Decorative sheet and method for producing decorative sheet

Abstract

To provide a decorative sheet having an improved three-dimensional appearance and a method for producing a decorative sheet.SOLUTION: There is provided a decorative sheet 10 which comprises a raw fabric layer 1, a pattern layer 2 provided in random order on the upper UP of the raw fabric layer 1, a pearl layer 3 containing first particles 31 and a metal scale layer 4 containing second particles 41 which average particle diameter is 0.5 times or less than the first particles 31. There is provided a method for producing a decorative sheet 10 which comprises: a picture printing step of forming the picture pattern layer 2; a large diameter particle layer printing step of forming the pearl layer 3 containing the first particles 31; and a small diameter particle layer printing step of forming the metal scale layer 4 containing second particles 41 which average particle diameter is 0.5 times or less than the first particles 31, wherein the pattern layer 2, the metal scale layer 4 and the pearl layer 3 are laminated in the thickness direction V in random order.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a decorative sheet and a method for producing a decorative sheet. [Background technology]

[0002] Conventionally, decorative sheets used for furniture, building materials, and the like have a three-dimensional effect imparted by laminating a picture pattern layer on which a picture is printed and a layer that imparts a sense of brightness to the picture in the picture pattern layer.

[0003] For example, a layer having high brilliance due to containing a pearl pigment or a metal is used as a layer that imparts a sense of brilliance to the design of the design pattern layer. Conventionally, either a pearl pigment or a metal has often been used as a layer that imparts a sense of brilliance to the design.

[0004] A decorative sheet having a layer containing metal is described in Patent Document 1. The decorative sheet described in Patent Document 1 has a support that serves as the base of the decorative sheet, a metallic layer that contains a plurality of large-diameter metal flakes and small-diameter metal flakes, and a picture pattern layer on which a pattern is formed. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2020-49725 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, decorative sheets having a layer containing a pearl pigment and conventional decorative sheets having a layer containing a metal, such as the decorative sheet described in Patent Document 1, may not be able to fully express a three-dimensional effect. Therefore, there is a demand for decorative sheets with improved three-dimensional effect.

[0007] In view of the above circumstances, an object of the present invention is to provide a decorative sheet with improved three-dimensional effect and a method for producing the decorative sheet. [Means for solving the problem]

[0008] In order to solve the above problems, the present invention proposes the following means. The decorative sheet of the present invention comprises an original fabric layer, and, provided in any order on the upper side of the original fabric layer, a picture pattern layer, a pearl layer containing first particles, and a metal flake layer containing second particles whose average particle size is 0.5 times or less that of the first particles.

[0009] In the decorative sheet, the first particles may contain a pearl pigment, and the second particles may contain a metal.

[0010] In the decorative sheet, the base layer may contain polyvinyl chloride.

[0011] In the above decorative sheet, the picture pattern layer may be provided on the upper side of the base fabric layer, the pearl layer may be provided on the upper side of the picture pattern layer, and the metal scale layer may be provided on the upper side of the pearl layer.

[0012] The method for producing a decorative sheet of the present invention includes a pattern printing step for forming a pattern layer, a large particle layer printing step for forming a pearl layer containing first particles, and a small particle layer printing step for forming a metal flake layer containing second particles having an average particle size 0.5 times or less that of the first particles, and the pattern layer, the pearl layer, and the metal flake layer are laminated in the thickness direction in any order.

[0013] In the above-mentioned method for manufacturing a decorative sheet, the pattern printing step may form the pattern layer on the upper side of the base fabric layer, the large-diameter particle layer printing step may form the pearl layer on the upper side of the pattern layer, and the small-diameter particle layer printing step may form the metal flake layer on the upper side of the pearl layer. Effect of the Invention

[0014] According to the decorative sheet and method for producing a decorative sheet of the present invention, it is possible to provide a decorative sheet and a method for producing a decorative sheet with improved three-dimensional effect. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a cross-sectional view showing a schematic configuration of a decorative sheet according to an embodiment of the present invention. [Diagram 2] 4 is a flowchart showing an example of a method for producing the decorative sheet. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] An embodiment of the present invention will be described with reference to the drawings.

[0017] FIG. 1 is a cross-sectional view that illustrates a schematic configuration of a decorative sheet 10 according to this embodiment. In this embodiment, as shown in Figure 1, the thickness direction of the decorative sheet 10 is defined as the "vertical direction V", the side of the decorative sheet 10 on which the base fabric layer 1 is provided is defined as the "lower side LO" in the vertical direction V, and the side opposite the lower side LO is defined as the "upper side UP" in the vertical direction V.

