JP7255295B2 - Decorative materials, shaped sheets - Google Patents

Description

TECHNICAL FIELD The present invention relates to a decorative material and a shaping sheet for producing the decorative material.

Decorative materials are widely used as surface decoration materials for furniture, building materials, and the like. For example, Japanese Unexamined Patent Application Publication No. 2002-100002 discloses a technique related to a decorative material made of melamine resin. Decorative materials made of melamine resin have advantages such as excellent heat resistance, scratch resistance, and stain resistance, and are characterized by good productivity.

JP-A-58-197053

However, these decorative materials made of melamine resin have a problem that fingerprint marks are conspicuous when touched with a hand, and fingerprint resistance is low. Here, the degree to which fingerprint traces are conspicuous is described as "fingerprint resistance", and the more conspicuous the fingerprint resistance is, the lower the fingerprint resistance is, while the opposite is expressed as the high fingerprint resistance.
In particular, this tendency is conspicuous in a decorative material having a so-called matte surface, which is formed by forming fine irregularities such as pear-skin or sand grain on the surface.

In addition, such a decorative material with low luster has a problem that it takes time and effort to remove stains adhering to the surface by cleaning. Here, the degree to which dirt adhering to the surface can be easily removed is expressed as "cleanability", and the easier it is to remove dirt, the higher the cleanability, and conversely, the harder it is to remove dirt, the lower the cleanability. .

Therefore, an object of the present disclosure is to provide a decorative material that makes fingerprint traces less noticeable regardless of the type of material and that can improve cleanability. Also provided is a shaping sheet for producing this decorative material.

One aspect of the present disclosure is a decorative material having an uneven surface, which has a base material and a concave-convex shape part in which a plurality of convex filaments and concave parts are arranged on the surface of the base material, and the convex In a plan view of the decorative material, the filament has a different width depending on the position in the direction in which the convex filament extends, and the line connecting the center of the width at each position is a broken line or a curved line, and the line between the adjacent convex filament A decorative material in which recesses are arranged in the

The recess may be configured to have a portion of a spherical surface.

The base material and the concave-convex shape part may contain a melamine resin.

The ridge may be annular.

The protruding filar has both ends in the extending direction, and at least a part of the width of the protruding filament may be larger than the diameter of the recess.

Another aspect of the present disclosure is a shaped sheet for producing a decorative material, which includes a substrate, and a plurality of concave filaments and convex portions arranged on the surface of the substrate, and the concave filaments are In a plan view of the shaped sheet, the width varies depending on the position in the direction in which the concave filaments extend, and the line connecting the centers of the widths at each position is a broken line or a curved line, and a convex portion is formed between adjacent concave filaments. is arranged on the shaping sheet.

According to the present disclosure, it is possible to make fingerprint traces less conspicuous in the decorative material regardless of the type of material, and to improve cleanability.

FIG. 1 is a plan view showing an enlarged part of the surface of the decorative material 10. FIG. FIG. 2 is a perspective view schematically showing a part of the decorative material 10 for explaining the surface of the decorative material 10. As shown in FIG. FIG. 3 is a plan view schematically showing a part of the decorative material 10 for explaining the surface of the decorative material 10. As shown in FIG. FIG. 4 is a cross-sectional view of part of the decorative material 10. As shown in FIG. FIG. 5 is a diagram for explaining the plate (metal roll) 20. As shown in FIG. FIG. 6 is a perspective view schematically showing a part of the shaped sheet 10' for explaining the surface of the shaped sheet 10'. FIG. 7 is a schematic perspective view for explaining a modification of the shaped sheet 10'. FIG. 8 is a plan view showing an enlarged part of the surface of the decorative material 30. As shown in FIG. FIG. 9 is a perspective view schematically showing a part of the decorative material 30 for explaining the surface of the decorative material 30. As shown in FIG. FIG. 10 is a plan view schematically showing a part of the decorative material 30 for explaining the surface of the decorative material 30. FIG. FIG. 11 is a cross-sectional view of part of the decorative material 30. As shown in FIG. FIG. 12 is a perspective view schematically showing a part of the shaped sheet 30' for explaining the surface of the shaped sheet 30'. FIG. 13 is a schematic perspective view for explaining a modification of the shaped sheet 30'. 14 is a plan view showing an enlarged part of the surface of the decorative material of Example 3. FIG. FIG. 15 is a plan view showing an enlarged part of the surface of the decorative material of the comparative example.

Hereinafter, each form will be described with reference to the drawings. Note that in the drawings shown below, the sizes and ratios of members may be changed or exaggerated for clarity. In addition, for the sake of visibility, parts that are not required for explanation and repetitive symbols may be omitted.

FIG. 1 is a plan view (plan view) of a part of the decorative material 10 according to the first embodiment, which is enlarged and viewed from the concave-convex shape part 12 side.
For convenience, FIG. 1 also shows arrows (x, y, z) representing directions, that is, a coordinate system. Here, the xy direction is the in-plane direction of the surface of the decorative material 10, the z-direction is the thickness direction, and is also the normal direction of the xy plane representing the spread of the decorative material in the in-plane direction. Therefore, FIG. 1 is a view of the decorative material 10 viewed from the z-direction, which is the concave-convex shape portion 12 side. It should be noted that, as shown in FIG. 1, the observation of the decorative material 10 from the thickness direction (z direction) of the decorative material is also referred to as a plan view, and the diagram showing the plan view is also referred to as a plan view.
FIG. 2 is a perspective view schematically showing a part of FIG. 1 extracted and enlarged.
FIG. 3 is a plan view schematically showing an enlarged part of FIG. 1. FIG. 4 is a cross-sectional view along IV-IV in FIG.

