Decorative sheet and decorative member

Abstract

Provided are a decorative sheet and a decorative member which have a texture closer to a genuine article and an excellent design. This decorative sheet (1) comprises a pattern layer (5), a transparent thermoplastic resin layer (6), and a surface protective layer (7) which are sequentially laminated on one surface of a colored thermoplastic resin layer (2), wherein: a region (pattern part (3) for gloss mat expression), which contains a predetermined material having light absorption properties with respect to infrared rays compared to the colored thermoplastic resin layer (2), is disposed on the surface on the reverse side of the colored thermoplastic resin layer (2) from the pattern layer (5), in synchronization with the pattern of pattern layer (5); the pattern part (3) for gloss mat expression has an infrared transmittance of at most 60% at a wavelength of 2,000 nm; and an embossed part (7a) is formed at a position of the surface protective layer (7) which overlaps with a portion formed of the predetermined material in a plan view.

Description

Decorative sheets and decorative materials

[0001] The present invention relates to a decorative sheet and a decorative member.

[0002] Decorative sheets have been developed and expanded as the residential construction industry has grown. Originally, homes were built using materials suited to the local characteristics, such as wood and stone. However, as the housing industry has developed, industrialization has progressed, resulting in a shift from natural materials to artificial materials. In recent years, the widespread use of high-quality wood and stone has led to concerns that it could lead to deforestation and environmental problems, which has also contributed to the growing demand for decorative sheets. For example, decorative materials in which decorative sheets are bonded to wood substrates such as plywood, MDF (medium-density fiberboard), and particle board, resin substrates, inorganic non-combustible substrates, and metal substrates are widely used (see, for example, Patent Document 1). Furthermore, decorative sheet designs often mimic the surfaces of wood, stone, and other materials.

[0003] Patent No. 5045180

[0004] Incidentally, decorative sheets tend to have a flat surface texture compared to real wood or stone. Actual wood and stone have different textures due to differences in the surface material and structure, resulting in unevenness in different locations. Areas with different textures often also have different colors, but this is not expressed in decorative sheets, and in terms of design, more expensive real ones are far superior.

[0005] The present invention has been made in view of the above-mentioned points, and has as its object to provide a decorative sheet and decorative member that have a texture closer to the real thing and have excellent design properties.

[0006] In order to solve the above problems, one aspect of the present invention provides a decorative sheet having a pattern layer, which comprises a pattern layer, a transparent resin layer, and a surface protective layer laminated in that order on one side of a colored resin layer, and on the other side of the colored resin layer, an area containing a predetermined material that is more light-absorbent to infrared rays than the colored resin layer is arranged in sync with the pattern of the pattern layer, and the area containing the predetermined material has an infrared transmittance of 60% or less at a wavelength of 2000 nm, and an embossed portion is formed on the surface protective layer at a position that overlaps with the area containing the predetermined material in a planar view.

[0007] Another aspect of the present invention provides a decorative member comprising a substrate and a decorative sheet provided on at least one side of the substrate, wherein the substrate is any one of a wood substrate, a resin substrate, a non-flammable substrate, or a metal substrate.

[0008] According to the aspects of the present invention, it is possible to provide a decorative sheet and decorative member that has a texture closer to the real thing and has excellent design properties.

[0009] FIG. 1 is a cross-sectional view schematically showing an example of a decorative sheet according to a first embodiment of the present invention. FIG. 2 is a process chart schematically showing an example of a manufacturing procedure for a decorative sheet according to the first embodiment of the present invention. FIG. 3 is a cross-sectional view schematically showing an example of a decorative member according to a modified example of the first embodiment of the present invention. FIG. 4 is a cross-sectional view schematically showing an example of a decorative sheet according to a second embodiment of the present invention. FIG. 5 is a cross-sectional view schematically showing an example of a decorative sheet according to a modified example of the second embodiment of the present invention. FIG. 6 is a cross-sectional view schematically showing an example of a decorative sheet according to a modified example of the third embodiment of the present invention. FIG. 7 is a cross-sectional view schematically showing an example of a decorative sheet according to a modified example of the third embodiment of the present invention.

[0010] Hereinafter, embodiments of the present technology will be described with reference to the drawings. In this embodiment, decorative sheets and decorative materials for floors or building materials will be described as examples, but decorative sheets for use in other parts may also be used. Here, the drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, etc. differ from the actual ones. Furthermore, the embodiments shown below are merely examples of configurations for embodying the technical idea of ​​the present invention, and the technical idea of ​​the present invention is not limited to the materials, shapes, structures, etc. of the components described below. The technical idea of ​​the present invention can be modified in various ways within the technical scope defined by the claims.

[0011] [First embodiment] First, a first embodiment of the present invention will be described. A decorative sheet according to one embodiment of the present invention is a decorative sheet having a design layer, comprising a design layer, a transparent resin layer, and a surface protective layer laminated in this order on one side of a colored resin layer, a region containing a predetermined material that is more light-absorbent than the colored resin layer and is arranged in phase with the design of the design layer on the other side of the colored resin layer, the region containing the predetermined material having an infrared transmittance of 60% or less at a wavelength of 2000 nm, and an embossed portion formed in the surface protective layer at a position that overlaps with the portion formed of the predetermined material in a plan view.

[0012] Furthermore, a decorative member according to one embodiment of the present invention comprises a base material and the decorative sheet provided on at least one side of the base material, and the base material is a decorative member that is any one of a wood base material, a resin base material, a non-flammable base material, or a metal base material.

[0013] 1, a decorative sheet 1 according to one embodiment of the present invention is formed by laminating, in this order, a colored thermoplastic resin layer 2, a design layer 5, a transparent thermoplastic resin layer (transparent resin layer) 6, and a surface protective layer 7, with an embossed portion (embossed shape) 7a formed in the surface protective layer 7. Furthermore, on the surface of the colored thermoplastic resin layer 2 opposite the design layer 5, a pattern layer 8a consisting of a matte gloss-producing pattern portion 3, and a primer layer 8 are formed. As will be described in more detail below, the matte gloss-producing pattern portion 3 is a region containing a predetermined material that is light-absorbent with respect to light of a predetermined wavelength (e.g., infrared light).

[0014] [Colored Thermoplastic Resin Layer] Examples of the colored thermoplastic resin layer 2 as a substrate include polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, ionomer, acrylic acid ester, methacrylic acid ester, etc. Among these, polyolefin-based resins are preferably used in terms of environmental compatibility, processability, and cost. The grade and composition of the resin can also be selected taking into consideration ease of sheeting, printability, and suitability for bending.

[0015] The color of the colored thermoplastic resin layer 2 can be appropriately selected as the base color of the design layer 5. The colored thermoplastic resin layer 2 can be colored, for example, by mixing or kneading a colorant such as a pigment into the thermoplastic resin during sheeting. Alternatively, a colored layer can be formed as a solid ink layer using a coating or printing technique before forming the matte gloss pattern portion 3.

[0016] [Pattern Layer] The pattern layer 5 is a printed layer on which a pattern is printed to impart design to the decorative sheet 1. Known printing methods can be used to form the pattern layer 5. The printing method is not particularly limited, but gravure printing is preferred in consideration of productivity and pattern quality. For example, if the colored thermoplastic resin layer 2 is available in a rolled state, printing to form the pattern layer 5 can be performed using a roll-to-roll printing device. Other printing methods include offset printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, and transfer printing from a transfer sheet. When using such printing methods, the pattern of the pattern layer 5 can be formed by multicolor printing using the usual process colors of yellow, red, blue, and black, or by multicolor printing using special colors, in which plates of the individual colors that make up the pattern are prepared.

[0017] The design pattern of the design layer 5 may be any design, taking into consideration the design of the flooring or fittings. For example, a marble grain pattern can be used to resemble a stone floor such as marble. For wood-based designs, various wood grains or cork can be used. In addition to natural material designs, artificial designs based on natural materials, such as artificial patterns or geometric patterns, can also be used. Other examples of design patterns include wood grain patterns composed of spring and autumn wood regions and vessels in the cross section of tree rings, leather (grain) patterns, stone grain patterns on the surface of stone materials such as marble, granite, and sandstone, sand grain patterns, tile patterns, brickwork patterns, fabric patterns, geometric shapes, letters, symbols, abstract patterns, floral patterns, landscapes, and characters. Printing ink is a mixture of solvents and solid components such as colorants and binder resins.

[0018] Examples of the solvent include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water. One type of solvent may be used alone, or two or more types may be used in combination.

[0019] Examples of binder resins include chlorine-based resins, urethane resins, acrylic urethane resins, acrylic resins, polyester resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins (nitrocellulose), and cellulose acetate resins. Examples of chlorine-based resins include polyvinyl chloride resins such as polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, ethylene-vinyl chloride copolymers, vinyl chloride-vinyl acetate copolymers, and vinyl chloride-vinyl acetate-(meth)acrylic copolymers; polypropylene chloride; and chlorinated polypropylene. Here, (meth)acrylic means acrylic or methacrylic. The binder resin may be a single type or a combination of two or more types.

