Decorative sheet and method for producing decorative sheet

Abstract

To provide a decorative sheet and a method for producing the decorative sheet that allow enhanced concealment of a substrate.SOLUTION: In a decorative sheet 1 including, at least in this order, a surface protective layer 5, a printed pattern layer 4, an aggregate layer 3, and a base layer 2, the aggregate layer 3 includes at least an acrylic resin and an inorganic filler. The inorganic filler has a median diameter d50 in a range of 0.1 μm or more and 10 μm or less. With the inorganic filler having a relatively small diameter with the median diameter d50 in the range of 0.1 μm to 10 μm, the inorganic filler can be densely arranged when forming a close-packed structure in the aggregate layer 3. This dense arrangement improves the concealment of the aggregate layer 3, and accordingly, the concealment of the decorative sheet 1 can be also enhanced.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] Conventionally, as a decorative sheet used for decorating the inner and outer wall surfaces of buildings, etc., a sheet imitating natural stone has been proposed. Also, a sheet is formed by using a resin added with a filler as a coating material, and further, a sheet having a sense of thickness is proposed by providing an uneven pattern on the surface (see, for example, Patent Documents 1 and 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in a decorative sheet using a coating material obtained by adding a filler to a resin, the particle diameter of the filler to be added is selected in consideration of preventing aggregation and thickening of the resin and further considering the stability in the state of the coating material before forming the sheet film.

[0005] However, if the particle diameter of the filler to be added is large, even if the fillers are densely arranged, the gaps between the fillers are large. Therefore, when a decorative sheet is formed using this coating material, there is a problem that the concealment of the base is low.

[0006] The present invention has been made in view of the above points, and an object thereof is to provide a decorative sheet and a method for manufacturing the decorative sheet capable of further improving the concealment of the base.

Means for Solving the Problems

[0007] A decorative sheet according to one aspect of the present invention has at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order. The aggregate layer contains at least an acrylic resin and an inorganic filler, and the inorganic filler has a median diameter d50 in the range of 0.1 μm or more and 10 μm or less.

[0008] Further, a method for manufacturing a decorative sheet according to another aspect of the present invention is a method for manufacturing a decorative sheet having at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order. The method is characterized in that the aggregate layer is formed using a coating material containing an inorganic filler having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and an acrylic resin.

Effects of the Invention

[0009] According to one aspect of the present invention, a decorative sheet with high concealability with respect to the substrate can be easily obtained.

Brief Description of the Drawings

[0010]

Figure 1

Modes for Carrying Out the Invention

[0011] Hereinafter, embodiments of the present technology will be described with reference to the drawings.

[0012] Here, the drawings are schematic, and the relationship between thickness and planar dimensions, the ratio of the thickness of each layer, etc. are different from the actual ones. As long as it is within the scope of the present disclosure, it is not necessarily required to be laminated in the order shown in the drawings. Also, layers not described in these drawings may be added. Further, the following embodiments illustrate configurations for embodying the technical idea of the present disclosure, and the technical idea of the present disclosure is not limited to the materials, shapes, structures, etc. of the components being the following. The technical idea of the present disclosure can be variously modified within the technical scope defined by the claims described in the claims.

[0013] Also, the directions of "left and right" and "up and down" in the following description are merely definitions for convenience of explanation and do not limit the technical idea of the present disclosure. Therefore, for example, if the paper surface is rotated by 90 degrees, "left and right" and "up and down" are read in exchange, and if the paper surface is rotated by 180 degrees, "left" becomes "right" and "right" becomes "left", of course.

[0014] (Configuration of the decorative sheet) FIG. 1 is a cross-sectional view schematically showing an example of a decorative sheet 1 according to an embodiment of the present invention. As shown in FIG. 1, the decorative sheet 1 includes a base material layer 2, an aggregate layer 3, a printed pattern layer 4, and a surface protection layer 5, and these layers are laminated in this order. Further, an uneven pattern 6 is provided on the surface of the surface protection layer 5 on the side opposite to the printed pattern layer 4.

