Method for manufacturing a transfer original and method for manufacturing a decorative sheet

Abstract

The present invention relates to a method for manufacturing a transfer original and a method for manufacturing a decorative sheet. The method for manufacturing a transfer original includes: irradiating a surface on which an ionizing radiation-curable resin is applied with first ionizing radiation having energy capable of cutting a high molecular chain of the ionizing radiation-curable resin to cause the surface of the ionizing radiation-curable resin to shrink, thereby forming a concavo-convex shape for an original on the surface of the ionizing radiation-curable resin; and irradiating the shrunk ionizing radiation-curable resin with second ionizing radiation that causes the ionizing radiation-curable resin to cure to cause the ionizing radiation-curable resin to cure, thereby forming a transfer original that is a resin material having the concavo-convex shape for an original on the surface.

Description

[0001] This application is a divisional application of application number 2021800261156, filed on January 6, 2021, entitled "Method for manufacturing decorative sheet, decorative panel, original for transfer printing and method for manufacturing decorative sheet". Technical Field

[0002] This disclosure relates to methods for manufacturing decorative sheets, decorative panels, transfer printing plates, and methods for manufacturing decorative sheets. Background Technology

[0003] In the past, from a design point of view, the matte finish of decorative sheets has been adjusted by adding a gloss modifier (matte additive) to the surface protective layer of the decorative sheet (for example, see Patent Document 1).

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2001-129959 Summary of the Invention

[0007] The problem to be solved by the present invention

[0008] However, gloss modifiers reduce the oleophobicity of layers formed from resin materials. Therefore, decorative sheets with a surface protective layer containing gloss modifiers are prone to fingerprint adhesion.

[0009] This disclosure was made in view of the following problem, and its purpose is to obtain a method for manufacturing a decorative sheet, a decorative plate, a transfer printing plate, and a method for manufacturing a decorative sheet, which have excellent fingerprint resistance on the surface of the decorative sheet.

[0010] Methods for solving problems

[0011] To address the aforementioned issues, one aspect of the decorative sheet disclosed herein is characterized by comprising: a raw material layer, a colored pattern layer disposed on one surface of the raw material layer, and a first surface protective layer disposed on a surface of the colored pattern layer opposite to the raw material layer and having an uneven surface shape.

[0012] In addition, one aspect of the decorative panel disclosed herein is characterized by comprising: the aforementioned decorative sheet, and a substrate layer disposed on the side of the original material layer opposite to the colored pattern layer.

[0013] Furthermore, one aspect of the present disclosure relates to a method for manufacturing a transfer printing plate, characterized in that a first ionizing radiation with energy capable of cutting the polymer chains of the ionizing radiation-curable resin is irradiated onto a surface coated with ionizing radiation-curable resin, causing the surface of the ionizing radiation-curable resin to shrink, thereby forming a plate-like uneven shape on the surface of the ionizing radiation-curable resin. A second ionizing radiation is then irradiated onto the shrunken ionizing radiation-curable resin to cure it, thereby forming a transfer printing plate as a resin material with a plate-like uneven shape on its surface.

[0014] Furthermore, the method for manufacturing a transfer printing plate according to other aspects of this disclosure is characterized in that a first ionizing radiation with energy capable of cutting the polymer chains of the ionizing radiation-curable resin is irradiated onto a surface coated with the resin, causing the surface of the ionizing radiation-curable resin to shrink, thereby forming a plate-like uneven shape on the surface of the ionizing radiation-curable resin. A second ionizing radiation that cures the ionizing radiation-curable resin is then irradiated onto the shrunken ionizing radiation-curable resin to cure the resin, thereby forming a transfer printing plate as a resin material with a plate-like uneven shape on its surface.

[0015] Furthermore, one aspect of the method for manufacturing a decorative sheet disclosed herein is characterized in that a resin material is coated on one surface of a raw material layer, and a transfer plate formed by the above-described method for manufacturing a transfer plate is used to transfer the plate onto the resin material in an uneven shape, and by curing the resin material, a first surface protective layer is formed on one surface of the raw material layer, wherein the uneven shape corresponds to the uneven shape of the plate is provided on the surface of the resin material.

[0016] The effects of the invention

[0017] According to the present disclosure, it is possible to obtain a decorative sheet, a decorative panel, a transfer printing plate, and a method for manufacturing a decorative sheet that can combine the matte finish and fingerprint resistance of the decorative sheet surface. Attached Figure Description

[0018] [ Figure 1 This is a cross-sectional view illustrating a configuration example of a decorative sheet according to the first embodiment of this disclosure.

[0019] [ Figure 2 This is a cross-sectional photograph illustrating an example of the configuration of the first surface protective layer of the decorative sheet according to the first embodiment of this disclosure.

[0020] [ Figure 3 This is a schematic diagram illustrating an example of a method for manufacturing a decorative sheet according to the first embodiment of this disclosure.

[0021] [ Figure 4 This is a cross-sectional view illustrating a configuration example of the decorative sheet according to the second embodiment of this disclosure.

[0022] [ Figure 5 This is a plan view photograph showing an example of the configuration of the surface of the first surface protective layer of the decorative sheet according to the second embodiment of this disclosure.

[0023] [ Figure 6 This is a cross-sectional photograph illustrating an example of the configuration of the first surface protective layer of the decorative sheet according to the second embodiment of this disclosure.

[0024] [ Figure 7 [This is an enlarged cross-sectional view showing an example of the configuration of a decorative sheet according to the second embodiment of this disclosure.]

[0025] [ Figure 8 This is a process diagram illustrating an example of a method for manufacturing a transfer original used in the manufacture of a decorative sheet according to the second embodiment of this disclosure.

[0026] [ Figure 9 This is a schematic diagram illustrating an example of a method for manufacturing a decorative sheet according to a second embodiment of the present disclosure.

[0027] [ Figure 10 This is a cross-sectional view showing a configuration example of a decorative sheet according to a third embodiment, which is a variation of the decorative sheet according to the first embodiment of this disclosure.

[0028] [ Figure 11 This is a cross-sectional view showing a configuration example of a decorative sheet according to a third embodiment, which is a variation of the decorative sheet according to the first embodiment of this disclosure.

[0029] [ Figure 12 This is a cross-sectional view showing a configuration example of a decorative sheet according to a third embodiment, which is a variation of the decorative sheet according to the first embodiment of this disclosure.

[0030] [ Figure 13 This is a cross-sectional view showing a configuration example of a decorative sheet according to a third embodiment, which is a variation of the decorative sheet according to the first embodiment of this disclosure.

[0031] [ Figure 14 This is a cross-sectional view showing an example of the configuration of a decorative panel according to the fourth embodiment of this disclosure. Detailed Implementation

[0032] The present disclosure will now be described through embodiments, but these embodiments do not limit the invention as defined in the claims. Furthermore, not all combinations of features described in the embodiments are necessary for the inventive solution. Additionally, the accompanying drawings schematically illustrate the invention as defined in the claims; the width, thickness, and other dimensions of the parts differ from actual dimensions, as do their ratios.

[0033] The decorative sheet disclosed herein will be described. The decorative sheet involved in this disclosure is, for example, a decorative sheet that is installed on walls, doors, windows, furniture, etc. It should be noted that, in the following description, sometimes the side of the decorative sheet that contacts the substrate is referred to as "lower" and the side of the decorative sheet opposite to the side that contacts the substrate (surface) is referred to as "upper".

[0034] The following is for reference Figures 1 to 14 Each embodiment of the present disclosure will be described in detail.

[0035] 1. First Implementation Method

[0036] use Figures 1 to 3 The decorative sheet 1 according to the first embodiment of this disclosure will be described.

[0037] (1.1) Basic Components of Decorative Pieces

[0038] use Figure 1 The basic structure of the decorative sheet according to the first embodiment of this disclosure will be described. Figure 1 This is a cross-sectional view illustrating a configuration example of the decorative sheet 1 according to the first embodiment of this disclosure. Figure 1 As shown, the decorative piece 1 comprises: a raw material layer 11, a colored pattern layer 12, and a first surface protective layer 13. The decorative piece 1 is composed of the raw material layer 11, the colored pattern layer 12, and the first surface protective layer 13 stacked sequentially.

