Method for constructing decorative sheet

Abstract

To provide a method for constructing a decorative sheet capable of exhibiting a gloss matte expression even when a coating agent is applied a plurality of times and adjusting the degree of the gloss matte expression according to the number of applications.SOLUTION: When applying a coating agent on a gloss matte layer (surface protective layer 7) of a flooring material (decorative sheet 1) having the gloss matte layer as a surface protective layer 7 on the outermost surface layer, which exhibits a gloss matte expression by using embossed portions 7a and a non-embossed area 7b where the embossed portions 7a are not formed, the coating agent is overcoated by the number of times so as to achieve the target degree of the gloss matte expression.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for applying a cosmetic sheet.

Background Art

[0002] Conventionally, cosmetic sheets have been proposed that enhance the design by expressing a gloss-matte expression. As a method for expressing the gloss-matte expression, for example, a high-luster region composed of a lustrous ink layer and a low-luster region not formed by the lustrous ink layer are provided on one surface of the substrate (see, for example, Patent Document 1), or a method for expressing the gloss-matte expression has been proposed by providing unevenness on the surface of the substrate.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, when a cosmetic sheet is used as a floor material, etc., scratches or dirt may adhere to the surface of the cosmetic sheet, and there are cases where the surface needs to be painted and corrected. In addition, there are also cases where a wax coating agent is applied in advance before scratches or dirt occur. However, in the method of expressing the gloss-matte expression by forming, for example, a high-luster region and a low-luster region, or forming unevenness as described above, when a wax coating agent is applied to the entire surface of the cosmetic sheet, it is considered that the luster of the entire surface of the cosmetic sheet becomes high and the degree of the gloss-matte expression weakens. Therefore, it has been considered that the application of the wax coating agent is limited to about 1 to 2 times.

[0005] The inventors have completed the present invention by finding that a gloss-matte expression can be achieved by utilizing a region where a concavo-convex shape is formed and a region where no concavo-convex shape is formed, even when a wax coating agent is applied multiple times.

Means for Solving the Problems

[0006] A method for applying a cosmetic sheet according to an aspect of the present invention is a method for applying a cosmetic sheet having a gloss-matte layer that expresses a gloss-matte expression using a region where a concavo-convex shape is formed and a region where no concavo-convex shape is formed on the outermost layer, wherein when applying a coating agent on the gloss-matte layer, the coating agent is applied multiple times by the number of times that results in the target degree of gloss-matte expression. Here, the degree of gloss-matte expression refers to the degree of gloss difference.

Effects of the Invention

[0007] According to an aspect of the present invention, a gloss-matte expression can be achieved even when a coating agent is applied multiple times to the gloss-matte layer, and by adjusting the number of times the coating agent is applied, a gloss-matte expression of the target degree can be achieved.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Modes for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present technology will be described with reference to the drawings. In this embodiment, the case of forming a concavo-convex shape (embossed portion) using an embossing plate will be described. However, the method of forming the concavo-convex shape is not limited to this, and any method may be used as long as a gloss matte expression can be achieved by using a region where the concavo-convex shape is formed and a region where the concavo-convex shape is not formed.

[0010] Here, the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thicknesses of the respective layers, etc. are different from the actual ones. Further, the embodiments shown below are examples of configurations for embodying the technical idea of the present invention, and the technical idea of the present invention is not limited to the materials, shapes, structures, etc. of the constituent parts being the following. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

[0011] The decorative sheet 1 is formed by laminating a colored thermoplastic resin layer (colored resin layer) 2, a pattern layer 5, a transparent thermoplastic resin layer (transparent resin layer) 6, and a surface protection layer 7 in this order, for example, as shown in FIG. 1. An embossed portion (concavo-convex shape) 7a is formed in the surface protection layer 7. Further, a pattern layer 8a composed of a gloss matte expression pattern portion 3 and a primer layer 8 are formed on the surface of the colored thermoplastic resin layer 2 on the side opposite to the pattern layer 5.

[0012] 〔Colored thermoplastic resin layer〕 The colored thermoplastic resin layer 2 as a base material includes, for example, polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, ionomer, acrylic acid ester, methacrylic acid ester, and the like. Among them, polyolefin-based resins can be preferably used in terms of environmental compatibility, processability, and price. The grade and composition of the resin can be selected in consideration of other factors such as ease of seating, printability, and suitability for bending processing.

[0013] As the colored thermoplastic resin layer 2, the hue can be appropriately selected as the base color of the pattern layer 5. The colored thermoplastic resin layer 2 can be colored, for example, by mixing and kneading a coloring agent such as a pigment during the sheeting of the thermoplastic resin. Alternatively, before providing the gloss / matte pattern portion 3, a coloring layer can be provided as a betaine ink layer using a coating or printing method.

[0014] 〔Pattern layer〕 The pattern layer 5 is a printed layer on which a pattern is printed in order to impart design properties to the decorative sheet 1. As a method for forming the pattern layer 5, a known printing method can be adopted. The printing method is not particularly limited, but in consideration of productivity and pattern quality, the gravure printing method is preferable. Also, for example, when the colored thermoplastic resin layer 2 can be prepared in a wound state, printing for forming the pattern layer 5 can be performed by using a roll-to-roll printing apparatus. In addition to these, examples of the printing method include an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, an inkjet printing method, a transfer printing method from a transfer sheet, and the like. When using such a printing method, the pattern of the pattern layer 5 can be formed by multicolor printing using ordinary process colors of yellow, red, blue, and black, and can also be formed by multicolor printing with characteristics performed by preparing individual color plates constituting the pattern.

