Decorative sheet, method for producing the same and decorative material

Abstract

To provide a decorative sheet capable of suppressing deterioration in designability and hygiene even if containing a recycled resin, a method for producing the same and a decorative material.SOLUTION: There is provided a decorative sheet having a colored resin layer, a printed layer including a pattern part and a transparent resin layer in this order, wherein at least the colored resin layer includes a recycled resin, the recycled resin includes a chemically recycled resin and an embossed part is provided at a position overlapping the pattern part in the thickness direction of the decorative sheet on a surface opposite to the pattern part of the transparent resin layer.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a cosmetic sheet, a method for manufacturing the same, and a cosmetic material.

Background Art

[0002] As a member constituting a cosmetic sheet, a laminate in which a printed layer having a pattern portion such as a pattern is provided on a colored resin layer is used. Generally, a transparent resin layer formed of a transparent resin material is further laminated on the printed layer to improve the design property. For example, in Patent Document 1 below, a printed layer having a pattern portion, a transparent resin layer, and a surface protective layer are laminated in this order on one surface of a colored resin layer, and a light-absorbing pattern layer arranged in synchronization with the pattern portion is laminated on the other surface of the colored resin layer. A cosmetic sheet is disclosed in which an embossed portion is formed at a position where the surface protective layer overlaps the pattern layer in a plan view.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, conventionally, most of the resins used for cosmetic sheets were petroleum-derived resins. However, with the increasing environmental problems, recycled resins are being used to reduce the environmental load.

[0005] However, the cosmetic sheet described in Patent Document 1 above had the following problems. That is, even if the resin contained in the colored resin layer is a recycled resin, when the recycled resin is a recycled resin containing contaminants, so-called material recycled resin, foreign substances such as impurities, gels, and aggregates may appear on the surface. In the decorative sheet of Patent Document 1, it is desired that a gloss matte (mat finish) synchronized with the pattern portion is expressed by the embossed portion. However, due to the above-mentioned impurities and foreign substances, a gloss matte may also be expressed in a portion different from the pattern portion. The decorative sheet described in Patent Document 1 had room for improvement in terms of suppressing a decrease in design quality.

[0006] Further, in the decorative sheet described in Patent Document 1, even if the resin contained in the colored resin layer is a recycled resin, when the recycled resin is a material recycled resin, an odor component generated due to thermal degradation of the resin is detected, and there is also room for improvement in terms of hygiene.

[0007] An object of the present disclosure is to provide a decorative sheet, a method for manufacturing the same, and a decorative material that can suppress a decrease in design quality and hygiene even when containing a recycled resin.

Means for Solving the Problems

[0008] In order to solve the above problems, the present disclosure provides the following decorative sheet, a method for manufacturing the same, and a decorative material.

[0009] [1] A decorative sheet including a colored resin layer, a printed layer including a pattern portion, and a transparent resin layer in this order, at least the colored resin layer contains a recycled resin, the recycled resin contains a chemical recycled resin, An embossed portion is provided on the surface of the transparent resin layer on the side opposite to the pattern portion at a position overlapping the pattern portion in the thickness direction of the decorative sheet. [2] The decorative sheet according to [1], wherein the recycled resin contains a post-consumer recycled resin. [3] The colored resin layer further includes an infrared absorption layer on the surface opposite to the pattern portion. The cosmetic sheet according to [1] or [2], wherein the infrared absorption layer and the pattern portion overlap each other in the thickness direction of the cosmetic sheet. [4] The cosmetic sheet according to [3], wherein the infrared absorption layer contains carbon black. [5] A method for manufacturing a cosmetic sheet for manufacturing the cosmetic sheet according to any one of [1] to [4], comprising: a laminate preparation step of preparing a laminate having the colored resin layer, a printing layer including the pattern portion, and the transparent resin layer in this order; An embossing portion forming step of forming the embossing portion on a surface of the transparent resin layer of the laminate opposite to the pattern portion; At least the colored resin layer contains a recycled resin; A method for manufacturing a cosmetic sheet, wherein the recycled resin contains a chemical recycled resin. [6] In the laminate preparation step, the laminate further includes an infrared absorption layer disposed at a position overlapping the pattern portion in the thickness direction of the laminate on a surface of the colored resin layer opposite to the pattern portion; The method for manufacturing a cosmetic sheet according to [5], further comprising an infrared irradiation step of irradiating the infrared absorption layer with infrared rays after the laminate preparation step. [7] A cosmetic material comprising a base material and a cosmetic sheet adhered to the base material; The cosmetic sheet is the cosmetic sheet according to any one of [1] to [4].

