Decorative sheet and decorative laminate as well as method for producing decorative sheet and decorative laminate

Abstract

To provide a decorative sheet and a decorative laminate having stereo-feeling, and excellent in designability and coating suitability as well as a method for producing a decorative sheet and a decorative laminate.SOLUTION: A decorative sheet 10 includes a sheet base material 1, a pattern layer 2 provided on the upper side UP of the sheet base material 1, a first surface protective layer 3 positioned on the upper side UP of the pattern layer 2, a thin film part, and a thick film part partially provided on the upper side UP of the thin film part and a second surface protective layer 4 provided on the upper side UP of the first surface protective layer 3, where a thickness of the thin film part is more than 20% and less than or equal to 65% of the thickness of the portion of the second surface protective layer 4 where the thick film part is provided with a first inclined portion defined at the boundary with the thin film part in cross-section along a vertical direction V, and a second inclined portion with a different slope relative to the first inclined portion, where the slope of the first inclined portion is smaller than that of the second inclined portion.SELECTED DRAWING: Figure 1

Description

[Technical field]

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

[0002] Conventionally, decorative sheets used as surface materials for furniture and residential building materials include decorative sheets that have a visual three-dimensional effect formed by multiple surface protective layers with different glosses, and decorative sheets that have a three-dimensional effect to the touch by forming unevenness on the surface by embossing or the like.

[0003] For example, in a wood grain pattern decorative sheet, by imparting a visual and tactile three-dimensional effect to the vascular portion of the wood grain pattern, it is possible to provide a wood grain pattern decorative sheet that more closely resembles the appearance of natural wood.

[0004] A decorative sheet having a three-dimensional effect is disclosed in Patent Document 1. The decorative sheet disclosed in Patent Document 1 has a visual three-dimensional effect by partially laminating a second surface protective layer having a different gloss from that of the first surface protective layer on the upper side of a first surface protective layer that is laminated on the upper side of a picture pattern layer. In addition, a three-dimensional effect is provided by touching the third surface protective layer having a thickness four or more times that of the second surface protective layer on the upper side of the second surface protective layer. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2017-24318 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, the decorative sheet described in Patent Document 1 may have poor design because the boundary between the second and third surface protective layers is conspicuous due to the difference in gloss between the second and third surface protective layers. In addition, it is necessary to form three surface protective layers, which may increase the number of printing steps and may limit the printers that can be used. In addition, three gravure plates are required to print the surface protective layers, which may increase printing costs.

[0007] In view of the above circumstances, an object of the present invention is to provide a decorative sheet and decorative board that have a three-dimensional appearance and are excellent in design and coatability, and a method for producing the decorative sheet and decorative board. [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 a sheet base material, a picture pattern layer provided on the upper side of the sheet base material, a first surface protective layer provided on the upper side of the picture pattern layer, a thin film portion, and a thick film portion partially provided on the upper side of the thin film portion, and a second surface protective layer provided on the upper side of the first surface protective layer, wherein the thickness of the thin film portion is 20% or more and 65% or less of the thickness of the portion of the second surface protective layer where the thick film portion is provided, and the thick film portion has, in a cross section along the vertical direction, a first inclined portion provided at the boundary with the thin film portion and a second inclined portion whose inclination with respect to the plate surface direction is different from that of the first inclined portion, and the inclination of the first inclined portion is smaller than that of the second inclined portion.

[0009] In the decorative sheet, the second surface protective layer may have a gloss different from that of the first surface protective layer.

[0010] In the decorative sheet, the second surface protective layer may be partially provided on the upper side of the first surface protective layer.

[0011] In the decorative sheet, the second surface protective layer may include a particle portion made of synthetic resin beads or an inorganic compound filler and forming the thick film portion, and the particle portion may have an average particle size of 15 μm or more.

[0012] In the decorative sheet, the particle portion may include acrylic resin beads.

[0013] The decorative board of the present invention comprises any one of the decorative sheets described above and a substrate provided below the decorative sheet.

[0014] The method for manufacturing a decorative sheet of the present invention includes a picture printing step of forming a picture pattern layer on the upper side of a sheet substrate, a first surface protective layer forming step of forming a first surface protective layer on the upper side of the picture pattern layer, and a second surface protective layer forming step of forming a second surface protective layer on the upper side of the first surface protective layer, the second surface protective layer having a thin film portion and a thick film portion partially provided on the upper side of the thin film portion, wherein the second surface protective layer forming step forms the second surface protective layer so that the thickness of the thin film portion is 20% or more and 65% or less of the thickness of the portion of the second surface protective layer where the thick film portion is provided, and the second surface protective layer is formed so that, in a cross section along the vertical direction, the thick film portion has a first inclined portion provided at the boundary with the thin film portion and a second inclined portion whose inclination with respect to the plate surface direction is different from that of the first inclined portion, and the inclination of the first inclined portion is smaller than the inclination of the second inclined portion.

