ２ More preferably, 300 mJ / cm ２ More preferably, 100 mJ / cm ２ The following is particularly preferable: 10 mJ / cm ２ The following applies:

[0195] The ultraviolet irradiance is preferably 1 mW / cm². ２ More preferably 5 mW / cm² ２ More preferably 10 mW / cm² ２ That concludes the explanation. Furthermore, the ultraviolet irradiance is preferably 10 W / cm². ２ The following is more comfortable at 3 W / cm². ２ More preferably, 1 W / cm ２ The following applies, especially considering productivity: UV irradiance should be 500 mW / cm². ２ The following is preferred: 300 mW / cm² ２ The following is more preferable: 150 mW / cm² ２ The following are even more preferable.

[0196] Furthermore, the oxygen concentration when irradiating with the first wavelength light is preferably lower, preferably 1,000 ppm or less, more preferably 750 ppm or less, even more preferably 500 ppm or less, and particularly preferably 300 ppm or less.

[0197] In the surface layer formation step, it is preferable to perform irradiation with a first wavelength light of 100 nm or more and less than 200 nm as described in (i) above, followed by irradiation with at least one of the electron beam and a second wavelength light of 200 nm or more and 400 nm as described in (ii) above.

[0198] The irradiation conditions of the electron beam used in the irradiation treatment described in (ii) above are not particularly limited as long as the resin composition is cured. The acceleration voltage of the electron beam is preferably 10 kV or more, more preferably 30 kV or more, even more preferably 50 kV, and even more preferably 75 kV or more. The acceleration voltage of the electron beam is also preferably 300 kV or less, more preferably 250 kV or less, and even more preferably 200 kV or less. When the acceleration voltage of the electron beam is within the above range, the cured product tends to retain the shape of the wrinkle structure, so the uneven layer tends to take on the surface shape described above. Also, for the same reasons as above, the irradiation dose of the electron beam is preferably 5 kGy or more, more preferably 10 kGy or more, and even more preferably 15 kGy or more. Also, the irradiation dose of the electron beam is preferably 150 kGy or less, more preferably 125 kGy or less, and even more preferably 100 kGy or less.

[0199] The electron source is not particularly limited as long as it can achieve the above irradiation conditions. For example, various electron beam accelerators such as Cockcroft-Walton type, Van de Graft type, resonant transformer type, insulated core transformer type, and linear type, dynamitron type, and high-frequency type can be used.

[0200] The second wavelength light between 200 nm and 400 nm used in the irradiation process described in (ii) above can be irradiated using an ultraviolet irradiation device that uses, for example, an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, or a metal halide lamp as a light source. Alternatively, excimer light between 200 nm and 400 nm, such as 222 nm (KrCl), 247 nm (KrF), or 308 nm (XeCl), may be used.

[0201] The wavelength of the second wavelength light used in the irradiation process described in (ii) above is preferably 330 nm or more and 390 nm or less. When the wavelength of the second wavelength light is within the above range, it is easier to maintain the shape of the wrinkle structure. For the same reasons as above, the output of the ultraviolet irradiation device is preferably 50 W / cm or more, more preferably 100 W / cm or more. The output of the ultraviolet irradiation device is preferably 300 W / cm or less, more preferably 200 W / cm or less. The irradiation speed is preferably 1 r / min or more, more preferably 3 r / min or more. The irradiation speed is preferably 50 r / min or less, more preferably 10 r / min or less.

[0202] Furthermore, before the irradiation treatments described in (i) and (ii) above, the (iii) irradiation treatment for pre-curing may be performed. Pre-curing the entire coated layer by the (iii) irradiation treatment for pre-curing above imparts appropriate viscosity to the resin composition. As a result, the sagging of the wrinkle structure formed by the irradiation treatment described in (i) above is suppressed, and the retention of the wrinkle structure can be improved.

[0203] The wavelength of ionizing radiation used in the irradiation treatment for pre-curing described in (iii) above may be, for example, light with a wavelength greater than 320 nm, preferably light with a wavelength greater than 320 nm and less than or equal to 400 nm, and more preferably light with a wavelength of 385 nm and less than or equal to 400 nm (ultraviolet light). By using the above wavelength of light (ultraviolet light) in the irradiation treatment described in (iii) above, the overall pre-curing of the coated layer can be efficiently performed.

[0204] The ultraviolet irradiance in the irradiation treatment described in (iii) above is preferably 0.01 W / cm². ２ The above is more comfortable at 0.1 W / cm². ２ More preferably 0.3 W / cm² ２ That concludes the explanation. Furthermore, the ultraviolet irradiance is preferably 5 W / cm². ２ The following is more comfortable at 3 W / cm². ２ More preferably, 2 W / cm ２ The following applies: When the ultraviolet irradiance is within the above range, the entire pre-curing of the coating layer can be efficiently performed without the coating layer becoming completely cured.

[0205] The wavelength light used in the irradiation process described in (iii) above can be irradiated using an ultraviolet irradiation device that uses, for example, an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, a metal halide lamp, or an LED light as a light source.

[0206] As described above, a textured layer capable of forming a surface layer (transfer layer) with a specific surface shape can be obtained.

[0207] (2) Transfer layer As shown in Figure 3(a), the transfer layer 20 is formed from the release support 3 side, with the first protective layer 22 and the adhesion layer 21 in the thickness direction D Ｔ In this case, they may be present in this order. The transfer layer is the same as the surface layer described in "A. Decorative Material" above, so its explanation is omitted here.

[0208] (3) Method for manufacturing a transfer sheet The method for manufacturing a transfer sheet includes, for example, a release support manufacturing step of forming an uneven layer on one side of a resin film to produce the release support, and a first protective layer forming step of forming the first protective layer on the side of the release support that has the uneven layer. Each step will be described below.

[0209] (a) Process for manufacturing a release support: First, a release support is manufactured by forming an uneven layer on one side of the resin film. The method for manufacturing the release support has been described above, so it will not be explained here.

[0210] (b) First protective layer formation step Next, a first protective layer is formed on the surface of the release support on the uneven layer side. For example, the first protective layer is formed by coating and curing a first composition containing the curable resin X described above. The first composition is a composition for forming the first protective layer and includes, for example, the curable resin X described above. The first composition preferably contains a weather-resistant agent.