[0039] The base material layer 11 is the substrate layer of the decorative piece 1. It is used to absorb unevenness or step differences on the bonding surface to ensure a smooth installation of the decorative piece 1 and to conceal the color of the bonding surface.

[0040] Patterned layer. Colored patterned layer 12 is a layer that imparts at least one of color and pattern to the decorative piece 1. First surface protective layer 13 is a layer used to protect the base material layer 11 and the colored patterned layer 12 from damage, etc.

[0041] The following is a detailed description of each layer: the raw material layer 11, the colored pattern layer 12, and the first surface protective layer 13.

[0042] <Material Layer>

[0043] The raw material layer 11 is the layer (sheet) that serves as the substrate for the decorative sheet 1.

[0044] The raw material layer 11 is, for example, a paper material mainly composed of pulp or cellulose fiber, or a resin layer or resin sheet formed of resin material.

[0045] When the base material layer 11 is paper, paper strength enhancers, additives for improving concealment, cellulose nanofibers, colorants and other additives can be added.

[0046] Furthermore, when the base material 11 is a resin material, thermoplastic resins such as polypropylene, polyethylene, and polyester are preferably used as the resin material. Thermoplastic resins may contain inorganic materials such as titanium dioxide and calcium carbonate as additives. By using at least one of polypropylene, polyethylene, and polyester as the thermoplastic resin, the dispersibility of inorganic materials is improved. Furthermore, by using polypropylene as the thermoplastic resin, the dispersibility of inorganic materials is further improved.

[0047] Furthermore, when the base material layer 11 is a resin film, a membrane material primarily composed of polyethylene terephthalate is preferred. The resin film may contain the aforementioned inorganic materials as additives. Additionally, when the base material layer 11 is a resin film, it may be a resin film formed by uniaxial or biaxial stretching. The base material layer 11 formed from a resin film formed by uniaxial or biaxial stretching may contain internal voids.

[0048] When the base material layer 11 is a resin material or a resin film, the content of inorganic material relative to the base material layer 11 is preferably set in the range of 1% to 90% by mass, more preferably in the range of 5% to 80% by mass, and even more preferably in the range of 20% to 80% by mass. By setting the content of inorganic material within the above range, sufficient non-flammability or sufficient flame retardancy can be reliably obtained, while printability and lamination adaptability can be reliably improved, and cracks generated in the bending portion of the sheet can be reliably reduced.

[0049] The thickness of the raw material layer 11 is preferably in the range of 20 μm to 250 μm, more preferably in the range of 25 μm to 250 μm, and even more preferably in the range of 70 μm to 200 μm. When the thickness of the raw material layer 11 is within the above range, the lamination adaptability can be improved, and the cracks generated in the bending portion of the sheet can be reduced.

[0050] Surface treatments such as corona treatment or plasma treatment can be applied to the surface of the base material layer 11. As a result, the adhesion (tightness) between the base material layer 11 and the colored pattern layer 12 is improved.

[0051] <Colored Pattern Layer>

[0052] A colored pattern layer 12 is disposed on one surface of the base material layer 11. The colored pattern layer 12 may have, for example, a colored layer 12A disposed on the base material layer 11 and a pattern layer 12B disposed on the colored layer 12A. It should be noted that the colored pattern layer 12 may have at least one of the colored layer 12A or the pattern layer 12B, depending on the desired design.

[0053] Coloring layer 12A is a layer used to impart the design qualities of the decorative piece 1 with the desired color, while concealing the color / pattern of the base material to which the decorative piece 1 is adhered. Coloring layer 12A is formed, for example, by solid application of ink.

[0054] The pattern layer 12B is disposed on the surface side of the decorative piece 1, which is located higher than the coloring layer 12A, and imparts the design features of the decorative piece 1 with the desired pattern. The pattern layer 12B is formed on top of the coloring layer 12A, and can be formed, for example, by printing wood grain patterns, stone patterns, sand patterns, tile patterns, brick pile patterns, fabric patterns, leather patterns, geometric patterns, and other patterns.

[0055] The coloring layer 12A and the pattern layer 12B are formed, for example, by screen printing with ink. As the ink used to form the coloring layer 12A and the pattern layer 12B, any one or a mixture of isoindolinone yellow, polyazo red, phthalocyanine blue, carbon black, iron oxide, and titanium oxide can be used alone as a pigment. Furthermore, these inks can be aqueous solvents or organic solvents; for example, ethyl acetate, n-butyl acetate, isobutanol, and methyl isobutyl ketone can be used as organic solvents.

[0056] The thicknesses of the coloring layer 12A and the pattern layer 12B of the coloring pattern layer 12 are sufficient to adequately represent the desired design level. The thickness of the coloring layer 12A is preferably set in the range of 2 μm to 20 μm. By setting the thickness of the coloring layer 12A within the aforementioned range, even when the coloring is white or light-colored, sufficient concealment of the color and stains of the base material layer 11 can be achieved, and the reduction in the adhesion strength between the ink layers constituting the coloring layer 12A can be prevented, thereby obtaining sufficient durability. Furthermore, the thickness of the pattern layer 12B is preferably set in the range of 0.1 μm to 10 μm. Here, "thickness of the pattern layer 12B" refers to the thickness of the portion printed with ink. The pattern layer 12B may not cover the entire surface of the coloring layer 12A, and the coloring layer 12A may be exposed from the pattern layer 12B. By setting the thickness of the pattern layer 12B within the aforementioned range, the pattern can be clearly displayed, or the design can be enhanced by adding tonal gradations to the pattern. In addition, when printing multiple colors overlay, the color width that can be represented by a limited number of colors can be increased because the colors of the upper and lower layers overlap.

[0057] <First Surface Protective Layer>

[0058] A first surface protective layer 13 is disposed on the side of the colored pattern layer 12 opposite to the original material layer 11, and has an uneven surface shape. The first surface protective layer 13 includes a core portion 13A as a lower layer (back side) region within the layer, and a protruding portion 13B (an example of a convex protrusion) as an upper layer (surface side) region within the layer, and has an uneven surface shape. The first surface protective layer 13 has a core portion 13A and a protruding portion 13B that protrudes in a ridge shape from one side of the core portion 13A. Thus, an uneven surface shape is formed on the surface of the first surface protective layer 13.

[0059] Figure 2 A cross-sectional photograph showing the composition of the surface (top) of the first surface protective layer 13. Figure 2 A cross-sectional photograph and cross-sectional view are provided to show the cross-section of the protrusion 13B in the width direction. Here, Figure 2 These are planar and cross-sectional photographs obtained using an optical microscope (digital microscope, KEYENCE VHX-6000).

[0060] like Figure 2 As shown in the cross-sectional photograph, the protrusion 13B has an uneven shape formed by mechanical processing such as embossing. The height of such protrusion 13B is preferably greater than 15 μm, for example. In addition, the period p of adjacent protrusions 13B (for example, the interval between the vertices of protrusions 13B) is preferably greater than 50 μm.

[0061] The first surface protective layer 13 is formed of a resin material. The resin material can be any of an ionizing radiation-curing resin, a thermosetting resin, or a thermoplastic resin.

[0062] For example, as an ionizing radiation-curing resin, a UV-curing resin can be used. Examples of UV-curing resins include (meth)acrylic resins, silicone resins, polyester resins, urethane resins, amide resins, and epoxy resins. The UV-curing resin can be either a water-based resin or a non-water-based (organic solvent-based) resin.

