Decorative material

Abstract

 The present invention provides a decorative material that represents recesses and protrusions by means of difference in the state of luster of the surface, and also represents an improved three-dimensional impression at lower cost without requiring a complicated structure and a complicated manufacturing method.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a decorative material used to provide an aesthetic effect on the surface of the interior and/or exterior of a building, joinery, furniture, etc. Particularly, the present invention relates to a decorative material which provides a three-dimensional impression of recesses and protrusions by means of difference in the level of luster on the surface.

BACKGROUND OF THE INVENTION

[0002] To produce recesses and protrusions on a decorative material that has been used in knock-down furniture, a building material, furniture or the like, there is such a method that provides a visual effect of a three-dimensional impression of recesses or protrusions by differentiating the level of the state of luster between portions to be seen as protruding or portions to be seen as recessed on the surface so as to take advantage of the visual illusion of human recognition, instead of forming real recesses and protrusions on the decorative material. This method causes a portion having higher luster to be seen as if protruding and a portion having lower luster to be seen as if recessed by the human eye, when in fact there are no recesses and protrusions.

[0003] The above-mentioned method is implemented, for example, by forming a synthetic resin paint layer, from a transparent or semi-transparent synthetic resin paint layer having a lower level of luster, over the entire surface of a substrate whereon an appropriate design including a recess pattern is printed, then forming a transparent or semi-transparent synthetic resin paint having a higher level of luster on a portion of the surface of the synthetic resin paint layer except for the portion where the recess pattern is formed. As a matter of course, when the relation of the level of luster is reversed, it is possible to obtain a decorative material in which the relation of recesses and protrusions is reversed.

[0004] This method enables the rendering of a three-dimensional impression of recesses and protrusions to any substrate simply by preparing two kinds of paints having different luster levels, without using any special chemical. In addition, since the layers having different luster levels can be formed by a common printing method such as gravure printing after forming the design pattern, no special facility is required so that the process can be carried out with high productivity and matching with the design pattern can be easily achieved. Also because the paint layer can be far thinner than the height difference between the recesses and protrusions to be represented, consumption of the resin can be decreased and higher flexibility is achieved so that a decorative material having an excellent property on bending processing can be easily provided. Also because the decorative material does not have significant surface irregularities, there is such an advantage that stains do not accumulate in recesses.

[0005] Due to the many advantages described above, the decorative material based on the above-mentioned method has been used in large quantities, but have not yet excelled in a method of actually forming a high quality of recesses and protrusions. The reason can be considered as follows. A mechanical embossing method, for example, is capable of representing the configuration of the recesses and protrusions such as vessels of natural wood accurately including the sectional configuration. With this method that uses two kinds of paints having different luster levels, in contrast, surface luster is provided in two levels and therefore recesses and protrusions that can be represented are also provided in two levels. As a result, there is a problem that this method is not capable of representing the configuration of recesses and protrusions having slopes where depth (height) changes continuously as in the case of vessels of natural wood.

[0006] Accordingly, such a decorative material has been proposed (see, for example, Japanese Patent No. 3,629,964) that represents the configuration of recesses and protrusions having slopes where depth (height) changes continuously as in the case of vessels of natural wood, by providing a luster control layer that represents the configuration of recesses and protrusions having slopes where a depth (height) changes continuously.

[0007] However, a difference in the state of luster must be provided so as to obtain an improved three-dimensional impression, and also the state of luster of the portion representing recesses or protrusions must be changed by adjusting the amount of an additive in the decorative material of Japanese Patent No. 3,629,964. There is a physical limitation and also a design limitation only by an adjustment of the amount. There is also a limitation in the state of luster of the portion representing neither recesses nor protrusions of the surface, the state of the luster of the portion provided being different from that of the portion representing recesses or protrusions.

[0008] Meanwhile, there is proposed a structure comprising multiple layers having a gradation region, that are stacked while changing the state of luster. However, this structure requires high cost and also requires labor and time, and a design effect corresponding to the cost cannot be obtained even when using in combination with a stepwise gradation method.