[0211] Methods for applying the first composition include, for example, gravure printing, bar coating, roll coating, reverse roll coating, and comma coating. By applying the first composition, a first coating layer is obtained. Methods for curing the first coating layer include, for example, irradiation with ionizing radiation such as electron beams and ultraviolet rays, and application of heat.

[0212] (c) Second protective layer formation step In the method for manufacturing the transfer sheet, after the formation of the first protective layer, a second protective layer may be formed on the side of the first protective layer opposite to the release support (second protective layer formation step). For example, the second protective layer is formed by coating and curing a second composition containing the curable resin Y described above. The second composition is a composition for forming the second protective layer and, for example, contains the curable resin Y described above. The second composition preferably contains a weather-resistant agent.

[0213] Methods for applying the second composition include, for example, gravure printing, bar coating, roll coating, reverse roll coating, and comma coating. Applying the second composition yields a second coating layer. Methods for curing the second coating layer include, for example, applying heat.

[0214] (d) Adhesion layer formation step In addition, in the method for manufacturing the transfer sheet, an adhesion layer may be formed on the side opposite to the release support with respect to the first protective layer (adhesion layer formation step). For example, an adhesion layer is formed on the side of the first protective layer (or the second protective layer if the transfer layer has a second protective layer) opposite to the release support. For example, an adhesion layer can be formed by coating the side of the first protective layer opposite to the release support with an adhesion layer formation composition and drying it.

[0215] III. Preferred Embodiment As shown in Figure 5, the decorative material 10 in this disclosure is preferably a resin-impregnated decorative board 60. Since Figure 5 has been explained above, its explanation is omitted here.

[0216] Figures 6 and 7 are schematic cross-sectional views illustrating a method for manufacturing a resin-impregnated decorative panel according to this disclosure. First, as shown in Figure 6(a), a decorative sheet 14 having a porous substrate 11 is prepared. The decorative sheet 14 may have a design layer 12 on one side of the porous substrate 11. Next, as shown in Figure 6(b), the porous substrate 11 of the decorative sheet 14 is impregnated with a curable resin α. At this time, a curable resin layer 13' containing the curable resin α is formed on at least one surface of the decorative sheet 14 (impregnation treatment). Next, as shown in Figure 6(c), the decorative sheet 14 (or the side of the decorative sheet 14 with the design layer 12 if the decorative sheet 14 has a design layer 12) and the transfer layer 20 of the transfer sheet 50 are placed opposite each other and laminated to obtain a laminate precursor 55'. Next, as shown in Figure 7(a), the curable resin is cured by heating and pressurizing the laminate precursor 55' to obtain a laminate 55 (laminated body formation step).

[0217] Next, as shown in Figure 7(b), the release support 3 on the transfer sheet 50 is peeled off from the laminate 55 (peeling step). This yields the resin-impregnated decorative board 60.

[0218] The resin-impregnated decorative laminate in this disclosure has a surface layer that exhibits the above-mentioned color difference ΔE and gloss value difference ΔG. Therefore, it becomes a resin-impregnated decorative laminate with excellent design visibility. Furthermore, resin-impregnated decorative laminates manufactured using transfer sheets in this manner are less prone to peeling defects compared to resin-impregnated decorative laminates manufactured using shaping sheets.

[0219] Figure 8 shows a schematic cross-sectional view of a method for manufacturing a resin-impregnated decorative panel using a shaping sheet. As shown in Figure 8(a), the shaping sheet 70 comprises a shaping layer 72 having a surface shape with a wrinkled structure, and a support layer 71 that supports the shaping layer 72. As shown in Figure 8(b), a precursor 75' of a laminate is obtained by laminating the shaping sheet 70 onto a decorative sheet 14 containing a curable resin via a curable resin layer 13'. Next, as shown in Figure 8(c), the precursor 75' of the laminate is hot-pressed to obtain a laminate 75. In the laminate 75, the adhesion force between the curable resin layer 13 and the shaping layer 72 becomes large. Therefore, as shown in Figure 8(d), when peeling off the shaping sheet 70, the shaping layer 72 may remain on the decorative sheet 14 side, resulting in peeling failure. Also, although not specifically shown, the curable resin layer may peel off together with the shaping sheet.

[0220] On the other hand, when a transfer sheet is used, the adhesion force between the transfer layer 20 and the cured resin layer 13 in the cured laminate 55 of Figure 7(a) is higher than the adhesion force between the release support 3 and the transfer layer 20 in the transfer sheet, making it less likely for the transfer sheet to peel off poorly. Therefore, it becomes easier to adjust the surface layer of the decorative material to a specific surface shape. The layers of the resin-impregnated decorative board will be described in detail below.

[0221] The resin-impregnated decorative panel has, for example, a porous substrate containing a cured product of a curable resin α. Furthermore, it is preferable that the resin-impregnated decorative panel has a core paper containing a cured product of the curable resin α on the side of the porous substrate opposite to the surface layer side. The decorative material body 1 may also have a design layer 12 on the side of the porous substrate 11 facing the surface layer 2. On the other hand, although not particularly shown, the porous substrate 11 may also serve as the design layer (coloring layer) 12. A cured resin layer 13 containing a cured product of the curable resin α may be present in at least one of the spaces between the porous substrate 11 and the surface layer 2, and between the porous substrate 11 and the core material 15.

[0222] 1. Porous Substrate The porous substrate contains a cured product of the curable resin α. Examples of porous substrates include permeable fibrous substrates. Examples of permeable fibrous substrates include paper, synthetic paper, nonwoven fabrics, and woven fabrics. Examples of the above-mentioned paper include titanium paper, tissue paper, kraft paper, linter paper, cardboard, gypsum board paper, fine paper, coated paper, parchment paper, and Japanese paper. In addition, vinyl wallpaper raw material (paper dry-laminated with polyvinyl chloride resin) can also be used as a fibrous substrate. Other examples of fibrous substrates include nonwoven or woven fabrics containing inorganic fibers such as glass fibers, asbestos, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers. In addition, other examples of fibrous substrates include nonwoven or woven fabrics containing synthetic resin fibers such as polyester, vinylon, polyethylene, and polypropylene. Among these porous substrates, titanium paper, tissue paper, kraft paper, coated paper, art paper, sulfuric acid paper, glassine paper, parchment paper, paraffin paper, and Japanese paper are preferred in terms of impregnation with uncured resin. In particular, titanium paper is preferred as a porous substrate because it has excellent impregnation properties for uncured resin (curable resin α) and also has excellent opacity.