As can be seen from FIGS. 1 and 2, the decorative material 10 of this embodiment comprises a substrate 11 and an uneven portion 12 formed on one surface of the substrate 11 . The substrate 11 has a flat plate shape, and the surface side of the substrate 11 that can be touched by human eyes and hands (in FIGS. 1 to 4, the +z direction side of the pair of surfaces parallel to the xy plane) Concavities and convexities are formed by the concavo-convex shape portion 12 on the surface (that is, the surface shown in FIGS. 1 and 3).
In this embodiment, the surface of the substrate 11 opposite to the side provided with the concave-convex shape portion 12 is a flat surface. However, although illustration is omitted, the surface of the base material 11 opposite to the concave-convex shaped portion 12 has an anchoring effect (reinforcing effect on the adhesive strength) for the adhesive, so that it may be a rough surface composed of fine irregularities or a wall surface. It is also possible to provide grooves, protuberances, mounting brackets, etc. as auxiliary means for construction on the construction surface such as.

The configuration of the cosmetic material 10 will be described in more detail below.

The base material 11 is a sheet-like member that serves as a base for the concave-convex shaped portion 12 and has a function of imparting strength to the decorative material 10 . The material of the base material 11 is not particularly limited as long as it has the same functions as conventionally known decorative materials. For example, the material of the base material includes polyolefin resins such as polyethylene, polypropylene, olefin thermoplastic elastomers, and ionomers, acrylic resins such as polymethyl methacrylate and polybutyl methacrylate, and thermoplastic polyester resins such as polyethylene terephthalate and polybutylene terephthalate. , thermoplastic urethane resin, vinyl chloride resin, ABS resin (acrylonitrile-butadiene-styrene copolymer), thermosetting resin such as styrene resin, melamine resin, unsaturated polyester resin, two-component curable urethane resin, etc. A resin, or an ionizing radiation-curable resin such as a radical polymerization type acrylate type or a cationic polymerization type epoxy type that is cured by ionizing radiation (ultraviolet rays, electron beams, etc.) can be used. In addition, when the material of the base material is a resin, it may be colored with a known coloring agent.
In addition, paper, non-woven fabric, metal, wood, etc. can also be used in the form of sheets, plates, three-dimensional objects, etc., and can also be used by appropriately laminating them with the above resin materials.
In this manner, the decorative material 10 can improve fingerprint resistance regardless of the material used.

Among these, the construction of so-called melamine resin decorative materials obtained by impregnating paper with an uncured liquid composition of melamine resin, which has been conventionally used from the viewpoint of heat resistance, scratch resistance, and productivity, and curing the composition. A substrate consisting of can be preferably used. A general melamine resin decorative material consists of the following layer structure and manufacturing method. About 2 to 5 sheets of core paper made by impregnating kraft paper with a basis weight of 50 g/m ² or more and 250 g/m ² or less with an uncured composition of phenolic resin are stacked, and the surface side (exposed and visible during use) Titanium paper impregnated with an uncured composition of melamine resin and having a basis weight of 50 g/m ² or more and 250 g/m ² or less (paper mixed with titanium dioxide particles as a white concealing pigment) is layered on the side to be coated), and further An overlay paper made by impregnating α-cellulose pulp paper with a basis weight of about 15 g/m ² or more and 50 g/m ² or less with an uncured composition of melamine resin is superposed on the surface side. Then, the laminate is heated and pressurized to cure each uncured composition and to obtain a laminated body in which each layer is bonded and integrated.

As for the layer structure of the melamine resin decorative material, it is also possible to omit some of the layers of the above-described laminated structure according to the required performance, price, application, and the like. Alternatively, it is also possible to adopt a structure in which various layers are added to the above laminated structure.
As an additional layer, titanium paper impregnated with melamine resin (also called balance paper) is used to offset the warp of the melamine resin decorative material laminated with different materials. It can be laminated on the opposite side. In addition, in order to improve the concealability of the melamine resin decorative material, melamine resin-impregnated titanium paper (also called barrier paper) can be laminated between the decorative paper and the overlay paper in the laminated structure.

From the above point of view, representative examples of the laminated structure of the melamine resin decorative material are as follows.
(1) Core paper (appropriate number of layers)/melamine resin-impregnated decorative paper/overlay paper (laminated structure described above)
(2) Melamine resin-impregnated balance paper/core paper (appropriate number of layers)/melamine resin-impregnated decorative paper/overlay paper (3) Core paper (appropriate number of layers)/melamine resin-impregnated decorative paper/melamine resin-impregnated barrier Paper/overlay paper (4) Melamine resin impregnated balance paper/core paper (as appropriate number of layers)/melamine resin impregnated decorative paper/melamine resin impregnated barrier paper/overlay paper (5) Overlay paper only (as appropriate number of layers)
(6) Only melamine resin-impregnated decorative paper (appropriate number of layers)
(7) Melamine resin impregnated decorative paper/overlay paper

According to the decorative material 10 in which the concave-convex shape part 12 is formed on the surface side of the base material 11 having the structure of the melamine resin decorative material as described above, fingerprint resistance and cleanability are improved even if the melamine resin is used as the material. Is possible.

