JP2018171844A - Decorative plate and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative plate capable of expressing an ornamental design feeling of a rugged shape, and a manufacturing method thereof.SOLUTION: A decorative plate 1 includes a support sheet 2 having a first principal plane S1 and a second principal plane S2, a first layer 3 arranged on a part of the first principal plane S1, and a second layer 4 arranged on the rest of the first principal plane S1. The first layer 3 includes a wide part 31 whose width is 20-100 μm. The second layer 4 includes an opening 40 exposing at least part of the wide part 31. In a cross section of the decorative plate 1, if a width of the wide part 31 is WB, a height of the wide part 31 is HB and a height of the second layer 4 is H, H>HB and WB≥(H-HB) are satisfied. In the cross section, at least part of the wide part 31 is exposed from the opening 40 of the second layer 4.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a decorative board and a manufacturing method thereof.

  Conventionally, the surface of tables, counters, walls, floors, etc. is impregnated with a porous base material such as titanium paper impregnated with an uncured resin solution of melamine resin, and laminated with phenol core paper as necessary. A decorative board is used in which the liquid is cured by hot pressing. A decorative board impregnated and cured with such a melamine resin exhibits physical properties such as strength, hardness and heat resistance.

  The decorative board as described above is required to have a high-grade design, and an uneven appearance is imparted to the surface. Various shapes can be adopted as such a concavo-convex shape, and among them, a groove-like concavo-convex shape of a wood grain conduit portion, a gloss matte concavo-convex shape, and the like are representative and frequently used. The “gross matte concavo-convex shape” means a concavo-convex shape in which a high gloss region and a low gloss region are mixed in a pattern on the surface of an article. The surface of the article having such a configuration is characterized in that the low-gloss area appears to be recessed compared to the high-gloss area visually, regardless of the physical irregularities, and thereby the three-dimensional design appearance can be reproduced. The “gross mat-like uneven shape” itself is well known as disclosed in Patent Document 1 and Patent Document 2.

  In Patent Document 3, hot pressing is performed using an embossed plate (textured mirror surface plate) with a desired uneven shape formed on the surface as a decorative plate having a surface with a textured appearance such as gloss matte. Pressed decorative panels have been proposed.

  However, in the case of imparting a desired concavo-convex design to the surface of the decorative plate described in Patent Document 3, a specular plate that has been surface-treated only for the type of design is required, which increases costs. Moreover, it is difficult for this decorative board to synchronize the uneven shape with the underlying pattern, and it is difficult to improve the design.

  In Patent Document 4, as a method for producing a decorative board in which a concave portion or the like synchronized with a pattern is formed, a permeation preventive layer and a liquid repellent pattern layer are provided on the surface of a base paper to impregnate a thermosetting resin. There has been proposed a manufacturing method for preventing a phenomenon in which a liquid repellent pattern is covered with a thermosetting resin film during hot pressing.

  However, in the manufacturing method described in Patent Document 4, it is difficult to completely prevent the thermosetting resin from being coated, and the decorative board manufactured by such a manufacturing method has a clear textured design feeling. It is difficult to express.

  In Patent Document 5, a porous substrate is used as a method for producing a decorative board having a release layer in a partial area of the surface and having a thermosetting resin layer in the remaining area of the surface without the release layer. First step of providing a release layer on a part of the top, impregnating a porous substrate with a thermosetting resin and coating the release layer with a thermosetting resin, and then heating the thermosetting resin by heating There has been proposed a manufacturing method including a second step of curing, and a third step of peeling off the thermally cured resin film in the region covering the release layer.

  The decorative board described in Patent Document 5 can express a clear gloss matte design feeling when the thermosetting resin layer and the release layer exhibit different design feelings.

Japanese Patent Publication No.49-39166 Japanese Patent Publication No. 1-20065 JP-A-47-14273 JP 2002-166501 A International Publication No. 2016/148091

  However, in the decorative board described in Patent Document 5, when the width of the release layer is narrow (for example, when the release layer is aligned with the wood grain conduit), the thermosetting resin film covering the release layer There is a possibility that the peelability is lowered and destabilized, and the thermosetting resin film is not sufficiently peeled from the release layer. Therefore, it is difficult for the decorative board described in Patent Document 5 to express a design feeling based on a clear uneven shape when the width of the release layer is narrow.

  Then, even if it is a case where the width | variety of a mold release layer is narrow, this invention aims at providing the decorative board which can express the design feeling based on a clear uneven | corrugated shape, and its manufacturing method.

In order to solve the above problems, the present invention provides the following decorative board and a method for producing the same.
[1] having a first direction, a second direction and a thickness direction orthogonal to each other;
A support sheet having a first main surface and a second main surface located on the opposite side of the first main surface;
A first layer provided on a part of the first main surface so as to extend along the first direction;
A second layer provided to surround the first layer on the remaining portion of the first main surface;
A decorative board comprising:
The first layer has a wide portion having a width of 20 μm or more and 100 μm or less,
The second layer has an opening exposing at least a part of the wide portion;
In a cut surface formed by cutting the decorative board, in a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outline of the wide portion in plan view When the width of the wide portion is WB, the height of the wide portion is HB, and the height of the second layer is H, H> HB and WB ≧ (H−HB),
In the cut surface, at least a part of the wide portion is exposed from the opening of the second layer.
[2] The decorative board according to [1], wherein a difference (H−HB) between the height of the second layer and the height of the first layer is 1 μm or more on the cut surface.
[3] The decorative board according to [1] or [2], wherein an area of a portion of the wide portion exposed from the opening of the second layer is 80% or more of an area of the wide portion.
[4] The decorative board according to any one of [1] to [3], wherein the first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin.
[5] The decorative board according to any one of [1] to [4], wherein the second layer is a cured resin layer containing a cured product of a thermosetting resin.
[6] The decorative board according to [5], wherein the thermosetting resin includes a water-soluble thermosetting resin.
[7] The decorative board according to [6], wherein the water-soluble thermosetting resin contains a melamine resin.
[8] The decorative board according to any one of [1] to [7], wherein the first layer and / or the second layer includes a silicone release agent.
[9] The support sheet includes a base sheet, and the base sheet is positioned on the first main surface side of the support sheet, and the second main surface side of the support sheet. The decorative board according to any one of [1] to [8], which has a second main surface located on the surface.
[10] The decorative board according to [9], wherein the support sheet further includes a decorative layer provided on the first main surface of the base sheet.
[11] The decorative board according to [9] or [10], wherein the base sheet is a porous sheet.
[12] The decorative board according to [11], wherein the support sheet further includes a cured product of a thermosetting resin filled in a gap of the porous sheet.
[13] A method for producing a decorative board according to any one of [1] to [12],
The method comprises
(1) preparing the support sheet;
(2) forming the first layer on a part of the first main surface of the support sheet;
(3) forming a coating layer surrounding the first layer and covering at least a part of the first layer on the remaining portion of the first main surface of the support sheet;
(4) including a step of peeling a portion covering the first layer of the coating layer along the first direction and forming a second layer on the remaining portion of the first main surface of the support sheet;
Cutting the intermediate body obtained in step (3) with a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outline of the wide portion in plan view; In the cut surface to be formed, when the width of the wide portion is WB and the thickness of the portion of the coating layer covering the wide portion is TB, WB ≧ TB.
[14] The method according to [13], wherein, in the cut surface, a thickness (TB) of a portion of the coating layer that covers the wide portion is 1 μm or more.
[15] The first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin,
The step (2)
(2-1) Using an ionizing radiation curable resin composition containing the ionizing radiation curable resin, an ionizing radiation curable resin composition layer covering a part of the first main surface of the support sheet is formed. And the process of
(2-2) The method according to [13] or [14], including a step of curing the ionizing radiation curable resin composition layer to form the cured resin layer as the first layer.
[16] The method according to [15], wherein the ionizing radiation curable resin composition contains a silicone-based release agent.
[17] The coating layer is a cured resin layer containing a cured product of a thermosetting resin,
The step (3)
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the remaining portion of the first main surface of the support sheet, and the first layer Forming a thermosetting resin composition layer covering at least a part of
(3-2) The method according to any one of [13] to [16], including a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer.
[18] The method according to [17], wherein the thermosetting resin includes a water-soluble thermosetting resin.
[19] The method according to [18], wherein the water-soluble thermosetting resin contains a melamine resin.
[20] The method according to any one of [17] to [19], wherein the thermosetting resin composition contains a silicone-based release agent.
[21] The support sheet includes a base sheet, and the base sheet is positioned on the first main surface side of the support sheet, and the second main surface side of the support sheet. The method according to any one of [13] to [20], wherein the second main surface is located on the surface.
[22] The method according to [21], wherein the support sheet further includes a decorative layer provided on the first main surface of the base sheet.
[23] The method according to [21] or [22], wherein the base sheet is a porous sheet.
[24] The coating layer is a cured resin layer containing a cured product of a thermosetting resin,
The step (3)
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the remaining portion of the first main surface of the support sheet, and the first layer Forming a thermosetting resin composition layer covering at least a part of
(3-2) including a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer,
In the step (3-1), the porous sheet is impregnated with the thermosetting resin composition,
The method according to [23], wherein in the step (3-2), the thermosetting resin composition impregnated in the porous sheet is cured.

  ADVANTAGE OF THE INVENTION According to this invention, the decorative board which can express the design feeling based on a clear uneven | corrugated shape, and its manufacturing method are provided.

FIG. 1 is a plan view of a decorative board according to an embodiment of the present invention. FIG. 2 is an enlarged view of a region indicated by a symbol R in FIG. FIG. 3 is a cross-sectional view taken along line AA in FIG. 4 is a cross-sectional view taken along line BB in FIG. 5 is a cross-sectional view taken along the line CC of FIG. FIG. 6 is a plan view showing an embodiment in which the angle formed between the extending direction of the first layer and the first direction of the decorative plate is + 30 °. FIG. 7 is a plan view showing an embodiment in which the angle formed between the extending direction of the first layer and the first direction of the decorative plate is −30 °. FIG. 8 is an explanatory diagram for explaining an embodiment of a method for manufacturing the decorative board shown in FIG. 1. FIG. 9 is an explanatory view (continuation of FIG. 8) for explaining an embodiment of the method for manufacturing the decorative board shown in FIG. FIG. 10 is a cross-sectional view of the intermediate obtained in step (3). FIG. 11 is a cross-sectional view of the intermediate obtained in step (3). FIG. 12 is an explanatory diagram for explaining a method of measuring peel weight.

Veneer below with reference to the accompanying drawings, embodiments will be described veneer according to the present invention. FIG. 1 is a plan view of a decorative board according to an embodiment of the present invention, FIG. 2 is an enlarged view of a region indicated by a symbol R in FIG. 1, and FIG. 4 is a sectional view taken along line B-B in FIG. 2, and FIG. 5 is a sectional view taken along line CC in FIG. 2.

  As shown in FIGS. 1-5, the decorative board 1 which concerns on one Embodiment of this invention has the 1st direction X, the 2nd direction Y, and the thickness direction Z which are mutually orthogonally crossed. In the present embodiment, the first direction X corresponds to the longitudinal direction of the decorative board 1, and the second direction Y corresponds to the short direction of the decorative board 1, but the first direction X corresponds to the short direction of the decorative board 1. The second direction Y may correspond to the longitudinal direction of the decorative board 1.

  As shown in FIGS. 2 to 5, the decorative board 1 includes a support sheet 2 having a first main surface S1 and a second main surface S2 located on the opposite side of the first main surface S1, and a first of the support sheets 2. The first layer 3 is surrounded by the first layer 3 provided to extend along the first direction X in a part of the main surface S1 and the remaining portion of the first main surface S1 of the support sheet 2. And a second layer 4 provided on the surface.

  As shown in FIG. 2, the planar view shape of the first layer 3 in the present embodiment is a pattern having an elongated outline (contour line) extending in the extending direction D <b> 1 and orthogonal to the extending direction D <b> 1. The dimension in the width direction is gradually expanded from the lower end to the upper end in FIG. 2, reaches the maximum width at the substantially central portion in the extending direction D1, and then gradually decreases.

  As shown in FIGS. 2 to 4, the first layer 3 has a wide portion 31 having a width of 20 μm or more, and the second layer 4 has an opening 40 that exposes at least a part of the wide portion 31. . That is, the wide part 31 in this embodiment is an area | region which has a width | variety of 20 micrometers or more including the center part among the 1st layers 3 which have the elongate shape from which a width | variety changes continuously in planar view. Both end portions of the first layer 3 constitute a narrow portion 32 described later.

  As shown in FIGS. 2 to 4, the opening 40 of the second layer 4 forms a recess 5 on the surface of the decorative plate 1, and at least a part of the bottom of the recess 5 is formed by the wide portion 31. ing.

As shown in FIG. 3, the decorative board 1 is cut by a plane extending in a direction perpendicular to the extending direction D <b> 1 of the first layer 3 through an arbitrary point located on the outline in the plan view of the wide portion 31. In the cut surface formed in this manner, the following conditions are satisfied.
[Feature 1] When the width of the wide portion 31 is WB, the height of the wide portion 31 is HB, and the height of the second layer 4 is H, H> HB and WB ≧ (H−HB).
[Feature 2] At least a part of the wide portion 31 is exposed from the opening 40 of the second layer 4.

  Satisfaction of condition 1 and condition 2 can be confirmed by observing the cut surface with a scanning microscope (SEM). In the present invention, “plan view” refers to observing the target member or part from the normal direction of the first main surface of the support sheet (corresponding to the thickness direction Z in FIGS. 1 to 5). Means. For example, in FIGS. 3 to 5, this means looking down from above toward the same figure. In addition, “plan view” is a virtual concept that treats a target member or portion as observable even when the target member or portion is hidden behind other members or portions and cannot be actually observed. That is, “plan view” corresponds to projecting a target member or part onto a virtual plane perpendicular to the thickness direction Z of the decorative board.