[0223] In this disclosure, the porous substrate can also serve as the design layer (colored layer) described later.

[0224] The porous substrate may be transparent or opaque. If the porous substrate is opaque, it can serve as a decorative layer.

[0225] Porous substrates may be colored. When a porous substrate is colored, it can become a design layer (colored layer). For example, a colored porous substrate can be obtained by incorporating a coloring agent during the manufacturing stage of the porous substrate. For example, if the porous substrate is paper, colored paper can be obtained by incorporating a coloring agent during the papermaking stage. Examples of coloring agents include inorganic pigments such as titanium dioxide, carbon black, and iron oxide, organic pigments such as phthalocyanine blue, and various dyes. Furthermore, the porous substrate may contain various additives as needed, such as fillers, matting agents, foaming agents, flame retardants, lubricants, antistatic agents, antioxidants, ultraviolet absorbers, and light stabilizers.

[0226] The basis weight of the porous substrate is not particularly limited, but for example, it is 40 g / m ２ or more and 150 g / m ２ or less. The thickness of the porous substrate is not particularly limited, but for example, it is 50 μm or more and 170 μm or less. For example, in order to enhance the adhesion of the ink forming the design layer, corona discharge treatment may be performed on the surface of the porous substrate on the design layer side.

[0227] The cured product of the curable resin α filled in the porous substrate and the cured product of the curable resin α contained in the cured resin layer are formed of the same curable resin α as described later.

[0228] 2. The design layer resin-impregnated decorative board may have a design layer. The design layer is disposed, for example, on one surface of the porous substrate. The design layer has, for example, at least one of a pattern layer and a coloring layer. Further, when the design layer has a pattern layer and a coloring layer, it is preferable that the coloring layer is disposed closer to the porous substrate side than the pattern layer.

[0229] The design layer contains, for example, a colorant and a resin component. Examples of the colorant and the resin component include the same ones as the colorant and the binder resin in the above-described decorative layer. <op

[0230] [[ID=ID=18]] The design layer preferably contains a resin having at least one polar group selected from a hydroxy group, an amino group, and a carboxy group as the resin component. By containing the resin having the polar group, the impregnation property of the curable resin α with respect to the porous substrate becomes good.

[0231] The resin having a polar group contains, as the polar group, at least one of a hydroxy group (—OH), an amino group (—NH ２ ), and a carboxy group (—COOH). The polar group may be ionized and stabilized, for example, due to the influence of a solvent and other functional groups. Therefore, the above “hydroxy group (—OH)” is a concept including “—O － ” in an ionized state, and the above “amino group (—NH ２ )” is “—NH ３ ＋The concept includes "carboxy group (-COOH)", and the ionized state is "-COOH － This is a concept that includes "[...]."

[0232] Hydroxyl group (-OH), amino group (-NH) ２ Examples of resins having one or more polar groups, such as carboxyl groups (-COOH), include aqueous proteins such as casein, cellulose, acetylcellulose, nitrated cotton, hydroxypropylcellulose, carboxymethylcellulose, and other cellulose derivatives, polyvinyl alcohol, polyvinyl alcohol derivatives such as polyvinyl butyral resin, amino resins such as melamine resin, (meth)acrylic acid resins, phenolic resins, acrylic polyols, and natural polymers (e.g., polynucleotides, polypeptides, polysaccharides).

[0233] The design layer preferably contains one or more of the following polar group-containing resins: casein, melamine resin, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, and cellulose derivatives, and more preferably casein. As the casein, α-casein, β-casein, γ-casein, or mixtures thereof can be used. In addition, derivatives such as sodium caseinate and ammonium caseinate can be used alone or in combination as the casein.

[0234] The proportion of the resin having polar groups described above to the resin components contained in the design layer is, for example, 20% by mass or more, may be 30% by mass or more, may be 40% by mass or more, or may be 50% by mass or more. On the other hand, the above proportion of the resin having polar groups is, for example, 100% by mass or less, or may be 90% by mass or less. If the content of the resin having polar groups is within the above range, the penetration of the curable resin α into the porous substrate is less likely to be inhibited.

[0235] The design layer may contain additives such as fillers (e.g., silica), extender pigments (e.g., organic beads), neutralizing agents, and surfactants, as needed. The thickness of the design layer is not particularly limited, but is, for example, 0.1 μm or more and 20 μm or less.

[0236] One method for forming a design layer is a coating method using an ink for forming a design layer that contains a colorant, a resin component, and a solvent (or dispersion medium). For example, a design layer can be obtained by coating one side of a porous substrate with the ink for forming a design layer and drying it.

[0237] Examples of the above-mentioned solvents (or dispersion media) include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water.

[0238] Examples of the above coating methods include printing. Examples of printing methods include gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing. Examples of coating methods for forming a solid layer include roll coating, knife coating, air knife coating, die coating, lip coating, comma coating, kiss coating, flow coating, and dip coating.

[0239] 3. Core Material As shown in Figure 5, it is preferable that the resin-impregnated decorative panel 60 has a core paper 15 containing a cured product of the curable resin α on the side opposite to the surface layer 2 side of the porous substrate 11. Examples of core substrates include phenol resin-impregnated paper. Phenolic resin-impregnated paper is, for example, paper obtained by impregnating kraft paper, which is the core paper, with phenol resin and drying it.

[0240] 4. Cured Resin Layer The cured resin layer contains a cured product of curable resin α. A wide range of thermosetting resins can be used as curable resin α. Examples of curable resin α include melamine resins (melamine resin precursors), melamine-urea cocondensation resins, unsaturated polyester resins, polyurethane resins (including two-component curable polyurethanes), epoxy resins, aminoalkyd resins, phenolic resins, urea resins, diallyl phthalate resins, guanamine resins, silicon resins, and polysiloxane resins.

[0241] The thickness of the cured resin layer is not particularly limited, but is preferably 1 μm or more, and more preferably 5 μm or more. Sufficient abrasion resistance can be obtained when the thickness of the cured resin layer is within the above range. On the other hand, the thickness of the cured resin layer is preferably, for example, 50 μm or less, more preferably 30 μm or less, even more preferably 27 μm or less, and particularly preferably 20 μm or less.

[0242] IV. Uses The uses of the decorative material in this disclosure include, for example, building materials and furniture. Building materials may be interior materials or exterior materials. Examples of building materials include walls, floors, ceilings, doors, and shelves. Examples of furniture include tables, desks, and cabinets.