[0015] Note that in FIG. 1, the decorative sheet 1 includes a base material layer 2, an aggregate layer 3, a printed pattern layer 4, and a surface protection layer 5, but it is not limited thereto. For example, the surface protection layer 5 may be multilayered in order to adjust the glossiness. Also, in order to improve the adhesion strength between the printed pattern layer 4 and the aggregate layer 3, a primer layer may be provided between the printed pattern layer 4 and the aggregate layer 3. Further, an adhesive layer may be provided on the surface of the decorative sheet 1 on the side opposite to the surface protection layer 5, that is, the side to be attached to the base material or the like, and a joint layer that serves as a joint may also be provided.

[0016] Further, the decorative sheet 1 includes at least a base material layer 2, an aggregate layer 3, a printed pattern layer 4, and a surface protection layer 5, and is formed such that the thinnest part among the entire thickness of the decorative sheet 1 is 0.1 mm or more. When there is an additional layer in addition to the four layers of the base material layer 2, the aggregate layer 3, the printed pattern layer 4, and the surface protection layer 5, including this layer, the thickness of the thinnest part of the entire decorative sheet 1 is formed to be 0.1 mm or more.

[0017] (Base material layer) The base material layer 2 preferably has flexibility, water vapor permeability, etc. For example, glass non-woven fabric, woven fabric, non-woven fabric, mesh, cloth, etc. can be applied.

[0018] (Aggregate layer) The aggregate layer 3 is formed by including an acrylic resin and an inorganic filler. The inorganic filler has a value within the range of 0.1 μm or more and 10 μm or less for the median diameter d50 in its particle size distribution.

[0019] By adding an inorganic filler to the aggregate layer 3, aggregation and thickening of the acrylic resin can be prevented, and further, stability in the state of the coating material before film formation of the sheet can be ensured. Further, since the median diameter d50 of the inorganic filler is within the range of 0.1 μm or more and 10 μm or less, the inorganic filler can take a closest-packed structure in the aggregate layer 3, whereby the gaps between the inorganic fillers can be made smaller, and as a result, the hiding property can be improved.

[0020] The aggregate layer 3 contains at least 50 g / m 2 or more. Here, 50 g / m 2 or more refers to the content of the inorganic filler when in the state of being formed into a film in the state of the decorative sheet 1.

[0021] As the inorganic filler, calcium carbonate, titanium oxide, talc, etc. can be applied, and any one of these, or a mixture of a plurality of fillers can be used as the inorganic filler. Calcium carbonate is white and inexpensive, so it is suitable as an inorganic filler from the viewpoint of hiding power. Titanium oxide is a typical inorganic pigment and is preferable as an inorganic filler because of its high hiding power. As the inorganic filler, common inorganic fillers such as mica, fibrous fillers, and silica can also be applied. Among them, white fillers are more preferable because the range of colors that can be expressed in the printed pattern layer 4 is wider compared to black and other colors.

[0022] Further, the aggregate layer 3 preferably contains a flame retardant as a functional filler. By adding a flame retardant as a functional filler to the aggregate layer 3, the total heat release amount of the decorative sheet can be suppressed, and the decorative sheet can be imparted with non-combustibility. As the functional filler, common flame retardants can be applied, for example, aluminum hydroxide, etc. can be applied. Since the total heat release amount of the decorative sheet 1 can be suppressed, by using the decorative sheet 1 as a non-combustible material for interior decoration etc., treatment such as leveling of the base material becomes unnecessary, and the construction period can be shortened accordingly. Also, as the flame retardant (functional filler), the above-mentioned aluminum hydroxide, hydrated metal-based materials such as magnesium hydroxide, phosphorus-based materials such as red phosphorus and phosphorus compounds, nitrogen-based materials such as ammonium carbonate, triazine compounds such as melamine cyanurate and guanidine compounds, silicon-based materials such as silicon polymer, halogen-based materials such as various metal compounds such as zinc oxide, zinc borate, and zinc stannate can be applied. Hydrated metal-based materials are particularly preferable because of their high decomposition temperature and large endothermic amount.

[0023] Further, the aggregate layer 3 preferably contains a mixture of at least 5% by mass or more and 15% by mass or less of an acrylic resin and 85% by mass or more and 95% by mass or less of an inorganic filler. By forming the aggregate layer 3 containing such a mixture, the total heat release amount of the decorative sheet 1 can also be suppressed.