The thickness of the substrate is not particularly limited, but in the case of a sheet-like substrate or film-like substrate, the thickness is, for example, about 20 μm or more and 1000 μm or less, and in the case of a plate-like substrate, the thickness is, for example, 1 mm or more and 20 mm or less. A certain amount can be used.

The concave-convex shaped portion 12 is formed on one surface of the base material 11 to impart anti-fingerprint property to the surface of the decorative material 10 and to make the surface of the decorative material 10 easier to clean than conventional ones. Therefore, in this embodiment, the concave-convex portion 12 has the following form.

As can be seen from FIGS. 1 to 4, the concave-convex portion 12 is provided with convex filaments 13 in plan view of the decorative material 10, and a plurality of convex linear shapes 13 are arranged in the xy plane. The ridges 13 have different widths depending on the positions in the direction in which the ridges 13 extend in a plan view of the decorative material, and can be configured such that the line connecting the centers of the widths at each position is a broken line or a curved line. . Among them, in this embodiment, the protruding filaments 13 are annular, and furthermore, this has a portion forming a mesh shape.
In addition to this, a concave portion 14 is arranged inside the annular shape formed by the convex filaments 13 . That is, the concave portions 14 are arranged between the convex filaments 13 facing each other.
In this embodiment, the convex filaments 13 and the concave portions 14 provide the decorative material 10 with anti-fingerprint function, and also enhances the cleanability.

In addition, by arranging such convex filaments 13 and concave portions 14 on the surface, the incident light is diffusely reflected, so that a so-called matte surface can be obtained. Among conventional decorative materials having matte surface irregularities such as pear-skin and grain, those using melamine resin in particular have a matte surface where fingerprint marks are visually conspicuous and the fingerprint resistance is low. was the problem. On the other hand, according to the decorative material 10 of the present embodiment, the specific concave-convex shape portion 12 can improve fingerprint resistance even with a matte surface. The matte evaluation can be performed by measuring the gloss of the decorative material using a gloss meter (60 degrees, measuring instrument BYK Gardner, Microgloss).

In addition, such a decorative material with low luster has a problem that it takes time and effort to remove stains adhering to the surface by cleaning. On the other hand, by arranging such protruding filaments 13 and recessed portions 14 on the surface, it is possible to improve the cleanability.

The shape and arrangement of the protruding filaments 13 and the recessed portions 14 provided in the concave-convex shaped portion 12 may be configured so as to have anti-fingerprint property and good cleaning property.
Here, the fingerprint resistance means the conspicuousness of fingerprint traces, and the fingerprint resistance makes the fingerprint traces inconspicuous. As a specific index of anti-fingerprint resistance, color difference ΔE is used for evaluation, and ΔE is 1.5 or less. can be evaluated as having high fingerprint resistance.
Here, the color difference ΔE means “color difference ΔE ^* _ab in the L ^* a ^* b ^* color space”, and the fingerprint resistance index represented by the color difference ΔE is obtained by producing a decorative material using melamine resin, After one drop of oleic acid is dropped on the surface, the surface after 10 reciprocating dry wipings with a cotton cloth and the surface before dropping are represented by the color difference ΔE (ΔE ^* _ab ). Therefore, the color in the L ^* a ^* b ^* color space of the surface before dripping oleic acid and the color in the L ^* a ^* b ^* color space of the surface after dripping oleic acid and dry-wiping as described above. The distance is ΔE(ΔE ^* _ab ). Such a color difference can be measured by Konica Minolta Co., Ltd., spectrophotometer CM-370, or the like.

On the other hand, the cleanability means the ease of wiping off stains adhering to the surface of the decorative material, and the cleanability makes traces of contaminants less noticeable. Color difference ΔE is also used as a specific indicator of cleanability, and ΔE should be 0.6 or less. Cleanability is good when ΔE is 0.4 or less, and high when ΔE is 0.2 or less. It can be evaluated as having cleanability. The meaning of the color difference .DELTA.E, the measurement method, etc. are the same as those described above for the anti-fingerprint property. However, in place of the "oleic acid" used in ΔE representing fingerprint resistance, one drop of "water-based ink" was used in ΔE representing cleanability.

In order to provide anti-fingerprint property and cleanability, in this embodiment, the convex filaments 13 are ring-shaped, and include a portion where a plurality of rings are arranged in the xy plane to form a mesh. . Further, the concave portion 14 is arranged inside the annular shape formed by the convex filaments 13 .

From the viewpoint of further improving fingerprint resistance, delustering property, and cleanability, it is preferable that the convex stripes and concave portions have the following forms.

The width of the projected filaments 13 is preferably 1 μm or more and 250 μm or less, more preferably 1 μm or more and 150 μm or less.
The width of the ridges 13 can be measured by observing with an optical microscope.

The height difference between the projection filament 13 and the bottom of the recess 14 is preferably 0.1 μm or more and 100 μm or less, more preferably 0.1 μm or more and 50 μm or less.
The height difference between the convex filament 13 and the bottom of the recessed portion 14 is determined by using a microtome to prepare a cross section, performing Pt sputtering treatment (E-1045, manufactured by Hitachi High-Technologies Corporation), and observing it with an electron microscope (S-4800 TYPE2, Hitachi High-Technologies Corporation). (manufactured by High Technologies, Inc.).