  In the present embodiment, the height of the wide portion 31 on the cut surface is constant. When the height of the wide portion 31 on the cut surface is not constant, the minimum height of the wide portion 31 is set as the height HB of the wide portion 31 on the cut surface. In the present embodiment, the height of the second layer 4 at the cut surface is constant. When the height of the second layer 4 at the cut surface is not constant, the maximum value of the height of the second layer 4 is set as the height H of the second layer 4 at the cut surface.

  The heights H and HB may be measured by uniquely determining a reference (reference point or reference surface) of height = 0 with respect to the decorative board 1, and the reference is arbitrary. In the present embodiment, as shown in FIG. 3, the heights H and HB are measured using the surface on the first main surface S1 side of the decoration layer 22 as a reference (height = 0).

  The difference (H−HB) between the height H of the second layer 4 and the height HB of the wide portion 31 at the cut surface is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 5 μm or more. Although the upper limit of the difference (H−HB) between the height H of the second layer 4 and the height HB of the wide portion 31 at the cut surface is not particularly limited, the design appearance reproducibility of the decorative board 1 is usually a concave portion. When the depth of 5, that is, the difference (H−HB) exceeds a certain level, it tends to saturate, and when the depth of the recess 5 increases to a certain level, the difficulty in manufacturing technology also tends to increase. Therefore, from a practical viewpoint, it is preferable to keep the upper limit of the difference (H−HB) between the height H of the second layer 4 and the height HB of the wide portion 31 to some extent. Specifically, when the decorative layer 22 forms a wood grain pattern and the first layer 3 is aligned with the wood grain pattern conduit portion, the height H of the second layer 4 and the height of the wide portion 31 in the cut surface. The upper limit value of the difference from HB (H−HB) is preferably 50 μm, more preferably 30 μm, and still more preferably 15 μm.

The decorative board 1 is manufactured by a manufacturing method including steps (1) to (4) as described later. A plane extending in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outline of the wide portion 31 in plan view, and cutting the intermediate obtained in the step (3). The following conditions are satisfied in the cut surface formed by:
[Condition 3] When the width of the wide portion 31 is WB and the thickness of the portion CL11 of the coating layer CL that covers the wide portion 31 is TB, WB ≧ TB.

  As a result of the manufacturing method of the decorative sheet 1 satisfying the condition 3, the decorative sheet 1 satisfies the condition 1. Moreover, when the manufacturing method of the decorative board 1 satisfies the condition 3, in the step (4), when the portion CL1 that covers the first layer 3 of the coating layer CL is peeled along the first direction X, the wide portion. The peelability of the portion CL11 covering 31 is improved and stabilized. As a result, the decorative board 1 satisfies the condition 2. When the decorative board 1 satisfies the condition 2, as shown in FIG. 4, the portion of the wide portion 31 exposed from the opening 40 of the second layer 4 exists over the entire wide portion 31. Therefore, the concave portion 5 has a depth reaching the wide portion 31 over the entire region, and the surface height difference between the concave portion 5 and the region other than the concave portion 5 becomes significant.

  On the other hand, as shown in FIG. 5, the decorative plate is a plane extending in a direction perpendicular to the extending direction D <b> 1 of the first layer 3 through an arbitrary point positioned on the outline of the narrow portion 32 in plan view. In the cut surface formed by cutting 1, WN <(H−HN) where WN is the width of the narrow portion 32, HN is the height of the narrow portion 32, and H is the height of the second layer 4. ). For this reason, in the step (4), when the portion CL1 that covers the first layer 3 in the coating layer CL is peeled along the first direction X, the peelability of the portion CL12 that covers the narrow portion 32 decreases. It becomes unstable. Therefore, as shown in FIGS. 2, 4, and 5, the narrow portion 32 is covered with the second layer 4 and is not exposed from the opening 40 of the second layer 4. A part of the narrow portion 32 may be exposed from the opening 40 of the second layer 4, but the portion of the narrow portion 32 exposed from the opening 40 of the second layer 4 is the portion of the narrow portion 32. It does not exist throughout.

  As shown in FIGS. 2 to 4, the portion adjacent to the recess 5 in the surface of the decorative plate 1 is a relatively convex portion, and the surface of the decorative plate 1 has an uneven shape. . As for the decorative board 1 which is the result of the manufacturing method including process (1)-(4) mentioned later, the surface of the recessed part 5 (including the surface of the wide part 31 exposed from the opening part 40 of the 2nd layer 4) is relative. The surface of the region other than the concave portion 5 including the convex portion becomes a mirror surface relatively with the characteristic that the surface is rough and has a low-gloss region having diffuse reflectivity with respect to the incident light. It has a feature of constituting a high-gloss area having reflectivity. Therefore, the decorative board 1 can express a glossy matte design feeling based on the uneven shape. In particular, the decorative board 1 has an excellent gloss matte design feeling by aligning the uneven shape of the decorative board 1 (that is, the high gloss area and the low gloss area) with the pattern of the decorative layer 22 described later. Can be expressed. For example, in the case where the decorative layer 22 forms a wood grain pattern, the concave portion 5 is formed into a conduit portion in the wood grain pattern (that is, a groove portion of a line formed by a cut surface opening of the conduit, also referred to as a conduit groove). The positions of the two portions in plan view are synchronized so that the region other than the concave portion 5 including the convex portion is a region other than the conduit portion in the wood grain pattern (also called a bark portion or the like) By aligning the positions so that the positions in plan view coincide with each other, the conduit portion in the wood grain pattern exhibits a relatively concave appearance, whereby the decorative board 1 has a surface uneven shape similar to a real wood grain pattern. The design feeling (texture) can be expressed.

  Since the concave portion 5 has a depth reaching the wide portion 31 over the entire region, and the surface height difference between the concave portion 5 and the region other than the concave portion 5 is significant, the decorative board 1 is based on a clear concave and convex shape. It is possible to express a glossy matte design feeling and a textured texture (surface texture).

In the decorative plate 1, the entire wide portion 31 may be exposed from the opening 40 of the second layer 4 to form the bottom of the recess 5, but this is not necessarily required. A part of the wide part 31 may be covered with the second layer 4. In particular, when the wide portion 31 is aligned with the wood-patterned conduit portion formed by the decorative layer 22, the portion corresponding to the peripheral portion of the conduit portion of the wide portion 31 may be covered with the second layer. . In addition, within the range in which the unevenness of the concavo-convex shape composed of the concave portion 5 and the convex portion (second layer 4) is sufficiently ensured in terms of visual appearance and there is no practical problem in terms of surface physical properties such as wear resistance. In addition, the second layer may remain in a minute amount as a residue or a trace over the entire surface of the wide portion 31. When a certain wide portion 31 is viewed in plan, the area (S _31P ) of the wide portion 31 exposed from the opening 40 of the second layer 4 is the total area (S _31T ) of the wide portion 31. Is preferably 80% or more, more preferably 90% or more, and still more preferably 95% or more. The area ratio S _31P / S _31T can be adjusted by appropriately selecting the forming material composition and thermoforming conditions of the first layer 3 and the second layer 4, the material of the release film, the release rate, and the like. When the area ratio S _31P / S _31T is within the above range, the surface height difference between the recessed portion 5 and the region other than the recessed portion 5 becomes significant, and the decorative board 1 has a glossy matte design based on a clear uneven shape. It is possible to express the feeling and the design feeling (texture) of the surface uneven shape. For each wide part 31, the area ratio S _31P / S _31T is preferably in the above range.

Further, in a plan view, the ratio (S _31T / S ₃ ) of the total area (S _31T ) of the wide portion 31 in the first layer 3 to the total area (S ₃ ) of a single first layer 3 is Since it also depends on the type of pattern expressed by the first layer 3 and the formation ratio of the recess 5 in the wide portion 31 described above, it cannot be specified unconditionally. As a design guideline regarding the ratio, when the first layer 3 represents a wood grain-shaped conduit portion, considering the formation ratio of the concave portion 5 in the wide portion 31 described above, (S _31T / S ₃ ) is 80%. Preferably, it is 90% or more, and more preferably 95% or more. For each of the first layer 3, it is preferable that the area ratio _S 31T / _{S 3} within the above range.

  As shown in FIGS. 3 to 5, the decorative board 1 further includes a reinforcing layer 6 provided on the second main surface S <b> 2 of the support sheet 2. In addition, embodiment with which the reinforcement layer 6 is not provided in 2nd main surface S2 of the support sheet 2 is also included by this invention.

The support sheet support sheet 2 is a sheet that supports the first layer 3 and the second layer 4.
As shown in FIGS. 3 to 5, the support sheet 2 includes a base sheet 21 having a first main surface T <b> 1 and a second main surface T <b> 2 located on the opposite side of the first main surface T <b> 1, and the base sheet 21. And a decorative layer 22 provided on the first main surface T1.

As shown in FIGS. 3 to 5, the base sheet 21 has a first main surface T <b> 1 located on the first main surface S <b> 1 side of the support sheet 2, and a second main surface T <b> 2 of the support sheet 2. It arrange | positions so that it may be located in 2 main surface S2 side. In the present embodiment, the second main surface T2 of the base sheet 21 forms the second main surface S2 of the support sheet 2.

Although the base material sheet 21 is not specifically limited, Preferably, it is a porous sheet. The porous sheet is not particularly limited as long as it has liquid permeability. When the base sheet 21 has liquid permeability, for example, the base sheet 21 can be impregnated with a resin composition used as a raw material for forming the second layer 4. As a porous sheet, a fiber sheet etc. are mentioned, for example. Examples of the fiber sheet include paper, non-woven fabric, and woven fabric. Examples of the paper include thin paper, kraft paper, titanium paper, linter paper, paperboard, high-quality paper, coated paper, parchment paper, and Japanese paper. Examples of other fiber sheets include sheets composed of inorganic fibers such as glass fibers, asbestos, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers. The porous sheet is preferably titanium paper, thin paper, kraft paper, Japanese paper, or the like, more preferably titanium paper, from the viewpoint of liquid impregnation. Although the basic weight of the base material sheet 21 can be suitably adjusted with the use of a final product, a usage method, etc., it is 40-150 g / m < ² >, for example. Although the thickness of the base material sheet 21 can be suitably adjusted with the use of a final product, a usage method, etc., it is 50-170 micrometers, for example. In the present specification, a numerical range expressed as “numerical value A to numerical value B” is a numerical range in which the numerical value A is an upper limit value and the numerical value B is a lower limit value (that is, a numerical value), unless otherwise specified. Numerical value range including A and numerical value B).

  When the base material sheet 21 is a porous sheet, it is preferable that the void of the porous sheet is filled with a cured product of a curable resin. Thereby, the intensity | strength of the decorative board 1 can be improved. When the 2nd layer 4 contains the hardened | cured material of curable resin, the hardened | cured material of the curable resin with which the space | gap of the porous sheet was filled is integrated with the hardened | cured material of the curable resin contained in the 2nd layer 4. Preferably it is. Thereby, the joint strength between the support sheet 2 and the second layer 4 can be improved. For example, when forming the second layer 4, the curable resin composition that is a raw material for forming the second layer 4 is impregnated into the porous sheet and cured, so that the curable resin filled in the voids of the porous sheet is filled. And the cured product of the curable resin contained in the second layer 4 can be integrated.

  In the present invention, the porous sheet used as the base sheet 21 is not filled with a cured product of a curable resin, and the base sheet 21 is made of a curable resin in the porous sheet. Although the cured product is filled, the cured product of the curable resin filled in the voids of the porous sheet is not integrated with the cured product of the curable resin included in the second layer 4. Is done.

  The base material sheet 21 may be colored. In the production stage of the base sheet 21 (for example, if the base sheet 21 is paper, the paper making stage), the base sheet 21 can be colored by blending a colorant (pigment or dye) with the forming raw material. it can. Moreover, when forming the 2nd layer 4, the base material sheet 21 is colored by using the resin composition containing a coloring agent as a forming raw material of the 2nd layer 4, and making the base material sheet 21 impregnate this. be able to. Examples of the colorant include carbon black, iron black, titanium white, antimony white, yellow lead, titanium yellow, petal, cadmium red, ultramarine, cobalt blue, and other inorganic pigments; quinacridone red, isoindolinone yellow Organic pigments or dyes composed of particles such as phthalocyanine blue; Metal pigments composed of scaly foils such as aluminum and brass; Pearlescent pigments composed of scaly foils such as titanium dioxide-coated mica and basic lead carbonate Etc. A coloring agent may be used individually by 1 type, and may be used in combination of 2 or more type. The blending amount of the colorant can be appropriately adjusted according to a desired color tone or the like.

  The base sheet 21 may contain additives such as a filler, a matting agent, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, and a light stabilizer as necessary. .

Decoration Layer As shown in FIGS. 3 to 5, the decoration layer 22 is provided on the first main surface T <b> 1 of the base sheet 21. The decoration layer 22 may be formed on the entire first main surface T1 of the base sheet 21 or may be formed on a part of the first main surface T1 of the base sheet 21. When the decoration layer 22 is formed on the entire first main surface T <b> 1 of the base sheet 21, the first main surface S <b> 1 of the support sheet 2 is formed by the surface of the decoration layer 22. When the decoration layer 22 is formed on a part of the first main surface T1 of the base sheet 21, the first main surface S1 of the support sheet 2 is a part of the first main surface T1 of the base sheet 21 (decoration layer). The portion 22 is not provided) and the surface of the decorative layer 22.

  In addition, embodiment by which the decoration layer 22 is not formed in 1st main surface T1 of the base material sheet 21 is also included by this invention. In the embodiment in which the decoration layer 22 is not formed on the first main surface T <b> 1 of the base sheet 21, the first main surface S <b> 1 of the support sheet 2 is formed by the first main surface T <b> 1 of the base sheet 21.

  The decorative layer 22 imparts decorative properties (design properties) to the decorative board 1. The decoration layer 22 is, for example, a colored layer, a picture layer, or a combination thereof.

  The colored layer imparts a desired color to the decorative board 1. The colored layer is, for example, a full surface solid layer formed on the entire first main surface T1 of the base sheet 21. The color of the colored layer is usually an opaque color, but may be a transparent color in the case where a base color or pattern such as the substrate sheet 21 is utilized. In addition, when the base color or pattern of the base material sheet 21 or the like is utilized, the colored layer may not be formed.

