Decorative sheet

Abstract

To provide a decorative sheet exhibiting a superior appearance with a gloss distinct from that of conventional ones.SOLUTION: Disclosed is a decorative sheet formed by laminating a resin sheet layer and a mesh layer, wherein the mesh layer is composed of monofilaments; and on the surface of the mesh layer, a metal particle layer and a silicon layer are laminated in this order from the mesh layer side.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a decorative sheet having a unique gloss.

Background Art

[0002] Conventionally, various materials having a gloss, such as fabrics and sheets, have been used. For example, sheets made of resin having a gloss like that of metal are also used for various purposes by utilizing their decorative properties. For example, Patent Document 1 proposes a decorative sheet having a high-brightness metallic design.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The decorative sheet of Patent Document 1 is a decorative sheet in which a support and a decorative layer are laminated, and the decorative layer has a metallic layer made of a resin containing a plurality of large-particle-size metal flakes and small-particle-size metal flakes. According to the decorative sheet of Patent Document 1, it is said that a decorative sheet with improved brightness and adhesion of the outermost layer can be obtained while maintaining low cost.

[0005] Although sheets having a metallic gloss have been proposed in various ways, there is a demand for sheets having a gloss different from that of conventional sheets with a gloss, or sheets having a more excellent appearance gloss.

[0006] An object of the present application is to provide a decorative sheet having an excellent appearance with a gloss different from that of the conventional one.

Means for Solving the Problems

[0007] That is, the means for solving the above problems are as follows.

[0008] (1) A decorative sheet in which a resin sheet layer and a mesh layer are laminated, wherein the mesh layer is formed of monofilaments, and a metal particle layer and a silicon layer are laminated in this order from the mesh layer side on the surface of the mesh layer.

[0009] (2) A decorative sheet in which a resin sheet layer and a mesh layer are laminated, wherein the mesh layer is formed of monofilaments, and a silicon layer is formed on the surface of the mesh layer.

[0010] (3) The decorative sheet according to (1) above, wherein the metal particle layer is a layer formed by a sputtering method.

[0011] (4) The decorative sheet according to (1) above, wherein the metal particle layer is formed of aluminum.

[0012] (5) The decorative sheet according to (1) or (2) above, wherein the silicon layer is a layer formed by a sputtering method.

[0013] (6) The decorative sheet according to (1) or (2) above, wherein the monofilaments of the mesh layer are any one of polyester, polyethylene, and nylon.

[0014] (7) The decorative sheet according to (1) or (2) above, wherein the mesh layer has a mesh count of 50 meshes or more and 350 meshes or less.

[0015] (8) The decorative sheet according to (1) or (2) above, wherein the resin sheet layer is formed of polyvinyl chloride.

[0016] According to the present invention, it is possible to provide a decorative sheet having an excellent appearance with a gloss different from the conventional one.

Brief Description of the Drawings

[0017]

Figure 1

Figure 2

Mode for Carrying Out the Invention

[0018] Hereinafter, the decorative sheet 1 of the present embodiment will be described with reference to the drawings. FIG. 1 is a configuration diagram showing the configuration of the decorative sheet 1 of the present embodiment, and shows the laminated structure of the decorative sheet 1. The decorative sheet 1 is a decorative sheet in which a resin sheet layer 2 and a mesh layer 6 are laminated, and the mesh layer 6 is formed of monofilaments. On the surface of the mesh layer 6, a metal particle layer 8 and a silicon layer 10 are laminated in this order from the mesh layer 6 side. Note that FIG. 1 schematically shows the structure of the decorative sheet 1, and the thickness of each layer does not necessarily correspond to the ratio of the actual thickness of each layer.

[0019] As described above, the decorative sheet 1 is a laminate having a resin sheet layer 2, an adhesive layer 4, a mesh layer 6, a metal particle layer 8, and a silicon layer 10. In the following description of the embodiment, the outer surface on the silicon layer 10 side of the decorative sheet 1 is the decorative surface side, and the outer surface (outer surface 2a) of the resin sheet layer 2 is described as the back surface side. However, it is not necessarily limited to this, and it may be used with the front and back reversed.

[0020] The decorative sheet 1 of the present embodiment has a characteristic gloss on the surface on which the silicon layer 10 is formed. And the decorative sheet 1 is a sheet having a unique gloss and color different from the conventional one on the surface on the silicon layer 10 side due to the laminated structure from the resin sheet layer 2 to the silicon layer 10.

