U.S. patent application number 11/690605 was filed with the patent office on 2008-03-27 for decorative material.
Invention is credited to Kaori Imamichi, Hideaki Mori, Takeshi Nakamura.
Application Number | 20080075966 11/690605 |
Document ID | / |
Family ID | 38830418 |
Filed Date | 2008-03-27 |
United States Patent
Application |
20080075966 |
Kind Code |
A1 |
Mori; Hideaki ; et
al. |
March 27, 2008 |
Decorative Material
Abstract
A decorative material, which can express uneven irregular shapes
due to the differences in the surface gloss state even when the
thickness thereof is thin and which is high in productivity and
which includes a substrate; an expression region, which is a recess
or a salient; a picture pattern on the substrate which corresponds
to the expression region; and an ionizing radiation-curable resin
layer; wherein the ionizing radiation-curable resin layer is
provided in a vicinity of an outline of the picture pattern except
immediately above the picture pattern so as to have a stepwise
gradation in gloss conditions, and wherein a viscosity of the
ionizing radiation-curable resin layer is 0.1 to 1 Pas.
Inventors: |
Mori; Hideaki; (Noda-Shi,
JP) ; Imamichi; Kaori; (Kashiwa-shi, JP) ;
Nakamura; Takeshi; (Kashiwa-shi, JP) |
Correspondence
Address: |
ST. ONGE STEWARD JOHNSTON & REENS, LLC
986 BEDFORD STREET
STAMFORD
CT
06905-5619
US
|
Family ID: |
38830418 |
Appl. No.: |
11/690605 |
Filed: |
March 23, 2007 |
Current U.S.
Class: |
428/542.2 |
Current CPC
Class: |
B44C 3/02 20130101; B44F
7/00 20130101 |
Class at
Publication: |
428/542.2 |
International
Class: |
A47G 35/00 20060101
A47G035/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 22, 2006 |
JP |
P2006-257232 |
Claims
1. A decorative material comprising: a substrate; an expression
region, which is a recess or a salient; a picture pattern on the
substrate which corresponds to the expression region; and an
ionizing radiation-curable resin layer; wherein the ionizing
radiation-curable resin layer is provided in a vicinity of an
outline of the picture pattern except immediately above the picture
pattern so as to have a stepwise gradation in gloss conditions, and
wherein a viscosity of the ionizing radiation-curable resin layer
is 0.1 to 1 Pas.
2. The decorative material according to claim 1 further comprising
a gloss adjusting layer, wherein the gloss adjusting layer has a
gloss after formation thereof which is different from that of the
ionizing radiation-curable resin layer after formation thereof and
forms a surface of the expression region, which is a recess or a
salient, and wherein the ionizing radiation-curable resin layer is
provided on the gloss adjusting layer.
3. The decorative material according to claim 1 further comprising
a base pattern, wherein the base pattern is provided on an entire
surface of the substrate and the picture pattern is partially
provided in the base pattern.
4. The decorative material according to claim 1, wherein the
picture pattern is formed from a water-based ink.
5. The decorative material according to claim 4 further comprising
a sealer layer, wherein the sealer layer is provided between the
picture pattern and the substrate and is formed from an aqueous
resin.
6. The decorative material according to claim 4, wherein the
ionizing radiation-curable resin layer is formed from a
(meth)acrylate-based resin.
7. The decorative material according to claim 5, wherein the
ionizing radiation-curable resin layer is formed from a
(meth)acrylate-based resin.
8. The decorative material according to claim 6 further comprising
silicone oil, wherein the silicone oil is added to the ionizing
radiation-curable resin layer.
9. The decorative material according to claim 2 further comprising
a base pattern, wherein the base pattern is provided on an entire
surface of the substrate and the picture pattern is partially
provided in the base pattern.
10. The decorative material according to claim 7 further comprising
silicone oil, wherein the silicone oil is added to the ionizing
radiation-curable resin layer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed on Japanese Patent Application No.
2006-257232, filed Sep. 22, 2006, the content of which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a decorative material to be
used for interior and exterior finishing of buildings and
architecture, fittings, or surface decorations or the like of
furniture. More specifically, the present invention relates to a
decorative material which, in the case of a woodgrain pattern for
example, expresses uneven irregularities such as vessel parts
stereoscopically by differences in surface gloss.
BACKGROUND OF THE INVENTION
[0003] When uneven irregular shapes are expressed by decorative
materials, which have been used in assembled furniture of a knock
down system, building materials of residences, furniture, or the
like, instead of actually forming the shapes on the surface of
decorative materials, there is a method to visually express the
stereoscopic vision of irregularities using an illusion caused by
the human eye by mutually differentiating surface gloss conditions
among the parts to be expressed as a recess or a salient. According
to this method, even when uneven irregular shapes do not actually
exist, the parts with relatively high gloss and the parts with
relatively low gloss are recognized as a salient and recess
respectively by the human eye.
[0004] Specifically, the following exemplifies the above method. A
synthetic-resin coated layer which is transparent or
semitransparent and which has low gloss is formed on the entire
printing surface of the substrate where appropriate patterns
including recess patterns are printed. Thereafter, on the surface
of the synthetic resin layer except the part which corresponds to
the recess patterns, a synthetic-resin coated layer which is
transparent or semitransparent and which has high gloss is formed.
Needless to say, when the relationship between high and low gloss
is reversed, it is possible to obtain a decorative material where
the relationship between recesses and salients is reversed.