  The pattern layer gives a desired pattern to the decorative board 1. The pattern layer is, for example, a printed layer formed on a part or the whole of the first main surface T1 of the base sheet 21 or a part or the whole of the surface of the colored layer. Examples of the patterns that make up the pattern layer include stones on the surface of stone such as spring and autumn wood areas, cross-sections of wood rings, leather (leather) patterns, marble, granite, sandstone, etc. Eye patterns, grain patterns, tiled patterns, brickwork patterns, cloth patterns, geometric figures, characters, symbols, abstract patterns, and the like can be mentioned.

  As shown in FIG. 1, the decorative layer 22 in the present embodiment gives a wood grain pattern to the decorative board 1.

  Although the thickness of the decoration layer 22 can be suitably adjusted according to a product characteristic etc., it is 0.1-20 micrometers, for example.

The first layer 1 corresponds to the release layer described in Patent Document 5 (International Publication No. 2016/148091).

  As shown in FIG. 2, the first layer 3 extends along the first direction X in plan view. “The first layer 3 extends along the first direction X” means that the angle between the extending direction D1 of the first layer 3 and the first direction X of the decorative board 1 is ± 30 ° or less. It means that there is. The extending direction D1 of the first layer 3 corresponds to the longitudinal direction of a rectangle circumscribing the outline of the first layer 3 in plan view. In the present embodiment, the extending direction D1 of the first layer 3 coincides with the first direction X of the decorative board 1. An embodiment in which the angle formed between the extending direction D1 of the first layer 3 and the first direction X of the decorative board 1 is + 30 ° is shown in FIG. 6. The extending direction D1 of the first layer 3 and the decorative board 1 FIG. 7 shows an embodiment in which the angle formed by the first direction X is −30 °.

  When manufacturing the decorative board 1 by the manufacturing method including the steps (1) to (4) described later, in the step (4), the portion CL1 of the coating layer CL that covers the first layer 3 is along the first direction X. And peeled off. When the angle between the extending direction D1 of the first layer 3 and the first direction X of the decorative board 1 is ± 30 ° or less, the extending direction D1 of the first layer 3 is As in the case of matching with the first direction X, in the step (4), the portion covering the wide portion 31 when the portion CL1 covering the first layer 3 of the coating layer CL is peeled along the first direction X. The peelability of CL11 is improved and stabilized.

  As shown in FIG. 2, the first layer 3 includes a wide portion 31 having a width of 20 μm or more and 100 μm or less, and a narrow portion 32 having a width of less than 20 μm. The maximum width of the wide portion 31 is not particularly limited as long as it is 20 μm or more and 100 μm or less. However, when the decorative layer 22 forms a wood grain pattern and the first layer 3 is aligned with the wood grain pattern conduit, the maximum width of the wide section 31 is obtained. The significant is preferably 30 μm or more and 100 μm or less. The minimum width of the narrow portion 32 is zero. In the present embodiment, the minimum width of the wide portion 31 is 20 μm, but the minimum width of the wide portion 31 may exceed 20 μm. In the present embodiment, the first layer 3 includes the wide portion 31 and the narrow portion 32, but the first layer 3 may include only the wide portion 31. In the present embodiment, the wide portion 31 has a minimum width and a maximum width, but the width of the wide portion 31 may be constant.

  The width of the first layer 3 is defined as follows. As shown in FIGS. 2, 6, and 7, in a plan view, an arbitrary point located on the outline of the first layer 3 is P, the first line 3 passes through the outline and the point P, and the first The distance between the point P and the point Q is the width W of the first layer 3 where Q is the intersection point with a straight line extending in the direction perpendicular to the extending direction D1 of the layer 3. When an arbitrary point P is located on the outline of the wide portion 31, the distance (width W) between the point P and the point Q is 20 μm or more, and the arbitrary point P is located on the outline of the narrow portion 32 The distance (width W) between point P and point Q is less than 20 μm.

  As shown in FIGS. 3 to 5, the first layer 3 is provided on a part of the first main surface S <b> 1 of the support sheet 2 in a desired pattern, for example. The first layer 3 has a portion whose thickness is smaller than that of the adjacent second layer 4, and at least a part of this portion is exposed from the opening 40 of the adjacent second layer 4, and the decorative plate The bottom of the concave portion 5 on the surface of 1 is formed.

  Of the first main surface S1 of the support sheet 2, the region where the first layer 3 is provided may be one continuous region or a plurality of discontinuous regions. The first layer 3 may be composed of one continuous layer, or may be composed of a plurality of discontinuous layers. When the first layer 3 is composed of one continuous layer, the thickness of the first layer 3 may be constant or may be partially different. When the first layer 3 is composed of a plurality of discontinuous layers, the thickness of each layer may be constant or may be partially different. When the first layer 3 is composed of a plurality of discontinuous layers, the thickness of one layer and the thickness of another layer may be the same or different. Although the thickness of the 1st layer 3 is not specifically limited, Preferably it is 0.1-100 micrometers, More preferably, it is 1-20 micrometers.

  The first layer 3 is, for example, a resin layer. Examples of the resin layer include a cured resin layer and a thermoplastic resin layer. The first layer 3 may include two or more types of layers made of different materials.

  The cured resin layer is a layer formed by curing the curable resin composition, and includes a cured product of the curable resin. Examples of the curable resin contained in the curable resin composition include a thermosetting resin and an ionizing radiation curable resin. From the viewpoint of surface hardness (scratch resistance), convex shape retention, productivity, etc., it is preferable that at least a part of the curable resin contained in the curable resin composition is an ionizing radiation curable resin, and the curable resin composition More preferably, all of the curable resin contained in the product is an ionizing radiation curable resin.

  The first layer 3 is preferably formed in a predetermined pattern on the first main surface S1 of the support sheet 2, and is visually concave or low glossy (matte) in the pattern formed by the decorative layer 22. More preferably, it is formed in a pattern that is aligned with the desired region. As the pattern formed by the first layer 3, for example, when the decorative layer 22 is a wood grain pattern, a concave part of a wood grain plate, a concave part such as a spring wood area or a low gloss area, and a stone pattern, a concave part of a travertine marble board , Stone surface irregularities such as crevice on the cleaved surface of granite plate, cloth surface texture in the case of textured pattern, leather wrinkle shape in the case of leather pattern, joint recess in the case of tiled pattern or brickwork pattern, etc. In addition, there are patterns such as satin, grain, hairline, ridges, letters, symbols, and geometric patterns.

  The first layer 3 may contain a silicone release agent. The silicone release agent contained in the first layer 3 is derived from a silicone release agent (silicone oil) added to the raw material for forming the first layer 3. The silicone release agent added to the raw material for forming the first layer 3 may be a reactive silicone release agent or a non-reactive silicone release agent. In the case where the silicone release agent added to the raw material for forming the first layer 3 is a reactive silicone release agent, the silicone release agent is used as the other component of the first layer 3 (for example, the curable resin). 1st layer 3 in the state couple | bonded with hardened | cured material etc.). A silicone type mold release agent may be used individually by 1 type, and may be used in combination of 2 or more type.

2nd layer As shown in FIGS. 3-5, the 2nd layer 4 is provided in the remainder of 1st main surface S1 of the support sheet 2 so that a part or whole of the 1st layer 3 may be surrounded. . The “remaining portion of the first main surface S1” means a region of the first main surface S1 of the support sheet 2 where the first layer 3 is not provided. Of the first main surface S1 of the support sheet 2, the region where the second layer 4 is provided may be the entire remaining portion of the first main surface S1 or a part of the remaining portion of the first main surface S1. May be. For example, when a layer other than the first layer 3 (for example, a layer composed only of a narrow portion having a width of less than 20 μm) is provided on a part of the first main surface S1 of the support sheet 2, The region where the layer 4 is provided is a part of the remaining portion of the first main surface. Of the first main surface S1 of the support sheet 2, the region where the second layer 4 is provided may be one continuous region or a plurality of discontinuous regions. The second layer 4 may be composed of one continuous layer, or may be composed of a plurality of discontinuous layers. When the second layer 4 is composed of one continuous layer, the thickness of the second layer 4 may be constant or may be partially different. When the second layer 4 is composed of a plurality of discontinuous layers, the thickness of each layer may be constant or may be partially different. When the second layer 4 is composed of a plurality of discontinuous layers, the thickness of one layer and the thickness of another layer may be the same or different. In addition, from the point of clarification of the contour shape of the concavo-convex shape that appears on the surface of the decorative board 1 and securing the surface height difference between the first layer 3 and the second layer 4, the second layer It is preferable that 4 does not remain at all. However, it may be difficult to completely remove and remove the precursor layer (covering layer CL) of the second layer 4 once formed on the first layer 3 without any trace or residue. In that case, the height difference of the concave and convex shape composed of the concave portion 5 and the convex portion (second layer 4) is sufficiently ensured in visual appearance, and within the range where there is no practical problem in terms of surface physical properties such as wear resistance. The second layer can be allowed to remain in a minute amount as a residue or a trace over the entire surface of the first layer 3.

  The area (Sa) of the region where the second layer 4 is provided in the first main surface S1 of the support sheet 2 and the area where the first layer 3 is provided in the first main surface S1 of the support sheet 2 ( The ratio (Sa: Sb) to Sb) is preferably 3: 7 to 9: 1, more preferably 5: 5 to 8: 2. When the area ratio is within the above-described range, the design of the uneven shape expressed by the decorative board 1 becomes clearer.

  As shown in FIGS. 2 to 4, the second layer 4 has an opening 40 that exposes at least a part of the wide portion 31. As shown in FIG. 4, the portion of the wide portion 31 exposed from the opening 40 of the second layer 4 exists over the entire wide portion 31. As shown in FIG. 2, the opening 40 of the second layer 4 is aligned with the wide portion 31 in plan view. In the present invention, “position tuning” means that the entire wide portion 31 overlaps at least a part of the opening 40 in plan view. The opening 40 may have a portion that does not overlap the wide portion 31 in plan view. For example, the opening 40 may have a portion that overlaps the narrow portion 32 in plan view.

  As shown in FIGS. 2 to 4, the opening 40 of the second layer 4 forms a recess 5 on the surface of the decorative plate 1. At least a part of the bottom of the recess 5 is formed by the wide portion 31.

  The depth of the recessed part 5 becomes like this. Preferably it is 1-50 micrometers, More preferably, it is 2-30 micrometers. When the depth of the concave portion 5 is within the above-described range, the design feeling of the concave and convex shape expressed by the decorative board 1 becomes clearer.

  The depth of the recessed part 5 is the area | region (area | region where the 2nd layer 4 is formed) in which the 1st layer 3 is formed among the surfaces of the decorative board 1, and the area | region (the 1st layer 3 is formed). It is measured as the difference in height from the portion CL of the covering layer CL where the portion CL11 covering the wide portion 31 is peeled off. The measurement is performed according to a method defined in JIS B 0601: 2013 using a three-dimensional surface roughness measuring device SE-30K manufactured by Kosaka Laboratory. The maximum height roughness (Rz) of the surface is used as a height difference parameter, and the average value at 10 locations is defined as “height difference”.

  The second layer 4 is, for example, a resin layer. Examples of the resin layer include a cured resin layer and a thermoplastic resin layer. The second layer 4 may include two or more types of layers made of different materials.

  The cured resin layer is a layer formed by curing the curable resin composition, and includes a cured product of the curable resin. Examples of the curable resin contained in the curable resin composition include a thermosetting resin and an ionizing radiation curable resin. When the first layer 3 is a cured resin layer formed by curing the ionizing radiation curable resin composition, the second layer 4 is a cured resin layer formed by curing the thermosetting resin composition. Is preferred.

  Although the thickness of the 2nd layer 4 is not specifically limited, Preferably it is 2-250 micrometers, More preferably, it is 2-50 micrometers.

  The second layer may include a silicone release agent. The silicone release agent contained in the second layer 4 is derived from a silicone release agent (silicone oil) added to the raw material for forming the second layer 4. The silicone release agent added to the raw material for forming the second layer 4 may be a reactive silicone release agent or a non-reactive silicone release agent. It is a non-reactive silicone release agent. In the case where the silicone release agent added to the raw material for forming the second layer 4 is a reactive silicone release agent, the silicone release agent is used as the other component of the second layer 4 (for example, the curable resin). The second layer 4 may be included in a state of being bonded to a cured product or the like. A silicone type mold release agent may be used individually by 1 type, and may be used in combination of 2 or more type.

  A water-curable thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.), it is preferable to use polyether-modified silicone as the silicone-based mold release agent. Since the polyether-modified silicone has properties such as water solubility and water dispersibility, when the silicone-based release agent is a polyether-modified silicone, the silicone-based release agent is miscible with the water-soluble thermosetting resin composition. This makes it easy to effectively exhibit the release properties of the silicone release agent while preventing localization of the silicone release agent. The second layer 4 may contain a non-reactive silicone other than the polyether-modified silicone. Non-reactive silicones other than polyether-modified silicones may be used alone or in combination of two or more.

A water-curable thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.) as a silicone release agent, a silicone release agent having an HLB value of 6 or more and 16 or less (particularly a polyether-modified silicone having an HLB value of 6 or more and 16 or less) Is preferably used. The HLB value of the silicone release agent is more preferably 10 or more and 15 or less, and still more preferably 12 or more and 14 or less. The higher the HLB value, the easier it is to mix the silicone release agent with the water-soluble thermoplastic resin, and the localization of the silicone release agent can be prevented. However, if the HLB value is too high, The mold releasability may be reduced. When the HLB value of the silicone release agent is within the above range, the release property of the silicone release agent can be effectively exhibited while preventing the localization of the silicone release agent. In addition, HLB (hydrophilic lipophilic balance: Hydrophile-Lypophile Balance) value is a value which shows the affinity to water and oil of surfactant, and can be calculated | required from following Formula by the Griffin method.
HLB = 20 × [(molecular weight of hydrophilic group contained in surfactant) / (molecular weight of surfactant)]

As a raw material for forming the thermosetting resin composition first layer 3 and / or the second layer 4, a thermosetting resin composition can be used. In particular, it is preferable to use a thermosetting resin composition as a raw material for forming the second layer 4. Examples of the thermosetting resin contained in the thermosetting resin composition include unsaturated polyester resin, polyurethane resin (including two-component curable polyurethane), epoxy resin, amino alkyd resin, phenol resin, urea resin, and diallyl phthalate. Examples thereof include resins, melamine resins, guanamine resins, melamine-urea cocondensation resins, silicon resins, polysiloxane resins, and the like. The thermosetting resin composition used as a raw material for forming the second layer 4 preferably contains a melamine resin. A melamine resin is preferable in that it has heat resistance and stain resistance and has high hardness.