[0015] In addition, as the pattern of the pattern layer 5, any pattern may be adopted in consideration of the design property as a floor material or a fixture. For example, imaging a stone floor such as marble, the grain of marble or the like can be used as the pattern. Also, for example, in the case of a woody pattern, various wood grains and cork can be used as the pattern. Further, for example, in addition to the pattern of natural materials, artificial pattern motifs such as artificial pattern motifs and geometric patterns using these as motifs can also be used. In addition to these, examples of the pattern include a wood grain pattern composed of, for example, a spring wood region and an autumn wood region of a cross section of an annual ring, a conduit portion, etc., a leather (skin texture) pattern, a grain pattern on the surface of a stone material such as marble, granite, sandstone, etc., a sand pattern, a tile pasting pattern, a brick stacking pattern, a cloth pattern, geometric figures, characters, symbols, abstract patterns, floral patterns, landscapes, characters, etc.

[0016] The printing ink is a mixture of a solvent and solid components such as a colorant and a binder resin. Examples of the solvent include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water. The solvent may be used alone or in combination of two or more.

[0017] In addition, examples of the binder resin include chlorine-based resins, urethane resins, acrylic urethane resins, acrylic resins, polyester resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins (nitrocellulose), cellulose acetate resins, and the like. Examples of the chlorine-based resins include polyvinyl chloride-based resins such as polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, ethylene-vinyl chloride copolymer, vinyl chloride-vinyl acetate copolymer, and vinyl chloride-vinyl acetate-(meth)acrylic copolymer; and polypropylene chloride, chlorinated polypropylene, and the like. Here, (meth)acrylic means acrylic or methacrylic. The binder resin may be a single type or a combination of two or more types.

[0018] In addition, examples of the colorant include inorganic pigments such as carbon black, iron black, titanium white (titanium oxide), antimony white, lead yellow, titanium yellow, cadmium yellow, cadmium red, ultramarine blue, and cobalt blue; and organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue. The colorant may be a single type or a combination of two or more types. Here, the solvent contained in the printing ink finally volatilizes. Therefore, the pattern layer 5 is mainly formed of solid components such as a colorant and a binder resin.

[0019] In addition, the printing ink may contain, as other components, a stabilizer, a plasticizer, a catalyst, a curing agent, and the like. As the printing ink, an ink corresponding to the printing method may be employed. In particular, it is preferably selected in consideration of the adhesion to the colored thermoplastic resin layer 2, the printability, and the weather resistance as a floor material or a fixture. The thickness of the pattern layer 5 can be appropriately adjusted in consideration of the required decorativeness of the pattern layer 5, the three-dimensional moldability of the decorative sheet 1, and the like. The thickness of the pattern layer 5 is usually 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.

[0020] For the purpose of improving the adhesiveness between the pattern layer 5 and the transparent thermoplastic resin layer 6, an adhesive layer (not shown) may be provided on the surface of the pattern layer 5 that is in contact with the transparent thermoplastic resin layer 6. By strengthening these adhesions, the decorative sheet 1 can be imparted with bendability to follow curved surfaces or right-angled surfaces. The resin used for the adhesive layer (not shown) is not particularly limited. For example, a two-component curable urethane-based resin can be employed. Also, an adhesive resin may be adhered to the pattern layer 5 with a urethane-based adhesive. For the application of the resin used for the adhesive layer (not shown), for example, a coating device or a gravure printing device can be adopted.

[0021] Further, for the purpose of suitably imparting design effects such as a sense of depth and a sense of brightness to the decorative sheet 1, a brilliance layer (not shown) may be provided between the pattern layer 5 and the transparent thermoplastic resin layer 6. The brilliance layer (not shown) preferably contains a brilliance pigment and a binder resin. Examples of the brilliance pigment include pearl pigments and metal pigments. In particular, pearl pigments are preferable because they can suppress a decrease in the light transmittance of the brilliance layer and do not impair the visibility of the pattern layer 5.

[0022] A pearl pigment is a pigment that can impart a true pearl luster. For example, those in which the surface of the matrix particles is coated with a metal oxide can be mentioned. As the matrix particles, flaky particles such as mica are preferable. Examples of the metal oxide include oxides of metals such as titanium, iron, zirconium, silicon, aluminum, and cerium. The metal oxide may be used alone or in combination of two or more. Specific examples include oxide-coated mica such as mica titanium, iron oxide-coated mica, iron oxide-coated mica titanium, ultramarine-coated mica titanium, ultramarine-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; flaky foil pieces such as basic lead carbonate, lead hydrogen arsenate, and bismuth oxychloride; fish scale powder, shell pieces, and pearl pieces.

[0023] In addition, examples of the metallic pigment include metals such as aluminum, brass, stainless steel, tin, zinc, copper, nickel, bronze powder, and silver, and pigments composed of alloys of these metals. The metallic pigment may be used alone or in combination of two or more kinds.

