Decorative sheet and method for producing decorative sheet

Abstract

To provide a decorative sheet having excellent designability and a method for producing a decorative sheet.SOLUTION: There is provided a decorative sheet which exhibits a gloss matte expression by using embossed portions 7a and an area where the embossed portions 7a are not formed and is formed so that the difference value ΔGM(Sa) between the arithmetic mean heights Sa of each of an area where the embossed portions 7a are formed and a non-embossed area 7b which is an area where the embossed portions 7a are not formed of a surface protective layer 7 satisfies the expression, ΔGM(Sa)≥1.6 and the difference value ΔGM(Sz) of each maximum height Sz satisfies the expression, ΔGM(Sz)≥5.4, the decorative sheet can exhibit a gloss matte expression and have excellent designability.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, cosmetic sheets have been proposed that enhance the design property by expressing a gloss-matte expression. As a method for expressing the gloss-matte expression, for example, by providing a high-luster region composed of a lustrous ink layer and a low-luster region not formed of the lustrous ink layer on the surface of one side of the substrate (see, for example, Patent Document 1), a method for expressing the gloss-matte expression, and a method for expressing the gloss-matte expression by providing irregularities on the surface of the substrate have also been proposed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As a method for improving the design property by synchronizing the pattern and the gloss-matte expression, for example, it is conceivable to arrange the pattern and the low-luster region so as to accurately overlap in a top view. Furthermore, by expressing a gloss-matte expression that matches the pattern, further improvement in the design property can be expected. An object of the present invention is to provide a cosmetic sheet having excellent design property and a method for manufacturing the cosmetic sheet.

Means for Solving the Problems

[0005] The cosmetic sheet according to one aspect of the present invention has an uneven shape on the outermost layer, and expresses a gloss-matte expression by using the region where the uneven shape is formed and the region where the uneven shape is not formed on the outermost layer. In the cosmetic sheet, the difference value ΔGM(Sa) of the arithmetic mean height Sa of each of the region where the uneven shape is formed and the region where the uneven shape is not formed satisfies ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum height Sz satisfies ΔGM(Sz)≧5.4.

[0006] Moreover, the method for manufacturing a cosmetic sheet according to another aspect of the present invention is a method for manufacturing a cosmetic sheet that has an uneven shape that synchronizes with a pattern layer on the outermost layer, and expresses a gloss-matte expression by using the region where the uneven shape is formed and the region where the uneven shape is not formed on the outermost layer. In the method, on one surface of a colored resin layer, the pattern layer, the transparent resin layer, and the surface protection layer as the outermost layer are laminated in this order. On the other surface of the colored resin layer, a pattern layer that synchronizes with the pattern of the pattern layer is formed by using a predetermined material that has light absorptivity with respect to light of a predetermined wavelength more than the colored resin layer. After irradiating 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 uneven shape is formed by embossing an embossing plate on the surface protection layer, and the image density of the predetermined material is determined according to the degree of the target gloss-matte expression. Here, the degree of the gloss-matte expression refers to the degree of the gloss difference.

Advantages of the Invention

[0007] According to one aspect of the present invention, it is possible to provide a cosmetic sheet capable of easily and effectively expressing a highly artistic gloss-matte expression.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Mode for Carrying Out the Invention

[0009] 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 following in terms of the material, shape, structure, etc. of the components. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

[0010] As shown in FIG. 1, for example, the cosmetic sheet 1 is formed by laminating a colored thermoplastic resin layer (colored resin layer), a pattern layer 5, a transparent thermoplastic resin layer (transparent resin layer) 6, and a surface protection layer 7 in this order, and an embossed portion (concavo-convex shape) 7a is formed on the surface protection layer 7. Further, on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5, a pattern layer 8a composed of a gloss matte expression pattern portion 3 and a primer layer 8 are formed.

[0011] 〔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 sheeting, printability, and suitability for bending.

[0012] 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 colorant such as a pigment during the sheeting of the thermoplastic resin. Alternatively, before providing the gloss / matte pattern portion 3, a colored layer can be provided as a betaine ink layer by using a coating or printing method.