[0243] B. Method for manufacturing cosmetic material The present disclosure provides a method for manufacturing a cosmetic material, comprising the steps of: preparing a transfer sheet comprising a release support and a transfer layer including at least the first protective layer; forming a laminate in which the cosmetic material body and the transfer layer of the transfer sheet are arranged to face each other; and peeling the release support from the transfer sheet to the laminate.

[0244] The method for manufacturing decorative materials described in this disclosure uses a transfer sheet, making it possible to easily manufacture decorative materials with excellent design visibility. The method for manufacturing decorative materials described in this disclosure will be explained separately for two forms: one in which the decorative material is a resin-impregnated decorative board (first form), and another in which the decorative material is a decorative material other than a resin-impregnated decorative board (second form).

[0245] 1. Figures 6 and 7 of the first embodiment are schematic cross-sectional views illustrating a method for manufacturing a decorative material when the decorative material in this disclosure is a resin-impregnated decorative panel. Figures 6 and 7 have been described in detail in "A. Decorative Material," so their explanation is omitted here.

[0246] (1) Transfer Sheet Preparation Process The transfer sheet to be prepared in this process and its manufacturing method have been described in detail in "A. Decorative Materials", so the explanation here will be omitted.

[0247] (2) Laminate Formation Process In this process, a laminate is formed in which the decorative material body and the transfer layer of the transfer sheet are arranged to face each other. When manufacturing a resin-impregnated decorative board, this process preferably includes a decorative sheet preparation step of preparing a decorative sheet having a porous substrate and impregnated with a curable resin, a lamination step of laminating the decorative sheet and the transfer layer side of the transfer sheet facing each other to obtain a precursor of the laminate, and a heating and pressurizing step of heating and pressurizing the precursor of the laminate to cure the curable resin and obtain the laminate.

[0248] (i) Preparation process for decorative sheet The decorative sheet used in the manufacture of resin-impregnated decorative board has a porous substrate. As shown in Figure 6(a), the decorative sheet 14 may have a porous substrate 11 and a design layer 12. Alternatively, the porous substrate may also serve as the design layer. As shown in Figure 6(b), the porous substrate 11 of the decorative sheet 14 is impregnated with a curable resin α. If the decorative sheet 14 has a design layer 12, the curable resin α is impregnated through the design layer 12. The decorative sheet is as described above.

[0249] In this process, for example, the decorative sheet is immersed in a curable resin composition containing curable resin α. After immersion, drying is preferable. At this time, a portion of the curable resin may be cured, leaving it in a semi-cured state. Methods for impregnating with curable resin α include, for example, immersing the decorative sheet in a bathtub containing curable resin α; coating the decorative sheet with curable resin α using a coater such as a kiss coater or comma coater; or spraying the decorative sheet with curable resin α using a spray device or shower device.

[0250] The proportion of curable resin α in the curable resin composition is, for example, 50% by mass or more, may be 70% by mass or more, or 90% by mass or more. The curable resin composition may contain, for example, water, alcohol, or an organic solvent as a solvent.

[0251] (ii) Lamination process As shown in Figure 6(c), after impregnating the decorative sheet 14 with curable resin α, the decorative sheet 14 (or the side with the design layer 12 if the decorative sheet has a design layer 12) and the transfer layer 20 of the transfer sheet 50 are placed opposite each other and laminated to obtain a precursor 55' of the laminate.

[0252] In this case, for example, the transfer sheet 50 described above is placed on the decorative sheet 14 impregnated with the curable resin α and on the curable resin layer 13' so as to face the curable resin layer 13'. Alternatively, the core substrate 15 may be placed on the side of the decorative sheet 14 opposite to the transfer sheet 50.

[0253] Another method for forming a precursor to a laminate involves, for example, arranging a core substrate opposite a porous substrate in a decorative sheet, and forming a curable resin layer containing curable resin α while impregnating the core substrate and the porous substrate with curable resin α. Subsequently, a transfer sheet is placed on the design layer side of the decorative sheet. This also allows for obtaining a precursor to a laminate.

[0254] (iii) Heating and Pressurizing Step In this step, as shown in Figure 7(a), the curable resin is cured by heating and pressurizing the precursor 55' of the laminate to obtain the laminate 55 (heating and pressurizing step). The cured resin layer 13 is formed from the curable resin layer 13'. In this disclosure, it is preferable that the transfer layer 20 in the transfer sheet 50 has an adhesion layer 21. In this case, the adhesion strength between the cured resin layer 13 and the transfer layer 20 in the laminate 55 is increased. Therefore, in the subsequent peeling step, the transfer layer can be easily left on the decorative sheet side.

[0255] Furthermore, from the viewpoint of increasing the adhesion strength between the cured resin layer and the transfer layer, it is preferable that the heating temperature and applied pressure be low enough to prevent curing defects in the curable resin α. By lowering the heating temperature and applied pressure, it is possible to prevent the curable resin α from curing too quickly, allowing it to penetrate the adhesion layer or the first protective layer, thereby improving the adhesion strength between the cured resin layer and the transfer layer. The heating temperature is, for example, 160°C or lower, preferably 150°C or lower, and more preferably 140°C or lower. On the other hand, the heating temperature is, for example, 100°C or higher. The applied pressure is, for example, 15 MPa or lower, preferably 10 MPa or lower. On the other hand, the applied pressure is, for example, 5 MPa or higher. The heating and pressurizing time is, for example, 30 seconds or more and 60 minutes or less.

[0256] (3) Peeling process In this process, as shown in Figures 7(a) and 7(b), the release support 3 of the transfer sheet 50 is peeled off from the laminate 55. As a result, the transfer layer 20 remains on the decorative material body 1 side. The resin-impregnated decorative board 60 is obtained.

[0257] 2. Figure 3 of the second embodiment is a schematic cross-sectional view illustrating a method for manufacturing a decorative material when the decorative material in this disclosure is not a resin-impregnated decorative panel. Figure 3 has been described in detail in "A. Decorative Material," so its explanation is omitted here.

[0258] (1) Transfer Sheet Preparation Process The transfer sheet to be prepared in this process and its manufacturing method have been described in detail in "A. Decorative Materials", so the explanation here will be omitted.