[0024] From the viewpoint of imparting an excellent design effect, the average particle diameter of the bright pigment is preferably 40 μm or less, more preferably 30 μm or less, when forming a bright layer using, for example, gravure printing. From the same viewpoint, the ratio of [average particle diameter of bright pigment / thickness of bright layer] is preferably 0.01 or more and 15 or less, more preferably 0.5 or more and 10 or less. In this specification, the "average particle diameter" is a value that can be obtained as the mass average value D50 in the particle size distribution measurement by the laser light diffraction method.

[0025] Examples of the binder resin include thermoplastic resins and cured products of curable resin compositions, and cured products of curable resin compositions are preferred from the viewpoint of durability. Examples of the cured product of the curable resin composition include cured products of thermosetting resin compositions and cured products of radiation-curable resin compositions. From the viewpoint of interlayer adhesion, cured products of thermosetting resin compositions are preferred.

[0026] Examples of the thermosetting resin composition used for the bright layer include polyester resin compositions, epoxy resin compositions, polyurethane resin compositions, aminoalkyd resin compositions, melamine resin compositions, guanamine resin compositions, urea resin compositions, and thermosetting acrylic resin compositions. These thermosetting resin compositions include monomers and / or prepolymers constituting each resin, and curing agents added as necessary. As the radiation-curable resin composition used for the bright layer, the same composition as the radiation-curable resin composition of the surface protective layer 7 described later can be used.

[0027] The content of the phosphorescent pigment in the phosphorescent 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, based on 100 parts by mass of the binder resin. By setting the content of the phosphorescent pigment to 10 parts by mass or more, a sufficient luster can be imparted, and by setting it to 90 parts by mass or less, it is possible to suppress the impairment of the visibility of the pattern layer described later. From the same viewpoint, the thickness of the phosphorescent layer is preferably 1 μm or more and 30 μm or less, more preferably 5 μm or more and 20 μm or less.

[0028] The phosphorescent layer can form an arbitrary pattern according to the design to be imparted. For example, wood grain patterns, leather patterns, stone patterns, sand patterns, tile pasted patterns, brick stacked patterns, cloth patterns, geometric figures, characters, symbols, abstract patterns, flower patterns, landscapes, characters, etc. can be mentioned. Further, in order to enhance the design effect, it is preferable that the arbitrary pattern has gradation. The gradation may be formed from the size and thickness of the halftone dots, but it is preferable to form it from the coarseness and fineness of the halftone dots (that is, the size of the halftone dots is uniform and the gradation is formed by the density of the halftone dots).

[0029] The phosphorescent layer can be formed, for example, by applying a coating solution containing a phosphorescent pigment and a binder resin by a general printing means such as gravure printing. When the gradation of the phosphorescent layer is formed from the coarseness and fineness of the halftone dots, the halftone dots of the printing plate may be formed by an FM (frequency modulation) screen.

[0030] 〔Transparent thermoplastic resin layer〕 The transparent thermoplastic resin layer 6 is a resin layer for protecting the pattern layer 5 and imparting good surface physical properties so as to give a thickness and depth in terms of design and improve the weather resistance and abrasion resistance of the decorative sheet 1. As the material of the transparent thermoplastic resin layer 6, for example, vinyl chloride resin, acrylic resin, polyolefin-based resins (polypropylene resin, polyethylene resin) can be used. In particular, considering environmental compatibility, processability, and price, polyolefin-based resins are preferred. Also, the grade and composition of the resin can be selected in consideration of environmental compatibility, processability, price, ease of sheeting, printability, and suitability for bending processing in addition to these. It is important to select the suitability for bending processing in consideration of no whitening or cracking occurring in the bent portion.

[0031] As a method for forming the transparent thermoplastic resin layer 6, a lamination technique can be adopted. Also, for example, when the transparent thermoplastic resin layer 6 and an adhesive layer (not shown) are formed simultaneously, a method of simultaneously extruding and forming both by coextrusion can be adopted.

[0032] 〔Surface protection layer〕 The surface protection layer 7 is a layer for imparting surface physical properties such as abrasion resistance to the decorative sheet 1. Also, the surface protection layer 7 is also a layer for adjusting the gloss of the surface of the decorative sheet 1. The surface protection layer 7 may be a single layer or multiple layers. For example, as the surface protection layer 7, two layers of a first surface protection layer (not shown) and a second surface protection layer (not shown) can also be provided in this order on the transparent thermoplastic resin layer 6. When providing the surface protection layer 7 composed of the first surface protection layer (not shown) and the second surface protection layer (not shown), each layer can be applied and the coating film can be cured using a known coating device, hot drying device, and ionizing radiation irradiation device according to the type of curable resin.

[0033] The surface protective layer 7 is mainly composed of a curable resin. That is, it is preferable that the resin component of the surface protective layer 7 is substantially composed of a curable resin. Substantially means, for example, 80 parts by mass or more when the total resin is 100 parts by mass. The surface protective layer 7 may contain, as necessary, weathering agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, and the like.

