The manufacturing method of decorative sheets and decorative sheets

Abstract

A method for manufacturing decorative sheets that provides a texture closer to that of the genuine product and has excellent design features is provided. Therefore, the method includes: a process of forming a patterned layer (5) with a pattern on it using a predetermined material that has light absorption properties for infrared rays compared to the transparent thermoplastic resin layer (6) (Fig. 2(a)); a process of sequentially laminating the transparent thermoplastic resin layer (6) and a surface protective layer (7) on the patterned layer (5) (Fig. 2(b)); a process of irradiating infrared rays after the lamination process (Fig. 2(c)); and a process of pressing an embossing plate onto the surface protective layer (7) after irradiating infrared rays (Fig. 2(d)).

Description

Technical Field

[0001] This invention relates to a method for manufacturing decorative sheets and to decorative sheets themselves. Background Technology

[0002] Decorative sheets were developed and evolved as the residential building industry progressed. Originally, housing used materials such as wood and stone, which were appropriate for local conditions. However, with the development of the housing industry and the continuous advancement of industrialization, a shift is underway from natural raw materials to artificial ones. Furthermore, the large-scale use of high-grade wood or stone in recent years may lead to deforestation and environmental problems, which is also a major reason for the increased demand for decorative sheets. For example, decorative materials are widely used by bonding decorative sheets to wood-based substrates such as plywood, MDF (medium-density fiberboard), and particleboard, as well as resin-based substrates, inorganic non-combustible substrates, and metal substrates (see, for example, Patent Document 1).

[0003] In addition, as decorative pieces, most designs mimic the surfaces of wood or stone.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent No. 5045180 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, compared to real wood or stone, the surface texture of decorative panels tends to be flatter. Actual wood or stone varies in texture and unevenness depending on the surface material and structure. The color tone also differs significantly in areas with different textures, but this is not reflected in decorative panels. In terms of design, high-priced genuine products have a greater advantage.

[0009] The present invention was made in view of the above-mentioned problems, and its object is to provide a method for manufacturing decorative sheets with a texture that is closer to that of genuine products and with excellent design, as well as decorative sheets.

[0010] Methods for solving problems

[0011] To address the aforementioned issues, one aspect of the present invention provides a method for manufacturing a decorative sheet comprising a raw material layer, a pattern layer, a transparent resin layer, and a surface protective layer, and having an embossed shape synchronized with the pattern of the pattern layer. The method includes: a step of forming a pattern layer with a pattern depicted on it using a predetermined material that absorbs light of a predetermined wavelength relative to the transparent resin layer; a step of sequentially laminating the transparent resin layer and the surface protective layer onto the pattern layer; a step of irradiating the pattern layer with irradiating light of a predetermined wavelength having a power stronger than that of light of other wavelengths, after the lamination step; and a step of pressing an embossing plate for forming the embossed shape onto the surface protective layer after the irradiation step.

[0012] In addition, another aspect of the present invention provides a method for manufacturing a decorative sheet having an embossed shape synchronized with a pattern, comprising: a step of sequentially laminating a pattern layer, a transparent resin layer, and a surface protective layer on one side of a colored resin layer; a step of forming a pattern layer synchronized with the pattern on the other side of the colored resin layer using a predetermined material having light absorption properties for a predetermined wavelength of light relative to the colored resin layer; a step of irradiating with light of a predetermined wavelength having a power stronger than that of light of other wavelengths after the lamination step and the step of forming the pattern layer; and a step of pressing an embossing plate for forming the embossed shape against the surface protective layer after the step of irradiating with the irradiated light.

[0013] In addition, another aspect of the present invention provides a decorative sheet having a raw material layer, a pattern layer, a transparent resin layer, and a surface protective layer, comprising: a patterned layer formed of a predetermined material having light absorption properties for a predetermined wavelength relative to the transparent resin layer; and a transparent resin layer and a surface protective layer sequentially stacked on the patterned layer, wherein an embossed portion is formed at a position where the surface protective layer partially overlaps with the portion formed of the predetermined material in a plan view.

[0014] Furthermore, another aspect of the present invention provides a decorative sheet having a patterned layer, comprising: a patterned layer, a transparent resin layer, and a surface protective layer sequentially stacked on one side of a colored resin layer; a patterned layer formed by synchronously configuring a predetermined material having light absorption properties relative to the colored resin layer for a predetermined wavelength of light stacked on the other side of the colored resin layer, and an embossed portion formed at a position where the surface protective layer partially overlaps with the portion formed by the predetermined material in a plan view.

[0015] The effects of the invention

[0016] According to one aspect of the present invention, decorative sheets with excellent design features can be provided, which have a texture similar to that of wood, stone, and other surfaces used in building materials. Attached Figure Description

[0017] [ Figure 1 [This is a cross-sectional view schematically showing an example of a decorative sheet produced by the method for manufacturing a decorative sheet according to the first embodiment of the present invention.]

[0018] [ Figure 2 [This is a process diagram schematically illustrating an example of the manufacturing steps of the decorative sheet according to the first embodiment.]

[0019] [ Figure 3 [This is a cross-sectional view schematically illustrating another example of a decorative sheet produced by the method for manufacturing a decorative sheet according to the second embodiment of the present invention.]

[0020] [ Figure 4 [This is a process diagram illustrating an example of the manufacturing steps of the decorative sheet according to the second embodiment.]

[0021] [ Figure 5 [This is a cross-sectional view schematically illustrating other examples of decorative sheets produced by the method for manufacturing decorative sheets according to the third embodiment of the present invention.]

[0022] [ Figure 6 [This is a process diagram illustrating an example of the manufacturing steps of the decorative sheet according to the third embodiment.] Detailed Implementation

[0023] Hereinafter, embodiments of the present technology will be described with reference to the accompanying drawings. In this embodiment, decorative panels and decorative materials for floors or doors and windows will be used as examples, but decorative panels for other parts may also be used.

[0024] The accompanying drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, etc., differ from actual conditions. Furthermore, the embodiments shown below are examples of configurations used to embody the technical concept of the present invention. In the technical concept of the present invention, the materials, shapes, and structures of the constituent components are not limited to those described below. The technical concept of the present invention can be modified in various ways within the scope of the claims as defined in the claims.

