Decorative sheet and method for manufacturing decorative sheet

Abstract

To provide a decorative sheet having an excellent weather resistance and reduced thickness, and a method for manufacturing the decorative sheet.SOLUTION: There is provided a decorative sheet 10, comprising: a colored raw fabric layer 1; a pattern printed layer 2 containing an inorganic pigment ink and provided on an upper side UP of the colored raw fabric layer 1; a clear layer 3 having a surface with embossing and provided on the upper side UP of the pattern printed layer 2; and a top coat layer 4 provided on the upper side UP of the clear layer 3. A thickness of the clear layer 3 is 50 μm or more, and the embossing in the clear layer 3 is formed using an embossing plate with a plate depth of 20 μm or less.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] Conventionally, as a cosmetic sheet used as a surface material for furniture and building materials for housing, there is a cosmetic sheet having a three-dimensional feeling by touch by forming irregularities (embossing) on the surface by embossing or the like. For example, in a wood grain pattern cosmetic sheet, by imparting a three-dimensional feeling by touch to the conduit portion of the wood grain pattern, a wood grain pattern cosmetic sheet closer to the appearance of natural wood can be provided.

[0003] The cosmetic sheet used as a surface material may be applied in a place where sunlight hits, and in order to prevent weathering deterioration of the layer printed with the pattern, it is required to have sufficient weather resistance. Also, due to the reduction of CO2 emissions and petrochemical products, a cosmetic sheet with a thinner layer thickness is required.

[0004] As a cosmetic sheet subjected to embossing, there is a cosmetic sheet described in Patent Document 1. The cosmetic sheet described in Patent Document 1 is a cosmetic sheet having a pattern layer, a first adhesive layer, a polyester resin layer, and a surface protection layer in this order on a thermoplastic resin base sheet. Further, the manufacturing method of the cosmetic sheet described in Patent Document 1 is characterized by performing embossing after laminating the surface protection layer by dry lamination.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] Conventional cosmetic sheets such as those described in Patent Document 1 improve weather resistance by laminating a protective layer on the upper side of a pattern printing layer with a printed pattern.

[0007] For example, in conventional cosmetic sheets, in order to impart sufficient weather resistance, it was necessary to laminate a protective layer with a thickness of 60 μm or more on the upper side of the pattern printing layer, and the plate depth of the embossing plate that embosses the surface of the protective layer should be 30 μm or less. Thus, in conventional cosmetic sheets, there was a risk that the layer thickness of the cosmetic sheet would increase in order to improve weather resistance.

[0008] In view of the above circumstances, an object of the present invention is to provide a cosmetic sheet excellent in weather resistance and with suppressed thickness, and a method for manufacturing the cosmetic sheet.

Means for Solving the Problems

[0009] In order to solve the above problems, the present invention proposes the following means. The cosmetic sheet of the present invention includes a coloring original reaction layer, a pattern printing layer provided on the upper side of the coloring original reaction layer and containing inorganic pigment ink, a clear layer provided on the upper side of the pattern printing layer and having an emboss on the surface, and a top coat layer provided on the upper side of the clear layer. The thickness of the clear layer is 50 μm or more, and the emboss of the clear layer is an emboss formed by an embossing plate with a plate depth of 20 μm or less.

[0010] In the above cosmetic sheet, the particle size distribution of the inorganic pigment ink contained in the pattern printing layer may be 0.1 μm or more and 2.0 μm or less.

[0011] In the above cosmetic sheet, the clear layer may contain a thermoplastic resin.

[0012] In the above cosmetic sheet, the top coat layer may contain a thermosetting resin, an ultraviolet curable resin, or an electron beam curable resin.

[0013] The manufacturing method of the cosmetic sheet of the present invention includes a pattern printing step of printing a pattern printing layer containing inorganic pigment ink on the upper side of the colored original layer, a clear layer laminating step of laminating a clear layer on the upper side of the pattern printing layer so that the thickness becomes 50 μm or more, an embossing step of forming an embossing on the surface of the clear layer with an embossing plate having a plate depth of 20 μm or less, and a top coat layer laminating step of laminating a top coat layer on the upper side of the clear layer.