[0063] The first surface protective layer 13 may contain inorganic particles. Examples of inorganic particles include microparticles formed from inorganic materials such as silica, glass, alumina, titanium dioxide, zirconium oxide, calcium carbonate, and barium sulfate. Preferably, the amount of inorganic particles added to the first surface protective layer 13 relative to 100 parts by mass of ionizing radiation-curing resin is more than 0% by mass and less than 5% by mass, more preferably more than 0% by mass and less than 3% by mass, more preferably more than 0% by mass and less than 1% by mass, and even more preferably more than 0.1% by mass and less than 0.5% by mass. The first surface protective layer 13, by containing the above-mentioned amount of inorganic particles, exhibits improved abrasion resistance and damage resistance, and is therefore preferred. Furthermore, while the presence of inorganic particles in the first surface protective layer 13 improves damage resistance compared to the absence of inorganic particles, excessive amounts of inorganic particles can cause them to detach from the surface of the first surface protective layer 13, or adversely affect fingerprint resistance, such as fingerprint adhesion. Therefore, the amount of inorganic particles added is preferably more than 0% by mass and less than 3% by mass.

[0064] Depending on the needs, for example, one or more additives selected from colorants, matting agents, fillers, ultraviolet absorbers, light stabilizers, heat stabilizers, antioxidants, antistatic agents, lubricants, flame retardants, antibacterial agents, mildew inhibitors, friction reducers, and light scattering agents may be added to the first surface protective layer 13. However, the first surface protective layer 13 does not contain gloss modifiers that reduce oleophobicity and thus facilitate fingerprint adhesion.

[0065] The first surface protective layer 13 only needs to completely cover the colored pattern layer 12, and can function as a surface protective layer on the entire surface of the decorative piece 1. In addition, the density of the first surface protective layer 13 can be adjusted according to the target gloss and performance.

[0066] The thickness of the first surface protective layer 13 is preferably set in the range of 20 μm to 50 μm. By setting the thickness of the first surface protective layer 13 within the above range, design damage can be suppressed by protecting the raw material layer 11 and the colored pattern layer 12. When the thickness of the first surface protective layer 13 is 20 μm or more, it can sufficiently possess the functions such as wear resistance required for a surface protective layer. In addition, when the thickness of the first surface protective layer 13 is 50 μm or less, the first surface protective layer 13 does not become unnecessarily thick, thereby having the effect of not excessively increasing manufacturing costs.

[0067] (1.2) Manufacturing method of decorative sheet

[0068] Figure 3 This is a schematic diagram illustrating the manufacturing method of decorative piece 1. (For example...) Figure 3As shown, the decorative sheet 1 is formed by extrusion molding using flat metal rollers 101 and 102, a metal roller 110 with a desired uneven surface, a T-die 104, and an ultraviolet lamp 105. The resin material constituting the first surface protective layer 13 of the decorative sheet 1 can be any of an ionizing radiation-curing resin, a thermosetting resin, or a thermoplastic resin, but the case of using an ultraviolet-curing resin as an ionizing radiation-curing resin will be described.

[0069] First, using a resin film as the base layer 11, ink of the desired color is printed on the base layer 11 to form a coloring layer 12A. Next, ink of the desired color is printed on the coloring layer 12A in the desired pattern to form a patterned layer 12B. Thus, a laminate 50 is formed.

[0070] Next, as Figure 3 As shown, UV-curable resin 13' is sprayed onto the laminate 50 using, for example, a T-die 104. At this time, the UV-curable resin 13' is sprayed in such a way that it imparts the desired uneven shape to the side of the metal roller 110 on the surface.

[0071] The uneven shape of the surface of the metal roller 110 is transferred onto the UV-curable resin 13' sprayed onto the laminate 50. Then, the UV-curable resin 13' is cured by irradiating it with ultraviolet light with a wavelength of less than 400 nm by the UV lamp 105.

[0072] Thus, a decorative piece 1 with a first surface protective layer 13 is formed, the first surface protective layer 13 having an uneven shape, having a core 13A and a protruding portion 13B that protrudes in a ridge shape from one side of the core 13A.

[0073] It should be noted that the first surface protective layer 13 formed in this way is formed of a resin material with a generally uniform composition.

[0074] The above describes a decorative piece 1 having a first surface protective layer 13 with protrusions 13B, but the configuration is not limited to this.

[0075] For example, the first surface protective layer 13 may also have an uneven shape formed by providing recessed grooves on the surface instead of protrusions (an example of convex protrusions). In this case, the depth of the recessed grooves corresponds to the height of the protrusions 13B described in this embodiment, and the spacing of the recessed grooves corresponds to the spacing of the protrusions 13B.

[0076] <Effects of the First Implementation Method>

[0077] The decorative piece 1 involved in this embodiment has the following effects.

[0078] (1) The decorative sheet 1 of this embodiment has a first surface protective layer 13 with an uneven shape formed on its surface.

[0079] According to this configuration, even if the first surface protective layer 13 does not contain a gloss modifier (matte additive), the gloss (gloss level) of the first surface protective layer 13 can still be adjusted. Gloss modifiers reduce the oleophobicity of the layer formed from the resin material, making it easier for fingerprints to adhere. Since the first surface protective layer 13 does not contain a gloss modifier, it does not absorb oil, and its oleophobicity is relatively improved. Therefore, fingerprints are difficult to adhere to the decorative piece 1 having the first surface protective layer 13 in various situations, including on-site construction, furniture assembly, and the daily life of residents.

[0080] (2) The decorative sheet 1 of this embodiment has a first surface protective layer 13 with an uneven shape formed on its surface.

[0081] According to this configuration, the oleophobicity of the first surface protective layer 13 is improved, thereby inhibiting the adsorption of oil and pollutants on the surface of the decorative piece 1.

[0082] 2. Second Implementation Method

[0083] use Figures 4 to 9 The decorative sheet 2 according to the second embodiment of this disclosure will be described.

[0084] The decorative sheet 2 according to the second embodiment has the same structure as the decorative sheet 1 according to the first embodiment. The difference between the decorative sheet 2 according to the second embodiment and the decorative sheet 1 according to the first embodiment is that the decorative sheet 2 according to the second embodiment is formed using a transfer plate manufactured by a different method than the method used in the manufacture of the transfer plate according to the first embodiment.

[0085] The following describes the structure of the decorative sheet 2 according to the second embodiment, the method for manufacturing the original plate for transfer, and the method for manufacturing the decorative sheet 2. It should be noted that the basic structure of the decorative sheet 2 is the same as that of the decorative sheet 1 according to the first embodiment; the differences will be described separately.

[0086] (2.1) Basic Components of Decorative Pieces

[0087] like Figure 4 As shown, the decorative sheet 2 includes: a raw material layer 11, a colored pattern layer 12, and a first surface protective layer 23. The raw material layer 11 and the colored pattern layer 12 are the same as those of the decorative sheet 1 according to the first embodiment, so their description is omitted.

[0088] <First Surface Protective Layer>

[0089] The first surface protective layer 23 is disposed on the side of the colored pattern layer 12 opposite to the original material layer 11. The first surface protective layer 23 includes a core portion 23A as a lower layer (back side) region within the layer, and a ridge portion 23B (an example of a convex protrusion) as an upper layer (surface side) region within the layer.

[0090] Figure 5 A planar photograph showing the composition of the surface (top) of the first surface protective layer 23, Figure 6 A cross-sectional photograph showing the structure of the surface (top) of the first surface protective layer 23. Additionally, Figure 7 A cross-sectional view schematically showing the structure of the surface (top) of the first surface protective layer 23. Figure 6 and Figure 7 A cross-sectional photograph and cross-sectional view are provided to show the cross-section of the ridge portion 23B in the width direction. Here, Figure 5 and Figure 6 These are planar and cross-sectional photographs obtained using an optical microscope (digital microscope, KEYENCE VHX-6000).

[0091] like Figure 5 As shown, the ridge 23B is an elongated, raised shape that is connected in a linear fashion in a plan view. As described later, the ridge 23B is formed using a transfer template formed by irradiating the surface of an ionizing radiation-curable resin with ionizing radiation of a specific wavelength, causing the surface of the ionizing radiation-curable resin to shrink.