[0025] One embodiment of the present invention relates to a method for manufacturing a decorative sheet comprising a raw material layer, a pattern layer, a transparent resin layer, and a surface protective layer, and having an embossed shape synchronized with the pattern of the pattern layer. The method includes: a step of forming a pattern layer depicting the pattern using a predetermined material having light absorption properties for a predetermined wavelength relative to the transparent resin layer; a step of sequentially laminating the transparent resin layer and the surface protective layer onto the pattern layer; a step of irradiating the predetermined wavelength with light having a power stronger than that of other wavelengths of light after the lamination step; and a step of pressing an embossing plate for forming the embossed shape against the surface protective layer after the irradiation step.

[0026] In addition, other embodiments of the present invention relate to a method for manufacturing decorative sheets having embossed shapes synchronized with patterns, comprising: a step of sequentially laminating a pattern layer, a transparent resin layer, and a surface protective layer on one side of a coloring resin layer; a step of forming a pattern layer synchronized with the pattern on the other side of the coloring resin layer using a predetermined material having light absorption properties for a predetermined wavelength relative to the coloring resin layer; a step of irradiating with irradiation light having a power stronger than that of light of other wavelengths after the lamination step and the step of forming the pattern layer; and a step of pressing an embossing plate for forming the embossed shape against the surface protective layer after the step of irradiating with the irradiation light.

[0027] In addition, other embodiments of the present invention relate to a decorative sheet having a raw material layer, a pattern layer, a transparent resin layer, and a surface protective layer, comprising: a pattern layer formed from a predetermined material having light absorption properties for a predetermined wavelength relative to the transparent resin layer; and the transparent resin layer and the surface protective layer sequentially stacked on the pattern layer, wherein an embossed portion is formed on the surface protective layer at a position where it partially overlaps with the portion formed from the predetermined material in a plan view.

[0028] Furthermore, other embodiments of the present invention relate to a decorative sheet having a patterned layer, comprising: a patterned layer, a transparent resin layer, and a surface protective layer sequentially stacked on one side of a colored resin layer; a patterned layer formed by synchronously configuring a predetermined material having light absorption properties relative to the colored resin layer for a predetermined wavelength with the pattern of the patterned layer, stacked on the other side of the colored resin layer; and an embossed portion formed at a position in the surface protective layer that overlaps with the portion formed by the predetermined material in a plan view.

[0029] [First Implementation Method]

[0030] First, the first embodiment of the present invention will be described.

[0031] like Figure 1 As shown, the decorative sheet 1 formed using the decorative sheet manufacturing method according to the first embodiment of the present invention is formed by sequentially layering a colored thermoplastic resin layer (raw material layer) 2, a pattern layer 5 including a matte pattern portion 3, a transparent thermoplastic resin layer (transparent resin layer) 6, and a surface protective layer 7. Embossed portions (embossed shapes) 7a are formed on the transparent thermoplastic resin layer 6 and the surface protective layer 7. The matte pattern portion 3 is disposed in the pattern layer 5 at a position intended to synchronize with the embossed portion 7a. Synchronization means that, in a plan view, at least a portion of the matte pattern portion 3 overlaps with the embossed portion 7a.

[0032] exist Figure 1 The example also illustrates a case where a primer layer 8 is provided on the side of the colored thermoplastic resin layer 2 opposite to the side where the patterned layer 5 is formed.

[0033] [Colored thermoplastic resin layer (raw material layer)]

[0034] Examples of coloring thermoplastic resin layers 2 used as the substrate include polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylate copolymer, ionomer, acrylate, and methacrylate. Among these, polyolefin resins are preferred in terms of environmental suitability, processability, and price. Furthermore, the resin grade and composition can be selected considering ease of sheeting, printability, and adaptability to bending processes.

[0035] As the colored thermoplastic resin layer 2, a suitable hue can be selected as the base color of the pattern layer 5. The colored thermoplastic resin layer 2 can be colored, for example, by pre-mixing or compounding pigments or other colorants during the sheeting of the thermoplastic resin. Alternatively, the colored layer can be applied as a solid ink layer using a coating or printing method before setting the matte pattern section 3. A colored thermoplastic resin can be used as the base layer, but the base layer can also be uncolored and can be colorless and transparent.

[0036] [Matte finish pattern section]

[0037] The matte pattern section 3 is formed of a material that absorbs light of a predetermined wavelength, such as a material that absorbs infrared light. Alternatively, the matte pattern section 3 is formed of a material containing carbon black ink, such as a urethane-based printing ink. The matte pattern section 3 is provided as part of the pattern layer 5 and is formed at a position where it is desired to be synchronized with the embossed section 7a; in other words, it is formed at the position where the embossed section 7a is desired to be formed. For example, in the case of a wood grain pattern layer 5, the matte pattern section 3 is positioned at a location overlapping the wood grain guide groove of the pattern layer 5.

[0038] [Pattern Layer]

[0039] Pattern layer 5 is a printed layer on which a pattern is printed to give the decorative piece 1 a design. Known printing methods can be used to form pattern layer 5. There are no particular limitations on the printing method, but gravure printing is preferred considering productivity and pattern quality. Alternatively, if the colored thermoplastic resin layer 2 can be prepared in a rolled state, printing for forming pattern layer 5 can be performed using a roll-to-roll printing apparatus. 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 pattern layer 5 can be formed not only by multi-color printing using common yellow, red, blue, and black process colors, but also by multi-color printing based on features using plates for each color constituting the pattern.

[0040] Furthermore, the patterns in pattern layer 5 can be any design element, suitable for flooring materials or doors and windows. For example, imagine marble or other stone flooring; the marble grain could be used as the pattern. Alternatively, for wood-based patterns, various wood grains and cork could be used. In addition to patterns based on natural materials, artificial patterns or geometric designs based on them can also be used. Other examples of patterns include wood grain patterns formed by the springwood and autumnwood regions of the annual rings, the vascular bundles, leather patterns, stone grain patterns from marble, granite, sandstone, etc., sand patterns, tile patterns, brickwork patterns, fabric patterns, geometric shapes, text, symbols, abstract patterns, floral patterns, landscapes, and characters.

[0041] The pattern layer 5 has a matte pattern section 3 and a non-matte pattern section 5a made of a material containing ink, forming a layer in which a pattern is formed by the matte pattern section 3 and the non-matte pattern section 5a. Moreover, the matte pattern section 3 is positioned in the pattern of the pattern layer 5 at a position that is to be synchronized with the embossing section 7a.

[0042] The printing ink for the non-matte finish pattern section 5a is a mixture of solid components such as solvents, colorants, and adhesive resins.

[0043] Examples of suitable solvents 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 methanol, ethanol, n-propanol, isopropanol, isobutanol, 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. A single solvent can be used, or two or more solvents can be used in combination.