[0014] In the manufacturing method of the above cosmetic sheet, in the pattern printing step, the pattern printing layer may be printed with the inorganic pigment ink having a particle size distribution of 0.1 μm or more and 2.0 μm or less.

Effects of the Invention

[0015] According to the cosmetic sheet and the manufacturing method of the cosmetic sheet of the present invention, it is possible to provide a cosmetic sheet and a manufacturing method of the cosmetic sheet that are excellent in weather resistance and have a suppressed thickness.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0017] An embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view schematically showing a cosmetic sheet 10 according to this embodiment.

[0018] In this embodiment, as shown in FIG. 1, the thickness direction of the cosmetic sheet 10 is defined as the "vertical direction V", the side where the top coat layer 4 of the cosmetic sheet 10 is provided is defined as the "upper side UP" in the vertical direction V, and the side opposite to the upper side UP is defined as the "lower side LO" in the vertical direction V.

[0019] The cosmetic sheet 10 includes a coloring original layer 1, a pattern printing layer 2, a clear layer 3, a top coat layer 4, and a primer layer 5.

[0020] The coloring original layer 1 is a layer provided on the upper side UP of the primer layer 5. Details of the primer layer 5 will be described later. As the coloring original layer 1, a thermoplastic resin can be adopted. For example, as the coloring original layer 1, a polyolefin resin such as polyethylene or polypropylene can be adopted. The thickness of the coloring original layer 1 in the vertical direction V is preferably 50 μm or more.

[0021] The pattern printing layer 2 is a layer provided on the upper side UP of the coloring original layer 1. The pattern printing layer 2 is formed, for example, by applying a pattern such as a wood grain, a stone grain, or a sand grain on the upper side UP of the coloring original layer 1.

[0022] As the pattern printing layer 2, an inorganic pigment ink can be adopted. By using the inorganic pigment ink for the pattern printing layer 2, the weather resistance of the pattern printing layer 2 can be improved as compared with the case of using an organic pigment ink.

[0023] The particle size distribution of the inorganic pigment ink used for the pattern printing layer 2 is preferably 0.1 μm or more and 2.0 μm or less. Further, the average particle diameter of the inorganic pigment contained in the inorganic pigment ink used for the pattern printing layer 2 is preferably about 1.0 μm.

[0024] By using an inorganic pigment ink having a particle size distribution of 0.1 μm or more and 2.0 μm or less for the pattern printing layer 2, it is possible to suppress a decrease in the ink transfer rate even when continuous production is performed, and it is possible to suppress a color change of the pattern printing layer 2.

[0025] The pattern printing layer 2 is printed, for example, by a gravure plate formed of a cylindrical metal roll. The pattern printing layer 2 is continuously printed on the upper side UP surface of the coloring original layer 1 by pressing the gravure plate against the coloring original layer 1 that is fed in conjunction with the rotation of the gravure plate.

[0026] Even when continuous production is carried out in this way, by setting the particle size distribution of the inorganic pigment ink used for the pattern printing layer 2 to be 0.1 μm or more and 2.0 μm or less, the color change of the pattern printing layer 2 can be suppressed, and the deterioration of the design property of the decorative sheet 10 can be suppressed. For example, by printing the pattern printing layer 2 using an inorganic pigment ink with a particle size distribution of 0.1 μm or more and 2.0 μm or less, the design property can be maintained even when continuous production of about 12,000 m is carried out.

[0027] As a printing method for the pattern printing layer 2, for example, known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be adopted.

[0028] The clear layer 3 is a layer provided on the upper side UP of the pattern printing layer 2. As the clear layer 3, a thermoplastic resin can be adopted. For example, as the clear layer 3, polyolefin resins such as polyethylene and polypropylene can be adopted. It is preferable to adopt a transparent or translucent material for the clear layer 3 to such an extent that the pattern of the pattern printing layer 2 can be seen through. The clear layer 3 is formed, for example, by extrusion lamination.