SUMMARY OF THE INVENTION

[0009] The present invention has been devised to solve the problems described above, with an obj ect of providing a decorative material that represents a three-dimensional expression of recesses and protrusions by means of difference in the state of luster of the surface, and also represents an improved three-dimensional impression at lower cost without requiring a complicated structure and a complicated manufacturing method.

[0010] In order to solve the problems described above, the present invention proposes the following means.

[0011] The decorative material of the present invention comprises a substrate; a solid concealing layer formed on the substrate; a design pattern provided on the solid concealing layer to correspond to an expression region that represents recesses or protrusions; a first luster control layer that covers the design pattern and solid concealing layer, and adjusts the luster level; and a second luster control layer that is provided on the first luster control layer with a state of luster different from that of the first luster control layer, while having a gradation region where the state of luster is changed stepwise in the vicinity of the outline of the design pattern except for the portion directly above the design pattern; wherein the gradation region of the second luster control layer is not provided up to a location corresponding to 20% of the thickness of the second luster control layer from an interface of the first luster control layer side to the surface side, and the gradation region is formed within a range from the location to the surface side.

[0012] In the decorative material of the present invention, in the case of representing recesses and protrusions by means of two layers, the first luster control layer and the second luster control layer, that are controlled to have different states of luster, stepwise gradation of the state of luster is provided by the gradation region. It becomes more effective by providing the gradation region at the surface side that exerts a large visual influence. Since gradation is not provided up to a location corresponding to 20% of the thickness of the second luster control layer from the interface of the first luster control layer side to the surface side, cost required to provide the gradation region can be reduced.

[0013] It is more preferable that the decorative material has a surface pattern formed on the first luster control layer directly above the design pattern.

[0014] Forming the surface pattern on the decorative material of the present invention enables the provision of a design that is recognized as a color pattern, independent from the recesses and protrusions provided in the gradation region.

[0015] In the decorative material of the present invention, since the gradation region of the second luster control layer is provided within a range from a location corresponding to 20% of the thickness of the second luster control layer to the surface side, from the interface of the first luster control layer side to the surface side, a three-dimensional impression can be further improved by exerting stepwise degradation of the state of luster at lower cost without requiring a complicated structure and a complicated manufacturing method.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 

Fig. 1 is a sectional view of a decorative material according to a first embodiment of the present invention.

Fig. 2 is a sectional view of a decorative material according to a second embodiment of the present invention.

Brief Description of the Reference Numerals

[0017] 

1, 10:

Decorative material

2:

Substrate

3:

Colored solid concealing layer

4:

Design pattern

5:

First luster control layer

6:

Second luster control layer

6a:

Interface of first luster control layer side

6b:

Surface

6c:

Location corresponding to 20% of thickness of second luster control layer

7:

Gradation region

9:

Expression region

11:

Surface pattern

DETAILED DESCRIPTION OF THE INVENTION

First Embodiment

[0018] Fig. 1 shows the first embodiment of the present invention. As shown in Fig. 1, the decorative material 1 of this embodiment comprises a substrate 2, a colored solid concealing layer 3 provided on the substrate 2, a design pattern 4 provided on the colored solid concealing layer 3 to correspond to an expression region 9 representing recesses or protrusions, a first luster control layer 5 that covers the colored solid concealing layer 3 and the design pattern 4 and adjusts the state of luster, and a second luster control layer 6 provided on the first luster control layer 5 with a state of luster different from that of the first luster control layer. Now the constitution will be described in detail.