[0044] In addition, examples of adhesive resins include chlorinated 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 chlorinated resins include polyvinyl chloride (PVC), chlorinated polyethylene, polyvinylidene chloride (PVDC), ethylene-vinyl chloride copolymers, vinyl chloride-vinyl acetate copolymers, and vinyl chloride-vinyl acetate-(meth)acrylic acid copolymers; polypropylene chloride (PVC) and chlorinated polypropylene (PP). Here, (meth)acrylic acid refers to acrylic acid or methacrylic acid. Adhesive resins can be used alone or in combination of two or more.

[0045] In addition, examples of colorants include inorganic pigments such as carbon black, iron black, titanium dioxide, antimony white, chrome yellow, titanium yellow, violet lacquer (ben), cadmium red, ultramarine, and cobalt blue; and organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue. A single colorant can be used, or two or more can be used in combination.

[0046] Here, the solvents contained in the printing ink eventually evaporate. Therefore, the non-matte pattern section 5a is mainly formed of solid components such as colorants and adhesive resins.

[0047] Furthermore, the printing ink for the non-matte pattern section 5a may also contain stabilizers, plasticizers, catalysts, curing agents, etc., as other components. As long as the printing ink is appropriate for the printing method, it is acceptable. In particular, it is preferable to select the ink considering the adhesion or printability of the colored thermoplastic resin layer 2, and its weather resistance as a flooring material or for doors and windows. The thickness of the pattern layer 5 can be appropriately adjusted considering the required decorative properties of the pattern layer 5, the three-dimensional forming properties of the decorative piece 1, etc. The thickness of the pattern 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.

[0048] To improve the adhesion between the pattern layer 5 and the transparent thermoplastic resin layer 6, an adhesive layer (not shown) can be provided on the side of the pattern layer 5 that contacts the transparent thermoplastic resin layer 6. By making these bonds strong, the decorative piece 1 can be given bending workability to follow curved or right-angled surfaces. There are no particular limitations on the resin used for the adhesive layer (not shown). For example, a two-component curable urethane resin can be used. Alternatively, an adhesive resin can be bonded to the pattern layer 5 using a urethane adhesive. In coating the resin used for the adhesive layer (not shown), for example, a coating apparatus or a gravure printing apparatus can be used.

[0049] Furthermore, to appropriately impart design effects such as depth and brightness to the decorative piece 1, a glossy layer (not shown) can be provided between the pattern layer 5 and the transparent thermoplastic resin layer 6. The glossy layer (not shown) preferably contains a glossy pigment and an adhesive resin. Examples of glossy pigments include pearl pigments and metallic pigments. In particular, pearl pigments are preferred because they can suppress the reduction of light transmittance in the glossy layer, thus not compromising the visibility of the pattern layer 5.

[0050] Pearl pigments are pigments that impart a pearly luster. Examples include substances obtained by coating the surface of matrix particles with metal oxides. Preferably, the matrix particles are flake-like particles such as mica. Examples of metal oxides include oxides of metals such as titanium, iron, zirconium, silicon, aluminum, and cerium. The metal oxide can be a single type or two or more types. Specific examples include oxide-coated mica such as titanium mica, iron oxide-coated mica, iron oxide-coated mica titanium, dark blue-coated mica titanium, dark 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 powders such as titanium oxide-coated glass powder and iron oxide-coated glass powder; oxide-coated metal particles such as titanium oxide-coated aluminum powder; flake-like foils such as alkaline lead carbonate, lead hydrogen arsenate, and bismuth oxychloride; fish scale powder, shell flakes, and pearl flakes.

[0051] In addition, metallic pigments can be categorized as those composed of metals such as aluminum, brass, stainless steel, tin, zinc, copper, nickel, gold powder, and silver, as well as alloys of these metals. Metallic pigments can be used alone or in combination of two or more.

[0052] From the viewpoint of achieving excellent design results, for example, when forming a glossy layer using gravure printing, the average particle size of the glossy pigment is preferably 40 μm or less, more preferably 30 μm or less. Similarly, the ratio of [average particle size of the glossy pigment / thickness of the glossy layer] is preferably 0.01 to 15, more preferably 0.5 to 10. It should be noted that, in this specification, "average particle size" refers to a value that can be obtained as the mass average value D50 in particle size distribution measurement using laser diffraction.

[0053] Furthermore, examples of adhesive resins include thermoplastic resins and cured products of curable resin compositions. From a durability viewpoint, cured products of curable resin compositions are preferred. 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.

[0054] Examples of thermosetting resin compositions for the glossy layer include polyester resin compositions, epoxy resin compositions, polyurethane resin compositions, amino alkyd resin compositions, melamine resin compositions, guanidine resin compositions, urea resin compositions, and thermosetting acrylic resin compositions. These thermosetting resin compositions may include the monomers and / or prepolymers constituting each resin, and curing agents added as needed. As an ionizing radiation-curing resin composition for the glossy layer, the same composition as the ionizing radiation-curing resin composition for the surface protective layer 7 described later can be used.

[0055] The content of glossy pigment in the glossy layer is preferably 10 parts by mass or more and 90 parts by mass or less, more preferably 50 parts by mass or more and 80 parts by mass or less, relative to 100 parts by mass of adhesive resin. By setting the content of glossy pigment to 10 parts by mass or more, sufficient gloss can be imparted, and by setting it to 90 parts by mass or less, damage to the visibility of the pattern layer described later can be suppressed. From the same point of view, the thickness of the glossy layer is preferably 1 μm or more and 30 μm or less, more preferably 5 μm or more and 20 μm or less.

[0056] The glossy layer can be formed into any pattern to suit the desired design. Examples include wood grain, leather grain, stone grain, sand grain, tile patterns, brickwork patterns, fabric patterns, geometric shapes, text, symbols, abstract patterns, floral patterns, landscapes, and characters. Furthermore, to further enhance the design effect, any pattern should preferably have varying degrees of density. This density can be created by the size or thickness of the dots, but is preferably created by the density of the dots (i.e., uniformly sized dots, with density used to create varying degrees of density).

[0057] The glossy layer can be formed, for example, by using a coating solution containing glossy pigments and binder resin, or by using common printing methods such as gravure printing. It should be noted that when the density of the glossy layer is determined by the density of the dots, the dots on the printing plate can be formed by FM (frequency modulation) halftone printing.