[0092] Here, in the decorative piece 2 of this embodiment, "ridge-like" refers to a shape that is elongated and raised, connected by lines in a plan view. The ridge-like portion 23B can be curved or straight in a plan view, but... Figure 6 and Figure 7 As shown, from the viewpoint of fingerprint resistance of the decorative piece 2 surface, a curved shape is preferred. Furthermore, in this disclosure, the ridge portion 23B is, for example, the portion from the lowest point to the top point of the uneven shape provided on the surface of the first surface protective layer 23, and the core portion 23A refers to the portion of the first surface protective layer 23 other than the ridge portion 23B.

[0093] The height of such ridges 23B is preferably 15 μm or less, more preferably 8 μm or less. Furthermore, the period of adjacent ridges 23B (e.g., the interval between the vertices of ridges 23B) p is preferably 50 μm or less, more preferably 10 μm or less, and more preferably 6.5 μm or less. Compared to the uneven shape formed on the surface of the surface protective layer by mechanical processing such as embossing, the uneven shape (ridges 23B) on the surface of the first surface protective layer 23 manufactured by using a transfer template formed by irradiating a high-energy ionizing radiation onto an ionizing radiation-curable resin has a fine structure. By forming such a fine uneven shape on the surface of the first surface protective layer 23, fingerprint resistance can be improved while maintaining the matte finish of the decorative sheet 2 surface.

[0094] As an ionizing radiation-curing resin, an ultraviolet-curing resin can be used, for example. Examples of ultraviolet-curing resins include (meth)acrylic resins, silicone resins, polyester resins, urethane resins, amide resins, and epoxy resins. The ultraviolet-curing resin can be either a water-based resin or a non-water-based (organic solvent-based) resin.

[0095] The first surface protective layer 23 may contain the same inorganic particles as the first surface protective layer 13.

[0096] In addition, similar to the first surface protective layer 13, one or more additives selected from colorants, matting agents, fillers, ultraviolet absorbers, light stabilizers, heat stabilizers, antioxidants, antistatic agents, lubricants, flame retardants, antibacterial agents, mildew inhibitors, friction reducers, and light scattering agents may be added to the first surface protective layer 23 as needed. However, the first surface protective layer 23 does not contain gloss modifiers that reduce oleophobicity and thus facilitate fingerprint adhesion.

[0097] The thickness of the first surface protective layer 23 is preferably set in the range of 1.0 μm to 50 μm. By setting the thickness of the first surface protective layer 23 within the above range, design damage can be suppressed by protecting the raw material layer 11 and the colored pattern layer 12. When the thickness of the first surface protective layer 23 is 1.0 μm or more, it can sufficiently possess the functions such as wear resistance required for a surface protective layer. In addition, when the thickness of the first surface protective layer 23 is 50 μm or less, the first surface protective layer 23 does not become unnecessarily thick, thereby having the effect of not excessively increasing manufacturing costs.

[0098] Although this type of decorative sheet 2 does not contain gloss modifiers (matte additives), its gloss level is below 5.0, making it a decorative sheet with extremely low gloss. In traditional decorative sheets, when the gloss level of a decorative sheet with a surface protective layer is around 8 or below, the content of gloss modifiers in the surface protective layer is high, causing the surface protective layer to become cloudy. Therefore, the color and pattern of the colored pattern layer may not be clearly displayed, or the design of the decorative sheet may be reduced. Furthermore, in order to obtain a decorative sheet with a gloss level close to 0, the content of gloss modifiers in the surface protective layer is further increased, making it difficult to form a smooth surface protective layer without producing streaks, spots, etc.

[0099] While maintaining the same level of performance as decorative sheets 2 with a gloss level of 20±3 or higher, a low-gloss decorative sheet with a gloss level of 5.0 or lower, preferably 2.0 or lower, can be obtained. Here, "gloss level" is the measured value when measured using a gloss meter at an incident angle of 60 degrees. Therefore, a decorative sheet 2 that maintains the performance required for decorative sheet 2 while exhibiting high oleophobicity and resistance to fingerprint adhesion can be obtained.

[0100] (2.2) Manufacturing method of decorative sheet

[0101] <Method for manufacturing original plates for transfer printing>

[0102] Reference Figure 8 and Figure 9 The manufacturing method of the original plate for transfer printing and the manufacturing method of the decorative sheet using the original plate for transfer printing are explained. Figure 8 This is a cross-sectional process diagram showing the manufacturing method of the transfer printing plate according to the second embodiment. Figure 9 This is a cross-sectional process diagram showing the manufacturing method of the decorative sheet according to the second embodiment.

[0103] like Figure 8 As shown in (A), a resin film is used as a substrate 201, and an ionizing radiation-curable resin 203A is coated on the substrate 201. At this time, the coating amount of the ionizing radiation-curable resin 203A is adjusted to a thickness that can achieve the desired unevenness.

[0104] Next, as Figure 8As shown in (B), the surface of the ionizing radiation-curable resin 203A coated with ionizing radiation is irradiated with a first ionizing radiation having energy capable of cleaving at least one of the carbonyl bonds and carbon-carbon bonds, causing the surface of the ionizing radiation-curable resin 203A to shrink. The first ionizing radiation can be a single ionizing radiation having a predetermined wavelength, or it can be multiple ionizing radiations having different wavelengths. Examples of the first ionizing radiation include, for instance, a high-energy excimer laser. The medium for the excimer laser can be any conventionally used medium (discharge gas), as long as it has energy capable of cleaving at least one of the carbonyl bonds and carbon-carbon bonds. The discharge gas can be a rare gas such as Xe, Ar, or Kr, or a mixture of rare gases and halogen gases such as ArBr, ArF, KrCl, XeI, XeCl, XeBr, KrBr, or KrF. Excimer lasers have different wavelengths (center wavelengths) depending on the medium, such as approximately 172 nm (Xe), approximately 126 nm (Ar), approximately 146 nm (Kr), approximately 165 nm (ArBr), approximately 193 nm (ArF), approximately 222 nm (KrCl), approximately 253 nm (XeI), approximately 308 nm (XeCl), approximately 283 nm (XeBr), approximately 207 nm (KrBr), and approximately 248 nm (KrF).

[0105] By irradiating the ionizing radiation-curable resin 203A with high-energy ionizing radiation, an uneven shape is formed on the surface of the ionizing radiation-curable resin 203A. The shrinkage rate of the ionizing radiation-curable resin 203A is then adjusted by regulating the resin coating amount and the ionizing radiation irradiation time. This allows for the adjustment of the final gloss of the decorative sheet 2 with the uneven shape transferred onto it.

[0106] When forming the raised or recessed shape, the tactile feel and visual effect of the decorative sheet 2 with the raised or recessed shape can be altered by changing the type of the first ionizing radiation irradiated onto the ionizing radiation-curing resin 203A. For example, the ionizing radiation-curing resin 203A is irradiated with a first ionizing radiation of approximately 250 nm, and then irradiated with a first ionizing radiation of approximately 172 nm to form the raised or recessed shape, followed by curing the ionizing radiation-curing resin 203A. This allows for adjustment of the tactile feel of the decorative sheet 2. Alternatively, for example, the ionizing radiation-curing resin 203A can be irradiated with a first ionizing radiation of approximately 172 nm to form the raised or recessed shape, followed by curing the ionizing radiation-curing resin 203A. This allows for smoothing the surface of the decorative sheet 2 with the raised or recessed shape and adjusting it to a low gloss, or for imparting a glossy-matte effect (visual embossing) to the surface of the decorative sheet 2.

[0107] Next, as Figure 8As shown in (C), a second ionizing radiation is irradiated onto the surface-shrinking ionizing radiation-curable resin 203A to cure it. This forms a resin layer 203 with an uneven surface shape 203B. Examples of the second ionizing radiation include ultraviolet light with a wavelength of 400 nm or less. The ionizing radiation used to cure the ionizing radiation-curable resin 203A has a broad wavelength range (i.e., a wide spectrum) in the area below 400 nm.