[0259] (2) Laminate Formation Process In this process, a laminate is formed in which the decorative material body and the transfer layer of the transfer sheet are arranged to face each other. If the transfer layer of the transfer sheet has an adhesion layer, the decorative material body and the transfer layer of the transfer sheet may be arranged to face each other as they are to form the laminate. On the other hand, if the transfer layer of the transfer sheet does not have an adhesion layer, an adhesion layer formation process may be performed after the transfer sheet preparation process and before the laminate formation process to form an adhesion layer on at least one of the surfaces of the decorative material body that face the transfer layer and the surfaces of the transfer layer that face the decorative material body.

[0260] It is preferable to pressurize the laminate after forming the above-mentioned laminate. The pressurization may be at room temperature or by heating. Furthermore, the pressurization conditions are not particularly limited and should be adjusted to obtain the desired decorative material. Examples of pressurization methods include laminators using rollers.

[0261] (3) Peeling process In this process, as shown in Figures 3(a) and 3(b), the release support 3 of the transfer sheet 50 is peeled off from the laminate 55. As a result, as shown in Figure 3(c), the transfer layer 20 remains on the decorative material body 1 side. The decorative material 10 is thus obtained.

[0262] C. Transfer Sheet The present disclosure provides a transfer sheet having a release support and a transfer layer disposed on one side of the release support, wherein the transfer layer has at least a first protective layer, and after peeling off the release support, the surface of the transfer layer on the side with the first protective layer has a color difference ΔE of 3.0 or less between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009, and a difference ΔG of gloss values ​​of 5.0 or less between the 75° gloss value and the 60° gloss value measured under JIS Z 8741:1997.

[0263] Figure 2 is a schematic cross-sectional view illustrating a transfer sheet in this disclosure. As Figure 2 and the release support and transfer layer constituting the transfer sheet have been described above, further explanation is omitted here.

[0264] As described above, by using the transfer sheet in this disclosure and transferring the transfer layer to the decorative material body, a decorative material with excellent design visibility can be obtained.

[0265] This disclosure is not limited to the embodiments described above. The embodiments described above are illustrative, and any configuration that is substantially identical to the technical idea described in the claims of this disclosure and achieves similar effects is included within the technical scope of this disclosure.

[0266] [Example 1-1] (Manufacture of Transfer Sheet 1) On a resin film (polyester resin film) with a thickness of 75 μm, the following uneven layer-forming resin composition was applied at a coating amount of 5 g / m² when dried, and a coating layer was formed. With respect to the coating layer, ultraviolet rays were irradiated (LED-UV irradiation, wavelength 395 nm, maximum illuminance 0.6 W / cm², integrated light quantity 30 to 100 mJ / cm²) using a UV irradiation device composed of LEDs to perform preliminary curing. Next, ultraviolet rays were irradiated using an excimer light irradiation device (excimer irradiation, wavelength 172 nm (Xe), ultraviolet output density 30 mW / cm², integrated light quantity 5 to 100 mJ / cm², nitrogen atmosphere). Furthermore, electron beams were irradiated (acceleration voltage 100 to 150 kV, irradiation dose 30 to 100 kGy) to form an uneven layer on the resin film. Thus, the release support 1 was obtained ２ when dried, and a coating layer was formed. With respect to the coating layer, ultraviolet rays were irradiated (LED-UV irradiation, wavelength 395 nm, maximum illuminance 0.6 W / cm² ２ , integrated light quantity 30 to 100 mJ / cm² ２ ) to perform preliminary curing. Next, ultraviolet rays were irradiated using an excimer light irradiation device (excimer irradiation, wavelength 172 nm (Xe ２ ), ultraviolet output density 30 mW / cm² ２ , integrated light quantity 5 to 100 mJ / cm² ２ , nitrogen atmosphere). Furthermore, electron beams were irradiated (acceleration voltage 100 to 150 kV, irradiation dose 30 to 100 kGy) to form an uneven layer on the resin film. Thus, the release support 1 was obtained. It was confirmed that the surface on the uneven layer side of the release support 1 had a wrinkle structure.

[0267] <Resin Composition for Forming Uneven Layer>- 3-functional urethane (meth)acrylate oligomer (polyfunctional oligomer): 30 parts by mass - Monofunctional acrylate monomer (monofunctional monomer): 40 parts by mass - Bifunctional acrylate monomer (polyfunctional monomer): 30 parts by mass - Photopolymerization initiator (benzophenone-based): 0.8 parts by mass

[0268] On the uneven layer of the release support 1, the following Ink 1 for Forming the First Protective Layer was applied. After coating, it was dried and irradiated with electron beams (pressure voltage: 175 kV, 5 Mrad (50 kGy)) to form a first protective layer with a thickness of 10 μm.

[0269] <Ink 1 for Forming the First Protective Layer>- Urethane acrylate (bifunctional caprolactone-modified urethane acrylate / polyfunctional urethane acrylate = 50 / 50 (mass ratio)): 100 parts by mass - Ultraviolet absorber (product name: Tinuvin 479, manufactured by BASF): 1.5 parts by mass - Light stabilizer (product name: LS-34, manufactured by Nippon Emulsion Co., Ltd.): 3 parts by mass - Solvent (methyl ethyl ketone): appropriate amount

[0270] Next, the second protective layer forming ink 1 described below was applied to the formed first protective layer and dried to form a second protective layer with a thickness of 2 μm.

[0271] <Ink 1 for forming the second protective layer> - Polycarbonate-based urethane-acrylic copolymer (urethane component / acrylic component = 90 / 10 (mass ratio)): 100 parts by mass - UV absorber: 30 parts by mass ("Tinuvin 479" (manufactured by BASF) 16 parts by mass, "Tinuvin 400" (manufactured by BASF) 14 parts by mass) - Light stabilizer ("Tinuvin 123" (manufactured by BASF)): 3 parts by mass - Hexamethylene diisocyanate-based curing agent: 10 parts by mass - Solvent (methyl ethyl ketone): appropriate amount

[0272] Next, the adhesion layer forming ink 1 described below was applied to the formed second protective layer and dried to form an adhesion layer with a thickness of 2 μm. This obtained a transfer sheet 1. The first protective layer, the second protective layer, and the adhesion layer form the transfer layer.