[0058] [Transparent thermoplastic resin layer]

[0059] The transparent thermoplastic resin layer 6 is a resin layer used to protect the pattern layer 5 and impart good surface properties, allowing it to display the designed thickness and depth, and improving the weather resistance and abrasion resistance of the decorative sheet 1. Materials for the transparent thermoplastic resin layer 6 can include, for example, vinyl chloride resin, acrylic resin, and polyolefin resins (polypropylene resin, polyethylene resin). In particular, polyolefin resins are preferred considering environmental suitability, processability, and price. Furthermore, the grade and composition of the resin are selected not only considering environmental suitability, processability, and price, but also considering ease of sheet forming, printability, and adaptability to bending processes. Regarding adaptability to bending processes, it is important to select a material that will not cause whitening or cracking at the bend.

[0060] As a method for forming the transparent thermoplastic resin layer 6, a lamination method can be used. Alternatively, for example, in the case of simultaneously forming the transparent thermoplastic resin layer 6 and the adhesive layer (not shown), a method can be used to simultaneously extrude both by co-extrusion.

[0061] [Surface Protective Layer]

[0062] The surface protective layer 7 is a layer used to impart surface properties such as abrasion resistance to the decorative piece 1. Additionally, the surface protective layer 7 is also a layer used to adjust the gloss of the surface of the decorative piece 1. The surface protective layer 7 can be a single layer or multiple layers. For example, as the surface protective layer 7, two layers, a first surface protective layer (not shown) and a second surface protective layer (not shown), can be sequentially applied onto the transparent thermoplastic resin layer 6. When the surface protective layer 7 is composed of the first surface protective layer (not shown) and the second surface protective layer (not shown), each layer can be applied and the coating cured using any of a known coating apparatus, a heat drying apparatus, or an ionizing radiation irradiation apparatus, depending on the type of curable resin.

[0063] The surface protective layer 7 is primarily composed of a curable resin. That is, the resin composition of the surface protective layer 7 is preferably substantially composed of a curable resin. "Substantially" means, for example, 80 parts by mass or more when the total resin content is set at 100 parts by mass. The surface protective layer 7 may also contain, as needed, weather-resistant agents, plasticizers, stabilizers, fillers, dispersants, dyes, pigments, and solvents.

[0064] The material used for the surface protective layer 7 can be, for example, an ionizing radiation-curing resin or a two-component curing urethane resin. There are no particular limitations on the ionizing radiation-curing resin. For example, a transparent resin whose main components are a prepolymer (including oligomers) containing free radical polymerizable double bonds in its molecule that can undergo polymerization and crosslinking reactions upon irradiation by ionizing radiation such as infrared, ultraviolet, or electron beams, and / or monomers. These prepolymers or monomers can be used alone or in combination. Specifically, compounds having free radical polymerizable unsaturated groups such as (meth)acryloyl groups and (meth)acryloyloxy groups, and cationic polymerizable functional groups such as epoxy groups in their molecules can be listed as prepolymers or monomers. Furthermore, polyene / thiol prepolymers obtained by combining polyenes and polythiols are preferred. Here, (meth)acryloyl group refers to acryloyl or methacryloyl group.

[0065] Examples of prepolymers with unsaturated groups capable of free radical polymerization include polyester (meth)acrylates, urethane (meth)acrylates, epoxy (meth)acrylates, melamine (meth)acrylates, triazine (meth)acrylates, and organosilicon (meth)acrylates. Their molecular weight is preferably around 2.5 million to 100,000.

[0066] Furthermore, monomers possessing unsaturated groups capable of free radical polymerization can be categorized as follows: For example, monofunctional monomers include methyl methacrylate, 2-ethylhexyl methacrylate, and phenoxyethyl methacrylate. Polyfunctional monomers include, for example, diethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

[0067] In addition, examples of prepolymers with cationic polymerizable functional groups include epoxy resins such as bisphenol type epoxy resins and phenolic varnish type epoxy compounds; and prepolymers of vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers.

[0068] In addition, examples of polyene-based prepolymers include prepolymers formed by adding allyl alcohol to both ends of a polyurethane formed from a glycol and a diisocyanate. Examples of thiol-based prepolymers include trimethylolpropane trithiodiol ester, pentaerythritol tetrathiodiol ester, and other polythiols.

[0069] As ionizing radiation, electromagnetic waves or charged particles with energy capable of causing a curing reaction in the molecules of an ionizing radiation-curable resin (composition) can be used, for example. As a curing reaction, cross-linking curing reactions can be cited as an example. Furthermore, as an ultraviolet light source, light sources such as ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, dim light, and metal halide lamps can be used, for example. As for the wavelength of ultraviolet light, 190 nm to 380 nm is preferred, for example. Furthermore, as an electron beam source, electron beam accelerators such as Cockroft-Walton type, Van de Graaf type, resonant transformer type, insulated core transformer type, linear type, Dynamitron type, and high-frequency type can be used, for example. In particular, accelerators capable of irradiating electrons with energy of 100 keV to 1000 keV (more preferably electrons with energy of 100 keV to 300 keV) are preferred.

[0070] Furthermore, there are no particular limitations on two-component curable urethane resins. For example, substances containing a polyol component with OH groups as the main agent and an isocyanate component as the curing agent can be used. Examples of polyol components with OH groups include acrylic polyols, polyester polyols, polyether polyols, and epoxy polyols. Examples of isocyanate components include toluene diisocyanate, hexamethylene diisocyanate, and isophthalic diisocyanate.

[0071] [Light of a predetermined wavelength]

[0072] As described above, the matte patterned section 3 is formed of a material that absorbs light of a predetermined wavelength. Examples of light of a predetermined wavelength include infrared, ultraviolet, visible light, electron beams, X-rays, and ion beams.

[0073] [Embossing Section]

[0074] To achieve a predetermined design, an embossed section 7a with a raised or recessed pattern is formed on the surface of the surface protective layer 7. Examples of raised or recessed patterns include wood grain panel grooves, the raised or recessed surface of a stone slab (such as a split granite surface), fabric texture, satin (pear-shaped), sand grain, hairline, and wavy lines. This embossed section 7a is set in a manner where its raised or recessed pattern is synchronized with the pattern of the pattern layer 5.

[0075] Embossing can be used as a method to create raised or recessed patterns. There are no particular limitations on the embossing method. For example, a known single-piece embossing machine or a rotary embossing machine can be used.

[0076] [Primer coat]

[0077] The primer layer 8 serves as a base layer, used to improve the adhesion and corrosion resistance between the colored thermoplastic resin layer 2 and the substrate (not shown) to which the decorative piece 1 is attached. The primer layer 8 is applied to the surface of the colored thermoplastic resin layer 2 opposite to the matte patterned portion 3. The primer layer 8 is formed, for example, using polyester resin, organic additives, pigments, etc. To improve corrosion resistance, anti-rust pigments may also be incorporated into the primer layer 8. The thickness of the primer layer 8 is, for example, in the range of 1 μm to 10 μm.