[0020] Examples of colorants include inorganic pigments such as carbon black, iron black, titanium white (titanium oxide), antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; and organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue. The colorant may be a single type or a combination of two or more types. The solvent contained in the printing ink will eventually volatilize. Therefore, the design layer 5 is primarily formed from solid components such as colorants and binder resins.

[0021] The printing ink may also contain other components such as stabilizers, plasticizers, catalysts, and curing agents. The printing ink may be selected based on the printing method. It is particularly preferable to select the printing ink taking into consideration adhesion to the colored thermoplastic resin layer 2, printability, and weather resistance as a flooring material or building material. The thickness of the design layer 5 can be adjusted appropriately taking into consideration the decorative properties required of the design layer 5, the three-dimensional formability of the decorative sheet 1, and the like. The thickness of the design layer 5 is typically 1 μm or more and 1 mm or less, preferably 2 μm or more and 0.1 mm or less, and more preferably 2 μm or more and 50 μm or less.

[0022] In order to improve the adhesion between the design layer 5 and the transparent thermoplastic resin layer 6, an adhesive layer (not shown) may be provided on the surface of the design layer 5 that comes into contact with the transparent thermoplastic resin layer 6. By strengthening this adhesion, the decorative sheet 1 can be given the ability to be bent to conform to curved surfaces and right-angled surfaces. The resin used in the adhesive layer (not shown) is not particularly limited. For example, a two-component curing urethane resin can be used. Alternatively, the adhesive resin may be adhered to the design layer 5 with a urethane adhesive. For example, a coating device or a gravure printing device can be used to apply the resin used in the adhesive layer (not shown).

[0023] Furthermore, a glittering layer (not shown) may be provided between the picture layer 5 and the transparent thermoplastic resin layer 6 for the purpose of suitably imparting design effects such as a sense of depth and brightness to the decorative sheet 1. The glittering layer (not shown) preferably contains a glittering pigment and a binder resin. Examples of glittering pigments include pearlescent pigments and metallic pigments. In particular, pearlescent pigments are preferred because they can prevent a decrease in the light transmittance of the glittering layer and do not impair the visibility of the picture layer 5.

[0024] Pearl pigments are pigments that can impart pearlescent luster. Examples include base particles whose surfaces are coated with a metal oxide. The base particles are preferably scaly particles such as mica. Examples of metal oxides include oxides of metals such as titanium, iron, zirconium, silicon, aluminum, and cerium. The metal oxides may be of one type alone or two or more types. Specific examples include oxide-coated mica such as titanium mica, iron oxide-coated mica, iron oxide-coated mica titanium, Prussian blue-coated mica titanium, Prussian blue-iron oxide-coated mica titanium, chromium oxide-coated mica titanium, carmine-coated mica titanium, organic pigment-coated mica titanium, titanium oxide-coated mica, and titanium oxide-coated synthetic mica; oxide-coated glass powder such as titanium oxide-coated glass powder and iron oxide-coated glass powder; oxide-coated metal particles such as titanium oxide-coated aluminum powder; scaly flakes of basic lead carbonate, lead hydrogen arsenate, bismuth oxide chloride, etc.; fish scale powder, shell fragments, and pearl fragments.

[0025] Examples of metallic pigments include pigments made of metals such as aluminum, brass, stainless steel, tin, zinc, copper, nickel, gold powder, and silver, as well as alloys of these metals. Metal pigments may be used singly or in combination of two or more. From the perspective of providing excellent design effects, the average particle size of the luster pigment is preferably 40 μm or less, and more preferably 30 μm or less, when the luster layer is formed using gravure printing. From the same perspective, the ratio of [average particle size of the luster pigment / thickness of the luster layer] is preferably 0.01 or more and 15 or less, and more preferably 0.5 or more and 10 or less. In this specification, the term "average particle size" refers to the mass average value D50 determined by particle size distribution measurement using laser diffraction.

[0026] Examples of binder resins include thermoplastic resins and cured products of curable resin compositions, with cured products of curable resin compositions being preferred from the viewpoint of durability. Examples of cured products of curable resin compositions include cured products of thermosetting resin compositions and cured products of ionizing radiation-curable resin compositions. From the viewpoint of interlayer adhesion, cured products of thermosetting resin compositions are preferred. Examples of thermosetting resin compositions used in the glossy layer include polyester resin compositions, epoxy resin compositions, polyurethane resin compositions, aminoalkyd resin compositions, melamine resin compositions, guanamine resin compositions, urea resin compositions, and thermosetting acrylic resin compositions. These thermosetting resin compositions include monomers and / or prepolymers constituting each resin, and a curing agent added as needed. The ionizing radiation-curable resin composition used in the glossy layer can be the same as the ionizing radiation-curable resin composition of the surface protective layer 7 described below.

[0027] The content of the glittering pigment in the glittering layer is preferably 10 parts by mass or more and 90 parts by mass or less, and more preferably 50 parts by mass or more and 80 parts by mass or less, relative to 100 parts by mass of the binder resin. By setting the content of the glittering pigment to 10 parts by mass or more, it is possible to impart a sufficient glossy appearance, and by setting it to 90 parts by mass or less, it is possible to prevent impairment of the visibility of the pattern layer described below. From the same viewpoint, the thickness of the glittering layer is preferably 1 μm or more and 30 μm or less, and more preferably 5 μm or more and 20 μm or less.

[0028] The glittering layer can be formed into any pattern depending on the desired design. Examples include wood grain, leather, stone, sand, tile, brickwork, fabric, geometric shapes, letters, symbols, abstract patterns, floral patterns, landscapes, and characters. Furthermore, it is preferable for the arbitrary pattern to have shading to further enhance the design effect. Shading can be formed by varying the size or thickness of the halftone dots, but is preferably formed by varying the density of the halftone dots (i.e., the size of the halftone dots is uniform, and the shading is formed by the density of the halftone dots). The glittering layer can be formed, for example, by a general-purpose printing method such as gravure printing using a coating liquid containing a glittering pigment and a binder resin. When the shading of the glittering layer is formed by varying the density of the halftone dots, the halftone dots on the printing plate can be formed using an FM (frequency modulation) screen.

[0029] [Transparent Thermoplastic Resin Layer] The transparent thermoplastic resin layer 6 is a resin layer that provides thickness and depth for design purposes, as well as protecting the design layer 5 and imparting good surface properties to improve the weather resistance and abrasion resistance of the decorative sheet 1. Materials that can be used for the transparent thermoplastic resin layer 6 include, for example, vinyl chloride resin, acrylic resin, and polyolefin-based resin (polypropylene resin, polyethylene resin). Considering environmental compatibility, processability, and cost, polyolefin-based resins are particularly preferred. The grade and composition of the resin can be selected based on factors such as ease of sheeting, printability, and suitability for bending, as well as environmental compatibility, processability, and cost. For suitability for bending, it is important to consider the prevention of whitening or cracking at bent portions. The transparent thermoplastic resin layer 6 can be formed by lamination. Furthermore, for example, when the transparent thermoplastic resin layer 6 and an adhesive layer (not shown) are formed simultaneously, a co-extrusion method can be used.

[0030] [Surface Protective Layer] The surface protective layer 7 is a layer that imparts surface properties such as abrasion resistance to the decorative sheet 1. The surface protective layer 7 also adjusts the surface gloss of the decorative sheet 1. The surface protective layer 7 may be a single layer or a multilayer. For example, the surface protective layer 7 may be formed by providing two layers, a first surface protective layer (not shown) and a second surface protective layer (not shown), in this order on the transparent thermoplastic resin layer 6. When providing the surface protective layer 7 consisting of the first surface protective layer (not shown) and the second surface protective layer (not shown), each layer may be applied and cured using a known coating device, heat drying device, or ionizing radiation irradiation device, depending on the type of curable resin. The surface protective layer 7 is primarily composed of a curable resin. That is, it is preferable that the resin component of the surface protective layer 7 is substantially composed of a curable resin. "Substantially" refers to, for example, 80 parts by mass or more when the total resin is 100 parts by mass. The surface protective layer 7 may contain weatherproofing agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, and the like, as required.

[0031] Examples of materials that can be used for the surface protection layer 7 include ionizing radiation-curable resins and two-component curable urethane-based resins. The ionizing radiation-curable resins are not particularly limited. For example, transparent resins primarily composed of prepolymers (including oligomers) and / or monomers containing radically polymerizable double bonds in the molecule that can undergo polymerization and crosslinking reactions upon exposure to ionizing radiation such as infrared, ultraviolet, or electron beams can be used. These prepolymers or monomers can be used alone or in combination. Specific examples of prepolymers or monomers include compounds containing radically polymerizable unsaturated groups such as (meth)acryloyl groups and (meth)acryloyloxy groups, and cationically polymerizable functional groups such as epoxy groups in the molecule. Polyene / thiol-based prepolymers, which are combinations of polyenes and polythiols, are also preferred. Here, the term "(meth)acryloyl group" refers to an acryloyl group or a methacryloyl group.