[0005] According to this method, only by preparing two kinds of
coating materials with different glosses without any need or
special agents or the like, it is possible to readily confer a
stereoscopic appearance of uneven irregularities to any substrates.
Moreover, since coated layers of coatings with different glosses
can be formed by conventional printing methods such as the gravure
printing method following the formation of picture patterns,
special appliances are not required at all while the production
efficiency thereof is high and the conformity with the picture
pattern is also readily accomplished. In addition, since the
thickness of the coated layers is far thinner compared to
differences in levels of irregularities to be expressed, not only
resin usage can be reduced but also flexibility thereof can be
improved and thus, it is possible to readily realize decorative
materials which are excellent in processing suitability for
folding. Furthermore, since there are no irregularities with a
large unevenness on the surface of decorative materials, there is
also an advantage of avoiding contaminants to accumulate in
recesses.
[0006] From the viewpoints of many advantages as such, decorative
materials which adopt this method are already used in large
quantities. However, the actual situation of the above method is
that it is still inferior to the method, which forms actual uneven
irregularities, in terms of giving people the impression of high
quality. The reason for the above situation can be considered as
the follows. According to the embossing method by machinery, for
example, uneven irregular shapes of vessels of natural wood or the
like can truly be reproduced including the cross-sectional shape
thereof. On the other hand, this method using two kinds of coating
materials with different glosses can express only two kinds of
irregularity levels since the level of surface gloss is of two
kinds. Accordingly, there is a problem in that uneven irregular
shapes, which have sloping sections where the depth (height)
thereof changes continuously, like vessels of natural wood or the
like cannot be expressed.
[0007] Accordingly, by providing a gloss adjusting layer which
expresses uneven irregular shapes, which have sloping sections
where the depth (height) thereof changes continuously, a decorative
material expressing uneven irregular shapes, which have sloping
sections where the depth (height) thereof changes continuously,
like vessels of natural wood or the like has been proposed (for
example, refer to Patent document 1).
[0008] However, when such a gloss adjusting layer is coated at a
high speed of 80 m/min or more for example, satisfactory drying is
not achieved and blocking may occur at the time of retrieving,
which makes the production thereof difficult.
[0009] On the other hand, the decorative material, which is
provided with a surface-protective layer formed of an ionizing
radiation-curable resin, is known (for example, refer to Patent
document 2). Since this surface-protective layer is cured by
irradiating an electron beam, blocking does not occur even when
coating is carried out with relatively high speed. However, in
order to avoid the effects of mutual adhesion with the ink layer or
shrinkage due to the curing of resin, a certain coating thickness
or an intermediate layer is required.
[0010] [Patent document 1] Japanese Patent Publication No.
3629964
[0011] [Patent document 2] Japanese Patent Publication No.
3756406
SUMMARY OF THE INVENTION
[0012] The present invention is made in view of the above
circumstances and its object is to provide a decorative material
which can express uneven irregular shapes due to the differences in
the surface gloss conditions even when the thickness thereof is
thin and which is high in productivity.
[0013] The present invention adopts the following method in order
to solve the above problems.
[0014] A first aspect of the decorative material according to the
present invention is a decorative material provided with a picture
pattern corresponding to an expression region, which is a salient
or a recess, on a substrate and characterized in that an ionizing
radiation-curable resin layer is provided with a stepwise gradation
in gloss conditions in the vicinity of the outline of the picture
pattern except immediately above thereof and the viscosity of the
ionizing radiation-curable resin layer is 0.1 to 1 Pas.
[0015] Since this invention is provided with the ionizing
radiation-cured resin layer on the surface thereof so as to have a
gradation in gloss conditions, it is possible to produce decorative
materials expressing uneven irregular shapes where the depth
(height) thereof changes continuously, with higher speed. Moreover,
since the viscosity of the ionizing radiation-curable resin is 0.1
to 1 Pas, it is possible to favorably express uneven irregular
shapes where the depth (height) thereof changes continuously
without the ionizing radiation-curable resin being too soft to run
off and it is also possible to produce continuously with high speed
without difficulties in providing the layer due to the resin being
too hard.
[0016] In addition, a second aspect of a decorative material
according to the present invention is the aforementioned decorative
materials characterized in that a gloss adjusting layer having a
gloss after its formation different to that of the ionizing
radiation-curable resin layer after the formation thereof and also
forms the surface of the aforementioned expression region, which is
a recess or a salient, is provided and the ionizing
radiation-curable resin layer is provided on the gloss adjusting
layer.
[0017] In this invention, when the ionizing radiation-curable resin
layer is made as a high gloss layer and the gloss adjusting layer
is made as a low gloss layer for example, uneven irregular shapes
expressed due to gloss will be more explicit. The invention also
satisfies the effect of stress relaxation at the time of curing the
ionizing radiation-curable resin due to this gloss adjusting layer
and thus, can maintain excellent design.
[0018] Moreover, a third aspect of the decorative material
according to the present invention is characterized in that it is
the above-mentioned decorative material where a base pattern is
provided on the entire surface of the substrate and the picture
pattern is partially provided in the base pattern.
[0019] This invention can achieve an excellent design
stereoscopically by the base pattern present on the entire surface
and the partially provided picture pattern, which expresses a
recess or a salient.