[0019] It is possible to use, as the substrate 2, those which are usually used as a stencil paper of a decorative material without any limitation. It is possible to use, as the substrate, conventionally known optional materials, for example, papers such as a tissue paper having a basis weight of about 23 to 100 g/m², a resin mixed paper, a titanium paper, a resin impregnated paper, a flame-resistant paper, and an inorganic paper; woven or nonwoven fabrics made of a natural fiber or a synthetic fiber; synthetic resin-based substrates comprising a polyolefinic resin such as a homo or random polypropylene resin or a polyethylene resin, a copolyester resin, a crystalline polyester resin in an amorphous state, a polyethylene naphthalate resin, a polybutylene resin, an acrylic resin such as a methyl methacrylate resin or a polymethyl methacrylate resin, a styrenic resin, a polyamide-based resin, a cellulose-based resin, a polycarbonate resin, a polyvinyl chloride resin, a polyvinylidene chloride resin, and a fluorine-based resin; woody substrates such as a wood veneer, a fancy veneer, a plywood, a glued laminated board, a particle board, and a middle density fiber board; inorganic-based substrates such as a gypsum board, a cement board, a calcium silicate board, and a ceramic board; metal-based substrates such as iron, copper, aluminum, and stainless steel; and composites and laminates thereof. Examples of the shape include, but are not limited to, film or sheet, plate and anisotropic-shaped molded article.

[0020] While there is no restriction on the constituent material used to form the colored solid concealing layer 3 and the design pattern 4, generally a printing ink or a coating material constituted from a coloring agent such as a dye or a pigment and a proper vehicle (matrix) dissolved or dispersed in a proper solvent is used.

[0021] It is possible to use, as the coloring agent, inorganic pigments such as carbon black, titanium white, zinc white, blood red, chrome yellow, Prussian 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 kinds thereof.

[0022] It is possible to use, as the vehicle, various synthetic resins such as an oil pyroxylin resin, a two-component urethane resin, an acrylic resin, a styrenic resin, a polyester-based resin, an urethane-based resin, a polyvinyl-based resin, an alkyd resin, a petroleum-based resin, a ketone resin, an epoxy-based resin, a melamine-based resin, a fluorine-based resin, a silicone-based resin, a cellulose-based resin, and a rubber-based resin, or mixtures or copolymers thereof.

[0023] It is possible to use, as the solvent, toluene, xylene, cyclohexane, ethyl acetate, butyl acetate, methyl alcohol, ethyl alcohol, isopropyl alcohol, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, and water, or mixtures thereof.

[0024] And, if necessary, various additives such as extender pigments, plasticizers, dispersing agents, surfactants, tackifiers, bonding auxiliaries, desiccants, curing agents, curing accelerators, and delayed curing agents can be appropriately used.

[0025] To form a wood grain pattern, for example, it is a common practice to print the pattern with separate plates that represent the solid background, the wood grain pattern, the vessel pattern, etc. In the decorative material 1 of the present invention, the solid background and the wood grain pattern are provided as the colored solid concealing layer 3, while the vessel pattern is provided as the design pattern 4 that corresponds to the expression region representing recesses or protrusions. Of course the colored solid concealing layer 3 of the present invention is not limited to a wood grain pattern, and can be applied to a stone texture, an abstract pattern or the like.

[0026] The colored solid concealing layer 3 and the design pattern 4 are usually formed by a gravure printing method, an offset printing method, a screen printing method, an electrostatic printing method, an inkjet printing method or the like. However, the present invention is not limited to these methods, and the solid background, for example, may be formed by a coating process such as roll coating, knife coating or die coating. Other patterns may also be formed by any known image forming method. A sealer layer may be provided between the substrate 2 and the colored solid concealing layer 3,

[0027] The first luster control layer 5 is formed by using a printing ink or a coating material that is similar to the constituent material used to form the colored solid concealing layer 3 and the design pattern 4 described above. The first luster control layer 5, however, is required to have transparency or semi-transparency so that at least the colored solid concealing layer 3 and the design pattern 4 can be seen therethrough, and therefore must be formed from a printing ink or a coating material that does not contain a coloring agent such as a dye or a pigment, or contains only a minimum necessary amount of the coloring agent that does not impair the transparency.

