Decorative sheet and method for manufacturing decorative sheet

Abstract

To provide a method for manufacturing a decorative sheet having texture closer to a genuine material and excellent designability, and a decorative sheet.SOLUTION: A decorative sheet comprises: a pattern layer 2, a transparent thermoplastic resin layer 3 and a surface protective layer 4 which are laminated in order on one face of a colored thermoplastic resin layer 1; and a pattern part 5 for gloss / matte expression which is synchronously arranged with a pattern of the pattern layer 2 on a face on the opposite side of the transparent thermoplastic resin layer 3 of the surface protective layer 4, and is formed of a material having infrared absorption action, where an embossed part 4a is formed on a portion of the surface protective layer 4 which overlaps with the pattern part 5 for gloss / matte expression. When the surface of the surface protective layer 4 including the pattern part 5 for gloss / matte expression is irradiated with infrared ray, an area overlapping the pattern part 5 for gloss / matte expression has low infrared transmittance and higher heat absorption efficiency, which causes a large glossiness difference when embossing is performed, and a decorative sheet 10 having high gloss / matte designability can be obtained.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a cosmetic sheet and a method for manufacturing the cosmetic sheet.

Background Art

[0002] Conventionally, a cosmetic sheet has been proposed in which the design property is enhanced by expressing a gloss-matte expression. As a method for expressing the gloss-matte expression, for example, a method has been proposed in which a high-luster region composed of a lustrous ink layer and a low-luster region not formed of the lustrous ink layer are provided on the surface of one side of a substrate, thereby expressing the gloss-matte expression (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, compared with real wood, stone, etc., the surface texture of a cosmetic sheet tends to be flat. In actual wood and stone, there are differences in unevenness and texture differences from place to place due to differences in the surface material, structure, etc. In parts with different textures, the color tone is often different, but this expression is not shown in the cosmetic sheet. Furthermore, further improvement in design property is desired, and for this reason, a method for more accurately synchronizing a pattern and a gloss-matte expression is desired.

[0005] The present invention has been made in view of the above points, and an object thereof is to provide a method for manufacturing a cosmetic sheet and a cosmetic sheet having a texture closer to the real thing and excellent design property.

Means for Solving the Problems

[0006] The cosmetic sheet according to one aspect of the present invention includes a pattern layer, a transparent resin layer, and a surface protection layer laminated in order on one surface of a colored resin layer, and on the surface of the surface protection layer opposite to the transparent resin layer, there is provided a gloss-matte pattern portion made of a predetermined material that is arranged in synchronization with the pattern of the pattern layer and has higher light absorbency than the surface protection layer for light of a predetermined wavelength. An embossed portion is formed in a portion of the surface protection layer that overlaps with the gloss-matte pattern portion.

[0007] Also, a method for manufacturing a cosmetic sheet according to another aspect of the present invention includes a step of laminating a transparent resin layer and a surface protection layer, printing a pattern layer on the surface of the transparent resin layer opposite to the surface protection layer, and printing a gloss-matte pattern portion made of a predetermined material that is arranged in synchronization with the pattern of the pattern layer and has higher light absorbency than the surface protection layer for light of a predetermined wavelength on the surface of the surface protection layer opposite to the transparent resin layer, a step of forming a colored resin layer on the surface of the pattern layer opposite to the transparent resin layer, a step of irradiating the surface of the surface protection layer including the gloss-matte pattern portion with irradiation light in which the power of light of the predetermined wavelength is stronger than the power of light of other wavelengths, and a step of pressing an embossing plate against the surface of the surface protection layer including the gloss-matte pattern portion after the step of irradiating the irradiation light. The printing step is characterized in that the pattern layer and the gloss-matte pattern portion are printed using a double-sided printing machine so that the pattern of the pattern layer and the gloss-matte pattern portion are in synchronization.