[0034] As the material of the surface protective layer 7, for example, an ionizing radiation curable resin or a two-component curable urethane resin can be adopted. The ionizing radiation curable resin is not particularly limited. For example, a transparent resin mainly composed of a prepolymer (including oligomers) and / or monomer containing a radically polymerizable double bond capable of undergoing a polymerization crosslinking reaction by irradiation with ionizing radiation such as infrared rays, ultraviolet rays, and electron beams can be adopted. These prepolymers or monomers can be used alone or in combination of a plurality. Specifically, examples of the prepolymer or monomer include compounds having a radically polymerizable unsaturated group such as a (meth)acryloyl group and a (meth)acryloyloxy group, and a cationically polymerizable functional group such as an epoxy group in the molecule. Also, a polyene / thiol-based prepolymer formed by a combination of a polyene and a polythiol is also preferable. Here, the (meth)acryloyl group means an acryloyl group or a methacryloyl group.

[0035] Examples of the prepolymer having a radically polymerizable unsaturated group include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, silicone (meth)acrylate, and the like. The molecular weight of these is preferably about 250 to 100,000.

[0036] In addition, examples of the monomer having a radically polymerizable unsaturated group include, as monofunctional monomers, methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, phenoxyethyl (meth)acrylate, and the like. Examples of the polyfunctional monomers include 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, dipentaerythritol hexa(meth)acrylate, and the like.

[0037] Examples of the prepolymer having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol type epoxy resins and novolak type epoxy compounds, and vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. Examples of the polyene-based prepolymer include those obtained by adding allyl alcohol to both ends of a polyurethane made of a diol and a diisocyanate. Examples of the thiol-based prepolymer include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.

[0038] As the ionizing radiation, for example, electromagnetic waves or charged particles having energy capable of causing a curing reaction of molecules in an ionizing radiation-curable resin (composition) can be employed. Examples of the curing reaction include a crosslinking curing reaction. As the ultraviolet light source, for example, light sources such as a super-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, and a metal halide lamp can be employed. As the wavelength of the ultraviolet light, for example, 190 nm or more and 380 nm or less is preferable. As the electron beam source, for example, electron beam accelerators such as a Cockcroft-Walton type, a Van de Graaff type, a resonant transformer type, an insulated core transformer type, a linear type, a dynatron type, and a high frequency type can be employed. In particular, those capable of irradiating electrons having an energy of 100 keV or more and 1000 keV or less (more preferably electrons having an energy of 100 keV or more and 300 keV or less) are preferable.

[0039] Further, the two-component curable urethane resin is not particularly limited. For example, those containing a polyol component having an OH group as the main agent and an isocyanate component as the curing agent component can be employed. Examples of the polyol component having an OH group include acrylic polyol, polyester polyol, polyether polyol, and epoxy polyol. Examples of the isocyanate component include tolylene diisocyanate, hexamethylene diisocyanate, and metaxylylene diisocyanate.

[0040] 〔Embossed portion〕 On the surface of the surface protection layer 7, an embossed portion 7a formed of a concavo-convex pattern is formed in order to impart a given design property. Examples of the concavo-convex pattern include a wood grain plate conduit groove, a stone slab surface concavo-convexity (such as a granite split surface), a cloth surface texture, a satin finish, a grained finish, a hairline, and a multi-line groove. This embossed portion 7a is provided such that the concavo-convex pattern thereof is synchronized with the pattern of the pattern layer 5.

[0041] As a method for forming the concavo-convex pattern, for example, embossing can be adopted. The method of embossing is not particularly limited. For example, a known sheet-fed embossing machine or a rotary embossing machine can be adopted. In the region where the embossed portion 7a is formed, it becomes a matte region, and in the region where the embossed portion 7a is not formed, it becomes a gloss region. With the matte region and the gloss region, a gloss-matte expression can be achieved.

[0042] 〔Pattern portion for expressing gloss-matte〕 The pattern portion 3 for expressing gloss-matte is formed of a material having light absorbency with respect to light of a predetermined wavelength, and is formed of, for example, a material having an infrared absorption effect. The pattern portion 3 for expressing gloss-matte is formed of a material containing ink containing carbon black, and is formed of, for example, urethane-based printing ink. The pattern portion 3 for expressing gloss-matte is arranged at a position that synchronizes with the pattern of the pattern layer 5. For example, in the case of the pattern layer 5 having a wood grain pattern, the pattern portion 3 for expressing gloss-matte is formed at a position overlapping the wood grain board conduit groove of the pattern layer 5 in plan view. Here, the synchronization means that the pattern portion 3 for expressing gloss-matte and the pattern of the pattern layer 5 are formed to coincide with each other in plan view.

[0043] The thickness of the pattern portion 3 for expressing gloss-matte may be such that the transparent thermoplastic resin layer 6 and the surface protective layer 7 can be softened to a degree that the concavo-convex shape can be sufficiently formed on the surface protective layer 7 during the embossing process described later. Also, in order to achieve a sufficient gloss-matte expression, it is preferable that the difference in glossiness between the portion where the pattern portion 3 for expressing gloss-matte is formed and the portion where it is not formed is 5 or more in plan view, that is, the image density level of the pattern portion 3 for expressing gloss-matte is preferably 60% or more.

[0044] Note that the pattern portion 3 for expressing gloss-matte is not limited to a material containing ink, and a material containing any ink composed of a component having light absorbency with respect to light of a predetermined wavelength may be used. In this case, instead of the infrared irradiation described later, the transparent thermoplastic resin layer 6 and the surface protective layer 7 may be partially softened by irradiating the light of the predetermined wavelength.