  The thermosetting resin composition may contain a component involved in the curing reaction of the thermosetting resin, for example, a catalyst, a curing agent (including a crosslinking agent, a polymerization initiator, a polymerization accelerator, and the like) as necessary. Good. For example, curing agents such as unsaturated polyester resins and polyurethane resins include isocyanates and organic sulfonates, and curing agents such as epoxy resins include organic amines, and radical initiation of unsaturated polyester resins. Examples of the agent include peroxides such as methyl ethyl ketone peroxide, and azoisobutyl nitrile.

As a material for forming the ionizing radiation curable resin composition first layer 3 and / or the second layer 4, an ionizing radiation curable resin composition can be used. In particular, it is preferable to use an ionizing radiation curable resin composition as a raw material for forming the first layer 3. The ionizing radiation curable resin contained in the ionizing radiation curable resin composition is a resin that undergoes a crosslinking polymerization reaction upon irradiation with ionizing radiation and changes to a three-dimensional polymer structure. Examples of the ionizing radiation include visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), X-rays, electron beams, ion beams, and the like, preferably ultraviolet light and electron beams.

  Examples of the ionizing radiation curable resin contained in the ionizing radiation curable resin composition include, for example, a monomer having a polymerizable unsaturated bond, epoxy group or the like that can be cross-linked by irradiation with ionizing radiation in the molecule, an oligomer, a prepolymer, etc. One or more can be used. In particular, it is preferable to use one or more of polyfunctional monomers and oligomers. Examples of the ionizing radiation curable resin include acrylate resins such as urethane acrylate, polyester acrylate, and epoxy acrylate, silicon resins such as siloxane, polyester resins, and epoxy resins.

  Examples of the polymerizable monomer include (meth) acrylate monomers having a radically polymerizable unsaturated group in the molecule. In particular, polyfunctional (meth) acrylate is preferable. “(Meth) acrylate” means acrylate or methacrylate. The polyfunctional (meth) acrylate is not particularly limited as long as it is a (meth) acrylate having two or more ethylenically unsaturated bonds in the molecule. A polyfunctional (meth) acrylate may be used individually by 1 type, and may be used in combination of 2 or more type. A monofunctional (meth) acrylate may be used in combination with the polyfunctional (meth) acrylate for the purpose of reducing the viscosity.

  Examples of the polymerizable oligomer include oligomers having radically polymerizable unsaturated groups in the molecule, such as epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, and polyether (meth) acrylate. Can be mentioned. Polymerizable oligomers include polybutadiene (meth) acrylate oligomers with high hydrophobicity that have (meth) acrylate groups in the side chains of polybutadiene oligomers, silicone (meth) acrylate oligomers with polysiloxane bonds in the main chain, small An aminoplast resin (meth) acrylate oligomer obtained by modifying an aminoplast resin having many reactive groups in the molecule can be used. Examples of the oligomer having a cationically polymerizable functional group in the molecule include novolak type epoxy resins, bisphenol type epoxy resins, aliphatic vinyl ethers, and aromatic vinyl ethers.

  The weight average molecular weight of the ionizing radiation curable resin is preferably 500 or more, more preferably 1000 or more. When the first layer 3 and / or the second layer 4 is formed when the weight average molecular weight of the ionizing radiation curable resin is within the above range, the curable resin composition used as a forming raw material is formed on the base sheet 21. Since it is difficult to penetrate, the first layer 3 and / or the second layer 4 are easily formed. This effect is great when the substrate sheet 21 is a porous sheet.

  The weight average molecular weight of the ionizing radiation curable resin is preferably 80000 or less, and more preferably 50000 or less. When the weight average molecular weight of the ionizing radiation curable resin is in the above range, it is easy to adjust the viscosity of the resin composition to a viscosity suitable for coating.

  The “weight average molecular weight” is a value measured using polystyrene as a standard substance by gel permeation chromatography (GPC).

  The ionizing radiation curable resin is preferably at least one selected from polyfunctional monomers and oligomers having a weight average molecular weight of 500 or more. Examples of such polyfunctional monomers or oligomers include acrylate resins such as dipentaerythritol hexaacrylate, dipentaerythritol pentaacrylate, urethane acrylate, polyester acrylate, and epoxy acrylate.

  The ionizing radiation curable resin composition may contain a component involved in the curing reaction of the ionizing radiation curable resin, for example, a photopolymerization initiator (sensitizer), if necessary. For example, when the ionizing radiation curable resin composition is cured by irradiation with ultraviolet rays, the ionizing radiation curable resin composition preferably contains a photopolymerization initiator (sensitizer). In addition, since the ionizing radiation curable resin is sufficiently cured when irradiated with an electron beam, when the ionizing radiation curable resin composition is cured by irradiation with an electron beam, the ionizing radiation curable resin composition is a photopolymerization initiator ( (Sensitizer) may not be included.

  When the ionizing radiation curable resin has a radically polymerizable unsaturated group, examples of the photopolymerization initiator include acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler benzoylbenzoate, Michler ketone, diphenyl sulfide, At least one of dibenzyl disulfide, diethyl oxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate and the like can be used. In addition, when the ionizing radiation curable resin composition has a cationic polymerizable functional group, examples of the photopolymerization initiator include aromatic diazonium salts, aromatic sulfonium salts, metallocene compounds, benzoin sulfonic acid esters, and freeloxy sulfone. At least one kind such as xonium diallyl iodosyl salt can be used.

  Although the addition amount of a photoinitiator is not specifically limited, It is 0.1-10 mass parts normally with respect to 100 mass parts of ionizing radiation curable resins.

  The ionizing radiation curable resin composition preferably contains a polyfunctional polymerizable monomer in order to improve heat resistance and crosslinking density.

As a raw material for forming the thermoplastic resin composition first layer 3 and / or the second layer 4, a thermoplastic resin composition can be used. Examples of the thermoplastic resin contained in the thermoplastic resin composition include polyester resins (for example, polyethylene terephthalate, polybutylene terephthalate, etc.), (meth) acrylic resins, polyolefin resins (for example, polyethylene (high density, medium density or Low density), polypropylene (isotactic or syndiotactic), polybutene, ethylene-propylene copolymer, ethylene-propylene-butene copolymer, etc.), polyvinyl chloride resin, polystyrene, ABS resin, polycarbonate resin, Polyamide resin etc. are mentioned.

Silicone Release Agent A silicone release agent may be included in the first layer 3 and / or the second layer 4. The silicone-based mold release agent is a modified silicone having an organopolysiloxane structure as a basic structure and having an organic group introduced into the side chain and / or terminal. The end into which the organic machine is introduced may be one end or both ends.

  The reactive silicone release agent refers to a modified silicone having an organic group introduced into the side chain and / or the terminal thereof, which has reactivity depending on the nature of the organic group to be introduced. Examples of the reactive silicone release agent include amino-modified silicone, epoxy-modified silicone, mercapto-modified silicone, carboxyl-modified silicone, carbinol-modified silicone, phenol-modified silicone, methacryl-modified silicone, and different functional group-modified silicone. . More specifically, amino-modified polydimethylsiloxane, epoxy-modified polydimethylsiloxane, mercapto-modified polydimethylsiloxane, carboxyl-modified polydimethylsiloxane, carbinol-modified polydimethylsiloxane, phenol-modified polydimethylsiloxane, methacryl-modified polydimethylsiloxane, heterogeneous Examples thereof include functional group-modified polydimethylsiloxane. A reactive silicone type mold release agent may be used individually by 1 type, and may be used in combination of 2 or more type.

  The non-reactive silicone release agent is not particularly limited as long as it is a silicone having no reactive functional group such as amino group, epoxy group, mercapto group, carboxy group, hydroxy group, (meth) acryloyl group, and allyl group. Examples of the non-reactive silicone release agent include, in addition to silicone made of polysiloxane, polyether modified silicone, aralkyl modified silicone, fluoroalkyl modified silicone, long chain alkyl modified silicone, higher fatty acid ester modified silicone, higher fatty acid amide. Examples thereof include modified silicone and phenyl-modified silicone. More specifically, polyether-modified polydimethylsiloxane, aralkyl-modified polydimethylsiloxane, fluoroalkyl-modified polydimethylsiloxane, long-chain alkyl-modified polydimethylsiloxane, higher fatty acid ester-modified polydimethylsiloxane, higher fatty acid amide-modified polydimethylsiloxane, Examples include phenyl-modified polydimethylsiloxane. One type of non-reactive silicone release agent may be used alone, or two or more types may be used in combination.

A thermosetting resin composition is used as a raw material for forming the polyether-modified silicone second layer 4, and the thermosetting resin composition is a water-soluble thermoplastic resin composition (for example, melamine resin, urea resin, sulfonamide resin, glyoxal). In the case of including a resin, a guanamine resin, etc.), it is preferable to use a polyether-modified silicone as the silicone-based mold release agent contained in the second layer 4. The polyether-modified silicone has a main chain of polysiloxane and has one or more polyoxyalkylene groups as substituents. The main chain may form a ring.

  The bonding position of the polyoxyalkylene group in the polyether-modified silicone can be any suitable bonding position. For example, the polyoxyalkylene group may be bonded to both ends of the main chain, may be bonded to one end of the main chain, or may be bonded to a side chain. The polyether-modified silicone is preferably a side-chain polyether-modified silicone in which a polyoxyalkylene group is bonded to a side chain.

  The side chain type polyether-modified silicone is represented, for example, by the general formula (1).

In general formula (1), each R independently represents an alkyl group having 1 to 3 carbon atoms, R ¹ represents an alkylene group having 1 to 4 carbon atoms, and R ² represents a hydrogen atom or 1 to 15 carbon atoms. It represents an alkyl group, ^{R 3} is _{- (C 2 H 4 O)} a - (C 3 H 6 O) b - a polyoxyalkylene group represented, a is 1 to 50, b is 0 30, m is 1 to 7000, and n is 1 to 50.

  In general formula (1), R is preferably a methyl group.

  Examples of the polyether-modified silicone include trade names “KF-6011” (HLB: 14.5), “KF-6011P” (HLB: 14.5), “KF-6012” (manufactured by Shin-Etsu Silicone Co., Ltd.). HLB: 7.0), “KF-6013” (HLB: 10.0), “KF-6015” (HLB: 4.5), “KF-6016” (HLB: 4.5), “KF-6017 (HLB: 4.5), "KF-6017P" (HLB: 4.5), "KF-6043" (HLB: 14.5), "KF-6004" (HLB: 9.0), "KF351A ”(HLB: 12),“ KF352A ”(HLB: 7),“ KF353 ”(HLB: 10),“ KF354L ”(HLB: 16),“ KF355A ”(HLB: 12),“ KF615A ”(HLB: 10) ), KF945 (HLB: 4), KF-640 (HLB: 14), KF-642 (HLB: 12), KF-643 (HLB: 14), KF-644 (HLB: 11) ), “KF-6020” (HLB: 4), “KF-6204” (HLB: 10), “X22-4515” (HLB: 5), etc., side chain type (linear type) polyether-modified silicone oil; Side-chain type (branched chain type) polyether-modified silicone oil such as “KF-6028” (HLB: 4.0) and “KF-6028P” (HLB: 4.0) manufactured by Shin-Etsu Silicone Co., Ltd .; Examples include a side chain type (branched chain type, alkyl co-modified type) polyether-modified silicone oil such as a trade name “KF-6038” (HLB: 3.0) manufactured by Shin-Etsu Silicone Co., Ltd.

The reinforcing layer reinforcing layer 6 is a layer that reinforces the decorative board 1. 3-5, the reinforcement layer 6 is laminated | stacked on the main surface on the opposite side to the 1st layer 3 and the 2nd layer 4 among the main surfaces of the support sheet 2, ie, 2nd main surface S2. Yes. The reinforcing layer 6 includes, for example, a porous sheet and a cured product of a thermosetting resin that exists in the voids of the porous sheet. The reinforcing layer 6 can be formed, for example, by heating a thermosetting resin-impregnated sheet and curing the thermosetting resin. Examples of thermosetting resins include unsaturated polyester resins, polyurethane resins (including two-component curable polyurethane), epoxy resins, amino alkyd resins, phenol resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, and melamines. -Urea co-condensation resin, silicon resin, polysiloxane resin and the like. Examples of the thermosetting resin-impregnated sheet include phenol resin-impregnated paper that is widely used as core paper for melamine resin decorative boards and the like.

The phenol resin-impregnated paper is usually a paper manufactured by impregnating a kraft paper having a basis weight of 150 to 250 g / m ^{2 with} a phenol resin so that the impregnation rate is 45 to 60% and drying at 100 to 140 ° C. is there. A commercially available product can be used for the phenol resin-impregnated paper. When the phenol resin impregnated paper is laminated, the second main surface S2 of the support sheet 2 may be subjected to corona discharge treatment or a primer layer may be formed as necessary.