[0010] According to the cosmetic sheet according to [1] above, since the colored resin layer contains a recycled resin and the recycled resin contains a chemical recycled resin, even if the recycled resin is contained, a decrease in design property and hygiene can be suppressed.

[0011] The inventors of the present disclosure speculate on the reasons for obtaining such effects as follows. That is, the chemical recycling resin contained in the recycled resin is a recycled resin produced by polymerizing after once being depolymerized through a process such as a process of gasifying, oilifying, and purifying waste resin into monomers via naphtha, or a process of monomerizing by depolymerization according to the material properties. Therefore, the chemical recycling resin is less likely to be contaminated with foreign substances such as impurities, gels, and aggregates compared to the material recycling resin, which is a resin that is washed, pulverized, and then heated and melted to be recycled into raw materials after the resin products such as recovered used packaging materials are washed and pulverized. In addition, unlike the material recycling resin, the chemical recycling resin is not affected by heat treatment such as heating and melting after going through the recycling process, so thermal degradation is less likely to occur. For this reason, unevenness due to impurities and foreign substances is less likely to occur on the surface of the colored resin layer. As a result, when the decorative sheet is viewed from the embossed portion side, the appearance of gloss and matte due to the uneven portions formed by impurities and foreign substances in the portions other than the embossed portion is suppressed, and the deterioration of the design property of the decorative sheet is suppressed. Furthermore, since the recycled resin contains the chemical recycling resin, the generation of odor components caused by the mechanical recycling resin is suppressed, and the deterioration of the hygiene of the decorative sheet is suppressed. From the above, the inventors of the present disclosure speculate that the above effects can be obtained.

[0012] According to the decorative sheet according to the above [2], the recycled resin contains the post-consumer recycled resin, and the post-consumer recycled resin can secure a large quantity in the market and has stable quality compared to the recycled materials collected from ordinary industrial waste. Therefore, the decorative sheet according to the above [2] can also stabilize its quality.

[0013] According to the cosmetic sheet according to [3] above, since infrared rays are absorbed by the infrared absorption layer, when the cosmetic sheet is viewed from the embossed portion side, a gloss matte is effectively exhibited at the position of the embossed portion. Further, since there is an infrared absorption layer, for example, when the cosmetic sheet is applied outdoors, infrared rays are absorbed by the infrared absorption layer, and the temperature of the infrared absorption layer rises, so that the temperatures of the colored resin layer and the transparent resin layer also rise. Therefore, even when the cosmetic sheet is bent, the colored resin layer and the transparent resin layer are softened and less likely to crack.

[0014] According to the cosmetic sheet according to [4] above, since the infrared absorption layer contains carbon black, the blackness degree of the infrared absorption layer increases, and the visual influence of the infrared absorption layer can be alleviated, so that a synchronized gloss matte expression in light colors becomes possible.

[0015] According to the method for manufacturing a cosmetic sheet according to [5] above, since the colored resin layer of the laminate contains a recycled resin and the recycled resin contains a chemical recycled resin, it is possible to manufacture a cosmetic sheet that can suppress a decrease in design and hygiene even when containing a recycled resin.

[0016] According to the method for manufacturing a cosmetic sheet according to [6] above, since the manufacturing method further includes an infrared irradiation step of irradiating the infrared absorption layer with infrared rays between the laminate preparation step and the embossed portion formation step, infrared rays are absorbed by the infrared absorption layer and the temperature of the infrared absorption layer rises, and the temperature of the portion of the transparent resin layer that overlaps with the infrared absorption layer rises, and this portion is likely to soften, so that it becomes easier to form the embossed portion.

[0017] According to the cosmetic material according to [7] above, since the cosmetic sheet is attached to the base material, the colored resin layer contained in the cosmetic sheet contains a recycled resin, and the recycled resin contains a chemical recycled resin, it is possible to suppress a decrease in design and hygiene even when containing a recycled resin.

Effects of the Invention

[0018] According to the present disclosure, it is possible to provide a decorative sheet, a method for manufacturing the same, and a decorative material that can suppress a decrease in design and hygiene even when containing recycled resin.

Brief Description of Drawings

[0019]

Figure 1

Figure 2

Figure 3

Embodiments for Carrying Out the Invention

[0020] Hereinafter, embodiments of the present disclosure will be described in detail.