[0021] The decorative sheet 1 is a sheet-like material that can be used for various purposes, and can be used, for example, as industrial materials or materials for fashion accessories. Since the resin sheet layer 2 provides water resistance and wind resistance, the decorative sheet 1 can be used, for example, for the canopy or side curtain of an event tent, or for raincoats and windbreakers in places that require design, such as events and shows. In addition, it can also be used for exterior and interior materials of various articles, interior materials of automobiles and buildings, exterior materials of home appliances, interior and exterior materials of furniture, wallpaper, carpets, etc., fabrics for miscellaneous goods such as bags and pouches, and materials for clothing.

[0022] The resin sheet layer 2 is laminated in close contact with the mesh layer 6, and is a layer that plays a part in expressing the complex gloss of the decorative sheet 1 by reflecting (or absorbing) the light that has passed through the mesh.

[0023] The material of the resin sheet layer 2 is not particularly limited as long as it contributes to the improvement of the strength of the mesh layer and can reflect (or absorb) the light that has passed through the mesh. Examples include olefin resins such as polyethylene, polypropylene, and chlorinated polyethylene, polystyrene resin, polyvinyl acetate resin, polyurethane resin, polyester resin, copolymers having acrylic acid, acrylic acid ester, methacrylic acid, and methacrylic acid ester as the main chain, acrylic-styrene resin, fluorine-based resin, cellulose-based resins such as ethyl cellulose, resins derived from drying oils such as castor oil, linseed oil, and tung oil (so-called biomass plastics), natural resins such as shellac and copal, and leather. Among them, polyvinyl chloride (PVC) is preferably used because it is inexpensive, has good processability, and has weather resistance and water resistance.

[0024] In addition, when the resin sheet layer 2 is used for a tent canopy or the like of a decorative sheet 1, it is preferably weather-resistant, water-resistant, and wind-resistant. For weather resistance, a weathering agent may be added as needed for further improvement. Water resistance only needs to be able to suppress the passage and penetration of water and does not have to be completely water-resistant. Similarly, for wind resistance, it only needs to be able to suppress the passage of wind (air) and does not have to be completely wind-resistant. If it is a resin sheet of the above-mentioned materials, water resistance and wind resistance can be obtained.

[0025] Furthermore, as additives to the resin sheet layer 2, a plasticizer, a desiccant, a curing agent, an anti-sagging agent, a flattening agent, an anti-dripping agent, an anti-mold agent, an ultraviolet absorber, a heat ray absorber, a lubricant, a surfactant, a thickener, a viscosity modifier, a stabilizer, a drying regulator, etc. may be added. These additives can be used alone or in combination of two or more. Furthermore, an antiviral composition, an antibacterial composition, an antifungal composition, an anti-allergen composition, a catalyst, an anti-reflection material, a material having heat shielding properties, etc. may be added and used.

[0026] The thickness of the resin sheet layer 2 is not particularly limited, but it is preferably 50 μm or more and 2 mm or less. When used as an industrial material such as a tent material, strength is important, so it is preferably 100 μm or more and 2 mm or less. However, when used as a clothing material, an interior / exterior decoration material, or a fabric for miscellaneous goods, a thinner one of 50 μm or more and 500 μm or less is preferred in terms of texture and ease of sewing. Thus, the thickness can be appropriately selected according to the usage scenario.

[0027] The resin sheet layer 2 may be colored in a color similar to or the same as the intended color of the decorative sheet 1, or it may be colored in a different color. Also, it does not necessarily have to be the same color or a similar color to the color imparted by the metal particle layer 8 and the silicon layer 10. For example, when the entire decorative sheet 1 is a blue sheet, the mesh layer 6 having the metal particle layer 8 and the silicon layer 10 may be colored blue, and the resin sheet layer 2 may be blue or another color such as black.

[0028] The outer surface 2a, which is the surface of the resin sheet layer 2 on the side opposite to the mesh layer 6, may be processed to impart decorativeness. For example, resin processing may be performed to give a gloss, or a gloss may be obtained by flattening the surface by press processing such as calendering. By these processes, a glossiness can be obtained, and decorativeness can also be imparted to the outer surface 2a, which is the back side of the decorative sheet 1.