Advantages of the Invention

[0008] According to one aspect of the present invention, it is possible to provide a cosmetic sheet having a texture close to that of the real thing and excellent design.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Mode for Carrying Out the Invention

[0010] Hereinafter, embodiments of the present technology will be described with reference to the drawings. 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 components being specified as follows. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

[0011] As shown in FIG. 1, the cosmetic sheet 10 is formed by laminating a pattern layer 2, a transparent thermoplastic resin layer (transparent resin layer) 3, and a surface protective layer 4 in this order on one surface of a colored thermoplastic resin layer (colored resin layer) 1. At a position on the surface of the surface protective layer 4 opposite to the transparent thermoplastic resin layer 3 and in synchronization with the pattern of the pattern layer 2, a gloss matte expression pattern portion 5 is provided. An embossed portion 4a having an uneven shape is formed in a portion where the gloss matte expression pattern portion 5 and the surface protective layer 4 overlap. Further, a primer layer 6 is provided on the surface of the colored thermoplastic resin layer 1 opposite to the pattern layer 2.

[0012] 〔Colored Thermoplastic Resin Layer〕 The colored thermoplastic resin layer 1 as the 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, etc. 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 sheeting, printability, and suitability for bending processing.

[0013] As the colored thermoplastic resin layer 1, the hue can be appropriately selected as the base color of the pattern layer 2. The colored thermoplastic resin layer 1 can be colored, for example, by mixing a colorant such as a pigment or kneading it during the sheeting of the thermoplastic resin. Alternatively, as a solid ink layer, the colored thermoplastic resin layer 1 can be provided by using a coating or printing method.

[0014] 〔Pattern layer〕 The pattern layer 2 is a printed layer with a pattern printed thereon to impart design properties to the decorative sheet 10. As a method for forming the pattern layer 2, a known printing method can be adopted. The printing method is not particularly limited, but the gravure printing method is preferable in consideration of productivity and pattern quality. Also, for example, when the colored thermoplastic resin layer 1 can be prepared in a wound state, printing for forming the pattern layer 2 can be performed by using a roll-to-roll printing device. In addition to these, examples of the printing method include the offset printing method, screen printing method, flexographic printing method, electrostatic printing method, inkjet printing method, transfer printing method from a transfer sheet, etc. When using such a printing method, the pattern of the pattern layer 2 can be formed by multicolor printing using normal process colors of yellow, red, blue, and black, and also by multicolor printing with special features prepared by preparing individual color plates constituting the pattern.

[0015] In addition, as the pattern of the pattern layer 2, any pattern may be adopted in consideration of the design property as a floor material or a fixture. For example, imagining a floor of a stone material such as marble, the grain of marble or the like can be used as the pattern. Further, 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 a spring wood region and an autumn wood region of an annual ring cross section, a conduit portion, etc., a leather (leather texture) pattern, a stone 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, flower 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] Examples of the colorant include inorganic pigments such as carbon black, iron black, titanium white (titanium oxide), antimony white, lead yellow, titanium yellow, chrome 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 2 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 adopted. In particular, it is preferably selected in consideration of the adhesion to the colored thermoplastic resin layer 1, the printability, and the weather resistance as a floor material or a fixture. The thickness of the pattern layer 2 can be appropriately adjusted in consideration of the required decorativeness of the pattern layer 2, the three-dimensional formability of the decorative sheet 10, and the like. The thickness of the pattern layer 2 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 adhesion between the pattern layer 2 and the transparent thermoplastic resin layer 3, an adhesive layer (not shown) may be provided on the surface of the pattern layer 2 that contacts the transparent thermoplastic resin layer 3. By strengthening these adhesions, the decorative sheet 10 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 2 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 luminance to the decorative sheet 10, a brilliance layer (not shown) may be provided between the pattern layer 2 and the transparent thermoplastic resin layer 3. 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 2.

[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, gold 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 types. 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, for example, when forming a bright layer using 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 the present specification, the "average particle diameter" can be obtained as the mass average value D50 in the particle size distribution measurement by the laser light diffraction method.

[0024] 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, a cured product of a thermosetting resin composition is preferred. 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 4 described later can be used.