[0020] Moreover, a fourth aspect of the decorative material
according to the present invention is characterized in that it is
the above-mentioned decorative material where the picture pattern
is formed from a water-based ink.
[0021] Since this invention uses the water-based ink, it is
possible to reduce the amount of volatile organic compounds.
[0022] Moreover, a fifth aspect of the decorative material
according to the present invention is characterized in that it is
the above-mentioned decorative material where a sealer layer formed
from an aqueous resin is provided between the picture pattern and
the substrate.
[0023] Since the sealer layer formed of an aqueous resin is
provided, this invention is excellent in adhesive properties among
respective layers and is capable of improving various surface
resistances.
[0024] Moreover, a sixth aspect of the decorative material
according to the present invention is characterized in that it is
the above-mentioned decorative material where the ionizing
radiation-curable resin layer is formed from a monomer of
(meth)acrylate-based resins.
[0025] Since the monomer based on (meth)acrylate is used, this
invention is excellent in adhesive properties among layers with
respect to the lower layer after coating while having a favorable
viscosity and is capable of improving various surface resistances
even when the thickness thereof is thin.
[0026] Moreover, a seventh aspect of the decorative material
according to the present invention is characterized in that it is
the above-mentioned decorative material where silicone oil is added
to the ionizing radiation-curable resin layer.
[0027] Since silicone oil is added, it is possible this invention
to improve the surface stain resistance.
[0028] According to the present invention, it is possible to
express uneven irregular shapes by the differences in surface gloss
conditions even if the thickness is thin and also to improve
productivity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is an explanatory drawing showing the cross-sectional
structure of a decorative material according to one embodiment of
the present invention.
[0030] FIG. 2 is an explanatory drawing showing the cross-sectional
structure of a modified example of a decorative material according
to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] One embodiment according to the present invention will be
described by referring to FIG. 1.
[0032] A decorative material 1 according to the present embodiment
is a decorative material where a picture pattern 4 corresponding to
an expression region 3, which is a recess or a salient, is provided
on a substrate 2. The decorative material 1 has the picture pattern
4 partially provided in a base pattern 5, which is provided on the
entire surface of the substrate 2, a gloss adjusting layer 6
provided by covering the picture pattern 4 and which forms the
surface of the expression region 3, which is a recess or a salient,
and an ionizing radiation-curable resin layer 7 provided in the
vicinity of the outline of the picture pattern 4 except the
expression region 3, which is a recess or a salient and which is
immediately above the picture pattern 4, and which has a stepwise
gradation in terms of gloss conditions. A sealer layer 8 formed
from an aqueous resin is provided between the picture pattern 4 and
substrate 2. Note that the expression region 3, which is a recess
or a salient, means a region to visually express as a recess or a
salient when compared to the part in which the ionizing
radiation-curable resin layer 7 is provided.
[0033] For the substrate 2, various materials can be used depending
on the purpose as conventionally known. Specifically, paper such as
tissue paper, titanium paper, resin-impregnated paper, flameproof
paper, and mineral paper; woven or non-woven fabrics formed from
natural fibers or synthetic fibers; substrates based on synthetic
resins such as homo- or random polypropylene resins,
polyolefin-based resins such as polyethylene resins, copolyester
resins, crystalline polyester resins in an amorphous state,
polyethylene naphthalate resins, polybutylene resins, acrylic
resins such as methylmethacrylate resins and polymethylmethacrylate
resins, styrene-based resins, polyamide-based resins,
cellulose-based resins, polycarbonate resins, polychlorinated vinyl
resins, polychlorinated vinylidene resins, and fluorine resins;
wood-based substrates such as a wood veneer, sliced veneer,
plywood, glued laminated wood, particle board, and medium density
fiber board; mineral substrates such as a gypsum board, cement
plate, calcium silicate board, and ceramic board; metal substrates
such as iron, copper, aluminium, and stainless steel; complexes
thereof, laminated bodies thereof, or the like which are
conventionally known arbitrary materials can be used and shapes
thereof are not limited at all and film-forms, sheet-forms,
board-forms, or atypical compact-forms can be adopted, for
example.
[0034] Although materials constituting the base pattern 5 and
picture pattern 4 are not particularly limited, together with an
appropriate binder resin, printing ink or coating materials, which
are formed by dissolving or dispersing coloring agents such as dyes
or pigments in an appropriate solvent, are generally used.
[0035] As such coloring agents, for example, inorganic pigments
such as carbon black, titanium white, zinc white, red iron oxide,
chrome yellow, iron blue, and cadmium red; organic pigments such as
azo pigments, lake pigments, anthraquinone pigments, phthalocyanine
pigments, isoindolinone pigments, and dioxazine pigments; or
mixtures of two or more of these pigments can be used.
[0036] As binder resins, for example, various synthetic resins such
as acrylic resins, styrene resins, polyester resins, urethane
resins, polyvinyl resins, alkyd resins, petroleum resins, ketone
resins, epoxy resins, melamine resins, fluororesins, silicone
resins, cellulose resins, and gum resins, mixtures thereof, or
copolymers thereof can be used.
[0037] As a solvent, for example, toluene, xylene, cyclohexane,
ethyl acetate, butyl acetate, methyl alcohol, ethyl alcohol,
isopropyl alcohol, acetone, methyl ethyl ketone,
methylisobutylketone, cyclohexanone, water, or the like, or a
mixture thereof can be used.