[0029] The adhesive layer 4 is a layer that adheres the resin sheet layer 2 and the mesh layer 6, and is a layer of an adhesive that adheres both of them. The adhesive layer 4 can adhere the resin sheet layer 2 and the mesh layer 6, and a known adhesive is used, but it is preferably one that does not impair the flexibility of the material (decorative sheet 1).

[0030] As the adhesive layer 4, for example, epoxy adhesives such as polyether-based adhesives, polyester-based adhesives, silicone-based adhesives, and polyamine-based adhesives, urethane-based adhesives, rubber-based adhesives, vinyl-based adhesives, silicone-based adhesives, vinyl acetate-based adhesives, ethylene-vinyl acetate copolymer-based adhesives, epoxy-based adhesives, acrylic-based adhesives, phenol-based adhesives, and olefin-based adhesives can be used. Among them, hot melt adhesives are preferable because they can be adhered simultaneously with the calendering of the resin sheet layer 2. Examples of hot melt adhesives include polyolefin-based resins such as polyethylene and polypropylene, and polyester-based resins such as polyethylene terephthalate, polybutylene terephthalate, and polylactic acid. Among these, polyolefin-based resins such as polyethylene and polypropylene are preferable.

[0031] The mesh layer 6 is a layer for forming a metal particle layer 8 and a silicon layer 10 for obtaining a gloss on the surface. By forming the metal particle layer 8 and the silicon layer 10 that impart a gloss on the fabric-like mesh layer 6, a complex glossiness and color that change depending on the viewing angle can be obtained. In addition, a decorative sheet having a unique gloss with a three-dimensional feeling (depth) and a transparent feeling can be obtained.

[0032] The mesh layer 6 is a mesh (fabric) formed of monofilaments. By being formed of monofilaments, a sheet having a better gloss can be formed. When light hits a monofilament, diffuse reflection occurs at the same angle. However, in the case of multifilaments, since the uneven shape on the fiber surface is not uniform, diffuse reflection occurs at random angles, so it is difficult to obtain an excellent gloss like in the case of monofilaments. Also, when the decorative sheet 1 is used for outdoor items such as tent curtains, the monofilament fabric is lighter than the multifilament fabric, so the overall weight can be reduced. Furthermore, in rainy weather, etc., it is less likely to absorb rainwater than multifilaments and is less likely to become heavy, which is preferable.

[0033] The weave of the mesh layer 6 is not particularly limited and may be plain weave, twill weave, damask weave, etc. When used as an industrial material, plain weave is preferable because of its excellent strength. Also, when used for clothing materials, miscellaneous fabric, interior and exterior materials, etc., fabrics of various weaves can be applied depending on the design.

[0034] The material of the fibers of the mesh layer 6 may be any polymer that can form monofilaments. For example, polyester fibers such as polyethylene terephthalate, polybutylene terephthalate, and polytetramethylene terephthalate, and polymer materials such as polyethylene, polypropylene, polyvinyl chloride, nylon, acrylic, polytetrafluoroethylene, polyvinyl alcohol, Kevlar (registered trademark), polyacrylic acid, polymethyl methacrylate, rayon, cupra, Tencel, polynosic, acetate, triacetate, cotton, hemp, wool, silk, bamboo, spider silk, etc. can be used. Polyester, polyethylene, and nylon are preferable because of their excellent mass productivity.

[0035] The fiber diameter of the fiber used for the mesh layer 6 is preferably 20 μm or more and 200 μm or less. When used for industrial materials such as tent materials, it is preferably 50 μm or more and 200 μm or less. This is because sufficient strength can be obtained when it is 50 μm or more. If it is thicker than 200 μm, the weight increases, and the yarn becomes conspicuous, lacking in design. When used for apparel, miscellaneous goods, interior materials, etc., since texture is often required, 20 μm or more and 100 μm or less are preferred.

[0036] The mesh count of the mesh layer 6 is preferably 50 meshes or more and 350 meshes or less. This is because more luster can be obtained with the mesh count within this range. It is preferable that the mesh counts in the vertical and horizontal directions of the mesh layer 6 are the same. This is because better luster can be obtained when the mesh counts are the same in both the vertical and horizontal directions. Note that the mesh count is the number of warp or weft yarns (yarns / inch) per 25.4 mm (1 inch) length parallel to the warp or weft yarns of the mesh (fabric) forming the mesh layer 6. When used for industrial materials such as tent materials, it is preferably 50 meshes or more and 200 meshes or less. This is because the strength is more excellent within this range.