  The decorative board 1 may have the other reinforcement layer laminated | stacked on one or both among the both surfaces of the reinforcement layer 6, as needed. For example, when the decorative board 1 is a melamine resin decorative board, so-called titanium mixed with a titanium white pigment is used to conceal that the black-brown color tone of the core paper used as the reinforcing layer 6 is seen through the decorative board surface. A barrier paper made of paper can be laminated between the core paper and the support sheet 2. Further, in order to cancel the warping of the decorative plate 1 that occurs during hot-press molding, a balance paper made of titanium paper or the like is used as the back surface of the reinforcing layer 6 (the surface opposite to the second main surface S2 of the support sheet 2). ). These other reinforcing layers are impregnated with an uncured resin composition containing a thermosetting resin such as a melamine resin and then hot-press molded together with the other layers (for example, the support sheet 2). Can be integrated with the other layers.

The adhesive layer decorative board 1 may have an adhesive layer as necessary. The adhesive layer can be formed, for example, between the support sheet 2 and the first layer 3 and / or between the support sheet 2 and the second layer 4 in order to increase the adhesion of these layers. . The adhesive layer is preferably a transparent adhesive layer. “Transparency” includes any of colorless and transparent, colored and transparent, translucent and the like.

  An adhesive agent is not specifically limited, A well-known adhesive agent in the field of a decorative board can be selected suitably, and can be used. Examples of the adhesive include thermoplastic resins such as polyamide resin, acrylic resin and vinyl acetate resin, and thermosetting resins such as urethane resin. An adhesive agent may be used individually by 1 type, and may be used in combination of 2 or more type. Further, a two-component curable polyurethane resin or polyester resin using isocyanate as a curing agent can also be used.

  Although the thickness of an adhesive bond layer is not specifically limited, The thickness after drying is 0.1-30 micrometers, for example, Preferably it is 1-20 micrometers.

The primer layer decorative board 1 has a primer layer on the second main surface S2 of the support sheet 2 and the back surface of the reinforcing layer 6 (the surface opposite to the second main surface S2 of the support sheet 2) as necessary. You may do it. Providing the primer layer is useful when, for example, the decorative plate 1 and the adherend are laminated to produce a decorative member. Examples of the adherend include plate materials of various materials, plate materials such as curved plates, three-dimensional articles, sheets (or films), and the like. Specifically, wood members used as plate materials such as wood fiber boards such as wood veneer, wood plywood, particle board, MDF (medium density fiber board), and three-dimensional shaped articles; plate materials such as iron and aluminum and steel plates , Metal members used as three-dimensional articles or sheets; glass materials, ceramics such as ceramics, non-cement ceramic materials such as gypsum, non-ceramic ceramic materials such as ALC (lightweight cellular concrete) plates and three-dimensional materials Ceramic materials used as shaped articles, etc .; polyolefin resins such as acrylic resin, polyester resin, polystyrene resin, polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) resin, phenol resin, vinyl chloride resin, cellulose resin, Resin members used as plates such as rubber, three-dimensional shaped articles, or sheets It is below. Moreover, these members can be used individually by 1 type or in combination of 2 or more types.

  The adherend may be appropriately selected according to the application, and uses for interior / exterior members such as walls, ceilings and floors, window frames, doors, handrails, skirting boards, edges, and malls. In such a case, a wood member, a metal member, a resin member, or a combination of these members is preferable. What is necessary is just to select the thickness of a to-be-adhered material suitably according to a use and material, and is 0.1-5 mm normally, Preferably it is 0.1-3 mm.

  The primer layer can be formed by applying a known primer agent to the second main surface S2 of the support sheet 2, the back surface of the reinforcing layer 6 (the surface opposite to the second main surface S2 of the support sheet 2), and the like. Examples of the primer agent include a urethane resin-based primer agent made of an acrylic-modified urethane resin (acrylic urethane resin), a urethane-cellulose resin (for example, a resin obtained by adding hexamethylene diisocyanate to a mixture of urethane and nitrified cotton) ), A resinous primer agent made of a block copolymer of acrylic and urethane, and the like. You may mix | blend an additive with a primer agent as needed. Examples of the additive include a filler such as calcium carbonate and clay, a flame retardant such as magnesium hydroxide, an antioxidant, a lubricant, a foaming agent, an ultraviolet absorber, and a light stabilizer. The blending amount of the additive can be appropriately adjusted according to the product characteristics.

Although the application amount of the primer agent is not particularly limited, it is usually 0.1 to 100 g / m ² , preferably 0.1 to 50 g / m ² . Although the thickness of a primer layer is not specifically limited, Usually, 0.01-10 micrometers, Preferably it is 0.1-1 micrometer.

  The decorative board 1 is a decorative board having a high design property because it has a sharp uneven shape and can express a design feeling of an uneven shape including a glossy matte uneven shape. The decorative board 1 can be used for various purposes by performing a predetermined molding process or the like. For example, the decorative board 1 is laminated on a base material such as a wood base material, a metal base material, a non-metal base material, a resin base material, and interiors of buildings such as walls, ceilings, floors, vehicles, vehicles, ships, etc. It can be used for interior cabinets, furniture, cabinets for light electrical appliances or office automation equipment. Specific examples of wood base materials include veneer, wood veneer, wood plywood, particle board, medium density fiberboard ( MDF), laminated material, chip board, or composite base material on which chip boards are laminated. Examples of the gold plating base material include a single metal plating such as iron, copper, aluminum, and titanium, or a base material made of an alloy containing one or more of these metal platings. Examples of the non-golden inorganic material base material include ceramic materials such as calcium silicate, gypsum, cement, and ceramics, or base materials made of stone such as granite and limestone. Examples of the resin base material include base materials made of polyvinyl chloride, polystyrene, polyester resin, acrylic resin, polyolefin resin, phenol resin, urea resin, and the like.

The wear-resistant layer decorative plate 1 may further include a wear-resistant layer. The wear-resistant layer can be provided on the second layer 4 or between the support sheet 2 and the second layer 4, for example.

  The thickness of the abrasion-resistant layer is not particularly limited, but the thickness when the abrasion-resistant ink is applied is, for example, 10 to 100 μm, and the thickness after drying is, for example, 2 to 20 μm.

  For the formation of the abrasion resistant layer, for example, an abrasion resistant ink can be used. As the resin contained in the abrasion-resistant ink, a curable resin such as a thermosetting resin or an ionizing radiation curable resin, or a thermoplastic resin can be used. Since the explanation regarding these resins is the same as described above, the explanation is omitted. The resin contained in the abrasion-resistant ink is preferably a polyurethane resin (including a two-component curable polyurethane) in that an abrasion-resistant layer can be easily formed. A crosslinking agent, a curing agent, a polymerization accelerator and the like can be added to the abrasion-resistant ink.

  The wear-resistant ink preferably contains a filler for the purpose of imparting wear resistance. The filler is not particularly limited, and an inorganic filler or an organic filler can be used.

  Examples of the inorganic filler include calcium carbonate, magnesium carbonate, silica, kaolin, clay, calcium oxide, magnesium oxide, titanium oxide, zinc oxide, barium sulfate, calcium hydroxide, aluminum hydroxide, alumina, magnesium hydroxide, talc, Examples include mica, hydrotalcite, aluminum silicate, magnesium silicate, calcium silicate, calcined talc, wollastonite, potassium titanate, magnesium sulfate, calcium sulfate, magnesium phosphate and the like.

  Organic fillers include polyolefin resins such as polyethylene and polypropylene; fluorine resins; styrene resins; epoxy resins; melamine resins; urea resins; acrylic resins; phenol resins; Examples thereof include polyester resins. Moreover, the copolymer of these resin can also be used.

  As the filler, it is preferable to use an inorganic filler in terms of excellent wear resistance, and it is particularly preferable to use alumina, silica, or zirconia. A filler may be used individually by 1 type and may be used in combination of 2 or more type.

  The shape of the filler is not particularly limited, and may be any shape such as a polyhedral sphere, a sphere, or a polyhedral shape.

  The average particle diameter of the filler is preferably 3 to 50 μm, more preferably 5 to 30 μm. By setting the average particle size of the filler in the above range, the wear resistance of the wear resistant layer becomes more excellent. In addition, the average particle diameter of a filler is a value measured by the laser diffraction scattering method.

  A preferred lower limit of the Mohs hardness of the filler is 4, and a preferred upper limit is 9. A more preferred lower limit is 7. By using a filler having a Mohs hardness in the above range, the decorative board 1 can exhibit more excellent wear resistance.

  The Mohs hardness of the filler is a value measured by a Mohs hardness meter. Specifically, the Mohs hardness is a tenth mineral ranging from soft minerals to harder minerals in a box, showing the rank of hardness as 1 degree, 2 degrees, ... 10 degrees from the softest one. is there. Standard minerals are as follows (numbers indicate hardness). 1: Kaseki 2: Gypsum 3: Boulder stone 4: Firefly stone 5: Rinkai stone 6: Seiko stone 7: Sekiei 8: Topaz 9: Corundum 10: Diamond

  When the surface of a mineral sample for which hardness is desired is to be scratched by scratching with these minerals, the hardness is compared by a resistance (whether it is scratched or not). For example, when the calcite is scratched, the hardness of the sample is greater than 3 degrees. If the fluorite is scratched and the fluorite is not scratched, the hardness of the sample is less than 4 degrees. At this time, the hardness of the sample is 3 to 4 or 3.5. When the scratches are somewhat scratched, the hardness of the sample shows the same level of hardness as the standard mineral used.

  The content of the filler in the abrasion-resistant ink is preferably 5 to 50 mass%, more preferably 10 to 30 mass%, with the abrasion-resistant ink as 100 mass%. By adjusting the filler content in the abrasion resistant ink to the above range, the abrasion resistance of the abrasion resistant layer is more excellent and the surface smoothness of the second layer 4 is not impaired. However, it will be easier to express the glossy design.

  The abrasion resistant ink may be colorless or colored. When coloring, the thing similar to the coloring agent used with the pattern pattern layer mentioned later can be used.

  The abrasion-resistant ink may contain a solvent for the purpose of adjusting the viscosity. Solvents include water; hydrocarbon compounds such as toluene and xylene; alcohol compounds such as methanol, ethanol and methyl glycol; ketone compounds such as acetone and methyl ethyl ketone; ester compounds such as methyl formate and ethyl acetate; N-methylpyrrolidone, N , N-dimethylformamide and the like; ether compounds such as terahydrofuran and dioxane; halogenated hydrocarbon compounds such as methylene chloride and chloroform; dimethyl sulfoxide and the like. These solvent can be used individually by 1 type or in mixture of 2 or more types. The amount of the solvent in the abrasion-resistant ink can be appropriately set according to the viscosity of the ink.

  A well-known additive can be mix | blended with abrasion-resistant ink according to the desired physical property obtained. As additives, for example, ultraviolet absorbers, infrared absorbers, light stabilizers, polymerization inhibitors, crosslinking agents, antistatic agents, antioxidants, leveling agents, coupling agents, plasticizers, antifoaming agents, fillers, Examples include a thermal radical generator and an aluminum chelating agent.

  The abrasion resistant layer can be formed, for example, by applying an abrasion resistant ink to a predetermined surface and drying and / or curing a resin contained in the abrasion resistant ink. Examples of the method for applying the abrasion-resistant ink include a roll coating method, a comma coating method, a curtain coating method, a squeeze coating method, a blade coating method, and a gravure coating method.

Method for manufacturing a decorative plate below with reference to drawings, a description will be given of embodiment of a method for manufacturing a decorative laminate according to the present invention. 8 and 9 are explanatory views for explaining an embodiment of a method for manufacturing a decorative board according to the present invention. FIG. 9 is a continuation of FIG.

The manufacturing method of the decorative board 1 according to this embodiment is as follows.
(1) preparing a support sheet 2 having a first main surface S1 and a second main surface S2 located on the opposite side of the first main surface S1,
(2) A step of forming the first layer 3 on a part of the first main surface S1 of the support sheet 2;
(3) forming a covering layer CL surrounding the first layer 3 and covering at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2;
(4) A step of peeling the portion CL1 covering the first layer 3 of the coating layer CL along the first direction X and forming the second layer 4 on the remaining portion of the first main surface S1 of the support sheet 2 is included. .
Hereinafter, each step will be described.

Process (1)
In step (1), as shown in FIG. 8A, a support sheet 2 having a first main surface S1 and a second main surface S2 located on the opposite side of the first main surface S1 is prepared.

  As shown in FIG. 8A, the support sheet 2 includes a first main surface T1 located on the first main surface S1 side of the support sheet 2 and a second main surface located on the second main surface S2 side of the support sheet 2. It has the base material sheet 21 which has the surface T2, and the decoration layer 22 provided in 1st main surface T1 of the base material sheet 21. FIG.

  The support sheet 2 can be manufactured by forming the decoration layer 22 on the first main surface T1 of the base sheet 21. Before forming the decoration layer 22 on the first main surface T1 of the base sheet 21, the first main surface T1 of the base sheet 21 may be subjected to treatment such as corona discharge treatment, plasma treatment, ozone treatment, and the like. Thereby, the adhesiveness of the decoration layer 22 can be improved.

  The decoration layer 22 is, for example, a colored layer, a picture layer, or a combination thereof. As shown in FIG. 1, the decorative layer 22 in the present embodiment gives a wood grain pattern to the decorative board 1.

  The colored layer is, for example, a solid layer formed on the entire surface of the first main surface T1 of the base sheet 21. Examples of the method for forming the solid layer include coating methods such as roll coating, knife coating, air knife coating, die coating, lip coating, comma coating, kiss coating, flow coating, and dip coating. It is done.

  The pattern layer is, for example, a printed layer formed on a part or the whole of the first main surface T1 of the base sheet 21 or a part or the whole of the surface of the colored layer by a printing method. Examples of the printing method used for forming the pattern layer include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method.

  The ink used for forming the decoration layer 22 is, for example, a mixture of a solvent or a dispersion medium and components such as a colorant and a binder resin. The ink may contain a colorant, extender pigment, stabilizer, plasticizer, catalyst, curing agent, and the like as other components. The ink may be an aqueous composition from the viewpoint of reducing the VOC (volatile organic compound) of the sheet.