[0045] [Light of a predetermined wavelength] As described above, the handle portion 3 for expressing the gloss matte is formed of a material having light absorptivity with respect to light of a predetermined wavelength. Examples of the light of a predetermined wavelength include infrared rays, ultraviolet rays, visible rays, electron beams, X-rays, ion beams, and the like.

[0046] [Pattern layer] The pattern layer 8a is formed on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5. The pattern layer 8a is composed of only the handle portion 3 for expressing the gloss matte formed of a material having light absorptivity with respect to infrared rays, for example. [Primer layer] The primer layer 8 is a base layer, and is a layer for improving the adhesion and corrosion resistance to a base material (not shown) to which the decorative sheet 1 is attached. The primer layer 8 is provided on the side of the pattern layer 8a opposite to the colored thermoplastic resin layer 2.

[0047] The primer layer 8 is formed using, for example, a polyester resin, an organic additive, a pigment, and the like. A rust preventive pigment may be blended in the primer layer 8 for the purpose of improving the corrosion resistance. The thickness of the primer layer 8 is, for example, in the range of 1 μm or more and 10 μm or less.

[0048] [Method for manufacturing a decorative sheet] Next, an example of the method for manufacturing the decorative sheet according to the present embodiment will be described with reference to FIG. 2. First, the colored thermoplastic resin layer 2 is formed. For example, it is formed using PBT (polybutylene terephthalate resin) with a thickness of, for example, 50 μm (FIG. 2(a)). Next, the pattern layer 5 is printed on the colored thermoplastic resin layer 2 using, for example, urethane-based printing ink, and further, PP (polypropylene) with a thickness of, for example, 38 μm is laminated as the transparent thermoplastic resin layer 6 on the pattern layer 5. Then, a surface protection layer 7 mainly composed of an acrylic resin composition is laminated on the transparent thermoplastic resin layer 6.

[0049] Next, a pattern layer 8a is formed by forming a pattern portion 3 for expressing gloss and matte on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5. For example, using a urethane-based ink containing carbon black, the pattern portion 3 for expressing gloss and matte is formed at a predetermined position in synchronization with the pattern of the pattern layer 5 (Fig. 2(b)). Next, a primer layer 8 made of, for example, a polyester resin is laminated on the colored thermoplastic resin layer 2 including the pattern portion 3 for expressing gloss and matte so as to fill the gaps between the pattern portions 3 for expressing gloss and matte and cover the upper surface thereof.

[0050] Subsequently, infrared rays are used as irradiation light in which the power of light of a predetermined wavelength is stronger than the power of light of other wavelengths, and the entire laminate in which the above-described layers are laminated is irradiated with infrared rays (Fig. 2(d)). Immediately after the infrared ray irradiation, an embossing plate such as an embossing roll is pressed against the surface of the surface protective layer 7 (Fig. 2(e)). Thereby, an embossed portion 7a is formed, and the decorative sheet 1 is formed.

[0051] Here, the pattern portion 3 for expressing gloss and matte is formed of an ink having infrared absorption characteristics. Therefore, when the laminate is irradiated with infrared rays, the portion of the surface protective layer 7 that overlaps the pattern portion 3 for expressing gloss and matte in plan view is more likely to soften the transparent thermoplastic resin layer 6 and the surface protective layer 7 than the portion that does not overlap the pattern portion 3 for expressing gloss and matte. That is, in the transparent thermoplastic resin layer 6 and the surface protective layer 7 after the infrared ray irradiation, there are portions that are easily softened and portions that are hardly softened. Therefore, when an embossing plate is pressed against the transparent thermoplastic resin layer 6 and the surface protective layer 7 in this state, unevenness is easily formed in the softened portion, and unevenness is hardly formed in the portion that is hardly softened. That is, unevenness is easily formed in the softened portion of the transparent thermoplastic resin layer 6 and the surface protective layer 7, that is, the portion that overlaps the pattern portion 3 for expressing gloss and matte in plan view. As a result, it becomes easy to form an embossed portion 7a having an uneven shape synchronized with the pattern portion 3 for expressing gloss and matte only at the position where the transparent thermoplastic resin layer 6 and the surface protective layer 7 overlap the pattern portion 3 for expressing gloss and matte in plan view.

[0052] As a result, the embossed portion 7a can be formed at a position synchronized with the pattern layer 5, that is, the embossed portion 7a synchronized with the pattern layer 5 can be easily created without performing a highly accurate positioning operation.

[0053] Note that the timing of pressing the embossing plate against the transparent thermoplastic resin layer 6 and the surface protection layer 7 after performing the infrared irradiation is not limited to immediately after the infrared irradiation. As long as it is the timing at which the uneven shape can be selectively formed on the portion softened by the infrared irradiation by pressing the embossing plate against the surfaces of the transparent thermoplastic resin layer 6 and the surface protection layer 7, it is acceptable.

[0054] Also, other processes may be included between the process of creating the surface protection layer 7 and the process of performing the infrared irradiation. The key is that the infrared irradiation may be performed in a state where the transparent thermoplastic resin layer 6 and the surface protection layer 7 are formed.

[0055] 〔Features of the decorative sheet〕 (1) After performing infrared irradiation on the laminate in which each layer of the decorative sheet 1 is laminated, by pressing an embossing plate, in a plan view, strong embossing can be performed on the portion overlapping with the gloss matte appearance pattern portion 3. That is, even if the positioning of the area where the embossing plate is pressed is not performed with high accuracy, the embossed portion can be easily formed at a desired position. As a result, a decorative sheet having excellent design can be easily obtained.