[0015] In the above-mentioned decorative sheet manufacturing method, the second surface protective layer forming step may form the second surface protective layer using a gravure plate, and when the plate depth of the portion of the gravure plate where the thick film portion is formed is taken as 100%, the boundary between the portion of the gravure plate where the first inclined portion is formed and the portion of the gravure plate where the second inclined portion is formed may be located at a position where the plate depth is 70% or more.

[0016] A method for producing a decorative board of the present invention includes any of the methods for producing a decorative sheet described above, and a substrate adhering step of attaching a substrate to the underside of the decorative sheet. Effect of the Invention

[0017] According to the decorative sheet and decorative board and the method for producing the decorative sheet and decorative board of the present invention, it is possible to provide a decorative sheet and decorative board that has a three-dimensional effect and is excellent in design and coatability. [Brief description of the drawings]

[0018] [Figure 1] 1 is a cross-sectional view showing a schematic diagram of a decorative board according to an embodiment of the present invention. [Diagram 2] FIG. 3 is a cross-sectional view showing a schematic diagram of a second surface protective layer in the decorative board. [Diagram 3] FIG. 2 is a cross-sectional view showing a schematic diagram of a gravure plate for printing the second surface protective layer. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] An embodiment of the present invention will be described with reference to the drawings.

[0020] FIG. 1 is a cross-sectional view that illustrates a decorative board 100 according to this embodiment. In this embodiment, as shown in FIG. 1, the thickness direction of the decorative board 100 is defined as the "vertical direction V", the side of the decorative board 100 on which the base material 20 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. In addition, the board surface direction of the decorative board 100 is defined as the "width direction C". Here, the "board surface direction (width direction C)" of the decorative board 100 refers to a direction perpendicular to the vertical direction V. For example, when the vertical direction V refers to the vertical direction, the board surface direction (width direction C) refers to the horizontal direction.

[0021] The decorative board 100 comprises a decorative sheet 10 and a substrate 20 . The substrate 20 is a layer provided on the lower side LO of the decorative board 100. Particle board, medium density fiberboard (MDF), or the like can be used as the substrate 20. Alternatively, the substrate 20 may be a metal plate-like member such as aluminum or stainless steel, or a composite plate in which a metal such as aluminum is attached to both sides of a core material made of resin such as polyethylene.

[0022] The decorative sheet 10 comprises a sheet substrate 1, a picture pattern layer 2, a first surface protective layer 3, and a second surface protective layer 4.

[0023] The sheet substrate 1 is a layer provided on the lower side LO of the decorative sheet 10. The sheet substrate 1 is a sheet-like layer made of a known material on which printing can be performed.

[0024] The sheet substrate 1 includes a first paper substrate 1a, a moisture-proof resin layer 1b, and a second paper substrate 1c. The first paper base material 1a is a layer provided on the upper side UP of the moisture-proof resin layer 1b. The second paper base material 1c is a layer provided on the lower side LO of the moisture-proof resin layer 1b. As the first paper base material 1a and the second paper base material 1c, a fibrous sheet such as tissue paper or titanium paper can be used.

[0025] The moisture-proof resin layer 1b is a layer made of moisture-proof resin that does not allow water vapor to pass through. Thermoplastic resins such as olefin resins can be used as the moisture-proof resin layer 1b. By sandwiching the moisture-proof resin layer 1b, which does not allow water vapor to pass through, between the first paper substrate 1a and the second paper substrate 1c, which are made of fibrous sheets, moisture-proof properties can be imparted to the sheet substrate 1.

[0026] The picture pattern layer 2 is a layer provided on the upper side UP of the sheet substrate 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 sheet substrate 1. As a printing method for the picture pattern layer 2, a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be used. For the picture pattern layer 2, a known printing ink suitable for the printing method to be adopted can be used.

[0027] The first surface protective layer 3 is a layer provided on the upper side UP of the picture pattern layer 2. A thermosetting resin having a urethane bond or an ionizing radiation curable resin such as an acrylic resin can be used as the first surface protective layer 3. It is preferable to use a transparent or semi-transparent material for the first surface protective layer 3 so that the picture of the picture pattern layer 2 can be seen through it.

[0028] A known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, inkjet printing, etc. can be used as a method for laminating the first surface protective layer 3. The first surface protective layer 3 may also be laminated using a known coating device.

[0029] The second surface protective layer 4 is a layer provided on the upper side UP of the first surface protective layer 3. As shown in Fig. 1, the second surface protective layer 4 is partially provided on the upper side UP of the first surface protective layer 3. A thermosetting resin having a urethane bond or an ionizing radiation curable resin such as an acrylic resin can be used as the second surface protective layer 4. It is preferable to use a transparent or semi-transparent material for the second surface protective layer 4 so that the pattern of the picture pattern layer 2 can be seen through the first surface protective layer 3.