  Examples of colorants contained in the ink include inorganic pigments such as carbon black, iron black, titanium white, antimony white, yellow lead, titanium yellow, petal, cadmium red, ultramarine, and cobalt blue; quinacridone red, isoindolinone Organic pigments or dyes such as yellow and phthalocyanine blue; metal pigments composed of scaly foils such as aluminum and brass; pearlescent pigments composed of scaly foils such as titanium dioxide-coated mica and basic lead carbonate Can be mentioned. A colorant may be used individually by 1 type and may be used in combination of 2 or more type.

  Examples of the binder resin contained in the ink include urethane resin, acrylic urethane resin, vinyl chloride / vinyl acetate copolymer resin, vinyl chloride / vinyl acetate / acrylic copolymer resin, chlorinated polypropylene resin, acrylic resin, and polyester resin. , Polyamide resin, butyral resin, polystyrene resin, nitrocellulose resin (nitrified cotton), cellulose acetate resin and the like. Binder resin may be used individually by 1 type, and may be used in combination of 2 or more type.

  Examples of the solvent or dispersion medium contained in the ink include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, acetic acid -2-Ethoxyethyl and other ester organic solvents; methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol and other alcohol organic solvents; acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, etc. Ketone-based organic solvents; diethyl ether, dioxane, tetrahydrofuran and other ether-based organic solvents; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloro Chlorinated organic solvents such as ethylene; inorganic solvents such as water. A solvent or a dispersion medium may be used individually by 1 type, and may be used in combination of 2 or more type.

  The decoration layer 22 may be formed by a method such as a hand-drawn method, an ink sink method, a photographic method, a transfer method, a laser beam drawing method, or an electron beam drawing method. When the decoration layer 22 is a metal layer (metal thin film) such as aluminum, chromium, gold, silver, or copper, the decoration layer 22 can be formed by a method such as a vapor deposition method, a sputtering method, or an etching method.

  The thickness of the decoration layer 22 can be appropriately adjusted according to the product characteristics, but the thickness at the time of ink coating is, for example, 1 to 200 μm, and the thickness after drying is, for example, 0.1 to 20 μm. It is.

Process (2)
In the step (2), as shown in FIG. 8B, the first layer 3 is formed on a part of the first main surface S1 of the support sheet 2. Thereby, the intermediate body M1 provided with the support sheet 2 and the 1st layer 3 formed in a part of 1st main surface S1 of the support sheet 2 is formed. The first layer 3 is formed on a part of the first main surface S1 of the support sheet 2 so as to extend along the first direction X.

  As a resin composition (coating liquid) for forming the first layer 3, for example, a thermosetting resin composition, an ionizing radiation curable resin composition, a thermoplastic resin composition, or the like can be used. When the thermosetting resin composition is used, for example, the thermosetting resin composition is printed in a predetermined pattern on a part of the first main surface S1 of the support sheet 2, and heated to be cured, One layer 3 can be formed. When using the ionizing radiation curable resin composition, for example, the ionizing radiation curable resin composition is printed in a predetermined pattern on a part of the first main surface S1 of the support sheet 2 and cured by irradiating with ionizing radiation. By doing so, the first layer 3 can be formed. When the thermoplastic resin composition is used, for example, the first layer 3 is formed by printing the thermoplastic resin composition in a predetermined pattern on a part of the first main surface S1 of the support sheet 2 and drying it. can do. Examples of the printing method used for forming the first layer 3 include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method. The resin composition for forming the first layer 3 may be applied to a part of the first main surface S1 of the support sheet 2 by a method other than the printing method. As a method for applying the resin composition, for example, Examples of the coating method include a roll coating method and a gravure coating method.

  When the resin composition for forming the first layer 3 contains a silicone release agent (silicone oil), the silicone release agent is oriented on the surface of the first layer 3 when the resin composition is cured. , Releasability is imparted to the first layer 3. Thereby, in process (4), when peeling part CL1 which coat | covers the 1st layer 3 among the coating layers CL, the peelability of the part CL1 which coat | covers the 1st layer 3 can be improved.

  The usage-amount of a silicone type mold release agent (silicone oil) is 0.1-50 mass parts normally per 100 mass parts of resin contained in the resin composition for forming the 1st layer 3, Preferably 0.5- 20 mass parts, More preferably, it is 3-20 mass parts, More preferably, it is 3-10 mass parts. When the usage amount of the silicone-based release agent (silicone oil) is within the above range, the first layer 3 is coated when the portion CL1 of the coating layer CL that covers the first layer 3 is peeled off in the step (4). The peelability of the portion CL1 to be improved can be improved.

  As the resin composition (coating liquid) for forming the first layer 3, it is preferable to use an ionizing radiation curable resin. In this case, the first layer 3 is a cured resin layer containing a cured product of an ionizing radiation curable resin, and the step (2) includes (2-1) an ionizing radiation curable resin composition containing an ionizing radiation curable resin. A step of forming an ionizing radiation curable resin composition layer covering a part of the first main surface S1 of the support sheet 2, and (2-2) curing the ionizing radiation curable resin composition layer. And forming a cured resin layer as the first layer 3.

  When ultraviolet rays are used as the ionizing radiation for curing the ionizing radiation curable resin composition layer, 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 A light source such as a lamp can be used. The wavelength of the ultraviolet light is, for example, 190 to 380 nm. In the case of using an electron beam as ionizing radiation for curing the ionizing radiation curable resin composition layer, as an electron beam source, for example, cockcroft-wald type, bande graft type, resonant transformer type, insulated core transformer type An electron beam accelerator such as a linear type, a dynamitron type, or a high frequency type can be used. The energy of the electron beam is preferably 100 to 1000 keV, more preferably 100 to 300 keV. The irradiation amount of the electron beam is preferably 2 to 15 Mrad.

  The coating liquid for forming the first layer 3 preferably contains extender pigments. Thereby, thixotropy can be imparted to the coating liquid, and the pattern shape of the coating liquid can be maintained when the coating liquid is printed using a plate. Examples of extender pigments include silica, talc, clay, barium sulfate, barium carbonate, calcium sulfate, calcium carbonate, and magnesium carbonate. Of these, silica, which is a material having a high degree of freedom in material design and excellent in design properties, whiteness, and coating stability as an ink, is preferable, and fine powder silica is particularly preferable.

  The content of the extender pigment in the coating liquid is usually 0.1 to 20 parts by mass, preferably 0.5 to 15 parts by mass, more preferably 2 to 15 parts by mass, per 100 parts by mass of the resin contained in the coating liquid. And more preferably 5 to 15 parts by mass. By setting the content of the extender within the above range, sufficient thixotropy can be imparted to the coating liquid, and an effect of imparting a raised shape and a fine uneven surface can be obtained.

  The coating solution may be colorless or colored. When coloring, the same colorant used in the decorative layer can be used.

  The coating liquid may contain a solvent for the purpose of adjusting the viscosity. Solvents include water; hydrocarbon compounds such as toluene and xylene; alcohol compounds such as methanol, ethanol and methyl glycol; ketone compounds such as acetone and methyl ethyl ketone; ester compounds such as methyl formate and ethyl acetate; N-methylpyrrolidone, N , N-dimethylformamide and the like; ether compounds such as terahydrofuran and dioxane; halogenated hydrocarbon compounds such as methylene chloride and chloroform; dimethyl sulfoxide and the like. These solvent can be used individually by 1 type or in mixture of 2 or more types. The amount of the solvent in the coating liquid can be appropriately set according to the viscosity of the coating liquid.

  In the coating liquid, known additives can be appropriately blended according to desired physical properties. As additives, for example, ultraviolet absorbers, infrared absorbers, light stabilizers, polymerization inhibitors, crosslinking agents, antistatic agents, antioxidants, leveling agents, coupling agents, plasticizers, antifoaming agents, fillers, Examples include a thermal radical generator and an aluminum chelating agent.

The first layer 3 is preferably formed in a predetermined pattern on the first main surface S1 of the support sheet 2. The pattern of the first layer 3 preferably corresponds to a region that becomes a concave portion or a low gloss (matte) region on the surface of the decorative board 1. Examples of the pattern of the first layer 3 include a wood grain plate conduit portion, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grain, a hairline, a ridge, a character, a symbol, a geometric pattern, and the like. In the present embodiment, the first layer 3 is formed on the first main surface S <b> 1 of the support sheet 2 in a pattern of a wood grain conduit portion.
The pattern of

  The thickness of the 1st layer 3 is not specifically limited, The thickness at the time of coating is 1-200 micrometers, for example, and the thickness after drying is 0.1-20 micrometers, for example.

Step (3)
For example, when the coating layer CL is a cured resin layer containing a cured product of a thermosetting resin, the step (3) uses (3-1) a thermosetting resin composition containing a thermosetting resin. A step of forming a thermosetting resin composition layer surrounding the first layer 3 and covering at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2; 3-2) A step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer CL is included.

  For example, when the substrate sheet 21 is a porous sheet and the coating layer CL is a cured resin layer containing a cured product of a thermosetting resin, the step (3) includes (3-1) a thermosetting resin. A thermosetting resin that surrounds the first layer 3 and covers at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2 using the thermosetting resin composition that is included. A step of forming a composition layer, and (3-2) a step of curing the thermosetting resin composition layer to form a cured resin layer as a coating layer CL. A sheet can be impregnated with the thermosetting resin composition, and in the step (3-2), the thermosetting resin composition impregnated in the porous sheet can be cured.

  In step (3), first, as shown in FIG. 8C, the first layer 3 is formed on the remaining portion of the first main surface S1 of the support sheet 2 (that is, the first main surface S1 of the support sheet 2). A region not formed) and at least a part of the first layer 3 are coated with a resin composition (coating liquid) for forming the second layer 4 and dried as necessary. Thus, the first layer 3 is surrounded by the support sheet 2, the first layer 3 formed on a part of the first main surface S1 of the support sheet 2, and the remaining portion of the first main surface S1 of the support sheet 2. And the intermediate body M2 provided with the resin composition layer PC formed so that at least one part of the 1st layer 3 may be coat | covered is formed.

  As a resin composition (coating liquid) for forming the second layer 4, for example, a thermosetting resin composition, an ionizing radiation curable resin, a thermoplastic resin composition, or the like can be used. When an ionizing radiation curable resin is used as the resin composition for forming the first layer 3, it is preferable to use a thermosetting resin composition as the resin composition for forming the second layer 4.

  When forming the resin composition layer PC so as to surround the first layer 3 and cover at least a part of the first layer 3 on the remaining portion of the first main surface S1 of the support sheet 2, the resin composition Is supplied from the first main surface S1 side of the support sheet 2, for example. When a porous sheet is used as the base sheet 21, a part of the supplied resin composition is impregnated into the base sheet 21, and the remainder that is not impregnated into the porous sheet is the first main sheet of the support sheet 2. The remaining part of the surface S1 and at least a part of the first layer 3 are covered. The resin composition does not impregnate the first layer 3 and covers the first layer 3. In order to promote the impregnation of the resin composition into the base sheet 21, in addition to the supply of the resin composition from the first main surface S1 side of the support sheet 2, the support sheet 2 from the second main surface S2 side The resin composition may be supplied. When a porous sheet is used as the base sheet 21, only the resin composition may be supplied from the second main surface S <b> 2 side of the support sheet 2. Similarly, when only the resin composition is supplied from the second main surface S2 side of the support sheet 2, a part of the supplied resin composition is impregnated into the base sheet 21, and the porous sheet The remaining portion that is not impregnated covers the remaining portion of the first main surface S1 of the support sheet 2 and at least a portion of the first layer 3. Examples of the method for supplying the resin composition include immersion in the resin composition; application with a coater such as a kiss coater or comma coater; and spraying with a spray device, a shower device, or the like.

  The resin composition only needs to cover at least a part of the first layer 3. For example, the entire area occupied by the first layer 3 (the first layer 3 of the first main surface S1 of the support sheet 2 is provided). It is sufficient that 30% or more of the area of the formed region is covered with the resin composition. The coating ratio of the resin composition in the entire area of the first layer 3 is preferably 50 to 100%.

  The thickness of the resin composition layer PC is not particularly limited, but is, for example, 2 to 250 μm at the time of coating, and 2 to 50 μm after drying, for example.

The filling rate of the resin composition filled in the voids of the porous sheet can be appropriately adjusted according to the performance required for the decorative board 1, the porosity of the porous sheet, and the like. The filling rate of the resin composition is preferably 30 to 200%, more preferably 50 to 150%. The filling rate of the resin composition is calculated by the following formula.
Filling rate (%) = [(weight of porous sheet after impregnating resin composition−weight of porous sheet before impregnating resin composition) / of porous sheet before impregnating resin composition Weight] × 100

  After forming the resin composition layer PC and before curing, if necessary, the gloss of the surface of the resin composition layer PC may be adjusted. For example, a method of curing in a state where a gloss-adjusted shaping sheet is laminated on the resin composition layer PC, a method of curing by setting an embossed template (a textured mirror plate) on the resin composition layer PC, etc. Thus, the gloss of the surface of the resin composition layer PC can be adjusted. Thereafter, in step (4), the part CL1 of the coating layer CL that covers the first layer 3 is peeled off, thereby adjusting the gloss on the surface of the decorative board 1 by fine irregularities by molding, and the coating layer A decorative board 1 having a three-dimensional and deep design including a deep mat design portion obtained by peeling a portion CL1 of the CL that covers the first layer 3 from the remaining portion CL2 of the coating layer CL can be obtained. .

  When using a thermosetting resin composition, the cured resin layer is formed as the coating layer CL by heating and curing the resin composition layer PC. When using an ionizing radiation curable resin composition, the cured resin layer is formed as the coating layer CL by irradiating the resin composition layer PC with ionizing radiation and curing it.

  When the resin composition for forming the second layer 4 contains a silicone release agent (silicone oil), the resin composition is oriented on the surface of the second layer 4 when the resin composition is cured. The releasability from the first layer 3 is imparted. Thereby, in process (4), when peeling part CL1 which coat | covers the 1st layer 3 among the coating layers CL, the peelability of the part CL1 which coat | covers the 1st layer 3 can be improved. When the silicone release agent is a non-reactive silicone oil, the silicone release agent is easily oriented on the surface of the second layer 4.