[0018] The decorative sheet 10 comprises an original fabric layer 1, a picture pattern layer 2, a pearl layer 3, and a metal scale layer 4. The picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 can be provided in any order on the upper side UP of the original fabric layer 1. Here, the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 are layers laminated in the thickness direction (vertical direction V) of the decorative sheet 10 on the upper side UP of the original fabric layer 1.

[0019] In this embodiment, a decorative sheet 10 is described in which a picture pattern layer 2, a pearl layer 3 and a metal scale layer 4 are provided on the upper side UP of a base fabric layer 1 in the order of picture pattern layer 2, pearl layer 3 and metal scale layer 4.

[0020] The raw fabric layer 1 is a layer provided on the lower side LO of the decorative sheet 10. Polyvinyl chloride can be used as the raw fabric layer 1. For the raw fabric layer 1, a resin material other than polyvinyl chloride or a fibrous sheet such as titanium paper may be used.

[0021] The picture pattern layer 2 is a layer provided on the upper side UP of the raw fabric layer 1. The picture pattern layer 2 is formed by printing a picture pattern such as wood grain, stone grain, or sand grain on the upper side UP of the raw fabric layer 1. The printing method for the picture pattern layer 2 can be a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing. For the picture pattern layer 2, a known printing ink suitable for the printing method to be adopted can be used.

[0022] The pearl layer 3 is a layer provided on the upper side UP of the picture pattern layer 2. For the pearl layer 3, it is desirable to adopt a transparent or semi-transparent material that allows the picture of the picture pattern layer 2 to be seen through. The material of the pearl layer 3 is not limited, but for example, a thermosetting resin, an ionizing radiation curing resin, an ultraviolet curing resin, or a mixture thereof can be adopted. For example, an acrylic resin, a vinyl chloride-vinyl acetate copolymer (vinyl chloride-vinyl acetate) resin, a urethane resin, a polyamide resin, a polyester resin, etc. may be adopted for the pearl layer 3.

[0023] Various additives such as ultraviolet absorbers, heat stabilizers, light stabilizers, surfactants, plasticizers, and extender pigments may be added to the pearl layer 3. The pearl layer 3 may be formed by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing. The pearl layer 3 may be formed by using a known coating device.

[0024] The pearl layer 3 contains first particles 31. For example, a known pearl pigment in which the surface of a mica particle is coated with titanium dioxide can be used as the first particles 31. The pearl layer 3 contains the first particles 31, which gives the pearl layer 3 high brilliance. The pearl layer 3 contains a plurality of first particles 31.

[0025] The metal scale layer 4 is a layer provided on the upper side UP of the pearl layer 3. For the metal scale layer 4, it is desirable to use a transparent or semi-transparent material that allows the pattern of the picture pattern layer 2 to be seen through the pearl layer 3. The material for the metal scale layer 4 is not limited, and examples of the material that can be used include thermosetting resin, ionizing radiation curing resin, ultraviolet curing resin, and mixtures thereof. For example, acrylic resin, vinyl chloride-vinyl acetate copolymer (vinyl chloride-vinyl acetate) resin, urethane resin, polyamide resin, polyester resin, etc. may also be used for the metal scale layer 4.

[0026] Various additives such as ultraviolet absorbers, heat stabilizers, light stabilizers, surfactants, plasticizers, and extender pigments may be added to the metal scale layer 4. Known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, and inkjet printing can be used to form the metal scale layer 4. The metal scale layer 4 may be formed using a known coating device.

[0027] The metal flake layer 4 contains second particles 41. As the second particles 41, for example, metals having a metallic luster such as aluminum, gold, silver, copper, tin, nickel, chromium, brass, etc. can be used. It is preferable to use aluminum particles having a good metallic luster as the second particles 41. By containing the second particles 41 in the metal flake layer 4, the metal flake layer 4 has high luster. The metal flake layer 4 contains a plurality of second particles 41.

[0028] The average particle size R2 of the second particles 41 is 0.5 or less times the average particle size R1 of the first particles 31. If the average particle size of the second particles is greater than 0.5 times the average particle size of the first particles, the difference in brilliance between the pearl layer and the metal scale layer will be insufficient, and the decorative sheet may not be able to achieve a sufficient three-dimensional effect.

[0029] By setting the average particle size R2 of the secondary particles 41 to 0.5 times or less the average particle size R1 of the primary particles 31, there is a sufficient difference in brilliance between the pearl layer 3 and the metal scale layer 4. Therefore, the decorative sheet 10 can express a sufficient three-dimensional effect.