[0078] [Manufacturing method of decorative panels]

[0079] Next, accompanied Figure 2 An example of a method for manufacturing a decorative sheet according to this embodiment will be described.

[0080] First, a colored thermoplastic resin layer 2 is formed. For example, PBT (polybutylene terephthalate resin) is used to form a layer with a thickness of 50 μm. Figure 2 (a) Next, matte pattern portion 3 and non-matte pattern portion 5a are formed to create pattern layer 5. For example, using a urethane-based ink containing carbon black, matte pattern portion 3 is formed at the position of the pattern synchronized with embossing portion 7a in the pattern of pattern layer 5, and non-matte pattern portion 5a is formed in other areas.

[0081] Next, a transparent thermoplastic resin layer 6, for example, with a thickness of 38 μm, is laminated on the patterned layer 5. Then, a surface protective layer 7 is laminated on the transparent thermoplastic resin layer 6. Figure 2 (b)).

[0082] Then, the laminate on which these layers are formed is irradiated with infrared light from the side of the surface protective layer 7. Figure 2 (c) Immediately after infrared irradiation, an embossing roller or other embossing plate is pressed against the surface of the surface protective layer 7. Figure 2 (d)).

[0083] Here, since the matte pattern portion 3 is formed of ink with infrared absorption properties, when the laminate is irradiated with infrared light, in a plan view, the portion of the surface protective layer 7 overlapping the matte pattern portion 3 and the portion overlapping the non-matte pattern portion 5a are more prone to softening than the portion overlapping the matte pattern portion 5a. That is, after infrared irradiation, there are easily softened portions and difficult-to-soften portions in the surface protective layer 7 and the transparent thermoplastic resin layer 6. Therefore, when an embossing plate is pressed against the surface protective layer 7 in this state, the softened portions are prone to forming embossing, while the difficult-to-soften portions are less prone to forming embossing. Therefore, embossing is easily formed in the softened portions, i.e., the portions overlapping the matte pattern portion 3 in the plan view. Thus, in a plan view, an embossed portion 7a, composed of embossed shapes synchronized with the matte pattern portion 3, is easily formed only at the position where the surface protective layer 7 overlaps with the matte pattern portion 3.

[0084] Next, a primer layer 8 is formed on the surface of the colored thermoplastic resin layer 2 opposite to the surface on which the patterned layer 5 is formed. Figure 2 (e)). Thus, a Figure 1 Decorative piece 1 is shown.

[0085] It should be noted that the time point at which the embossing plate is pressed against the surface protective layer 7 after infrared irradiation is not limited to immediately after infrared irradiation. It is acceptable as long as the embossing plate is pressed against the surface of the surface protective layer 7 and a concave-convex shape is selectively formed in the area softened by infrared irradiation.

[0086] Furthermore, other processes may be included between the process of fabricating the surface protective layer 7 and the process of infrared irradiation. In short, infrared irradiation can be performed as long as the surface protective layer 7 has been formed.

[0087] [Effects of the First Embodiment]

[0088] (1) According to the manufacturing method of the decorative sheet 1 in this embodiment, after the entire surface protective layer 7 is irradiated with infrared light, by pressing an embossing plate against the surface protective layer 7, the portion of the surface protective layer 7 that overlaps with the matte pattern portion 3 can be embossed in a plan view. That is, even without highly precise positioning of the area of ​​the surface protective layer 7 that presses against the embossing plate, the embossed portion can be easily formed only at the desired location. As a result, a decorative sheet with excellent design can be easily obtained.

[0089] (2) In addition, since the matte pattern part 3 is provided synchronously with the pattern of the pattern layer 5, the embossed part 7a can be formed at the position synchronous with the pattern of the pattern layer 5, that is, the matte effect can be easily expressed at the position synchronous with the pattern.

[0090] Furthermore, a transparent thermoplastic resin layer 6 and a surface protective layer 7 are stacked on a matte patterned portion 3 obtained by using ink with infrared absorption properties, and a patterned layer 5 formed using a material with low infrared light absorption compared to the matte patterned portion 3. An embossed portion 7a is further formed at the position where the surface protective layer 7 overlaps with the matte patterned portion 3 in a plan view. Therefore, the matte patterned portion 3 obtained by using ink can be regarded as part of the pattern.

[0091] (3) Furthermore, by creating an uneven surface on the surface protective layer 7 itself to achieve a matte finish, it is possible to suppress the occurrence of matte pattern peeling. Therefore, a simultaneous matte finish can also be achieved in materials such as flooring.

[0092] [Variation Example]

[0093] In the above embodiment, the surface protective layer 7 was partially softened by irradiating the matte patterned portion 3 with infrared light using a material containing ink, but this is not a limitation. The surface protective layer 7 can also be partially softened by using a material containing any ink composed of components that absorb light of a predetermined wavelength and a light source that irradiates the predetermined wavelength.

[0094] [Second Implementation]

[0095] Next, the second embodiment of the present invention will be described.

[0096] In the first embodiment described above, a case was described in which the matte pattern portion 3 is included as part of the pattern layer 5, and a pattern layer 5 is formed by the matte pattern portion 3 and the non-matte pattern portion 5a. However, as... Figure 3As shown, in the second embodiment, a matte pattern portion 31 is disposed on the main pattern layer 5b. That is, the pattern layer 51 according to the second embodiment includes a main pattern layer 5b and a pattern layer 5c stacked on the main pattern layer 5b. The pattern layer 5c is composed only of the matte pattern portion 31 arranged in a manner synchronized with the embossing portion 7a. The pattern of the pattern layer 51 is mainly formed by the main pattern layer 5b, and the pattern layer 5c, i.e., the matte pattern portion 31, is formed of a material that can recognize the main pattern layer 5b. Specifically, the matte pattern portion 31 differs from the matte pattern portion 3 according to the first embodiment above; it is not composed of a material containing ink, but is composed of a material with infrared absorption properties, and is formed using a colorless, transparent, or nearly transparent light-colored ink. Materials with infrared absorption properties can be inorganic materials such as tin-doped indium oxide (ITO), antimony-doped tin oxide (ATO), lanthanum hexaboride (LaB6), and cesium-doped tungsten oxide, as well as near-infrared or infrared absorbing materials, organic materials such as phthalocyanine materials, and existing materials with infrared absorption properties. Specifically, the matte pattern section 31 is formed from ink capable of recognizing the main pattern layer 5b.