[0029] The thickness of the clear layer 3 in the vertical direction V is 50 μm or more. By setting the thickness of the clear layer 3 to be 50 μm or more, the weather resistance of the decorative sheet 10 can be improved, and the weathering deterioration of the pattern printing layer 2 can be suppressed.

[0030] On the surface (the upper side UP surface) of the clear layer 3, an uneven shape (emboss) formed by pressing an embossing plate is provided.

[0031] FIG. 2 is a cross-sectional view schematically showing an embossing plate P for embossing the clear layer 3. As shown in FIG. 2, an emboss is formed on the surface of the clear layer 3 by pressing the unevenness of the embossing plate P. The plate depth H of the embossing plate P for embossing the clear layer 3 is 20 μm or less.

[0032] Here, the plate depth H of the embossing plate P refers to the height (depth) in the vertical direction V of the unevenness of the embossing plate P for forming an embossing on the clear layer 3. For example, a convex shape with a height of 20 μm or less in the vertical direction V is pressed against the clear layer 3 from the upper side UP.

[0033] Due to this convex shape with a height of 20 μm or less, a groove that is concave downward LO along the convex shape of the embossing plate P is formed on the surface of the clear layer 3, and an embossing (uneven shape) is formed. In reality, since the clear layer 3 slightly deforms due to elasticity or the like after the embossing process, the height in the vertical direction V of the embossing formed on the clear layer 3 is slightly different from the plate depth H of the embossing plate P.

[0034] By setting the plate depth H of the embossing plate P for embossing the decorative sheet 10 to 20 μm or less, it is possible to sufficiently ensure the layer thickness of the clear layer 3 to which the embossing process is applied, and sufficient weather resistance can be imparted to the decorative sheet 10.

[0035] The top coat layer 4 is a layer provided on the upper side UP of the clear layer 3. As the top coat layer 4, a thermosetting resin, an ultraviolet curable resin, an electron beam curable resin, or a mixture thereof can be adopted. As the top coat layer 4, for example, a urethane resin, an acrylic resin, or the like can be adopted. It is preferable to adopt a transparent or translucent material for the top coat layer 4 to such an extent that the pattern of the pattern printing layer 2 can be seen through the clear layer 3.

[0036] As a method for laminating the top coat layer 4, known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be adopted. Also, the top coat layer 4 may be laminated using a known coating device.

[0037] The primer layer 5 is a layer provided on the lower side LO of the coloring original layer 1. As the primer layer 5, a polyester resin, a urethane resin, an acrylic resin, or the like can be adopted. As a method of laminating the primer layer 5, a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing, or a forming method using a known coating device can be adopted.

[0038] Next, a manufacturing method for manufacturing the decorative sheet 10 by a decorative sheet manufacturing system will be described. Here, the decorative sheet manufacturing system is a system that executes the manufacturing of the decorative sheet 10 according to the present embodiment.

[0039] (Step S1) First, the decorative sheet manufacturing system performs Step S1 (pattern printing process). In Step S1, the decorative sheet manufacturing system prints a pattern on the upper side UP of the coloring original layer 1 to form a pattern printing layer 2. At this time, the ink used for the pattern printing layer 2 is inorganic pigment ink. Also, in order to suppress a decrease in designability during continuous production, the particle size distribution of the inorganic pigment ink used for the pattern printing layer 2 is preferably 0.1 μm or more and 2.0 μm or less.

[0040] (Step S2) Next, the decorative sheet manufacturing system performs Step S2 (clear layer lamination process). In Step S2, the decorative sheet manufacturing system laminates a thermoplastic resin on the upper side UP of the pattern printing layer 2 by extrusion lamination to form a clear layer 3. At this time, the clear layer 3 is laminated so that the thickness of the clear layer 3 becomes 50 μm or more.