[0032] Examples of prepolymers having a radically polymerizable unsaturated group include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, and silicone (meth)acrylate. The molecular weight of these is preferably about 250 to 100,000. Examples of monomers having a radically polymerizable unsaturated group include monofunctional monomers such as methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, and phenoxyethyl (meth)acrylate. Examples of polyfunctional monomers include diethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, trimethylpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

[0033] Examples of prepolymers having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol epoxy resins and novolac epoxy compounds, and vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. Examples of polyene prepolymers include those in which allyl alcohol is added to both ends of a polyurethane made from a diol and a diisocyanate. Examples of thiol prepolymers include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.

[0034] The ionizing radiation may be, for example, electromagnetic waves or charged particles having energy sufficient to cause a curing reaction of molecules in the ionizing radiation-curable resin (composition). Examples of the curing reaction include crosslinking curing reactions. The ultraviolet light source may be, 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, or a metal halide lamp. The wavelength of the ultraviolet light is preferably, for example, 190 nm or more and 380 nm or less. The electron beam source may be, for example, an electron beam accelerator such as a Cockcroft-Walton type, a Van de Graaf type, a resonant transformer type, an insulating core transformer type, a linear type, a dynamitron type, or a high-frequency type. In particular, those capable of irradiating electrons having an energy of 100 keV or more and 1000 keV or less (more preferably, an electron having an energy of 100 keV or more and 300 keV or less) are preferred.

[0035] The two-component curing urethane resin is not particularly limited. For example, a resin containing a polyol component having OH groups as a base component and an isocyanate component as a curing agent component can be used. Examples of the polyol component having OH groups include acrylic polyol, polyester polyol, polyether polyol, and epoxy polyol. Examples of the isocyanate component include tolylene diisocyanate, hexamethylene diisocyanate, and metaxylene diisocyanate.

[0036] [Embossed Section] An embossed section 7a consisting of a concave-convex pattern is formed on the surface of the surface protective layer 7 to impart a given design. Examples of concave-convex patterns include the vascular grooves of a wood grain board, the uneven surface of a stone slab (such as a cleavage plane of granite), fabric surface texture, matte finish, sand grain, hairline, and linear grooves. The embossed section 7a is provided so that its concave-convex pattern is in harmony with the pattern of the design layer 5. This allows the decorative sheet 1 to be imparted with a good texture close to that of actual wood or stone. The concave-convex pattern can be formed, for example, by embossing. The embossing method is not particularly limited. For example, a known sheet-fed embossing machine or a rotary embossing machine can be used.

[0037] [Gloss Matte Development Pattern Portion] The gloss matte development pattern portion 3 is a region formed of a material that is light-absorbent for light of a predetermined wavelength, and is formed of, for example, a material that has infrared absorption properties. As will be described in detail below, the gloss matte development pattern portion 3 is provided to facilitate the formation of embossed portions 7a at desired positions (positions that are in harmony with the pattern of the pattern layer 5), that is, to easily impart a texture similar to that of actual wood or stone to the decorative sheet 1. In this embodiment, the gloss matte development pattern portion 3 is formed using, for example, an ink containing a material that has infrared absorption properties. The ink used for the gloss matte development pattern portion 3 can be, for example, a urethane-based printing ink.

[0038] There are no particular restrictions on the color of the ink used for the gloss matte-producing pattern portion 3, and dark black ink, or colorless, transparent, or relatively nearly transparent, pale (light) ink can be used. The color (shade) of the ink can be selected appropriately depending on the design to be expressed, etc.

[0039] In the decorative sheet 1 according to this embodiment, the matt gloss developing pattern portion 3 is provided below the colored thermoplastic resin layer 2. Therefore, when the decorative sheet 1 is viewed from the surface protective layer 7 side, the visibility of the matt gloss developing pattern portion 3 is reduced. As a result, when a high-concentration black ink with infrared absorption properties is used as the matt gloss developing pattern portion 3, the visibility of the black ink forming the matt gloss developing pattern portion 3 can be reduced when the decorative sheet 1 is viewed from the surface protective layer 7 side. Therefore, it is not necessary to use a dark color pattern for the design layer 5 in order to reduce the visibility of the ink-containing matt gloss developing pattern portion 3, and as a result, it is possible to employ a light-color pattern for the design layer 5. In this way, the decorative sheet 1 according to this embodiment can suppress the constraints on pattern expression imposed by the design layer 5 due to the provision of the matt gloss developing pattern portion 3, and can express designs that are close to the real thing, such as actual wood or stone.

[0040] Furthermore, by using a colorless, transparent or light-colored ink as the ink containing a material with infrared absorbing properties, the decorative sheet 1 according to this embodiment can further reduce the visibility of the gloss matte-exhibiting pattern portion 3 from the surface protective layer 7 side. Therefore, even if the base color or pattern is a light color close to white, the original color can be seen, and the intended color can be more suitably expressed. Therefore, the decorative sheet 1 according to this embodiment can express good colors that are close to the real thing, such as actual wood or stone.

[0041] Furthermore, the gloss matte developing pattern portion 3 may have an infrared transmittance of 60% or less at a wavelength of 2000 nm, more preferably 40% or less, and even more preferably 15% or less. In other words, the gloss matte developing pattern portion 3 is formed with ink containing a material having infrared absorption properties, and the infrared absorption effect of the ink is such that the infrared transmittance at a wavelength of 2000 nm is 60% or less. By making the infrared transmittance at a wavelength of 2000 nm in the gloss matte developing pattern portion 3 60% or less, it is possible to suppress gloss and obtain a sufficient gloss matte effect.

[0042] The material having infrared absorption properties in the matte gloss pattern portion 3 can be at least one of inorganic materials such as carbon black, tin-doped indium oxide (ITO), antimony-doped tin oxide (ATO), lanthanum hexaboride (LaB6), cesium-doped tungsten oxide, etc. Furthermore, organic materials such as near-infrared absorbing materials, infrared absorbing materials, and phthalocyanine-based materials, as well as existing materials having infrared absorption properties, can also be used.

[0043] The matt gloss developing pattern portion 3 is arranged at a position that is in harmony with the pattern of the pattern layer 5. For example, in the case of a wood grain patterned pattern layer 5, the matt gloss developing pattern portion 3 is formed at a position that overlaps with the wood grain board vessel grooves of the pattern layer 5 in a plan view. Here, "in harmony" means that the matt gloss developing pattern portion 3 is formed at a position that overlaps with the pattern of the pattern layer 5 in a plan view.

[0044] The thickness of the matte gloss developing pattern portion 3 may be any thickness that can soften the transparent thermoplastic resin layer 6 and the surface protective layer 7 to an extent that, during the embossing process described below, a concave-convex shape can be sufficiently formed in the surface protective layer 7. In order to obtain a sufficient matte gloss effect, it is preferable that the difference in gloss between the area where the matte gloss developing pattern portion 3 is formed and the area where it is not formed is 5 or more, i.e., the image density level is preferably 60% or more.

[0045] Furthermore, by providing the gloss matte-producing pattern portion 3 as a lower layer of the colored thermoplastic resin layer 2, the decorative sheet 1 can have good bending processability when processed into a decorative member.

[0046] [Light of a predetermined wavelength] As described above, the pattern portion 3 for developing a matte gloss finish is formed from a material that is light-absorbent for light of a predetermined wavelength. Examples of light of a predetermined wavelength include the above-mentioned infrared light, as well as ultraviolet light, visible light, electron beams, X-rays, and ion beams. [Pattern layer] The pattern layer 8a is formed on the surface of the colored thermoplastic resin layer 2 opposite the picture layer 5. The pattern layer 8a is composed only of the pattern portion 3 for developing a matte gloss finish, which is formed from a material that is light-absorbent for infrared light, for example.

[0047] [Primer Layer] The primer layer 8 is a base layer that improves adhesion to a substrate (not shown) to which the decorative sheet 1 is attached, and corrosion resistance. The primer layer 8 is provided on the opposite side of the pattern layer 8a from the colored thermoplastic resin layer 2. The primer layer 8 is formed using, for example, a polyester resin, organic additives, pigments, etc. The primer layer 8 may contain an anti-rust pigment to improve corrosion resistance. The thickness of the primer layer 8 is, for example, in the range of 1 μm to 10 μm.

[0048] [Method for Manufacturing Decorative Sheet] Next, an example of a method for manufacturing a decorative sheet according to this embodiment will be described with reference to Figure 2. First, a colored thermoplastic resin layer 2 is formed. For example, a PBT (polybutylene terephthalate resin) layer having a thickness of, for example, 50 µm is formed (Figure 2(a)). Next, a design layer 5 is printed on the colored thermoplastic resin layer 2 using, for example, a urethane-based printing ink, and then a transparent thermoplastic resin layer 6 made of, for example, PP (polypropylene) having a thickness of 38 µm is laminated on the design layer 5. Then, a surface protective layer 7 is laminated on the transparent thermoplastic resin layer 6. That is, as shown in Figure 2(a), a lamination step is carried out in which the design layer 5, the transparent thermoplastic resin layer 6, and the surface protective layer 7 are laminated in this order on one side of the colored thermoplastic resin layer 2.