[0273] <Ink for forming an adhesion layer 1> - Polycarbonate-based urethane-acrylic copolymer (urethane component / acrylic component = 90 / 10 (mass ratio)): 100 parts by mass - UV absorber: 30 parts by mass ("Tinuvin 479" (manufactured by BASF) 16 parts by mass, "Tinuvin 400" (manufactured by BASF) 14 parts by mass) - Light stabilizer ("Tinuvin 123" (manufactured by BASF)): 3 parts by mass - Solvent (methyl ethyl ketone): appropriate amount

[0274] (Preparation of decorative sheet 1) Black base paper (PM-85P manufactured by KJ Special Paper Co., Ltd.) was prepared as a porous substrate and used as decorative sheet 1.

[0275] (Preparation of resin-impregnated decorative board) To the decorative sheet 1 described above, a liquid uncured melamine resin composition containing 60 parts by mass of uncured melamine resin (water-soluble methylol melamine resin, Nikaredin S-260 manufactured by Nippon Carbide Industries Co., Ltd.), 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol is impregnated using an impregnation device until the uncured melamine resin composition reaches 80 g / m². ２ The impregnated decorative sheet was manufactured by impregnating it to the ratio (when dry) and then drying it.

[0276] The impregnated decorative sheet was manufactured by impregnating kraft paper with a phenolic resin solution, with a basis weight of 245 g / m². ２ A core substrate consisting of three sheets of phenol resin-impregnated core paper (obtained by impregnating core craft paper with a liquid, uncured resin composition made of phenol resin) was laminated onto the core substrate, and then a transfer sheet 1 was laminated onto the impregnated decorative sheet so that the adhesion layer of the transfer sheet 1 was in contact with the curable resin layer of the impregnated decorative sheet, thereby obtaining a precursor of the laminate.

[0277] The resulting laminate precursor is sandwiched between two mirror plates, and a hot press is used to apply a pressure of 85 kg / cm². ２ The uncured melamine resin composition was then heat-molded at a molding temperature of 140°C for 30 minutes to form a cured resin layer (melamine layer) containing cured melamine resin. This resulted in obtaining a laminate.

[0278] Next, the release support of the transfer sheet was peeled off from the laminate, leaving the adhesion layer, the second protective layer, and the first protective layer. This yielded a resin-impregnated decorative panel. It was confirmed that the surface of the surface layer side of the resin-impregnated decorative panel had a wrinkled structure.

[0279] [Example 1-2] (Preparation of decorative sheet 2) White base paper (PM-77P manufactured by KJ Special Paper Co., Ltd.) was prepared as a porous substrate and used as decorative sheet 1.

[0280] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1-1, except that the decorative sheet 2 described above was used.

[0281] [Examples 1-3] (Preparation of decorative sheet 3) Yellow base paper (PM-44P manufactured by KJ Special Paper Co., Ltd.) was prepared as a porous substrate and used as decorative sheet 3.

[0282] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1-1, except that the decorative sheet 3 described above was used.

[0283] [Comparative Example 1-1] (Manufacturing of Transfer Sheet 2) A 50 μm thick resin film (polyester resin) was dry-coated with the following matte layer forming composition and dried to form a 7 μm thick matte layer on the resin film. This obtained a release support 2. A transfer sheet 2 was prepared in the same manner as in Example 1, except that the release support 2 was used. <Matte layer forming composition> Binder resin (polyurethane resin): 100 parts by mass Matting agent (silica): 12.5 parts by mass Solvent (methyl ethyl ketone): appropriate amount

[0284] (Preparation of resin-impregnated decorative laminate) A resin-impregnated decorative laminate was manufactured in the same manner as in Example 1, except that the transfer sheet 2 prepared above was used as the transfer sheet.

[0285] [Comparative Example 1-2] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1, except that the transfer sheet 2 prepared above was used as the transfer sheet and the decorative sheet 2 was used as the decorative sheet.

[0286] [Comparative Example 1-3] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1, except that the transfer sheet 2 prepared above was used as the transfer sheet and the decorative sheet 3 was used as the decorative sheet.

[0287] [Comparative Example 1-4] (Manufacturing of Transfer Sheet 3) A 50 μm thick resin film (Lumirror #50-X42G manufactured by Toray Industries, Inc.) with a matting agent kneaded into it was used as the release support 3. Except for the use of the release support 3, the transfer sheet 3 was manufactured in the same manner as in Example 1.

[0288] (Preparation of resin-impregnated decorative laminate) A resin-impregnated decorative laminate was manufactured in the same manner as in Example 1, except that the transfer sheet 3 prepared above was used as the transfer sheet.

[0289] [Comparative Example 1-5] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1, except that the transfer sheet 3 prepared above was used as the transfer sheet and the decorative sheet 2 was used as the decorative sheet.

[0290] [Comparative Example 1-6] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1, except that the transfer sheet 3 prepared above was used as the transfer sheet and the decorative sheet 3 was used as the decorative sheet.

[0291] [Comparative Example 1-7] (Manufacturing of Transfer Sheet 4) A film obtained by sandblasting a 50 μm thick resin film (polyester resin) was used as the release support 4. The transfer sheet 4 was manufactured in the same manner as in Example 1, except that the release support 4 was used.

[0292] (Preparation of resin-impregnated decorative laminate) A resin-impregnated decorative laminate was manufactured in the same manner as in Example 1, except that the transfer sheet 4 prepared above was used as the transfer sheet.

[0293] [Comparative Example 1-8] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1, except that the transfer sheet 4 prepared above was used as the transfer sheet and the decorative sheet 2 was used as the decorative sheet.

[0294] [Comparative Example 1-9] (Preparation of resin-impregnated decorative board) A resin-impregnated decorative board was manufactured in the same manner as in Example 1, except that the transfer sheet 4 prepared above was used as the transfer sheet and the decorative sheet 3 was used as the decorative sheet.

[0295] [Examples 1-4] (Manufacturing of Transfer Sheet 5) A first protective layer and a second protective layer were formed on the surface of the release support 1 in the same manner as in Example 1. Next, a design layer forming ink containing a resin component (a mixed resin of urethane resin and acrylic polyol resin, urethane resin:acrylic polyol resin = 20 parts by mass:80 parts by mass), a pigment (organic pigment or inorganic pigment), and a curing agent (hexamethylene diisocyanate, resin component:curing agent = 100 parts by mass:5 parts by mass) was applied to the surface of the second protective layer by gravure coating and dried to form a design layer (solid layer and pattern layer) with a thickness of 3 μm to 5 μm. A transfer sheet 5 was obtained. The first protective layer, the second protective layer, and the design layer become the transfer layer.