[0025] The content of the luminescent pigment in the luminescent 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 with respect to 100 parts by mass of the binder resin. By setting the content of the luminescent pigment to 10 parts by mass or more, a sufficient gloss can be imparted, and by setting it to 90 parts by mass or less, it is possible to suppress the visibility of the pattern layer 2 described later from being impaired. From the same viewpoint, the thickness of the luminescent layer is preferably 1 μm or more and 30 μm or less, more preferably 5 μm or more and 20 μm or less.

[0026] The luminescent layer can form an arbitrary pattern according to the desired design. For example, wood grain patterns, leather patterns, stone patterns, sand patterns, tile pasting patterns, brick stacking patterns, cloth patterns, geometric figures, characters, symbols, abstract patterns, floral patterns, landscapes, characters, etc. can be mentioned. Further, any pattern preferably has shading in order to enhance the design effect more. The shading 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 density of the halftone dots forms the shading).

[0027] The luminescent layer can be formed, for example, by applying a coating solution containing a luminescent pigment and a binder resin by a general printing means such as gravure printing. When the shading of the luminescent 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.

[0028] 〔Transparent thermoplastic resin layer〕 The transparent thermoplastic resin layer 3 is a resin layer for protecting the pattern layer 2 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 10. As the material of the transparent thermoplastic resin layer 3, for example, vinyl chloride resin, acrylic resin, polyolefin resin (polypropylene resin, polyethylene resin) can be used. In particular, considering environmental compatibility, processability, and price, polyolefin resin is preferred. Also, the grade and composition of the resin can be selected in consideration of ease of seating, printability, and suitability for bending in addition to environmental compatibility, processability, and price. It is important to select the suitability for bending in consideration of no whitening or cracking occurring in the bent portion.

[0029] As a method for forming the transparent thermoplastic resin layer 3, a lamination method can be adopted. Also, for example, a method of forming the transparent thermoplastic resin layer 3 as a film and performing dry lamination using an adhesive can be adopted.

[0030] 〔Surface protection layer〕 The surface protection layer 4 is a layer for imparting surface physical properties such as abrasion resistance to the decorative sheet 10. Also, the surface protection layer 4 is also a layer for adjusting the gloss of the surface of the decorative sheet 10. The surface protection layer 4 may be a single layer or multiple layers. For example, as the surface protection layer 4, two layers of a first surface protection layer (not shown) and a second surface protection layer (not shown) can be provided in this order on the transparent thermoplastic resin layer 3. When providing the surface protection layer 4 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, heat drying device, and ionizing radiation irradiation device according to the type of curable resin.

[0031] The surface protective layer 4 is mainly composed of a curable resin. That is, it is preferable that the resin component of the surface protective layer 4 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 4 may contain, as necessary, weathering agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, and the like.

[0032] As the material of the surface protective layer 4, 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 a 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.

[0033] 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. 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. Further, 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.

[0034] In addition, 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. In addition, examples of the polyene-based prepolymer include those obtained by adding allyl alcohol to both ends of a polyurethane formed from a diol and a diisocyanate. Further, examples of the thiol-based prepolymer include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.

[0035] 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 adopted. 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 adopted. 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 adopted. 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.

[0036] Also, 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 adopted. 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 metaxylene diisocyanate.

[0037] 〔Pattern part for expressing gloss matt〕 The handle portion 5 for matte expression is formed of a material having light absorbency with respect to light of a predetermined wavelength, for example, a material having an infrared absorption effect, and is formed using a colorless and transparent or light-colored ink that is relatively transparent. As the material having an infrared absorption effect, existing materials having an infrared absorption effect such as tin-doped indium oxide (ITO), antimony-doped tin oxide (ATO), lanthanum hexaboride (LaB6), cesium-doped tungsten oxide, and phthalocyanine-based materials can be used. Since the handle portion 5 for matte expression uses a colorless and transparent or light-colored ink that is relatively transparent, the pattern of the pattern layer 2 of the portion overlapping the handle portion 5 for matte expression can be visually recognized when viewed from the surface protection layer 4 side.