[0049] Next, a matte gloss developing pattern portion 3, which is a region containing a material that is light-absorbing for light of a predetermined wavelength, is formed on the surface of the colored thermoplastic resin layer 2 opposite the pattern layer 5, to form a pattern layer 8a. That is, a process is carried out in which the matte gloss developing pattern portion 3, which is a region containing a material that has infrared absorbing properties, is arranged in harmony with the pattern to form the pattern layer 8a. For example, the matte gloss developing pattern portion 3 is formed at a predetermined position in harmony with the pattern of the pattern layer 5 using an ink (black ink or a light-colored ink (including colorless and transparent)) containing an infrared absorbing material (FIG. 2(b)). Next, a primer layer 8 made of, for example, a polyester-based resin is laminated on the colored thermoplastic resin layer 2 containing the matte gloss developing pattern portion 3 so as to fill the gaps between the matte gloss developing pattern portions 3 and cover the upper surface thereof (FIG. 2(c)).

[0050] Next, the entire laminate in which these layers are stacked is irradiated with infrared light (irradiation light) (FIG. 2(d)), and immediately after the infrared irradiation, an embossing plate such as an embossing roll is pressed onto the surface of the surface protective layer 7 (FIG. 2(e)). This forms embossed portions 7a, forming the decorative sheet 1. In other words, a step of irradiating with irradiation light (e.g., infrared light) in which the power of light of a predetermined wavelength is stronger than the power of light of other wavelengths, and a step of pressing an embossing plate for forming an embossed shape onto the surface protective layer 7 are carried out after the step of irradiating with the irradiation light.

[0051] Here, the matte gloss developing pattern portion 3 is formed with an ink having infrared absorption properties. Therefore, when the laminate is irradiated with infrared rays, the transparent thermoplastic resin layer 6 and the surface protective layer 7 are more likely to soften in the portions of the surface protective layer 7 that overlap with the matte gloss developing pattern portion 3 in a planar view, compared to the portions that do not overlap with the matte gloss developing pattern portion 3. In other words, after infrared irradiation, the transparent thermoplastic resin layer 6 and the surface protective layer 7 have portions that are more likely to soften and portions that are less likely to soften. Therefore, when an embossing plate is pressed onto the transparent thermoplastic resin layer 6 and the surface protective layer 7 in this state, unevenness is more likely to form in the softened portions, and less likely to form in the less likely to soften portions. Therefore, unevenness is more likely to form in the softened portions of the transparent thermoplastic resin layer 6 and the surface protective layer 7, i.e., in the portions that overlap with the matte gloss developing pattern portion 3 in a planar view. Therefore, an embossed portion 7a having an uneven shape that is in harmony with the matte gloss developing pattern portion 3 is more likely to be formed only in the positions of the transparent thermoplastic resin layer 6 and the surface protective layer 7 that overlap with the matte gloss developing pattern portion 3 in a planar view. Furthermore, the gloss matte pattern portion 3 uses ink with infrared absorbing properties to make the infrared transmittance at a wavelength of 2000 nm 60% or less, thereby suppressing gloss and achieving a sufficient gloss matte effect.

[0052] This allows the embossed portion 7a to be formed at a position synchronized with the design layer 5; that is, the embossed portion 7a synchronized with the design layer 5 can be easily created without high-precision positioning operations. Therefore, a decorative sheet 1 can be provided that has a texture and a good color similar to the real thing, and has excellent design properties. The timing for pressing the embossing plate into the transparent thermoplastic resin layer 6 and the surface protective layer 7 after infrared irradiation is not limited to immediately after infrared irradiation, as long as the pressing of the plate into the surfaces of the transparent thermoplastic resin layer 6 and the surface protective layer 7 allows selective formation of a concave-convex shape in the portions softened by infrared irradiation. Furthermore, other steps may be included between the step of forming the surface protective layer 7 and the step of infrared irradiation. Essentially, infrared irradiation should be performed while the transparent thermoplastic resin layer 6 and the surface protective layer 7 have been formed.

[0053] Thus, according to the manufacturing method of the decorative sheet 1 of this embodiment, by irradiating the laminate in which the layers are stacked with infrared rays and then pressing the embossing plate, it is possible to strongly emboss the area that overlaps with the gloss matte-exhibiting pattern portion 3 in a plan view. In other words, the embossed portion 7a can be easily formed in the desired position without having to precisely position the area where the embossing plate is pressed. As a result, a decorative sheet with excellent design properties can be easily obtained.

[0054] Furthermore, because the matte gloss developing pattern portion 3 is provided below the colored thermoplastic resin layer 2, the visibility of the matte gloss developing pattern portion 3 is reduced when the decorative sheet 1 is viewed from the surface protective layer 7 side. As a result, although a colorless, transparent or light-colored ink having infrared absorbing properties is used as the matte gloss developing pattern portion 3, the visibility of the matte gloss developing pattern portion 3 can be further reduced when the decorative sheet 1 is viewed from the surface protective layer 7 side. For this reason, the visibility of the matte gloss developing pattern portion 3 can be significantly reduced without using a dark color pattern for the design layer 5, and as a result, a light-colored pattern can be employed for the design layer 5, and the constraints on pattern expression caused by the provision of the matte gloss developing pattern portion 3 can be significantly reduced.

[0055] Furthermore, a colored thermoplastic resin layer 2 and a picture layer 5, and further a transparent thermoplastic resin layer 6 and a surface protective layer 7 are laminated on top of a pattern layer 8a consisting of a gloss matte-exhibiting pattern portion 3 made using a colorless, transparent or light-colored ink containing a material with infrared absorption properties, and an embossed portion 7a is formed at a position on the surface protective layer 7 that overlaps with the gloss matte-exhibiting pattern portion 3 when viewed in plan.This further reduces the visibility of the gloss matte-exhibiting pattern portion 3, and greatly reduces the impact that the gloss matte-exhibiting pattern portion 3, which is useful in the manufacturing process of the decorative sheet 1, has on the appearance of the decorative sheet 1, allowing for a highly attractive decorative sheet 1 to be obtained in which the pattern of the picture layer 5 and the embossed portion 7a are in harmony.

[0056] Furthermore, since the pattern portion 3 for producing the gloss matte effect is provided in harmony with the pattern of the pattern layer 5, it is possible to form an uneven portion in harmony with the pattern of the pattern layer 5, that is, it is possible to easily produce a gloss matte effect in harmony with the pattern. Also, since the gloss matte effect is produced by providing unevenness, the abrasion resistance of the gloss matte design is improved and it is possible to prevent the gloss matte pattern from coming off. Therefore, for example, a synchronized gloss matte effect can be produced even in flooring materials.

[0057] [Effects of this embodiment] (1) The decorative sheet 1 according to this embodiment is a decorative sheet having a pattern layer 5, comprising a pattern layer 5, a transparent thermoplastic resin layer 6, and a surface protective layer 7 laminated in this order on one side of a colored thermoplastic resin layer 2, and a matte gloss-producing pattern portion 3, which is a region containing a predetermined material that is more absorbing of infrared light than the colored thermoplastic resin layer 2, arranged on the other side of the colored thermoplastic resin layer 2 in harmony with the pattern of the pattern layer 5, the matte gloss-producing pattern portion 3 having an infrared transmittance of 60% or less at a wavelength of 2000 nm, and an embossed portion 7a formed on the surface protective layer 7 at a position overlapping the matte gloss-producing pattern portion 3 in a planar view. This allows the embossed portion 7a to be provided in a position in harmony with the pattern layer 5 on the decorative sheet 1, and the infrared absorption properties of the matte gloss-producing pattern portion 3 suppress gloss, thereby achieving a sufficient matte gloss effect. Furthermore, the visibility of the matte gloss-producing pattern portion 3 from the surface protective layer 7 side can be reduced. Furthermore, the unevenness provides a glossy matte appearance, improving the abrasion resistance of the glossy matte design and preventing the glossy matte from peeling off. As a result, a decorative sheet can be obtained that has a texture closer to the real thing, has excellent design, and is able to prevent the pattern from peeling off. (2) Furthermore, the decorative sheet 1 according to this embodiment can use at least one inorganic material selected from the group consisting of carbon black, tin-doped indium oxide, antimony-doped tin oxide, lanthanum hexaboride, and cesium-doped tungsten oxide as the material that is optically absorptive of infrared light contained in the glossy matte-producing pattern portion 3. This ensures that the transparent thermoplastic resin layer 6 and the surface protective layer 7 are more reliably softened by infrared irradiation in the areas overlapping the glossy matte-producing pattern portion 3, thereby more reliably enabling the areas overlapping the glossy matte-producing pattern portion 3 to be strongly embossed. As a result, a decorative sheet with excellent design can be more easily obtained.

[0058] [Modifications] (1) In the above embodiment, a case has been described in which a material having infrared absorbing properties is used as the matt gloss pattern portion 3, and the transparent thermoplastic resin layer 6 and the surface protective layer 7 are partially softened by irradiating infrared rays, but the present invention is not limited to this. The matt gloss pattern portion 3 may be made of a material containing any ink made of a component that is optically absorbing for light of a predetermined wavelength other than infrared rays, and the transparent thermoplastic resin layer 6 and the surface protective layer 7 may be partially softened by using a light source that irradiates light of the predetermined wavelength.