[0056] (2) Since the handle part 3 for expressing gloss and matte is provided under the colored thermoplastic resin layer 2, when the decorative sheet 1 is viewed from the surface protection layer 7 side, the visibility of the handle part 3 for expressing gloss and matte is reduced. As a result, although an ink having high infrared absorption characteristics and high image density is used for the handle part 3 for expressing gloss and matte, it is possible to suppress the handle part 3 for expressing gloss and matte from being visually recognized when the decorative sheet 1 is viewed from the surface protection layer 7 side. For this reason, even if a dark pattern is not used for the pattern layer 5, it is possible to suppress the handle part 3 for expressing gloss and matte containing the ink from being visually recognized. As a result, it is also possible to adopt a light-colored pattern for the pattern layer 5, and it is possible to suppress the restriction on the pattern expression by the pattern layer 5 caused by providing the handle part 3 for expressing gloss and matte.

[0057] Further, on the pattern layer 8a composed of the handle part 3 for expressing gloss and matte using an ink having high infrared absorption characteristics and high ink image density, the colored thermoplastic resin layer 2 and the pattern layer 5, and further, the transparent thermoplastic resin layer 6 and the surface protection layer 7 are laminated, and an embossed part 7a is formed at a position overlapping the handle part 3 for expressing gloss and matte in a plan view of the surface protection layer 7. Therefore, the visibility of the handle part 3 for expressing gloss and matte using the ink can be reduced, and the influence of the useful handle part 3 for expressing gloss and matte on the appearance of the decorative sheet 1 during the manufacturing process of the decorative sheet 1 can be suppressed, and a decorative sheet 1 with high design quality in which the pattern of the pattern layer 5 and the embossed part 7a are synchronized can be obtained.

[0058] (3) Since the handle part 3 for expressing gloss and matte is provided in synchronization with the pattern of the pattern layer 5, it is possible to form concavo-convex parts synchronized with the pattern of the pattern layer 5, that is, it is possible to easily express a gloss and matte expression synchronized with the pattern.

[0059] (4) Since the surface protection layer 7 itself is provided with unevenness to express a gloss and matte expression, it is possible to suppress the occurrence of gloss and matte pattern peeling and the like. Therefore, for example, a synchronized gloss and matte expression can also be performed on a floor material or the like.

[0060] 〔Method for installing decorative sheet〕 Here, the case where the cosmetic sheet 1 is used as a floor material and a wax coating agent is applied as a coating agent to the entire floor material will be described.

[0061] The cosmetic sheet 1 has an embossed portion 7a formed on the surface protective layer 7, and there are an embossed portion 7a and a region where the embossed portion 7a is not formed (hereinafter also referred to as a non-embossed region) 7b. Therefore, a gloss matte expression is exhibited on the floor material. From this state, the first application of the wax coating agent is performed on the entire floor material. After the wax coating agent is sufficiently dried, the degree of the glossiness difference of the gloss matte expression is confirmed. When it is desired to increase the glossiness difference, the second wax application is performed to apply the wax coating agent in multiple layers.

[0062] This operation is repeated, and the wax coating agent is repeatedly applied in multiple layers until the degree of the gloss matte expression of the entire floor material reaches the target degree of the gloss matte expression.

[0063] Here, each time the multiple-layer application is performed, the glossiness of the embossed portion 7a and the non-embossed region 7b increases. At this time, the embossed portion 7a is an uneven region, and the wax coating agent is applied along the uneven shape. However, as the number of times of the multiple-layer application increases, the glossiness of the non-embossed region increases, while the rate of increase in the glossiness of the embossed portion 7a is smaller than the rate of increase in the non-embossed region 7b. Therefore, as the number of times of the multiple-layer application increases, the glossiness difference between the embossed portion 7a and the non-embossed region 7b becomes larger, that is, the degree of the gloss matte expression becomes stronger. That is, each time the multiple-layer application is repeated, the degree of the gloss matte expression becomes stronger. Therefore, the degree of the gloss matte expression can be adjusted according to the number of times of the multiple-layer application.

[0064] Here, the case where a wax coating agent (main components are acrylic and urethane) is used as the coating agent has been described, but it is not limited to this. For example, a UV coating agent (main component is urethane acrylate), a glass coating agent (main component is silicon), a silicon coating agent, or an aqueous urethane coating agent (main component is aqueous two-component urethane) can also be applied as the coating agent, and it is also possible to use a coating agent mainly composed of an acrylic resin, a urethane resin, or water. When these are used as the coating agent, the greater the number of overcoats, the greater the gloss difference can be made, and by adjusting the number of overcoats, the degree of expression of the gloss-matte appearance can be adjusted.

[0065] Note that the operation of checking the degree of the gloss-matte appearance after applying the coating agent may be performed each time the operation of applying the coating agent once is carried out, or may be performed each time the operation of applying the coating agent multiple times is carried out.

[0066] Also, although the case of performing overcoating while checking the degree of the gloss-matte appearance has been described, it is not limited to this. For the decorative sheet to be constructed in advance, the degree of the gloss-matte appearance obtained for each number of overcoats may be detected, and the number of overcoats may be determined according to the degree of the gloss-matte appearance required for the decorative sheet at the construction site. In that case, while checking the actual degree of the gloss-matte appearance based on the determined number of overcoats as a guide, overcoating may be performed.