[0024] In addition, as the inorganic filler, a plurality of fillers of different types may be added. That is, the median diameter d50 of the plurality of fillers of different types added may be a value within the range of 0.1 μm or more and 10 μm or less, and in this case, the same effects as described above can be obtained.

[0025] Further, as the inorganic filler, fillers of different types and having different median diameters may be added. That is, for example, titanium oxide (the first material) having a median diameter d50 within the range of 0.1 μm or more and 10 μm or less, and calcium carbonate (the second material) having a median diameter d50 within the range of 50 μm or more and 500 μm or less may be added as the inorganic filler. Here, when only a filler with a relatively small median diameter d50 is added, a large amount of filler needs to be added to ensure hiding power, which leads to an increase in the weight of the decorative sheet 1. By adding a filler with a relatively small median diameter d50 and a filler with a relatively large median diameter d50, an increase in the weight of the decorative sheet 1 can be suppressed. At this time, the filler with a small median diameter d50 enters the gaps between the fillers with a large median diameter d50 and forms a closest packing structure in these gaps, thereby ensuring hiding power. Therefore, it is possible to improve the hiding power while suppressing an increase in the weight of the decorative sheet 1. In addition, when only a filler with a small median diameter d50 is added, the surface area of the filler increases, so the dispersibility may decrease. To suppress this and achieve both hiding power and dispersibility, it is more preferable to add two or more types of fillers having different median diameters d50.

[0026] Moreover, it is not limited to the case of adding titanium oxide and calcium carbonate as the inorganic filler. For example, other combinations of materials such as silica and calcium carbonate may be used.

[0027] The same applies when the inorganic filler consists of three or more materials. In this case, the median diameters d50 of the different materials are different, and at least one of the materials should have a median diameter d50 within the range of 0.1 μm or more and 10 μm or less.

[0028] Also, when only an inorganic filler having a certain median diameter d50 is used, when the inorganic filler takes on a closest-packed structure, it is difficult for unevenness to occur on the surface of the decorative sheet 1. However, when two or more inorganic fillers with different median diameters d50 are mixed, appropriate unevenness occurs on the surface of the decorative sheet 1, improving the flatness concealment property.

[0029] When adding a plurality of types of inorganic fillers with different median diameters d50, it is preferable to select a median diameter d50 such that the gaps between the relatively large-diameter inorganic fillers can be filled by the relatively small-diameter inorganic fillers.

[0030] (Printed pattern layer) The printed pattern layer 4 is formed by including a pigment component mainly composed of an inorganic pigment. By forming the printed pattern layer 4 using a pigment component mainly composed of an inorganic pigment, deterioration of the printed pattern layer 4 over time and due to light can be suppressed, and concealment can be maintained.

[0031] The printed pattern layer 4 can be printed by known printing methods such as inkjet printing, gravure printing, intaglio printing, flexographic printing, silk printing, etc. The forming method of the printed pattern layer 4 is not necessarily limited to this. Also, the ink used is a known one, that is, a coloring agent such as a dye or pigment and an extender pigment, etc. are added to a vehicle, and further a plasticizer, stabilizer, wax, grease, desiccant, curing agent, thickener, dispersant, filler, etc. are optionally added and kneaded well with a solvent, diluent, etc. It can be an ink thus formed.

[0032] As the pattern formed by the printed pattern layer 4, any pattern can be used, but for example, it is formed into a stone pattern.

[0033] The thickness of the printed pattern layer 4 is preferably in the range of 1 μm or more and 10 μm or less. This is because when the thickness of the printed pattern layer 4 is 1 μm or more, printing can be made clear. Also, when the thickness of the printed pattern layer 4 is 10 μm or less, the print workability in manufacturing the decorative sheet 1 is improved, and the manufacturing cost can be suppressed.

[0034] Further, to the printed pattern layer 4, for imparting various functions, for example, functional additives such as extender pigments, plasticizers, dispersants, surfactants, tackifiers, adhesion aids, desiccants, curing agents, curing accelerators, and curing retarders may be added.

[0035] (Surface protection layer) The surface protection layer 5 is a layer provided to impart functions such as weather resistance, scratch resistance, stain resistance, and design to the decorative sheet 1.

[0036] The surface protection layer 5 is formed of a resin mainly composed of any one of acrylic resins, fluororesins, and silicone resins, or a mixture of any plurality of these resins, or a copolymer of any plurality of these resins.