[0059] (2) As shown in Fig. 3, the decorative sheet 1 according to the above embodiment may be attached to a substrate 9, which is a substrate for a decorative material, to form a decorative member 10. In the decorative member 10, the decorative sheet 1 may be provided on at least one side of the substrate 9, or may be provided on both sides.

[0060] [Substrate] The substrate 9 can be a wood substrate or a metal substrate. Examples of wood substrates that can be used include wood veneers, wood plywood, laminated lumber, particle board, medium-density fiberboard, and hard fiberboard. Examples of metal substrates that can be used include steel plates and aluminum plates. The substrate 9 can also be made of a resin such as plastic, or a composite material thereof. That is, the substrate 9 can be a resin substrate. The substrate 9 can also be a non-combustible substrate made of, for example, a non-combustible steel plate or a non-combustible material as specified in Ministry of Construction Notification No. 1400.

[0061] Thus, decorative member 10 comprises substrate 9 and decorative sheet 1 provided on at least one surface of substrate 9. Substrate 9 can be any of a wood substrate, a resin substrate, a non-flammable substrate, and a metal substrate. This makes it possible to provide a decorative material that has a texture closer to the real thing, has excellent design properties, and is able to prevent pattern removal.

[0062] Second Embodiment Next, a second embodiment of the present invention will be described. In the first embodiment described above, the matte gloss developing pattern portion, which is a region of the picture layer containing a material that is light-absorbing to infrared rays, is provided below the colored thermoplastic resin layer. However, the matte gloss developing pattern portion may also be provided in the picture layer. In other words, the picture layer may have the matte gloss developing pattern portion. For example, as shown in FIG. 4 , the decorative sheet 11 according to this embodiment may be configured such that the matte gloss developing pattern portion 31 is part of the picture layer 51, and the matte gloss developing pattern portion 31 and the non-matte gloss developing pattern portion 51 a form a single picture. The decorative sheet 11 differs from the decorative sheet 1 in the first embodiment described above in that the matte gloss developing pattern portion 31 is provided as part of the picture layer 51.

[0063] For example, in the case of a wood grain pattern picture layer 51, the gloss matte developing pattern portion 31 is arranged at a position overlapping with the wood grain board vessel grooves of the picture layer 51. In this embodiment, the gloss matte developing pattern portion 31 is formed from a material containing black ink containing carbon black. Furthermore, similar to the gloss matte developing pattern portion 3 in the first embodiment, the gloss matte developing pattern portion 31 in this embodiment only needs to have an infrared transmittance at a wavelength of 2000 nm of 60% or less, more preferably 40% or less, and even more preferably 15% or less.

[0064] The design layer 51 has a matte gloss-developing pattern portion 31 made of a material containing black ink and a non-matte gloss-developing pattern portion 51a, and the matte gloss-developing pattern portion 31 and the non-matte gloss-developing pattern portion 51a form a single layer that defines a single design. The matte gloss-developing pattern portion 31 is positioned in a position in the design layer 51 that is to be synchronized with the embossed portion 7a. The printing ink for the non-matte gloss-developing pattern portion 51a is a mixture of solvent and solid components such as colorants and binder resins. In other words, the non-matte gloss-developing pattern portion 51a may have a configuration equivalent to that of the design layer 5 in the first embodiment. Note that in FIG. 4, components similar to those in the first embodiment are designated by the same reference numerals and will not be described again.

[0065] In this embodiment, when creating the pattern layer 51, for example, a urethane-based black ink containing carbon black is used to form the pattern portion 31 for expressing gloss matte at a position of the pattern in the pattern layer 51 that is to be synchronized with the embossed portion 7a, and the pattern portion 51a for expressing non-gloss matte is formed in other areas.

[0066] As described above, the decorative sheet 11 according to this embodiment is a decorative sheet having a pattern layer 51, which comprises the pattern layer 51, a transparent thermoplastic resin layer 6, and a surface protective layer 7 laminated in this order on one side of the colored thermoplastic resin layer 2. The pattern layer 51 has a matte gloss-exhibiting pattern portion 31, which is a region containing a predetermined material that is more absorbing of infrared light than the transparent thermoplastic resin layer 6. The matte gloss-exhibiting pattern portion 31 has an infrared transmittance of 60% or less at a wavelength of 2000 nm. An embossed portion 7a is formed in the surface protective layer 7 at a position that overlaps the matte gloss-exhibiting pattern portion 31 in a planar view. This allows the embossed portion 7a to be provided in a position on the decorative sheet 11 that is more in tune with the pattern of the pattern layer 51, and the infrared absorption properties of the matte gloss-exhibiting pattern portion 31 suppress gloss, thereby achieving a sufficient matte gloss effect. Furthermore, the unevenness provides a matte gloss effect, which improves the abrasion resistance of the matte gloss design and prevents the matte gloss from coming off. As a result, a decorative sheet can be obtained that has a texture closer to the real thing, has excellent design properties, and is able to prevent the pattern from coming off. Furthermore, a portion of the design of the design layer 51 may be formed with the gloss matte-exhibiting design portion 31. This allows the embossed portion 7a to be positioned in a more reliable harmony with the design (e.g., the wood grain board duct grooves), and the gloss matte-exhibiting design portion 31, which uses black ink, can be visually recognized as part of the design, further improving the design properties through the gloss matte effect.

[0067] [Modifications] (1) In the above embodiment, the case where the matt gloss developing pattern portion 31 is part of the picture layer 51 and the matt gloss developing pattern portion 31 and the non-matt gloss developing pattern portion 51a form a single picture has been described, but the configuration of the decorative sheet according to this embodiment is not limited to this. For example, as shown in Figure 5, the decorative sheet 12 according to a first modification of this embodiment may have the matt gloss developing pattern portion 32 provided on the main picture layer 5b. Note that in Figure 5, components similar to those in the first embodiment are designated by the same reference numerals and will not be described again.

[0068] Specifically, the design layer 52 in the decorative sheet 12 includes a main design layer 52b and a pattern layer 52c laminated on the main design layer 52b. The pattern layer 52c consists solely of a matte gloss-exhibiting design portion 32 arranged in harmony with the embossed portion 7a. The design of the design layer 52 is primarily formed by the main design layer 52b, and the pattern layer 52c, i.e., the matte gloss-exhibiting design portion 32, is formed from a material that allows the main design layer 52b to be seen. Specifically, unlike the matte gloss-exhibiting design portion 31 of the second embodiment, the matte gloss-exhibiting design portion 32 is formed from a material that absorbs infrared rays rather than a material containing black ink, and is formed using a colorless, transparent, or light-colored ink. Like the matte gloss-exhibiting design portion 3 of the first embodiment, the matte gloss-exhibiting design portion 32 of this embodiment should have an infrared transmittance of 60% or less at a wavelength of 2000 nm, preferably 40% or less, and even more preferably 15% or less.

[0069] Furthermore, the matte gloss-exhibiting pattern portion 32 in this embodiment can be made of at least one inorganic material having infrared absorption properties, such as tin-doped indium oxide (ITO), antimony-doped tin oxide (ATO), lanthanum hexaboride (LaB6), cesium-doped tungsten oxide, etc. That is, the matte gloss-exhibiting pattern portion 32 is formed with a colorless, transparent, or light-colored ink that has infrared absorption properties and allows the main design layer 52b to be visible. In this embodiment, the design layer 52 is formed by laminating the main design layer 52b on the colored thermoplastic resin layer 2, forming the matte gloss-exhibiting pattern portion 32 as a pattern layer 52c on the main design layer 52b, and laminating a transparent thermoplastic resin layer 6 on the pattern layer 52c. That is, the transparent thermoplastic resin layer 6 is laminated on the main design layer 52b and the matte gloss-exhibiting pattern portion 32 so as to fill the gaps between the matte gloss-exhibiting pattern portions 32 and cover their upper surfaces.

[0070] As described above, the decorative sheet 12 according to this embodiment is a decorative sheet having a pattern layer 52, which includes the pattern layer 52, the transparent thermoplastic resin layer 6, and the surface protective layer 7, laminated in this order on one side of the colored thermoplastic resin layer 2. The pattern layer 52 includes a main pattern layer 52b forming a pattern and a matte gloss-exhibiting pattern portion 32, which is a region containing a predetermined material that is more light-absorbent than the transparent thermoplastic resin layer 6, and the matte gloss-exhibiting pattern portion 32 is arranged on the main pattern layer 52b in harmony with the pattern. This allows the same effect as in the second embodiment to be obtained even when the matte gloss-exhibiting pattern portion 32 is laminated on the main pattern layer 52b. Furthermore, because the matte gloss-exhibiting pattern portion 32 is formed using a material that is colorless and transparent or has a pale color that is relatively nearly transparent, the pattern of the main pattern layer 52b can be seen through the matte gloss-exhibiting pattern portion 32, even when the matte gloss-exhibiting pattern portion 32 is laminated on the main pattern layer 52b. In addition, the infrared absorption properties of the gloss matte-producing pattern portion 32 suppress gloss, allowing for a sufficient gloss matte effect. Furthermore, by providing the unevenness, the gloss matte effect is expressed, improving the abrasion resistance of the gloss matte design and preventing the gloss matte pattern from peeling off. As a result, a decorative sheet can be obtained that has a texture closer to the real thing, has excellent design properties, and is able to prevent the pattern from peeling off.