[0028] The first luster control layer 5 constitutes the outermost layer of the decorative material 1 in the expression region 9 representing recesses or protrusions as will be described later, and is therefore preferably formed from a material containing a curable resin as the main component so as to provide a surface physical property such as wear resistance, scratch resistance, solvent resistance and stain resistance that are required of the decorative material 1. A thermosetting resin such as a melamine-based resin, an epoxy-based resin, an aminoalkyd-based resin, a urethane-based resin, a polyester-based resin or a silicone-based resin, or an ionizing radiation-curable resin such as an acrylic resin may be preferably used. To a mixture thereof, a luster control agent such as silica, alumina, calcium carbonate, barium sulfate or the like can be added. The ionizing radiation mentioned above refers to a radiation that generally has the effect of ionizing a substance, and includes X-rays, γ-rays, β-rays (electron beam) and short wavelength ultraviolet rays. In this specification, the term "ionizing radiation" is used to include long wavelength ultraviolet rays that do not have an ionizing effect, since an ultraviolet-curable resin that employs a photochemical initiator can be used in the present invention.

[0029] The second luster control layer 6 is, as the first luster control layer 5, preferably formed from the above-mentioned curable resin constituted from a transparent or semi-transparent printing ink or coating agent, and particularly preferably the ionizing radiation-curable resin. As the ionizing radiation-curable resin, for example, an ionizing radiation-curable monomer that does not increase the viscosity over the course of time during printing is used. This resin does not undergo a curing reaction in the state of a liquid being applied at the normal temperature during printing, and therefore the viscosity thereof does not increase. When irradiated with an ionizing radiation, the resin rapidly cures and eventually attains full hardness, and provides such an advantage that blocking due to insufficient drying does not occur when the printed matter is wound up or stacked one upon another.

[0030] As the ionizing radiation-curable monomer, a compound having an ethylenically unsaturated double bond can be used and includes a monofunctional monomer, a difunctional monomer and a tri- or higher polyfunctional monomer. Usually, the monomer is a nonhydrophilic monomer having no hydrophilicity and has neither of a -CHO group, an -OH group and a -COOH group.

[0031] Specific examples of the monofunctional monomer having an ethylenically unsaturated double bond 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 nonylphenol (meth)acrylate, propoxylated nonylphenol (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) acrylated diipropylene glycol (meth)acrylate. As used herein, stearyl (meth)acrylate means stearyl acrylate and/or stearyl methacrylate (the same shall apply hereinafter).

[0032] Examples of the difunctional monomer 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, hydroxypivalic acid neopentyl glycol 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-butyl-propanediol di(meth)acrylate, and 1,9-nonanediol di(meth)acrylate.

[0033] Examples of the polyfunctional monomer 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.

[0034] The ionizing radiation-curable monomer is preferably a monomer such as urethane (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, or polyacryl (meth)acrylate because the coated surface may be smooth due to low viscosity and also an anchor effect to the colored solid concealing layer 3, etc. is improved.

[0035] To the ionizing radiation-curable monomer used as the second luster control layer 6, a silicone oil is added. The silicone oil is added as a stain inhibitor so as to prevent adhesion of stains onto the surface of the second luster control layer 6 and to make it easy to remove adhered stains with various detergents and solvents. The silicone oil is incorporated into a matrix resin composed of an ionizing radiation-curable monomer.