[0038] Other agents including various additives such as extender
pigments, plasticizers, dispersing agents, surfactants, tackifiers,
adhesion auxiliaries, desiccants, curing agents, curing
accelerators, or concrete retarders are used where appropriate.
[0039] The base pattern 5 needs to contain, at least, the picture
pattern 4 which corresponds to the expression region 3, which is a
recess or a salient. On the other hand, it is also possible to make
a decorative material 10 as one which is provided with, although
not essential, a surface pattern 9 as shown in FIG. 2 in order to
confer designs visually recognized as a color pattern, which is
independent of uneven surface irregularities, in the vicinity of
the outline of, but excluding immediately above, the picture
pattern 4 which corresponds to the expression region 3, which is a
recess or a salient.
[0040] For example, in the case of woodgrain patterns, it is common
to separately print a base solid, woodgrain form, vessel pattern,
or the like as conventionally known. Among them, the base solid and
woodgrain form are provided as the base pattern 5 in the decorative
material 1 of the present invention and the vessel pattern is
provided as the picture pattern 4 which corresponds to the
expression region 3, which is a recess or a salient. Needless to
say, the base pattern 5 in the present invention is not limited to
woodgrain patterns and it can be appropriately applied to rift
patterns, abstract patterns, or the like.
[0041] FIG. 1 is described so that the picture pattern 4 which
corresponds to the expression region 3, which is a recess or a
salient, is provided on the surface of the base pattern 5. However,
this does not necessarily define the upper and lower relationship
between the two patterns and both patterns may be provided as a
continuous picture form on an identical surface or in a manner
where the upper and lower relationship between the two is reversed,
or a transparent layer (transparent substrate is also possible) or
the like may be interposed between the two patterns. In addition,
the entire base pattern 5 or a part thereof may also be formed by
being integrated with the substrate 2 by mixing or infiltrating
coloring agents in the substrate 2. In short, when observed from
the surface side of a decorative material, it is fine as long as
the picture pattern 4 corresponding to the expression region 3,
which is a recess or a salient, and the base pattern 5 are
configured so that the two patterns can be identified in terms of
colors.
[0042] The base pattern 5 and picture pattern 4 are generally
formed by appropriate printing methods such as the gravure printing
method, offset printing method, screen printing method,
electrostatic printing method, and ink-jet printing method.
However, methods are not limited to those above and, for example,
the aforementioned base solid may also be formed by coating methods
such as the roll coating method, knife coating method, and die
coating method. In addition, other patterns can also be formed by
arbitrary image-forming methods which are conventionally known.
[0043] The gloss adjusting layer 6 is constituted from printing
ink, coating agents, or the like, which are similar to those cited
as the aforementioned constituting materials of the base pattern 5
and picture pattern 4. This is with the proviso that, since the
gloss adjusting layer 6 needs to be provided with transparency,
which makes at least the base pattern 5 and picture pattern 4
possible to be seen through the layer, as a printing ink, coating
agents, or the like which form the layer, it is necessary to use
those which contain no coloring agents such as dyes or pigments at
all or only in a small amount to an extent where the required
transparency is not impaired.
[0044] Additionally, since the gloss adjusting layer 6 is one which
constitutes the most outer surface layer of the decorative material
1 in the expression region 3, which is a recess or a salient, the
layer is preferably constituted from materials having a hardening
resin as a major component to achieve surface physical properties
required by the decorative material 1 such as abrasion resistance,
scratch resistance, solvent resistance, and stain resistance.
Specifically, for example, thermosetting resins such as melamine
resins, epoxy resins, aminoalkyd resins, urethane resins, polyester
resins, and silicone resins; or ionizing radiation-curable resins
such as acrylic resins can favorably be used. Although the term
"ionizing radiation" generally refers to a radiation which imposes
ionization effects on substances and includes X-rays, .gamma.-rays,
.beta.-rays (electron rays), and short wavelength ultraviolet rays,
in the present invention, since UV-curable resins due to
photoinitiators can also be used, the term also includes long
wavelength ultraviolet rays, which do not impose ionization
effects.
[0045] In order to express continuous changes in depth (height) by
the changes in gloss conditions, the ionizing radiation-curable
resin layer 7 is configured so as to change the gloss conditions
thereof continuously or stepwise in the vicinity of the outline of
the expression region 3, which is a recess or a salient. In other
words, when proceeding from the outline of the expression region 3,
which is a recess or a salient, towards the inside thereof, the
gloss conditions change from one close to that of the surface of
the region 3 to that in the part other than the vicinity of the
picture pattern 4, which corresponds to the region 3.
[0046] To describe more specifically, when expressing the
expression region 3 as a recess, the ionizing radiation-curable
resin layer 7 is designed so as to have a higher gloss than that of
the surface of the region 3. In addition, the ionizing
radiation-curable resin layer 7 is formed by being provided with a
gradation so that in the vicinity of the outline of the region 3,
when departing from the outline of the region 3 and proceeding to
the inside of the part where the ionizing radiation-curable resin
layer 7 is formed, the gloss of the ionizing radiation-curable
resin layer 7 gradually becomes higher.