[0021] <Decorative Sheet> FIG. 1 is a cross-sectional view showing an embodiment of the decorative sheet of the present disclosure. The decorative sheet 100 shown in FIG. 1 includes a colored resin layer 10, a printing layer 20 including a pattern portion 21, and a transparent resin layer 30 in this order. On the surface of the transparent resin layer 30 opposite to the pattern portion 21, an embossed portion 31 is provided at a position overlapping the pattern portion 21 in the thickness direction of the decorative sheet 100. In the decorative sheet 100, at least the colored resin layer 10 contains recycled resin, and the recycled resin is chemical recycled resin.

[0022] The decorative sheet 100 may further include an adhesive layer 25 between the printing layer 20 and the transparent resin layer 30. Further, the decorative sheet 100 may further have a surface protection layer 50 on the side of the transparent resin layer 30 opposite to the pattern portion 21. An embossed portion 51 may be provided at a position overlapping the pattern portion 21 in the thickness direction of the decorative sheet 100 on the surface of the surface protection layer 50 opposite to the pattern portion 21. Furthermore, the cosmetic sheet 100 may further include an infrared absorption layer 70 at a position overlapping the pattern portion 21 in the thickness direction of the cosmetic sheet 100 on the surface of the colored resin layer 10 opposite to the pattern portion 21. Furthermore, the cosmetic sheet 100 may further have a back primer layer 60 that covers the infrared absorption layer 70 on the surface of the colored resin layer 10 opposite to the pattern portion 21.

[0023] According to the cosmetic sheet 100, since the colored resin layer 10 contains a recycled resin and the recycled resin contains a chemical recycled resin, even if it contains a recycled resin, it is possible to suppress a decrease in design and hygiene.

[0024] Hereinafter, the colored resin layer 10, the ink primer layer, the printing layer 20, the adhesive layer 25, the transparent resin layer 30, the surface protective layer 50, the back primer layer 60, and the infrared absorption layer 70 will be described in detail.

[0025] (Colored Resin Layer) The colored resin layer 10 is a layer made of a resin composition containing a thermoplastic resin. The resin composition further contains a colorant. The colored resin layer 10 may be a layer formed by forming a layer containing a colorant on the surface of a layer made of a resin composition not containing a colorant.

[0026] Examples of the thermoplastic resin include polyolefin resin, polyester resin, polyamide resin, and polycarbonate resin. Among them, from the viewpoints of environmental compatibility and processability, polyolefin resin is preferably used. Examples of the polyolefin resin include polyethylene and polypropylene. These can be used alone or in combination of two or more. Examples of the polyester resin include polyethylene terephthalate and polybutylene terephthalate. These can be used alone or in combination of two or more.

[0027] The thermoplastic resin includes recycled resin. The thermoplastic resin may be composed of only recycled resin or may further include non-recycled resin. The recycled resin includes chemical recycled resin. The recycled resin may be composed of only chemical recycled resin or may further include mechanical recycled resin. The recycled resin may be post-consumer recycled resin (PCR), post-industrial recycled resin (PIR), or a mixture thereof, but preferably includes PCR. Since PCR can secure a large quantity in the market and has stable quality compared to recycled materials collected from ordinary industrial waste, it can also stabilize the quality of the cosmetic sheet 100. The chemical recycled resin may be composed of a single chemical recycled resin or may be composed of a mixture of multiple types of chemical recycled resins. The mechanical recycled resin may be composed of a single mechanical recycled resin or may be composed of a mixture of multiple types of mechanical recycled resins. The content rate of the chemical recycled resin in the recycled resin is not particularly limited, but from the viewpoints of suppressing the reduction of design property and hygiene property, it is preferably 30% by mass or more, more preferably 50% by mass or more, and particularly preferably 100% by mass.

[0028] The non-recycled resin may be a petroleum-derived resin obtained using a petroleum-derived raw material monomer, a biomass-derived resin obtained using a biomass-derived raw material monomer, or a mixture thereof, but from the viewpoint of reducing the environmental load, it is preferably a biomass-derived resin.

[0029] Examples of the coloring agent include pigments and dyes. The coloring agent may be appropriately selected so that the colored resin layer 10 exhibits the base color of the pattern portion 21. Examples of the pigment include inorganic pigments such as titanium oxide and iron oxide, and organic pigments such as isoindolinone, disazo, polyazo, diketopyrrolopyrrole, quinacridone, and phthalocyanine. Examples of the dye include dyes such as methylene blue, rhodamine, and indigo.

[0030] The colored resin layer 10 may further contain additives such as an ultraviolet absorber, a light stabilizer, an antioxidant, an antistatic agent, a plasticizer, a lubricant, and a light-shielding pigment, if necessary.