[0067] 〔Effect〕 The decorative sheet 1 expresses a gloss-matte appearance by forming the embossed portion 7a. Therefore, even if a coating agent is applied to the outermost layer of the decorative sheet 1, the uneven shape of the embossed portion 7a can be maintained, and a gloss-matte appearance can be expressed.

[0068] In addition, each time the coating agent is applied in multiple layers, the glossiness of the decorative sheet 1 and the glossiness difference between the embossed portion 7a and the non-embossed region 7b increase. Therefore, by adjusting the number of times of applying in multiple layers, the glossiness of the floor material and the degree of the gloss-matte expression can be easily adjusted. That is, by adjusting the number of times of applying in multiple layers, a plurality of types of decorative sheets with different degrees of gloss-matte expression can be obtained from a single decorative sheet. Therefore, the degree of the gloss-matte expression can be adjusted in more stages.

[0069] Here, the case where the decorative sheet 1 is used as the floor material has been described, but it is not limited to the case of being used as the floor material, and it can also be applied to the case where the coating agent is applied to the surface of the decorative sheet 1 for use.

Example

[0070] Hereinafter, examples and comparative examples of the construction method of the floor material according to the present invention will be described. Note that the present invention is not limited to the following examples.

[0071] 〔Creation of scale plate〕 (Example) A decorative sheet to be evaluated as an example was created as a scale plate. Specifically, first, as the base material, that is, the colored thermoplastic resin layer 2, a polybutylene terephthalate resin with a thickness of 50 μm was used, and the gloss-matte expression pattern portion 3 was printed on the back surface of the colored thermoplastic resin layer 2. For this gloss-matte expression pattern portion 3, a printing plate with a shaken image density level was used, and the ink was solid-printed on the back surface of the colored thermoplastic resin layer 2. The ink image density was set to six types: 0%, 20%, 40%, 60%, 80%, and 90%. As a result, on the back surface of the colored thermoplastic resin layer 2, printing regions of the gloss-matte expression pattern portion 3 with ink image densities of 0%, 20%, 40%, 60%, 80%, and 90% were respectively formed.

[0072] After laminating PP (polypropylene) with a thickness of 38 μm as the transparent thermoplastic resin layer 6 on the surface of the printing original negative (colored thermoplastic resin layer 2 printed with ink), post-embossing was performed. That is, the sheet laminated with the transparent thermoplastic resin layer 6 was heated by an infrared heater, and then an embossing roll was pressed against it to create the embossed portion 7a. At this time, the paper surface temperature was 135 °C, the nip pressure was 850 kg, and embossing was performed to form a matte pattern with an embossing depth of 60 μm.

[0073] From the embossed decorative sheet formed in this way, a scale plate with a size of 300 mm × 300 mm was cut out, and this was used as a test decorative sheet for the scale plate. A coating agent was applied to the surface layer (the embossed surface) of the cut-out scale plate. At this time, the coating agent was applied up to a maximum of 5 times. As the coating agent, a wax coating agent was applied.

[0074] 〔Evaluation method〕 〔Status of gloss matte appearance〕 Each time the coating agent was applied, after drying the coating agent, the gloss matte design property of the scale plate was visually confirmed. The coating agent was applied up to a maximum of 5 times.

[0075] ◎: It can be confirmed visually that the gloss matte expression is present, and it can be confirmed that the gloss matte is stably present. 〇: The degree of gloss matte expression is weak, but it can be visually recognized. ×: The degree of gloss matte expression is weak and not visually recognizable

[0076] 〔Glossiness measurement〕 For the scale plate, glossiness measurement was performed at a measurement angle of 85° to check whether the gloss-matte expression was exhibited. Specifically, the gloss value at the position where the ink image density was 0% and the gloss value at the position where the ink image density was 90% were measured, and the difference value between them was obtained. The glossiness measurement was carried out using a micro-tri-gloss glossmeter (manufactured by Big Chemistry Japan Co., Ltd.).

[0077] [Measurement of Coating Amount of Coating Agent] The coating amount (g / m 2 ) of the coating agent was calculated from the weight change of the test cosmetic sheet before and after coating. At that time, the coating amount before the applied coating agent dried and the coating amount after drying were calculated.

[0078] [Evaluation Results] For the scale plate, the coating amount of the coating agent before and after drying and the expression status of the gloss-matte expression at each coating time are shown in Table 1.

[0079] [Table 1]

[0080] As shown in Table 1, by repeating the overcoating, the coating amount increases as the number of repetitions increases, but the design property of the gloss-matte expression is not impaired. Also, for the scale plate, the gloss value at the position where the ink image density was 0% and the gloss value at the position where the ink image density was 90% were measured and the difference between them was obtained. The correspondence with the coating amount (after drying) at that time is shown in Table 2.