[0097] The decorative sheet 11 according to the second embodiment is formed by laminating a main pattern layer 5b on a colored thermoplastic resin layer 2, forming a matte pattern portion 31 as a pattern layer 5c on the main pattern layer 5b, and laminating a transparent thermoplastic resin layer 6 on the pattern layer 5c. That is, the transparent thermoplastic resin layer 6 is laminated on the main pattern layer 5b and the matte pattern portion 31 in such a way that the gaps between the matte pattern portions 31 are filled and covered thereon.

[0098] Furthermore, after the surface protective layer 7 is laminated on the transparent thermoplastic resin layer 6, the laminate with these layers is subjected to infrared irradiation. Under infrared irradiation, in a plan view, the portion of the surface protective layer 7 overlapping the matte pattern portion 31 softens more, while the portion overlapping the portion where the matte pattern portion 31 is not formed softens more. As a result, after infrared irradiation, by pressing an embossing plate against the surface protective layer 7, an embossed portion 7a is formed in the more easily softened portion overlapping the matte pattern portion 31 in a plan view. Therefore, even when the matte pattern portion 31 is laminated on the main pattern layer 5b, the same effect as in the first embodiment described above can be obtained.

[0099] Furthermore, since the matte pattern section 31 is formed using a colorless, transparent or light-colored material that is close to transparent, the pattern of the main pattern layer 5b can be identified through the matte pattern section 31 even when it is layered on the main pattern layer 5b.

[0100] exist Figure 3In this case, since a matte pattern portion 31 is superimposed on the main pattern layer 5b, the pattern of the pattern layer 51 can be selected without considering the placement of the matte pattern portion 31. Furthermore, since the matte pattern portion 31 does not obstruct the visibility of the main pattern layer 5b, a matte effect can be easily achieved without reducing the visibility of the pattern on the pattern layer 51.

[0101] Figure 4 This illustrates an example of the manufacturing process of a decorative piece 11 made by forming a matte pattern portion 3 on the main pattern layer 5b. For example... Figure 4 As shown, a main pattern layer 5b with a predetermined pattern is formed. Figure 4 (a) On it, a matte pattern portion 31 is formed at a position corresponding to a predetermined pattern in the pattern of the main pattern layer 5b to form a pattern layer 5c. Figure 4 (b) Next, a transparent thermoplastic resin layer 6 is laminated on the main pattern layer 5b, which includes the matte pattern portion 31. Figure 4 (c)). After the surface protective layer 7 is laminated on the transparent thermoplastic resin layer 6 ( Figure 4 (d)) Infrared irradiation ( Figure 4 (e)), pressing an embossed plate against the surface protective layer 7. Figure 4 (f)). Thus, it is possible to create an embossed portion 7a that is synchronized with the matte pattern portion 31, and to create a decorative piece 11 by setting a primer layer 8. Figure 4 (g)).

[0102] [Third Implementation Method]

[0103] In the second embodiment described above, the case where a matte pattern portion 31 is provided on the main pattern layer 5b was explained, but as... Figure 5 As shown, in the third embodiment, the decorative sheet 12 has a matte pattern portion 32 disposed on the surface of the colored thermoplastic resin layer 2 opposite to the main pattern layer 5b. That is, the pattern layer 52 in the third embodiment is formed solely from the main pattern layer 5b. It should be noted that the same reference numerals are used for the parts that are the same as in the first and second embodiments, and their detailed descriptions are omitted.

[0104] [Patterned Layers]

[0105] The pattern layer 8a consists solely of a matte pattern section 32 arranged in sync with the embossing section 7a. Similar to the matte pattern section 3 in the first embodiment described above, the matte pattern section 32 is formed of a material that absorbs light of a predetermined wavelength, such as a material that absorbs infrared light. Specifically, the matte pattern section 32 is formed of a material containing carbon black ink, such as a urethane-based printing ink. The matte pattern section 32 is positioned in sync with the pattern of the main pattern layer 5b. For example, if the main pattern layer 5b is a wood grain pattern, the matte pattern section 32 is formed in a plan view at a position overlapping with the wood grain conduit groove of the main pattern layer 5b.

[0106] The thickness of the matte pattern portion 32 is sufficient to soften the transparent thermoplastic resin layer 6 and the surface protective layer 7 during the embossing process described later, to the point that a sufficiently raised / recessed shape can be formed on the surface protective layer 7. Furthermore, to obtain a sufficient matte effect, the gloss difference between the portion where the matte pattern portion 32 is formed and the portion where the matte pattern portion 32 is not formed is preferably 5 or more; that is, the image density level is preferably 60% or more.

[0107] [Light of a predetermined wavelength]

[0108] As described above, the matte patterned portion 32 is formed of a material that absorbs light of a predetermined wavelength. Examples of light of the predetermined wavelength include infrared, ultraviolet, visible light, electron beams, X-rays, and ion beams.

[0109] [Manufacturing method of decorative panels]

[0110] Next, accompanied Figure 6 An example of a method for manufacturing the decorative piece 12 according to the third embodiment will be described.

[0111] First, a colored thermoplastic resin layer 2 is formed. Figure 6 (a) Next, for example, a main pattern layer 5b is printed on the colored thermoplastic resin layer 2 using urethane-based printing ink, and a transparent thermoplastic resin layer 6 is further laminated on the main pattern layer 5b. Then, a surface protective layer 7 is laminated on the transparent thermoplastic resin layer 6.

[0112] Next, a matte pattern portion 32 is formed on the surface of the colored thermoplastic resin layer 2 opposite to the main pattern layer 5b, forming a pattern layer 8a. Figure 6 (b)).

[0113] Next, a primer layer 8, for example made of polyester resin, is laminated onto the colored thermoplastic resin layer 2 containing the matte pattern portions 32 in such a way that the gaps between the matte pattern portions 32 are filled and the primer layer 8 covers the matte pattern portions 32. Figure 6 (c)).

[0114] Next, the entire laminate containing these layers is irradiated with infrared light (irradiation light) from the side of the surface protective layer 7. Figure 6 (d) Immediately after infrared irradiation, the embossing roller and other embossing plates are pressed against the surface of the surface protective layer 7. Figure 6 (e)). This forms the embossed part 7a, and the decorative piece 12.