[0071] (2) The decorative sheet 11 according to the second embodiment may be bonded to a substrate for a decorative material to form a decorative member. In this case, the substrate 9 (see FIG. 3) in the decorative member 10 according to the modified example of the first embodiment may be used as the decorative substrate. In this case, the decorative sheet 11 only needs to be provided on at least one side of the substrate 9, and may also be provided on both sides. Furthermore, instead of the decorative sheet 11, a decorative sheet 12 may be provided on at least one side of the substrate 9 to form a decorative member. This makes it possible to provide a decorative member that has a texture closer to the real thing, has excellent design properties, and is capable of suppressing pattern removal, similar to the decorative member 10 according to the modified example of the first embodiment.

[0072] [Third embodiment] Next, a third embodiment of the present invention will be described. In the first and second embodiments described above, the matt gloss-producing pattern portion, which is a region containing a material that is light-absorbing to infrared rays, is configured to be provided either in the lower layer of the colored thermoplastic resin layer or in the picture layer, but the configuration of the decorative sheet in the present invention is not limited to these. For example, the matt gloss-producing pattern portion may be provided in both the lower layer of the colored thermoplastic resin layer and the picture layer.

[0073] For example, as shown in Fig. 6, the decorative sheet 13 according to this embodiment may be configured such that the matte gloss developing pattern portion 3 is provided in the lower layer of the colored thermoplastic resin layer 2, the matte gloss developing pattern portion 31 is part of the picture layer 51, and the matte gloss developing pattern portion 31 and the non-matte gloss developing pattern portion 51a form a single picture. The decorative sheet 13 differs from the decorative sheet 1 in the first and second embodiments in that it includes the matte gloss developing pattern portion 3 provided in the lower layer of the colored thermoplastic resin layer 2 and the matte gloss developing pattern portion 31 provided as part of the picture layer 51. In the decorative sheet 13 shown in Fig. 6, components similar to those in the first and second embodiments are designated by the same reference numerals and detailed description thereof will be omitted.

[0074] 6, in the decorative sheet 13, the pattern layer 51 has a matte gloss developing pattern portion 31 and a non-matte gloss developing pattern portion 51a, as in the second embodiment, and the matte gloss developing pattern portion 31 and the non-matte gloss developing pattern portion 51a form a single layer that forms a single pattern. For example, in the case of a wood grain pattern pattern layer 51, the matte gloss developing pattern portion 31 is arranged in a position that overlaps with the wood grain board vessel groove of the pattern layer 51.

[0075]

[0046] Furthermore, in the decorative sheet 13 according to this embodiment, a matte gloss developing pattern portion 3 is provided below the colored thermoplastic resin layer 2, as in the first embodiment. In this embodiment, the matte gloss developing pattern portion 3 is arranged in a position that harmonizes with the pattern of the pattern layer 51. For example, in the case of a wood grain patterned pattern layer 51, the matte gloss developing pattern portion 3 is formed in a position that overlaps with the wood grain duct grooves of the pattern layer 51 in a plan view. In other words, the matte gloss developing pattern portion 3 is arranged in a position that harmonizes with the part of the pattern of the pattern layer (the pattern formed by the matte gloss developing pattern portion 31). For this reason, as shown in Fig. 6, in the decorative sheet 13, the matte gloss developing pattern portion 3 arranged in a position that harmonizes with the pattern of the pattern layer 51 and the matte gloss developing pattern portion 31 provided as part of the pattern layer 51 are arranged in a position that overlaps with each other in a plan view. This allows the embossed portion 7a to be provided in a position on the decorative sheet 13 that is more reliably in sync with the pattern of the pattern layer 51, and the gloss can be further suppressed by the infrared absorption properties of the gloss matte-exhibiting pattern portion 3 and the gloss matte-exhibiting pattern portion 31, thereby more fully achieving the gloss matte effect. It also reduces the visibility of the gloss matte-exhibiting pattern portion 3 from the surface protective layer 7 side. Furthermore, since the gloss matte expression is achieved by providing unevenness, the abrasion resistance of the gloss matte design is improved, and it is possible to prevent the gloss matte pattern from coming off or the like.

[0076] As described above, the decorative sheet 13 according to this embodiment is a decorative sheet having a pattern layer 51, and includes the pattern layer 51, the transparent thermoplastic resin layer 6, and the surface protective layer 7, laminated in this order on one side of the colored thermoplastic resin layer 2. The pattern layer 51 has a matte gloss-producing pattern portion 31, which is a region containing a predetermined material that is more light-absorbent to infrared rays than the transparent thermoplastic resin layer 6, and the matte gloss-producing pattern portion 31 has an infrared transmittance of 60% or less at a wavelength of 2000 nm. A portion of the pattern of the pattern layer 51 is formed by the matte gloss-producing pattern portion 31. Furthermore, on the other side of the colored thermoplastic resin layer 2 of the decorative sheet 13, a matte gloss-producing pattern portion 3, which is a region containing a predetermined material that is more light-absorbent to infrared rays than the colored thermoplastic resin layer 2, is arranged in phase with the portion of the pattern of the pattern layer 5 (the matte gloss-producing pattern portion 31), and the matte gloss-producing pattern portion 3 has an infrared transmittance of 60% or less at a wavelength of 2000 nm. An embossed portion 7a is formed on the surface protective layer 7 at a position that overlaps with the matte gloss developing pattern portion 3 and the matte gloss developing pattern portion 31 in a plan view.

[0077] The decorative sheet 13 has the above-described configuration, which allows it to achieve the effects of the first and second embodiments described above, and as a result, it is possible to obtain a decorative sheet that has a texture that is closer to the real thing, has better design properties, and can more reliably prevent the pattern from coming off.

[0078] [Variations] (1) In the third embodiment (present embodiment) described above, a configuration was described in which a matte gloss-exhibiting pattern portion is provided in both the lower layer of the colored thermoplastic resin layer and the picture layer, and in the picture layer, a single picture is formed by the matte gloss-exhibiting pattern portion and the non-matte gloss-exhibiting pattern portion, but the configuration of the decorative sheet according to this embodiment is not limited to this. For example, as shown in Fig. 7, a decorative sheet 14 according to a first variation of this embodiment (third embodiment) may have a matte gloss-exhibiting pattern portion 3 provided in the lower layer of the colored thermoplastic resin layer 2, and in the picture layer 5, a matte gloss-exhibiting pattern portion 32 provided on the main picture layer 5b. Note that in Fig. 7, components similar to those of the decorative sheet 1 of the first embodiment and the decorative sheet 12 of the first variation of the second embodiment are designated by the same reference numerals and will not be described again.

[0079] As shown in FIG. 7 , in the decorative sheet 14, the design layer 52 includes a main design layer 52b and a pattern layer 52c laminated on the main design layer 52b, similar to the first modification of the second embodiment. The pattern layer 52c consists solely of a matte gloss-exhibiting design portion 32 positioned at a location that matches the design (e.g., the vascular grooves of a wood grain pattern) that is to be synchronized with the embossed portion 7a. In other words, the matte gloss-exhibiting design portion 32 is positioned in synchronization with the design formed by the main design layer 52b. The design of the design layer 52 is primarily formed by the main design layer 52b, and the pattern layer 52c, i.e., the matte gloss-exhibiting design portion 32, is formed from a material that allows the main design layer 52b to be seen. Similar to the first modification of the second embodiment, the matte gloss-exhibiting design portion 32 is formed from a material that absorbs infrared rays rather than a material containing black ink, and may be formed using a colorless, transparent, or light-colored ink.

[0080] Furthermore, in the decorative sheet 14 according to this embodiment, similar to the third embodiment, a matte gloss developing pattern portion 3 is provided below the colored thermoplastic resin layer 2. In this modification, the matte gloss developing pattern portion 3 is arranged in a position that matches the pattern (e.g., the wood grain vessel grooves in a wood grain pattern) of the pattern layer 52 (main pattern layer 52b). Therefore, as shown in Fig. 7, in the decorative sheet 14, the matte gloss developing pattern portion 3 arranged in a position that matches the pattern of the main pattern layer 52b and the matte gloss developing pattern portion 32 that constitutes the pattern layer 52c laminated on the main pattern layer 52b are arranged in positions that overlap in a plan view. As a result, even when the gloss matte-exhibiting pattern portion 32 is laminated on the main pattern layer 52b, the embossed portion 7a can be positioned to more reliably synchronize with the pattern of the pattern layer 52 (main pattern layer 52b). Furthermore, the infrared absorption properties of the gloss matte-exhibiting pattern portion 3 and the gloss matte-exhibiting pattern portion 32 further suppress gloss, thereby more fully achieving the gloss matte effect. Furthermore, the visibility of the gloss matte-exhibiting pattern portion 3 from the surface protective layer 7 side can be reduced. Furthermore, the gloss matte effect is achieved by providing the unevenness, which improves the abrasion resistance of the gloss matte design and prevents the gloss matte pattern from peeling off. Furthermore, by forming the gloss matte-exhibiting pattern portion 32 using a colorless, transparent material or a pale, nearly transparent material, as in the first modification of the second embodiment, the pattern of the main pattern layer 52b can be seen through the gloss matte-exhibiting pattern portion 32, even when the gloss matte-exhibiting pattern portion 32 is laminated on the main pattern layer 5b.