[0030] As described above, the picture pattern layer 2, pearl layer 3, and metal scale layer 4 can be provided in any order on the upper side UP of the base fabric layer 1. As long as the average particle size R2 of the second particles 41 is 0.5 times or less the average particle size R1 of the first particles 31, the decorative sheet 10 can have a sufficient three-dimensional effect regardless of the stacking order of the picture pattern layer 2, pearl layer 3, and metal scale layer 4.

[0031] Next, a description will be given of a manufacturing method of the decorative sheet 10. Fig. 2 is a flow chart showing an example of a process for manufacturing the decorative sheet 10 by a decorative sheet manufacturing system. Here, the decorative sheet manufacturing system is a system that executes the manufacturing of the decorative sheet 10.

[0032] First, the decorative sheet manufacturing system performs step S1 (pattern printing step). In step S1, a pattern is printed on the upper side UP of the raw fabric layer 1 to form a pattern layer 2.

[0033] Next, the decorative sheet manufacturing system performs step S2 (large particle layer printing step). In step S2, a pearl layer 3 is formed on the upper side UP of the picture pattern layer 2. At this time, the pearl layer 3 contains first particles 31 including a pearl pigment or the like.

[0034] Next, the decorative sheet manufacturing system performs step S3 (small diameter particle layer printing process). In step S3, a metal scale layer 4 is formed on the upper side UP of the pearl layer 3. At this time, the metal scale layer 4 contains second particles 41 including metal particles and the like. In addition, the average particle size R2 of the second particles 41 is 0.5 times or less the average particle size R1 of the first particles 31. The manufacturing process of the decorative sheet 10 is completed by forming the metal flake layer 4.

[0035] Here, the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 can be provided in any order on the upper side UP of the original fabric layer 1. Therefore, in the manufacturing method of the decorative sheet 10, the picture printing step S1, the large particle layer printing step S2, and the small particle layer printing step S3 may be performed in any order. In other words, the decorative sheet 10 is manufactured by stacking the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 in the thickness direction (vertical direction V) on the upper side UP of the original fabric layer 1, regardless of the order in which they are stacked.

[0036] For example, the decorative sheet 10 may be manufactured by performing the pattern printing step S1, the small particle layer printing step S3, and the large particle layer printing step S2 in that order, or the decorative sheet 10 may be manufactured by performing the large particle layer printing step S2, the pattern printing step S1, and the small particle layer printing step S3 in that order.

[0037] The decorative sheet 10 and the manufacturing method for the decorative sheet 10 of this embodiment include an original fabric layer 1, a picture pattern layer 2, a pearl layer 3, and a metal scale layer 4, which are provided in no particular order on the upper side UP of the original fabric layer 1. The pearl layer 3 contains first particles 31. The metal scale layer 4 contains second particles 41. The average particle size R2 of the second particles 41 is 0.5 times or less the average particle size R1 of the first particles 31.

[0038] Therefore, the difference in brightness between the pearl layer 3 and the metal scale layer 4 allows the decorative sheet 10 to have a sufficient three-dimensional appearance.

[0039] Furthermore, the order in which the picture pattern layer 2, pearl layer 3, and metal scale layer 4 of the decorative sheet 10 are laminated on the upper side UP of the base fabric layer 1 is random. Since the decorative sheet 10 comprises the pearl layer 3 containing the first particles 31 and the metal scale layer 4 containing the second particles 41 having an average particle size 0.5 times or less that of the first particles 31, the difference in brilliance between the pearl layer 3 and the metal scale layer 4 allows the decorative sheet 10 to have a sufficient three-dimensional effect even if the layers are laminated in random order.

[0040] As a result, a decorative sheet 10 and a method for manufacturing the decorative sheet 10 with improved three-dimensional effect can be provided.

[0041] Although one embodiment of the present invention has been described in detail above with reference to the drawings, the specific configuration is not limited to this embodiment, and design modifications and the like within the scope of the present invention are also included. In addition, the components shown in the above-mentioned embodiment and the modified examples shown below can be appropriately combined to form a configuration.

[0042] (Variation 1) In the above embodiment, the decorative sheet 10 has the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 in this order on the upper side UP of the base fabric layer 1, but the embodiment of the decorative sheet 10 is not limited to this. The decorative sheet 10 may have the picture pattern layer 2, the metal scale layer 4, and the pearl layer 3 in this order on the upper side UP of the base fabric layer 1.

[0043] (Variation 2) In the above embodiment, the decorative sheet 10 has the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 in this order on the upper side UP of the base fabric layer 1, but the embodiment of the decorative sheet 10 is not limited to this. The decorative sheet 10 may have the pearl layer 3, the picture pattern layer 2, and the metal scale layer 4 in this order on the upper side UP of the base fabric layer 1.