[0115] Here, the matte pattern portion 32 is formed of ink with infrared absorption properties. Therefore, when the laminate is irradiated with infrared light, in a plan view, the portion of the surface protective layer 7 that overlaps with the matte pattern portion 32 is more prone to softening than the portion that does not overlap with the matte pattern portion 32. That is, after infrared irradiation, there are easily softened portions and difficult-to-soften portions in the transparent thermoplastic resin layer 6 and the surface protective layer 7. Therefore, when an embossing plate is pressed against the transparent thermoplastic resin layer 6 and the surface protective layer 7 in this state, the softened portions are prone to forming unevenness, while the difficult-to-soften portions are difficult to form unevenness. Therefore, the softened portions of the transparent thermoplastic resin layer 6 and the surface protective layer 7—that is, the portions that overlap with the matte pattern portion 32 in a plan view—are prone to forming unevenness. Therefore, in a plan view, an embossed portion 7a, consisting of a concave-convex shape synchronized with the matte pattern portion 32, can be easily formed only at the position where the transparent thermoplastic resin layer 6 and the surface protective layer 7 overlap with the matte pattern portion 32.

[0116] Therefore, the embossed portion 7a can be formed at a position synchronized with the main pattern layer 5b, that is, the embossed portion 7a synchronized with the main pattern layer 5b can be easily produced without performing a high-precision positioning operation.

[0117] It should be noted that the time point at which the embossed plate is pressed onto the transparent thermoplastic resin layer 6 and the surface protective layer 7 after infrared irradiation is not limited to immediately after infrared irradiation. It is acceptable as long as the embossed plate is pressed onto the surface of the transparent thermoplastic resin layer 6 and the surface protective layer 7, so that the embossed plate can selectively form a concave-convex shape in the area softened by infrared irradiation.

[0118] Furthermore, other steps may be included between the step of fabricating the surface protective layer 7 and the step of infrared irradiation. In short, infrared irradiation can be performed as long as the transparent thermoplastic resin layer 6 and the surface protective layer 7 are formed.

[0119] [Effects of the Third Implementation]

[0120] The decorative piece 12 according to the third embodiment can easily form an embossed part at the desired location, and can achieve the same effect as the first and second embodiments described above.

[0121] Furthermore, in the decorative sheet 12 according to the third embodiment, since a matte pattern portion 32 is provided on the lower layer of the colored thermoplastic resin layer 2, the visibility of the matte pattern portion 32 is reduced when the decorative sheet 12 is viewed from the surface protective layer 7 side. As a result, even if a high-concentration ink with infrared absorption characteristics is used as the matte pattern portion 32, the matte pattern portion 32 can be suppressed from being seen when the decorative sheet 12 is viewed from the surface protective layer 7 side. Therefore, even if a dark pattern is not used as the main pattern layer 5b, the visibility of the matte pattern portion 32 containing ink can be suppressed. Consequently, a light-colored pattern can also be used as the main pattern layer 5b, and the restriction of the main pattern layer 5b on the pattern expression caused by the provision of the matte pattern portion 32 can be suppressed.

[0122] Furthermore, on the pattern layer 5d, which is composed of a matte pattern portion 32 obtained using ink with high concentration of infrared absorption properties, a colored thermoplastic resin layer 2 and a main pattern layer 5b are layered, and a transparent thermoplastic resin layer 6 and a surface protective layer 7 are further layered. An embossed portion 7a is formed at the position where the surface protective layer 7 overlaps with the matte pattern portion 32 in a plan view. Therefore, the visibility of the matte pattern portion 32 using ink can be reduced, and the influence of the matte pattern portion 32, which is useful during the manufacturing process of the decorative sheet 12, on the appearance of the decorative sheet 12 can be suppressed. As a result, a highly designed decorative sheet 12 with the pattern of the main pattern layer 5b synchronized with the embossed portion 7a can be obtained.

[0123] Example

[0124] (Example 1)

[0125] A laminate consisting of the following layers was fabricated: a colored thermoplastic resin layer 2 consisting of a PBT layer with a thickness of 50 μm; a matte patterned section 3 formed by pattern printing with an ink consisting of a urethane-based printing ink, and a non-matte patterned section 5a formed adjacent to the matte patterned section 3 using urethane-based printing ink; a transparent thermoplastic resin layer 6 consisting of a PP layer with a thickness of 38 μm; and a surface protective layer 7 consisting mainly of an acrylic resin composition.

[0126] A transparent thermoplastic resin layer 6 is formed on the pattern layer 5 by lamination. After the surface protective layer 7 is formed, the laminate is heated using an infrared heater, and then an embossing roller is pressed onto the surface protective layer 7 to form an embossed portion 7a. A primer layer 8 is then formed, thus obtaining... Figure 1 Decorative piece 1 is shown.

[0127] (Example 2)

[0128] The following layers are formed: a 50 μm thick colored thermoplastic resin layer 2 composed of a PBT layer; a main pattern layer 5b formed using urethane-based ink; a matte pattern section 31 formed by pattern printing with transparent ink composed of urethane-based printing ink containing infrared absorbing material; and a 38 μm thick transparent thermoplastic resin layer 6 composed of a PP layer, thereby creating a laminate composed of a surface protective layer 7 as the main component. The transparent thermoplastic resin layer 6 is formed on the main pattern layer 5b by lamination. After the surface protective layer 7 is formed, the laminate is heated using an infrared heater. Then, an embossing roller is pressed onto the surface protective layer 7 to form an embossed section 7a. A primer layer 8 is further formed, thereby obtaining... Figure 3 Decorative piece 11 is shown.

[0129] (Example 3)

[0130] A laminate was fabricated as follows: a main pattern layer 5b composed of urethane-based printing ink was sequentially laminated onto one side of a colored thermoplastic resin layer 2 consisting of a PBT layer with a thickness of 50 μm; a transparent thermoplastic resin layer 6 consisting of a PP layer with a thickness of 38 μm; and a surface protective layer 7 mainly composed of an acrylic resin composition. The transparent thermoplastic resin layer 6 was formed on the main pattern layer 5b by lamination.

[0131] In addition, on the other side of the colored thermoplastic resin layer 2, an ink composed of urethane-based printing ink is printed to form a matte pattern portion 32, and a primer layer 8 is formed on the colored thermoplastic resin layer 2 containing the matte pattern portion 32, thereby obtaining a laminate.

[0132] After the primer layer 8 is formed, the laminate is heated using an infrared heater. Then, an embossing roller is pressed onto the surface protective layer 7 to form the embossed portion 7a, resulting in... Figure 5 Decorative piece 12 is shown.

[0133] (Comparative Example 1)

[0134] As a raw material, a colored thermoplastic resin layer 2 consisting of a PBT layer with a thickness of 50 μm was prepared, thereby obtaining a sheet material consisting only of the raw material.