[0081] The matte gloss developing pattern portion 32 may be formed of a material containing black ink containing carbon black, similar to the matte gloss developing pattern portion 31. In this case, for example, if the design layer 52 has a wood grain pattern, the vessel grooves of the wood grain board may be expressed by the matte gloss developing pattern portion 32. In the design layer 52, the pattern layer 52c formed by the matte gloss developing pattern portion 32 forms part of the design, so that the embossed portion 7a can be provided at a position that is more reliably in sync with the design (for example, the vessel grooves of the wood grain board), and the matte gloss developing pattern portion 32 made of black ink can be visually recognized as part of the design.

[0082] As described above, the decorative sheet 13 according to this embodiment is a decorative sheet having a pattern layer 51, and includes the pattern layer 51, the transparent thermoplastic resin layer 6, and the surface protective layer 7, laminated in this order on one side of the colored thermoplastic resin layer 2. On the other side of the colored thermoplastic resin layer 2, a matte gloss-producing pattern section 3, which is a region containing a predetermined material that is more absorbing of infrared light than the colored thermoplastic resin layer 2, is arranged in harmony with the pattern of the pattern layer 52, and the matte gloss-producing pattern section 3 has an infrared transmittance of 60% or less at a wavelength of 2000 nm. The pattern layer 52 also has a main pattern layer 52b that forms the pattern, and a matte gloss-producing pattern section 32, which is a region containing a predetermined material that is more absorbing of infrared light than the transparent thermoplastic resin layer 6, and the matte gloss-producing pattern section 32 has an infrared transmittance of 60% or less at a wavelength of 2000 nm. The matte gloss-producing pattern section 32 is arranged on the main pattern layer 52b in harmony with the pattern. Furthermore, embossed portions 7a are formed on the surface protective layer 7 at positions that overlap the matte gloss developing pattern portions 3 and 32 in plan view.

[0083] The decorative sheet 14 has the above-described configuration, and can achieve the effects of the first embodiment and the first modification of the second embodiment. As a result, a decorative sheet can be obtained that has a texture that is closer to the real thing, has better design properties, and can more reliably prevent pattern removal.

[0084] (2) The decorative sheet 13 according to the third embodiment may also be bonded to a substrate for a decorative material to form a decorative member. In this case, the substrate 9 (see FIG. 3) in the decorative member 10 according to the modified example of the first embodiment may be used as the decorative substrate. In this case, the decorative sheet 13 only needs to be provided on at least one side of the substrate 9, and may also be provided on both sides. Furthermore, instead of the decorative sheet 13, a decorative sheet 14 may be provided on at least one side of the substrate 9 to form a decorative member. This makes it possible to provide a decorative member that has a texture that is closer to the real thing, has excellent design properties, and is capable of preventing pattern removal, similar to the decorative member 10 according to the modified example of the first embodiment.

[0085] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples.

[0086] Example 1: A design layer 5 made of a urethane-based printing ink, a transparent thermoplastic resin layer 6 made of a 90 μm-thick PP (polypropylene) layer, and a surface protection layer 7 mainly composed of an ultraviolet-curable resin containing an acrylic resin composition were laminated in this order on one side of a colored thermoplastic resin layer 2 made of a 55 μm-thick PE (polyethylene) layer. Furthermore, a pattern was printed on the other side of the colored thermoplastic resin layer 2 (the side opposite the design layer 5) using a black ink made of a urethane-based printing ink containing carbon black to form a matte gloss-exhibiting pattern portion 3 (pattern layer 8a). A primer layer 8 was then formed on the colored thermoplastic resin layer 2 including the matte gloss-exhibiting pattern portion 3, resulting in a laminate. The matte gloss-exhibiting pattern portion 3 had an infrared transmittance of 8% at a wavelength of 2000 nm.

[0087] In this case, multiple laminates having gloss / matt pattern areas 3 with different image density levels were produced by solid printing with black ink using printing plates with varying image density levels. The image density levels were 0%, 20%, 40%, 60%, 70%, 80%, and 90%. The image density level here refers to the percentage of the area coated with ink within a given area. The transparent thermoplastic resin layer 6 was formed by laminating it onto the design layer 5 via an adhesive layer made of an adhesive resin (urethane adhesive). After forming the primer layer 8, the laminate was heated with an infrared heater as an after-embossing process, and an embossing roll was pressed against the surface protective layer 7 to form the embossed area 7a, thereby obtaining the decorative sheet shown in Figure 1.

[0088] (Example 2) The infrared transmittance of the gloss matte developing pattern portion 3 at a wavelength of 2000 nm was set to 38%. Except for this, the decorative sheet 1 shown in Figure 1 was obtained in the same manner as in Example 1 above. (Example 3) The infrared transmittance of the gloss matte developing pattern portion 3 at a wavelength of 2000 nm was set to 58%. Except for this, the decorative sheet 1 shown in Figure 1 was obtained in the same manner as in Example 1 above. (Example 4) The infrared transmittance of the gloss matte developing pattern portion 3 at a wavelength of 2000 nm was set to 15%. Except for this, the decorative sheet 1 shown in Figure 1 was obtained in the same manner as in Example 1 above.

[0089] Example 5: A pattern of a transparent urethane-based printing ink containing an infrared-absorbing material was printed on the other surface of the colored thermoplastic resin layer 2 (the surface opposite the design layer 5) to form a matte gloss-exhibiting pattern portion 3. Otherwise, the decorative sheet 1 shown in FIG. 1 was obtained in the same manner as in Example 1 above. Example 6: A laminate was prepared comprising a colored thermoplastic resin layer 2 made of a 50 μm-thick PBT layer, a design layer 51 made of a matte gloss-exhibiting pattern portion 31 pattern-printed with a black ink made of a urethane-based printing ink, and a non-matte gloss-exhibiting pattern portion 51a formed adjacent to the matte gloss-exhibiting pattern portion 31 using a urethane-based printing ink, a transparent thermoplastic resin layer 6 made of a 38 μm-thick PP layer, and a surface protective layer 7 primarily composed of an acrylic resin composition. The matte gloss-exhibiting pattern portion 31 had an infrared transmittance of 24% at a wavelength of 2000 nm. The transparent thermoplastic resin layer 6 was formed by laminating it onto the design layer 51, forming a surface protective layer 7. The laminate was then heated with an infrared heater, and an embossing roll was then pressed against the surface protective layer 7 to form an embossed portion 7a. A primer layer 8 was then formed, yielding the decorative sheet shown in Figure 4. (Example 7) A design layer 52 was formed from a 50-μm-thick colored thermoplastic resin layer 2 made of PBT, a main design layer 52b formed using a urethane-based ink, and a gloss matte-exhibiting design portion 32 pattern-printed with a transparent ink made of a urethane-based printing ink containing an infrared-absorbing material. A transparent thermoplastic resin layer 6 made of PP with a thickness of 38 μm was then formed on top of the design layer 52, resulting in a laminate comprising a surface protective layer 7 primarily composed of an acrylic resin composition. The gloss matte-exhibiting design portion 32 had an infrared transmittance of 25% at a wavelength of 2000 nm. The transparent thermoplastic resin layer 6 was formed by laminating it onto the pattern layer 52, and after forming the surface protective layer 7, the laminate was heated with an infrared heater, and then an embossing roll was pressed against the surface protective layer 7 to form an embossed portion 7a, and then a primer layer 8 was formed to obtain the decorative sheet shown in Figure 5.