  A water-curable thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.), it is preferable to use polyether-modified silicone oil as the silicone-based mold release agent. Since the polyether-modified silicone oil has properties such as water solubility and water dispersibility, when the silicone-based release agent is a polyether-modified silicone oil, the silicone-based release agent is easily mixed with the water-soluble thermoplastic resin. Thus, the release property of the silicone release agent can be effectively exhibited while preventing the localization of the silicone release agent. In addition, the silicone release agent mixed with the water-soluble thermosetting resin composition in an uncured state inhibits the curing of the water-soluble thermosetting resin and reduces the strength of the cured product of the thermosetting resin. Is expected. The decrease in the strength of the cured product of the thermosetting resin is due to the peelability of the portion CL1 covering the first layer 3 when the portion CL1 covering the first layer 3 of the coating layer CL is peeled in the step (4). This is thought to contribute to improvement of The thermosetting resin composition may contain a non-reactive silicone oil other than the polyether-modified silicone oil. Non-reactive silicones other than the polyether-modified silicone oil may be used alone or in combination of two or more.

  A water-curable thermosetting resin composition (for example, melamine resin, urea resin, sulfonamide resin) in which a thermosetting resin composition is used as a raw material for forming the second layer 4 and the thermosetting resin composition is in an uncured state. , Glyoxal resin, guanamine resin, etc.) as a silicone release agent, a silicone release agent having an HLB value of 6 to 16 (particularly, a polyether-modified silicone oil having an HLB value of 6 to 16) ) Is preferably used. The HLB value of the silicone release agent is more preferably 10 or more and 15 or less, and still more preferably 12 or more and 14 or less. The higher the HLB value, the easier it is to mix the silicone oil release agent with the water-soluble thermosetting resin composition in an uncured state, and the localization of the silicone release agent can be prevented. If the value is too high, the release property of the silicone release agent may be lowered. When the HLB value of the silicone release agent is within the above range, the release property of the silicone release agent can be effectively exhibited while preventing the localization of the silicone release agent. In addition, the silicone mold release agent mixed with the water-soluble thermosetting resin composition in the uncured state inhibits the curing of the water-soluble thermosetting resin composition in the uncured state, and the thermosetting resin is cured. It is expected to reduce the strength of the object. The decrease in the strength of the cured product of the thermosetting resin is due to the peelability of the portion CL1 covering the first layer 3 when the portion CL1 covering the first layer 3 of the coating layer CL is peeled in the step (4). This is thought to contribute to improvement of

  The usage-amount of a silicone type mold release agent (silicone oil) is 0.1-50 mass parts normally per 100 mass parts of resin contained in the resin composition for forming the 2nd layer 4, Preferably 0.5- 20 mass parts, More preferably, it is 3-20 mass parts, More preferably, it is 3-10 mass parts. When the usage amount of the silicone-based release agent (silicone oil) is within the above range, the first layer 3 is coated when the portion CL1 of the coating layer CL that covers the first layer 3 is peeled off in the step (4). The peelability of the portion CL1 to be improved can be improved.

  When using a thermosetting resin composition as a resin composition for forming the 2nd layer 4, hardening of resin composition layer PC can be performed as follows.

  First, as shown in FIG. 8D, the peeling film PF is laminated on the resin composition layer PC, and the reinforcing sheet PP is laminated on the second main surface S <b> 2 of the support sheet 2. Accordingly, the support sheet 2, the first layer 3 formed on a part of the first main surface S1 of the support sheet 2, the remaining part of the first main surface S1 of the support sheet 2, and at least a part of the first layer 3 An intermediate body M3 is formed, which includes a resin composition layer PC covering the substrate, a peeling film PF laminated on the resin composition layer PC, and a reinforcing sheet PP laminated on the second main surface S2 of the support sheet 2. The The lamination of the peeling film PF to the resin composition layer PC may be performed at any time before, after, and simultaneously with the lamination of the reinforcing sheet PP to the second main surface S2 of the support sheet 2.

  As the peeling film PF, for example, an easily adhesive resin film can be used. Examples of the easily adhesive resin film include a thermoplastic resin film. Examples of the thermoplastic resin include polyolefin resins such as polyethylene, polypropylene, and polymethylpentene; vinyl chloride-vinyl acetate copolymer, ethylene- Vinyl resins such as vinyl acetate copolymer and ethylene-vinyl alcohol copolymer; polyester resins such as polyethylene terephthalate and polybutylene terephthalate; polymethyl methacrylate, polyethyl methacrylate, polyethyl acrylate, polybutyl acrylate, etc. Acrylic resin: a single film of a synthetic resin such as polystyrene, polycarbonate, polyarylate, polyimide, or a laminate of these films.

  An easy-adhesion layer may be formed on the surface of the easy-adhesion resin film by applying an easy-adhesion resin. Prior to the formation of the easy-adhesion layer, the surface of the easy-adhesion resin film may be subjected to treatments such as corona discharge treatment, plasma treatment, and ozone treatment in order to improve the adhesion of the easy-adhesion layer.

  Examples of the resin contained in the easy adhesion layer (sometimes called a primer layer or an anchor layer) include acrylic resin, vinyl chloride-vinyl acetate copolymer, polyester resin, urethane resin, chlorinated polypropylene, and chlorinated polyethylene. It is done.

  As the peeling film PF, it is preferable to use a peeling film in which the peeling weight with the resin film to be peeled (part CL1 of the coating layer CL covering the first layer 3) is adjusted. For example, in the case of a thermosetting film of melamine resin, it is preferable to adjust the peel weight to 0.1 to 10 N / inch. If the peel weight is less than 0.1, it is difficult to peel off the thermosetting film of the melamine resin, and if the peel weight exceeds 10 N / inch, the peeling film is broken or a resin film other than the resin film to be peeled off (Parts other than the part CL1 that covers the first layer 3 in the coating layer CL) may be peeled off. By using a film for peeling whose peel weight is adjusted to 0.1 to 10 N / inch, the resin film (part CL1 covering the first layer 3 of the coating layer CL) can be easily removed. can do.

  The peel weight is a value measured using a Tensilon universal material testing machine RTB-1250A manufactured by Orientec Co., Ltd., and a specific measuring method is as follows. In the intermediate M4, which will be described later, the peeling film PF is cut into a width of 1 inch, a part of the peeling film PF is peeled off with a width of 1 inch, and a part of the peeling film PF is peeled off as shown in FIG. One end (lower part) of the intermediate body M4 is fixed to the testing machine. The weight when the peeling film PF peeled 180 ° is peeled in the upper direction (arrow direction) at a speed of 100 mm / min is measured, and this is defined as “peeling weight”.

  As the peeling film whose peel weight is adjusted to 0.1 to 10 N / inch, for example, a film having a base film and a cured resin layer formed on the base film can be used. . This film is preferably used so that the surface on the cured resin layer side is in contact with the resin composition layer PC. A base film is not specifically limited, For example, paper, a nonwoven fabric, a thermoplastic resin sheet etc. are mentioned. The base film is preferably a thermoplastic resin sheet, and a polyester resin sheet such as polyethylene terephthalate is particularly preferable from the viewpoint of heat resistance. The thickness of a base film is not specifically limited, Usually, it is 10-200 micrometers. The cured resin layer is preferably a cured resin layer formed by curing an ionizing radiation curable resin composition. Thereby, it becomes easy to adjust the peeling weight with the thermosetting film | membrane of a melamine resin to 0.1-10 N / inch. The above description is applied to the ionizing radiation curable resin composition. The ionizing radiation curable resin composition may optionally contain components such as extender pigments for the purpose of adjusting the peel weight. The thickness of the curable resin layer is usually 1 to 30 μm.

As the reinforcing sheet PP, for example, a thermosetting resin-impregnated sheet can be used. The thermosetting resin-impregnated sheet has a porous sheet and a thermosetting resin impregnated in the porous sheet. Examples of thermosetting resins include unsaturated polyester resins, polyurethane resins (including two-component curable polyurethane), epoxy resins, amino alkyd resins, phenol resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, and melamines. -Urea co-condensation resin, silicon resin, polysiloxane resin and the like. Examples of the thermosetting resin-impregnated sheet include phenol resin-impregnated paper, which is widely used as a core paper for a decorative board. Phenol resin impregnated paper is generally produced by impregnating kraft paper having a basis weight of 150 to 250 g / m ² as core paper with phenol resin so that the impregnation rate is 45 to 60% and drying at 100 to 140 ° C. Paper. A commercially available product can be used for the phenol resin-impregnated paper. When the phenol resin impregnated paper is laminated, the second main surface S2 of the support sheet 2 may be subjected to corona discharge treatment or a primer layer may be formed as necessary.

  Next, as shown in FIG. 8 (e), the intermediate M3 is sandwiched between the two mirror-finished metal plates P1 and P2, and pressurized and heated to cure the resin composition layer PC. Thereby, the cured resin layer is formed as the coating layer CL. When a porous sheet is used as the substrate sheet 21, the resin composition impregnated in the voids of the porous sheet is also cured at this stage. When a thermosetting resin impregnated sheet is used as the reinforcing sheet PP, the thermosetting resin of the thermosetting resin impregnated sheet is also cured at this stage, and the reinforcing layer 6 is formed. The peeling film PF adheres to the coating layer CL at this stage.

  The heating temperature and the heating time can be appropriately adjusted depending on the type of thermosetting resin used. For example, in the case of an isocyanate curable unsaturated polyester resin or a urethane curable polyurethane resin, it is 1 to 5 days at 40 to 60 ° C., and in the case of a polysiloxane resin, it is 1 to 30 minutes at 80 to 150 ° C., and a melamine resin In this case, the temperature is 90 to 160 ° C. for 30 seconds to 30 minutes.

The pressure applied by the mirror-finished metal plates P1 and P2 is, for example, 5 to 100 kg / cm ² .

  Accordingly, as shown in FIG. 9 (f), the support sheet 2, the first layer 3 formed on a part of the first main surface S <b> 1 of the support sheet 2, and the first main surface S <b> 1 of the support sheet 2. The remaining portion surrounds the first layer 3 and covers at least a part of the first layer 3, a peeling film PF laminated on the coating layer CL, and a support sheet An intermediate body M4 including the reinforcing layer 6 laminated on the second second main surface S2 is formed.

  As shown in FIG. 9F, the coating layer CL has a portion CL1 that covers the first layer 3, and a portion CL2 that does not cover the first layer 3. The portion CL1 that covers the first layer 3 is formed on the surface of the first layer 3 so as to cover the first layer 3. The portion CL2 that does not cover the first layer 3 is formed on the surface of the first main surface S1 of the support sheet 2 so as to surround the first layer 3.

  As shown in FIG. 9 (f), the portion CL 1 that covers the first layer 3 has a portion CL 11 that covers the wide portion 31 and a portion CL 12 that covers the narrow portion 32.

As shown in FIG. 10, in a step (3), the plane extends in a direction perpendicular to the extending direction D1 of the first layer 3 through an arbitrary point located on the outline of the wide portion 31 in plan view. In the cut surface formed by cutting the resulting intermediate, the following conditions are satisfied.
[Condition 3] When the width of the wide portion 31 is WB and the thickness of the portion CL11 of the coating layer CL that covers the wide portion 31 is TB, WB ≧ TB.

  As a result of the manufacturing method of the decorative sheet 1 satisfying the condition 3, the decorative sheet 1 satisfies the condition 1. Moreover, when the manufacturing method of the decorative board 1 satisfies the condition 3, in the step (4), when the portion CL1 that covers the first layer 3 of the coating layer CL is peeled along the first direction X, the wide portion. The peelability of the portion CL11 covering 31 is improved and stabilized. As a result, the decorative board 1 satisfies the above condition 2. When the decorative board 1 satisfies the above condition 2, as shown in FIG. 4, the portion of the wide portion 31 exposed from the opening 40 of the second layer 4 exists over the entire wide portion 31. Therefore, the concave portion 5 has a depth reaching the wide portion 31 over the entire region, and the surface height difference between the concave portion 5 and the region other than the concave portion 5 becomes significant.

  On the other hand, as shown in FIG. 11, in a plane extending in a direction perpendicular to the extending direction D <b> 1 of the first layer 3 through an arbitrary point located on the outline of the narrow portion 32 in plan view, the process ( In the cut surface formed by cutting the intermediate obtained in 3), when the width of the narrow portion 32 is WN and the thickness of the portion CL12 covering the narrow portion 32 of the coating layer CL is TN, WN <TN. For this reason, in the step (4), when the portion CL1 that covers the first layer 3 in the coating layer CL is peeled along the first direction X, the peelability of the portion CL12 that covers the narrow portion 32 decreases. It becomes unstable. Therefore, as shown in FIGS. 2, 4, and 5, the narrow portion 32 is covered with the second layer 4 and is not exposed from the opening 40 of the second layer 4. A part of the narrow portion 32 may be exposed from the opening 40 of the second layer 4, but the portion of the narrow portion 32 exposed from the opening 40 of the second layer 4 is the portion of the narrow portion 32. It does not exist throughout.

Step (4)
In step (4), as shown in FIG. 9G, the portion CL1 of the coating layer CL that covers the first layer 3 is peeled along the first direction X, and the first main surface of the support sheet 2 is peeled off. The second layer 4 is formed on the remaining part of S1. “Peeling along the first direction X” means that the peeling direction matches the first direction X in plan view. As long as the peeling direction coincides with the first direction X in plan view, the peeling direction may be a direction parallel to the first direction X or may be a direction intersecting the first direction X. The portion CL1 of the coating layer CL that covers the first layer 3 is more easily peeled off than the remaining portion CL2 of the coating layer CL. However, of the portion CL1 that covers the first layer 3, the portion CL12 that covers the narrow portion 32 is less likely to be peeled off than the portion CL11 that covers the wide portion 31. Therefore, the portion CL11 covering the wide portion 31 is peeled off together with the peeling film PF while being adhered to the peeling film PF, while the portion CL12 covering the narrow portion 32 and the remaining portion CL2 of the coating layer CL are supported. The second layer 4 is formed on the remaining portion of the first main surface S1 of the sheet 2. By removing the portion CL11 covering the wide portion 31 of the first layer 3 in the covering layer CL, the opening 40 of the second layer 4 is formed, and at least a part of the wide portion 31 is the second portion. A recess 5 on the surface of the decorative board 1 is formed through the opening 40 of the layer 4. Thereby, as shown in FIG.9 (h), the decorative board 1 is manufactured.