[0037] The surface protection layer 5 may contain, as necessary, various additives such as weathering agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, ultraviolet absorbers, heat stabilizers, light stabilizers, antiblocking agents, catalyst scavengers, colorants, light diffusing agents, and gloss modifiers.

[0038] Further, the surface protection layer 5 may contain, as necessary, functional additives such as antibacterial agents and antifungal agents.

[0039] (Uneven pattern) The uneven pattern 6 is formed by embossing the surface of the aggregate layer 3 after applying a coating material that will become the aggregate layer 3, and laminating a printed pattern layer 4 and a surface protection layer 5 in this order on the aggregate layer 3 having the uneven shape on its surface, thereby forming it on the surface of the decorative sheet 1. By providing the uneven pattern 6, when lighting or the like hits the surface protection layer 5, the color difference of the base material is reduced by shadows or the like, leading to an improvement in concealment. Note that the uneven pattern 6 does not necessarily have to be provided.

[0040] (Manufacturing method of decorative sheet) Hereinafter, an example of the manufacturing method of the decorative sheet 1 according to the present embodiment will be briefly described. Prepare a coating material obtained by adding an inorganic filler to an acrylic emulsion. On one surface of a base material layer 2 made of glass non-woven fabric or the like, uniformly apply the coating material to form an aggregate layer 3.

[0041] When providing an uneven shape to the aggregate layer 3, after applying the coating material, press a silicon mold onto the surface of the applied coating material to form an uneven shape. After drying the aggregate layer 3, form a printed pattern layer 4 on the surface of the aggregate layer 3, for example, by inkjet printing, and apply an acrylic resin or the like on the printed pattern layer 4 to form a surface protection layer 5. By sequentially forming the printed pattern layer 4 and the surface protection layer 5 along the uneven shape of the aggregate layer 3, an uneven pattern 6 is formed on the surface of the surface protection layer 5. Thereby, the decorative sheet 1 according to the present embodiment is formed.

[0042] Note that the above-described embodiment is an example of the present invention, and the present invention is not limited to the above-described embodiment, and various modifications can be made according to the design or the like as long as it does not deviate from the technical idea of the present invention even in forms other than this embodiment.

[0043] (Effect) (1) The decorative sheet 1 according to this embodiment forms the aggregate layer 3 including at least an acrylic resin and an inorganic filler. At this time, the inorganic filler is a filler having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less in the particle size distribution. In the aggregate layer 3, since the inorganic filler takes a closest-packed structure, the inorganic filler exists densely, and further, for example, the gaps between the inorganic fillers are smaller compared to the case where the median diameter d50 is 500 μm. Therefore, the hiding property of the aggregate layer 3 is improved, that is, the hiding property of the decorative sheet 1 can be improved. As a result, for example, the hiding property of the decorative sheet 1 can be easily improved by adjusting the particle diameter of the inorganic filler without coloring the aggregate layer 3 or separately providing a hiding layer.

[0044] Also, by using as the inorganic filler a filler (for example, titanium oxide) made of a first material and having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and a filler (for example, calcium carbonate) made of a second material different from the first material and having a median diameter d50 in the range of 50 μm or more and 500 μm or less, for example, the small-diameter filler enters the gaps between the large-diameter fillers, and both the large-diameter and small-diameter fillers take a closest-packed structure, so that the hiding property of the aggregate layer 3 can be improved. At this time, when only the small-diameter filler is used, the addition amount of the small-diameter filler increases as the hiding property of the aggregate layer 3 is increased, and as a result, the weight of the decorative sheet 1 increases. On the other hand, by using not only the small-diameter filler but also inorganic fillers having different median diameters d50 such as large-diameter fillers, the gaps become smaller, and the hiding property can be improved while suppressing an increase in the weight of the decorative sheet 1.

[0045] (2) In the aggregate layer 3, by setting the addition amount of the inorganic filler to 50 g / m 2 or more and setting the thickness of the thinnest part of the decorative sheet 1 to 0.1 mm or more, the hiding property of the decorative sheet 1 can be more reliably ensured. In addition, by forming a printed pattern layer containing a pigment component mainly composed of an inorganic pigment, deterioration over time and by light can be suppressed, so that a decrease in concealability can be suppressed. Further, by providing an uneven pattern 6 on the surface of the aggregate layer 3, the color difference of the base material can be suppressed by the shadow caused by illumination, and the concealability can be improved.