[0038] The handle portion 5 for matte expression is disposed at a position synchronized with the pattern of the pattern layer 2. For example, in the case of the pattern layer 2 with a wood grain pattern, the handle portion 5 for matte expression is formed at a position overlapping the wood grain conduit groove of the pattern layer 2 in plan view. Here, the synchronization means that the handle portion 5 for matte expression and the pattern of the pattern layer 2 are formed so as to substantially coincide in plan view. The thickness of the handle portion 5 for matte expression should be such that when the embossing process described later is performed, the handle portion 5 for matte expression, the surface protection layer 4, and the transparent thermoplastic resin layer 3 can be softened to such an extent that an uneven shape can be sufficiently formed from the handle portion 5 for matte expression to the surface protection layer 4 and the transparent thermoplastic resin layer 3.

[0039] As a method for forming the pattern portion 5 for gloss matte expression, known printing techniques can be employed. However, from the perspective of synchronizing the pattern of the pattern portion 5 for gloss matte expression with the pattern of the pattern layer 2, it is preferable to perform continuous printing within a single printing machine using a double-sided printing machine capable of printing the pattern layer 2 and the pattern portion 5 for gloss matte expression on both the transparent thermoplastic resin layer 3 and the surface protection layer 4. By using such a double-sided printing machine in this way, the thermal shrinkage of the colored thermoplastic resin layer 1 can be minimized. For example, compared to the case of performing printing individually by a printing machine for printing the pattern layer 2 and a printing machine for printing the pattern portion 5 for gloss matte expression, the printing alignment of both the pattern layer 2 and the pattern portion 5 for gloss matte expression can be performed with high precision. As a result, the pattern of the pattern layer 2 and the pattern portion 5 for gloss matte expression can be synchronized with higher precision. Note that by using a sheet-fed or roll-fed double-sided printing machine as the double-sided printing machine, it can be applied in either the case of sheet paper or roll paper.

[0040] [Light of a predetermined wavelength] As described above, the pattern portion 5 for gloss matte expression is formed of a material having light absorptivity with respect to light of a predetermined wavelength. Examples of light of a predetermined wavelength include infrared rays, ultraviolet rays, visible light rays, electron beams, X-rays, ion beams, and the like.

[0041] [Embossed portion] On the surface of the surface protection layer 4, an embossed portion 4a having an uneven pattern (uneven shape) is formed in order to impart a given design property. The embossed portion 4a is formed by imparting an uneven shape from the pattern portion 5 for gloss matte expression to the surface protection layer 4 and the transparent thermoplastic resin layer 3. Examples of the uneven pattern include wood grain board conduit grooves, unevenness on the surface of a stone slab (such as a granite split surface), fabric surface texture, satin finish, sand finish, hairline, and multi-line grooves. The embossed portion 4a is provided such that its uneven pattern is synchronized with the pattern of the pattern layer 2.

[0042] As a method for forming the concavo-convex pattern, for example, embossing can be employed. The method of embossing is not particularly limited. For example, a known sheet-fed embossing machine or a rotary embossing machine can be used. In the region where the embossed portion 4a is formed, it becomes a matte region, and in the region where the embossed portion 4a is not formed, it becomes a gloss region. By the matte region and the gloss region, a gloss-matte expression can be achieved.

[0043] 〔Primer layer〕 The primer layer 6 is a layer serving as a base, and is a layer for improving the adhesion and corrosion resistance to a base material (not shown) to which the decorative sheet 10 is attached. The primer layer 6 is provided on the surface of the colored thermoplastic resin layer 1 opposite to the pattern layer 2. The primer layer 6 is formed, for example, using a polyester-based resin, an organic additive, a pigment, etc. A rust-preventive pigment may be blended into the primer layer 6 for the purpose of improving corrosion resistance. The thickness of the primer layer 6 is, for example, in the range of 1 μm or more and 10 μm or less.