[0036] It is possible to use, as the silicone oil, a non-modified silicone oil, an amino modified silicone oil, an epoxy modified silicone oil, a carboxy modified silicone oil, a mercapto modified silicone oil, a carbinol modified silicone oil, a methacryl modified silicone oil, a phenol modified silicone oil, and an ionizing radiation reactive silicone oil. As the ionizing radiation reactive silicone oil, for example, a polymer, a prepolymer or a monomer of silicone that is solidified by causing a crosslinking polymerization reaction with ionizing radiation is used. Specifically, a compound with a functional group having an acryloyl group, a methacryloyl group, a thiol group, an epoxy group and a double bond at one end, both ends, or a side chain of silicone can be used. In the case of a functional group having a thiol group, an epoxy group and a double bond, each crosslinking agent is added. Of these ionizing radiation reactive silicone oils, an ionizing radiation reactive silicone oil having an average molecular weight of 1000 or more and 3000 or less and an acryloyl or methacryloyl group containing functional groups of 1 or more and 20 or less in a molecule is more preferable because dispersibility in the ionizing radiation-curable resin and reactivity are improved. The amount of the silicon oils described above is preferably from 0.01 to 5% by weight based on the total weight of the ionizing radiation-curable monomer by following reason. When the amount of the silicon oil is less than 0.01% by weight, the addition effect is not obtained. In contrast, when the amount is more than 5% by weight, the aqueous resin of the design pattern 4 repels to cause poor adhesion.

[0037] The second luster control layer 6 provided on the first luster control layer 5 has a gradation region 7 where the state of luster is changed stepwise in the vicinity of the outline of the design pattern 4 except for the portion directly above the design pattern 4, and forms the expression region 9, that represents the visual impression of recesses and protrusions, from a region 8 where the first luster control layer 5 is exposed directly above the design pattern 4 and the gradation region 7. The gradation region 7 is formed so that the state of luster changes continuously or stepwise, in such a way as the state of luster changes from that of the surface of the expression region 9 that represents recesses or protrusions at a position along the outline of the expression region 9 to the state of luster of a portion except for the vicinity of the design pattern 4 that corresponds to the expression region 9.

[0038] The constitution described above will be more specifically described. In order to provide the expression region 9 that represents recesses or protrusions in the form of recesses, the second luster control layer 6 is designed so as to have a higher level of luster than the surface of the expression region 9. Moreover, the second luster control layer 6 is formed with gradation so that the luster of the second luster control layer 6 gradually increases from the outline of the expression region 9 toward the inside of the second luster control layer 6, in the vicinity of the outline of the expression region 9.

[0039] In order to provide the expression region 9 representing recesses or protrusions in the form of protrusions, on the other hand, the second luster control layer 6 is designed so as to have a lower level of luster than the surface of the expression region 9. Moreover, the second luster control layer 6 is formed with gradation so that the luster of the second luster control layer 6 gradually decreases from the outline of the expression region 9 toward the inside of the second luster control layer 6, in the vicinity of the outline of the expression region 9. In the case a gravure printing plate is used, use of a laser printing plate in addition to the Porshel method based on etching that uses a film when printing (liable to misalignment due to shrinkage or elongation of the film) and the Helioglascho method leads to a larger volume of the cell of the plate, which makes it possible to represent gradation with higher accuracy because misalignment is less likely to occur in this case even when multiple stage etching is carried out.

[0040] In the thickness direction of the second luster control layer 6, a gradation region 7 is not provided within 6d up to a location 6c corresponding to 20% of a thickness T6 of the second luster control layer 6 from an interface 6a of the first luster control layer 5 to the surface 6b side, while gradation is provided within a range 6e from a location 6c to the surface 6b side. It is possible to provide stepwise gradation of the state of luster by providing the gradation region at the range 6e that is closer to the surface 6a side from the location 6c corresponding to 20% of the thickness T6 of the second luster control layer 6, that exerts a large visual influence.

[0041] The outline of the design pattern 4 that corresponds to the expression region 9 representing recesses or protrusions is not necessarily required to be placed with precise alignment with the stepwise expression region 9, and may be displaced somewhat toward the inside or outside from the outline of the stepwise expression region 9. Rather, visual impression of recesses and protrusions can be adjusted by intentionally displacing the outlines of these regions. Also it is made possible to change the impression of recesses and protrusions from point to point by changing the direction and distance of the displacement between the outlines within the stepwise expression region 9.