[0031] The thickness of the colored resin layer 10 is not particularly limited and may be 30 μm or more or 50 μm or more. The thickness of the colored resin layer 10 may be 90 μm or less or 70 μm or less. When the thickness of the colored resin layer 10 is 30 μm or more, the decorative sheet 100 can absorb irregularities and steps of a floor material or the like serving as a base, and the decorative sheet 100 can be easily and favorably installed on a base material (not shown). Further, when the thickness of the colored resin layer 10 is 90 μm or less, the bending process of the decorative sheet 100 becomes easy.

[0032] (Printing layer) The printing layer 20 is a layer including a pattern portion 21. The pattern portion 21 is a portion where a pattern is formed with a plurality of colors. The printing layer 20 may further include a plain portion composed of a single color. Examples of the pattern include a wood grain pattern, a stone grain pattern, a cloth grain pattern, a leather grain pattern, a geometric pattern, letters, symbols, line drawings, and the like.

[0033] The printing layer 20 contains a binder resin. The pattern portion 21 further contains a colorant in addition to the binder resin. Examples of the binder resin include a chlorine-based resin, a urethane resin, an acrylic urethane resin, an acrylic resin, a polyester resin, a polyamide resin, a butyral resin, a polystyrene resin, a nitrocellulose resin (nitrocellulose), and a cellulose acetate resin. Examples of the colorant include a pigment and a dye. Examples of the pigment include inorganic pigments such as carbon black, iron black, titanium white (titanium oxide), antimony white, lead yellow, titanium yellow, bengala, cadmium red, ultramarine, and cobalt blue, and organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue. Examples of the dye include dyes such as methylene blue, rhodamine, and indigo.

[0034] The thickness of the printing layer 20 is not particularly limited and can be appropriately set according to the characteristics of the decorative sheet 100, and may be, for example, 1 μm or more, 2 μm or more. Also, the thickness of the printing layer 20 may be 10 mm or less, 0.1 mm or less, or 50 μm or less. The thickness of the printing layer 20 is usually 1 μm or more and 10 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.

[0035] (Adhesive layer) The adhesive layer 25 is provided between the printing layer 20 and the transparent resin layer 30 and is a layer that adheres the printing layer 20 and the transparent resin layer 30. As the adhesive layer 25, for example, a two-component curable urethane-based resin can be used. Also, an adhesive resin may be adhered to the printing layer 20.

[0036] (Transparent resin layer) The transparent resin layer 30 is a layer for improving the weather resistance and abrasion resistance of the decorative sheet 100 and protecting the pattern portion 21 of the printing layer 20. The transparent resin layer 30 is a layer containing a thermoplastic resin and has a light transmittance that allows the printing layer 20 to be visually recognized. Examples of the thermoplastic resin include vinyl chloride resin, acrylic resin, polyolefin resin, and polyester resin. Among them, from the viewpoints of environmental compatibility and processability, polyolefin resin is preferably used. Examples of the polyolefin resin include polyethylene and polypropylene. These can be used alone or in combination of two or more.

[0037] The thermoplastic resin may be a non-recycled resin, a recycled resin, or a mixture thereof. The recycled resin may be a chemical recycled resin, a mechanical recycled resin, or a mixture thereof. From the perspective of suppressing the generation of odor components, the recycled resin preferably contains a chemical recycled resin. The recycled resin may be a post-consumer recycled resin (PCR), a post-industrial recycled resin (PIR), or a mixture thereof, but preferably contains PCR. Since PCR can secure a large quantity in the market and its quality is stable compared to recycled materials collected from ordinary industrial waste, it can also stabilize the quality of the cosmetic sheet 100. The chemical recycled resin may be composed of a single chemical recycled resin or a mixture of multiple types of chemical recycled resins. The mechanical recycled resin may be composed of a single mechanical recycled resin or a mixture of multiple types of mechanical recycled resins.

[0038] The non-recycled resin may be a petroleum-derived resin obtained using a petroleum-derived raw material monomer, a biomass-derived resin obtained using a biomass-derived raw material monomer, or a mixture thereof. From the perspective of reducing environmental impact, it is preferably a biomass-derived resin.

[0039] The transparent resin layer 30 may further contain additives such as fillers, ultraviolet absorbers, light stabilizers, antioxidants, antistatic agents, plasticizers, lubricants, and light-shielding pigments, if necessary.