[0030] The first surface protective layer 3 and the second surface protective layer 4 have different glosses. One method for imparting a difference in gloss between the first surface protective layer 3 and the second surface protective layer 4 is to add a matting agent to the first surface protective layer 3 or the second surface protective layer 4. For example, when a matting agent is added to the first surface protective layer 3 but not to the second surface protective layer 4, the first surface protective layer 3 has a lower gloss than the second surface protective layer 4.

[0031] Different amounts of a matting agent may be added to the first surface protective layer 3 and the second surface protective layer 4 to the extent that a difference in gloss can be imparted between the first surface protective layer 3 and the second surface protective layer 4. The difference in gloss between the first surface protective layer 3 and the second surface protective layer 4 can provide a visual three-dimensional effect by utilizing an optical illusion of the human eye.

[0032] The second surface protective layer 4 includes a particle portion 5. The particle portion 5 is made of synthetic resin beads or an inorganic compound filler, and imparts a three-dimensional feel to the second surface protective layer 4. For the particle portion 5, it is preferable to adopt a transparent or semi-transparent material that allows the pattern of the picture pattern layer 2 to be seen through the first surface protective layer 3 and the second surface protective layer 4. For the particle portion 5, it is preferable to adopt acrylic resin beads with an average particle size of 15 μm or more, which are highly transparent and can impart a three-dimensional feel to the touch.

[0033] The second surface protective layer 4 has a thin film portion 41 and a thick film portion . 2, the thin film portion 41 is a portion of the second surface protective layer 4 provided on the surface of the upper side UP of the first surface protective layer 3. The thin film portion 41 is laminated on the upper side UP of the first surface protective layer 3 with a substantially constant thickness.

[0034] The thick film portion is provided partially on the upper side UP of the thin film portion 41, and is a portion formed by the particle portion 5. That is, in the second surface protective layer 4, the particle portion 5 is disposed in the thick film portion .

[0035] In the second surface protective layer 4, the portion where the thick film portion 42 is formed is raised upward UP compared to the portion where the thin film portion 41 is formed due to the particle size of the particle portion 5. Therefore, the thickness H1 of the thin film portion 41 is smaller than the thickness H2 of the portion where the thick film portion 42 is formed in the second surface protective layer 4. Specifically, the thickness H1 of the thin film portion 41 is 20% or more and 65% or less of the thickness H2 of the portion where the thick film portion 42 is formed in the second surface protective layer 4.

[0036] In the second surface protective layer 4, the thickness differs between the portion where the thick film portion 42 is formed and the portion where the thick film portion 42 is not formed and only the thin film portion 41 is present, so that the decorative sheet 10 can give a three-dimensional feel to the touch due to the difference in partial thickness of the second surface protective layer 4.

[0037] Furthermore, by setting the thickness H1 of the thin film portion 41 to be 20% or more and 65% or less of the thickness H2 of the portion of the second surface protective layer 4 where the thick film portion 42 is formed, the second surface protective layer 4 can have a sufficient thickness difference, and the three-dimensional feeling to the touch can be more emphasized.

[0038] Further, the thick film portion 42 has, in a cross section taken along the up-down direction V, a first inclined portion 42a and a second inclined portion 42b.

[0039] 2, the first inclined portion 42a is provided at the boundary with the thin film portion 41 in the thick film portion 42 in a cross section taken along the up-down direction V. The second inclined portion 42b is a portion of the thick film portion 42 in a cross section taken along the up-down direction V that has a different inclination with respect to the width direction C (plate surface direction) from the first inclined portion 42a. The second inclined portion 42b is connected to the thin film portion 41 in the up-down direction V by the first inclined portion 42a.

[0040] 2, the first inclined portion 42a is a portion that has a smaller (gentler) inclination (slope) with respect to the width direction C than the second inclined portion 42b in a cross section along the up-down direction V. For example, when the inclination of the second inclined portion 42b with respect to the width direction C is 90°, the second inclined portion 42b extends parallel to the up-down direction V. In addition, at this time, since the inclination of the first inclined portion 42a with respect to the width direction C is smaller than that of the second inclined portion 42b, the inclination of the first inclined portion 42a with respect to the width direction C is smaller than 90°.

[0041] Here, for example, when the pattern of the picture pattern layer 2 is a wood grain pattern, the second surface protective layer 4 is disposed at a position that is in harmony with the duct portion of the wood grain pattern. In a decorative sheet having a wood grain pattern, the duct portion is generally formed to extend in one direction in the sheet surface direction of the decorative sheet. Therefore, the second surface protective layer 4 in harmony with the duct portion is formed on the upper UP surface of the first surface protective layer 3 so as to extend in one direction in the sheet surface direction.