[0041] Also, the decorative sheet manufacturing system laminates the primer layer 5 on the lower side LO of the coloring original layer 1.

[0042] (Step S3) Next, the cosmetic sheet manufacturing system performs step S3 (embossing process). In step S3, the cosmetic sheet manufacturing system presses the embossing plate P against the upper UP surface of the clear layer 3 formed in step S2 to form an embossing on the surface of the clear layer 3.

[0043] At this time, the plate depth H of the embossing plate P for embossing the surface of the clear layer 3 is 20 μm or less.

[0044] (Step S4) After embossing the surface of the clear layer 3, the cosmetic sheet manufacturing system performs step S4 (top coat layer lamination process). In step S4, the cosmetic sheet manufacturing system laminates a thermosetting resin, an ultraviolet curable resin, an electron beam curable resin, or a mixture thereof on the upper UP of the embossed clear layer 3 to form a top coat layer 4, thereby forming the cosmetic sheet 10.

[0045] According to the cosmetic sheet 10 of the present embodiment, it includes a coloring original reaction layer 1, a pattern printing layer 2 provided on the upper UP of the coloring original reaction layer 1 and containing inorganic pigment ink, a clear layer 3 provided on the upper UP of the pattern printing layer 2 and having an embossing on the surface, and a top coat layer 4 provided on the upper side of the clear layer 3. The thickness of the clear layer 3 is 50 μm or more. The embossing of the clear layer 3 is an embossing formed by an embossing plate P with a plate depth H of 20 μm or less.

[0046] By adopting inorganic pigment ink in the pattern printing layer 2, setting the plate depth H of the embossing plate P for embossing the surface of the clear layer 3 to 20 μm or less, and setting the thickness of the clear layer 3 to 50 μm or more, a cosmetic sheet 10 with excellent weather resistance can be realized.

[0047] Also, compared with the conventional cosmetic sheet that required the plate depth of the embossing plate to be 30 μm or less and the thickness of the clear layer to be 60 μm or more in order to impart sufficient weather resistance, a cosmetic sheet 10 with a suppressed thickness can be realized.

[0048] As a result, it is possible to provide a decorative sheet 10 having excellent weather resistance and suppressing thickness, and a method for manufacturing the decorative sheet 10.

[0049] Further, by setting the particle size distribution of the inorganic pigment ink used for the pattern printing layer 2 to be 0.1 μm or more and 2.0 μm or less, it is possible to provide a decorative sheet 10 and a method for manufacturing the decorative sheet 10 that can suppress a decrease in design quality even when continuous production is performed.

[0050] As described above, one embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and design changes and the like within the scope not departing from the gist of the present invention are also included. In addition, the constituent elements shown in the above-described one embodiment and the modification examples shown below can be combined as appropriate.

[0051] (Modification Example 1) In the above embodiment, the decorative sheet 10 includes the primer layer 5, but the aspect of the decorative sheet 10 is not limited to this. The decorative sheet may not include the primer layer 5.

[0052] The primer layer 5 is, for example, a layer for improving the adhesion between the decorative sheet 10 and a base material (such as a wood base material) attached to the lower side LO of the decorative sheet 10 when forming a decorative board. Therefore, when the adhesion between the decorative sheet 10 and the base material attached to the lower side LO of the decorative sheet 10 is sufficient even without providing the primer layer 5, the decorative sheet may not include the primer layer 5.

[0053] The present invention will be described in detail with reference to the following examples. The present invention is not limited to the following examples.

[0054] (Example 1) A colored original reaction layer 1 having a thickness of 50 μm or more formed of a thermoplastic resin was prepared. A pattern was printed on the upper side UP of the colored original reaction layer 1 by gravure printing to form a pattern printing layer 2. At this time, inorganic pigment ink was used for the pattern printing layer 2.