[0108] Thus, a transfer original 200 with a surface having an uneven shape 203B was obtained.

[0109] Here, the uneven shape 203B formed by the shrinkage of the ionizing radiation-curable resin 203A has a different composition than the unshrinked portion of the ionizing radiation-curable resin 203A. Specifically, the uneven shape 203B formed by the shrinkage of the ionizing radiation-curable resin 203A has a composition in which, compared to the unshrinked portion of the ionizing radiation-curable resin 203A located deep within the resin, the ratio of carbonyl bonds (C=O) and carbon-carbon bonds (double bonds (C=C) and triple bonds (C≡C)) contained in the resin is reduced. For example, compared to the unshrinked portion of the ionizing radiation-curable resin 203A located deep within the resin, the ratio of carbonyl bonds and carbon-carbon bonds contained in the uneven shape 203B is preferably reduced by 10% or more, more preferably by 20% or more. This is because, by irradiating the ionizing radiation-curable resin 203A with high-energy ionizing radiation, the polymer chains (carbonyl bonds and carbon-carbon bonds (double bonds, triple bonds)) contained in the resin are broken. In the ionizing radiation-cured resin 203A irradiated with high-energy ionizing radiation, new bonds are formed at the broken bond sites (rebonding, recrosslinking), causing the surface of the ionizing radiation-cured resin 203A to shrink and form an uneven shape 203B. This difference in composition between the unshrinked portion of the ionizing radiation-cured resin 203A and the uneven shape 203B is a characteristic feature of the uneven shape 203B formed when ionizing radiation is applied.

[0110] Furthermore, by irradiating the ionizing radiation-curable resin 203A with high-energy ionizing radiation, the polymer chains contained in the resin are cleaved, rebonded, and recrosslinked under conditions of hydrogen atom abstraction. Therefore, compared to the unshrinked portion of the deep-layered ionizing radiation-curable resin 203A, the uneven shape 203B formed by the cleaving, rebonding, and recrosslinking of the polymer chains results in a structure with a high crosslinking density. Consequently, the porosity of the resin constituting the uneven shape 203B, which forms the outermost layer of the transfer master 200, is reduced, and the surface hardness of the transfer master 200 is increased.

[0111] Such uneven shape 203B appears curved in cross-sectional view. The uneven shape 203B is formed by the shrinkage of the ionizing radiation-cured resin 203A after being irradiated with ionizing radiation of a specific wavelength. That is, by irradiating the surface of the ionizing radiation-cured resin 203A with a strong laser, the ionizing radiation-cured resin 203A, which locally becomes a high-temperature surface, evaporates, and atoms, molecules, plasma, and their clusters disperse, thereby forming the uneven shape 203B. Thus, the uneven shape 203B, which appears curved in cross-sectional view, has the same uneven shape as the ridge 23B formed on the surface of the surface protective layer through mechanical processing such as embossing (see reference). Figure 4 () Clearly different shapes.

[0112] Therefore, a smooth, uneven shape 203B is formed on the surface of the resin layer 203 due to surface tension. Specifically, the free radicals of the aforementioned ionizing radiation directly cleave the carbonyl bonds and carbon-carbon double or triple bonds in the resin constituting the ionizing radiation-cured resin 203A. Furthermore, irradiation with high-energy ionizing radiation such as vacuum ultraviolet light generates ozone or oxygen free radicals from oxygen molecules, which may cleave carbonyl bonds and carbon-carbon double or triple bonds. In this case, ozone or oxygen free radicals are generated from oxygen molecules at a concentration (for example) limited to 2000 ppm, preferably 1000 ppm or less, more preferably 400 ppm or less in a vacuum atmosphere. The cleaved bonds re-bond with adjacent carbon, oxygen, nitrogen atoms, or free radicals present in the atmosphere, causing the surface of the ionizing radiation-cured resin 203A to shrink, thereby forming a gently curving shape. The gentle shape of the uneven shape 203B is also a characteristic of the transfer original 200, which is formed on the surface by irradiation with ionizing radiation.

[0113] The height of the raised and recessed shapes 203B on the surface of the transfer original 200 is preferably 15 μm or less, more preferably 8 μm or less. Furthermore, the period (e.g., the interval between the vertices of the raised and recessed shapes 203B) p between adjacent raised and recessed shapes 203B is preferably 50 μm or less, more preferably 10 μm or less, and more preferably 6.5 μm or less. Compared to raised and recessed shapes formed on the surface of the surface protective layer by mechanical processing such as embossing, the raised and recessed shapes 203B on the surface of the transfer original 200 formed by irradiating the ionizing radiation-curable resin 203A with high-energy ionizing radiation has a finer structure. By transferring such fine raised and recessed shapes 203B onto the surface of the first surface protective layer 23 using the transfer original 200, fingerprint resistance can be improved while maintaining the matte finish of the decorative sheet 2 surface.

[0114] The mechanism by which the uneven shape 203B is formed by irradiation with the first ionizing radiation will be explained in more detail below.

[0115] Vacuum ultraviolet (VUV) light can use photon energy to break bond energies lower than that photon energy. Therefore, by irradiating the surface of ionizing radiation-curable resin 203A with vacuum ultraviolet light, the molecular bonds of organic matter in the ionizing radiation-curable resin 203A can be broken. The bonding state of the polymers on the surface of the ionizing radiation-curable resin 203A changes, thereby modifying (shrinking) the surface.

[0116] When rare gases, halogen gases, and mercury are combined as the medium for the first ionizing radiation, a near-monochromatic light source can be obtained with wavelength intervals of 20 nm to 30 nm within a wavelength range of 100 nm to 500 nm. Any of these light sources can be used as the first ionizing radiation for forming the uneven shape 203B. However, considering the magnitude of the resulting photon energy and the difference between the wavelength and the bond energy of the organic material, a xenon lamp emitting an excimer laser with a center wavelength of 172 nm is most preferably used as the light source. The lower the wavelength and the higher the energy of the first ionizing radiation, the more effectively it can break the molecular bonds of the organic material, thus more easily causing surface shrinkage, which is therefore preferable. On the other hand, when considering the cost of equipment maintenance and the availability of materials, a xenon lamp is most preferably used as the light source.

[0117] Here, light with wavelengths below 380 nm is referred to as ultraviolet (UV), and light with wavelengths below 200 nm is referred to as vacuum ultraviolet (VUV). This light is attenuated by absorption by oxygen in the atmosphere. Therefore, by removing oxygen from the first ionizing radiation irradiation environment, the surface modification effect of the ionizing radiation-curable resin 203A can be further improved. Furthermore, it is preferable to introduce the desired reaction gas (e.g., nitrogen) to control the reaction atmosphere, or to use a chamber system where the oxygen concentration is suppressed to below 2000 ppm to irradiate the ionizing radiation-curable resin 203A with ultraviolet light (especially light below 250 nm). The light energy breaks the molecular bonds of the organic matter in the ionizing radiation-curable resin 203A, resulting in hydrogen atom abstraction, which easily changes the molecular structure and thus readily induces surface modification (shrinkage) of the ionizing radiation-curable resin 203A.

[0118] To prevent stains such as hand oil and fingerprints from adhering to the resin surface, oleophobicity is required. Therefore, by irradiating the surface with ionizing radiation at the lowest possible oxygen concentration (ideally below 400 ppm), the properties required for the decorative sheet in this application can be achieved. The desired surface properties can be achieved by adjusting the oxygen concentration during light irradiation.

[0119] Photons excited by excimer laser irradiation are strongly absorbed into the polymer chains of the ionizing radiation-curable resin 203A, which serves as a surface protective layer on the decorative sheet, reaching a depth of tens to hundreds of nm, generating polymer free radicals. These free radicals cause the polymer chains of the ionizing radiation-curable resin 203A to be cleaved, rebonded, and re-crosslinked. As a result, the molecular weight of the ionizing radiation-curable resin 203A increases, and the free volume (porosity) within the polymer decreases, creating a wavy, textured, folded, and corrugated micro-texture 203B.