[0044] 〔Manufacturing method of decorative sheet〕 Next, an example of the manufacturing method of the decorative sheet 10 according to the present embodiment will be described with reference to FIG. 2. First, a transparent thermoplastic resin layer 3 is formed. For example, using polypropylene (PP), a transparent resin film with a thickness of 80 μm is formed into a film (FIG. 2(a)). Next, a surface protection layer 4 mainly composed of an acrylic resin composition is laminated on one surface of the transparent thermoplastic resin layer 3 (FIG. 2(b)).

[0045] Subsequently, after printing the pattern layer 2 on the surface of the transparent thermoplastic resin layer 3 opposite to the surface protection layer 4 using, for example, urethane-based printing ink, a pattern portion 5 for expressing gloss-matte is printed on the surface of the surface protection layer 4 opposite to the transparent thermoplastic resin layer 3 (FIG. 2(c)). At this time, by printing the pattern layer 2 and the pattern portion 5 for expressing gloss-matte as a series of steps using a double-sided printing machine, the pattern of the pattern layer 2 and the pattern portion 5 for expressing gloss-matte can be synchronized with higher precision.

[0046] Subsequently, an adhesive resin is adhered to the surface of the pattern layer 2 on the side opposite to the transparent thermoplastic resin layer 3 of the pattern layer 2 by a urethane-based adhesive, and for example, a colored resin film as the colored thermoplastic resin layer 1 and the pattern layer 2 are laminated using a dry lamination method (Fig. 2(d)). The colored resin film is formed using, for example, polyethylene (PE) with a thickness of 55 μm.

[0047] Next, infrared irradiation is performed from the side of the surface protection layer 4 toward the surface of the surface protection layer 4 including the gloss / matte pattern portion 5 (that is, the surface on the side opposite to the transparent thermoplastic resin layer 3 of the surface protection layer 4) (Fig. 2(e)). After the infrared irradiation, an embossing plate such as an embossing roll is pressed onto the surface of the surface protection layer 4 including the gloss / matte pattern portion 5 (that is, the surface on the side opposite to the transparent thermoplastic resin layer 3 of the surface protection layer 4) (Fig. 2(f)). As a result, an embossed portion 4a is formed in the region overlapping the gloss / matte pattern portion 5 in plan view, and the decorative sheet 10 is formed.

[0048] Here, the gloss / matte pattern portion 5 is formed of a material having infrared absorption characteristics. Therefore, when infrared irradiation is performed on the surface of the surface protection layer 4 including the gloss / matte pattern portion 5, the portion of the surface protection layer 4 overlapping the gloss / matte pattern portion 5 in plan view is more likely to soften than the portion not overlapping the gloss / matte pattern portion 5. That is, in the surface protection layer 4 and the transparent thermoplastic resin layer 3 after the infrared irradiation, there are portions that are likely to soften and portions that are less likely to soften.

[0049] Therefore, when an embossing plate is pressed against the surface of the surface protection layer 4 including the gross matte pattern portion 5 in this state, unevenness is likely to be formed in the softened portion, and unevenness is less likely to be formed in the portion that is difficult to soften. That is, unevenness is likely to be formed in the softened portions of the surface protection layer 4 and the transparent thermoplastic resin layer 3, that is, the portions that overlap with the gross matte pattern portion 5 in plan view. As a result, an embossed portion 4a having an uneven shape synchronized with the gross matte pattern portion 5 is likely to be formed only at the position overlapping the gross matte pattern portion 5 of the surface protection layer 4 and the transparent thermoplastic resin layer 3 in plan view. Since the gross matte pattern portion 5 is provided at a position synchronized with the pattern of the pattern layer 2, the embossed portion 4a can be formed at a position synchronized with the pattern layer 2, that is, the embossed portion 4a synchronized with the pattern of the pattern layer 2 can be easily created without performing a highly accurate positioning operation.

[0050] 〔Effects of the Embodiment〕 (1) By pressing the embossing plate after irradiating the decorative sheet 10 with infrared rays, strong embossing can be performed on the portion overlapping the gross matte pattern portion 5 in plan view. That is, the embossed portion 4a can be easily formed at a desired position without performing high-precision positioning of the region where the embossing plate is pressed.