[0055] The clear layer 3 was laminated on the upper side UP of the handle printing layer 2 by an extruder, and embossing was performed on the upper surface UP of the clear layer 3 using an embossing plate P. At this time, the thickness of the clear layer 3 was set to 50 μm, and the plate depth H of the embossing plate P for embossing the clear layer 3 was set to 10 μm.

[0056] A primer layer 5 was laminated on the lower side LO of the colored original layer 1. Further, a top coat layer 4 was laminated on the upper side UP of the clear layer 3 to obtain the decorative sheet 10 of Example 1.

[0057] (Example 2) The decorative sheet 10 of Example 2 was obtained in the same manner as in Example 1, except that the plate depth H of the embossing plate P for embossing the clear layer 3 was set to 20 μm.

[0058] (Example 3) The decorative sheet 10 of Example 3 was obtained in the same manner as in Example 1, except that the thickness of the clear layer 3 was set to 60 μm.

[0059] (Example 4) The decorative sheet 10 of Example 4 was obtained in the same manner as in Example 1, except that the thickness of the clear layer 3 was set to 60 μm and the plate depth H of the embossing plate P for embossing the clear layer 3 was set to 20 μm.

[0060] (Comparative Example 1) The decorative sheet of Comparative Example 1 was obtained in the same manner as in Example 1, except that the plate depth of the embossing plate for embossing the clear layer was set to 30 μm.

[0061] (Comparative Example 2) The decorative sheet of Comparative Example 2 was obtained in the same manner as in Example 1, except that the plate depth of the embossing plate for embossing the clear layer was set to 40 μm.

[0062] (Comparative Example 3) The decorative sheet of Comparative Example 3 was obtained in the same manner as in Example 1, except that the thickness of the clear layer was set to 60 μm and the plate depth of the embossing plate for embossing the clear layer was set to 30 μm.

[0063] (Comparative Example 4) A decorative sheet of Comparative Example 4 was obtained in the same manner as in Example 1, except that the thickness of the clear layer was 60 μm and the plate depth of the embossing plate for embossing the clear layer was 40 μm.

[0064] (Comparative Example 5) A decorative sheet of Comparative Example 5 was obtained in the same manner as in Example 1, except that a pattern printing layer was printed using organic pigment ink.

[0065] (Comparative Example 6) A decorative sheet of Comparative Example 6 was obtained in the same manner as in Example 1, except that the plate depth of the embossing plate for embossing the clear layer was 20 μm and a pattern printing layer was printed using organic pigment ink.

[0066] (Comparative Example 7) A decorative sheet of Comparative Example 7 was obtained in the same manner as in Example 1, except that the plate depth of the embossing plate for embossing the clear layer was 30 μm and a pattern printing layer was printed using organic pigment ink.

[0067] (Comparative Example 8) A decorative sheet of Comparative Example 8 was obtained in the same manner as in Example 1, except that the plate depth of the embossing plate for embossing the clear layer was 40 μm and a pattern printing layer was printed using organic pigment ink.

[0068] (Comparative Example 9) A decorative sheet of Comparative Example 9 was obtained in the same manner as in Example 1, except that the thickness of the clear layer was 60 μm and a pattern printing layer was printed using organic pigment ink.

[0069] (Comparative Example 10) A decorative sheet of Comparative Example 10 was obtained in the same manner as in Example 1, except that the thickness of the clear layer was 60 μm, the plate depth of the embossing plate for embossing the clear layer was 20 μm, and a pattern printing layer was printed using organic pigment ink.

[0070] (Comparative Example 11) The thickness of the clear layer was set to 60 μm, the plate depth of the embossing plate for embossing the clear layer was set to 30 μm, and a decorative sheet of Comparative Example 11 was obtained in the same manner as in Example 1, except that the pattern printing layer was printed using organic pigment ink.

[0071] (Comparative Example 12) The thickness of the clear layer was set to 60 μm, the plate depth of the embossing plate for embossing the clear layer was set to 40 μm, and a decorative sheet of Comparative Example 12 was obtained in the same manner as in Example 1, except that the pattern printing layer was printed using organic pigment ink.