In the present embodiment, the size of the annular ring (mesh size) of the projected filaments 13 in plan view is preferably 1 μm or more and 500 μm or less, and more preferably 1 μm or more and 350 μm or less. Here, the "mesh size" is the diameter of the circumscribed circle of the annular portion in plan view.
The diameter of the concave portion 14 is preferably 0.1 μm or more and 100 μm or less, more preferably 0.1 μm or more and 70 μm or less. Here, the "diameter of the recess" is the diameter of the circumscribed circle of the recess in plan view.
In addition, regarding the area ratio of the protruding filaments 13 and the recessed portions 14, it is preferable that the area of the protruding filaments 13 is 1% or more and 35% or less than the area of the recessed portions 14 in plan view, and more preferably 5%. % or more and 25% or less.

The size of the ring formed by these ridges 13 in plan view, the diameter of the recesses 14, and the area ratio between the ridges 13 and the recesses 14 were measured using a digital microscope (VHX-6000, manufactured by Keyence Corporation). It can be measured by observing the shape portion 12 and detecting the convex filament 13 and the concave portion 14 using the brightness of the photographed image as a threshold value.

It is preferable that the ridges 13 have different widths (sizes in the direction orthogonal to the extending direction) in the extending direction as described above. That is, it is preferable that the width of the protruding filament 13 is not constant, and that it becomes thicker and thinner.
As can be seen from the circular shape, the line connecting the width centers at each position is a broken line or a curved line, and is not straight.
Further, in this embodiment, the width of the widest portion of the protruding line 13 may be smaller than the diameter of the recess 14 .

The cross-sectional shape of the protruding filaments 13 is not particularly limited, and may be semicircular, square, elliptical, other polygonal, indefinite, combinations thereof, or the like.

On the other hand, recess 14 is preferably a recessed recess that does not extend significantly in either direction. That is, it is a depression having a part of a spherical surface (for example, a hemispherical surface), a cubic surface, a rectangular parallelepiped surface, or the like.

According to the decorative material 10 described above, fingerprint resistance and cleanability can be improved regardless of the material used for the decorative material. For example, even when configured as a so-called melamine resin decorative board using melamine resin as a material, it is excellent in fingerprint resistance and cleanability.

In addition, according to the concave-convex shape portion 12 as described above, the surface of the decorative material can be provided with a matte feature. Thus, even with such a matte surface, both anti-fingerprint property and cleanability can be achieved.

Applications of the decorative materials described above are not particularly limited, but examples include interior materials for buildings such as walls, floors, and ceilings; exterior materials for exterior walls, roofs, gates, fences, and fences; Fittings such as frames and door frames, surface materials for fixtures such as rims, baseboards and handrails, surface materials for housings of home electric appliances such as TV receivers and refrigerators, surface materials for furniture such as desks, dining tables and chests of drawers , surface materials for containers such as boxes and resin bottles, interior or exterior materials for vehicles, interior or exterior materials for ships, and the like.

Next, the manufacturing method S10, which is an example of the manufacturing method of the decorative material, will be described. However, the method of manufacturing the decorative material is not limited to this.
The decorative material manufacturing method S10 of this example includes a pattern creating step S11, a plate creating step S12, a shaped sheet creating step S13, and a shaping step S14. Each step will be described below.

<Pattern creation step S11>
In the pattern creation step S11, an uneven shape to be expressed in the uneven shape portion 12 is formed to create pattern data, which is stored as digital data in a storage device.
The pattern data to be created in this step is planar image data in which the planar view shape created using computer graphics software has shading like the photograph in FIG. A set of points (X, Y) that satisfy ≤ X ≤ b, c ≤ Y ≤ d, where a, b, c, and d are determined to correspond to the metal roll surface described later.) of each point (X , Y) are associated with image density values D(X, Y) as shown in FIG.

<Plate making step S12>
In the plate making step S12, the pattern data (shading image data) obtained in the pattern creating step S11 is used to form the unevenness (height) formed on the uneven portion 12 of the decorative material in the same plan view shape, and , a plate (molding mold for shaping sheet) having the same unevenness on the surface is produced. Specifically, the manufacture of unevenness includes the following steps (1) to (5).

(1) Gradient Image Data Creation Process Digital grayscale image data corresponding to the plan view pattern of the convex filaments 13 and the recessed portions 14 forming the concave-convex shape portion 12 is created. The grayscale image data is data in which the image density is associated with each coordinate of the surface of the metal roll, which will be described later. Here, for the grayscale image data, the planar view pattern data obtained in the pattern creation step S11 is used. The grayscale image data obtained in the pattern creation step S11 is adjusted and corrected in consideration of laser engraving characteristics so as to obtain a desired uneven shape. Here, the grayscale image data for the laser light engraving process can be created in TIFF format with 8-bit image grayscale (256 grayscales) and a resolution of 2540 dpi.

(2) Metal Roll Preparing Step In parallel with the above step (1), a metal roll 20 for plate engraving as shown in FIG. 5 is prepared. The metal roll 20 is formed by plating a copper layer on the surface of a hollow iron cylinder having rotary drive shafts 21 at both ends in the axial direction. The surface of the metal roll 20 is roughened by polishing with a whetstone to prevent a decrease in engraving efficiency due to specular reflection of engraving laser light.