[0013] 〔Pattern layer〕 The pattern layer 5 is a printed layer on which a pattern is printed in order to impart design characteristics 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 special features performed by preparing individual color plates constituting the pattern.

[0014] 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, imagining a floor of a stone material 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 using these as motifs or artificial pattern motifs such as geometric patterns can also be used. In addition to these, examples of the pattern include a wood grain pattern composed of, for example, the spring wood region and the autumn wood region of the cross section of the annual ring, the conduit part, 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 texture pattern, a tile pasting pattern, a brick stacking pattern, a cloth texture pattern, geometric figures, letters, symbols, abstract patterns, flower patterns, landscapes, characters, etc.

[0015] 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.

[0016] In addition, examples of the binder resin include chlorinated 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 chlorinated 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.

[0017] 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, 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 5 is mainly formed of solid components such as a colorant and a binder resin.

[0018] 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 preferable to select 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.

[0019] For the purpose of improving the adhesion 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 contacts the transparent thermoplastic resin layer 6. By strengthening these adhesions, the decorative sheet 1 can be imparted with bendability that follows 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.

[0020] 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 brightening layer (not shown) may be provided between the pattern layer 5 and the transparent thermoplastic resin layer 6. The brightening layer (not shown) preferably contains a brightening pigment and a binder resin. Examples of the brightening 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 brightening layer and do not impair the visibility of the pattern layer 5.

[0021] A pearl pigment is a pigment that can impart a true pearl luster. For example, those obtained by coating the surface of matrix particles 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 two or more kinds. Specific examples include 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, titanium oxide-coated synthetic mica, and other oxide-coated mica; titanium oxide-coated glass powder, iron oxide-coated glass powder, and other oxide-coated glass powders; titanium oxide-coated aluminum powder and other oxide-coated metal particles; basic lead carbonate, lead hydrogen arsenate, bismuth oxychloride, and other flaky foil pieces; fish scale powder, shell pieces, pearl pieces, and the like.

[0022] 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 kinds. From the viewpoint of imparting an excellent design effect, the average particle diameter of the glitter pigment is preferably 40 μm or less, more preferably 30 μm or less, when forming a glitter layer using, for example, gravure printing. From the same viewpoint, the ratio of [average particle diameter of glitter pigment / thickness of glitter 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.

[0023] 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.

[0024] Examples of the thermosetting resin composition used for the glitter 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 glitter layer, the same composition as the radiation-curable resin composition of the surface protective layer 7 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, based on 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 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 design to be imparted. 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, in order to enhance the design effect, it is preferable that the arbitrary pattern has shading. 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 forming the shading of the luminescent layer 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 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 resin (polypropylene resin, polyethylene resin) can be used. In particular, considering environmental compatibility, processability, and price, polyolefin-based resin is 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.

[0029] 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 both by coextrusion can be adopted.

[0030] 〔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 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, heat drying device, and ionizing radiation irradiation device according to the type of curable resin.

[0031] 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.

[0032] 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 radical 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. Specifically, examples of the prepolymer or monomer include compounds having a radical polymerizable unsaturated group such as a (meth)acryloyl group and a (meth)acryloyloxy group, and a cationic polymerizable functional group such as an epoxy group in the molecule. Also, a polyene / thiol-based prepolymer formed by combining 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 radical 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.

[0034] 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.

[0035] In addition, examples of the prepolymer having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol type epoxy resins and novolac 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.

[0036] 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 resonance 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.

[0037] 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.

[0038] [Embossed portion] On the surface of the surface protection layer 7, an embossed portion 7a having an uneven pattern (uneven shape) is formed in order to impart a given design property. Examples of the uneven pattern include a wood grain board conduit groove, a stone slab surface unevenness (such as a granite split surface), a cloth surface texture, a satin finish, a matte finish, a hairline, and a multi-line groove. This embossed portion 7a is provided such that the uneven pattern thereof is synchronized with the pattern of the pattern layer 5.