[0042] In the expression of fine recesses and protrusions like a wood grain vessel, the portion in which gradation is provided in the second luster control layer 6 becomes fine as a matter of course, and high resolution to a printing plate or a printing ink is required. In a conventional two-component curable resin that is often used as a surface coating agent of a decorative material, a curing reaction sometimes proceeds during printing to cause plate fill in, resulting in deterioration of reproducibility of gradation.

[0043] Therefore, a resin having a viscosity of 0.1 to 3.5 Pa-s is used as the second luster control layer 6. When the viscosity is within the above range, interlayer adhesion properties are improved. When the viscosity is less than 0.1 Pa·s, the resulting layer is likely to collapse because it becomes too flexible. In contrast, when the viscosity is more than 3.5 Pa.s, the layer becomes rigid and adhesion with an adjacent layer decreases.

[0044] It is often advantageous to change the gradation of luster of the graduation region 7 provided on the second luster control layer 6 in a stepwise manner in terms of a three-dimensional impression of recesses and protrusions as shown in Fig. 1, even when it is intended to represent a continuous change in depth (height). Particularly in such a case as vessel grooves of wood, where continuous gradation is not capable of representing the vivid feeling of the three-dimensional touch of the cross section of the vessel grooves of natural wood despite the very fine recesses and protrusions, stepwise gradation is preferably employed.

[0045] The state of luster of the second luster control layer 6 is provided in gradation by, for example, a gravure printing method, while changing the plate depth or area ratio of the gravure printing plate so as to achieve the desired gradation. In addition, an ordinary offset printing method, a screen printing method, an electrostatic printing method, an inkjet printing method or the like may also be employed.

[0046] The gradation is not limited to that achieved by varying the amount of the ionizing radiation-curable resin, and may be achieved by varying the area ratio of dots (not shown) or by combining the variation of the amount of applied resin and the variation of area ratio (not shown).

[0047] However, even a pattern designed as dots of the printing plate usually becomes somewhat continuous due to the fluidity of the resin during the printing process, and therefore the difference described above is not essential. While the drawing shows the case of stepwise variation for sake of simplicity as shown in Fig. 1, all of the various techniques of producing the gradation are included.

[0048] In order to provide the expression region 9 that represents recesses or protrusions in the form of recesses, the surface of the expression region 9 representing recesses or protrusions must have a low level of luster. For this purpose, in the case the colored solid concealing layer 3 that corresponds to expression region 9 representing recesses or protrusions is exposed on the surface of the expression region 9 as shown in Fig. 1, it is necessary to add a luster control agent to the printing ink used to form the colored solid concealing layer 3 so as to control the state of luster to a low level. In contrast, in order to provide the expression region 9 representing recesses or protrusions in the form of protrusions, it is necessary to use a printing ink that provides higher luster to the surface after printing for the printing ink used to form the design pattern 4 that corresponds to the expression region 9.

[0049] Now the subject of the positional relationship between the expression region 9 representing recesses or protrusions and the colored solid concealing layer 3 that corresponds to the expression region 9 will be described again. In order to represent recesses or protrusions having a color different from that of the other portion only at the bottom of the recess or the top of the protrusion, it is necessary to form the colored solid concealing layer 3 with the same outline as the expression region 9. In order to represent recesses or protrusions having the same color as that of the bottom or the top also on the slope on the outline of recesses or protrusions, it is preferable to form the colored solid concealing layer 3 in a region where the second luster control layer 6 extends to the outline of a region that has the gradation of the outside of the expression region 9. For example, the latter constitution is recommended in the case it is aimed to imitate the vessel grooves in the cross section of natural wood.

[0050] In order to represent the state of color changing continuously on the slope on the outline of recesses or protrusions, gradation may be given to the color of the colored solid concealing layer 3 in the region where the second luster control layer 6 in the vicinity of the outline of the expression region 9 has gradation. Alternatively, a similar visual effect of representation can be achieved also by positioning the outline of the colored solid concealing layer 3 at a mid point between the inner and outer outlines of the region where the second luster control layer 6 has gradation. In addition, the various representation techniques may be combined in accordance to the position, so as to represent complicated configuration of recesses and protrusions where impression of recesses and protrusions changes with the position.