[0047] On the other hand, when expressing the expression region 3
as a salient, the ionizing radiation-curable resin layer 7 is
designed so as to have a lower gloss than that of the surface of
the region 3. Moreover, the ionizing radiation-curable resin layer
7 is formed by being provided with a gradation so that in the
vicinity of the outline of the region 3, when departing from the
outline of the region 3 and proceeding to the inside of the part
where the ionizing radiation-curable resin layer 7 is formed, the
gloss of the ionizing radiation-curable resin layer 7 gradually
becomes lower. When using a printing plate for the gravure printing
method, in addition to the methods which use a film at the time of
printing such as the chemical etching method (in which deviations
in multistage alignment occur easily due to expansion and
contraction of the film) or the mechanical engraving method, use of
a laser-made plate will result in the large cell volume of the
printing plate and difficulties in positional deviations even when
multistage etching is carried out. Thus, it is possible to express
gradation with better register accuracy.
[0048] Note that the outline of the picture pattern 4 corresponding
to the expression region 3, which is a recess or a salient, does
not necessarily precisely coincide with the outline of the
stair-like region 3 and it may be deviated to the inside or outside
of the outline of the stair-like region 3 to some extent. It is
also possible to appropriately adjust the virtual appearance of
uneven irregularities by positively deviating the outlines of both
patterns slightly from each other. In addition, it is also possible
to confer changes in virtual appearance of uneven irregularities
depending on places by changing directions or distances of
deviations between the outlines of both patterns inside the
stair-like region 3.
[0049] When expressing minute recesses or salients such as
woodgrains and vessels, the parts in ionizing radiation-curable
resin layer 7 where gradation is provided will also naturally
become minute and a high degree of resolution is required also in
printing plates, printing ink, or the like. On the other hand, in
general two-component curable resins which are heavily used as
surface coating agents of decorative materials, a curing reaction
proceeds during printing resulting in the increase in viscosity
thereof causing so-called plate fill in and thus, reproducibility
of gradation is reduced in some cases.
[0050] Accordingly, resins used for the ionizing radiation-curable
resin layer 7 are those having a viscosity of 0.1 to 1 Pas. This is
because when the viscosity is within this range, favorable adhesive
properties among layers are achieved. In addition, when the
viscosity is lower than 0.1 Pas, layers will become too flexible
and will easily collapse and when the viscosity exceeds 1 Pas,
layers will become stiff and adhesive properties with the adjacent
layers will be deteriorated.
[0051] As such resins, specifically, ionizing radiation-curable
monomers, which do not increase the viscosity thereof with time
during printing, are used. These resins do not increase the
viscosity thereof since a curing reaction does not proceed when
they are in a coating-liquid state at normal temperature during
printing. On the other hand, since a curing reaction proceeds
rapidly after resins are irradiated with ionizing radiation and
resins are cured completely, there are advantages such as the lack
of generation of blocking due to poor drying even when printed
matter is retrieved or laminated
[0052] As ionizing radiation-curable monomers, the compounds having
ethylenic unsaturated double bonds can be used and these include
monofunctional monomers, difunctional monomers, and polyfunctional
monomers such as trifunctional monomers. Usually, the monomers are
those which are not hydrophilic and for example, they do not have
any of --CHO group, --OH group, and --COOH group.
[0053] Specific examples of monofunctional monomers which have
ethylenic unsaturated double bonds include 2-(2-ethoxyethoxy)ethyl
(meth)acrylate, stearyl(meth)acrylate,
tetrahydrofurfuryl(meth)acrylate, lauryl (meth)acrylate,
2-phenoxyethyl(meth)acrylate, isodecyl(meth)acrylate,
isooctyl(meth)acrylate, tridecyl(meth)acrylate, caprolactone
(meth)acrylate, ethoxylated nonyl phenol (meth)acrylate,
propoxylated nonyl phenol (meth)acrylate,
phenoxyethyl(meth)acrylate, phenoxydiethylene (meth)acrylate,
ethylene oxide-modified nonylphenyl(meth)acrylate,
methoxytriethylene glycol (meth)acrylate, ethylene oxide
2-ethylhexyl (meth)acrylate, and isobonyl(meth)acrylate dipropylene
glycol (meth)acrylate. When it is described as
"stearyl(meth)acrylate", for example, this shows it means stearyl
acrylate and/or stearyl methacrylate (and same applies to others
hereinafter).
[0054] Examples of difunctional monomers include 1,3-butanediol
di(meth)acrylate, 1,4-butanediol di(meth)acrylate, polyethylene
glycol di(meth)acrylate, polypropylene glycol di(meth)acrylate,
neopentyl glycol di(meth)acrylate, propoxylated neopentyl glycol
di(meth)acrylate, ethoxylated neopentyl glycol di(meth)acrylate,
neopentyl glycol hydroxypivalate di(meth)acrylate, (hydrogenated)
bisphenol A di(meth)acrylate, (hydrogenated) ethylene
oxide-modified bisphenol A di(meth)acrylate, (hydrogenated)
propylene glycol-modified bisphenol A di(meth)acrylate,
1,6-hexanediol di(meth)acrylate, 2-ethyl-2-butylpropanediol
di(meth)acrylate, and 1,9-nonanediol di(meth)acrylate.
[0055] Examples of polyfunctional monomers include
tris(2-hydroxyethyl)isocyanurate tri(meth)acrylate, ethoxylated
trimethylolpropane tri(meth)acrylate, propoxylated
trimethylolpropane tri(meth)acrylate, propoxylated glyceryl
tri(meth)acrylate, pentaerythritol tri(meth)acrylate,
trimethylolpropane (meth)acrylate, ethylene oxide-modified
trimethylolpropane (meth)acrylate, propylene oxide-modified
trimethylolpropane (meth)acrylate, tris(acryloxyethyl)
isocyanurate, pentaerythritol tetra(meth)acrylate,
ditrimethylolpropane tetra(meth)acrylate, ethoxylated
pentaerythritol tetra(meth)acrylate, penta(meth)acrylate ester, and
dipentaerythritol hexa(meth)acrylate.