[0039] 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 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.

[0040] In order to achieve a sufficient gloss-matte expression, the surface roughness of the region where the concavo-convex shape of the surface of the embossed portion 7a is formed is formed to satisfy the following conditions. That is, for the concavo-convex shape of the embossed portion 7a and the concavo-convex shape of the surface protection layer 7 (the region where the embossed portion 7a is not formed, hereinafter also referred to as the non-embossed region) 7b, the difference value ΔGM(Sa) of the arithmetic mean height Sa of these surfaces satisfies ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum height Sz satisfies ΔGM(Sz)≧5.4. It is more preferable that for the concavo-convex shape of the embossed portion 7a and the non-embossed region 7b of the surface protection layer 7, the difference value ΔGM(Sa) of the arithmetic mean height Sa of these surfaces satisfies ΔGM(Sa)>1.8, and the difference value ΔGM(Sz) of the maximum height Sz satisfies ΔGM(Sz)>9.4.

[0041] 〔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, for example, a material having an infrared absorption effect. The pattern portion 3 for expressing gloss-matte is formed of a material containing ink with carbon black, for example, urethane-based printing ink. The pattern portion 3 for expressing gloss-matte is arranged at a position synchronized with the pattern of the pattern layer 5. For example, in the case of the pattern layer 5 with a wood grain pattern, the pattern portion 3 for expressing gloss-matte is formed at a position overlapping the wood grain conduit grooves 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 so as to substantially coincide in plan view.

[0042] The thickness of the pattern portion 3 for matte expression should be such that the transparent thermoplastic resin layer 6 and the surface protective layer 7 can be softened to a degree sufficient to sufficiently form uneven shapes on the surface protective layer 7 during the embossing process described later. Further, in order to exhibit sufficient matte expression, it is preferable that the glossiness difference between the portion where the pattern portion 3 for matte expression is formed and the portion where it is not formed is 5 or more in plan view.

[0043] Also, in order to exhibit sufficient matte expression, as described above, the surface roughness of the embossed portion 7a and the surface roughness of the non-embossed region 7b need to satisfy the difference value ΔGM(Sa) of the arithmetic mean height Sa of these being ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum height Sz being ΔGM(Sz)≧5.4. Therefore, it is preferable that the ink image density (image density) of the pattern portion 3 for matte expression is 20% or more. Further, since the surface roughness of the embossed portion 7a changes according to the ink image density of the pattern portion 3 for matte expression, and the degree of matte expression exhibited changes according to the difference value of the surface roughness between the embossed portion 7a and the non-embossed region 7b, the ink image density of the pattern portion 3 for matte expression is determined so as to exhibit the target degree of matte expression, and by forming the pattern portion 3 for matte expression with the determined ink image density, the target degree of matte expression can be exhibited.

[0044] Note that the pattern portion 3 for matte expression 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 light of the predetermined wavelength.

[0045] 〔Light of a predetermined wavelength〕 As described above, the pattern portion 3 for matte expression is formed of a material having light absorbency 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 gloss matte pattern portion 3 formed of a material having light absorbency with respect to infrared rays, for example.

[0047] 〔Primer layer〕 The primer layer 8 is a base layer and is a layer for improving the adhesion and corrosion resistance with 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. The primer layer 8 is formed using, for example, a polyester resin, an organic additive, a pigment, etc. An anticorrosive pigment may be blended into the primer layer 8 for the purpose of improving 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)).

[0049] 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.

[0050] Next, a pattern layer 8a is formed by forming a gloss / matte expression pattern portion 3 on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5. For example, a urethane-based ink containing carbon black is used to form the gloss / matte expression pattern portion 3 at a predetermined position in synchronization with the pattern of the pattern layer 5 (Fig. 2(b)). At this time, the gloss / matte expression pattern portion 3 is created with an ink image density set in advance that can express a sufficient gloss / matte expression. This ink image density is such that the difference value ΔGM(Sa) of the arithmetic mean height Sa between the surface roughness of the embossed portion 7a and the non-embossed region 7b of the generated decorative sheet satisfies ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum height Sz satisfies ΔGM(Sz)≧5.4, and is set to a value set in advance as the ink image density.