[0046] (3) Further, by adding a functional filler made of a flame retardant to the aggregate layer 3, it can be used as a non-combustible material.

[0047] (4) In a decorative sheet having at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order, an inorganic filler having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and an acrylic resin are used. Since the aggregate layer 3 is formed using the coating material containing the above, the inorganic filler is densely present in the aggregate layer 3, so that the gaps become small, and the concealability of the aggregate layer 3 can be easily improved, that is, the concealability of the decorative sheet 1 can be easily improved.

Example

[0048] Hereinafter, the present invention will be described in detail by showing examples and comparative examples. Note that the present invention is not limited to the following examples.

[0049] (Example 1) Titanium oxide (TiO2) was added as an inorganic filler to 1000 g of an acrylic emulsion to prepare a coating material. The median diameter d50 of the inorganic filler was in the range of 0.1 μm or more and 10 μm. The inorganic filler had a basis weight of 500 g / m 2 and was added accordingly. This coating material was uniformly applied to a base material layer made of a glass nonwoven fabric to obtain a sheet having a thickness of 2.0 mm. After drying this sheet, a printed pattern was applied to the surface of this sheet by inkjet printing, and a surface protection layer made of an acrylic resin was further applied with a thickness of 15 μm to produce a decorative sheet. The inkjet printing was performed using an organic printing pigment. The thickness of the thinnest part of the decorative sheet was set to 0.1 mm.

[0050] (Example 2) An inorganic filler was added so that the basis weight was 250 g / m 2 A decorative sheet of Example 2 was obtained in the same manner as in Example 1 above, except for the addition.

[0051] (Example 3) An inorganic filler was added so that the basis weight was 100 g / m 2 A decorative sheet of Example 3 was obtained in the same manner as in Example 1 above, except for the addition.

[0052] (Example 4) An inorganic filler was added so that the basis weight was 50 g / m 2 A decorative sheet of Example 4 was obtained in the same manner as in Example 1 above, except for the addition.

[0053] (Example 5) A decorative sheet of Example 5 was obtained in the same manner as in Example 4 above, except that talc was added as the inorganic filler.

[0054] (Example 6) A decorative sheet of Example 6 was obtained in the same manner as in Example 4 above, except that calcium carbonate (CaCO3) was added as the inorganic filler.

[0055] (Example 7) A decorative sheet of Example 7 was obtained in the same manner as in Example 4 above, except that inkjet printing was performed using an inorganic printing pigment.

[0056] (Example 8) A decorative sheet of Example 8 was obtained in the same manner as in Example 7 above, except that after applying a coating material to a glass nonwoven fabric to form a sheet and before drying, a silicon mold was embossed on the sheet surface to form a concavo-convex shape.

[0057] (Example 9) For 5 g of the acrylic emulsion, an inorganic filler was added to obtain a coating material such that the basis weight was 50 g / m 2 A decorative sheet of Example 9 was obtained in the same manner as in Example 8 except that the coating material was prepared by adding the inorganic filler.

[0058] (Example 10) As the functional filler, aluminum hydroxide (Al(OH)3) was added such that the basis weight was 5 g / m 2 A decorative sheet of Example 10 was obtained in the same manner as in Example 8 except for the above addition.

[0059] (Example 11) As the inorganic filler, titanium dioxide (TiO2) having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and calcium carbonate (CaCO3) having a median diameter d50 in the range of 50 μm or more and 500 μm or less were used. Titanium dioxide (TiO2) was added such that the basis weight was 25 g / m 2 and calcium carbonate (CaCO3) was added such that the basis weight was 25 g / m 2 A decorative sheet of Example 11 was obtained in the same manner as in Example 10 except for the above addition.

[0060] (Comparative Example 1) A decorative sheet of Comparative Example 1 was obtained in the same procedure as in Example 6 except that calcium carbonate (CaCO3) having a median diameter d50 in the range of 50 μm or more and 500 μm or less was used as the inorganic filler.