[0042] The cross section shown in Fig. 2 is, for example, a cross section perpendicular to one direction in which the second surface protective layer 4 extends in synchronization with the conduit portion in the plate direction of the decorative sheet 10. The second surface protective layer 4 extends toward the back or front of the paper surface in Fig. 2 while substantially maintaining the shape shown in Fig. 2.

[0043] The direction in which the second surface protective layer 4 extends is not limited to one direction, and may be curved or branched, for example, in a plan view from the upper side UP. In a cross section perpendicular to the direction in which the second surface protective layer 4 extends and parallel to the up-down direction V, the thick film portion 42 has a first inclined portion 42a provided at the boundary with the thin film portion 41, and a second inclined portion 42b whose inclination with respect to the width direction C is different from that of the first inclined portion 42a, as shown in Fig. 2, and it is sufficient that the inclination of the first inclined portion 42a with respect to the width direction C is smaller than the inclination of the second inclined portion 42b.

[0044] In the second surface protective layer 4, since the thick film portion 42 has a first inclined portion 42a at the boundary between the thin film portion 41 and the thick film portion 42, the inclination with respect to the width direction C increases stepwise from the thin film portion 41 toward the face or point on the upper side UP of the thick film portion 42. That is, the thickness (height) of the second surface protective layer 4 in the up-down direction V increases stepwise.

[0045] Therefore, in the second surface protective layer 4, the difference in gloss between the thin film portion 41 and the thick film portion 42 is less noticeable. If the thick film portion does not have the first inclined portion and the thickness of the second surface protective layer changes suddenly at the boundary between the thin film portion and the thick film portion, the difference in gloss between the thin film portion and the thick film portion will be noticeable, and there is a risk of poor design. By having the thick film portion 42 have the first inclined portion 42a and gradually changing the thickness of the second surface protective layer 4 at the boundary between the thin film portion 41 and the thick film portion 42, it is possible to prevent the difference in gloss between the thin film portion 41 and the thick film portion 42 from being noticeable.

[0046] The decorative sheet 10 and decorative board 100 have a three-dimensional feel to the touch due to the difference in thickness between the thin film portion 41 and the thick film portion 42 of the second surface protective layer 4.

[0047] Furthermore, since the first surface protective layer 3 and the second surface protective layer 4 have different glosses, the decorative sheet 10 and the decorative board 100 have a visual three-dimensional appearance.

[0048] Moreover, the thin film portion 41 and the thick film portion 42 are included in the second surface protective layer 4. Furthermore, the thick film portion 42 has, in a cross section along the up-down direction V, a first inclined portion 42a and a second inclined portion 42b that have different inclinations with respect to the width direction C, and the inclination of the first inclined portion 42a provided at the boundary with the thin film portion 41 is smaller than the inclination of the second inclined portion 42b, so that the boundary between the thin film portion 41 and the thick film portion 42 is less noticeable, and the decorative sheet 10 and the decorative board 100 have excellent design properties.

[0049] Furthermore, since the three-dimensional feel due to the touch can be expressed only by the second surface protective layer 4, it is possible to suppress restrictions on the printing press and an increase in the number of gravure plates. Therefore, the decorative sheet 10 and the decorative board 100 have excellent suitability for coating.

[0050] Intaglio printing such as gravure printing can be used as a method for laminating the second surface protective layer 4. For example, in the grooves of a gravure plate used in gravure printing into which a printing resin (resin forming the second surface protective layer 4) is poured, the printing resin and the particle parts 5 flow into grooves having a depth (plate depth) greater than the particle diameter of the particle parts 5, while only the printing resin flows into grooves having a depth less than the particle diameter of the particle parts 5, without the particle parts 5 flowing into them.

[0051] As a result, the second surface protective layer 4 has a portion where the particulate portion 5 is arranged and a portion where the particulate portion 5 is not arranged. The portion where the particulate portion 5 is arranged forms a thick film portion 42, and the portion where the particulate portion 5 is not arranged forms a thin film portion 41.

[0052] Next, a description will be given of a method for producing the decorative sheet 10 and the decorative board 100 by a decorative board production system. Here, the decorative board production system is a system that executes the production of the decorative sheet 10 and the decorative board 100 according to this embodiment.

[0053] First, the decorative board manufacturing system performs a pattern printing process. In the pattern printing process, a pattern is printed on the upper side UP of the sheet base material 1 to form a pattern layer 2.

[0054] Next, the decorative board manufacturing system performs a first surface protective layer forming step. In the first surface protective layer forming step, a resin for forming the first surface protective layer 3 is printed on the upper side UP of the picture design layer 2 to form the first surface protective layer 3.

[0055] Next, the decorative board manufacturing system performs a second surface protective layer forming process. In the second surface protective layer forming process, a resin for forming the second surface protective layer 4 is printed on the upper side UP of the first surface protective layer 3 to form the second surface protective layer 4.