[0051] Subsequently, a primer layer 8 made of, for example, a polyester-based resin is laminated on the colored thermoplastic resin layer 2 including the gloss / matte expression pattern portion 3 so as to fill the gaps between the gloss / matte expression pattern portions 3 and cover the upper surface thereof.

[0052] 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 onto the surface of the surface protection layer 7 (Fig. 2(e)). As a result, an embossed portion 7a is formed in a region overlapping the gloss / matte expression pattern portion 3 in plan view, and the decorative sheet 1 is formed.

[0053] Here, the pattern portion 3 for gloss-matte expression is formed of an ink having infrared absorption characteristics. Therefore, when the laminate is irradiated with infrared rays, in a plan view, the portion of the surface protective layer 7 that overlaps with the pattern portion 3 for gloss-matte expression is more likely to soften the transparent thermoplastic resin layer 6 and the surface protective layer 7 compared to the portion that does not overlap with the pattern portion 3 for gloss-matte expression. That is, in the transparent thermoplastic resin layer 6 and the surface protective layer 7 after the infrared irradiation, there are portions that are likely to soften and portions that are less likely to soften. 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 likely to be formed in the softened portion, and unevenness is less likely to be formed in the portion that is less likely to soften. That is, unevenness is likely to be formed in the softened portion of the transparent thermoplastic resin layer 6 and the surface protective layer 7, that is, the portion that overlaps with the pattern portion 3 for gloss-matte expression in a plan view. As a result, an embossed portion 7a having an uneven shape synchronized with the pattern portion 3 for gloss-matte expression is likely to be formed only at the position where the transparent thermoplastic resin layer 6 and the surface protective layer 7 overlap with the pattern portion 3 for gloss-matte expression in a plan view.

[0054] Thereby, 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 high-precision positioning operation.

[0055] At this time, since the ink image density of the pattern portion 3 for gloss-matte expression is set to a value capable of expressing a predetermined sufficient gloss-matte expression, the surface roughness of the embossed portion 7a and the non-embossed region 7b of the generated decorative sheet satisfies the difference value ΔGM(Sa) of the arithmetic mean height Sa of these, ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum height Sz satisfies ΔGM(Sz)≧5.4. As a result, a sufficient gloss-matte expression is achieved.

[0056] On one hand, when expressing a target degree of gloss-matte expression, first, determine the degree of the target gloss-matte expression of the cosmetic sheet to be created, and determine the ink image density of the pattern portion for gloss-matte expression necessary to obtain this target degree of gloss-matte expression. For example, by detecting in advance the correspondence between the ink image density of the pattern portion for gloss-matte expression and the degree of gloss-matte expression obtained when forming the pattern portion for gloss-matte expression with this ink image density, etc., obtain the correspondence information between the degree of gloss-matte expression and the ink image density of the pattern portion for gloss-matte expression, and based on this correspondence information, specify the ink image density of the pattern portion 3 for gloss-matte expression necessary to obtain the target degree of gloss-matte expression.

[0057] Then, using the pattern portion 3 for gloss-matte expression having the specified ink image density, create a cosmetic sheet in the same manner as above. In this case, since the ink image density of the pattern portion 3 for gloss-matte expression is set to a value that expresses the target degree of gloss-matte expression, when infrared irradiation is performed, the transparent thermoplastic resin layer 6 and the surface protection layer 7 have a degree of softening corresponding to the ink image density. As a result, the surface shape of the embossed portion 7a becomes a surface roughness corresponding to the ink image density. Therefore, the difference value ΔGM(Sa) of the arithmetic mean height Sa between the surface roughness of the obtained embossed portion 7a and the surface roughness of the non-embossed region 7b satisfies ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum height Sz satisfies ΔGM(Sz)≧5.4. Furthermore, it becomes a surface roughness capable of expressing the target degree of gloss-matte expression. As a result, the target degree of gloss-matte expression is expressed.