[0061] [Evaluation] For each of the decorative members of the examples and comparative examples, evaluations were conducted on the color hiding property, unevenness hiding property, weather resistance, and total heat release amount during combustion. The evaluation methods are as follows.

[0062] (Color hiding property) A white base paper and a black base paper were placed under the decorative sheet to be evaluated, and colorimetry was performed using a colorimeter (manufactured by Konica Minolta, Inc.) from above the decorative sheet to measure the lightness (L*) and chromaticity (a*, b*), and the color difference ΔE (= (a *2 + b *2 + L *2 ) 1 / 2Evaluate the concealability from

[0063] ΔE > 4.0: △ ΔE = 3.0 or more and less than 4.0: ○ ΔE < 3.0: ◎

[0064] (Uneven concealability) Use double-sided tape (manufactured by 3M Japan Limited) on the uneven wall, stick the decorative sheet to be evaluated, and evaluate by touching the surface of the decorative sheet by hand.

[0065] When the unevenness of the wall surface is not visible: ◎ When the unevenness of the wall surface is slightly visible: 〇 When the unevenness of the wall surface is clearly visible: △

[0066] (Weather resistance) Using a sunshine weather meter (manufactured by Suga Test Instruments Co., Ltd.), in the mode of rainfall for the first 18 minutes within 120 minutes, taking the decorative sheet to be evaluated as a sample, obtain samples left for 1000 hours, 2000 hours, 3000 hours, and 4000 hours respectively. Check the samples after the test and detect the time when discoloration is not confirmed.

[0067] (Total heat release during combustion) Apply a construction sealer to a standard gypsum board (non-combustible or semi-non-combustible), and then dry it. Next, apply a construction paste on the construction sealer, then paste the decorative sheet to be evaluated as a test piece, and then dry it in a desiccator for 48 hours or more. By heating this sample with a cone heater, ignite and burn the generated gas with a spark igniter, and examine the calorific value by measuring the oxygen concentration of the combustion gas. When the total heat release is 8.0 MJ / m 2 The following, it falls within the range of non-combustible materials for fire protection certification. The total heat release is 8 MJ / m 2 or more: 〇 The total heat release is 8 MJ / m 2 or less: ◎

[0068]

Table 1

[0069] From Table 1, it was confirmed that good evaluation results can be obtained if an inorganic filler with a median diameter d50 in the range of 0.1 μm or more and 10 μm or less is added, and also if the basis weight is 50 g / m 2 or more. Furthermore, it was confirmed that by adding an inorganic filler (TiO2) with a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and an inorganic filler different in type and median diameter d50 from this inorganic filler (for example, CaCO3 with a median diameter d50 in the range of 50 μm or more and 500 μm or less), higher evaluation results can be obtained in all evaluation items.

[0070] On the other hand, when only an inorganic filler (CaCO3) with a median diameter d50 in the range of 50 μm or more and 500 μm or less is added as the inorganic filler, sufficient color hiding power could not be obtained as compared with the case where only an inorganic filler with a median diameter d50 in the range of 0.1 μm or more and 10 μm or less is added. Also, it was confirmed that the weather resistance is improved when the printed pattern layer is formed using an inorganic printing pigment as compared with the case where it is formed using an organic printing pigment.