[0081] [Table 2]

[0082] As shown in Table 2, when the number of coating applications is increased, the coating amount on the scale plate increases with each coating application. Accordingly, the gloss value at the position where the ink image density is 0% and the gloss value at the position where the ink image density is 90% each increase. However, the increase in the gloss value at the position where the ink image density is 90% is smaller than the increase in the gloss value at the position where the ink image density is 0%. As a result, it was confirmed that the difference between these gloss values becomes larger as the number of overcoating applications increases. That is, as the number of overcoating applications increases, the gloss value of the entire scale plate increases, but a gloss-matte expression is exhibited, and the degree of the gloss-matte expression becomes stronger. That is, even when the number of coating applications is increased, a gloss-matte expression can be exhibited, and furthermore, it was confirmed that the degree of the gloss-matte expression becomes stronger as the number of coating applications increases.

[0083] (Comparative Example) As a comparative example, for a decorative sheet (Fapex: manufactured by Toppan Printing Co., Ltd.) having a gloss-matte coat layer that exhibits a gloss-matte expression by providing a high-gloss region and a low-gloss region on the outermost layer, a wax coating agent was repeatedly applied on the gloss-matte coat layer, and the gloss-matte design property was visually evaluated. The evaluation criteria are the same as those in the examples. Table 3 shows the coating amount of the coating agent before and after drying and the state of expression of the gloss-matte expression at each number of coating applications.

[0084]

Table 3

[0085] As shown in Table 3, when the wax coating agent was applied for the first time, a gloss-matte expression could not be confirmed. At this time, the coating amount of the wax coating agent before drying was 12.3 g / m 2 which is less than the coating amount of 14.1 g / m when the wax coating agent was applied for the first time as an example as shown in Table 1, and a gloss-matte expression was not exhibited in the first overcoating. 2

[0086] Incidentally, the present invention can have, for example, the following configurations. (1) A method for applying a decorative sheet having a gloss matte layer that exhibits a gloss matte expression using a region with an uneven shape and a region without the uneven shape on the outermost layer, when applying a coating agent on the gloss matte layer, the coating agent is applied in multiple layers the number of times that results in the target degree of gloss matte expression. A method for applying a decorative sheet, characterized by this. (2) The method for applying a decorative sheet according to (1) above, characterized in that as the target degree of gloss matte expression is stronger, the number of times the coating agent is applied in multiple layers is increased to increase the glossiness difference of the gloss matte layer. (3) The operation of applying the coating agent once or multiple times and the operation of confirming the degree of gloss matte expression are repeated, When the target degree of gloss matte expression is reached, the application of the coating agent is terminated. A method for applying a decorative sheet according to (1) or (2) above, characterized by this. (4) The uneven shape is a satin pattern. A method for applying a decorative sheet according to any one of (1) to (3) above, characterized by this. (5) The coating agent is a wax coating agent. A method for applying a decorative sheet according to any one of (1) to (3) above, characterized by this. (6) The decorative sheet has the uneven shape that matches the pattern of the pattern layer on the surface protective layer, On one surface of the colored resin layer, the pattern layer, the transparent resin layer, and the surface protection layer are laminated in this order. On the other surface of the colored resin layer, a pattern layer that synchronizes with the pattern is formed using a predetermined material having light absorptivity with respect to light of a predetermined wavelength rather than the colored resin layer. After irradiating with irradiation light in which the power of the light of the predetermined wavelength is stronger than the power of the light of other wavelengths, the embossing die for forming the uneven shape is embossed on the surface protection layer, whereby the uneven shape is formed. The method for applying the decorative sheet according to any one of the above (1) to (5).

Explanation of symbols

[0087] 1 Decorative sheet 2 Colored thermoplastic resin layer 3 Glossy matte pattern part 5 Pattern layer 6 Transparent thermoplastic resin layer 7 Surface protection layer 7a Embossed part 7b Non-embossed area 8 Primer layer 8a Pattern layer

Claims

1. A method for applying a decorative sheet having a gloss matte layer on the outermost layer, which expresses a gloss matte appearance by utilizing an area where a concave-convex shape is formed and an area where the concave-convex shape is not formed, The decorative sheet application method is characterized in that, when applying a coating agent onto the gloss matte layer, the coating agent is applied in multiple coats the number of times required to achieve a desired degree of gloss matte expression.

2. The decorative sheet application method according to claim 1, characterized in that the stronger the desired degree of gloss matte expression, the more times the coating agent is reapplied to increase the gloss difference of the gloss matte layer.

3. Repeat the operation of applying the coating agent once or a plurality of times and the operation of confirming the degree of the gloss / matt expression, 3. The decorative sheet application method according to claim 1, further comprising the step of: terminating application of said coating agent when said desired degree of gloss / matt expression is reached.

4. 3. The decorative sheet application method according to claim 1, wherein the uneven shape is a matte pattern.

5. 3. The decorative sheet application method according to claim 1, wherein the coating agent is a wax coating agent.

6. The decorative sheet has a surface protective layer having the uneven shape that is in harmony with a pattern on a pattern layer, 3. A method for applying a decorative sheet as described in claim 1 or claim 2, characterized in that the pattern layer, transparent resin layer and surface protective layer are laminated in this order on one side of a colored resin layer, a pattern layer that is in tune with the pattern is formed on the other side of the colored resin layer using a specified material that has greater light absorption for light of a specified wavelength than the colored resin layer, and after irradiating the surface protective layer with light having a power of the specified wavelength that is stronger than the power of light of other wavelengths, an embossing plate for forming the uneven shape is pressed onto the surface protective layer to form the uneven shape.

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