[0044] (Variation 3) In the above embodiment, the decorative sheet 10 has the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 in this order on the upper side UP of the base fabric layer 1, but the embodiment of the decorative sheet 10 is not limited to this. The decorative sheet 10 may also have the pearl layer 3, the metal scale layer 4, and the picture pattern layer 2 in this order on the upper side UP of the base fabric layer 1.

[0045] (Variation 4) In the above embodiment, the decorative sheet 10 has the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 in this order on the upper side UP of the base fabric layer 1, but the embodiment of the decorative sheet 10 is not limited to this. The decorative sheet 10 may have the metal scale layer 4, the picture pattern layer 2, and the pearl layer 3 in this order on the upper side UP of the base fabric layer 1.

[0046] (Variation 5) In the above embodiment, the decorative sheet 10 has the picture pattern layer 2, the pearl layer 3, and the metal scale layer 4 in this order on the upper side UP of the base fabric layer 1, but the embodiment of the decorative sheet 10 is not limited to this. The decorative sheet 10 may have the metal scale layer 4, the pearl layer 3, and the picture pattern layer 2 in this order on the upper side UP of the base fabric layer 1.

[0047] The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.

[0048] Example 1 A picture design layer 2, a pearl layer 3 and a metal scale layer 4 were printed by gravure printing on the upper side UP of a base layer 1 made of polyvinyl chloride, to obtain a decorative sheet 10 of Example 1.

[0049] In this case, the order of the picture pattern layer 2, the pearl layer 3 and the metal scale layer 4 laminated on the upper side UP of the raw fabric layer 1 was, from the lower side LO, the picture pattern layer 2, the pearl layer 3 and the metal scale layer 4.

[0050] The ratio (R2 / R1) of the average particle size R2 of the second particles 41 contained in the metal flake layer 4 to the average particle size R1 of the first particles 31 contained in the pearl layer 3 was set to 0.50. Hereinafter, the ratio (R2 / R1) of the average particle size R2 of the second particles 41 to the average particle size R1 of the first particles 31 will also be referred to as the average particle size ratio R2 / R1.

[0051] Example 2 The decorative sheet 10 of Example 2 was obtained in the same manner as in Example 1, except that the average particle size ratio R2 / R1 was set to 0.23.

[0052] Example 3 The decorative sheet 10 of Example 3 was obtained in the same manner as in Example 1, except that the average particle size ratio R2 / R1 was set to 0.10.

[0053] Example 4 The decorative sheet 10 of Example 4 was obtained in the same manner as Example 1, except that the order of the picture pattern layer 2, pearl layer 3 and metal scale layer 4 laminated on the upper side UP of the raw fabric layer 1 was, from the lower side LO, picture pattern layer 2, metal scale layer 4, pearl layer 3, and the average particle size ratio R2 / R1 was 0.23.

[0054] Example 5 The decorative sheet 10 of Example 5 was obtained in the same manner as Example 1, except that the order of the picture pattern layer 2, pearl layer 3 and metal scale layer 4 laminated on the upper side UP of the raw fabric layer 1 was, from the lower side LO, pearl layer 3, metal scale layer 4, and the average particle size ratio R2 / R1 was 0.23.

[0055] Example 6 The decorative sheet 10 of Example 6 was obtained in the same manner as Example 1, except that the order of the picture pattern layer 2, pearl layer 3 and metal scale layer 4 laminated on the upper side UP of the raw fabric layer 1 was, from the lower side LO, pearl layer 3, metal scale layer 4, picture pattern layer 2, and the average particle size ratio R2 / R1 was 0.23.

[0056] Example 7 The decorative sheet 10 of Example 7 was obtained in the same manner as Example 1, except that the order of the picture pattern layer 2, pearl layer 3 and metal scale layer 4 laminated on the upper side UP of the raw fabric layer 1 was, from the lower side LO, metal scale layer 4, picture pattern layer 2, pearl layer 3, and the average particle size ratio R2 / R1 was 0.23.

[0057] Example 8 The decorative sheet 10 of Example 8 was obtained in the same manner as Example 1, except that the order of the picture pattern layer 2, pearl layer 3 and metal scale layer 4 laminated on the upper side UP of the raw fabric layer 1 was, from the lower side LO, metal scale layer 4, pearl layer 3, picture pattern layer 2, and the average particle size ratio R2 / R1 was 0.23.

[0058] Comparative Example 1 A decorative sheet of Comparative Example 1 was obtained in the same manner as in Example 1, except that the ratio of the average particle size of the secondary particles to the average particle size of the primary particles (average particle size ratio) was set to 0.62.