[0037] The metal particle layer 8 and the silicon layer 10 are layers that impart luster and color such as metallic luster to the decorative sheet 1. And as described above, by forming the metal particle layer 8 and the silicon layer 10 on the fibers of the mesh, a complex luster feeling can be obtained. In FIG. 1, the metal particle layer 8 and the silicon layer 10 are schematically shown on the mesh layer 6, but more precisely, it is a structure in which metal particles and silicon are laminated on the surface of each fiber constituting the mesh.

[0038] The metal particle layer 8 is a layer that imparts luster to the decorative sheet 1 by reflecting light and is composed of fine metal particles. As the metal for the metal particle layer 8, aluminum, titanium, stainless steel, chromium, etc. can be used. Among these, aluminum particles are preferred because they increase the glossiness the most. The average particle diameter of the metal particles in the metal particle layer 8 is preferably 1 nm or more and 100 nm or less. The average particle diameter in the present application means that the surface of the decorative sheet is observed with an electron microscope such as a scanning electron microscope or a transmission electron microscope, 30 metal particles are randomly selected from the microscope image, the longest diameter of each particle is measured, and the arithmetic mean value of the 30 longest diameters is calculated.

[0039] The silicon layer 10 is a layer of silicon (Si) formed further outside the metal particles of the metal particle layer 8 on the fibers of the mesh layer 6. It may contain oxides such as silica and is a layer for imparting color to the decorative sheet 1. The silicon layer 10 is light-transmissive, and the incident light is reflected by the metal particle layer 8 and the like. At this time, depending on the thickness of the silicon layer 10, the optical refractive index and absorption coefficient change, and decorative sheets 1 of various colors can be formed. Also, due to the fine unevenness due to the weave of the mesh layer 6, the sagging of the sheet surface, or the viewing angle, the reflection and refraction of light change variously, and a decorative sheet 1 that appears to have a complicated change in the visible color, in other words, a shiny decorative sheet 1 having polychromatism can be obtained. The thickness of the silicon layer 10 can be appropriately adjusted so that the manufacturer can obtain the desired color tone. Also, the average particle diameter of silicon (or silica) in the silicon layer 10 is preferably 1 nm or more and 100 nm or less, and can be appropriately applied depending on the color to be developed.

[0040] Next, a method for manufacturing the decorative sheet 1 will be described. The decorative sheet 1 is formed by forming the metal particle layer 8 and the silicon layer 10 on the mesh of the mesh layer 6 and adhering the mesh layer 6 and the resin sheet layer 2 with an adhesive (adhesive layer 4). When imparting luster to the outer surface 2a of the resin sheet layer 2 as well, press working such as resin processing or calendar processing may be performed in advance before adhesion. Also, in the case of calendar processing, the mesh layer 6 may be laminated while performing calendar processing on the resin sheet layer 2.

[0041] The metal particle layer 8 and the silicon layer 10 are not particularly limited as long as they can form the films under the above respective conditions on the mesh, and vapor deposition methods, sputtering methods, ion plating methods, chemical vapor deposition methods, etc. can be used.

[0042] In the case of the sputtering method, sputtering is performed using a target of the metal constituting the metal particle layer 8 to form the metal particle layer 8. By controlling the input power and the processing time during sputtering, a metal particle layer 8 with a desired film thickness can be formed.

[0043] Next, the silicon layer 10 can also be formed by the sputtering method, and the silicon layer 10 can be formed by performing sputtering using a target of silicon (Si). Since the optical properties change by changing the thickness of the silicon layer, various colors can be adjusted. When sputtering silica, oxygen gas may be introduced during sputtering.

[0044] According to the above-described embodiment, since the metal particle layer 8 and the silicon layer 10 are formed on the mesh layer 6, a decorative sheet 1 having a complex gloss feeling in which the color tone changes depending on the viewing angle and position, rather than just a simple metallic luster, can be obtained as compared with a sheet in which a metal thin film is simply formed on a resin sheet. Further, since the mesh layer 6 is laminated on the resin sheet layer 2, a clear gloss feeling can be obtained.