[0296] (Preparation of decorative panel) A 10 mm thick calcium silicate board (non-combustible substrate) was prepared as the main decorative material, and its surface was smoothed by sanding with sandpaper. Next, a urethane resin sealer was applied to the smoothed surface to form an adhesion layer. Next, an adhesive containing polyurethane resin and a hardener (polyurethane resin: hardener = 100 parts by mass: 15 parts by mass) was applied to the surface of the design layer of the transfer sheet 5 to form an adhesion layer. Next, the calcium silicate board and the transfer sheet 5 were laminated so that the adhesion layers faced each other, and pressure was applied using a laminator under the conditions of lamination roll temperature: room temperature and conveying speed: 2 m / min. After curing at 40°C for 3 days, the release support of the transfer sheet 5 was peeled off from the laminate, leaving the design layer, second protective layer and first protective layer intact. A decorative panel was thus obtained. It was confirmed that the surface on the surface layer side of the decorative panel had a wrinkled structure.

[0297] [Parameter Measurement] (Color Difference ΔE) The color of the surface layer side of the obtained decorative laminate was measured using the method described above, in accordance with geometric condition a (45°c:0°) and in accordance with geometric condition c (de:8°) and in accordance with JIS Z 8722:2009, and the color difference ΔE was calculated.

[0298] (Difference in gloss value ΔG) For the surface of the surface layer side of the obtained decorative panel, the difference in gloss value ΔG between the 75° gloss value and the 60° gloss value was calculated using the method described above.

[0299] (Surface Properties) For the surface of the decorative laminate obtained in the examples and comparative examples, Ra (arithmetic mean roughness), RSm (average length of curved elements), and Rz (maximum height) were measured in accordance with JIS B0601:2013 using the following method. Ten arbitrary rectangular (1024 μm × 768 μm) samples were measured using a shape analysis laser microscope ("VK-X1000", manufactured by Keyence Corporation) with the following settings: objective lens: 50x, measurement mode: shape measurement mode, measurement pitch: 12 μm, measurement quality: high-speed mode, scan mode: laser confocal. The average values ​​of the measurements taken at the ten arbitrary locations were taken as Ra (arithmetic mean roughness), RSm (average length of curved elements), and Rz (maximum height). In addition, the variation σ1 of Ra, the variation σ2 of RSm, and the variation σ3 of Rz were calculated.

[0300] [Evaluation] Observers observed the visibility of the decorative panel design from various angles under indoor fluorescent lighting and scored the change in design visibility from angle on a 5-point scale from 1 to 5 (1 being the worst, and 5 being the best). A score of 1 was given for a significant change in design visibility, and a score of 5 was given for virtually no change in design visibility. This was performed by 10 observers, and the average score of all observers was calculated to evaluate the design visibility according to the following criteria: ・Evaluation criteria A: Average score when evaluating design visibility is 3 points or higher B: Average score when evaluating design visibility is 2 points or higher but less than 3 points C: Average score when evaluating design visibility is less than 2 points

[0301]

[0302]

[0303] As shown in Tables 1 and 2, the resin-impregnated decorative panels of Examples 1-1 to 1-3 had better design visibility compared to the resin-impregnated decorative panels of Comparative Examples 1-1 to 1-9. Comparing the resin-impregnated decorative panel of Example 1-1 with those of Comparative Examples 1-1, 1-4, and 1-7, it was confirmed that the variation σ of Ra and RSm in the resin-impregnated decorative panel of Example 1-1 was the smallest. It is presumed that because the wrinkle shape on the surface of the decorative panel is uniform and has little variation, scattered light is reflected uniformly, and ΔG and ΔE tend to fall within the predetermined range. In addition, the decorative panel of Example 1-4 also had good design visibility.

[0304] [Example 2, Comparative Examples 2-4] Using decorative sheets with porous substrates (colored base paper) in single colors of white, yellow, orange, brown, and black, and transfer sheet 1, resin-impregnated decorative boards were manufactured in the same manner as in Example 1 (Example 2). Similarly, resin-impregnated decorative boards were manufactured using transfer sheets 2-4 (Comparative Examples 2-4). Figure 9 shows the results of measuring ΔE and ΔG for the obtained resin-impregnated decorative boards.

[0305] As shown in Table 1 and Figure 9, the decorative panels (decorative materials) in this disclosure had a ΔE of 3.0 or less and a ΔG of 5.0 or less, regardless of the color of the decorative sheet.

[0306] [Example 3] Using decorative sheets with a porous substrate (colored base paper) in one of the following single colors: black, dark gray, light gray, dark brown, brown, light brown, orange, yellow, skin tone, and white, and a transfer sheet 1, a resin-impregnated decorative board was manufactured in the same manner as in Example 1, and the above ΔE was measured. The results are shown in Figure 10. As shown in Figure 10, it was confirmed that ΔE was 3.0 or less regardless of the color of the design layer.

[0307] Thus, the present disclosure provides, for example, the following inventions.

[0308] [1] A decorative material having a decorative material body and a surface layer, wherein the surface layer has at least a first protective layer, and the surface of the decorative material on the surface layer side satisfies the following conditions: the color difference ΔE between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009 is 3.0 or less, and the difference ΔG between the gloss values ​​of the 75° gloss value and the 60° gloss value measured under JIS Z 8741:1997 is 5.0 or less.

[0309] [2] The decorative material according to [1], wherein the first protective layer contains a cured product of an ionizing radiation-curable resin.

[0310] [3] The decorative material according to [1] or [2], wherein the surface layer has a second protective layer on the decorative material body side with respect to the first protective layer.

[0311] [4] The decorative material according to [3], wherein the second protective layer contains a cured product of a thermosetting resin.

[0312] [5] The decorative material according to [3] or [4], wherein at least one of the first protective layer and the second protective layer contains a weather-resistant agent.

[0313] [6] The decorative material according to any one of [1] to [5], wherein the surface layer has an adhesion layer on the decorative material body side with respect to the first protective layer.

[0314] [7] The decorative material is a resin-impregnated decorative board, as described in any of [1] to [6].

[0315] [8] The decorative material body is a non-combustible substrate, the decorative material according to any one of [1] to [6].

[0316] [9] The decorative material according to any one of [1] to [8], wherein the surface layer is the transfer layer in a transfer sheet comprising a release support and a transfer layer.