[0056] As ionizing radiation-curable monomers, monomers such as
urethane (meth)acrylate, polyester (meth)acrylate, polyether
(meth)acrylate, and polyacryl(meth)acrylate are desirable since
their surface easily becomes smooth after coating due to their low
viscosity and anchor effects to the sealer layer 8, base pattern 5,
or the like also improve.
[0057] Silicone oil is added to the ionizing radiation-curable
resin layer 7. This is added as an antipollution agent for
preventing surface contaminants of the ionizing radiation-curable
resin layer 7 from becoming attached or for allowing the attached
contaminants to be easily wiped away with various detergents or
solvents. Silicone oil is incorporated in the matrix resin
constituted from ionizing radiation-curable monomers.
[0058] As a silicone oil, unmodified silicone oil, amino-modified
silicone oil, epoxy-modified silicone oil, carboxy-modified
silicone oil, mercapto-modified silicone oil, carbinol-modified
silicone oil, methacryl-modified silicone oil, and phenol-modified
silicone oil can be used. The amount of silicone oil is preferably
0.01 to 5 weight % when the total weight of ionizing
radiation-curable monomers is taken as a standard. This is because
when the amount of silicone oil is less than 0.01 weight %, effects
of the addition thereof are not achieved and when the amount
exceeds 5 weight %, the aqueous resins of the picture pattern 4 or
the like are repelled to cause adhesive failures.
[0059] When the picture pattern 4 corresponding with the expression
region 3, which is a recess or a salient, is expressed as a recess
as described above, the gloss of the ionizing radiation-curable
resin layer 7 needs to be designed higher than that of the gloss
adjusting layer 6. On the other hand, when the picture pattern 4
corresponding with the expression region 3, which is a recess or a
salient, is expressed as a salient, the gloss of the ionizing
radiation-curable resin layer 7 needs to be designed lower than
that of the gloss adjusting layer 6. In order to appropriately
adjust gloss conditions of the ionizing radiation-curable resin
layer 7, gloss-adjusting agents such as silica, alumina, calcium
carbonate, and barium sulfate may be added where appropriate.
[0060] In many cases, it is more advantageous from the viewpoint of
visually-obtained stereoscopic vision of uneven irregularities that
the gradation provided in the ionizing radiation-curable resin
layer 7 be a stepwise gradation in terms of changes in gloss
conditions as shown in FIG. 1 even when the aim is to express
continuous changes in depth (height). In particular, since there
are many cases where continuous gradation results in a poor sense
of tone although the size of uneven irregularities is highly minute
(for example, like the case of vessel grooves of wood or the like
where stereoscopic vision present in the cross-sectional shape of a
natural vessel groove is not sufficiently expressed), it is
preferable that gradation be stepwise.
[0061] As a method to provide gradation in gloss conditions of the
ionizing radiation-curable resin layer 7, for example, a gravure
printing method is used and it is carried out by changing the depth
or area ratio of the gravure printing plate so that desired
gradation is achieved. Other printing methods such as a general
offset printing method, screen printing method, electrostatic
printing method, and ink jet method are also used where
appropriate.
[0062] Note that the abovementioned gradation is not limited to the
gradation due to changes in the coating amount of ionizing
radiation-curable resins and it is possible to express gradation
due to changes in area ratio of halftone dots or the like (not
illustrated) and it is also possible to use changes in the coating
amount and changes in the area ratio concomitantly (not
illustrated).
[0063] This is with the proviso that these differences are not
necessarily fundamental since generally speaking, even when the
design on the printing plate is in the form of halftone dots, it is
common to become more or less continuous due to resin flow at the
time of printing. Although a description is hereinafter provided
using the stepwise figure as shown in FIG. 1 to be brief, this
includes all the various techniques for the expression of gradation
mentioned above.
[0064] When the expression region 3 is expressed as a recess, the
surface of the expression region 3 must be in a low-gloss
condition. In order to achieve the condition, as shown in the
example in FIG. 1, when the base pattern 5 corresponding to the
expression region 3 is exposed in the surface in the region 3,
there is a need to adjust the pattern in a low-gloss condition by
appropriately adding gloss adjusting agents or the like to printing
ink or the like, which forms the base pattern 5. On the other hand,
when the expression region 3 is expressed as a salient, there is a
need to use printing ink, which makes the surface gloss after
printing high, as the printing ink to form the picture pattern 4
corresponding to the region 3.
[0065] The positional relationship between the expression region 3,
which is a recess or a salient, and the base pattern 5
corresponding to the region 3 is mentioned again here. When
expressing a recess or a salient where only the bottom face of the
recess or the top face of the salient has different colors from the
other parts, there is a need to form the base pattern 5 having an
identical outline to that of the region 3. On the other hand, when
expressing a recess or a salient where slope sections of the
outline of the recess or the salient also have identical colors to
that of the bottom face or the top face, it is preferable to form
the base pattern 5 in the region where the ionizing
radiation-curable resin layer 7 reaches the outline of a region,
which is outside the expression region 3 and has gradation. For
example, when imitation of vessel grooves in the cross-section of
natural wood is aimed at, the latter configuration is
recommended.