[0056] In the second surface protective layer forming step, the second surface protective layer 4 is formed so that the thickness H1 of the thin film portion 41 is 20% to 65% of the thickness H2 of the portion of the second surface protective layer 4 where the thick film portion 42 is provided. In this manner, the decorative sheet 10 is formed.

[0057] Here, the gravure plate for forming the second surface protective layer 4 will be described. Fig. 3 is a cross-sectional view showing a schematic diagram of a gravure plate for printing the second surface protective layer 4. Fig. 3 is a cross-sectional view showing a state in which printing resin 4R has flowed into the grooves of the gravure plate P. Here, the printing resin 4R is a resin (e.g., an acrylic resin) that forms the second surface protective layer 4. The gravure plate P into which the printing resin 4R has flowed is pressed against the surface of the upper side UP of the first surface protective layer 3, thereby forming the second surface protective layer 4.

[0058] 3 is a cross section perpendicular to the extension direction of the second surface protective layer 4 in the plate direction of the decorative sheet 10 and parallel to the up-down direction V, similar to the cross section shown in FIG.

[0059] In the example shown in Fig. 3, the upper side UP and the lower side LO in the vertical direction V correspond to the cross-sectional view shown in Fig. 1, but in general gravure printing, printing is often performed by pressing the gravure plate against the printing object from below in the vertical direction. Therefore, the upper and lower sides in the vertical direction V of the gravure plate P used in the printing process of the second surface protective layer 4 do not need to correspond to the upper side UP and the lower side LO shown in Fig. 3.

[0060] 3, a gravure plate P for printing the second surface protective layer 4 is formed with a thin film forming portion P1 and a thick film forming portion P2. Further, a first inclined forming portion P3 and a second inclined forming portion P4 are formed in the thick film forming portion P2.

[0061] The plate depth D1 of the thick film forming portion P2 is larger than the particle diameter of the particle portion 5. Therefore, the particle portion 5 flows into the thick film forming portion P2 together with the printing resin 4R, and the thick film portion 42 in the second surface protective layer 4 is formed.

[0062] Here, the "plate depth" of the gravure plate P refers to the dimension (depth) in the up-down direction V shown in FIG.

[0063] The plate depth D1 of the thick film forming portion P2 indicates the dimension in the up-down direction V from the surface of the lower side LO of the gravure plate P where no grooves are formed to the thick film forming portion P2.

[0064] Since the plate depth of the thin film forming portion P1 is smaller than the particle diameter of the particle portion 5, the particle portion 5 does not flow into the thin film forming portion P1, and only the printing resin 4R flows therein, forming the thin film portion 41.

[0065] The first inclined formation portion P3 is provided in the thick film formation portion P2 at the boundary with the thin film formation portion P1.

[0066] In the thick film forming portion P2 in the cross section along the up-down direction V, the second inclination forming portion P4 has an inclination with respect to the plate surface direction (width direction C) of the decorative sheet 10 that is different from that of the first inclination forming portion P3.

[0067] Furthermore, the inclination of the first inclined portion P3 with respect to the width direction C is smaller than the inclination of the second inclined portion P4.

[0068] Here, in the gravure plate P shown in Figure 3, when the surface of the lower side LO where no grooves are formed is defined as the part with a plate depth of 0%, the plate depth D1 of the thick film forming portion P2 indicates a plate depth in the range of 0 to 100% in the gravure plate P that forms the second surface protective layer 4.

[0069] In this way, when the plate depth of the portion forming the thick film portion 42 in the groove forming the second surface protective layer 4 is taken as 100%, the slope change portion Pb, which is the boundary between the first slope formation portion P3 and the second slope formation portion P4 and where the slope with respect to the width direction C changes in the cross section along the up-down direction V, is provided in the range of plate depth of 70 to 100% in the gravure plate P. In other words, the plate depth D3 of the slope change portion Pb is 70% or more of the plate depth D1 of the thick film formation portion P2.

[0070] Here, the plate depth D3 of the slope change portion Pb indicates the dimension in the up-down direction V from the surface of the lower side LO of the gravure plate P where no grooves are formed to the slope change portion Pb.

[0071] For example, when the plate depth D3 of the slope change portion Pb is 70% of the plate depth D1 of the thick film formation portion P2, the plate depth D2 of the remaining second slope formation portion P4 has a depth of 30% of the plate depth D1 of the thick film formation portion P2.

[0072] Here, the plate depth D2 of the second inclination forming portion P4 indicates the dimension of the second inclination forming portion P4 in the up-down direction V on the gravure plate P.