[0317]

[10] A method for manufacturing a cosmetic material according to any one of [1] to [9], comprising: a transfer sheet preparation step of preparing a transfer sheet comprising a release support and a transfer layer including at least the first protective layer; a laminate formation step of forming a laminate in which the cosmetic material body and the transfer layer of the transfer sheet are arranged to face each other; and a peeling step of peeling the release support from the transfer sheet from the laminate.

[0318]

[11] The method for manufacturing a decorative material according to

[10] , wherein the transfer sheet preparation step includes a release support preparation step of forming an uneven layer on one side of a resin film to produce the release support, and a first protective layer formation step of forming the first protective layer on the side of the release support facing the uneven layer.

[0319]

[12] The method for manufacturing a cosmetic material according to

[11] , wherein the transfer sheet preparation step includes an adhesion layer formation step in which an adhesion layer is formed on the side opposite to the release support with respect to the first protective layer.

[0320]

[13] The method for producing a decorative material according to

[11] or

[12] , wherein the mold release support preparation step involves applying a resin composition to one side of the resin film to form a coating layer, and curing the coating layer to form the uneven layer by performing at least the following irradiation treatments with ionizing radiation (i) and (ii) in this order: (i) Irradiation treatment with a first wavelength of light between 100 nm and less than 200 nm (ii) Irradiation treatment with at least one of an electron beam and a second wavelength of light between 200 nm and 400 nm

[0321]

[14] A method for manufacturing a decorative material according to any one of

[10] to

[13] , wherein the decorative material is a resin-impregnated decorative board, and the laminate formation step comprises: a decorative sheet preparation step of preparing a decorative sheet having a porous substrate and impregnated with a curable resin; a lamination step of laminating the decorative sheet and the transfer layer side of the transfer sheet facing each other to obtain a precursor of the laminate; and a heating and pressurizing step of heating and pressurizing the precursor of the laminate to cure the curable resin and obtain the laminate.

[0322]

[15] A method for manufacturing a decorative material according to any one of

[10] to

[14] , comprising an adhesion layer forming step, after the transfer sheet preparation step and before the laminate formation step, of forming an adhesion layer on at least one of the surfaces of the decorative material body on the transfer layer side and the surfaces of the transfer layer on the decorative material body side.

[0323]

[16] The method for manufacturing the decorative material according to

[15] , wherein the decorative material body is a non-combustible substrate.

[0324] 1...Main body of decorative material 2...Surface layer 3...Release support 10...Decorative material 20...Transfer layer 21...Adhesion layer 22...First protective layer 23...Second protective layer 24...Decorative layer 31...Resin film 32...Textured layer 50...Transfer sheet 60...Resin-impregnated decorative board

Claims

1. A decorative material comprising a decorative material body and a surface layer, wherein the surface layer has at least a first protective layer, and the surface of the decorative material on the surface layer side satisfies the following conditions: the color difference ΔE between the color measured under geometric condition a (45°c:0°) in accordance with JIS Z 8722:2009 and the color measured under geometric condition c (de:8°) in accordance with JIS Z 8722:2009 is 3.0 or less, and the difference ΔG between the gloss values ​​of the 75° gloss value and the 60° gloss value measured under JIS Z 8741:1997 is 5.0 or less.

2. The decorative material according to claim 1, wherein the first protective layer contains a cured product of an ionizing radiation-curable resin.

3. The decorative material according to claim 1, wherein the surface layer has a second protective layer on the decorative material body side with respect to the first protective layer.

4. The decorative material according to claim 3, wherein the second protective layer contains a cured product of a thermosetting resin.

5. The decorative material according to claim 3, wherein at least one of the first protective layer and the second protective layer contains a weather-resistant agent.

6. The decorative material according to claim 1, wherein the surface layer has an adhesion layer on the decorative material body side with respect to the first protective layer.

7. The decorative material according to claim 1, wherein the decorative material is a resin-impregnated decorative board.

8. The decorative material according to claim 1, wherein the decorative material body is a non-combustible substrate.

9. The decorative material according to claim 1, wherein the surface layer is the transfer layer in a transfer sheet comprising a release support and a transfer layer.

10. A method for manufacturing a cosmetic material according to any one of claims 1 to 9, comprising: a transfer sheet preparation step of preparing a transfer sheet comprising a release support and a transfer layer including at least the first protective layer; a laminate formation step of forming a laminate in which the cosmetic material body and the transfer layer of the transfer sheet are arranged to face each other; and a peeling step of peeling the release support from the transfer sheet from the laminate.

11. The method for manufacturing a decorative material according to claim 10, wherein the transfer sheet preparation step includes a release support manufacturing step of forming an uneven layer on one side of a resin film to produce the release support, and a first protective layer forming step of forming the first protective layer on the side of the release support facing the uneven layer.

12. The method for manufacturing a decorative material according to claim 11, wherein the transfer sheet preparation step includes an adhesion layer forming step in which an adhesion layer is formed on the side opposite to the release support with respect to the first protective layer.

13. The method for manufacturing a cosmetic material according to claim 10, wherein the mold release support manufacturing step involves applying a resin composition to one side of the resin film to form a coating layer, and curing the coating layer to form the uneven layer by performing at least the following irradiation treatments with ionizing radiation in this order: (i) Irradiation treatment with a first wavelength of light between 100 nm and less than 200 nm; (ii) Irradiation treatment with at least one of an electron beam and a second wavelength of light between 200 nm and 400 nm.

14. The method for manufacturing a decorative material according to claim 10, wherein the decorative material is a resin-impregnated decorative board, and the laminate formation step comprises: a decorative sheet preparation step of preparing a decorative sheet having a porous substrate and impregnated with a curable resin; a lamination step of laminating the decorative sheet and the transfer layer side of the transfer sheet facing each other to obtain a precursor of the laminate; and a heating and pressurizing step of heating and pressurizing the precursor of the laminate to cure the curable resin and obtain the laminate.

15. A method for manufacturing a decorative material according to claim 10, comprising an adhesion layer forming step, after the transfer sheet preparation step and before the laminate formation step, of forming an adhesion layer on at least one of the surfaces of the decorative material body on the transfer layer side and the surfaces of the transfer layer on the decorative material body side.

16. The method for manufacturing a decorative material according to claim 15, wherein the decorative material body is a non-combustible substrate.

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