[0120] The period (spacing between the concave and convex) I of the shrinkage microstructure generated by irradiating an excimer laser onto an ionizing radiation-cured resin 203A can be obtained from the Polanyi formula represented by equation (1) and the Polanyi formula represented by equation (2) which focuses on the 0th and 1st diffraction beams.

[0121]

[0122] I·sin[arctan(x / d)]=λ···(2)

[0123] Here, in equation (1), I represents the period of the microstructure, λ is the angle of the diffracted light of the excimer laser, m is an integer greater than or equal to 0, and λ is the wavelength of the excimer laser. In addition, in equation (2), x is the distance between the 0th and 1st diffracted light on the screen, and d is the distance between the screen on which the diffracted light is projected and the ionizing radiation-cured resin 203A, which is the sample.

[0124] By changing the incident angle θ of the laser irradiating the ionizing radiation-curable resin 203A, the pattern of the shrinking microstructure generated in the ionizing radiation-curable resin 203A can be controlled. When the incident angle of the excimer laser is close to 0 degrees, the pattern of the microstructure exhibits isotropy relative to the laser-irradiated area, producing random microstructures. On the other hand, the larger the incident angle θ of the laser, the greater the anisotropy of the microstructure pattern relative to the laser-irradiated area. The surface shape of the ionizing radiation-curable resin 203A, which shrinks due to the laser at an incident angle of 0 degrees, is effective in improving, for example, fingerprint resistance, stain resistance, and damage resistance. This is because, through the random microstructures arranged isotropically, the adhesion of contaminants, damage, and changes in gloss become less noticeable. The interval (period) I of the microstructures formed by irradiating the laser at an incident angle of 0 degrees is approximately the same as the wavelength λ of the irradiated excimer laser. Furthermore, when the incident angle θ is changed, the interval I changes while maintaining the vertical stripe pattern of the microstructure shape. The interval I is based on the incident angle θ of the laser and is obtained by the following equation (3).

[0125] I=λ / cosθ··· (3)

[0126] <Manufacturing Method of Decorative Sheets>

[0127] like Figure 9 As shown in (A), a resin film is used as the base layer 11, and ink of the desired color is printed on the base layer 11 to form a coloring layer 12A. Next, ink of the desired color is printed on the coloring layer 12A in the desired pattern to form a patterned layer 12B.

[0128] Next, as Figure 9 As shown in (B), an ionizing radiation-curable resin 23' is coated onto the coloring layer 12A (coloring pattern layer 12) on which the pattern layer 12B is formed. At this time, the coating amount of the ionizing radiation-curable resin 23' is at least sufficient to completely cover the coloring pattern layer 12, and can be adjusted according to the target gloss and performance; for example, it is preferably set to 2.0 g / m³. 2 Above 20g / m 2 Below, left and right.

[0129] Next, as Figure 9 As shown in (C), the raised and recessed shape 203B is transferred onto the ionizing radiation-curable resin 23' using a transfer template 200. Finally, as... Figure 9As shown in (D), an ionizing radiation-curable resin 23' with the raised and recessed shapes 203B of the transfer master 200 printed on its surface is irradiated with a second ionizing radiation to cure the ionizing radiation-curable resin 23'. Here, the second ionizing radiation can be the same radiation used for curing the ionizing radiation-curable resin when manufacturing the transfer master 200.

[0130] Thus, a decorative piece 2 with a first surface protective layer 23 is formed, the first surface protective layer 23 having a concave-convex shape on the surface formed by a core 23A and a ridge portion 23B that protrudes in a ridge shape from one side (top) of the core 23A.

[0131] It should be noted that the first surface protective layer 23 formed in this way is formed of a resin material with a generally uniform composition.

[0132] (2.3) Variations in the manufacturing method of decorative pieces

[0133] In the second embodiment, a transfer template 200 is formed by irradiating the ionizing radiation-curable resin 203A with high-energy ionizing radiation to cause the surface to shrink and then cure it. However, the configuration is not limited to this.

[0134] For example, a three-dimensional shape measuring device can be used to measure the uneven shape 203B formed on the surface of the resin layer 203, and obtain uneven shape data representing the uneven shape 203B, thereby forming a transfer master with an uneven shape formed based on the uneven shape data. In this case, by forming an uneven shape corresponding to the uneven shape 203B on the surface of a metal material such as a metal plate or metal roller based on the uneven shape data, a transfer master made of metal material with an uneven shape can be formed.

[0135] <Effects of the Second Implementation>

[0136] In addition to the effects described in the first embodiment, the decorative piece 2 according to this embodiment has the following effects.

[0137] (3) The decorative sheet 2 of this embodiment has a first surface protective layer 23 that does not contain a gloss modifier.

[0138] According to this configuration, when the surface of the decorative piece 2 is scratched, the particles of the gloss modifier will not fall off, thus making it difficult for the surface of the decorative piece 2 to undergo gloss changes or scratches.

[0139] (4) The decorative sheet 2 of this embodiment has a first surface protective layer 23 that does not contain a gloss modifier.

[0140] According to this configuration, the content of additives in the first surface protective layer 23 can be reduced, thus preventing the whitening of the first surface protective layer 23 and making it easier to form the first surface protective layer 23.

[0141] (5) The method for manufacturing decorative sheet 2 according to this embodiment uses a metal material as the transfer plate, which improves the productivity of the decorative sheet compared to the case of using a transfer plate made of resin material.

[0142] 3. Third Implementation Method

[0143] use Figures 10 to 13 The decorative sheet according to the third embodiment of this disclosure will be described. Hereinafter, as the third embodiment, the first to fifth configuration examples of the decorative sheet manufactured by the manufacturing method according to any one of the first to third embodiments will be described. Figures 10 to 13 These are cross-sectional views showing the configurations of decorative piece 3B described in the second configuration example, decorative piece 3C described in the third configuration example, decorative piece 3D described in the fourth configuration example, and decorative piece 3E described in the fifth configuration example, respectively, according to the third embodiment of this disclosure.

[0144] The decorative pieces of the first to fifth constituent examples will be described in turn below.

[0145] (3.1) Example 1

[0146] In the configuration example 1 of the third embodiment, a decorative sheet 3A (not shown) in which the first surface protective layer 13 is configured as a multilayer structure will be described.

[0147] Decorative sheet 3A has a first surface protective layer 13 formed by stacking multiple layers of the same ionizing radiation curable resin, or a first surface protective layer 13 formed by stacking multiple layers of different ionizing radiation curable resin, and the outermost surface of the first surface protective layer 13 is provided with an uneven shape.

[0148] (3.2) Example 2

[0149] use Figure 10 The decorative sheet 3B involved in the configuration example 2 of the third embodiment of this disclosure will be described.

[0150] like Figure 10 As shown, the decorative sheet 3B is composed of a multi-layered raw material layer 11, a colored pattern layer 12, and a first surface protective layer 13 stacked sequentially. That is, the decorative sheet 3B differs from the decorative sheet 1 according to the first embodiment in that a first film layer 11A and a second film layer 11B are provided to replace the single-layer raw material layer 11.

[0151] The following is a detailed description of the raw material layer 11 of the decorative sheet 3B. It should be noted that the other layers (colored pattern layer 12 and first surface protective layer 13) have the same structure as the other layers of the decorative sheet 1, so their descriptions are omitted.

[0152] <Material Layer>

[0153] The material layer 11 is composed of a first film layer 11A and a second film layer 11B stacked together.

[0154] The first film layer 11A and the second film layer 11B can be resin films formed from the same resin material, or they can be resin films formed from different resin materials. For example, the first film layer 11A is a polyethylene film and the second film layer 11B is a polypropylene film. In this case, it is preferable to provide a colored pattern layer 12 on the first film layer 11A, and to laminate an adhesive resin layer 14 and the second film layer 11B on the colored pattern layer 12. In addition, the first surface protective layer 13 is preferably provided on the second film layer 11B. With such a laminated configuration, the exposure of the colored pattern layer 12 can be prevented, thus avoiding a decrease in abrasion resistance, damage resistance, stain resistance, and weather resistance. Weather resistance is particularly prone to decrease when the colored pattern layer 12 is exposed. Therefore, when high weather resistance is required for the decorative sheet, it is preferable to use films (the first film layer 11A and the second film layer 11B) as the raw material layers and sandwich the colored pattern layer 12 between the films to obtain the decorative sheet 3B.