[0040] The thickness of the transparent resin layer 30 is not particularly limited and can be appropriately set according to the characteristics of the cosmetic sheet 100. For example, it may be 20 μm or more or 30 μm or more. Also, the thickness of the transparent resin layer 30 may be 200 μm or less or 150 μm or less. When the thickness of the transparent resin layer 30 is 20 μm or more, the printing layer 20 can be effectively protected. Also, when the thickness of the transparent resin layer 30 is 150 μm or less, the bending process of the cosmetic sheet 100 becomes easy. The ratio R of the thickness of the transparent resin layer 30 to the thickness of the colored resin layer 10 is not particularly limited and may be less than 1 or 1 or more. It is preferable that this ratio R is greater than 1, more preferably 1.1 or more, and particularly preferably 1.2 or more. This ratio R may be 2 or less, or 1.8 or less. The embossed portion 31 is for imparting a given design property to the decorative sheet 100 and is composed of a concave portion and a convex portion. Since light is scattered in the embossed portion 31, it is difficult for gloss to occur.

[0041] (Surface protective layer) The surface protective layer 50 is a layer that imparts abrasion resistance to the decorative sheet 100 and protects the surface of the transparent resin layer 30. The surface protective layer 50 is a transparent layer and can be formed by coating a resin composition containing a curable resin. As the curable resin, for example, a two-component curable urethane type can be used. For example, the surface protective layer 50 is formed by curing a resin composition containing acrylic polyol as a main agent and hexamethylene diisocyanate as a curing agent.

[0042] The thickness of the surface protective layer 50 is preferably 2 to 7 g / m in terms of solid content coating amount from the viewpoint of general applicability such as coatability and storability of the surface protective layer 50. 2 and more preferably 3 to 6 g / m. 2 That's it.

[0043] (Back primer layer) The back primer layer 60 is a layer for repairing fish eyes that appear on the surface of the colored resin layer 10 and improving the adhesion to a base material (not shown) to which the decorative sheet 100 is attached. The back primer layer 60 contains resin.

[0044] Examples of the resin include acrylic resins, urethane resins, vinyl chloride-vinyl acetate copolymers, epoxy resins, nitrocellulose, etc. The thickness of the back primer layer 60 is not particularly limited and may be 10 μm or less.

[0045] The thickness of the back primer layer 60 is preferably 0.5 μm or more and 10 μm or less, and more preferably 1 μm or more and 10 μm or less. When the thickness of the back primer layer 60 is 0.5 μm or more, the adhesion between the colored resin layer 10 and a base material (not shown) to which the decorative sheet 100 is adhered can be improved.

[0046] (Infrared absorption layer) The infrared absorption layer 70 is composed of an infrared absorption material. When the decorative sheet 100 includes the infrared absorption layer 70, for example, when the decorative sheet is installed outdoors, the infrared absorption layer 70 absorbs infrared rays, and the temperature of the infrared absorption layer 70 increases, so that the temperatures of the colored resin layer 10 and the transparent resin layer 30 also increase. Therefore, even when the decorative sheet 100 is bent, the colored resin layer 10 and the transparent resin layer 30 are softened and less likely to crack.

[0047] The infrared absorption material is not particularly limited as long as it is a material capable of absorbing infrared rays, but carbon black is preferred. Since the infrared absorption layer 70 contains carbon black, the blackness degree of the infrared absorption layer 70 increases, and the visual influence of the infrared absorption layer 70 can be alleviated, so that a light-colored coordinated gloss matte expression becomes possible.

[0048] The thickness of the infrared absorption layer 70 is not particularly limited, but is preferably 0.5 μm or more and 10 μm or less, and more preferably 1 μm or more and 10 μm or less. When the thickness of the infrared absorption layer 70 is 0.5 μm or more, the temperature of the infrared absorption layer 70 is increased by infrared irradiation, and the portion of the transparent resin layer 30 that overlaps the pattern portion 21 in the thickness direction of the decorative sheet 100 is easily softened. Also, when the thickness of the infrared absorption layer 70 is 10 μm or less, the flexibility of the decorative sheet 100 can be further improved.

[0049] (Decorative sheet) The content rate of the recycled resin in the cosmetic sheet 100 is not particularly limited as long as it is higher than 0% by volume, and it may be 10% by volume or more, 20% by volume or more, or 30% by volume or more. Also, the content rate of the recycled resin in the cosmetic sheet 100 may be 98% by volume or less, 90% by volume or less, 60% by volume or less, 50% by volume or less, or 40% by volume or less.

[0050] <Method for manufacturing a cosmetic sheet> Next, embodiments of the method for manufacturing the cosmetic sheet of the present disclosure will be described.