[0051] And since the gross matte pattern portion 5 is provided in synchronization with the pattern of the pattern layer 2, an uneven shape synchronized with the pattern of the pattern layer 2 can be formed, that is, a gross matte expression synchronized with the pattern can be easily expressed. Thereby, a decorative sheet having excellent design can be easily obtained.

[0052] (2) When viewed from the side of the surface protective layer 4, a pattern portion 5 for expressing gloss and matte is provided at a position of the surface protective layer 4 that overlaps with the pattern of the pattern layer 2, and infrared irradiation is being performed on the surface protective layer 4 including the pattern portion 5 for expressing gloss and matte. Therefore, for example, compared with the case where the pattern portion 5 for expressing gloss and matte is provided between the pattern layer 2 and the transparent thermoplastic resin layer 3 or the like, the heat absorption rate in the pattern portion 5 for expressing gloss and matte is high. As a result, even when infrared irradiation is performed under the same conditions, when the pattern portion 5 for expressing gloss and matte is provided on the surface, a clearer uneven shape is formed in the portion of the pattern portion 5 for expressing gloss and matte, and a stronger gloss and matte expression can be realized, and the gloss and matte design property can be improved. That is, a gloss and matte expression can be realized with a smaller amount of infrared irradiation.

[0053] (3) As the pattern portion 5 for expressing gloss and matte, transparent or light-colored ink is used. Therefore, even when the pattern portion 5 for expressing gloss and matte is provided on the outermost layer, it is possible to suppress the influence on the color tone of the pattern layer 2 by providing the pattern portion 5 for expressing gloss and matte.

[0054] (4) By providing an uneven shape on the decorative sheet 10 itself, a gloss and matte expression is achieved, so that it is possible to suppress the occurrence of gloss and matte pattern misregistration and the like. Therefore, for example, a synchronized gloss and matte expression can also be performed on floor materials and the like.

[0055] (5) Since the pattern layer 2 and the pattern portion 5 for expressing gloss and matte are printed in one printing machine using, for example, a double-sided printing machine, they can be synchronized with higher precision compared to the case where the pattern layer 2 and the pattern portion 5 for expressing gloss and matte are printed by separate printing machines. As a result, the gloss and matte design property can be improved.

[0056] [Modification Example] (1) In the above embodiment, a material having infrared absorption characteristics is used as the gloss matte pattern portion 5, and the case where the transparent thermoplastic resin layer 3 and the surface protective layer 4 are partially softened by performing infrared irradiation has been described, but the present invention is not limited thereto. As the material of the gloss matte pattern portion 5, a material containing an arbitrary ink composed of a component having light absorbency with respect to light having a predetermined wavelength other than infrared rays may be used, and by using a light source that irradiates the light having the predetermined wavelength instead of infrared rays, the surface protective layer 4 and the transparent thermoplastic resin layer 3 may be partially softened.

[0057] (2) Further, as shown in FIG. 3, the decorative sheet 10 according to the above embodiment may be bonded to a base material 21 which is a base material for a decorative material to form a decorative member 20. In the decorative member 20, the decorative sheet 10 may be provided on at least one surface side of the base material 21, and may be provided on both surfaces.

[0058] 〔Base material〕 As the base material 21, a wood base material or a metal base material can be used. As the wood base material, for example, a wood veneer, a plywood, a laminated wood, a particle board, a medium density fiber board, or a hard fiber board can be adopted. Further, as the metal base material, a steel plate, an aluminum plate, etc. can be adopted. Further, the base material 21 may be a resin such as plastic or a composite material thereof. That is, the base material 21 may be a resin base material. Further, the base material 21 may be, for example, a non-combustible steel plate or a non-combustible base material composed of a non-combustible material defined in the Ministry of Construction Notification No. 1400.

[0059] Thus, the decorative member 20 includes the base material 21 and the decorative sheet 10 provided on at least one surface side of the base material 21. Further, the base material 21 can be any one of a wood base material, a resin base material, a non-combustible base material, or a metal base material.