[0071] Note that the present invention can have, for example, the following configurations. (1) having at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order, the aggregate layer containing at least an acrylic resin and an inorganic filler, the inorganic filler having a value of median diameter d50 in the range of 0.1 μm or more and 10 μm or less, a decorative sheet. (2) The inorganic filler includes a plurality of fillers made of different types of materials, the median diameters d50 of the plurality of fillers are different from each other, and the median diameter d50 of one of the plurality of fillers is a value within the range of 0.1 μm or more and 10 μm or less. The decorative sheet according to (1) above, characterized in that. (3) The inorganic filler is a filler made of a first material and having a median diameter d50 within the range of 0.1 μm or more and 10 μm or less, and a filler made of a second material different from the first material and having a median diameter d50 within the range of 50 μm or more and 500 μm or less. The decorative sheet according to (1) above, characterized in that. (4) The aggregate layer contains 50 g / m 2 or more of the inorganic filler. The decorative sheet according to any one of (1) to (3) above, characterized in that. (5) The inorganic filler contains calcium carbonate. The decorative sheet according to any one of (1) to (4) above, characterized in that. (6) The inorganic filler contains titanium oxide. The decorative sheet according to any one of (1) to (5) above, characterized in that. (7) The surface protective layer is mainly composed of any one or a mixture of acrylic resin, fluororesin, and silicone resin, or a copolymer of any plurality of resins. The decorative sheet according to any one of (1) to (6) above, characterized in that. (8) The thickness of at least the thinnest part is 0.1 mm or more. The decorative sheet according to any one of (1) to (7) above, characterized in that. (9) The printed pattern layer contains a pigment component mainly composed of an inorganic pigment. The decorative sheet according to any one of (1) to (8) above, characterized in that. (10) The aggregate layer contains a mixture of 5% by mass or more and 15% by mass or less of the acrylic resin and 85% by mass or more and 95% by mass or less of the inorganic filler, and is characterized in that it is the decorative sheet according to any one of (1) to (9) above. (11) The aggregate layer contains a functional filler made of a flame retardant, and is characterized in that it is the decorative sheet according to any one of (1) to (10) above. (12) The decorative sheet according to any one of (1) to (11) above, wherein an uneven pattern is formed on the surface of the aggregate layer on the side of the printed pattern layer. (13) A method for manufacturing a decorative sheet having at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order, A method for manufacturing a decorative sheet, characterized in that the aggregate layer is formed using a coating material containing an inorganic filler having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and an acrylic resin.

Explanation of symbols

[0072] 1 Decorative sheet 2 Base material layer 3 Aggregate layer 4 Printed pattern layer 5 Surface protection layer 6 Uneven pattern

Claims

1. It has at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order, The aggregate layer contains at least an acrylic resin and an inorganic filler, The inorganic filler is characterized in that the median diameter d50 is a value within the range of 0.1 μm or more and 10 μm or less, and it is a decorative sheet.

2. The inorganic filler contains a plurality of types of fillers made of different materials, the median diameters d50 of the plurality of types of fillers are different from each other, and the median diameter d50 of one of the plurality of types of fillers is a value within the range of 0.1 μm or more and 10 μm or less. The decorative sheet according to Claim 1, characterized in that

3. The inorganic filler is a filler made of a first material and having a median diameter d50 within the range of 0.1 μm or more and 10 μm or less, and a filler made of a second material different from the first material and having a median diameter d50 within the range of 50 μm or more and 500 μm or less. The decorative sheet according to Claim 1, characterized in that

4. The aggregate layer contains 50 g / m or more of the inorganic filler. ２ The decorative sheet according to any one of claims 1 to 3, characterized in that it contains the above.

5. The inorganic filler contains calcium carbonate, and the decorative sheet according to any one of Claims 1 to 3, characterized in that

6. The inorganic filler contains titanium oxide, and the decorative sheet according to any one of Claims 1 to 3, characterized in that

7. The surface protection layer is mainly composed of any one or a mixture of a plurality of acrylic resins, fluororesins, and silicone-based resins, or a copolymer of any plurality of resins. The decorative sheet according to any one of Claims 1 to 3, characterized in that

8. The decorative sheet according to any one of Claims 1 to 3, characterized in that at least the thickness of the thinnest part is 0.1 mm or more.

9. The printed pattern layer contains a pigment component mainly composed of an inorganic pigment, and the decorative sheet according to any one of Claims 1 to 3, characterized in that

10. The aggregate layer contains a mixture of 5% by mass or more and 15% by mass or less of the acrylic resin and 85% by mass or more and 95% by mass or less of the inorganic filler. The decorative sheet according to any one of Claims 1 to 3, characterized in that

11. The aggregate layer contains a functional filler made of a flame retardant, and the decorative sheet according to any one of Claims 1 to 3, characterized in that

12. The decorative sheet according to any one of claims 1 to 3, characterized in that an uneven pattern is formed on the surface of the aggregate layer on the side of the printed pattern layer.

13. A method for manufacturing a decorative sheet having at least a surface protection layer, a printed pattern layer, an aggregate layer, and a base material layer in this order, A method for manufacturing a decorative sheet, characterized in that the aggregate layer is formed using a coating material containing an inorganic filler having a median diameter d50 in the range of 0.1 μm or more and 10 μm or less and an acrylic resin.

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