[0073] Thus, in the gravure plate P that forms the second surface protective layer 4, the boundary (slope change portion Pb) between the portion that forms the first inclined portion 42a (first inclined forming portion P3) and the portion that forms the second inclined portion 42b (second inclined forming portion P4) is located at a position (depth) of 70% or more when the plate depth D1 of the portion that forms the thick film portion 42 (thick film forming portion P2) is 100%.

[0074] When the plate depth D1 of the thick film forming portion P2 is taken as 100%, by forming the second surface protective layer 4 using a gravure plate P in which the slope change portion Pb, which is the boundary between the first slope forming portion P3 and the second slope forming portion P4, is provided at a position of 70% or more, it is possible to sufficiently secure the range occupied by the first slope portion 42a with respect to the thickness of the thick film portion 42. As a result, it is possible to further prevent the difference in gloss between the thin film portion 41 and the thick film portion 42 in the second surface protective layer 4 from becoming noticeable.

[0075] If the slope change portion is provided at a position 100% of the plate depth of the thick film forming portion, the thick film portion will be formed only by the first slope forming portion, and will have only the first slope portion without the second slope portion. In this case, the three-dimensional effect due to the touch of the second surface protective layer may be weakened.

[0076] Therefore, when the plate depth D1 of the thick film forming portion P2 in the gravure plate P is taken as 100%, it is preferable that the slope change portion Pb is provided in a range of 70% or more and less than 100%.

[0077] After forming the decorative sheet 10 by the above-mentioned second surface protective layer forming step, the decorative board manufacturing system performs a substrate bonding step. In the substrate bonding step, a substrate 20 is bonded to the lower side LO of the decorative sheet 10 to form the decorative board 100.

[0078] The substrate 20 may be bonded to the lower side LO of the decorative sheet 10 via an adhesive. Alternatively, the decorative sheet 10 and substrate 20 stacked in the vertical direction V may be sandwiched between press plates such as metal plates from the upper side UP and the lower side LO, and pressure or heat may be applied from the upper side UP and the lower side LO to bond the decorative sheet 10 and substrate 20. Methods for pressurizing or heating the decorative sheet 10 and substrate 20 include a flat pressure pressing method in contact with a metal plate and a circular pressure type continuous lamination method.

[0079] The decorative sheet 10 and decorative board 100 and the manufacturing method of the decorative sheet 10 and decorative board 100 of this embodiment include a sheet base material 1, a picture pattern layer 2 provided on the upper side UP of the sheet base material 1, a first surface protective layer 3 provided on the upper side UP of the picture pattern layer 2, and a second surface protective layer 4 provided on the upper side UP of the first surface protective layer 3. The second surface protective layer 4 has a thin film portion 41 and a thick film portion 42 partially provided on the upper side UP of the thin film portion 41, and a thickness H1 of the thin film portion is 20% to 65% of a thickness H2 of the portion of the second surface protective layer 4 where the thick film portion 42 is provided.

[0080] Furthermore, in a cross section along the vertical direction V, the thick film portion 42 has a first inclined portion 42a provided at the boundary with the thin film portion 41, and a second inclined portion 42b having an inclination relative to the plate surface direction different from that of the first inclined portion 42a, and the first inclined portion 42a has a smaller inclination relative to the plate surface direction than the second inclined portion 42b.

[0081] Therefore, the decorative sheet 10 and the decorative board 100 have a three-dimensional feel to the touch due to the difference in thickness between the thin film portion 41 and the thick film portion 42 of the second surface protective layer 4.

[0082] Furthermore, the boundaries between the thin film portions 41 and the thick film portions 42 are not easily noticeable, and the decorative sheet 10 and decorative board 100 have excellent design appeal.

[0083] Furthermore, because the three-dimensional feel of the touch can be achieved with only the second surface protective layer 4, restrictions on the printing press and an increase in the number of gravure plates required can be suppressed, and the decorative sheet 10 and decorative board 100 have excellent suitability for coating.

[0084] As a result, it is possible to provide a decorative sheet 10 and a decorative board 100 that have a three-dimensional appearance and are excellent in design and coatability, as well as a method for manufacturing the decorative sheet 10 and the decorative board 100.

[0085] Furthermore, the first surface protective layer 3 and the second surface protective layer 4 have different glosses, which allows the decorative sheet 10 and the decorative board 100 to have a visual three-dimensional appearance.

[0086] 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.

[0087] (Variation 1) In the above embodiment, the sheet substrate 1 includes the first paper substrate 1a, the moisture-proof resin layer 1b, and the second paper substrate 1c, but the form of the sheet substrate is not limited thereto. The sheet substrate may be a single-layer sheet such as a fibrous sheet or a resin sheet.

[0088] (Variation 2) In the above embodiment, the thick film portion 42 includes the first inclined portion 42a and the second inclined portion 42b that have different inclinations with respect to the width direction C in a cross section along the vertical direction V, but the aspect of the thick film portion is not limited to this. The thick film portion may include three or more inclined portions that have different inclinations with respect to the width direction in a cross section along the vertical direction.