[0155] The first film layer 11A and the second film layer 11B function as two base layers. The total thickness of the first film layer 11A and the second film layer 11B, which function as base layers, is preferably in the range of 50 μm to 250 μm, more preferably in the range of 70 μm to 200 μm. When the total thickness of the first film layer 11A and the second film layer 11B is within the above-mentioned range, lamination adaptability can be improved and cracks generated at the bending portion of the sheet can be reduced.

[0156] It should be noted that the membrane layer that functions as the original material layer can also be three or more layers.

[0157] (3.3) Example 3

[0158] use Figure 11 The decorative sheet 3C involved in the configuration example 3 of the third embodiment of this disclosure will be described.

[0159] In the configuration example 3 of the third embodiment, referring to Figure 11 The following describes the decorative sheet 3C in which the original material layer 11' is set as a multi-layered structure.

[0160] like Figure 11As shown, the decorative sheet 3C is composed of a multi-layered raw material layer 11', a colored pattern layer 12, and a first surface protective layer 13 stacked sequentially. That is, the decorative sheet 3C differs from the decorative sheet 1 in the first embodiment in that a raw material layer 11', which is obtained by stacking a first paper material 11C, a moisture-proof resin layer 11D, and a second paper material 11E sequentially, is used instead of a single raw material layer 11.

[0161] The following is a detailed description of the raw material layer 11' of the decorative sheet 3C. It should be noted that the other layers (coloring pattern layer 12 and first surface protective layer 13) have the same composition as the other layers of the decorative sheet 1, so the description is omitted.

[0162] <Material Layer>

[0163] The raw material layer 11' is composed of a first paper material 11C, a moisture-proof resin layer 11D, and a second paper material 11E stacked sequentially.

[0164] The moisture-proof resin layer 11D is formed, for example, from polyethylene resin. In this case, the moisture permeability can be finely adjusted according to the type of resin material constituting the moisture-proof resin layer 11D and the thickness of the moisture-proof resin layer 11D, and effects such as suppressing warping of the moisture-proof resin layer 11D can be obtained.

[0165] The first paper material 11C, the moisture-proof resin layer 11D, and the second paper material 11E function as three layers as raw material layers. The total thickness of the first paper material 11C, the moisture-proof resin layer 11D, and the second paper material 11E, which function as raw material layers, is preferably in the range of 50 μm to 250 μm, more preferably in the range of 70 μm to 200 μm. When the total thickness of the first paper material 11C and the second paper material 11E is within the above-mentioned range, lamination adaptability can be improved and cracks generated at the bending portions of the sheet can be reduced.

[0166] It should be noted that the paper material that functions as the base layer can also be three or more layers stacked with moisture-proof resin layers.

[0167] (3.4) Example 4

[0168] use Figure 12 The decorative sheet 3D involved in the configuration example 4 of the third embodiment of this disclosure will be described.

[0169] like Figure 12As shown, the decorative sheet 3D is composed of a raw material layer 11, a colored pattern layer 12, a transparent layer 15, a first surface protective layer 13, and a second surface protective layer 26 stacked sequentially. That is, the decorative sheet 2D differs from the decorative sheet 1 according to the first embodiment in that a transparent layer 15 is provided between the colored pattern layer 12 and the first surface protective layer 13.

[0170] The transparent layer 15 of the decorative sheet 3D will be described in detail below. It should be noted that the other layers (raw material layer 11, colored pattern layer 12, and first surface protective layer 13) have the same structure as the layers of the decorative sheet 1, so the description is omitted.

[0171] <Transparent Layer>

[0172] The transparent layer 15 is made of a resin material. The resin material constituting the transparent layer 15 can be, for example, a thermosetting resin, or an acrylic resin, silicone resin, polyester resin, urethane resin, amide resin, or epoxy resin. Additionally, an adhesive resin layer can be provided beneath the transparent layer 15.

[0173] Alternatively, the raw material layer 11 can also be made of polyolefin films such as polyethylene film and polypropylene film.

[0174] Such decorative 3D prevents the colored pattern layer 12 from being exposed, inhibiting the reduction of wear resistance, damage resistance, stain resistance and weather resistance.

[0175] (3.5) Example 5

[0176] use Figure 13 The decorative sheet 3E involved in the configuration example 5 of the third embodiment of this disclosure will be described.

[0177] Decorative sheet 3E comprises: a raw material layer 11, a colored pattern layer 12, a first surface protective layer 13, and a second surface protective layer 26. Decorative sheet 3E is formed by sequentially stacking the raw material layer 11, the colored pattern layer 12, the first surface protective layer 13, and the second surface protective layer 26. That is, the difference between decorative sheet 2 and decorative sheet 1 according to the first embodiment is that a second surface protective layer 26 is provided on top of the first surface protective layer 13.

[0178] The second surface protective layer 26 will be described below. It should be noted that the other layers (raw material layer 11, colored pattern layer 12, and first surface protective layer 13) have the same structure as the layers of the decorative piece 1, so their descriptions are omitted.

[0179] (3.5.1) Basic Components of Decorative Pieces

[0180] <Second Surface Protective Layer>

[0181] The second surface protective layer 26 is disposed on a portion of the uneven surface of the first surface protective layer 13. The second surface protective layer 26 is a layer that, by being partially formed on the first surface protective layer 13, creates a gloss difference with the first surface protective layer 13, thereby exhibiting a visual embossed feel through a glossy matte effect.

[0182] The second surface protective layer 26 is formed of a resin material such as an ionizing radiation-curable resin or a thermosetting resin, preferably an ionizing radiation-curable resin.

[0183] As an ionizing radiation-curing resin, the same material as the first surface protective layer 13 can be used.

[0184] From the viewpoint of gloss difference compared to the first surface protective layer 13, it is preferable to use a thermosetting resin having urethane bonds, such as a two-component curable urethane resin, as a thermosetting resin.

[0185] As a two-component curable urethane resin, for example, a urethane resin with polyol as the main component and isocyanate as the crosslinking agent (curing agent) can be used.

[0186] As a polyol, it can be a polyol with more than two hydroxyl groups in the molecule, such as: polyethylene glycol, polypropylene glycol, acrylic polyol, polyester polyol, polyether polyol, polycarbonate polyol, and polyurethane polyol.

[0187] In addition, polyisocyanates having two or more isocyanate groups in their molecules can be used as isocyanates. Examples of polyisocyanates that can be used include aromatic isocyanates such as 2,4-toluene diisocyanate, xylene diisocyanate, and 4,4′-diphenylmethane diisocyanate; or aliphatic (or alicyclic) isocyanates such as 1,6-hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated toluene diisocyanate, and hydrogenated diphenylmethane diisocyanate. Furthermore, adducts or polymers of the above-mentioned isocyanates can be used. Examples include adducts of toluene diisocyanate and toluene diisocyanate trimers. It should be noted that, among the above-mentioned isocyanates, aliphatic (or alicyclic) isocyanates are preferred in terms of good weather resistance and resistance to heat-induced yellowing; for example, 1,6-hexamethylene diisocyanate can be used.

[0188] The second surface protective layer 26 is partially formed on the first surface protective layer 13, and the coverage area can be adjusted according to design and target performance. The second surface protective layer 26 is preferably provided in a manner that covers 10% to 90% of the surface of the first surface protective layer 13. When exhibiting a glossy matte effect (visual embossing), it is preferably provided in a manner that covers 10% to 80% of the surface of the first surface protective layer 13. Furthermore, when improved scratch resistance, stain resistance, and oleophobicity are required for the decorative sheet 2, the second surface protective layer 26 is preferably provided in a manner that covers 10% to 80% of the surface of the first surface protective layer 13, and more preferably in a manner that covers 10% to 30%.