[0058] Note that the timing of embossing the embossing plate on the transparent thermoplastic resin layer 6 and the surface protection layer 7 after infrared irradiation is not limited to immediately after infrared irradiation. Any timing that can selectively form an uneven shape on the portion softened by infrared irradiation by embossing on the surfaces of the transparent thermoplastic resin layer 6 and the surface protection layer 7 is acceptable.

[0059] Further, other processes may be included between the process of forming the surface protective layer 7 and the process of performing infrared irradiation. In short, the infrared irradiation may be performed in a state where the transparent thermoplastic resin layer 6 and the surface protective layer 7 are formed.

[0060] 〔Effects of Embodiment〕 (1) After performing infrared irradiation on the laminate in which each layer of the decorative sheet 1 is laminated, by pressing the embossing plate, in a plan view, strong embossing can be performed on the portion overlapping the gloss-matte pattern portion 3 for expression. That is, even if the positioning of the area where the embossing plate is pressed is not performed with high precision, the embossing portion can be easily formed at a desired position. As a result, a decorative sheet having excellent design can be easily obtained.

[0061] (2) Since the gloss-matte pattern portion 3 for expression is provided below the colored thermoplastic resin layer 2, when the decorative sheet 1 is viewed from the surface protective layer 7 side, the visibility of the gloss-matte pattern portion 3 for expression is reduced. As a result, although ink having high infrared absorption characteristics and high ink image density is used as the gloss-matte pattern portion 3 for expression, when the decorative sheet 1 is viewed from the surface protective layer 7 side, the gloss-matte pattern portion 3 for expression can be suppressed from being visually recognized. For this reason, even if a dark pattern is not used as the pattern layer 5, the gloss-matte pattern portion 3 containing ink can be suppressed from being visually recognized. As a result, it is also possible to adopt a light-colored pattern as the pattern layer 5, and the restriction on the pattern expression by the pattern layer 5 caused by providing the gloss-matte pattern portion 3 for expression can be suppressed.

[0062] Further, on the pattern layer 8a composed of the gloss-matte expression handle portion 3 using ink having infrared absorption characteristics and a high ink image density, a colored thermoplastic resin layer 2, a pattern layer 5, a transparent thermoplastic resin layer 6, and a surface protection layer 7 are laminated, and an embossed portion 7a is formed at a position overlapping the gloss-matte expression handle portion 3 in a plan view of the surface protection layer 7. Therefore, the visibility of the gloss-matte expression handle portion 3 using ink can be reduced, the influence of the useful gloss-matte expression handle portion 3 in the manufacturing process of the decorative sheet 1 on the appearance of the decorative sheet 1 can be suppressed, and a decorative sheet 1 with high design properties in which the pattern of the pattern layer 5 and the embossed portion 7a are synchronized can be obtained.

[0063] (3) Since the gloss-matte expression handle portion 3 is provided in synchronization with the pattern of the pattern layer 5, concavo-convex portions synchronized with the pattern of the pattern layer 5 can be formed, that is, a gloss-matte expression synchronized with the pattern can be easily expressed.

[0064] (4) Since the surface roughness of the embossed portion 7a and the surface roughness of the non-embossed region 7b satisfy the difference value ΔGM(Sa) of the arithmetic mean height Sa such that ΔGM(Sa)≧1.6 and the difference value ΔGM(Sz) of the maximum height Sz such that ΔGM(Sz)≧5.4, a gloss-matte expression can be effectively expressed.

[0065] (5) Since the degree of gloss-matte expression can be changed according to the ink image density of the gloss-matte expression handle portion 3, a target degree of gloss-matte expression can be expressed. Further, by changing the ink image density of the gloss-matte expression handle portion 3, gloss-matte expressions with different degrees can be expressed. Therefore, with the same configuration, by simply changing only the ink image density, gloss-matte expressions with different degrees can be easily expressed, and the variations in the degree of gloss-matte expression can be increased. Therefore, for example, it is possible to respond finely to the requirements for the degree of gloss-matte expression.