[0051] Also as in the case of a decorative material 10 shown in Fig. 2, a surface pattern 11 may be formed on the first luster control layer 5, at a position directly above the design pattern 4 that corresponds to the expression region 9 representing recesses or protrusions. By providing the surface pattern 11 in this way, it is possible to provide a design that can be visually recognized as a color pattern independent of the recesses and protrusions given by the gradation region 7.

[0052] Representation of the vessel grooves of natural wood, as mentioned previously, is the most typical application of the decorative material 1, 10 of the present invention shown in Fig. 1 or Fig. 2. Since the vessel grooves are a physically recessed configuration, such a constitution is employed as the portion of the vessel pattern is formed with a low level of luster on the surface and the second luster control layer 6 having a high level of luster is formed on the surface except for the portion of vessel pattern. However, to represent such a type of wood that has pale color and vessel grooves looking as if standing out as in the case of a certain kind of conifer wood, a realistic impression can be obtained by reversing the relationship of high and low luster levels described above. Such a reversal of the relationship of high and low luster levels may sometimes produce an original and novel representation of the vessels not relevant to the preconception.

[0053] The decorative materials 1 and 10 have the second luster control layer 6 provided with gradation in the state of luster formed on the surface thereof, and are therefore capable of representing recesses and protrusions with continuously changing depth (height) as the vessels of natural wood. Since the gradation region 7 is provided within a range 6e from the location 6c corresponding to 20% of the thickness of the second luster control layer to the surface 6b side, from an interface 6a of the first luster control layer 5 side to the surface 6b side, a three-dimensional impression can be further improved by effectively providing stepwise degradation of the state of luster at lower cost without requiring a complicated structure and a complicated manufacturing method.

[0054] By adjusting the viscosity of the resin constituting the second luster control layer 6 within a range from 0.1 to 3.5 Pa.s, it is possible to express recesses and protrusions with continuously changing depth (height) without causing flow-out of the resin because it is too flexible and to continuously produce a decorative material 1 at a high speed because it does not become too hard to form. Also, stress produced during curing of the resin can be preferably relieved and thus it is possible to suppress separation between layers.

[0055] The present invention is not limited to the embodiments described above, and various modifications may be made without departing from the scope of the present invention. For example, it is assumed in the embodiments described above, that the state of luster of the second luster control layer 6 is constant in portions other than in the vicinity of the expression region 9 that represent recesses or protrusions. However, the state of luster of the second luster control layer 6 may be varied in sync with the wood grain pattern, in order to represent the difference in luster between a spring-grown portion and an autumn-grown portion of natural wood, or to represent the difference in luster due to the angle between the cut surface and the direction of the wood grain pattern. This makes it possible to produce a decorative material having very high design quality that mimics natural wood more accurately, in addition to accurate expression of the configuration of the vessel grooves described previously.

[0056] Now the decorative materials 1 and 10 of the first and second embodiments will be described in detail by way of Examples 1 and 2.

Example 1

[0057] The decorative material 1 shown in Fig. 1 was made by the following process.

[0058] On the surface of an impregnated paper (GFR-506 manufactured by KOHJIN Co., Ltd.) weighing 50 g/m² prepared for the substrate 2, the colored solid concealing layer 3 was printed in a single color by using an oil pyroxylin resin-based gravure printing ink (each color of ┌PCNT, PCRNT┘ manufactured by TOYO INK MFG. Co., Ltd.), and a wood grain pattern was further printed thereon. A vessel pattern (number of lines 150) was printed in sync therewith as the design pattern 4.