[0051] First, a laminate 101 shown in FIG. 2 is prepared (laminate preparation step). The laminate 101 has a colored resin layer 10, a printing layer 20 including a pattern portion 21, and a transparent resin layer 30 in this order. Here, the laminate 101 may further include an infrared absorption layer 70 disposed on the surface of the colored resin layer 10 opposite to the pattern portion 21 at a position overlapping the pattern portion 21 in the thickness direction of the laminate, and an adhesive layer 25 may be provided between the printing layer 20 and the transparent resin layer 30. Also, the laminate 101 may include a back primer layer 60 covering the infrared absorption layer 70 on the surface of the colored resin layer 10 opposite to the pattern portion 21, and a surface protection layer (not shown in FIG. 2) may be provided on the surface of the transparent resin layer 30 opposite to the pattern portion 21.

[0052] The laminate 101 can be obtained as follows. First, a printing layer 20 having a pattern portion 21 is formed on one surface of the colored resin layer 10, and an infrared absorption layer 70 is formed on the other surface of the colored resin layer 10 so as to overlap the pattern portion 21 in the thickness direction of the colored resin layer 10. At this time, if necessary, a back primer layer 60 may be formed so as to cover the infrared absorption layer 70. The back primer layer 60 can be formed by applying a resin composition (back primer) containing a resin and an organic solvent to the surface of the colored resin layer 10 and drying it.

[0053] Next, a transparent resin layer 30 is attached to the surface of the printing layer 20 using an adhesive layer 25. Alternatively, without using the adhesive layer 25, the transparent resin layer 30 may be laminated on the surface of the printing layer 20 by extrusion laminating a resin composition for forming the transparent resin layer 30.

[0054] Next, the infrared absorption layer 70 is irradiated with infrared rays (infrared irradiation step). The irradiation of infrared rays can be performed using, for example, an infrared (IR) heater or the like. When the infrared absorption layer 70 is irradiated with infrared rays, the infrared rays are absorbed by the infrared absorption layer 70, and the temperature of the infrared absorption layer 70 increases. As a result, the temperature of the portion of the transparent resin layer 30 that overlaps with the infrared absorption layer 70 in the thickness direction (also referred to as the "overlapping portion") increases, and this overlapping portion becomes more likely to soften.

[0055] At this time, an embossed portion 31 is formed on the surface of the transparent resin layer 30 of the laminate 101 on the side opposite to the pattern portion 21 in the overlapping portion (embossed portion forming step). At this time, since the overlapping portion is more likely to soften, the embossed portion 31 can be easily formed by pressing an embossing roll. When the laminate 101 further includes a surface protection layer 50, the embossing roll may be pressed against the surface of the surface protection layer 50. In this case, an embossed portion 51 is formed on the surface of the surface protection layer 50, and at the same time, an embossed portion 31 is also formed on the surface of the transparent resin layer 30. In this way, the decorative sheet 100 is obtained.

[0056] <Decorative material> Next, an embodiment of the decorative material of the present disclosure will be described. The decorative material of the present disclosure includes a base material and a decorative sheet bonded to the base material. FIG. 3 is a cross-sectional view showing an embodiment of the decorative material of the present disclosure. The decorative material 200 shown in FIG. 3 includes a base material 210 and a decorative sheet 100 bonded to the base material 210. The decorative material 200 may further include an adhesive layer 220 for bonding the decorative sheet 100 and the base material 210 therebetween.

[0057] In the above-described decorative material 200, the decorative sheet 100 is attached to the base material 210, the colored resin layer 10 contained in the decorative sheet 100 contains a recycled resin, and the recycled resin contains a chemical recycled resin. Thus, even if the recycled resin is contained, it is possible to suppress a decrease in design property and hygiene property.

[0058] The base material 210, which is the adherend of the decorative sheet 100, can be appropriately selected according to the use, type, etc. of the decorative material 200. For example, base materials made of materials such as inorganic (non-metallic) base materials, metallic base materials, wooden base materials, and plastic base materials can be mentioned.

[0059] Examples of the inorganic base material include tiles and gypsum boards. Examples of the metallic base material include steel plates and aluminum plates. Examples of the wooden base material include MDF (medium density fiberboard) and plywood. Examples of the base material such as plastic include boards such as polypropylene-based boards, PVC-based boards, polyester-based boards, acrylic-based boards, and styrene-based boards.

[0060] The adhesive layer 220 is obtained using an adhesive. Examples of the adhesive include hot melt adhesives, organic solvent-based adhesives, and water-based adhesives. The resin contained in the adhesive may be a urethane-based resin, an ester-based resin, an acrylic-based resin, a vinyl acetate-based resin, or the like.

Example

[0061] Hereinafter, the present disclosure will be specifically described with reference to examples, but the present disclosure is not limited to these examples.