[0090] Example 8 A picture layer 52 was formed on the colored thermoplastic resin layer 2, comprising a main picture layer 52b formed using a urethane-based ink and a gloss matte-producing pattern portion 32 pattern-printed with a transparent ink made of a urethane-based printing ink containing an infrared-absorbing material. The infrared transmittance (2) of the gloss matte-producing pattern portion 32 in the picture layer 52 at a wavelength of 2000 nm was set to 16.48%. Otherwise, the decorative sheet shown in FIG. 7 was obtained in the same manner as in Example 1. The infrared transmittance (1) of the gloss matte-producing pattern portion 3 on the other surface of the colored thermoplastic resin layer 2 at a wavelength of 2000 nm was set to 8%, the same as in Example 1. Example 9 A picture layer 52 (including the gloss matte-producing pattern portion 32) similar to that in Example 8 was formed on the colored thermoplastic resin layer 2. As a result, the infrared transmittance (2) of the gloss matte-producing pattern portion 32 in the picture layer 52 at a wavelength of 2000 nm was set to 16.48%. A decorative sheet shown in FIG. 7 was obtained in the same manner as in Example 3, except for the above. The infrared transmittance (1) of the matt gloss-producing pattern portion 3 on the other side of the colored thermoplastic resin layer 2 at a wavelength of 2000 nm was set to 58%, the same as in Example 3. (Example 10) A matt gloss-producing pattern portion 3 was not provided on the other side of the colored thermoplastic resin layer 2, and a picture layer 52 (including a matt gloss-producing pattern portion 32) similar to that in Example 8 was formed on the colored thermoplastic resin layer 2. As a result, the infrared transmittance (2) of the matt gloss-producing pattern portion 32 in the picture layer 52 at a wavelength of 2000 nm was set to 16.48%. A decorative sheet shown in FIG. 5 was obtained in the same manner as in Example 1, except for the above. (Example 11) A matt gloss-producing pattern portion 3 was not provided on the other side of the colored thermoplastic resin layer 2, and a picture layer 52 (including a matt gloss-producing pattern portion 32) similar to that in Example 8 was formed on the colored thermoplastic resin layer 2. As a result, the infrared transmittance (2) at a wavelength of 2000 nm of the gloss matte-exhibiting pattern portion 32 in the picture layer 52 was set to 16.48%. Otherwise, the decorative sheet shown in Figure 5 was obtained in the same manner as in Example 2. Note that the heating temperature by the infrared heater when forming the embossed portions 7a differs between Examples 10 and 11 (heating temperature in Example 10 > heating temperature in Example 11). Therefore, the depth of the embossed portions 7a of the decorative sheet according to Example 10 is deeper than the embossed portions 7a of the decorative sheet according to Example 11.

[0091] (Comparative Example 1) In Comparative Example 1, the gloss matte-producing pattern portion 3 was not provided on the other surface (the surface opposite the picture layer 5) of the colored thermoplastic resin layer 2, and the infrared transmittance at a wavelength of 2000 nm in the colored thermoplastic resin layer 2 was set to 61%. Otherwise, a decorative sheet was produced in the same manner as in Example 1. The image density levels were 0%, 20%, 40%, 60%, 70%, 80%, and 90%.

[0092] [Evaluation] Infrared transmittance was measured for each of the decorative sheets with different image density levels in Examples 1-11 and Comparative Example 1. Infrared transmittance was measured by the method described below. Gloss and gloss difference were obtained for each of the decorative sheets with each image density level in Examples 1-11 and Comparative Example 1. The method described below was used for obtaining the data. The results are shown in Table 1. The values ​​shown in Table 1 are average values ​​of the results measured for each image density level. Furthermore, gloss matte design was evaluated for each of the decorative sheets with each image density level in Examples 1-11 and Comparative Example 1.

[0093] [Measurement of Infrared Transmittance] The infrared transmittance of the matte gloss developing pattern portion was measured for each of the decorative sheets of Examples 1-11 and Comparative Example 1, which had different image density levels. Specifically, an ultraviolet-visible spectrophotometer UV3600 manufactured by Shimadzu was used to measure the infrared transmittance at a wavelength of 2000 nm. In Table 1 below, for Examples 8-11, the infrared transmittance of the matte gloss developing pattern portion 3 is described as "infrared transmittance (1)," and the infrared transmittance of the matte gloss developing pattern portion 32 is described as "infrared transmittance (2)." Note that for Examples 10 and 11, the matte gloss developing pattern portion 3 was not provided, so only the "infrared transmittance (2)" indicating the matte gloss developing pattern portion 32 is described, and no notation (-) is given for the "infrared transmittance (1)."

[0094] [Gloss Measurement] After embossing, the decorative sheets of Examples 1-11 and Comparative Example 1, which had different image density levels, were subjected to specular gloss measurement at an angle of incidence of 85° for the surface protective layer 7 directly above the matte gloss development pattern portion using a micro-TRI-gloss manufactured by BYK. [Gloss Difference] After embossing, the decorative sheets of Examples 1-11 and Comparative Example 1, which had different image density levels, were subjected to specular gloss measurement for the surface protective layer directly above the portion where the matte gloss development pattern portion was not formed, using the same method as used for gloss measurement, and the difference in gloss from the surface protective layer directly above the matte gloss development pattern portion was determined. The presence or absence of matte gloss development was confirmed based on the difference in gloss.

[0095] [Matte Gloss Design] The difference in gloss and the state of the matte gloss effect were visually evaluated for each of the decorative sheets of Examples 1-11, which had different image density levels, and the decorative sheet of Comparative Example 1. The evaluation criteria were as follows. In this example, a rating of "Good" or better was considered pass. Excellent: The difference in gloss is 3 or more, the matte gloss effect is stably expressed, and the matte gloss effect pattern is almost invisible from the surface protective layer side. Good: The difference in gloss is 3 or more, the matte gloss effect is stably expressed, but the matte gloss effect pattern is visible from the surface protective layer side. Bad: Regardless of the visibility of the matte gloss effect pattern from the surface protective layer side, the difference in gloss is less than 3, and the matte gloss effect is not fully expressed.

[0096]

[0097] [Results] Although there were some differences in glossiness in the decorative sheets of Examples 1-11, the difference in glossiness between the portions provided with the matte gloss-producing pattern portion and the portions not provided with the pattern portion was 3 or more, satisfying the gloss difference of 3 at which a matte gloss appearance is generally recognizable, and it was therefore confirmed that a sufficient matte gloss appearance could be obtained. In other words, it was confirmed that by providing a matte gloss-producing pattern portion having an infrared transmittance of 60% or less at a wavelength of 2000 nm on either the back surface of the colored thermoplastic resin layer or the picture layer, or both, a sufficient matte gloss appearance was possible, and that a decorative sheet with excellent design properties could be obtained that had a texture similar to the surface texture of wood, stone, and the like used in building materials.

[0098] DESCRIPTION OF SYMBOLS 1, 11, 12, 13, 14 Decorative sheet 2 Colored thermoplastic resin layer 3, 31, 32 Pattern portion for expressing gloss and matt 5, 51, 52 Design layer 6 Transparent thermoplastic resin layer 7 Surface protective layer 7a Embossed portion 8 Primer layer 8a, 5c Pattern layer 10 Decorative member

Claims

1. A decorative sheet having a pattern layer, comprising a pattern layer, a transparent resin layer, and a surface protective layer laminated in that order on one side of a colored resin layer, wherein on the other side of the colored resin layer, an area containing a specified material which is more light absorbing to infrared rays than the colored resin layer is arranged in harmony with the pattern of the pattern layer, the area containing the specified material has an infrared transmittance of 60% or less at a wavelength of 2000 nm, and an embossed portion is formed in the surface protective layer at a position which overlaps with the area containing the specified material in a planar view.

2. The decorative sheet according to claim 1, characterized in that the predetermined material is at least one inorganic material selected from the group consisting of carbon black, tin-doped indium oxide, antimony-doped tin oxide, lanthanum hexaboride, and cesium-doped tungsten oxide.

3. A decorative sheet having a pattern layer, comprising a pattern layer, a transparent resin layer and a surface protective layer laminated in that order on one side of a colored resin layer, the pattern layer having an area containing a specified material which is more absorptive of infrared rays than the transparent resin layer, the area containing the specified material having an infrared transmittance of 60% or less at a wavelength of 2000 nm, and an embossed portion formed in the surface protective layer at a position which overlaps with the area containing the specified material in a planar view.

4. The decorative sheet according to claim 3, characterized in that the pattern of the pattern layer is formed in an area partially containing the specified material.

5. The decorative sheet according to claim 3, characterized in that the pattern layer has a main pattern layer forming a pattern and an area containing the specified material, and the area containing the specified material is arranged on the main pattern layer in harmony with the pattern.

6. A decorative sheet as described in claim 4, wherein an area on the other side of the colored resin layer contains a specified material that is more light absorbing to infrared rays than the colored resin layer and has an infrared transmittance of 60% or less at a wavelength of 2000 nm, and is arranged in phase with the part of the pattern in the pattern layer, and the embossed portion is formed in the surface protection layer at a position that overlaps, in a planar view, with the area in the pattern layer containing the specified material and the area on the other side of the colored resin layer containing the specified material.

7. The decorative sheet as described in claim 1, characterized in that the pattern layer has a main pattern layer forming a pattern and a region containing a predetermined material which has greater infrared absorption than the transparent resin layer, the region containing the predetermined material in the pattern layer is arranged on the main pattern layer in sync with the pattern and has an infrared transmittance of 60% or less at a wavelength of 2000 nm, and the embossed portion is formed in the surface protective layer at a position which, when viewed in a plane, overlaps with the region containing the predetermined material on the other side of the colored resin layer and the region containing the predetermined material in the pattern layer.

8. A decorative member comprising: a substrate; and a decorative sheet according to any one of claims 1 to 7 provided on at least one surface side of the substrate, wherein the substrate is any one of a wood substrate, a resin substrate, a non-flammable substrate, or a metal substrate.

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