(3) Laser beam engraving process As schematically shown in FIG. 5, a laser beam direct engraving machine is used to convert the surface of the metal roll 20 prepared in step (2) into the grayscale image data created in step (1). Sculpture based on As a result, on the surface is formed an uneven shape that has the same planar shape as the unevenness on the surface of the decorative material as shown in FIG.
Therefore, the shape that the unevenness of the plate should have is the same as the unevenness relationship of the unevenness shape portion 12 of the above-described decorative material.

The metal roll 20 is driven by an electric motor via its rotary drive shaft 21 and rotates about the rotary drive shaft 21 as its central axis. The entire surface of the metal roll 20 is scanned with a fiber laser beam _LA emitted from the laser head 22 having an oscillation wavelength of 1024 nm, a laser spot diameter of 10 μm, and an output of 600 W. At that time, the laser light is switched ON-OFF (switching between irradiation and non-irradiation) according to the density value of the grayscale image data created in step (1). to form recesses with a depth of 10 μm. Scanning of the metal roll surface with such laser light is repeated 10 times. Further, in order to prevent the evaporated metal from turning into powder and remaining or adhering to the surface of the metal roll 20, the engraving liquid T was sprayed from the engraving liquid discharge port 23 onto the laser beam irradiated area of the surface of the metal roll 20. Laser light irradiation is performed in this state.
At that time, for example, at the position coordinates of the image density corresponding to the plate depth of 50 μm on the data, the laser light is irradiated (ON) only for the first five scans out of a total of ten scans, and for the remaining five scans The laser light is controlled to be non-irradiation (OFF).
By completing the scanning of the laser beam, a desired uneven shape is formed on the surface of the metal roll 20 .

(4) Electropolishing Step After cleaning the engraving liquid, electropolishing is performed to remove metal residue adhering to the surface of the metal roll 20 .

(5) Chromium Plating Step After step (4), a chromium layer having a thickness of 10 μm is formed on the surface of the metal roll by plating.

As described above, it is possible to obtain a plate (mold for shaping sheet) having on its surface the same uneven shape as the uneven shape formed on the surface of the uneven shape portion 12 .

<Shaped sheet preparation step S13>
In the shaped sheet producing step S13, a shaping method disclosed in Japanese Patent Application Laid-Open No. 57-87318, Japanese Patent Application Laid-Open No. 7-32476, etc. can be used. First, an uncured liquid composition of an ionizing radiation curable resin containing an acrylate monomer is applied to the uneven surface of the plate made of the metal roll prepared in the plate preparation step S12. Furthermore, an easy-adhesive side of a 50 μm-thick biaxially stretched PET sheet that has been subjected to an easy-adhesion treatment is superimposed on the above, and an electron beam is irradiated to cure the uncured liquid material to obtain a cured product. It is adhered to the sheet. Thereafter, the mold is released from the plate to produce a shaping sheet consisting of a PET sheet and a cured product layer of an ionizing radiation curable resin laminated on the PET sheet and having an uneven surface 12' (see FIG. 6). .

As a result, it is possible to obtain a shaping sheet 10' having an uneven shape (reverse unevenness) 12' having the same shape in plan view as the unevenness formed on the surface of the uneven shape portion 12 and having a reverse unevenness relationship (reverse unevenness) 12' on the surface. . FIG. 6 shows a diagram for explaining the irregularities on the surface of the shaped sheet 10'. As can be seen from FIG. 6, the surface of the cured product layer of the base material 11' of the shaped sheet 10' (consisting of a release base sheet and an ionizing radiation-curable acrylate monomer cured on one surface thereof) The concave-convex shaped portion 12' formed at the bottom has a concave filament 13' and a convex portion 14'. The recessed filaments 13' have the same shape in a plan view as the protrusions formed by the protruded filaments 13 of the concave-convex shaped portion 12, and have concaves opposite thereto. Similarly, the convex portion 14' has the same shape in plan view as the concave formed by the concave portion 14 of the concave-convex shaped portion 12, and has a convex shape opposite thereto. Therefore, the shapes of the concave filaments 13' and the convex portions 14' can be considered to be the same as those of the convex filaments 13 and the concave portions 14, except that the concavities and convexities are reversed.
As shown in FIG. 7, another base material (backing sheet) 11 ″ is laminated on the surface of the shaping sheet 10 ′ opposite to the surface of the base material 11 ′ on which the concave and convex portions 12 ′ are formed. good too.

<Shaping step S14>
The shaping step S14 is performed as follows.
First, a titanium paper base paper is impregnated with a liquid uncured composition of a thermosetting resin containing melamine formaldehyde resin using an impregnation device so that the uncured composition has a predetermined proportion when dried, and then dried. By doing so, an impregnated decorative sheet is obtained.
Next, this impregnated decorative sheet is laminated on a core paper impregnated with phenolic resin, which is obtained by impregnating kraft paper with a resin liquid composed of phenolic resin. The sheets are laminated so that the printed surface of the sheet is in contact with the surface of the impregnated decorative sheet on which the concave and convex portions 12' are formed.
The laminate thus formed is sandwiched between two metallic mirror plates, and while applying pressure using a heat press, heat molding is performed under predetermined temperature and time conditions to obtain the uncured composition. is heat cured. Thereby, a cured resin layer containing melamine resin is formed.
Finally, the decorative material 10 is obtained by removing the shaping sheet from the cured resin layer of the laminate taken out from the heat press after cooling to room temperature and releasing the pressure.