[0045] In this embodiment, the resin sheet layer 2 and the mesh layer 6 are adhered with an adhesive, but they may be adhered by heat welding or the like without using an adhesive. In that case, the adhesive layer 4 as an adhesive may not be provided.

[0046] (Modification example) FIG. 2 shows the configuration of the decorative sheet 100 according to the embodiment of the modified example. The decorative sheet 100 is different from the decorative sheet 1 in that it does not have a metal particle layer 8. For other configurations, they are common. The silicon layer 10 can be formed on the surface of the mesh layer 6 in the same manner as in the case of the decorative sheet 1. Even in the case of the decorative sheet 100 of the modified example, since light is reflected on the mesh surface of the mesh layer 6, although the glossiness is slightly weaker than that of the decorative sheet 1, a decorative sheet having a similarly complex gloss can be provided.

Example

[0047] The embodiment will be further specifically described with reference to examples.

[0048] (Example 1) A polyester monofilament fabric with 80 meshes, a fiber diameter of 100 μm, and plain weave was used as the mesh layer. A metal particle layer was formed on this polyester monofilament fabric by sputtering using an aluminum target. The average particle diameter of the metal particles at this time was 10 nm. The average particle diameter of the metal particles is a value obtained by randomly selecting 30 particles from an electron microscope image of the surface of the metal particle layer, measuring the longest diameter for each particle, and calculating the arithmetic mean of the longest diameters of the 30 measured particles. Next, a silicon layer was formed on the fabric on which the metal particle layer was formed by sputtering using a silicon target. The average particle diameter measured for the silicon particles of the formed silicon layer by the same method as described above was 18 nm.

[0049] Next, a PVC sheet with a thickness of 800 μm was subjected to single-sided calendering at 100°C to obtain a glossy surface. Then, while applying a polyolefin-based hot melt adhesive to the opposite surface of the glossy surface of the PVC sheet, it was adhered to the above mesh layer (fabric) to produce the decorative sheet of Example 1.

[0050] (Comparative Example 1) A sheet having only a mesh layer on which a metal particle layer and a silicon layer were formed, without laminating a resin sheet on the decorative sheet of Example 1, was produced as Comparative Example 1.

[0051] (Visual evaluation of gloss) The surfaces of the sheets of the examples and comparative examples on the silicon layer side were visually observed, and the gloss was evaluated according to the following criteria. The evaluation was carried out by five evaluators using the following sensory evaluation in three levels.

[0052] ○ indicates high transparency, excellent polychromatism when the angle is changed, and good gloss. △ indicates that there is gloss, but the polychromatism when the angle is changed is poor. × indicates that the gloss is weak and cannot be clearly visually recognized.

[0053] The evaluation results of the above tests are shown in Table 1 below.

[0054]

Table 1

[0055] From the above results, it was confirmed that the decorative sheet of the example is a decorative sheet with an excellent appearance with good gloss. On the other hand, in the sheet of the comparative example, light escaped from the openings of the mesh, resulting in poor gloss and polychromatism, and no design.

Explanation of symbols

[0056] 1, 100 Decorative sheet 2 Resin sheet layer 4 Adhesive layer 6 Mesh layer 8 Metal particle layer 10 Silicon layer

Claims

1. A decorative sheet in which a resin sheet layer and a mesh layer are laminated, wherein the mesh layer is formed of monofilaments, and a metal particle layer and a silicon layer are laminated in this order from the mesh layer side on the surface of the mesh layer. The decorative sheet is characterized by this.

2. A decorative sheet in which a resin sheet layer and a mesh layer are laminated, wherein the mesh layer is formed of monofilaments, and a silicon layer is formed on the surface of the mesh layer. The decorative sheet is characterized by this.

3. The decorative sheet according to claim 1, wherein the metal particle layer is a layer formed by a sputtering method.

4. The decorative sheet according to claim 1, wherein the metal particle layer is formed of aluminum.

5. The decorative sheet according to claim 1 or 2, wherein the silicon layer is a layer formed by a sputtering method.

6. The decorative sheet according to claim 1 or 2, wherein the monofilaments of the mesh layer are any one of polyester, polyethylene, and nylon.

7. The decorative sheet according to claim 1 or 2, wherein the mesh layer has a mesh count of 50 meshes or more and 350 meshes or less.

8. The decorative sheet according to claim 1 or 2, wherein the resin sheet layer is formed of polyvinyl chloride.

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