  The silicone-based mold release agent contained in the first layer 3 and / or the second layer 4 imparts releasability to the first layer 3 and / or the second layer 4, so that in the step (4), the coating layer CL Of these, the portion CL11 covering the wide portion 31 is easily peeled off. When both the first layer 3 and the second layer 4 contain a silicone release agent, this effect is increased.

  The method of peeling part CL1 which coat | covers the 1st layer 3 among the coating layers CL is not limited to the method using the film for peeling. For example, a method of attaching a protective film such as a masking film, an adhesive tape such as a cellophane tape or a gum tape, a molding sheet, etc. to the surface of the coating layer CL, and then peeling the film at the same time; adhesive tape, adhesive rubber A method of peeling with a roller, an adhesive rubber sheet, etc .; A method of applying a resin solution such as a chlorinated rubber resin, a urethane resin, or a polyester resin previously dissolved in a solvent to the coating layer CL, and drying and then peeling off; Examples include a method in which a hot melt adhesive is applied to the layer CL and then peeled off at a low temperature; a method in which a resin plate or a metal plate is attached to the coating layer CL and then peeled off.

  When peeling part CL1 which coat | covers the 1st layer 3 among coating layers CL using peeling films, such as an adhesive tape, a masking tape, and a shaping sheet, the resin film (the 1st of coating layers CL) It is preferable to use a film in which the peel weight with respect to the part CL1) covering the one layer 3 is adjusted. For example, in the case of a thermosetting film of melamine resin, it is preferable to adjust the peel weight to 0.1 to 10 N / inch. If the peel weight is less than 0.1, it is difficult to peel the thermosetting film of the melamine resin, and if the peel weight exceeds 10 N / inch, the peeling film may be torn off or a resin film other than the resin film to be peeled ( The portion other than the portion CL1 that covers the first layer 3 in the coating layer CL) may also be peeled off. By using a film for peeling whose peel weight is adjusted to 0.1 to 10 N / inch, the resin film (part CL1 covering the first layer 3 of the coating layer CL) can be easily removed. can do.

  The decorative board 1 manufactured by the said method has an uneven | corrugated shape on the surface. Therefore, the decorative board 1 can express the design feeling of the uneven shape based on the uneven shape. In particular, the decorative board as a result of the above manufacturing method has a relatively rough surface on the surface of the concave portion 5 (including the surface of the first layer 3 exposed from the opening 40 of the second layer 4), and is not incident light. On the other hand, the surface of the region other than the concave portion 5 including the convex portion is relatively specular with the feature of constituting a low gloss region having diffuse reflectivity, and constitutes a high gloss region having specular reflectivity with respect to incident light It has the feature to do. Therefore, the decorative board 1 can also express a glossy matte design feeling based on the uneven shape. For example, the decorative board 1 can exhibit an appearance with a concavo-convex shape including a glossy matte concavo-convex shape in which the concave portion exhibits a mat feeling and the convex portion exhibits a gloss feeling. In particular, the decorative board 1 can express the design feeling of an excellent concavo-convex shape by synchronizing the concavo-convex shape with the pattern of the decorative layer 22 in plan view. For example, when the decorative layer 22 forms a wood grain pattern, the decorative board 1 is made to synchronize so that the position of the concave portion and the conduit part of the wood grain pattern coincide with each other in a plan view. It is possible to express an appearance including a glossy matte design feeling (texture) similar to the above.

  Since the concave portion 5 has a depth reaching the wide portion 31 over the entire region, and the surface height difference between the concave portion 5 and the region other than the concave portion 5 is significant, the decorative board 1 is based on a clear concave and convex shape. It is possible to express a glossy matte design feeling and a textured texture (surface texture).

[Example 1]
(1) Production of release ink 60 parts by mass of ionizing radiation curable monomer (Aronix M400, manufactured by Toagosei Co., Ltd.), 0.6 parts by mass of reactive silicone (X-22-164B, manufactured by Shin-Etsu Chemical Co., Ltd.) A release ink was produced by stirring 40 parts by mass of methyl ethyl ketone (Maruzen Petrochemical Co., Ltd.) for 1 hour at a rotational speed of 2000 rpm using a process homogenizer PH91 (manufactured by SMT Co., Ltd.).

(2) Production of release film 50 μm thick PET film (Cosmo Shine (registered trademark) A4100 (50 μm) manufactured by Toyobo Co., Ltd.), ionizing radiation curable monomer (Aronix (registered trademark) manufactured by Toagosei Co., Ltd.) ) M350) 100 parts by weight, reactive silicone (manufactured by Shin-Etsu Chemical Co., Ltd., X-22-164B) 2 parts by weight, silica (Fuji Silysia Chemical Co., Ltd., Silicia 450) 8 parts by weight, and ethyl acetate 50 parts by weight The coating ink containing 5 g / m < ² > (at the time of drying) was applied, the electron beam irradiation of 5 Mrad was performed with the acceleration voltage of 165 kV, and it hardened | cured, and the film for peeling was manufactured.

(3) Manufacture of a decorative board ^On a white titanium paper (KJ Special Paper Co., Ltd., KW-1002P) having a basis weight of 100 g / m ² as a base paper, using printing ink (DIC Graphics Co., Ltd., Ode SPTI) After forming the printing layer, the pattern having a constant width (10 μm, 20 μm, 30 μm, 40 μm, 50 μm, or 60 μm) and a length (1 mm to 60 mm) using the release ink produced in (1) above. Was printed and irradiated with an electron beam of 5 Mrad at an acceleration voltage of 165 kV to form a release layer. The thickness of the release layer was 2 μm.

Subsequently, a liquid uncured composition of a thermosetting resin comprising 50 parts by mass of melamine formaldehyde resin, 45 parts by mass of water, and 5 parts by mass of isopropyl alcohol is obtained by using an impregnating apparatus for impregnation. The impregnated decorative sheet was obtained by impregnation so as to have a ratio of m ² (during drying) and drying. This impregnated decorative sheet is laminated on four sheets of phenol resin-impregnated core paper (Ota Sangyo Co., Ltd., Ota Core) having a basis weight of 245 g / m ² in which a kraft paper is impregnated with a resin solution comprising a phenol resin, and further impregnated. The peeling film produced in the above (2) was laminated on the decorative sheet so that the printing surface of the peeling film was in contact with the printing surface of the impregnated decorative sheet. The formed laminate is sandwiched between two mirror plates, and heat molded using a hot press machine at a pressure of 100 kg / cm ² and a molding temperature of 150 ° C. for 10 minutes, and the uncured composition is thermoset. By doing so, a cured resin layer containing a melamine resin was formed. At this time, a cured resin layer was formed on the release layer. The thickness of the cured resin layer formed on the release layer was 30 μm.

By peeling the release film from the cured resin layer, the cured resin layer formed on the release layer was peeled off.
When the width of the release layer was 10 to 20 μm, most of the cured resin layer was not peeled and remained on the release layer.
When the width of the release layer was 30 to 60 μm, most of the cured resin layer was peeled off, and the portion from which the cured resin layer was peeled was present throughout the release layer.

  SEM observation was performed on the release layer having a width of 30 to 50 μm, and the ratio of the area of the release layer from which the cured resin layer was peeled was measured and found to be 30% or more.

[Example 2]
The same operation as in Example 1 was performed except that the thickness of the cured resin layer formed on the release layer was changed to 40 μm.
When the width of the release layer was 10 to 30 μm, most of the cured resin layer was not peeled and remained on the release layer.
When the width of the release layer was 40 to 60 μm, most of the cured resin layer was peeled off, and the portion where the cured resin layer was peeled was present throughout the release layer.
SEM observation was performed on the release layer having a width of 40 to 60 μm, and the ratio of the area of the release layer from which the cured resin layer was peeled was measured to be 30% or more.

Example 3
The same operation as in Example 1 was performed except that the thickness of the cured resin layer formed on the release layer was changed to 50 μm.
When the width of the release layer was 10 to 40 μm, most of the cured resin layer was not peeled and remained on the release layer.
When the width of the release layer was 50 to 60 μm, most of the cured resin layer was peeled off, and the portion where the cured resin layer was peeled was present throughout the release layer.
SEM observation was performed on the release layer having a width of 50 to 60 μm, and the ratio of the area of the release layer from which the cured resin layer was peeled was measured and found to be 30% or more.

DESCRIPTION OF SYMBOLS 1 ... Decorative plate 2 ... Support sheet S1 ... 1st main surface S2 of a support sheet ... 2nd main surface 3 of a support sheet ... 1st layer 31 ... Wide part 32 ... Narrow part 4 ... second layer 40 ... second layer opening 5 ... concave part 6 on the surface of the decorative board 6 ... reinforcing layer

Claims (24)

Having a first direction, a second direction and a thickness direction orthogonal to each other;
A support sheet having a first main surface and a second main surface located on the opposite side of the first main surface;
A first layer provided on a part of the first main surface so as to extend along the first direction;
A second layer provided to surround the first layer on the remaining portion of the first main surface;
A decorative board comprising:
The first layer has a wide portion having a width of 20 μm or more and 100 μm or less,
The second layer has an opening exposing at least a part of the wide portion;
In a cut surface formed by cutting the decorative board, in a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outline of the wide portion in plan view When the width of the wide portion is WB, the height of the wide portion is HB, and the height of the second layer is H, H> HB and WB ≧ (H−HB),
In the cut surface, at least a part of the wide portion is exposed from the opening of the second layer.   The decorative board according to claim 1, wherein a difference (H−HB) between the height of the second layer and the height of the first layer is 1 μm or more on the cut surface.   The decorative board according to claim 1 or 2, wherein an area of a portion of the wide portion exposed from the opening of the second layer is 80% or more of an area of the wide portion.   The decorative board according to any one of claims 1 to 3, wherein the first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin.   The decorative board according to any one of claims 1 to 4, wherein the second layer is a cured resin layer containing a cured product of a thermosetting resin.   The decorative board according to claim 5, wherein the thermosetting resin includes a water-soluble thermosetting resin.   The decorative board according to claim 6, wherein the water-soluble thermosetting resin contains a melamine resin.   The decorative board according to any one of claims 1 to 7, wherein the first layer and / or the second layer contains a silicone-based release agent.   The support sheet includes a base sheet, and the base sheet is positioned on the first main surface side of the support sheet on the first main surface side and on the second main surface side of the support sheet. The decorative board according to any one of claims 1 to 8, comprising a second main surface.   The decorative board according to claim 9, wherein the support sheet further includes a decorative layer provided on the first main surface of the base sheet.   The decorative board according to claim 9 or 10, wherein the base sheet is a porous sheet.   The decorative board according to claim 11, wherein the support sheet further includes a cured product of a thermosetting resin filled in a gap of the porous sheet. A method for producing a decorative board according to any one of claims 1 to 12,
The method comprises
(1) preparing the support sheet;
(2) forming the first layer on a part of the first main surface of the support sheet;
(3) forming a coating layer surrounding the first layer and covering at least a part of the first layer on the remaining portion of the first main surface of the support sheet;
(4) including a step of peeling a portion covering the first layer of the coating layer along the first direction and forming a second layer on the remaining portion of the first main surface of the support sheet;
Cutting the intermediate body obtained in step (3) with a plane extending in a direction perpendicular to the extending direction of the first layer through an arbitrary point located on the outline of the wide portion in plan view; In the cut surface to be formed, when the width of the wide portion is WB and the thickness of the portion of the coating layer covering the wide portion is TB, WB ≧ TB.   14. The method according to claim 13, wherein a thickness (TB) of a portion covering the wide portion of the covering layer in the cut surface is 1 μm or more. The first layer is a cured resin layer containing a cured product of an ionizing radiation curable resin,
The step (2)
(2-1) Using an ionizing radiation curable resin composition containing the ionizing radiation curable resin, an ionizing radiation curable resin composition layer covering a part of the first main surface of the support sheet is formed. And the process of
(2-2) The method according to claim 13 or 14, comprising a step of curing the ionizing radiation curable resin composition layer to form the cured resin layer as the first layer.   The method according to claim 15, wherein the ionizing radiation curable resin composition comprises a silicone-based release agent. The coating layer is a cured resin layer containing a cured product of a thermosetting resin,
The step (3)
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the remaining portion of the first main surface of the support sheet, and the first layer Forming a thermosetting resin composition layer covering at least a part of
(3-2) The method according to any one of claims 13 to 16, comprising a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer.   The method of claim 17, wherein the thermosetting resin comprises a water-soluble thermosetting resin.   The method of claim 18, wherein the water soluble thermosetting resin comprises a melamine resin.   The method as described in any one of Claims 17-19 in which the said thermosetting resin composition contains a silicone type mold release agent.   The support sheet includes a base sheet, and the base sheet is positioned on the first main surface side of the support sheet on the first main surface side and on the second main surface side of the support sheet. 21. The method according to any one of claims 13 to 20, comprising a second major surface.   The method according to claim 21, wherein the support sheet further includes a decorative layer provided on the first main surface of the base sheet.   The method according to claim 21 or 22, wherein the substrate sheet is a porous sheet. The coating layer is a cured resin layer containing a cured product of a thermosetting resin,
The step (3)
(3-1) Using the thermosetting resin composition containing the thermosetting resin, the first layer is surrounded by the remaining portion of the first main surface of the support sheet, and the first layer Forming a thermosetting resin composition layer covering at least a part of
(3-2) including a step of curing the thermosetting resin composition layer to form the cured resin layer as the coating layer,
In the step (3-1), the porous sheet is impregnated with the thermosetting resin composition,
The method according to claim 23, wherein in the step (3-2), the thermosetting resin composition impregnated in the porous sheet is cured.

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