In the above steps S11 to S13, a shaping sheet can be produced by a shaping sheet producing step S13' using fine particles instead of step S13. In this case, a coating ink containing fine particles is applied to one of the surfaces of the base material to be the backing sheet, and a part of the fine particles protrudes to form the projections 14'. Then, by curing the coating ink, recessed lines 13' are formed in the process, and a shaped sheet having the same shape as the shaped sheet 10' can be obtained. For example, as in Examples described later, the type of resin binder in the ink to be coated, the particle size and amount of fine particles added, the coating amount of the ink, and the curing conditions of the ink can be adjusted to obtain a desired uneven shape. 12' is obtained.
After producing the shaped sheet, the decorative material can be obtained by the same steps as the shaping step S14.

FIG. 8 is a plan view (plan view) of a part of the decorative material 30 according to the second embodiment, which is enlarged and viewed from the concave-convex shape portion 32 side. The decorative material 10 according to the first embodiment and the decorative material 30 according to the present embodiment differ from the uneven shape portion 12 of the decorative material 10 in the form of unevenness formed in the uneven shape portion 32 of the decorative material 30. Only, other parts can be considered in the same way. Therefore, only the uneven portion 32 will be described here.
8 is a diagram corresponding to FIG. 1, FIG. 9 is a diagram corresponding to FIG. 2, FIG. 10 is a diagram corresponding to FIG. 3, and FIG. It is a sectional view.

As can be seen from FIGS. 8 to 11, the uneven shape portion 32 includes a plurality of protruding filaments 33 and recesses 34 arranged between adjacent protruding filaments 33 in a plan view of the decorative material 30. It is configured. Such protruding filaments 33 and recesses 34 provide the decorative material 30 with anti-fingerprint and cleanability functions.

In addition, by arranging such protruding filaments 33 and recesses 34 on the surface, the incident light is diffusely reflected, so that a so-called matte surface can be obtained.

Furthermore, such raised filaments 33 and recessed portions 34 can increase the degree of blackness compared to conventional matte surface unevenness. Here, the quantitative evaluation of the degree of blackness can be evaluated by the L value in the L*a*b* color space in the same manner as described above.
The cleanability can also be evaluated in the same manner as described above.

In order to improve the anti-fingerprint property and cleanability, the convex filaments 33 and the concave portions 34 have the form of a plurality of convex filaments 33 having both ends in plan view, as shown in FIGS. The grooves 34 are arranged so as to be distributed between the adjacent ridges 33 .

As can be seen from FIGS. 8 to 11, the ridges 33 are linearly extending ridges having both ends in a plan view. Although there is no particular limitation as long as it is such a convex portion, for example, the following forms can also be taken.
It is preferable that the ridges 33 have different widths (sizes in the direction orthogonal to the extending direction) in the extending direction. In other words, it is preferable that the width of the protruding filament 33 is not constant, and that it becomes thicker and thinner.
Further, it is preferable that the protruding filaments 33 do not extend in a constant direction and are not linear. In other words, when a line connecting the center points in the width direction of the protruding filament 33 is taken as its center line, it is preferable that this center line extends not as a single straight line but as a broken line or curved line.
In addition, it is preferable that adjacent protruding filaments 33 are arranged in different directions so that the center lines are not parallel to each other.

The cross-sectional shape of the protruding filaments 33 is not particularly limited, and may be semicircular, square, elliptical, other polygonal, indefinite, combinations thereof, or the like.

On the other hand, recess 34 is preferably a recessed recess that does not extend significantly in either direction. That is, it is a depression having a part of a spherical surface (for example, a hemispherical surface), a cubic surface, a rectangular parallelepiped surface, or the like.

From the viewpoint of further improving fingerprint resistance and cleanability, it is more preferable that the projections and recesses have the following shapes.

The width of the protruding filaments 33 is preferably 0.1 μm or more and 250 μm or less, more preferably 0.1 μm or more and 150 μm or less.
The width of the ridges 33 can be measured by observing with an optical microscope.

The height difference between the projection 33 and the bottom of the recess 34 is preferably 0.1 μm or more and 100 μm or less, more preferably 1 μm or more and 50 μm or less.
The height difference between the protruding filament 33 and the bottom of the recess 34 is determined by using a microtome to prepare a cross section, performing Pt sputtering treatment (E-1045, manufactured by Hitachi High-Technologies Corporation), and observing it with an electron microscope (S-4800 TYPE2, Hitachi High-Technologies Corporation). (manufactured by High Technologies, Inc.).

The diameter of the concave portion 34 is preferably 0.1 μm or more and 100 μm or less, more preferably 0.1 μm or more and 70 μm or less. Here, the "diameter of the recess" is the diameter of the circumscribed circle of the recess in plan view.

In this embodiment, in at least a part of the protruding filaments 33, the width of the protruding filaments 33 (the portion with the largest width among the protruding filaments 33) is larger than the diameter of the recesses 34 adjacent to the protruding filaments 33. can also be made larger.

In addition, regarding the area ratio of the protruding filament 33 and the recessed portion 34, the area of the protruding filament 33 in plan view is preferably 1% or more and 50% or less than the area of the recessed portion, and more preferably 3%. 40% or less.
The diameter of these concave portions 34 and the area ratio between the convex filaments 33 and the concave portions 34 are determined by observing the uneven shape portion 32 using a digital microscope (VHX-6000, manufactured by Keyence Corporation), and using the brightness of the captured image as a threshold. , ridges, and recesses.