[0135] Furthermore, as an embodiment of the lower concept equivalent to Embodiment 2, decorative pieces 11 as shown in Embodiments 4 to 9 were obtained.

[0136] (Example 4)

[0137] Lanthanum hexaboride (LaB6) was used as the infrared absorbing material to form the matte patterned portion 31. Otherwise, it was obtained in the same manner as in Example 2 described above. Figure 3 Decorative piece 11 is shown.

[0138] (Example 5)

[0139] As an infrared absorbing material, a transparent ink composed of a urethane-based printing ink utilizing cesium-doped tungsten oxide (CWO, manufactured by Sumitomo Metal Mining Co., Ltd.) was used to form a matte pattern section 31. Otherwise, the same as in Example 2 described above was obtained. Figure 3 Decorative piece 11 is shown.

[0140] (Example 6)

[0141] As an infrared absorbing material, a transparent ink composed of urethane-based printing ink utilizing antimony-doped tin oxide (ATO) was used to form a matte patterned portion 31. Otherwise, it was obtained in the same manner as in Example 2 described above. Figure 3 Decorative piece 11 is shown.

[0142] (Example 7)

[0143] As an infrared absorbing material, a transparent ink composed of urethane-based printing ink utilizing tin-doped indium oxide (ITO) was used to form a matte patterned portion 31. Otherwise, it was obtained in the same manner as in Example 2 described above. Figure 3 Decorative piece 11 is shown.

[0144] (Example 8)

[0145] As an infrared absorbing material, a transparent ink composed of urethane-based printing ink utilizing near-infrared absorbing material OPTLION (manufactured by TOYO VISUALSOLUTIONS) was used to form a matte patterned section 31. Otherwise, it was obtained in the same manner as in Example 2 described above. Figure 3 Decorative piece 11 is shown.

[0146] (Example 9)

[0147] As an infrared absorbing material, a transparent ink composed of urethane-based printing inks utilizing the EXCOLOR series (manufactured by NIPPON SHOKUBAI) infrared absorbing material was used to form a matte pattern section 31. Otherwise, the same as in Example 2 described above was obtained. Figure 3 Decorative piece 11 is shown.

[0148] [evaluate]

[0149] Infrared transmittance was measured for each decorative piece of Examples 1-9 and the raw material of Comparative Example 1. Infrared transmittance was measured by the method described below.

[0150] For each decorative piece of Examples 1-9 and the raw material of Comparative Example 1, color difference, gloss, and gloss difference were obtained. The methods described below were used to obtain these values. The results are shown in Tables 1 and 2.

[0151] [Infrared transmittance measurement]

[0152] Infrared transmittance was measured for the decorative sheets of Examples 1-9 and the raw material of Comparative Example 1, which had different image density levels. Specifically, infrared transmittance at a wavelength of 2000 nm was measured using a UV / Vis spectrophotometer UV3600 manufactured by SHIMADZU.

[0153] [Color Difference Measurement]

[0154] Based on the infrared transmittance measurement results, the color difference of the decorative sheets of Examples 1-9 and the raw material of Comparative Example 1 was measured. Specifically, the color difference ΔE relative to the standard plate was calculated using a CR-400 colorimeter manufactured by KONICA MINOLTA JAPAN.

[0155] [Gloss Measurement]

[0156] For the surface protective layer 7 after embossing of the decorative sheets of Examples 1-9, the specular gloss was measured at an incident angle of 85° using a micro-TRI-gloss measuring instrument manufactured by BYK. The specular gloss was measured for the raw material of Comparative Example 1 using the same procedure.

[0157] [Poor gloss]

[0158] The difference between the gloss of each decorative piece from Examples 1 to 9, as measured in the gloss measurement, and the gloss of the raw material of Comparative Example 1 was calculated. Based on the difference in gloss, the presence or absence of a matte finish was confirmed.

[0159] [Table 1]

[0160]

[0161] *1 Color difference from the standard plate

[0162] *2 Transmittance at a wavelength of 2000nm

[0163] *3 Gloss difference between raw material (without ink) and ink section

[0164] [Table 2]

[0165]

[0166] *1 Color difference from the standard plate

[0167] *2 Transmittance at a wavelength of 2000nm

[0168] *3 Gloss difference between raw material (without ink) and ink section

[0169] [result]

[0170] Although the gloss levels of any of the embodiments 1 to 9 differ somewhat, the gloss difference from the original material is approximately 5. That is, the gloss difference of any embodiment of the decorative piece forming the embossed portion 7a is approximately 5, which satisfies the generally acceptable gloss difference of 3. Therefore, a matte finish can be obtained. Furthermore, it is known that, regarding embodiments 2 to 9, since the color difference from the standard plate is suppressed to a low level, the matte finish pattern portion can be prevented from being visible.

[0171] Explanation of symbols

[0172] Decorative pieces 1, 11, and 12

[0173] 2 Colored thermoplastic resin layer

[0174] 3, 31, 32 Matte finish pattern section

[0175] 4 Concealed Real-world Layer

[0176] Pattern layers 5, 51, and 52

[0177] 5a Non-matte finish pattern section

[0178] 5b Main Pattern Layer

[0179] 5c Pattern Layer

[0180] 6 Transparent thermoplastic resin layer

[0181] 7 Surface Protective Layer

[0182] 7a Embossed section

[0183] 8. Primer layer

[0184] 8a Pattern Layer

Claims

1. A method for manufacturing a decorative sheet, comprising: manufacturing a decorative sheet having an embossed shape synchronized with a pattern, characterized in that it includes: The process of sequentially laminating a pattern layer, a transparent resin layer, and a surface protective layer on one side of a colored resin layer that serves as a substrate. On the other side of the colored resin layer, a pattern layer synchronized with the pattern is formed using a predetermined material that has light absorption properties for a predetermined wavelength compared to the colored resin layer; After the lamination process and the process of forming the pattern layer, a process of irradiating light of the predetermined wavelength with a power stronger than that of light of other wavelengths; and The process of pressing the embossing plate for forming the embossing shape against the surface protective layer after the process of irradiating the light.

2. A decorative sheet having a patterned layer, characterized in that it possesses: A pattern layer, a transparent resin layer, and a surface protective layer are sequentially stacked on one side of a colored resin layer that serves as a substrate. A pattern layer, consisting of a predetermined material that absorbs light of a predetermined wavelength relative to the coloring resin layer and is stacked on the other side of the pattern layer, is arranged synchronously with the pattern layer. An embossed portion is formed at a location where it overlaps with a portion formed of the predetermined material in a plan view of the surface protective layer.

Images