[0089] For example, when the thick film portion has three inclined portions with different inclinations with respect to the width direction in a cross section along the vertical direction, the thick film portion has a first inclined portion, a second inclined portion, and a third inclined portion. Here, in the thick film portion, the first inclined portion is provided at the boundary with the thin film portion. Also, the second inclined portion is provided to connect the first inclined portion and the third inclined portion.

[0090] In this case, in a cross section along the up-down direction, the second inclined portion has a smaller inclination with respect to the width direction than the third inclined portion. Also, the first inclined portion has a smaller inclination with respect to the width direction than the second inclined portion. Therefore, the thickness of the second surface protective layer changes stepwise in two stages at the boundary between the thin film portion and the thick film portion, and the difference in gloss between the thin film portion and the thick film portion can be more effectively prevented from being noticeable.

[0091] The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.

[0092] Example 1 A decorative paper base paper (HPN29 manufactured by Tenma Tokushu Paper Co., Ltd.) was prepared as the sheet substrate 1. A urethane ink (PCNT manufactured by Toyo Ink Mfg. Co., Ltd.) was printed on the upper side UP of the sheet substrate 1 by gravure printing to form a picture pattern layer 2.

[0093] An acrylic resin (G125HV manufactured by DIC Graphics Corporation) was applied by a gravure method to the upper side UP of the picture pattern layer 2 to form a first surface protective layer 3. A second surface protective layer 4 was formed on the upper side UP of the first surface protective layer 3 using the same acrylic resin as that of the first surface protective layer 3.

[0094] Here, acrylic beads (AR650MX manufactured by Toyobo Co., Ltd.) having an average particle size of 15 μm or more were mixed into the printing resin forming the second surface protective layer 4 as particle portion 5 to form thin film portion 41 and thick film portion 42 in the second surface protective layer 4.

[0095] Furthermore, the thickness H1 of the thin film portion 41 was set to be 20% or more and 65% or less of the thickness H2 of the portion of the second surface protective layer 4 where the thick film portion was provided.

[0096] In addition, in a cross section along the vertical direction V, the thick film portion 42 has a first inclined portion 42a provided at the boundary with the thin film portion 41, and a second inclined portion 42b having an inclination with respect to the width direction C different from that of the first inclined portion 42a, so that the inclination of the first inclined portion 42a with respect to the width direction C is smaller than the inclination of the second inclined portion 42b.

[0097] Furthermore, in the gravure plate P that forms the second surface protective layer 4, the boundary (slope change portion Pb) between the portion that forms the first inclined portion 42a (first inclined forming portion P3) and the portion that forms the second inclined portion 42b (second inclined forming portion P4) is located at a position (depth) of 70% or more when the plate depth D1 of the portion that forms the thick film portion 42 (thick film forming portion P2) is set to 100%. In this manner, the decorative sheet 10 of Example 1 was formed.

[0098] Comparative Example 1 A decorative sheet of Comparative Example 1 was formed in the same manner as in Example 1, except that the first inclined portion was not provided in the thick film portion.

[0099] Comparative Example 2 The decorative sheet of Comparative Example 2 was formed in the same manner as in Example 1, except that the thick film portion did not have a first inclined portion, and the thickness of the thin film portion was 20% or more and 80% or less of the thickness of the portion of the second surface protective layer where the thick film portion was provided.

[0100] Comparative Example 3 The decorative sheet of Comparative Example 3 was formed in the same manner as in Example 1, except that the thick film portion did not have a first inclined portion, and the thickness of the thin film portion was 45% or less of the thickness of the portion of the second surface protective layer where the thick film portion was provided.

[0101] (Experiment 1) A tactile evaluation test was carried out on the decorative sheets of Example 1 and Comparative Examples 1 to 3. In the tactile evaluation test, a sensory test was carried out by 10 testers on the tactile feel of the decorative sheets, and the degree of the tactile feel was evaluated. The evaluation criteria were on a four-point scale, with a rating of 4 being a pass. 4: 9 or more and 10 or less people rated the texture as good. 3: 7 or more and 8 or less people rated the texture as good. 2: 1 to 6 people rated the texture as good. 1: 0 people rated the texture as good.

[0102] (Experiment 2) A design evaluation test was carried out on the decorative sheets of Example 1 and Comparative Examples 1 to 3. In the design evaluation test, 10 testers carried out a sensory test on the design of the decorative sheet, and evaluated the degree of appearance of the design. The evaluation criteria were on a four-point scale, with a rating of 4 being a pass. 4: Between 9 and 10 people rated the appearance of the design as good. 3: Between 7 and 8 people rated the appearance of the design as good. 2: Between 1 and 6 people rated the design as good in appearance. 1: 0 people rated the design as looking good.