The decorative material 30 described above can also improve fingerprint resistance and cleanability regardless of the material used for the decorative material. For example, even when configured as a so-called melamine resin decorative material using melamine resin as a material, the anti-fingerprint property is excellent.

In addition, the surface of the decorative material can be provided with a matte feature by the concave-convex shape portion 32 as described above. In that case, even if the surface is matte, the anti-fingerprint property is compatible. Furthermore, the degree of blackness can be higher than that of the prior art.

The decorative material 30 can be manufactured in the same manner as the decorative material 10 described above.
FIG. 12 shows the external appearance of a shaped sheet 30' used in manufacturing. This figure corresponds to FIG. The shaping sheet 30' has the same uneven shape in plan view as the unevenness formed on the surface of the uneven shape portion 32, and has an uneven shape opposite to the uneven relationship (reverse unevenness, concave filament 33', convex portion 34'). is provided on the surface.
As shown in FIG. 13, another base material (backing sheet) 11'' is laminated on the surface of the shaping sheet 30' opposite to the surface of the base material 11' on which the concave and convex portions 32' are formed. good too.

Examples 1 to 3 were prepared by producing decorative materials. In addition, a decorative material having no concave-convex shape was produced as a comparative example.

[Shape and preparation of decorative material of Example 1]
The decorative material according to Example 1 is as shown in FIG. 1 in plan view. The shape and arrangement of the concave-convex portions provided in this decorative material are as follows. In addition, the following numerical values are the results of measuring within a range of 5 mm×5 mm in plan view of the decorative material. Measurement items and measurement methods are as described above.
・Width of protruding filament 13: maximum 115 μm, minimum 10 μm
・Difference in height between the convex filament 13 and the bottom of the concave portion 14: maximum 35 μm, minimum 3 μm
・Annular size (mesh size) by the convex filaments 13: maximum 215 μm, minimum 23 μm
・Diameter of concave portion 14: maximum 62 μm, minimum 2 μm
・Area ratio of convex linear portion 13 and concave portion 14: The area of the convex linear portion is 11% to 18% of the concave portion area

In Example 1, a shaped sheet was produced following the shaped sheet producing step S13'. Specifically, it is as follows.
A biaxially oriented PET sheet (Cosmoshine (registered trademark) A4100 (50 μm) manufactured by Toyobo Co., Ltd.) having a thickness of 50 μm and having an easy-adhesion treatment was prepared.
In addition, ionizing radiation-curable acrylate monomer (manufactured by Toagosei Co., Ltd., Aronix (registered trademark) M350) 100 parts by weight, reactive silicone (manufactured by Shin-Etsu Chemical Co., Ltd., X-22-164B) 2 parts by weight, average particle size 15 μm A coating ink containing 100 parts by mass of acrylic fine particles (manufactured by Toyobo Co., Ltd., Tuftic FHS015), 40 parts by mass of isopropyl alcohol, and 40 parts by mass of ethyl acetate was also prepared.
The prepared coating ink is applied to the easy-adhesive surface of the PET sheet by kiss reverse using an 80L95μ oblique plate, and is cured by irradiation with an electron beam of 5 Mrad at an acceleration voltage of 165 kV. A shaped sheet was obtained.

Next, following the shaping step S14, a decorative material according to an example was obtained. Specifically, it is as follows.
First, a liquid uncured composition of a thermosetting resin comprising 60 parts by mass of melamine formaldehyde resin, 35 parts by mass of water, and 5 parts by mass of isopropyl alcohol was prepared.
This uncured composition was impregnated into a titanium paper base paper having a basis weight of 100 g/m ² using an impregnation device. At this time, the impregnation was carried out so that the uncured composition had a dry ratio of 80 g/m ² (dry). By drying this, an impregnated decorative sheet was obtained.

Next, this impregnated decorative sheet was laminated on three sheets of phenolic resin-impregnated core paper (Ohta Core, Ohta Sangyo Co., Ltd.) having a basis weight of 245 g/m ² , which was obtained by impregnating kraft paper with a resin liquid composed of phenolic resin.
Furthermore, the shaping sheet prepared on the impregnated decorative sheet was laminated so that the uneven surface of the shaping sheet was in contact with the printed surface of the impregnated decorative sheet.
Thereafter, the formed laminate was sandwiched between two mirror plates, and heat-molded using a heat press under the conditions of a pressure of 100 kg/cm ² and a molding temperature of 150° C. for 10 minutes to heat the uncured composition. A cured resin layer containing a melamine resin was formed by curing.

Finally, the decorative material according to Example 1 was obtained by peeling the shaping sheet from the cured resin layer.

[Shape and preparation of decorative material of Example 2]
The decorative material according to Example 2 is shown in plan view in FIG. The shape and arrangement of the concave-convex portions provided in this decorative material are as follows. In addition, the following numerical values are the results of measuring within a range of 5 mm×5 mm in plan view of the decorative material. Measurement items and measurement methods are as described above.
・Width of protruding filament 33: maximum 115 μm, minimum 3 μm
・Difference in height between the convex filament 33 and the bottom of the concave portion 14: maximum 35 μm, minimum 3 μm
・Diameter of concave portion 34: maximum 50 μm, minimum 3 μm
・Area ratio of the convex linear portion 33 and the concave portion 34: the area of the convex linear portion is 8% to 34% of the concave portion area

In Example 2, a decorative material was produced in the same manner as the decorative material of Example 1, but a 90L100 μm oblique stencil was used in place of the 80L95 μm slanted slab.