[0066] In addition, when expressing the state where colors
continuously change in the slope sections of the outline of the
recess or the salient, it is good to provide gradation in the color
of the base pattern 5 in the region, which is in the vicinity of
the outline of the region 3 and where the ionizing
radiation-curable resin layer 7 has gradation. Alternatively, it is
also possible to achieve an analogous visual expression effect by
placing the outline of the base pattern 5 in the middle of internal
and external outlines of the region where the ionizing
radiation-curable resin layer 7 has gradation. Additionally, it is
also possible to express complex uneven irregular shapes where the
appearance of uneven irregularities changes depending on the
position by adopting the combinations of various expression
techniques described so far depending on the position.
[0067] Specific examples where the present invention is applied are
most represented by the expression of vessel grooves of natural
wood as already mentioned many times. Since vessel grooves are
physically recesses, the configuration where surface gloss of the
vessel-pattern part is made low and the ionizing radiation-curable
resin layer 7 having a high gloss is provided on the surface except
the vessel-pattern part is generally adopted. However, there are
also cases where it is better to reverse the high and low state of
gloss from the above to achieve reality like the case when
expressing the types of trees whose color tones of the wood surface
are light and vessel-groove parts appear to come to the surface
such as certain types of coniferous wood.
[0068] According to such a decorative material 1, it is possible to
express uneven irregular shapes where the depth (height) changes
continuously like vessels of natural wood or the like since the
ionizing radiation-curable resin layer 7 is provided on the surface
of the decorative material 1 so as to have gradation in gloss
conditions. By making the viscosity of the ionizing
radiation-curable resin 0.1 to 1 Pas at this juncture, it is
possible to favorably express uneven irregular shapes where the
depth (height) thereof changes continuously without the ionizing
radiation-curable resin being too soft to run off and it is also
possible to produce the decorative material 1 continuously at a
high speed without difficulties in providing the layer due to the
resin being too hard. Moreover, the stress generated at the time
when the ionizing radiation-curable resin is cured can be favorably
relaxed and peeling among layers can favorably be suppressed.
[0069] Additionally, by making the ionizing radiation-curable resin
layer 7 as the high gloss layer and by providing the gloss
adjusting layer 6 with low gloss between the layer 7 and the
picture pattern 4, it is possible to make the expression of uneven
irregular shapes due to gloss more distinctly. Furthermore, due to
this gloss adjusting layer 6, the stress generated when the
ionizing radiation-curable resin is cured can be relaxed and
peeling of the picture pattern 4 or the base pattern 5 or the like
can be suppressed. For this reason, it is possible to favorably
maintain more stereoscopically excellent design achieved by the
base pattern 5 on the entire surface and the picture pattern 4,
which is partially provided and which expresses a recess or a
salient.
[0070] In addition, by using a water-based ink in the picture
pattern 4, it is possible to reduce the amount of volatile organic
compounds. Moreover, since the sealer layer 8 formed of an aqueous
resin is provided on the substrate 2, adhesive properties among
respective layers will be excellent and various surface resistances
can be improved.
[0071] Additionally, by using monomers based on (meth)acrylate in
the ionizing radiation-curable resin layer 7, adhesive properties
among layers with respect to the lower layer after coating will be
excellent even with a favorable viscosity and various surface
resistances can be improved.
[0072] Moreover, since silicone oil is added to the ionizing
radiation-curable resin layer 7, it is possible to improve the
surface stain resistance.
[0073] Note that the scope of techniques of the present invention
is not limited to the above embodiment and various changes can be
made within the range not deviating from the scope of the present
invention.
[0074] For example, in the above embodiment, it is implicitly
assumed that gloss conditions of the ionizing radiation-curable
resin layer 7 in the part other than the vicinity of the expression
region 3, which is a recess or a salient, are constant. However,
for example, it is also possible to confer changes conforming with
woodgrain patterns to gloss conditions of the ionizing
radiation-curable resin layer 7 in order to express gloss
differences between the spring-wood part and autumn-wood part in
natural wood or gloss differences due to angles between sections
and woodgrain directions. By doing so, it is possible to achieve a
decorative material extremely excellent in design properties, which
is closer to natural wood, coupled with the aforementioned true
expression of shapes of vessel-groove parts.
EXAMPLE 1
[0075] Tissue paper with a basis weight of 29 g/m.sup.2 ("HPN-29"
produced by Tentok Paper Co., Ltd.) was used as the substrate 2. An
aqueous urethane-based coating (a mixture of 100 parts of "LWO59
SEALER" and 5 parts of "LT109 HARDERNER" both produced by Toyo Ink
MFG. Co., Ltd.) was coated on the surface thereof as a sealer layer
8 formed of an aqueous resin so that the coating amount after
drying will be 2 g/m.sup.2.
[0076] A colored solid layer of one color was printed thereon on
the entire surface by gravure printing using an aqueous acrylic
resin-based gravure printing ink ("PCW" produced by Toyo Ink MFG.
Co., Ltd.) as a water-based ink of the base pattern 5. Furthermore,
a woodgrain pattern was printed and a vessel pattern, which
conformed with the woodgrain pattern, was sequentially printed as
the picture pattern 4 corresponding to the expression region 3,
which is a recess or a salient.