Example

[0060] The decorative sheet according to the present invention was evaluated by evaluating an evaluation sheet. The evaluation sheet was created according to the following procedure. (Example 1) As the transparent thermoplastic resin layer, a transparent resin film made of polypropylene (PP) with a thickness of 80 μm was formed into a film.

[0061] Next, on one surface of the transparent resin film, infrared-absorbing ink as a handle portion for expressing gloss and matte was solid-printed using a printing plate with image density levels. As the infrared-absorbing ink, urethane-based printing ink was used. Next, a pattern layer was printed on the other surface of the transparent resin film using urethane-based printing ink.

[0062] Next, in the transparent resin film after printing the infrared-absorbing ink and the pattern layer, a urethane-based adhesive was applied to the pattern layer, and after dry-laminating a colored resin film as a colored thermoplastic resin layer, post-embossing was performed. Specifically, a colored resin film made of polyethylene (PE) with a thickness of 55 μm was dry-laminated, then heated by an infrared heater, and then an embossing roll was pressed against the surface on the infrared-absorbing ink side to perform embossing. Thereby, the evaluation sheet of Example 1 was obtained. The embossing was performed under the conditions that the paper surface temperature was 125 °C and the nip pressure was 850 kg, and was formed by die pressing using an embossing plate with a satin finish with a plate depth of 60 μm.

[0063] (Comparative Example 1) As the transparent thermoplastic resin layer, a transparent resin film was formed into a film. Next, a pattern layer was printed on one surface of the transparent resin film, and on the printed pattern layer, infrared-absorbing ink was solid-printed using the printing plate used in the decorative sheet of Comparative Example 1. Next, in the transparent resin film after printing the infrared-absorbing ink and the pattern layer, an adhesive was applied to the surface on the infrared-absorbing ink side, and after dry-laminating a colored resin film, post-embossing was performed. Specifically, after heating the dry-laminated transparent resin film with an infrared heater, an embossing roll was pressed against the surface on the transparent resin film side to perform embossing. Thereby, the evaluation sheet of Comparative Example 1 was obtained. The composition of each layer was the same as that of each layer in Example 1.

[0064] (Comparative Example 2) As the transparent thermoplastic resin layer, a transparent resin film was formed into a film. Next, a pattern layer was printed on one surface of the transparent resin film. Next, in the transparent resin film after printing the pattern layer, an adhesive was applied to the pattern layer and a colored resin film was dry laminated. Next, on the surface of the colored resin film opposite to the pattern layer, infrared absorbing ink was solid printed using the printing plate used in Example 1.

[0065] Thereafter, post-embossing was performed. Specifically, after heating the transparent resin film on which the infrared absorbing ink was solid printed with an infrared heater, an embossing roll was pressed against the surface on the transparent resin film side to perform embossing. Thereby, an evaluation sheet for Comparative Example 2 was obtained. The configuration of each layer was made the same as the configuration of each layer in Example 1.

[0066] 〔Evaluation Method〕 〔Color Difference Measurement〕 For each evaluation sheet, the hue when in the state of performing post-embossing was measured with a color difference meter, and the color difference ΔE with respect to the standard plate was calculated. As the color difference meter, a color and color difference meter CR-400 manufactured by Konica Minolta, Inc. was used. The color difference was measured for each printing area of the infrared absorbing ink at each image density. As a reference example, the color difference was measured only for the transparent resin film as the original stock.

[0067] 〔Infrared Transmittance Measurement〕 For each evaluation sheet, the infrared transmittance at a wavelength of 2000 nm when in the state of performing post-embossing was measured. As the ultraviolet / visible spectrophotometer, a UV-3600 manufactured by Shimadzu Corporation was used. The infrared transmittance was measured for each printing area of the infrared absorbing ink at each image density. As a reference example, the infrared transmittance was measured only for the transparent resin film as the original stock.