[0066] Also, in a single decorative sheet, by making the ink image density of the pattern part 3 for expressing gloss-matte not the same throughout the entire surface, but by partially changing the ink image density, for example, in the part of the pattern, different degrees of gloss-matte expression can be achieved within a single decorative sheet, and the design property of the decorative sheet 1 can be further improved.

[0067] (6) By providing unevenness, the gloss-matte expression is achieved, so it is possible to suppress the occurrence of problems such as the gloss-matte pattern coming off. Therefore, for example, in floor materials and the like, the synchronized gloss-matte expression can also be performed.

Example

[0068] Hereinafter, examples and comparative examples of the decorative sheet according to the present invention will be described. Note that the present invention is not limited to the following examples.

[0069] (Example) A decorative sheet to be evaluated as an example was created. 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 on the back surface of this colored thermoplastic resin layer 2, the pattern part 3 for expressing gloss-matte was printed. For this pattern part 3 for expressing gloss-matte, using a printing plate with different ink image density levels, the ink was solidly printed on the back surface of the colored thermoplastic resin layer 2. The ink image densities were set to 7 types: 0%, 20%, 40%, 60%, 70%, 80%, and 90%. As a result, on the back surface of the colored thermoplastic resin layer 2, printing areas of the pattern part 3 for expressing gloss-matte with ink image densities of 0%, 20%, 40%, 60%, 70%, 80%, and 90% were respectively formed.

[0070] On the surface of the printing original (colored thermoplastic resin layer 2 printed with ink), PP (polypropylene) with a thickness of 38 μm was laminated as the transparent thermoplastic resin layer 6, and then post-embossing was performed. That is, the sheet laminated with the transparent thermoplastic resin layer 6 was heated by an infrared heater, and then the 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.

[0071] 〔Evaluation method〕 〔Measurement of surface roughness〕 For the decorative sheet for evaluation, the surface roughness was measured for each ink image density (0%, 20%, 40%, 60%, 70%, 80%, and 90%). This measurement of the surface roughness was performed using a 3D measurement laser microscope LEXT OLS4100 (manufactured by Olympus Corporation). As indices of the surface roughness, the arithmetic mean height Sa and the maximum height Sz were measured, and the difference value ΔGM(Sa) between the arithmetic mean height Sa at the position where the ink image density is 0% and the arithmetic mean height Sa at each ink image density (20%, 40%, 60%, 70%, 80%, and 90%), and the difference value ΔGM(Sz) between the maximum height Sz at the position where the ink image density is 0% and the maximum height Sz at each ink image density (20%, 40%, 60%, 70%, 80%, and 90%) were calculated.

[0072] 〔Measurement of glossiness〕 For the decorative sheet for evaluation, glossiness was measured at a measurement angle of 85° to confirm whether the gloss-matte expression was exhibited. Specifically, the gloss value was measured for each ink image density, and the difference value between the gloss value at the position where the ink image density is 0% and the gloss values at each ink image density (20%, 40%, 60%, 70%, 80%, and 90%) was obtained. The measurement of glossiness was performed using a micro-tri-gloss gloss meter (manufactured by BYK-Chemie Japan Co., Ltd.).

[0073] 〔Gloss-matte design property〕 The gloss-matte design property was subjectively evaluated for each ink image density (20%, 40%, 60%, 70%, 80%, and 90%). The evaluation criteria are as follows. ◎: The gloss value difference from the gloss value at the position where the ink image density is 0% is greater than 3, and it can be confirmed that a stable gloss-matte expression is manifested even considering the variations in the production of the decorative sheet. 〇: The gloss value difference from the gloss value at the position where the ink image density is 0% is 3 or less, but it can be confirmed that a gloss-matte expression is manifested. ×: The degree of gloss-matte expression is weak and unrecognizable.