[0072] (Experiment 1) Weather resistance tests were conducted on the decorative sheets of Examples 1-4 and Comparative Examples 1-12. In the weather resistance test, a weather resistance test using a metal weather meter in accordance with JIS B 7753 was carried out for 240 hours. After the 240-hour weather resistance test, the appearance of the decorative sheet was observed, and the color change before and after the weather resistance test was evaluated by 10 testers. Also, the color change when the weather resistance test was carried out for 192 hours was observed and evaluated.

[0073] The evaluation criteria were divided into three levels, and ○ was regarded as passing. 〇 (Good): Nine or more and ten or fewer people evaluated that there was no color change due to weathering deterioration. △ (Fair): Seven or more and eight or fewer people evaluated that there was no color change due to weathering deterioration. × (Poor): Six or fewer people evaluated that there was no color change due to weathering deterioration.

[0074] (Experimental Result 1) The results of Experiment 1 are shown in Table 1. Table 1 shows the inks used for the pattern printing layers of Examples 1-4 and Comparative Examples 1-12. "Inorganic" in Table 1 indicates that an inorganic pigment ink was used for the pattern printing layer. "Organic" in Table 1 indicates that an organic pigment ink was used for the pattern printing layer.

[0075] Also, Table 1 shows the thickness of the clear layer and the plate depth of the embossing plate for Examples 1-4 and Comparative Examples 1-12.

[0076] In Examples 1-4 where inorganic pigment ink was used for the pattern printing layer 2 and the plate depth H of the embossing plate P was 20 μm or less, good results were shown in Experiment 1. The thickness of the clear layer 3 in Examples 1-4 was 50 μm or more.

[0077] Even for a decorative sheet using inorganic pigment ink for the pattern printing layer and having a clear layer thickness of 50 μm or more, Comparative Examples 1-2 and 4 in which the plate depth of the embossing plate was greater than 20 μm were disqualified.

[0078] Also, Comparative Example 6 in which organic pigment ink was used for the pattern printing layer was disqualified even though the thickness of the clear layer was 50 μm or more and the plate depth of the embossing plate was 20 μm or less.

[0079]

Table 1

[0080] (Experiment 2) The following Example 5 and Comparative Examples 13-14 were prepared and a continuous productivity test was carried out.

[0081] (Example 5) A colored original reaction layer 1 with a thickness of 50 μm or more formed of a thermoplastic resin was prepared, and a pattern was printed on the upper side UP of the colored original reaction layer 1 by gravure printing to form a pattern printing layer 2. For the pattern printing layer 2, inorganic pigment ink having a particle size distribution of 0.1 μm or more and 2.0 μm or less was used. At this time, the average particle diameter of the inorganic pigment ink used for the pattern printing layer 2 was 1.0 μm.

[0082] (Comparative Example 13) The pattern printing layer of Comparative Example 13 was formed in the same manner as in Example 5 except that inorganic pigment ink having a particle size distribution of 0.1 μm or more and 3.0 μm or less was used. At this time, the average particle diameter of the inorganic pigment ink used for the pattern printing layer was 2.0 μm.

[0083] (Comparative Example 14) A pattern printing layer of Comparative Example 14 was formed in the same manner as in Example 5, except that an inorganic pigment ink having a particle size distribution of 0.1 μm or more and 4.0 μm or less was used. At this time, the average particle diameter of the inorganic pigment ink used for the pattern printing layer was 3.0 μm.

[0084] In the continuous productivity test of Experiment 2, the color change of the pattern printing layer due to the decrease in ink transfer rate in Examples 5 and Comparative Examples 13-14, in which a pattern printing layer was formed on the upper surface of the coloring original layer using three types of inorganic pigment inks having different particle size distributions, was evaluated.

[0085] Specifically, in the pattern printing layers of Example 5 and Comparative Examples 13-14, samples were collected after printing at 0 m, 3000 m, 6000 m, 9000 m, and 12000 m, and compared with the design at the time of 0 m printing. The color change of the pattern printing layer due to the decrease in ink transfer rate was evaluated by 10 testers.