[0059] Then the colored solid concealing layer 3 and the design pattern 4 were covered by the first luster control layer 5 formed from a two-component curing urethane-based resin (100 parts by weight of [Hi-matte G-125HV manufactured by DAINIPPON INK AND CHEMICALS, INCORPORATED] and 10 parts by weight of [ a curing agent G-XA manufactured by DAINIPPON INK AND CHEMICALS, INCOPPORATED]) with a silica powder added so as to control the luster level lower, with the quantity of application controlled to achieve a dry density of 5 g/m².

[0060] Then the second luster control layer 6 was formed by printing a two-component curing urethane-based resin (50 parts by weight of ┌G-125 Gloss┘ , 50 parts by weight of ┌G-125 Matte┘ and ┌a curing agent G-XA manufactured by DAINIPPON INK AND CHEMICALS, INCORPORATED┘) prepared so that the level of luster becomes higher, on the surface excluding the design pattern 4 with gradation in the vicinity of the outline of the vessel pattern (number of lines 40 to 80 lines/cm, depth of 0.1 mm or less), so that the dry density would be 2 g/m², followed by curing with overheat drying in an air atmosphere to obtain the decorative material 1 of the present invention. In the thickness direction of the second luster control layer 6, gradation was not provided within 6d up to the location 6c corresponding to 20% of the thickness T6 of the second luster control layer 6 from an interface 6a of the first luster control layer 5 to the surface 6b side, while gradation was provided within the range 6e from the location 6c to the surface 6b side. Drying was conducted under the conditions of a temperature of 80 to 120°C and a line speed of 70 m/min, and no blocking occurred while winding.

Example 2

[0061] A decorative material 10 shown in Fig. 2 was made by the following process described in detail.

[0062] On the surface of the first luster control layer 5, a two-component urethane resin curable colored enamel paint (manufactured by TOYO INK MFG. Co., Ltd.) was provided as the surface pattern 11 only at the expression region 9 that represents recesses or protrusions. The other processes are same to those of Example 1. The decorative material 10 could be easily obtained without causing breakage of gradation or misalignment of location.

[0063] For comparison with Examples 1 and 2, the decorative paper of the following comparative example was made.

Comparative Example

[0064] A decorative material was made by the process same to that of Example 1 except that, in the second luster control layer 6, gradation was provided within 6d up to the location 6c corresponding to 20% of the thickness T6 of the second luster control layer 6 from an interface 6a of the first luster control layer 5 to the surface 6b side,

<Evaluation of Performance>

[0065] With respect to the decorative material 1 of Example 1, the decorative material 10 of Example 2, and the decorative material of the Comparative Example, the appearance was observed. As a result, with respect to the decorative material 1 of Example 1 and the decorative material 10 of Example 2, it was possible to make a design with a three-dimensional impression as compared with the decorative material of the Comparative Example.

[0066] Preferable examples of the present invention have been described. It is understood, however, that the present invention is not limited to these examples. 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 limited by the foregoing description but is only limited by the scope of the appended claims.

INDUSTRIAL APPLICABILITY

[0067] The decorative material of the present invention provides a three-dimensional impression of recesses and protrusions by the difference in the level of surface luster, and can be used to provide an aesthetic effect on the surface of the interior and/or exterior of a building, joinery, furniture, etc.

Claims

1. A decorative material comprising:

a substrate;

a solid concealing layer formed on the substrate;

a design pattern provided on the solid concealing layer to correspond to an expression region that represents recesses or protrusions;

a first luster control layer that covers the design pattern and solid concealing layer, and adjusts the luster level; and

a second luster control layer that is provided on the first luster control layer with a state of luster different from that of the first luster control layer, while having a gradation region where the state of luster is changed stepwise in a vicinity of an outline of the design pattern except for a portion directly above the design pattern; wherein

the gradation region of the second luster control layer is not provided up to a location corresponding to 20% of a thickness of the second luster control layer from an interface of the first luster control layer side to the surface side, and the gradation region is formed within a range from the location to the surface side.

2. The decorative material according to claim 1, which has a surface pattern formed directly above the design pattern on the first luster control layer.

Drawing