[Shape and preparation of decorative material of Example 3]
The plan view of the decorative material according to Example 3 is shown in FIG. The shape and arrangement of the concave-convex portions provided in this decorative material are intermediate between those of the first and second embodiments. In this way, the decorative material may have the features of both the decorative material 10 and the decorative material 30 .
The specific form of this example is as follows. In addition, the following numerical values are the results of measuring within a range of 5 mm×5 mm in plan view of the decorative material. Measurement items and measurement methods are as described above.
・Width of convex filaments: maximum 115 μm, minimum 5 μm
・The difference in height between the convex filament and the bottom of the recess: maximum 35 μm, minimum 3 μm
・Diameter of recess: maximum 55 μm, minimum 2 μm
・Area ratio of convex linear part and concave part: the area of the convex linear part is in the range of 8% or more and 25% or less with respect to the concave part area

In Example 3, a decorative material was produced in the same manner as in Example 1, but isopropyl alcohol was used as the diluent solvent instead of butyl acetate.

[Shape and preparation of decorative material of comparative example]
As the decorative material of the comparative example, a shaped sheet was produced using a so-called sandblasted matte film that does not have the above-described concave-convex shape portion. Using this shaped sheet, a decorative material of Comparative Example was obtained in the same manner as the decorative material of Example. FIG. 14 shows an enlarged plan view of a part of the decorative material according to the comparative example. FIG. 14 is the same viewpoint and scale as FIG.
The surface roughness of the obtained rough surface was JIS B 0601-1994 with an arithmetic mean roughness Ra of maximum 1.1 μm, minimum 0.7 μm, maximum height Ry of maximum 8.5 μm, minimum 7.5 μm, average length The height Sm was 175 μm at maximum and 165 μm at minimum.

[Evaluation method/result]
The decorative materials were evaluated in terms of luster, quantitative evaluation of fingerprint resistance based on color difference ΔE, and cleanability. Table 1 shows the results. Details of each evaluation are as follows.

The evaluation of gloss was measured with a gloss meter (60 degrees, measuring instrument BYK Gardner, Microgloss). As for the measurement results, the smaller the numerical value, the less the gloss.

Quantitative evaluation of anti-fingerprint property by color difference ΔE was obtained by Konica Minolta Co., Ltd.'s spectrophotometer CM-370 as described above.

For the evaluation of cleanability, the color difference ΔE between the decorative materials before and after cleaning with a cotton cloth after dripping water-based ink as described above was determined. In this example, instead of the cotton cloth, ΔE was similarly determined for a dry sponge made of melamine material and a sponge soaked with water made of melamine material.

If the gloss is 5.0 or less, a sufficient matting effect can be obtained, and all examples satisfy this requirement.
In addition, it can be seen that the decorative materials according to Examples 1 to 3 are superior to the comparative examples in terms of anti-fingerprint property and cleanability. Moreover, it can be seen that the example (example in FIG. 1) according to Example 1 is particularly good among them.

10, 30 Decorative material 11 Base material 12, 32 Concavo-convex shape part 13, 33 Convex filament 14, 34 Concave part 10', 30' Shaping sheet 13', 33' Concave filament 14', 34' Convex part

Claims (5)

A decorative material having unevenness on the surface,
A base material, and a concave-convex shape part in which a concave part having a plurality of convex filaments and a part of a spherical surface is arranged on the surface of the base material,
In a plan view of the decorative material, the ridges have different widths depending on the position in the direction in which the ridges extend, and a line connecting the centers of the widths at each position is a broken line or a curved line,
The concave portion is arranged between the adjacent convex filaments ,
The width of the protruding filament is 1 μm or more and 250 μm or less, the height difference between the protruding filament and the bottom of the recess is 0.1 μm or more and 100 μm or less, the diameter of the recess is 0.1 μm or more and 100 μm or less, and in plan view In the above, the area of the ridges is 1% or more and 35% or less than the area of the recesses,
cosmetic material. 2. The decorative material according to claim 1, wherein said base material and said concave-convex portion contain melamine resin. The decorative material according to claim 1 or 2, wherein the ridges are annular. 3. The decorative material according to claim 1, wherein said protruding filar has both ends in the extending direction, and at least part of said width of said protruding filament is larger than the diameter of said recess. A shaping sheet for manufacturing a decorative material,
A substrate, and a convex portion having a plurality of concave filaments and a part of a spherical surface are arranged on the surface of the substrate,
In the planar view of the shaped sheet, the width of the concave filament differs depending on the position in the direction in which the concave filament extends, and the line connecting the center of the width at each position is a broken line or a curved line,
The convex portion is arranged between the adjacent concave filaments ,
The width of the concave filament is 1 μm or more and 250 μm or less, the height difference between the concave filament and the bottom of the convex portion is 0.1 μm or more and 100 μm or less, the diameter of the convex portion is 0.1 μm or more and 100 μm or less, and In plan view, the area of the concave filament is 1% or more and 35% or less than the area of the convex portion.
Shaping sheet.

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