[0086] Here, the pattern printing layer at the time of 0 m printing is not exactly 0 m, but a sample when starting to print the pattern printing layer. Therefore, the pattern printing layer at the time of 0 m printing is in a state where a predetermined pattern of the pattern printing layer is printed. Also, the pattern printing layers after printing at 3000 m, 6000 m, 9000 m, and 12000 m are samples continuously printed up to each production length by a gravure plate.

[0087] The evaluation criteria were divided into three levels, and ○ was regarded as passing. 〇 (Good): Nine or more and ten or fewer people evaluated that there was no color change in the pattern printing layer due to the decrease in ink transfer rate. △ (Fair): Seven or more and eight or fewer people evaluated that there was no color change in the pattern printing layer due to the decrease in ink transfer rate. × (Poor): Six or fewer people evaluated that there was no color change in the pattern printing layer due to the decrease in ink transfer rate.

[0088] (Experimental Result 2) The results of Experiment 2 are shown in Table 2. Table 2 shows the particle size distribution and average particle diameter of the inorganic pigment ink used in the pattern printing layer of Example 5 and Comparative Examples 13-14. Also, in Experiment 2, since the design difference from the pattern printing layer at the time of 0 m printing was evaluated, the evaluation results at the time of 0 m printing are not shown in Table 2.

[0089] Example 5, which used an inorganic pigment ink with a particle size distribution of 0.1 μm or more and 2.0 μm or less, showed good results at each continuous production length in Experiment 2.

[0090] Comparative Example 13, which used an inorganic pigment ink with a particle size distribution of 0.1 μm or more and 3.0 μm or less, was unacceptable at continuous production lengths of 9000 m and 12000 m. Comparative Example 14, which used an inorganic pigment ink with a particle size distribution of 0.1 μm or more and 4.0 μm or less, was unacceptable at continuous production lengths of 6000 m, 9000 m, and 12000 m.

[0091]

Table 2

Explanation of Signs

[0092] 10 Cosmetic sheet 1 Coloring original layer 2 Pattern printing layer 3 Clear layer 4 Top coat layer 5 Primer layer P Embossing plate H Embossing depth of the embossing plate V Vertical direction UP Upper side LO Lower side S1 Pattern printing process S2 Clear layer lamination process S3 Embossing process S4 Top coat layer lamination process

Claims

1. A coloring original layer, A pattern printing layer provided above the coloring original layer and containing inorganic pigment ink, A clear layer provided above the pattern printing layer and having an emboss on the surface, A top coat layer provided above the clear layer, Comprising, The thickness of the clear layer is 50 μm or more, The emboss of the clear layer is an emboss formed by an embossing plate with an engraving depth of 20 μm or less, A decorative sheet.

2. The particle size distribution of the inorganic pigment ink contained in the pattern printing layer is 0.1 μm or more and 2.0 μm or less, The decorative sheet according to Claim 1.

3. The clear layer contains a thermoplastic resin, The decorative sheet according to Claim 1 or Claim 2.

4. The top coat layer contains a thermosetting resin, an ultraviolet curable resin or an electron beam curable resin, The decorative sheet according to Claim 1 or Claim 2.

5. A pattern printing step of printing a pattern printing layer containing inorganic pigment ink above the coloring original layer, A clear layer laminating step of laminating a clear layer so that the thickness becomes 50 μm or more above the pattern printing layer, An embossing step of forming an emboss on the surface of the clear layer with an embossing plate having an engraving depth of 20 μm or less, A top coat layer laminating step of laminating a top coat layer above the clear layer, Comprising, A method for manufacturing a decorative sheet.

6. In the pattern printing step, the pattern printing layer is printed with the inorganic pigment ink having a particle size distribution of 0.1 μm or more and 2.0 μm or less, The method for manufacturing a decorative sheet according to Claim 5.

Images