[0074] 〔Evaluation Results〕 For the decorative sheets for evaluation, the measurement results and evaluation results are shown in Table 1. In Table 1, the arithmetic mean height Sa and the maximum height Sz of the decorative sheets for evaluation are rounded measurement results.

[0075]

Table 1

[0076] As shown in Table 1, when the ink image density is 20% or more, the difference value of the arithmetic mean height Sa of the decorative sheets for evaluation satisfies ΔGM(Sa)≧1.6, and the difference value of the maximum height Sz satisfies ΔGM(Sz)≧5.4, confirming that the gloss-matte phenomenon is manifested. Also, when the ink image density is 40% or more, the gloss value difference is approximately 5.0, and a stable gloss-matte phenomenon is manifested. When the ink image density is 20%, although the gloss value difference is slightly small at about 2.4, it was confirmed that the gloss-matte phenomenon is manifested.

[0077] Furthermore, in the range where the ink image density is 20% - 60%, it was confirmed that as the ink image density increases, the gloss value difference increases and the degree of the gloss-matte phenomenon becomes stronger. That is, it was confirmed that as the ink image density increases, a stronger degree of gloss-matte phenomenon occurs.

Explanation of Symbols

[0078] 1 Cosmetic sheet 2 Colored thermoplastic resin layer 3 Pattern part for gloss matte expression 5 Pattern layer 6 Transparent thermoplastic resin layer 7 Surface protective layer 7a Embossed part 7b Non-embossed area 8 Primer layer 8a Pattern layer

Claims

1. A decorative sheet having an uneven surface on an outermost layer, and expressing a glossy matte appearance by utilizing an area of ​​the outermost layer where the uneven surface is formed and an area where the uneven surface is not formed, A decorative sheet characterized in that the difference value ΔGM(Sa) of the arithmetic mean heights Sa of the areas where the uneven shape is formed and the areas where the uneven shape is not formed satisfies ΔGM(Sa)≧1.6, and the difference value ΔGM(Sz) of the maximum heights Sz of the areas where the uneven shape is formed satisfies ΔGM(Sz)≧5.

4.

2. a pattern layer, a transparent resin layer, and a surface protective layer as the outermost layer, which are laminated in this order on one surface of the colored resin layer; a pattern layer, laminated on the other surface of the colored resin layer, in which a predetermined material having a higher light absorption property for light of a predetermined wavelength than the colored resin layer is arranged in synchronization with the pattern of the pattern layer; Equipped with The decorative sheet according to claim 1 , wherein the uneven shape is formed at a position of the surface protective layer that overlaps with a portion formed of the predetermined material in a plan view.

3. A method for producing a decorative sheet having an uneven surface shape in harmony with a pattern layer on an outermost layer, the uneven surface shape being formed in an area of ​​the outermost layer and an area where the uneven surface shape is not formed, and expressing a glossy matte appearance, the design layer, the transparent resin layer, and the surface protective layer as the outermost layer are laminated in this order on one surface of a colored resin layer, a pattern layer that is in tune with the design of the design layer is formed on the other surface of the colored resin layer using a predetermined material that is more light absorbing than the colored resin layer for light of a predetermined wavelength, and after irradiating the surface protective layer with light having a stronger power of light of the predetermined wavelength than the power of light of other wavelengths, an embossing plate is pressed onto the surface protective layer to form the uneven shape; A method for producing a decorative sheet, comprising determining an image density of said predetermined material according to a desired degree of gloss / matt expression.

4. 4. The method for producing a decorative sheet according to claim 3, wherein the stronger the degree of the desired gloss / matte expression, the higher the image density is set.

5. The method for manufacturing a decorative sheet according to claim 3 or claim 4, characterized in that the areas in which the uneven shape is formed and the areas in which the uneven shape is not formed are formed so that a difference value ΔGM(Sa) of their respective arithmetic mean heights Sa satisfies ΔGM(Sa) ≧ 1.6, and a difference value ΔGM(Sz) of their respective maximum heights Sz satisfies ΔGM(Sz) ≧ 5.4.

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