[0189] The material layer 11, the colored pattern layer 12, and the first surface protective layer 13 of the decorative piece 2 are formed in the same way as those of the decorative piece 1.

[0190] The second surface protective layer 26 is formed by, for example, by applying a resin material onto the first surface protective layer 13 and curing it, such as by screen printing, offset printing, or gravure printing.

[0191] Thus, decorative piece 2 is formed.

[0192] Decorative sheet 3E has a second surface protective layer 26 with higher gloss on a portion of the uneven surface of the first surface protective layer 13 with low gloss.

[0193] According to this configuration, in addition to the effects described in the first embodiment, a decorative sheet 2 can be obtained in which the first surface protective layer 13 and the second surface protective layer 26 do not produce turbidity and have a glossy matte effect (visual embossing).

[0194] (3.5.2) Variation Example

[0195] In decorative sheet 2, the pattern layer 12B of the colored pattern layer 12 can be synchronized with the glossy matte effect (visual embossing) produced by the gloss difference between the first surface protective layer 13 and the second surface protective layer 26. Compared with the glossy matte effect produced solely by the gloss difference between the first surface protective layer 13 and the second surface protective layer 26, decorative sheet 1, where the pattern layer 12B is synchronized with the visual embossing, can produce a superior visual embossing effect.

[0196] 4. Fourth Implementation Method

[0197] use Figure 14 The decorative panel according to the fourth embodiment of this disclosure will be described.

[0198] Figure 14 This is a cross-sectional view illustrating a configuration example of the decorative panel 30 according to the third embodiment of this disclosure.

[0199] The decorative panel 30 comprises a decorative sheet 1 and a substrate 31. The decorative panel 30 is composed of a substrate 31, a raw material layer 11, a colored pattern layer 12, and a first surface protective layer 13 stacked in sequence.

[0200] It should be noted that the decorative panel 30 may have a decorative piece 2 instead of the decorative piece 1. In addition, the decorative panel 30 may have decorative pieces 3A to 3D, which are variations of the decorative piece 1, instead of the decorative piece 1.

[0201] The substrate 31 will be described below. It should be noted that the layers other than the substrate 31 (including the original material layer 11, the colored pattern layer 12, and the first surface protective layer 13 of the decorative sheet) have the same structure as those described in the first and second embodiments, and therefore their descriptions are omitted.

[0202] (4.1) Basic Components of Decorative Pieces

[0203] <Substrate>

[0204] The substrate 31 can be, for example, a wood-based substrate or medium-density fiberboard (MDF). It can also be particleboard, a metal substrate, a non-combustible substrate, a composite substrate made of multiple materials, or a glossy substrate. Alternatively, the substrate 31 can be a combination of plywood and MDF.

[0205] Alternatively, a primer layer or a masking layer may be provided on the surface of the substrate 31 opposite to the decorative piece 1.

[0206] The scope of this disclosure is not limited to the exemplary embodiments illustrated, but includes all embodiments that have equivalent effects to the purpose of this disclosure. Furthermore, the scope of this disclosure is not limited to the combination of features of the invention as defined by the claims, but can be defined by all desired combinations of specific features among all the disclosed features.

[0207] Explanation of symbols

[0208] Decorative pieces 1,2,3A~3E

[0209] 11,11' Raw Material Layer

[0210] 11A First film layer

[0211] 11B Second Film Layer

[0212] 11C First Paper Material

[0213] 11D moisture-proof resin layer

[0214] 11E Second Paper Material

[0215] 12 Colored Pattern Layers

[0216] 12A shaded layer

[0217] 12B Pattern Layer

[0218] 13,23 First surface protective layer

[0219] 13' UV-curable resin

[0220] 13A Core

[0221] 13B Protrusion

[0222] 14 Adhesive resin layer

[0223] 15 Transparent Layers

[0224] 23' Ionizing radiation cured resin

[0225] 23A core

[0226] 23B Ridge

[0227] 26 Second surface protective layer

[0228] 30 Decorative Panels

Claims

1. A method for manufacturing a transfer printing plate, A first ionizing radiation with energy capable of cutting the polymer chains of an ionizing radiation-curable resin is irradiated onto a surface coated with such resin, causing the surface of the resin to shrink and thereby forming a raised or recessed shape for a template on the surface of the resin. The incident angle of the first ionizing radiation is 0 degrees. By irradiating the ionizing radiation-curable resin with a second ionizing radiation source after shrinkage, the ionizing radiation-curable resin is cured, thereby forming a transfer master as a resin material with the uneven shape of the master plate on its surface. The original plate has a random microstructure arranged isotropically, the height of the original plate has a height of 8 μm to 15 μm, and the period of adjacent original plate embossings is greater than 10 μm and less than 50 μm.

2. The method for manufacturing a transfer plate according to claim 1, wherein, The first ionizing radiation has energy capable of cleaving at least one of the carbonyl bond and the carbon-carbon bond.

3. The method for manufacturing a transfer plate according to claim 1 or 2, wherein, The transfer printing plate has a core formed of the ionizing radiation-curable resin and a ridge-shaped portion protruding from one side of the core. The ridge portion has a different composition from the core portion.

4. The method for manufacturing a transfer original plate according to claim 3, wherein, The ridge portion is integrally formed with the core portion. The ridge portion has a composition in which the ratio of carbonyl bonds to carbon-carbon bonds in the ionizing radiation-cured resin is reduced compared to the core portion.

5. The method for manufacturing a transfer original plate according to claim 4, wherein, The ridge portion has a composition in which the ratio of carbonyl bonds and carbon-carbon bonds in the ionizing radiation-cured resin is reduced by more than 10% compared to the core portion.

6. The method for manufacturing a transfer original plate according to claim 3, wherein, Compared to the core, the ridge has a higher cross-linking density.

7. The method for manufacturing a transfer plate according to claim 4 or 5, wherein, Compared to the core, the ridge has a higher cross-linking density.

8. The method for manufacturing a transfer plate according to claim 1 or 2, wherein, The ionizing radiation-curable resin is coated on the surface of the substrate.

9. The method for manufacturing a transfer plate according to claim 1 or 2, wherein, The ionizing radiation-curable resin is coated on the surface of the substrate. After the ionizing radiation-curable resin has cured, the substrate is peeled off.

10. A method for manufacturing a transfer printing plate, A first ionizing radiation with energy capable of cutting the polymer chains of an ionizing radiation-curable resin is irradiated onto a surface coated with such resin, causing the surface of the resin to shrink and thereby forming a transfer-grade raised / lower shape on the surface. The incident angle of the first ionizing radiation is 0 degrees. By irradiating the ionizing radiation-curable resin with a second ionizing radiation source after shrinkage, the ionizing radiation-curable resin is cured, thereby forming a resin layer with the transfer-grade uneven shape on its surface. The transfer-use embossed shapes have a random, isotropically arranged microstructure. The height of the embossed shapes is between 8 μm and 15 μm, and the period between adjacent embossed shapes exceeds 10 μm but is less than 50 μm. The transfer-use uneven shape formed on the surface of the resin layer is measured using a three-dimensional shape measuring device, and uneven shape data representing the transfer-use uneven shape is obtained. Based on the aforementioned concave-convex shape data, a master plate concave-convex shape corresponding to the transfer concave-convex shape is formed on the surface of the metal material, thereby forming a master plate for transfer as a metal material having the master plate concave-convex shape on its surface.

11. A method for manufacturing a decorative sheet, A resin material is coated on one surface of the original material layer. Using the transfer master plate formed by the manufacturing method of any one of claims 1 to 10, the master plate disposed on the surface of the transfer master plate is transferred onto the resin material in an uneven shape, and By curing the resin material, a first surface protective layer is formed on one surface of the original material layer, wherein the surface of the resin material has an uneven shape corresponding to the uneven shape of the original plate.

Images