[0068] 〔Glossiness Measurement〕 For each evaluation sheet, after the post-embossing process, glossiness was measured at a measurement angle of 85° to confirm whether the gloss-matte expression was achieved. The glossiness was measured using a micro-TRI-gloss manufactured by BYK. Also, as a reference example, the glossiness of only the transparent resin film as the original fabric was measured. Further, the difference between the glossiness of each measured evaluation sheet and the glossiness of the original fabric as the reference example was calculated as the glossiness difference.

[0069] 〔Gloss-Matte Design Character〕 The gloss-matte design character was evaluated by sensory evaluation. The evaluation criteria are as follows. ◎: It can be confirmed that the gloss-matte expression is stably achieved even considering the variations in the production of the decorative sheet. 〇: It can be confirmed that the gloss-matte expression is achieved. ×: The degree of the gloss-matte expression is weak and not visually recognizable.

[0070] 〔Evaluation Results〕 For each evaluation sheet, the measurement results and evaluation results are shown in Table 1. In addition, in Table 1, each measured value or evaluation result represents the measured value of the solid printing part. Also, as a reference example, the color difference, infrared transmittance, and glossiness were measured for a transparent resin film on which infrared-absorbing ink was not printed.

[0071]

Table 1

[0072] The color difference from the standard plate was equivalent between Example 1 and Comparative Example 1, and the color difference of Comparative Example 2 was smaller than that of Example 1. It was confirmed that there was a low possibility of affecting the color tone of the pattern layer by providing the infrared-absorbing ink. Since the infrared absorption ink is provided on the outermost layer in the evaluation sheet of Example 1, compared with Comparative Example 1 in which the infrared absorption ink is provided between the pattern layer and the transparent resin film, and Comparative Example 2 in which the infrared absorption ink is directed to the surface opposite to the pattern layer of the colored resin film, the infrared transmittance is low and the heat absorption efficiency is increased, so that a clearer embossing process can be performed, the glossiness of the printed area of the infrared absorption ink is lowered, and as a result, the glossiness difference between the area where the infrared absorption ink is not printed and the printed area of the infrared absorption ink is increased, and it was confirmed that the gloss-matte design property is enhanced.

Explanation of Signs

[0073] 1 Colored thermoplastic resin layer 2 Pattern layer 3 Transparent thermoplastic resin layer 4 Surface protection layer 4a Embossed portion 5 Gloss-matte expression pattern portion 6 Primer layer 10 Decorative sheet 20 Decorative member 21 Substrate

Claims

1. a pattern layer, a transparent resin layer, and a surface protective layer laminated in this order on one surface of the colored resin layer; A matt gloss pattern portion is disposed on the surface of the surface protective layer opposite to the transparent resin layer in synchronization with the pattern of the pattern layer, and is made of a predetermined material having a higher light absorption rate than the surface protective layer for light of a predetermined wavelength. A decorative sheet characterized in that an embossed portion is formed in the portion of the surface protective layer that overlaps with the pattern portion for expressing the gloss matte.

2. 2. The decorative sheet according to claim 1, wherein the predetermined material is colorless or light-colored.

3. laminating a transparent resin layer and a surface protective layer; a printing step of printing a pattern layer on the opposite side of the transparent resin layer from the surface protective layer, and printing a pattern portion for expressing gloss matte, which is made of a predetermined material having a higher light absorption rate than the surface protective layer for light of a predetermined wavelength, on the opposite side of the surface protective layer from the transparent resin layer in synchronization with the pattern of the pattern layer; forming a colored resin layer on the surface of the design layer opposite to the transparent resin layer; A step of irradiating a surface of the surface protection layer including the pattern portion for expressing the gloss matte with irradiation light having a power of light of the predetermined wavelength stronger than the power of light of other wavelengths; After the step of irradiating the light, a step of pressing an embossing plate onto the surface of the surface protective layer including the pattern portion for expressing the gloss matte; Equipped with A method for manufacturing a decorative sheet, characterized in that the printing process involves printing the picture layer and the pattern portion for expressing the gloss matte using a double-sided printing machine so that the picture layer and the pattern portion for expressing the gloss matte are synchronized.

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