[0062] <Production of decorative sheet> (Example 1) A colored resin layer (thickness: 55 μm) containing chemically recycled low-density polyethylene (PCR Chem R100%-LDPE), which is a post-consumer recycled resin (hereinafter also referred to as "PCR"), was prepared. Note that "PCR Chem R100%-LDPE" means that the content of Chem R LDPE (chemically recycled low-density polyethylene), which is PCR in the resin, is 100% by volume (100% by mass). Then, a printed layer having a pattern portion was formed on one surface of the colored resin layer so as to show a wood grain pattern, and ink for an infrared absorption layer was printed on the other surface of the colored resin layer so as to overlap the pattern portion in the thickness direction of the colored resin layer. Thus, a printing original sheet was prepared. As the ink, a resin composition containing carbon was used. Next, a transparent resin layer was laminated on the surface of the printed layer of the printing original sheet by extrusion lamination using a resin composition containing petroleum-derived low-density polyethylene (LDPE), and a surface protective layer was formed thereon using a UV-curable urethane resin to obtain a laminate. Thereafter, the laminate was heated with an IR heater, and then an embossing roll was pressed against the surface of the transparent resin layer to form an embossed portion at a position overlapping the pattern portion in the thickness direction of the colored resin layer. Thus, a decorative sheet was manufactured.

[0063] (Example 2) A decorative sheet was manufactured in the same manner as in Example 1, except that the petroleum-derived LDPE in the resin composition for forming the transparent resin layer was changed to chemically recycled low-density polyethylene (PCR Chem R100%-LDPE), which is PCR.

[0064] (Example 3) A decorative sheet was manufactured in the same manner as in Example 1, except that the petroleum-derived LDPE in the resin composition for forming the transparent resin layer was changed to material recycled low-density polyethylene (PCR MR100%-LDPE), which is PCR.

[0065] (Comparative Example 1) A cosmetic sheet was produced in the same manner as in Example 1, except that the PCR Chem R100%-LDPE in the colored resin layer was changed to material recycled low-density polyethylene (PCRMR100%-LDPE) which is PCR.

[0066] (Comparative Example 2) A cosmetic sheet was produced in the same manner as in Example 2, except that the PCR Chem R100%-LDPE in the colored resin layer was changed to material recycled low-density polyethylene (PCRMR100%-LDPE) which is PCR.

[0067] (Comparative Example 3) A cosmetic sheet was produced in the same manner as in Example 3, except that the PCR Chem R100%-LDPE in the colored resin layer was changed to material recycled low-density polyethylene (PCRMR100%-LDPE) which is PCR.

[0068] (Reference Example 1) A cosmetic sheet was produced in the same manner as in Example 1, except that the PCR Chem R100%-LDPE in the colored resin layer was changed to petroleum-derived low-density polyethylene (LDPE).

[0069] <Evaluation> For the cosmetic sheets of the Examples, Comparative Examples and Reference Examples prepared as described above, Evaluation 1 (generation of odor components), Evaluation 2 (fish eyes), Evaluation 3 (impurities) and Evaluation 4 (design property) were carried out as follows. Here, Evaluation 1 is an evaluation regarding hygiene.

[0070] (1) Evaluation 1 (generation of odor components: hygiene) First, the cosmetic sheet was analyzed using purge and trap gas chromatography mass spectrometry. Specifically, 1.0 gram of a sample was cut out from the cosmetic sheet, and this sample was placed in a 20 mL vial together with an odor component trap body, and heated at 60°C for 1 hour to adsorb the volatile components from the sample onto the trap body. The volatile components in the trap body were analyzed with a purge and trap gas chromatography mass spectrometer to obtain a total ion chromatogram. Next, in the total ion chromatogram obtained as described above, the ratio R1 of the peak area of nonanal to the total peak area value of all aliphatic hydrocarbon components, and the ratio R2 of the peak area of decanal to the total peak area value of all aliphatic hydrocarbon components, as indicators of the generation amount of odor components, were determined. And evaluation was performed based on the following evaluation criteria. The results are shown in Table 1. Note that the generation amount of odor components is an indicator of hygiene. (Evaluation Criteria) ◎ ··· R1 is less than 1.5% and R2 is less than 0.35% ○ ··· R1 is less than 1.5% and R2 is 0.35% or more, or R1 is 1.5% or more and R2 is less than 0.35% × ··· R1 is 1.5% or more and R2 is 0.35% or more