[0077] A resin ("LT097EB Primer" produced by Toyo Ink MFG. Co.,
Ltd.) formed from an acrylic resin, in which silica powder was
added to adjust the gloss thereof to low, urethane resin, casein,
trifunctional monomer, and an additive was coated on the entire
surface of the above patterns as the gloss adjusting layer 6 so
that the coating amount after drying will be 5 g/m.sup.2. Then an
ionizing radiation-curable resin (a mixture of 50 weight parts of
pentaerythritol tri(meth)acrylate, 50 weight parts of ethoxylated
trimethylolpropane (meth)acrylate, and 0.5 weight parts of
amino-modified silicone oil) formed from silicone acrylate monomer
to achieve high gloss was coated as the ionizing radiation-curable
resin layer 7 on the surface except the vessel-pattern part with a
coating amount of 4 g/m.sup.2 by providing gradation in the
vicinity of the outline of the vessel-pattern layer.
[0078] Thereafter, an electron beam was irradiated in a nitrogen
atmosphere under the irradiation conditions of 45 KGy (5 Mrad)
dose, 1.5 kV, 100 mA, and line speed of 200 m/min to cure the
ionizing radiation-curable resin.
[0079] When the decorative material obtained as described so far
was retrieved, blocking did not occur.
EXAMPLE 2
[0080] Tissue paper with a basis weight of 29 g/m.sup.2 ("HPN-29"
produced by Tentok Paper Co., Ltd.) was used as the substrate 2. A
colored solid layer of one color was printed thereon on the entire
surface using a gravure printing ink formed of an oil-based acrylic
resin ("PCNT" produced by Toyo Ink MFG. Co., Ltd.) as the base
pattern 5. Furthermore, a woodgrain pattern was printed and a
vessel pattern (150 lines in line number of a pattern
printing-plate), which conformed with the woodgrain pattern, was
sequentially printed as the picture pattern 4 corresponding to the
expression region 3, which is a recess or a salient.
[0081] A coating (a mixture of 100 parts of "EXP-UV60425 mat" and
10 parts of "W325N") formed from a two-component curable urethane
resin, in which silica powder was added to adjust the gloss thereof
to low, and a UV-curable resin was coated on the entire surface of
the above patterns as the gloss adjusting layer 6 so that the
coating amount after drying will be 5 g/m.sup.2.
[0082] Then a UV-curable resin (a mixture of 50 parts of
"EXP-UV60425 HighMat" and 50 parts of "EXP-UV60425 gloss" both
produced by Dainippon Ink and Chemicals Inc.) formed from a
urethane acrylate monomer to achieve high gloss was coated as the
ionizing radiation-curable resin layer 7 on the surface except the
vessel-pattern part with a coating amount after drying of 2
g/m.sup.2 by providing gradation (line number of 100 lines) in the
vicinity of the outline of the vessel-pattern layer.
[0083] Thereafter, ultraviolet rays were irradiated in an air
atmosphere under the irradiation conditions using two metal halide
lamps of 160 W/cm and a line speed of 100 m/min to cure the
UV-curable resin. When the decorative material obtained as
described so far was retrieved, blocking did not occur.
[0084] Thereafter, although an electron beam-curable colored enamel
coating (produced by Toyo Ink MFG. Co., Ltd.) is provided as the
surface pattern 9 only on the surface of the picture pattern 4
corresponding to the expression region 3, which is a recess or a
salient, the provision was easily carried out without any problems
such as gradation collapse or positional deviations.
COMPARATIVE EXAMPLE
[0085] In the configuration of Example 2, block isocyanate-curable
urethane resin (produced by Toyo Ink MFG. Co., Ltd.) was used
instead of the UV-curable resin (a mixture of 50 parts of
"EXP-UV60425 HighMat" and 50 parts of "EXP-UV60425 gloss" both
produced by Dainippon Ink and Chemicals Inc.). Although uneven
irregular shapes, which had sloping sections where the depth
(height) thereof changed continuously, are provided with a line
speed of 80 m/min in the vicinity of the region of the picture
pattern 4 corresponding to the expression region 3, which is a
recess or a salient, blocking occurred at the time of retrieving.
Although the surface pattern 9 was further provided thereafter,
gradation collapsed and design properties thereof were
impaired.
[0086] The decorative materials obtained in each of the
abovementioned Examples were decorative materials having an
appearance of uneven irregularities of vessel grooves, which is
analogous to natural vessels, due to the gradation in gloss
conditions in the outline section of the vessel pattern and
excellent in design properties. Moreover, they could be produced
with good workability without generating problems such as the
so-called plate fill in during printing, blocking due to poor
drying, or trapping.
INDUSTRIAL APPLICABILITY
[0087] The present invention can be used as a decorative material
for interior and exterior finishing of buildings and architecture,
fittings, or surface decorations or the like of furniture. More
specifically, the present invention can be used as a decorative
material which, in the case of a woodgrain pattern for example,
expresses uneven irregularities such as vessel parts
stereoscopically by differences in surface gloss.
[0088] While preferred embodiments of the invention have been
described and illustrated above, it should be understood that these
are exemplary of the invention and are not to be considered as
limiting. Additions, omissions, substitutions, and other
modifications can be made without departing from the spirit or
scope of the present invention. Accordingly, the invention is not
to be considered as being limited by the foregoing description, and
is only limited by the scope of the appended claims.
* * * * *