[0059] Comparative Example 2 A decorative sheet of Comparative Example 2 was obtained by providing no metal flake layer, providing a picture pattern layer on the upper side of the base layer, and providing a pearl layer on the upper side of the picture pattern layer.

[0060] Comparative Example 3 A decorative sheet of Comparative Example 3 was obtained by providing no pearl layer, providing a picture pattern layer on the upper side of the base layer, and providing a metal scale layer on the upper side of the picture pattern layer.

[0061] (Test 1) A three-dimensional effect evaluation test was conducted on the decorative sheets of Examples 1-8 and Comparative Examples 1-3. In the three-dimensional effect evaluation test, a sensory test was conducted by 10 testers on the three-dimensional effect on the surface (upper surface) of the decorative sheet, and the degree to which the three-dimensional effect was felt was evaluated. The evaluation criteria were three-level, with a score of 0 or above being considered a pass. ◯ (Good): Eight or more people rated the three-dimensional effect as excellent. △(Fair): Between 4 and 7 people rated the three-dimensional effect as excellent. × (Poor): Three or fewer people rated the three-dimensional effect as excellent.

[0062] (Test Results) The results of Test 1 are shown in Table 1. The "average particle size ratio" shown in Table 1 indicates the ratio of the average particle size of the second particles to the average particle size of the first particles. For example, when the average particle size ratio is 0.5, the average particle size of the second particles is 0.5 times the average particle size of the first particles. In addition, since Comparative Example 2-3 does not have either the pearl layer or the metal flake layer, the average particle size ratio in Table 1 is not shown.

[0063] The "layer structure" shown in Table 1 indicates the order of lamination of each layer provided on the upper side of the base layer. In the layer structure shown in Table 1, the left side of Table 1 corresponds to the lower side of the decorative sheet, and the right side corresponds to the upper side. For example, the layer structure in Example 1 in Table 1 indicates that a picture pattern layer 2 is provided on the upper UP of the raw fabric layer 1, a pearl layer 3 is provided on the upper UP of the picture pattern layer 2, and a metal scale layer 4 is provided on the upper UP of the pearl layer 3.

[0064] The decorative sheet 10 of Example 1-8, which has a picture pattern layer 2, a pearl layer 3 containing first particles 31, and a metal flake layer 4 containing second particles 41, and in which the average particle size ratio R2 / R1 of the second particles 41 to the first particles 31 is 0.5 or less, showed good results in Test 1.

[0065] The decorative sheet of Comparative Example 1, which had an average particle size ratio greater than 0.5, had a poorer three-dimensional effect than the decorative sheet 10 of Examples 1-8, and failed Test 1. Moreover, the decorative sheet of Comparative Example 2-3, which did not have either the pearl layer or the metal flake layer, failed Test 1 due to its poorer three-dimensional effect.

[0066] [Table 1] [Explanation of symbols]

[0067] 10 Decorative Sheet 1 Original layer 2. Pattern layer 3 Pearl Layer 31 First particle 4 Metal scale layer 41 Second particle V Vertical direction, thickness direction UP upper side LO Lower R1, R2 average particle size S1 Pattern printing process S2 Large particle layer printing process S3 Small diameter particle layer printing process

Claims

1. The original layer and The raw fabric layer is provided in any order on the upper side of the raw fabric layer. A pattern layer and a pearl layer containing first particles; a metal flake layer containing second particles having an average particle size of 0.5 times or less of the first particles; Equipped with Decorative sheet.

2. the first particles include a pearl pigment, The second particles include a metal. The decorative sheet according to claim 1 .

3. The raw fabric layer contains polyvinyl chloride. The decorative sheet according to claim 2.

4. The pattern layer is provided on the upper side of the base fabric layer, the pearl layer is provided on the upper side of the picture pattern layer, The metal flake layer is disposed on the upper side of the pearl layer. The decorative sheet according to any one of claims 1 to 3.

5. A pattern printing process for forming a pattern layer; a large particle layer printing step for forming a pearl layer containing first particles; a small particle layer printing step of forming a metal flake layer containing second particles having an average particle size of 0.5 times or less that of the first particles; Equipped with The pattern layer, the pearl layer, and the metal flake layer are laminated in a thickness direction in any order. A method for producing a decorative sheet.

6. The pattern printing step forms the pattern layer on the upper side of the raw fabric layer, The large particle layer printing step forms the pearl layer on the upper side of the picture pattern layer, The small particle layer printing step forms the metal flake layer on the upper side of the pearl layer. A method for producing the decorative sheet according to claim 5.

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