[0071] (2) Evaluation 2 (Fish Eye) A sample with dimensions of 1 m × 1 m was cut out from the cosmetic sheet. The sample was placed on a black table, and the number N1 of protrusions (raised foreign substances) with a diameter of 0.5 mm or more and less than 1 mm was visually counted as fish eye 1, and the number N2 of protrusions (raised foreign substances) with a diameter of 1 mm or more was visually counted as fish eye 2. Evaluation was performed based on the following evaluation criteria. The results are shown in Table 1. (Evaluation Criteria) ◎ ··· N1 is 10 or less and N2 is 0 ○ ··· N1 is 11 to 99 and N2 is 0 × ··· N1 is 100 or more or N2 is 1 or more

[0072] (3) Evaluation 3 (Impurities) Regarding the cosmetic sheet, analysis was performed using the total reflection measurement method (ATR: Attenuated Total Reflection) with a Fourier transform infrared spectrophotometer (FT-IR: Fourier Transform Infrared Spectroscopy) to obtain an ATR spectrum. At this time, a diamond prism was used as the prism to be adhered to the cosmetic sheet, and the incident angle with respect to the surface of the cosmetic sheet was set to 45°. Then, in the ATR spectrum, the ratio R3 of the absorption coefficient of C=O stretching near 1720 cm -1 derived from polyester and polyurethane to the absorption coefficient of methylene group C-H antisymmetric stretching near 2915 cm -1 derived from polyethylene was calculated, and evaluation was performed based on the following evaluation criteria. The results are shown in Table 1. (Evaluation Criteria) ◎···R3 is less than 0.05 ○···R3 is 0.05 or more and less than 0.1 ×···R3 is 0.1 or more

[0073] (4) Evaluation 4 (Designability) The surface of the cosmetic sheet where the embossed part is formed was visually observed, and evaluation was performed based on the following evaluation criteria. The results are shown in Table 1. (Evaluation Criteria) 〇···A gloss and matte that is in sync only with the pattern part of the printing layer is exhibited. ×···A gloss and matte are exhibited also in parts other than the pattern part of the printing layer.

[0074]

Table 1

[0075] From the results shown in Table 1, it was found that the cosmetic sheets of Examples 1 to 3 had few fish eyes even when the recycled resin was included in the colored resin layer, had few impurities, suppressed the deterioration of design quality, and had a small amount of odor components generated. On the other hand, it was found that the cosmetic sheets of Comparative Examples 1 to 3 had many fish eyes, many impurities, and did not suppress the deterioration of design quality when the recycled resin was included in the colored resin layer. In particular, for Comparative Example 3, it was found that the amount of odor components generated was large. From the above, it was confirmed that according to the cosmetic sheet of the present disclosure, even when a recycled resin is included, the deterioration of design quality and hygiene can be suppressed.

Explanation of Signs

[0076] 10... Colored resin layer, 20... Printing layer, 21... Pattern part, 30... Transparent resin layer, 31... Embossed part, 70... Infrared absorption layer, 100... Cosmetic sheet, 101... Laminate, 200... Cosmetic material, 210... Base material.

Claims

1. A decorative sheet including a colored resin layer, a printed layer including a pattern portion, and a transparent resin layer in this order, wherein at least the colored resin layer contains a recycled resin, the recycled resin contains a chemical recycled resin, and an embossed portion is provided on the surface of the transparent resin layer on the side opposite to the pattern portion at a position overlapping the pattern portion in the thickness direction of the decorative sheet.

2. The decorative sheet according to claim 1, wherein the recycled resin contains a post-consumer recycled resin.

3. The colored resin layer further includes an infrared absorption layer on the surface on the side opposite to the pattern portion, and the decorative sheet according to claim 1, wherein the infrared absorption layer and the embossed portion are arranged at a position where they overlap in the thickness direction of the decorative sheet.

4. The decorative sheet according to claim 3, wherein the infrared absorption layer contains carbon black.

5. A method for manufacturing a decorative sheet for manufacturing the decorative sheet according to any one of claims 1 to 4, including a laminate preparation step of preparing a laminate having the colored resin layer, the printed layer including the pattern portion, and the transparent resin layer in this order, and an embossed portion forming step of forming the embossed portion on the surface of the transparent resin layer of the laminate on the side opposite to the pattern portion, wherein at least the colored resin layer contains a recycled resin, and the recycled resin contains a chemical recycled resin.

6. In the laminate preparation step, the laminate further includes an infrared absorption layer arranged at a position overlapping the pattern portion in the thickness direction of the laminate on the surface of the colored resin layer on the side opposite to the pattern portion, and the method for manufacturing a decorative sheet according to claim 5, further including an infrared irradiation step of irradiating the infrared absorption layer with infrared rays after the laminate preparation step.

7. A decorative material including a base material and a decorative sheet bonded to the base material, wherein the decorative sheet is the decorative sheet according to any one of claims 1 to 4.

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