[0103] (Experimental Results) The results of Experiment 1-2 are shown in Table 1. The decorative sheet 10 of Example 1, in which the thickness H1 of the thin film portion 41 is 20% or more and 65% or less of the thickness H2 of the portion of the second surface protective layer 4 in which the thick film portion 42 is provided, and the thick film portion 42 has a first inclined portion 42a and a second inclined portion 42b, showed good results in Experiments 1 and 2.

[0104] In comparison example 1-3, in which the thick film portion does not have a first inclined portion, similar to example 1, comparison example 1, in which the thickness of the thin film portion is 20% or more and 65% or less of the thickness of the portion of the second surface protective layer in which the thick film portion is provided, failed in experiment 2.

[0105] Moreover, Comparative Example 2, in which the thickness of the thin film portion was 20% or more and 80% or less of the thickness of the portion of the second surface protective layer in which the thick film portion was provided, failed Experiment 1.

[0106] Moreover, Comparative Example 3, in which the thickness of the thin film portion was 45% or less of the thickness of the portion of the second surface protective layer in which the thick film portion was provided, failed Experiment 2.

[0107] [Table 1] [Explanation of symbols]

[0108] 100 Veneer 10 Decorative Sheet 1 Sheet substrate 1a First paper base material 1b Moisture-proof resin layer 1c Second paper base material 2. Pattern layer 3 First surface protective layer 4 Second surface protection layer 41 Thin Film Section 42 Thick film section 42a First slope part 42b Second slope part 5 Particle section 20 Base material V vertical direction UP upper side LO Lower C Width direction (board surface direction) H1 Thin film thickness H2 Thickness of the thick film portion of the second surface protective layer P Gravure version Pb gradient change section P1 Thin film forming part P2 Thick film forming part P3 First slope forming part P4 Second slope forming part D1 Plate depth of thick film forming area D2 Plate depth of second inclined forming part D3 Plate depth of slope change area 4R Printing resin (resin that forms the second surface protective layer)

Claims

1. A sheet base material; A picture pattern layer provided on the upper side of the sheet base material; A first surface protective layer provided on the upper side of the picture pattern layer; a second surface protective layer having a thin film portion and a thick film portion partially provided on the upper side of the thin film portion and provided on the upper side of the first surface protective layer; Equipped with a thickness of the thin film portion is 20% or more and 65% or less of a thickness of a portion of the second surface protective layer where the thick film portion is provided, the thick film portion has, in a cross section along the up-down direction, a first inclined portion provided at a boundary with the thin film portion, and a second inclined portion having an inclination with respect to a plate surface direction different from that of the first inclined portion, The first inclined portion has a smaller inclination than the second inclined portion. Decorative sheet.

2. The second surface protective layer has a gloss different from that of the first surface protective layer. The decorative sheet according to claim 1 .

3. The second surface protective layer is partially provided on the upper side of the first surface protective layer. The decorative sheet according to claim 1 .

4. the second surface protective layer includes a particle portion that is made of synthetic resin beads or an inorganic compound filler and that forms the thick film portion, The particle portion has an average particle size of 15 μm or more. The decorative sheet according to claim 1 .

5. The particle portion includes acrylic resin beads. The decorative sheet according to claim 4.

6. The decorative sheet according to any one of claims 1 to 5, A substrate provided on the lower side of the decorative sheet; Equipped with Decorative panel.

7. A pattern printing process for forming a pattern layer on the upper side of the sheet substrate; a first surface protective layer forming step of forming a first surface protective layer on the upper side of the picture pattern layer; a second surface protective layer forming step of forming a second surface protective layer on the upper side of the first surface protective layer, the second surface protective layer having a thin film portion and a thick film portion partially provided on the upper side of the thin film portion; Equipped with The second surface protective layer forming step includes: forming the second surface protective layer so that the thickness of the thin film portion is 20% or more and 65% or less of the thickness of a portion of the second surface protective layer where the thick film portion is provided; In a cross section along the up-down direction, the thick film portion has a first inclined portion provided at the boundary with the thin film portion and a second inclined portion whose inclination with respect to the plate surface direction is different from that of the first inclined portion, and the second surface protection layer is formed so that the inclination of the first inclined portion is smaller than the inclination of the second inclined portion. A method for producing a decorative sheet.

8. The second surface protective layer forming step includes: forming the second surface protective layer using a gravure plate; When the plate depth of the portion of the gravure plate that forms the thick film portion is taken as 100%, a boundary between the portion of the gravure plate that forms the first inclined portion and the portion of the gravure plate that forms the second inclined portion is provided at a position where the plate depth is 70% or more. A method for producing the decorative sheet according to claim 7.

9. A method for producing a decorative sheet according to claim 7 or 8, a substrate adhering step of adhering a substrate to the underside of the decorative sheet; Equipped with A method for manufacturing decorative panels.

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